Guidelines for Safe Operation of Electric Forklifts (Latest Version in 2025)

1、 Core Security Standards

1.1 Personnel Qualification Requirements

Certified for employment: Must hold the "Special Equipment Operator Certificate (Forklift)" issued by the market supervision department, reviewed every 5 years, with training hours increased to 40 hours, covering theory, practical operation, and typical accident case analysis.

Health requirements: Operators must be free from diseases that hinder their work, such as color blindness, deafness, and heart disease, with a visual acuity of ≥ 1.0 and normal hearing.

1.2 Daily equipment inspection

Daily inspection: covering 12 key indicators such as braking system, steering system, light signal, fork/door frame, battery/fuel, etc. The inspection results are signed and confirmed by the driver and entered into the digital management platform.

Special inspection of electric forklifts:

The battery terminals are not oxidized, and the electrolyte level is within the specified range.

The cables, plugs, and sockets are intact, without damage, aging, or exposure.

The motor and controller operate without any abnormal noise or odor.

1.3 Operational Restrictions

Speed limit:

Indoor speed ≤ 5km/h, outdoor speed ≤ 10km/h, turning/intersection speed ≤ 3km/h.

Do not accelerate rapidly, brake abruptly, or slide in neutral.

Fork height: When driving, the fork should be 20-30cm off the ground, and when loading and unloading, it should be raised to 30-40cm. Overloading (≤ rated load) is strictly prohibited.

2、 Application of Technological Innovation

2.1 Intelligent collision avoidance system

UWB collision warning: Real time monitoring of the forklift's surrounding environment through base station deployment and positioning engine, 360 ° no dead angle warning, reminding drivers to take measures.

Lidar and camera: Combined with AI behavior recognition, it automatically detects obstacles and stops, effectively avoiding collision accidents.

2.2 Remote Monitoring and Management

Digital platform: Real time tracking of forklift position, speed, and equipment status, automatic generation of corrective work orders for abnormal situations, forming a closed-loop management.

Emergency Response Points System: Linking drill performance with performance evaluation to incentivize all staff to participate in improving safety capabilities.

2.3 Special protection for lithium batteries

Charging area configuration: specialized fire blankets, gas fire extinguishing systems, and specialized training on lithium battery fire disposal.

Thermal runaway warning: Real time monitoring of battery status through temperature sensors, automatic power-off and alarm in case of abnormalities.

3、 Environmental and Management Measures

3.1 Division of homework areas

Dedicated channel: Set up forklift dedicated channels and pedestrian channels, and reduce the risk of mixed traffic between people and vehicles through physical isolation or warning signs.

Warning signs: Set up clear speed limit signs, reflectors, and blind spot warning devices in the forklift operation area.

3.2 Maintenance Strategy

Repair process: Implement the three-step process of "pressure relief support warning" and use lifting straps and support devices that comply with national standards.

Hazard reporting: Encourage employees to upload equipment abnormalities in real-time through the "Hazard Shooting" activity, and the backend will automatically generate a rectification work order.

3.3 Institutional optimization

Closed loop management: Establish a "discovery reporting rectification feedback" mechanism to ensure timely handling of hidden dangers.

FaaS model: Reduce maintenance costs by leasing intelligent forklifts and obtain remote monitoring and preventive maintenance services provided by suppliers.

4、 Accident prevention cases

4.1 Typical Accident Analysis

Shenzhen Longgang "2.5" forklift maintenance accident: Due to illegal operation of the hydraulic system, the attachments fell, exposing safety loopholes in the maintenance process. The solution includes strict implementation of pressure relief, support, and warning steps, and equipped with professional maintenance equipment.

4.2 Successful Application Cases

Asia Pacific Senbo Paper Industry: Through UWB positioning system and collision warning device, real-time monitoring and blind spot warning of forklifts in the factory area are achieved, effectively reducing collision risks and improving operational safety.

5、 Emergency response process

5.1 Fire Emergency Response

Cut off power: Immediately turn off the forklift's power or engine.

Fire extinguishing measures: Use dry powder fire extinguishers to extinguish fires, and do not use water to extinguish battery fires.

5.2 Emergency rollover

Driver protection: Hold the steering wheel tightly, lean in the opposite direction, and do not jump off the vehicle.

On site handling: Set up warning signs, protect the site and report it.

5.3 Personnel Injury

Immediate shutdown: Cut off the power and call the emergency number.

On site protection: Maintain order on site and assist rescue personnel.

The main equipment produced by Hebei Makita: stage electric hoist, electric chian hoist, wire rope electric hoist，Hand chain hoist, lever hoist, pneumatic hoist and other lifting equipment