Load shift is one of the top hidden risks in daily electric forklift operation, which may lead to cargo damage, personnel injury and equipment overturn if not handled properly. A standardized, step-by-step training system can help operators master relevant skills effectively and avoid unnecessary safety accidents.

The first part of the training focuses on basic theoretical knowledge input. In this session, trainers need to explain the core causes of load shift clearly, including excessive speed during turning, uncentered load placement on forks, improper mast tilt angle during travel, sudden braking on uneven road surfaces and incorrect operation on slopes. Trainers should also clarify the weight limit and load center range of the applicable electric forklift model, help operators form the awareness of checking load stability before each operation, and eliminate wrong cognition that heavy load is bound to stay stable during movement.

The second part is scenario-based risk identification training. Set up simulated operation scenarios that restore real daily warehouse conditions, place unbalanced stacked cargos, potholes on aisles, temporary obstacles on driving paths and other hidden points, guide trainees to find out all possible factors that may trigger load shift before starting the machine, and work out corresponding adjustment plans. This part of training helps operators transfer the awareness of risk pre-control to actual operation habits, rather than only memorizing rules on paper.

The third part is standard operation practical drill. Trainers demonstrate the correct operation specifications that prevent load shift, including keeping travel speed under the safe limit when turning, keeping the mast tilted back properly with load at low height when moving on flat ground, moving up and down slopes slowly without turning the steering wheel, adjusting the mast tilt slowly when picking up or placing loads. Trainees need to repeat the drill for a certain period under the supervision of trainers until they can complete all actions correctly without prompting.

The fourth part is emergency response drill. Teach trainees the correct handling steps when they notice slight load shift during operation: release the accelerator slowly, do not slam the brake or turn the steering wheel sharply, move the forklift to a flat open area steadily, and lower the load to the ground slowly to adjust the placement state, instead of trying to save the unbalanced load by risky operation which may cause bigger danger.

Regular refresh training and on-site assessment every 3 months can consolidate relevant skills, correct bad operation habits in time, and ensure long-term stable safe operation of electric forklifts.