As a "mainstay" of logistics operations, correct use of electric forklifts not only improves operational efficiency but also prevents equipment damage and safety accidents. Neglecting operational standards can lead to minor issues like cargo damage or equipment breakdowns, and in severe cases, personal injury or death. This blog breaks down electric forklift operation skills in four key modules—"Pre-Operation Preparation → Standard Operating Procedures → Core Safety Notes → Emergency Handling"—helping both new and experienced operators fill in the gaps!

I. Pre-Operation: 3-Minute Checks to Mitigate Risks Before Starting

Pre-operation inspections are the first line of safety defense—never skip them! Focus on these 5 key points:

1. Personnel Preparation: Certified & Alert

Operators must complete professional training and hold a valid operation certificate; uncertified operation is strictly prohibited. Ensure full energy before work—no operation under the influence of alcohol, fatigue, or distraction (e.g., using mobile phones, chatting). Wear non-slip work shoes and avoid loose clothing (to prevent entanglement in equipment).

2. Equipment Inspection: Check Item by Item, Start Only if Fault-Free

- Appearance: Inspect for body dents/deformation, fork bending or cracks, and properly inflated tires free of embedded debris;

- Functions: Test responsiveness of brakes, steering, lifting/tilting mechanisms, and verify that horns, warning lights, and reverse buzzers work normally;

- Battery: Check for sufficient power (remaining ≥30%), secure and corrosion-free battery terminals, undamaged charging ports, and no swelling or leakage (especially for lithium batteries);

- Safety Devices: Ensure seat belts fasten securely, emergency power-off switches are responsive, and mast limit devices function properly.

3. Environment Inspection: Clear Obstacles & Confirm Safe Zones

Check that the working area floor is flat (no potholes or oil stains) and that aisle width matches the forklift’s turning radius. Remove obstacles (cartons, tools) and confirm shelves/cargo are stable. Ensure good ventilation for indoor operations; monitor carbon monoxide levels in confined spaces (if using internal combustion auxiliary equipment).

4. Cargo Confirmation: Match Load Capacity & Secure Stacking

Confirm cargo weight in advance (never exceed the forklift’s rated load). Ensure cargo is stacked neatly with a centered center of gravity—avoid overloading or unbalanced loads. Secure fragile or high-value goods with straps; never transport loose, unsecur ed cargo or items that are overly long, wide, or tall (add protection if exceeding fork length/width).

II. Standard Operating Procedures: Follow Steps for Efficiency & Compliance

1. Startup & Warm-Up (1 Minute)

- After boarding, adjust seat height and backrest angle to ensure feet can firmly press pedals and hands naturally grip the steering wheel;

- Fasten the seat belt, insert the key or activate the start button, and check that the dashboard shows sufficient power and no fault lights (no alarm prompts);

- Test lifting and tilting functions in place to warm up the hydraulic system—only start driving if there are no jams or abnormal noises.

2. Driving Operation: Prioritize Smoothness & Speed Control

- Startup: Press the accelerator pedal slowly to avoid sudden acceleration (prevents cargo shifting); check for pedestrians/obstacles before releasing the brake;

- Speed Limits: 5km/h indoors (equivalent to walking speed), no more than 10km/h in open outdoor areas, and 2-3km/h in narrow aisles, when turning, or going downhill;

- Steering & Avoidance: Slow down and sound the horn before turning—avoid sharp turns (prevents rollovers). Yield to pedestrians proactively, maintain a safe distance of over 1 meter, and never reverse or cut in line;

- Incline Driving: Drive forward slowly with forks facing upward when going uphill; reverse with forks facing downward when going downhill (prevents cargo sliding). Never turn or park on inclines;

- Meeting & Overtaking: When meeting in narrow passages, pull over at a wide spot in advance—empty forklifts yield to loaded ones. Overtake only after confirming no obstacles ahead and sounding the horn to signal, passing on the left.

3. Loading & Unloading Operation: Precision & Smoothness to Avoid Cargo Damage

- Forking Cargo: Adjust fork spacing to match cargo width; insert forks fully under the cargo (depth ≥2/3 of cargo length). Lift forks slowly to 10-15cm above the ground, then tilt the mast slightly backward (10-15°) to prevent cargo sliding;

- Lifting & Moving: Lift cargo at a steady speed—avoid sudden lifting or lowering. Keep cargo height below 1.5 meters during movement (prevents blocking visibility); pass obstacles slowly;

- Stacking Cargo: Approach shelves at low speed, stop after aligning with the storage position. Lift cargo steadily to 10-20cm above the shelf, adjust position, then lower slowly. Confirm cargo is stable before pulling forks out;

- Unloading Cargo: Place cargo steadily on the ground or shelf, lower forks to 5-10cm above the ground, then pull forks out slowly to avoid scraping the cargo.

