Cases of forklift accidents and Prevention checklist

Forklifts as special-purpose motor vehiclesfor use within premises, are widely applied in logistics and productionprocesses. However, their operational safety issues have recently drawnsignificant public attention. On December 4, 2025, the State Administration forMarket Regulation released six typical cases of forklift accidents, all ofwhich were caused by unlicensed driving, improper operation, and inadequateimplementation of safety responsibilities by enterprises, highlighting theurgency of special equipment safety management.

On April 2024 in Laibin City, Guangxi, anoperator stood on the equipment being lifted in violation of regulations. Thedriver, despite knowing the danger, still operated the forklift in violation ofrules, resulting in the operator's fall and death. The enterprise had itsoperation certificate revoked and was fined. On July 1, 2025, in Foshan City,Guangdong Province, Zhang Mofa, a workshop supervisor, drove a forklift withouta license and blindly drove in a situation with obstructed vision, causing thedeath of another employee. On July 23, 2025, in a ship repair company inZhoushan City, Zhejiang Province, Su Mofu, an unlicensed driver, drove theforklift at excessive speed and failed to observe carefully, hitting andrunning over an employee, causing death. The investigation revealed that thedriver's unlicensed and improper operation was the main cause, and the relevantenterprise was held accountable. In these cases, issues such as unlicenseddriving, speeding, obstructed vision, and failure to wear seat belts wererepeatedly observed, and the involved enterprises were all fined, with thedirectly responsible personnel suspected of criminal offenses and transferredto judicial authorities.

Most forklift accidents result from typicalviolations. For instance, using the body as a counterweight to maintainbalance, speeding which can cause overturning, illegal high-altitudeoperations, drivers not wearing seat belts, and goods blocking the driver'sview. To prevent risks, forklift operations must strictly adhere to the"five musts": operations must be halted when personnel in the workarea do not maintain a safe distance; at intersections, forklifts must slowdown, sound the horn, and confirm the road conditions; when parking and leavingthe vehicle, the engine must be turned off, the key removed, and the handbrakeengaged; daily inspections must be conducted before operations; and operationsmust be stopped and reported immediately upon discovering any abnormalities.

Although forklift technology is advancingtowards intelligence and electrification, such as Clark Forklift expanding itsmarket in Poland, Anhui Heli promoting intelligent manufacturing of hydrauliccomponents, and Hangcha Group entering the Japanese market for new energyforklifts, safety remains the foundation of the industry. Recent accidentsindicate that technological upgrades must be accompanied by safety management.Enterprises should enhance personnel training and on-site supervision, andeliminate high-risk behaviors such as unlicensed operation.

Forklift operations must strictly adhere tosafety regulations. The following checklist integrates key operational points,inspection items, and management measures to help quickly identify andeliminate potential hazards, ensuring safe and efficient operations.

• Vehicle Condition: Check for cracks,deformations, or damages on the vehicle body, ensure the forks are not bent orworn, and verify that the tire pressure is normal and there are no bulges orcracks.

• Safety Devices: Verify that the brakingsystem, horn, lights, reversing alarm, and emergency power-off switch arefunctioning properly. Ensure that the seat belt and guardrails are secure andusable.

• Environmental Assessment: Confirm thatthe operation area has a flat ground free of oil or water, unobstructedpassageways, and clear visibility at ramps and intersections.

• Test Run: After starting, check thatthere are no fault lights on the dashboard, test the braking, steering, andlifting actions for smoothness, and ensure that the alarm and lighting systemsare functioning properly.

• Observe Speed Limits: Maintain a speed of5-10 km/h within the factory, avoid sharp turns to prevent rollovers, and slowdown and honk when turning.

• Vision Management: Keep the forks beloweye level, turn around to observe or use the rearview mirror when reversing; ifthe load blocks the view, assign a guide.

• Safe Distance: Maintain a brakingdistance of three times the vehicle length from other equipment or personnel.Drive uphill forward and downhill in reverse on ramps.

• Prohibit Violations: Do not overload,carry passengers, use the body as a counterweight, or perform high-altitudeoperations. Avoid unstable or overly wide loads that could cause imbalance.

• Personal Protection: Always wear a seatbelt to prevent ejection in case of a collision; wear reflective clothing whenworking at night or in low-light conditions.

• Parking Standards: Turn off the engine,remove the key, apply the handbrake, and lower the forks to the ground.

• Abnormal Handling: If equipmentmalfunctions or environmental risks are identified, stop operations immediatelyand report them, following the "stop, call, wait" principle.

• Certified Operators: Operators mustundergo professional training and hold certificates, and receive regularrefresher training to enhance defensive driving skills.

• Physical Isolation: Designate dedicatedforklift lanes and pedestrian areas, and install anti-collision barriers andreflective signs.

• Technological Upgrades: Install warninglights, speed limiters, and blind spot detection systems, such asmillimeter-wave radars or panoramic monitoring screens.

• Regular Maintenance: Inspect thehydraulic system, brakes, and steering components monthly, record faults, andrepair them promptly.

• Accident Prevention: Stop operationsimmediately if personnel are not maintaining a safe distance, and follow the"stop-observe-horn" procedure at intersections.

• Reporting Mechanism: Establish anintelligent monitoring system to provide real-time alerts for violations,ensuring rapid response.

This checklist encompasses the criticalaspects of daily operations. Through the integration of human, physical, andtechnological safeguards, it can significantly reduce the risk of accidents.