Preparation before loading and unloading
Check the status of goods: Confirm that the packaging of the goods is intact, without looseness or damage; if they are scattered goods, they should be fixed into a whole with pallets, ropes, or stretch films first to prevent individual items from sliding off.
Choose appropriate pallets: Pallets should be intact (without cracks or deformation) and their load-bearing capacity should match the weight of the goods; goods should be evenly placed in the center of the pallet to avoid leaning to one side (center of gravity 偏移 is the main cause of tilting).
Adjust the forklift forks: Adjust the distance between the forks according to the width of the goods to ensure that the forks are symmetrically distributed on both sides of the center of gravity of the goods; the forks must be fully inserted into the bottom of the pallet, and inserted as deeply as possible (at least more than 2/3 of the length of the pallet) to avoid uneven force caused by only partial insertion.
Operations during loading and unloading
Lift and lower slowly: When lifting goods, first raise the forks to just leave the ground (about 10-15 cm), pause to check if the goods are stable; after confirming that there is no tilting, slowly raise to the required height to avoid shaking of the goods caused by rapid lifting.
Keep goods moving at a low position: During driving, the goods should be as close to the ground as possible (30-50 cm from the ground) to lower the center of gravity and reduce the shaking amplitude when turning or braking.
Avoid sudden operations: Turn, brake, and start smoothly and slowly, especially when carrying tall goods, sufficient turning space should be reserved to prevent the goods from tilting due to centrifugal force.
Reinforcement of special goods: For goods with ultra-high, ultra-wide, or irregular shapes (such as steel pipes, plates), additional chains, straps, or forklift attachments (such as clamps) should be used for fixation to ensure that the goods are tightly connected to the forks or pallets.
Precautions when stacking
Stack goods neatly: When stacking goods, the upper layer of goods should be aligned with the lower layer to avoid "protruding" (extending beyond the edge of the lower pallet), and the stacking height should not exceed the height of the forklift's overhead guard (or the line of sight) to prevent blocking the view or making the center of gravity too high.
Follow the principle of "heavy not pressing light, large not pressing small": Heavier goods should be placed on the lower layer, and lighter ones on the upper layer to avoid the upper goods being too heavy to crush the lower layer and cause tilting.
II. What are the serious consequences of forklift overloading?
The rated lifting capacity of a forklift is the safety upper limit determined according to parameters such as structural strength and stability during design. Overloading will break the original balance and cause a series of dangers:
Directly cause the forklift to tip over
Overloading will make the center of gravity of the forklift move forward (when the weight of the goods exceeds the designed load, the center of gravity exceeds the support point of the front axle). When turning, braking, or on uneven ground, it is very easy to tip forward; if the goods are overloaded to one side, it may also cause lateral tipping, resulting in casualties of operators and damage to goods.
Damage key components of the forklift
Overloading will seriously increase the load on the forks, mast, and hydraulic system: The forks may bend or break; the mast guide rails may deform, causing lifting jams; the hydraulic cylinders and pumps may leak oil or burst due to overpressure, leading to hydraulic system failures.
The tires bear excessive pressure, which may lead to blowouts or excessive wear, affecting driving stability.
Affect operational safety
Overloading will cause the forklift's braking distance to become longer (increased inertia), making it difficult to stop quickly when braking, increasing the risk of collision.
The steering system may get stuck or fail due to excessive load, making it impossible to control the direction flexibly, further expanding the scope of the accident.
Violate safety regulations and bear legal responsibilities
Overloading is an illegal operation. If an accident is caused, the enterprise shall bear economic costs such as equipment maintenance and goods loss, and the operator may be punished for "violating operation rules"; if it causes casualties, it may also involve criminal liability.
In summary, the core of ensuring the stability of goods is "controlling the center of gravity, operating smoothly, and reinforcing in advance", and eliminating overloading is the bottom line to avoid accidents. Operators must strictly follow the operating procedures, and enterprises should also strengthen training and supervision to reduce safety risks from the source.
