Precautions for Load Handling Operations
The precautions for load handling must cover four modules: load pre-processing, core operation actions, special working condition control, and emergency response. Below is a structured, fully implementable full-process specification.
I. Load Pre-processing (Mandatory Before Operation)
Verify Key Load Parameters
Confirm the actual weight of the goods and strictly prohibit overloading (the load must not exceed the rated capacity of the forklift, including the weight of attachments). Check the load center distance (the standard common value is 500mm). For overlength, overwidth, or eccentric loads, recalculate the safe load capacity and derate the forklift if necessary.
Inspect Cargo Packaging and Condition
Ensure the goods are free from looseness, tilting, and sharp edges. Fragile goods or liquid cargo must be additionally secured to prevent shaking or leakage during lifting or traveling.
Standardize the Use of Forks and Attachments
ｉｎｓｅｒｔ the forks fully into the pallet with an insertion depth of not less than 2/3 of the pallet length. Ensure the fork spacing matches the pallet, and the goods are placed in the center. Strictly prohibit single-fork operation and eccentric loading operation.When installing attachments such as side shifters, fork positioners, or clamps, confirm that the rated load capacity of the attachments matches the forklift, and adjust the operation method in accordance with the attachment manual. The contact between the attachments and the goods must be firm without slipping risks.
Inspect Working Environment and Equipment
Check that the ground is flat and free from oil stains, accumulated water, or ice and snow, and that the passage is clear of obstacles. Verify that the forklift's braking system, steering system, hydraulic system, and stability devices (tilt alarm, load display) are functioning properly.Define a safe operation zone, prohibit non-operators from entering, and set up warning signs.
II. Precautions for Core Operation Actions (Strictly Implemented During Operation)
Operation Actions | Execution Key Points | Risk Prevention and Control |
Lifting and Lowering | 1.Confirm the forks are in place and the goods are secured before lifting. 2. Lift the goods only to the height required for the operation; during traveling, the forks must be lowered to 10-15 cm above the ground. 3. Lower the goods steadily and slowly; strictly prohibit impact operations to avoid shaking or falling of the goods | Prohibit sharp turns, acceleration, or braking when the load is lifted at height. Prohibit adjusting the goods while the heavy load is suspended in the air |
Horizontal Traveling | 1.When unloaded, slightly lift the forks (5-10 cm above the ground); when loaded, lower the forks as much as possible. 2. Travel in a straight line at a constant speed; strictly prohibit speeding, sudden acceleration, or sudden braking. 3. Reduce speed to below 5 km/h when turning; strictly prohibit simultaneous steering and braking | Reduce the speed by half on slippery or sloped roads; install anti-skid chains if necessary. Prohibit transverse traveling on slopes |
Stacking and Picking | 1.Operate perpendicular to the shelves; strictly prohibit oblique forking. 2. Confirm the shelves are stable and not shaking during lifting or lowering. 3. After placing the goods in position, confirm they are fully placed on the shelves before slowly withdrawing the forks | Prohibit adjusting the goods while the forks are suspended in the air. Prohibit colliding with the shelves |
Slope Operation | 1.When going uphill: drive forward with the forks facing forward. When going downhill: drive in reverse with the forks facing backward. 2. If the slope exceeds 5%, strictly prohibit steering, parking, or lifting/lowering goods. 3. Strictly prohibit lifting heavy loads on slopes | Activate the Hill-Start Assist Control (HAC) system to prevent slipping; use the handbrake for auxiliary braking if necessary |
III. Additional Precautions for Special Loads and Working Conditions
Overlength, Overwidth, or Eccentric Loads
- Calculate the load center distance based on the farthest end of the goods; the lifting height shall not exceed 1.5 m, and the traveling speed shall be ≤ 3 km/h.
- Secure the goods with straps or pallets; add counterweights or use special attachments if necessary.
- Avoid operating in narrow passages or turning areas; prioritize using forklifts with long wheelbases and wide wheel tracks.
Lightweight, Bulky, Fragile, or Liquid Cargo
- Prevent lightweight and bulky goods from tipping over; install baffle plates if necessary.
- For fragile goods, strictly prohibit impact operations; reduce the speed of lifting, lowering, and traveling to 50% of the normal speed.
- Keep liquid cargo horizontal to avoid leakage caused by tilting.
Severe Environments (Night, Low Temperature, Slippery Surfaces, etc.)
- Ensure sufficient lighting (illuminance ≥ 100 lux) for night operations to avoid blind spots in vision.
- In low-temperature environments, preheat the hydraulic system and check tire pressure and anti-skid performance.
- Avoid sudden braking and sharp turns on slippery or icy and snowy ground; suspend operations if necessary.
IV. Prohibited Operations & Emergency Response
Prohibited Behaviors
- Overloading, eccentric loading, and single-fork operation; traveling, turning, or braking when the load is lifted at height.
- Transverse traveling on slopes, lifting heavy loads on slopes, and unauthorized modification of attachments.
- Operating without a license, speeding, and working under the influence of alcohol or fatigue.
Emergency Response (Load-related Accidents)
- Goods shaking/tilting: Immediately stop the forklift slowly, do not move it, lower the forks to the ground, and re-secure the goods.
- Forklift tilting: Strictly prohibit jumping off the vehicle; grip the steering wheel tightly, move the body to the opposite direction of the tilt, brake slowly, and evacuate to a safe area after the forklift stabilizes.
- Goods falling: Evacuate immediately, set up a warning zone, and contact professional personnel for disposal.
V. Long-term Safeguard Measures
- Establish load operation cards to clarify the operation specifications for different load types.
- Conduct regular training and assessment for operators, focusing on strengthening their abilities in load calculation, special working condition operation, and emergency response.
- Install load monitoring systems (overload alarm, eccentric load warning, load display) to monitor the operation status in real time.