4. Parking Operation: Park Properly & Eliminate Risks

- Park in a flat, obstacle-free area—away from ramps, aisle entrances, and fire hydrants;

- Lower forks fully to the ground (complete contact), return the mast to a vertical position, turn off all control switches, and remove the key;

- Engage the handbrake; if parking on an incline (special circumstances), use wheel chocks to secure tires;

- For long-term parking (over 1 hour), turn off the emergency power-off switch and check the battery status to avoid undercharging.

III. Core Safety Notes: Red Lines That Must Never Be Crossed

1. Safety Operation Red Lines (Violations Easily Cause Accidents)

- Prohibited to Carry Passengers: Never allow people to stand on forks or pallets, or use the forklift to tow people or other vehicles;

- Prohibited to Overload/Unbalance Loads: Exceeding the rated load or shifting the cargo center of gravity can easily cause rollovers. Use a forklift of the appropriate tonnage for heavy cargo;

- Prohibited to Sudden Operations: Sudden acceleration, braking, or steering are major causes of rollovers—especially when loaded, operate extra smoothly;

- Prohibited to Overstack Cargo: If cargo height blocks visibility, have a guide or use a side shifter—avoid blind operation;

- Prohibited to Work Under the Forklift: Never allow personnel to enter under forks or inside the mast while the equipment is running or parked. Disconnect power and support the mast with safety brackets before maintenance.

2. Equipment Protection Notes

- Avoid Collisions: Stay alert to surroundings—do not hit shelves, walls, or other equipment; do not strike cargo with forks (prevents deformation);

- Battery Usage Standards: Do not wait until the battery is fully discharged to charge (charge when remaining power is 20%-30%); do not mix chargers; keep the area ventilated during charging and do not cover the battery;

- Hydraulic System Protection: Do not step hard on lifting/tilting pedals (avoids sudden pressure increases in the hydraulic system); check hydraulic oil levels regularly;

- Prohibited to Wade in Water: Electrical components of electric forklifts are water-sensitive—avoid driving in flooded areas (water depth not exceeding 1/3 of tire height). Take protective measures when operating outdoors on rainy days.

3. Operation Notes for Special Scenarios

- Indoor/Confined Spaces: Maintain ventilation to avoid stale air from prolonged operation. For cold storage operations, pre-warm the equipment and use cold-resistant battery models;

- Narrow Aisles: Use mini electric forklifts, rely on steering assist functions, and arrange for a guide at the rear if necessary to avoid scraping shelves;

- Night/Dim Environments: Turn on headlights and warning lights to ensure sufficient lighting in the working area. Do not stack or load/unload cargo in poorly lit areas.

IV. Emergency Handling: What to Do to Minimize Losses

1. Sudden Equipment Failures (e.g., Failure to Start, Lifting Malfunction)

Stop operation immediately, disconnect power, and evacuate nearby personnel. If cargo is lifted, support the mast with safety brackets—never allow anyone to stay under the cargo. Contact maintenance personnel, describe the fault, and do not disassemble the equipment without authorization.

2. Battery Abnormalities (Heating, Swelling, Leakage)

Stop using the forklift immediately, turn off the emergency power-off switch, and stay away from the battery (avoids corrosion from electrolyte). Ventilate to dissipate heat—do not pour water or touch the leakage. Contact professionals for handling; do not replace or repair the battery yourself.

3. Rollover/Collision Accidents

Stay calm—do not jump off the vehicle (jumping may lead to being crushed). Grip the steering wheel tightly and lean your body in the opposite direction of the rollover to reduce impact. After the accident, disconnect power immediately, check for injuries, call for rescue, protect the scene, and report the incident.

4. Cargo Sliding

Stop the forklift immediately and evacuate nearby personnel. If the cargo has not fully fallen, lower the forks slowly to set the cargo down steadily. If the cargo has scattered, clean it up before resuming operation to avoid secondary accidents.

V. Summary: Safety Is the Premise of Efficiency; Compliance Is the Guarantee of Longevity

The core of electric forklift operation is "stability" and "strictness"—smooth operation prevents accidents, and strict adherence to standards protects equipment and personnel. For enterprises, regular operation training and implementing safety inspection systems can significantly reduce accident rates. For operators, remembering "no violations, no impatience, more observation" can improve operational efficiency and safeguard personal safety.

In fact, standardized operation is not only a safety requirement but also the key to extending equipment life and reducing operating costs. Every compliant operation is a practice of "efficient, low-carbon, and safe" logistics.