Mục lục
- 1. Inspecting the forklift before operation
- 2. Operating a stand-up electric forklift
- 3. Operating a sit-down electric forklift
- 4. Safe load handling rules
- 5. Key points for driving inside the warehouse
- 6. Parking and ending the shift
- Battery protection: the 80/20 charging rule
- Optimal speed by floor surface
- Eco mode vs Power mode: when to use each
- Related articles
- Frequently asked questions about operating electric forklifts
- Contact ICD for Xilin electric forklifts and operator training
Operating an electric forklift safely follows a fixed sequence: run a pre-shift inspection, master the controls for your truck type (stand-up or sit-down), keep loads tucked tight against the mast and travel low, and end the shift with correct parking and a battery check. Skipping the start-of-shift inspection accounts for around 30 percent of warehouse forklift incidents, so this guide covers each stage step by step.
1. Inspecting the forklift before operation
Spending five minutes on a full check before each shift lets you take control of the machine and catch faults early. Start with a walk-around of the truck. Inspect the tyres for cracks, splits, or embedded debris. The lift chains should be properly greased and never slack. Look under the chassis for any sign of hydraulic oil leakage, since the hydraulic system is the lifeline for all lifting and lowering.
For the electrical system, make sure the battery connector is firmly seated with no signs of scorching. Check the display to confirm the battery is fully charged for a new shift. Test the warning devices - horn, flashing beacon, and rear-view mirrors - so you can interact safely with the surrounding environment. Finally, clean the cab and remove any objects that could jam the accelerator or brake pedal.
| Inspection area | What to check | Fault sign |
|---|---|---|
| Tyres | Cracks, splits, embedded debris | Wear, foreign objects |
| Lift chains | Grease, tension | Slack or dry chain |
| Hydraulics | Under-chassis leakage | Oil pooling |
| Battery | Connector seating, charge level | Scorching, low charge |
| Warning devices | Horn, beacon, mirrors | No sound or light |
2. Operating a stand-up electric forklift
Stand-up electric forklifts are used in narrow-aisle warehouses thanks to their tight manoeuvrability.
Starting and the safety pedal
After turning the key, stand squarely inside the cab. The most important difference is the safety pedal under your left foot. If you do not press this pedal, the control systems are fully cut off. This is a protective mechanism that keeps the operator in a safe position whenever the truck is moving.
Travelling and steering
Use the joystick to move: push it gently forward to advance and pull it back to reverse, with speed set by how far the joystick is tilted. A key note for new operators is that the steering wheel of a stand-up truck sits at the rear, so when you turn the steer, the tail swings out the opposite way. Always watch the clearance around you to avoid clipping the tail against racking.
Lifting and lowering are built into the joystick or the side levers. When picking from high racking, use the reach function to bring the forks accurately into the pallet, then retract the mast tight against the truck body before travelling to keep the centre of gravity stable.
3. Operating a sit-down electric forklift
Sit-down trucks give the operator comfort over long shifts and handle larger lifting capacities.
Seat, seatbelt and start-up
Adjust the seat so your feet reach the brake and accelerator comfortably, and always fasten the seatbelt. Before turning the key, make sure the gear selector is in neutral and the parking brake is applied.
Steering feel
Driving a sit-down truck is similar to an automatic car: steer with the wheel and accelerate with the right pedal. The steering is very responsive, though, and a small wheel movement can change direction quickly. Get used to this feel at low speed before working at pace.
The three hydraulic levers
| Lever | Function | Operating note |
|---|---|---|
| Lever 1 (Lift) | Raises or lowers the forks | Lower fully before leaving the truck |
| Lever 2 (Tilt) | Tilts the mast | Tilt back when carrying so the load does not slide forward |
| Lever 3 (Side-shift) | Shifts the forks left or right | Align without reversing to re-position |
4. Safe load handling rules
Preventing a tip-over is the number-one priority when working with an electric forklift. The truck’s centre of gravity shifts constantly with the height and weight of the load.
Always place the load tight against the backrest so the load centre sits as close as possible to the truck’s centre of gravity. Never lift with the fork tips, as this unbalances the truck and can bend the forks. Every truck has a load capacity plate; read it carefully and never lift above the rated limit.
When travelling with a load, lower it to about 15 to 20 cm above the floor and tilt the mast back. If the load is so high it blocks your forward view, the mandatory rule is to travel in reverse so you can see the path ahead and keep people around you safe.
5. Key points for driving inside the warehouse
Warehouse aisles are busy and space is limited, so speed is the factor to control. Always slow down at corners and through doorways. The forklift horn is an important means of communication - sound it before entering blind corners or intersections to warn others.
