Improper forklift operation poses constant risks! Please keep this safety regulation handy.
Forklifts are invaluable tools for improving cargo handling efficiency in factories, workshops, and logistics warehouses. However, improper operation can turn them into hidden killers endangering personal safety and property. To protect everyone's safety, today we'll combine professional regulations to guide you through the key points of safe forklift operation, preventing workplace injuries from the outset!
01. Pass the test before starting work; proper protection is essential. Forklifts are special equipment; simply knowing how to drive one doesn't mean you can operate it. Pre-job preparation is the first line of defense for safety:
1. Qualifications are mandatory: You must pass forklift safety operation training, obtain a special equipment operator certificate, and be familiar with forklift performance, the work area environment, and emergency response procedures. Operating without a certificate is like gambling with your safety.
2. Protective equipment is indispensable: Before starting work, you must wear appropriate personal protective equipment-non-slip safety shoes (for impact and puncture protection), tight-fitting work clothes without ribbons (to avoid being caught in machinery), and a safety helmet must be worn at all times when entering specific areas such as warehouses and workshops.
3. Maintain a focused mindset: Operating the forklift after drinking alcohol, while fatigued (e.g., working continuously for more than 4 hours without rest), or after taking sedatives is strictly prohibited. Work must also be suspended when experiencing significant emotional fluctuations, as even a second of distraction can lead to an accident.
02. Pre-start "Check-up": Early Elimination of Potential Hazards
Pre-start checks of the forklift are as important as the pre-driving inspection of a vehicle. They can prevent more than half of the mechanical failure risks. Specifically, these three steps should be taken:
1. Check the working environment:
Check the ground: Is it flat and firm? Are there any oil stains, standing water (which can be slippery), or obstacles (such as scattered parts or cables)?
Check the passageway: Is the width sufficient for the forklift to pass? Is the lighting adequate? Are pedestrians within the working area (a safe distance must be maintained)?
Check the goods: Understand the weight, dimensions, and center of gravity of the goods in advance to confirm that they meet the forklift's load-bearing requirements and avoid overloading or center of gravity shift.
2. Perform a thorough inspection around the vehicle (don't miss any key items):
Exterior Structure: Check the body, forklift, and overhead guards for deformation and cracks;
Tires and Wheels: Check tire pressure, wear, foreign objects embedded, and tighten nuts;
Fluids: Check fuel, engine oil, hydraulic fluid, coolant, and brake fluid levels; check for leaks;
Safety Devices: Check seat belts for integrity (buckles should lock securely), and lights (headlights, turn signals), reversing buzzer, and horn for proper function;
Control Components: Check the levers (lifting, tilting) for smooth operation, brake and clutch pedal travel for normal range, and handbrake for effective engagement.
3. Final Start-up Test:
Before starting: Ensure the levers are in neutral and the handbrake is engaged. Gently press the accelerator (if there's a preheating function, preheat first), starting for no more than 3 seconds (to avoid damaging the motor).
Idle Observation: Let the engine idle for 3-5 minutes, listen for abnormal noises, check the instrument panel (oil pressure, coolant temperature, voltage) for normal readings, and check for black/blue smoke from the exhaust (abnormalities may indicate engine malfunction). Functional Testing: Slowly raise and lower the forks and tilt the mast forward and backward to check the stability of the hydraulic system; lightly apply the brakes and turn the steering wheel to confirm the flexibility of braking and steering; test the smoothness of gear shifting by moving forward/backward at low speed.
03 During Operation: "Follow the Rules," Details Ensure Safety
Every operational detail during forklift operation and loading/unloading is related to safety. These "red lines" must never be crossed:
1. Starting & Driving: Stability First
1. Before starting: Observe the surrounding blind spots (especially behind and under the forks), sound the horn if necessary, and release the handbrake only after confirming safety. Accelerate slowly (sudden starts can easily cause the goods to sway).
2. While driving: Prioritize visibility: When moving tall goods that obstruct the view, you must reverse or have someone guide you. Never proceed "by feel."
Strict speed control: The speed limit within the factory area is generally no more than 5 km/h. Slow down (≤3 km/h) when turning, at entrances/exits, in densely populated areas, and on wet/slippery surfaces. Speeding to "rush time" is strictly prohibited.
Fork Height: When driving, the forks should be 150-200mm off the ground (slightly lower than the drive axle), with the mast tilted back appropriately to prevent cargo from slipping; driving with the forks raised is prohibited (prone to tipping over).
Passing and Avoiding Oncoming Vehicles: Drive on the right, maintaining a safe distance of ≥1 meter from pedestrians and other vehicles, and actively yield to pedestrians; at intersections and corners, "slow down, look around, and honk the horn" to avoid blind spot collisions.
