Crowded operation scenarios including peak-hour warehouse aisles, retail back-of-house sorting areas and cargo loading bays with mixed pedestrian and vehicle flows often bring hidden safety risks for electric pallet truck operators. Unlike open operating zones, these areas have limited moving space, stacked goods that easily block sightlines, and frequent unplanned pedestrian movements, so operators need to follow targeted standardized procedures to ensure safe and efficient operation.

Before entering any identified crowded zone, operators shall complete a targeted pre-check process apart from the regular daily vehicle inspection. First, confirm that the acoustic warning buzzer and strobe light on the body work normally, and the braking system shows sensitive and stable response under no-load condition. Then check the loaded goods to make sure all cargo is placed evenly on the pallet, no part of the load extends beyond the edge of the pallet to block the forward sight of the operator. Operators shall also confirm the temporary traffic rule of the target crowded zone in advance, mark out alternative routes if the main passage is temporarily blocked by stacked goods, and send operation notifications to nearby on-site staff via the site’s internal communication system before entering.

During the whole operation process in the crowded zone, operators shall keep the traveling speed below 3km/h, which is half of normal walking speed, to reserve enough reaction time for unexpected emergencies. Keep the operation handle at the normal low position, never lift the forks higher than 30cm above the ground to avoid hitting nearby staff or stacked goods. When passing through sight blind spots formed by high stacked cargo or shelves, operators shall trigger the acoustic warning signal actively, and if the sight blocking situation is serious, get off the vehicle briefly to confirm no pedestrian is staying in the moving path before proceeding. Once a pedestrian appears within 2 meters of the moving path, operators shall stop the vehicle completely immediately, wait until the pedestrian fully leaves the operation area and confirms that they notice the vehicle, then restart the operation slowly. It is strictly forbidden to carry any irrelevant person on the pallet or the vehicle body at any time.

Operators shall receive regular targeted training for crowded zone operation, summarize encountered hidden risk points during each shift handover, and adjust operation habits according to the actual site situation. If unexpected collision risks occur, operators shall press the emergency stop button directly instead of turning the steering wheel sharply to avoid cargo tipping and secondary risks. Following these guidance rules can effectively reduce unnecessary safety accidents, and build a more orderly and safe working environment for all on-site staff.