On a ramp there is a life-saving rule: always keep the load facing uphill. That means you drive forward going up and reverse going down. This stops the load from tumbling down and keeps the truck from tipping forward. Never attempt to turn around while the truck is on a slope.
6. Parking and ending the shift
Ending a shift correctly protects the equipment and readies it for the next operator. Park on level ground, away from shared walkways and fire-fighting equipment. Before leaving the cab, lower the forks flat to the floor so no one trips over them. Apply the parking brake firmly, return the gear selector to neutral, and switch off the key completely. Finally, check the battery level: if it is below 30 percent, take the truck to the charging station right away to protect battery life.
Battery protection: the 80/20 charging rule
Many guides simply say “charge it fully before unplugging” - wrong for lead-acid and only true for lithium. The correct rule depends on battery type.
| Battery type | Charging rule | Why |
|---|---|---|
| Lead-acid | Charge only at 20-30 percent, fill to 100 percent, rest at least 2 hours before use | Frequent shallow charges (above 50 percent) age the battery within 6-12 months |
| Lithium LFP | No need to fill - 20-80 percent is the optimal band; short top-ups each break beat one end-of-shift charge | Partial cycling extends LFP life |
| Both types | Avoid deep discharge below 10 percent | An alarm at 20 percent means return to charge immediately |
Optimal speed by floor surface
| Surface | Optimal speed (km/h) | Reason |
|---|---|---|
| New epoxy floor (clean, high grip) | 5-7 | Safe, no slipping |
| Old cement floor (worn, dusty) | 3-5 | Dust reduces grip, braking is less sharp |
| Wet epoxy floor | 2-3 | Friction drops 70 percent; the truck can slide 2 m when braking at 5 km/h |
| Cement floor with oil leak | 1-2 or STOP | More slippery than wet; clean it immediately |
| Industrial rubber floor | 4-6 | Good grip but wears PU wheels faster |
Eco mode vs Power mode: when to use each
- Eco mode (reduced speed and 30 percent lower acceleration): use for long unloaded travel over 50 m, or loads under 30 percent of capacity. Saves 20-25 percent battery.
- Power mode: use for heavy loads above 70 percent of capacity or ramps steeper than 2 degrees. Battery drain is 1.4 times Eco, but the truck does not bog down under heavy load.
- Common mistake: leaving Power mode on all shift cuts battery life by 25 percent. Set Eco as the default and switch to Power only when needed.
Related articles
| ICD EPT20 Electric Pallet Truck (Xilin) | Xilin electric forklifts at ICD Viet Nam |
Frequently asked questions about operating electric forklifts
1. How often should an electric forklift be serviced?
Monthly: check hydraulic oil and grease the wheel axles. Every 3 months: change the oil and inspect the seals. Every 6 months: a full inspection. ICD provides free checks during the 2-year warranty period.
2. Do operators need a licence to drive a forklift?
Hand pallet trucks need no licence. Counterbalance electric forklifts (sit-down) over 1 tonne require an operating certificate under Vietnam’s Circular 36/2019/TT-BLDTBXH.
3. Why must I keep the load facing uphill on a ramp?
Driving forward up the slope and reversing down keeps the load centre on the high side. This stops the load tumbling down and prevents the truck tipping forward. Never turn around while on a slope.
4. What is the safe travel height for a load?
Lower the load to about 15 to 20 cm above the floor and tilt the mast back when travelling. If the load blocks your forward view, travel in reverse so you can see the path ahead.
5. When should I recharge the battery?
For lead-acid, charge at 20-30 percent and fill to 100 percent. For lithium LFP, keep within 20-80 percent with short top-ups. For both, never discharge below 10 percent; an alarm at 20 percent means charge now.
6. What does ICD Viet Nam offer with its forklifts?
ICD is the exclusive distributor of Xilin (Ningbo Ruyi) forklifts in Vietnam, with a 2-year manufacturer warranty, on-site operator training, periodic maintenance, and technical support.
Contact ICD for Xilin electric forklifts and operator training
ICD Viet Nam Industrial Production Company Limited
North: Floor 3, Thang Long A1 Building, Bau Hamlet, Thien Loc Commune, Hanoi - 0983 797 186 / 090 345 9186 / 090 5859 186
Email: sales@icdvietnam.com.vn · Zalo: Chat on Zalo now
ICD supplies genuine Xilin electric forklifts with a 2-year warranty, trains your team on-site, and keeps your fleet running with periodic maintenance. Contact us for the right truck for your operation.