2. Uphill and Downhill: Remember "No Violations"
Uphill: Drive forward; turning or parking on slopes is strictly prohibited (prone to rolling backward).
Downhill: Reverse (especially when carrying cargo), use engine braking, and lightly apply the foot brake to control speed; coasting in neutral is absolutely prohibited (leading to loss of control).
Steep Slope Prohibitions: Avoid operating on slopes >10%; lateral driving is strictly prohibited (prone to tipping over); if necessary, place wheel chocks under the wheels to prevent slipping.
3. Loading & Unloading & Stacking: Precise Operation
1. Picking Up Goods: Park the forklift directly in front of the goods, adjust the fork width to ensure it is fully inserted into the pallet slots (fork tips should not extend beyond the pallet).
After confirming the goods' center of gravity is stable, tilt the mast back and slowly raise the goods to 150-200mm off the ground, then sound the horn and reverse away.
It is strictly forbidden to use a single fork to pick up goods or fork tips to insert into the goods (this can easily damage the goods or cause fork deformation).
2. Stacking Goods: Slowly align the forklift with the storage location, raise the forks to slightly above the rack height, and smoothly move the forklift into the storage location.
Slowly tilt the mast forward, and after confirming the goods are in contact with the rack, slowly lower the forks, make minor adjustments to the position to ensure the goods are stable, then reverse out.
It is strictly forbidden to stack goods beyond the rack's capacity or to exceed its weight limit, and to avoid collisions with light fixtures and fire sprinkler heads.
4 Absolutely Prohibited Behaviors (Even a Touch Indicates Risk)
Overloading or uneven loading;
Carrying personnel on the forklift (forklifts are not "mobility vehicles"; it is strictly forbidden to allow colleagues to stand on the forks or ride on the vehicle);
Extending body parts outside the cab (e.g., hands or feet, which can easily be scratched by obstacles);
Standing under the forks or walking under raised forks;
Using the forks to bump, push, or pull goods or vehicles (which can easily cause goods to tip over);
Leaving the forklift while the engine is running (even leaving for just 1 minute could lead to accidental operation by others).
04 "Follow the Rules" During Operation, Details Ensure Safety
After operation, proper parking and inspection lay the foundation for safe operation next time:
1. Choose the right parking spot: Park in a designated flat and sturdy area, away from fire-fighting facilities, access roads, charging areas, and heat sources, and without obstructing traffic or emergency evacuation.
2. Standard Parking Procedure: Lower the forks fully to the lowest position and adjust the mast to vertical or slightly forward tilt; Place the control lever in neutral, release the throttle, and let the engine idle for 1-2 minutes (essential after heavy load operation to protect the engine); Turn off the engine, remove the key, and engage the handbrake; If parking on a slope, wedges must be placed under the wheels to secure the forklift (to prevent it from rolling).
3. Pre-Departure Inspection: Check the forklift for oil, water, and air leaks; Clean the forks, mast, and radiator (to prevent debris buildup from affecting heat dissipation); Fill out the operation log. If any abnormal noises or malfunctions are found, report them to the maintenance department immediately. "Using a forklift with defects" is strictly prohibited.
05 Emergency Situation: Remain Calm and Minimize Injury
In case of an accident, proper handling can reduce the severity of injury. Remember these points:
1. Accident Handling: Stop the forklift immediately, protect the scene, and report to the supervisor and safety department as soon as possible. Rescue the injured while ensuring your own safety (to avoid secondary injury). 2. Cargo tipping: Quickly move away from the danger zone. Do not attempt to right the cargo (you may be injured by falling objects). Wait for professional personnel to handle the situation.
3. Forklift out of control: Remain calm and prioritize applying the brakes. If braking is impossible, try to crash into unoccupied obstacles (such as sandbags or tire walls) to minimize injury.
4. Fire response: Small fire in the engine compartment: Use the vehicle's fire extinguisher (aiming at the base of the fire). Larger fire or fuel leak: Evacuate immediately, turn off the engine (if possible), notify personnel to evacuate, and call the fire department.
5. Fuel leak: Immediately turn off the engine. Do not start the forklift. Use absorbent pads to soak up the leaked fuel (to prevent it from flowing into the sewers). Smoking and open flames are strictly prohibited. Report to the maintenance department.
Every step of forklift operation is linked to personal safety and factory order. Rather than remedying after an accident, prevention is worse than cure. By keeping procedures in mind, operating in a standardized manner, and conducting regular inspections, we can transform "I have to be safe" into "I want to be safe and I know how to be safe," so that forklifts can truly become "good helpers" for efficient operations, rather than "triggers" for workplace injuries.
