When an operator detects abnormal fault signals of a running lithium-ion forklift, including abnormal power fluctuation, unexpected system alarm, unusual battery temperature rise or strange operating noise, the first priority is to keep calm and avoid misoperation caused by panic. The operator should slowly turn the operating handle to drive the forklift to a flat, open area with no passing personnel, no stacked flammable and explosive goods and no high shelves nearby, do not slam the steering mechanism suddenly to prevent the lifting forks from shaking and colliding with surrounding facilities.

Next, the operator should keep sitting in the standard operation position, step on the brake pedal stably and keep continuous braking force until the whole vehicle is completely stationary. Then pull up the hand brake, turn the operation gear to the neutral position, and confirm that the load on the lifting fork has been lowered to a safe height close to the ground. After completing the above steps, press the dedicated red physical emergency stop button on the operation panel to cut off the main power output of the whole vehicle immediately.

After triggering the emergency stop, the operator should check the fault code displayed on the battery management system screen first. If there is high-risk warning such as battery thermal anomaly or main circuit short circuit, evacuate to the safe area at least 5 meters away from the faulty forklift immediately, do not try to disassemble the battery pack or troubleshoot privately. Report the detailed fault situation to the on-site safety management personnel as soon as possible, including the fault occurrence time, abnormal performance of the vehicle, and whether there is smoke or open flame, wait for professional operation and maintenance personnel to carry out follow-up disposal.

Operators should never skip the parking brake setting step for efficiency, or reach out for the emergency stop button before the vehicle is completely stationary, which may cause physical imbalance and personal injury. Relevant enterprises should include the emergency stop procedure under fault conditions as the core content of regular safety training, to ensure every certified operator can master the full process proficiently, so as to reduce the hidden safety risks in daily material handling operations effectively.