Electric forklifts are widely applied in warehouses, manufacturing workshops and logistics distribution sites for their zero-emission, low-noise and easy-operation features. Unstandardized daily operations will not only shorten the service life of core components, but also bring hidden safety risks to on-site personnel and goods. Most common operating errors are caused by unconscientious operation habits and lack of systematic training, which can be completely avoided through targeted guidance.

The first typical error is overloading the rated load during handling. Many operators tend to pursue higher work efficiency by lifting goods that exceed the maximum load mark of the equipment, which will cause extra wear to the drive motor, hydraulic lifting system and bearing parts, and may even lead to rollover accidents in the process of moving. To avoid this error, operators shall check the load identification mark on the equipment body before each operation, confirm the actual weight of goods to be handled, and insert the full length of the forks into the bottom of the goods to keep the center of gravity of the load within the safe range.

The second common error is traveling long distances with forks lifted at a high position. Some operators keep the forks at a height of more than 30 cm from the ground during the whole handling process, which blocks part of the driving sight and shifts the overall center of gravity of the equipment upward, greatly increasing the risk of tipping over when passing through uneven road surfaces. The correct operation specification requires that the forks should be kept 10 to 15 cm above the ground during normal traveling, and the lifting action can only be carried out after the forklift stops stably at the designated unloading position.

The third non-standard behavior is ignoring the pre-operation inspection work. Many operators skip the daily check before starting the equipment, and fail to find hidden problems such as insufficient battery power, reduced brake sensitivity, excessive tire wear and unresponsive steering function, which may lead to sudden equipment failure in the middle of operation. Operators are advised to spend 2 to 3 minutes completing the full patrol inspection before each shift, and report potential faults to the management in time instead of forcing the equipment to work.

The fourth common error is frequent aggressive acceleration, sudden braking and sharp turning. The power output of electric forklifts is more sensitive than internal combustion forklifts, and frequent violent operation actions will lead to slipping and falling of stacked goods, and also accelerate the attenuation of battery performance. Operators should maintain a smooth driving rhythm, slow down and honk when approaching corners or crowded areas, to ensure the safety of all surrounding personnel.

Developing standardized operation habits can effectively reduce the failure rate of electric forklifts, extend the overall service life of the equipment, and create a more stable and safe working environment for all on-site workers.