Mastering the correct operation method of electric forklifts is crucial for ensuring operational safety and improving efficiency. It is necessary to strictly follow the process of "Pre-operation Inspection → Startup and Operation → Post-operation Shutdown and Maintenance". The specific steps are as follows:
Before operation, a comprehensive inspection of the forklift's condition must be conducted to ensure there are no safety hazards before starting. The inspection items are as follows:
Appearance and Structure Inspection
- Check if the forklift body is deformed or dented, if the forks are bent or cracked, and if the fork tips are excessively worn (if wear affects load-bearing capacity, replace them promptly).
- Inspect the tire pressure (for pneumatic tires) to ensure it is normal; check if there are foreign objects stuck on or damage to the tire surface; verify that the connecting components of the steering wheels and drive wheels are secure.
- Confirm that the mast (lifting structure) is not deformed, the chains are not loose or broken, and the hydraulic hoses have no leaks (if oil stains are found, check if the joints are loose or the hoses are damaged).
Power System Inspection
- Check the battery level: Determine the level through the battery indicator on the instrument panel. If the power is below 20% (some models have a "low battery alarm threshold"), charge the battery first to avoid sudden power failure during operation.
- Inspect the battery connections: Ensure the positive and negative terminals are not loose or corroded, and the battery case has no bulges (for lead-acid batteries, also check the electrolyte level; if it is below the standard line, add distilled water; this step is not required for lithium-ion batteries).
- Test the lights and warning devices: Turn on the headlights, turn signals, and reverse lights, and press the horn to confirm they all work properly (the reverse warning sound is particularly critical for preventing collisions with personnel).
Control and Brake Inspection
- Sit in the driver's seat, test if the steering wheel turns flexibly without jamming or deviation; operate the lifting levers (for lifting, lowering, tilting forward, and tilting backward) to ensure the mast moves smoothly without delay or abnormal noise.
- Test the braking performance: In an unloaded state, drive slowly (at approximately 5 km/h), press the brake pedal, and confirm the forklift can stop smoothly without "rolling"; simultaneously check the parking brake (handbrake) – the forklift should remain stationary after the handbrake is pulled.
II. Startup and Basic Operation (Follow the Principle of "Low Speed, Stability, and Observation")
Pre-startup Preparation
- Adjust the driver's seat position: Ensure both feet can naturally press the pedals, arms are slightly bent when holding the steering wheel, and the field of vision is clear (use the seat's forward/backward and height adjustment functions to suit your height).
- Fasten the seatbelt: Regardless of whether the operating area is spacious, fasten the seatbelt to prevent injury to the operator in case of sudden braking or rollover.
- Confirm the gear and lever status: Set the direction gear (forward/reverse) to "Neutral (N)", place the lifting lever in the "Neutral position", and pull the parking brake to prevent the forklift from moving suddenly when starting.
Startup Operation
- Insert the key (or press the start button; some electric forklifts feature keyless startup), turn it clockwise (or press and hold the button), and wait for the instrument panel to light up. After confirming there are no fault warning lights (such as battery fault or hydraulic fault lights), release the parking brake.
- Shift to the required gear (Forward "F" or Reverse "R"), slowly press the accelerator pedal (electric forklifts have linear acceleration, so avoid sudden heavy pressing to prevent jolting). At the same time, observe the surrounding environment and start moving only after confirming there are no personnel or obstacles.
Core Function Operation (Lifting, Handling, Steering)
| Operational Function | Specific Steps | Safety Precautions |
|---|
| Load Lifting | 1. Drive the forklift directly in front of the load, adjust the distance between the forks (align with the load's center of gravity to avoid unbalanced loading);2. Operate the "lowering lever" to lower the forks to 5-10 cm below the bottom of the load;3. Move forward slowly to fully insert the forks into the bottom of the load (insert at least 2/3 of the fork length);4. Operate the "lifting lever" to raise the load to 10-15 cm above the ground (to avoid scraping the ground). | 1. Overloading is prohibited (the rated load capacity is marked on the side of the forklift; do not exceed it);2. Personnel are prohibited from standing under or around the forks during lifting. |
| Load Handling | 1. After the load is lifted, operate the "mast tilt-back lever" (tilt the mast backward by 5-10°) to prevent the load from sliding off;2. Drive slowly and reduce speed when turning (speed not exceeding 3 km/h) to avoid load deviation caused by centrifugal force;3. When encountering a slope (≤5°), drive forward when going uphill and backward when going downhill; diagonal driving is prohibited. | 1. During handling, the load height should not exceed the operator's line of sight (to avoid blocking the view);2. Sudden acceleration and sudden braking are prohibited to prevent the load from shaking. |
| Load Unloading | 1. Drive to the unloading location (such as a shelf or pallet area), adjust the position to align the load with the placement point;2. Operate the "mast tilt-forward lever" (to restore the mast to a vertical position), slowly operate the "lowering lever" to place the load stably;3. After confirming the load is stable, drive the forklift backward slowly to disengage the forks from the load;4. Operate the "lowering lever" to lower the forks to the lowest position. | 1. When unloading to high shelves, confirm the shelf's load-bearing capacity; overloaded placement is prohibited;2. Avoid scraping the load when the forks disengage from it. |
| Steering and Avoidance | 1. Steer when driving at low speed, and match the steering wheel rotation range with the speed (the higher the speed, the smaller the steering range);2. Look back (or use the rearview mirror) when reversing, and press the reverse horn for warning if necessary;3. When encountering personnel, reduce speed in advance and sound the horn, and proceed only after confirming the personnel have moved out of the way. | 1. When driving in narrow passages (such as warehouse aisles), confirm the passage width (at least 30 cm wider than the forklift);2. Overtaking or driving side by side at turns is prohibited. |
- Drive the forklift to the designated parking area (flat, free of obstacles, and far from fire sources and water sources), lower the forks to the lowest position (close to the ground), and restore the mast to a vertical state.
- Shift to "Neutral (N)", pull the parking brake, turn off the power (turn the key counterclockwise to "OFF" or press the shutdown button), and pull out the key (if applicable).
- Check if there are residual loads or stains on the forklift body; clean them if present; organize the area around the driver's seat to ensure no debris is left.
- If the battery level is below 20%, connect the charger for charging in a timely manner (lead-acid batteries must be fully charged before disconnecting to avoid "undercharging"; lithium-ion batteries can be charged at any time but over-discharging should be avoided).
- Record the forklift's usage status: such as operation duration and whether there are abnormalities (e.g., abnormal noise, slow braking). If faults are found, report them for repair promptly; using the forklift "with faults" is prohibited.
- Regularly (e.g., weekly) check the hydraulic oil level and chain lubrication. If the hydraulic oil is insufficient, replenish it (use the specified type of hydraulic oil); if the chains are dry, apply special lubricating oil.
- Operating under the influence of alcohol or when fatigued is prohibited; using mobile phones or being distracted during operation is strictly forbidden.
- Personnel are prohibited from standing on the forks, sitting on the mast, or being transported by the forklift.
- Adjusting the fork height or tilting the mast while the forklift is moving is prohibited.
- Using non-explosion-proof electric forklifts in flammable and explosive areas (such as gas stations and dangerous goods warehouses) is prohibited.
- Overloading and unbalanced loading are prohibited (load center of gravity deviation can cause the forklift to roll over, which is a common cause of accidents).
By following the above steps, the safe and efficient use of
electric forklifts can be ensured, and the service life of the equipment can be prolonged. New operators can only operate independently after receiving professional training and passing the assessment.
