To Systematically Improve Forklift Stability

A closed-loop solution must be formulated from five core dimensions: design and selection, load operation, vehicle maintenance, site environment, and personnel management, covering risk prevention and control for both static and dynamic operating conditions. Below is a structured and actionable implementation guide.

I. Optimization of Model Selection and Basic Configuration (Source Control)

Matching the Right Model to Operating Conditions

The rated load and load center distance must match the actual operation requirements: select models based on the standard load center distance (commonly 500mm). For frequent handling of long/wide items or eccentric loads, prioritize models with long wheelbase, wide track width, and low center of gravity. Install side shifters or fork positioners when necessary to avoid load offset.

Special configurations for specific operating conditions:

• For low-temperature/slippery sites, use solid tires with anti-slip patterns and install anti-tip brackets;
• For narrow aisles, choose three-way stackers or reach trucks to avoid sharp turns;
• For heavy-load/high-lifting operations, give priority to counterbalance forklifts; strictly prohibit overloading operations with electric pallet trucks.

Reinforcement of core components:

Select models equipped with Electronic Stability Program (ESP), load-sensing steering, and control systems for speed limiting, height limiting, and tilt angle limiting. Install rollover alarms, load indicators, and overload protection devices.

Optimization of Basic Parameters

1. Wheelbase and track width: Under the same conditions, a longer wheelbase combined with a wider track width can significantly improve lateral and longitudinal stability.
2. Center of gravity control: Prioritize electric forklifts with rear-mounted or bottom-mounted batteries to lower the overall center of gravity of the vehicle.
3. Tire configuration: Tires on the same axle must have identical specifications, air pressure, and tread patterns to prevent stability degradation caused by uneven wear.

II. Standardized Load Operation Specifications (Core Execution Layer)

(1) Load Pre-treatment

• Verify the weight and dimensions of goods; strictly prohibit overloading, eccentric loading, and single-fork operation.
• Ensure goods are centrally placed on the forks; secure them with straps or pallets when necessary to prevent shaking during lifting or traveling.
• For overlong/overwide goods, calculate the offset of the load center distance, and reduce the lifting height and traveling speed accordingly.

(2) Standards for Key Operating Actions

Operating Action	Stability Operation Key Points	Risk Prevention and Control
Lifting/Lowering	Confirm that forks are fully inserted into the pallet before lifting; lift only to the height required for the operation; lower forks to 10-15cm above the ground when traveling; lower goods smoothly and slowly to avoid impact	Strictly prohibit sharp turns or acceleration when forks are lifted to a high position
Traveling/Steering	Keep forks slightly raised when unloaded; lower forks as much as possible when loaded; travel straight at a constant speed; strictly prohibit speeding, sudden acceleration, or sudden braking; reduce speed to below 5km/h when turning; strictly prohibit braking while steering	Halve the speed on slippery/sloped surfaces to avoid sideslip
Slope Operation	Drive forward with forks facing uphill when ascending; reverse with forks facing downhill when descending; strictly prohibit turning or parking on slopes with an incline exceeding 5%; strictly prohibit lifting/lowering heavy loads on slopes	Install Hill-Start Assist Control (HAC) system to prevent vehicle slipping
Stacking/Picking	Operate perpendicular to the shelves; strictly prohibit oblique forking; confirm shelf stability before lifting/lowering; strictly prohibit adjusting goods while forks are suspended	Install shelf anti-collision devices to prevent shelf collapse

(3) Additional Requirements for Special Operating Conditions

• Eccentric load/long-item handling: Calculate the load center distance based on the farthest end; limit the lifting height to no more than 1.5m and the traveling speed to ≤3km/h.
• Slippery/icy and snowy sites: Prohibit sudden braking and sharp turns; install anti-skid chains when necessary; prioritize the use of four-wheel-drive models.
• Explosion-proof areas: Select models that comply with explosion-proof standards; strictly prohibit modifications; avoid generating sparks during operation.

III. Full-Life Cycle Vehicle Maintenance (Support Layer)

Daily Inspection (Before Each Shift)

• Tires: Check for normal air pressure, no damage, and consistent specifications on the same axle.
• Brake system: Ensure brakes are responsive, free of drag, and the parking brake is effective.
• Steering system: Check for no looseness or jamming, and verify that the steering angle meets standards.
• Hydraulic system: Ensure no leakage, smooth lifting/lowering, and effective safety valves.
• Stability devices: Confirm that rollover alarms, anti-tip brackets, and load indicators are functioning properly.

Regular Maintenance (In Accordance with the Manufacturer's Manual)

• Monthly: Inspect suspension, frame, and forks for deformation or cracks; calibrate load indicators and rollover alarms.
• Quarterly: Replace hydraulic oil and filters; inspect the clearance and wear of the steering and brake systems.
• Annually: Conduct stability tests (such as static rollover test and dynamic braking test) to evaluate the overall vehicle stability.
• Fault handling: Immediately shut down and repair the forklift if abnormalities such as tire defects, brake failure, or steering jamming are detected; strictly prohibit operating the forklift with faults.

IV. Site and Environment Management (Auxiliary Layer)

Site Planning

• Aisle width: Design based on the forklift turning radius plus a safety margin to avoid sharp turns in narrow aisles.
• Ground conditions: Ensure the ground is flat, free of potholes, oil stains, water accumulation, or ice and snow, with a slope ≤5%; the ground in heavy-load areas must be hardened (e.g., using concrete with a grade of C30 or higher).
• Markings and signage: Install speed limit signs, turn warnings, slope signs, and no-parking zone markings; separate pedestrian and forklift aisles.

Environmental Control

• Lighting: Ensure the illumination in the operation area is ≥100lux to avoid blind spots.
• Weather conditions: Promptly clear the ground during rainy or snowy weather; suspend outdoor operations if necessary.
• Obstacles: Timely remove debris in the aisles; ensure shelves and equipment are firmly fixed.

V. Personnel Training and Management System (Long-Term Mechanism)

• Certified operation: All forklift operators must complete professional training and obtain a Special Equipment Operator Certificate; strictly prohibit uncertified operation.
• Specialized training: Regularly carry out stability operation training covering load calculation, slope operation, special condition operation, and emergency response (such as self-rescue methods in case of rollover).
• Assessment and supervision: Establish an operation assessment mechanism to regularly evaluate operators' stability operation skills; set up on-site supervision posts to correct illegal operations (such as speeding, overloading, and sudden braking).
• Emergency plans: Formulate emergency plans for forklift rollover, goods falling, and other accidents; organize regular drills to improve emergency response capabilities.

VI. Evaluation and Continuous Improvement of Stability Enhancement Effects

• Regular stability evaluation: Assess the effectiveness of stability enhancement measures through accident statistics, operation records, and equipment testing data.
• Continuous optimization: Adjust the model selection plan, operation specifications, maintenance schedule, and site planning based on the evaluation results to form a closed-loop management system.

Supplementary: Key Emergency Response Points (In Case of Rollover)

1. Never jump off the forklift; firmly grip the steering wheel with both hands and move your body in the opposite direction of the forklift's tilt to lower the center of gravity.
2. Apply brakes slowly to avoid sideslip.
3. If goods fall, immediately evacuate to a safe area and contact professional personnel for disposal.