Electric pallet trucks are widely used in scenarios like warehouse material distribution, factory material turnover and retail logistics sorting, with easy operation and high handling efficiency features. Overloading is one of the top hidden causes of safety accidents in daily operation, which may lead to risks such as fork deformation, driving system failure, out-of-control vehicle movement and accidental collision with personnel or goods, bringing unnecessary loss to the whole operation team.

The first core measure to avoid overloading accidents is to complete pre-operation load specification confirmation before every task. All operators shall check the rated load mark on the equipment body clearly before starting work, and strictly confirm the total weight of the goods to be handled through the weight label on the outer package of goods or matched weighing equipment. It is not allowed to carry goods with total weight exceeding the rated load specified by the equipment, even for short-distance handling. Besides, operators shall also pay attention to the center of gravity of stacked goods: if the center of gravity of goods seriously deviates from the support center of the pallet truck, even if the total weight does not reach the rated load, the hidden danger of structural damage will still exist, and such goods are not allowed to be carried forcibly.

The second key work is to carry out standardized and regular safety operation training for all on-site operators. Many overloading behaviors happen because operators take chances in actual work, believing that slight overload will not cause damage to the equipment. The training work should focus on popularizing the long-term harm of repeated slight overload: it will cause cumulative wear of the driving motor, bearing parts and lifting structure, which may break out suddenly in subsequent normal operation and cause unexpected accidents. The training course can also teach operators to quickly identify the overload warning signal of the equipment, once the overload buzzer sends out prompt sound, the operators shall stop operation immediately, unload part of the goods to reduce the total load to the safe range, and continue the handling task after confirming no abnormality.

The third necessary measure is to implement routine equipment maintenance and inspection mechanism. The management team shall arrange special personnel to inspect the overload protection device of each electric pallet truck on a regular basis, regularly calibrate the load detection sensor to ensure the sensitivity and accuracy of the overload warning function. If the warning device fails to give an alarm normally, the equipment shall be taken out of service for maintenance immediately, and it is not allowed to continue to use the equipment with potential safety hazard. In the daily inspection work, the staff shall also check the deformation of the fork, the wear degree of the load-bearing wheel and the operating temperature of the driving motor, to find out the residual damage caused by previous hidden overloading behaviors in time.

By combining the above three dimensions of pre-operation check, personnel safety awareness improvement and equipment state guarantee, the occurrence rate of overloading related accidents can be effectively controlled, to create a stable and safe working environment for all logistics handling personnel.