The operation and maintenance of hydraulic forklifts (especially manual hydraulic forklifts) should revolve around the three core aspects of safety, efficiency, and service life. The following is a systematic explanation of key precautions:

1、 Pre operation safety check: eliminate hidden dangers and prevent accidents

Hydraulic system inspection

Hydraulic cylinder leakage: Check if there is any oil leakage in the hydraulic cylinder. If there is a leakage, stop immediately and repair it to prevent the fork from suddenly lowering due to insufficient hydraulic system pressure.

Hydraulic oil level and oil quality: Check the oil tank level in the cold state to ensure it is between the upper and lower limits of the scale; If the oil turns black, emulsified, or contains impurities, it should be replaced immediately (it is recommended to use L-HM 46 anti-wear hydraulic oil).

Exhaust operation: Regularly exhaust the air in the hydraulic system to prevent cavitation from causing unstable lifting or abnormal noise of the fork.

Mechanical component inspection

Wheels and bearings: Check whether the wheels rotate flexibly, without any jamming or abnormal noise; Remove foreign objects from the wheel axle and lubricate the bearings regularly (it is recommended to add lubricating grease every 3 months).

Fork and fork frame: Check whether the fork is deformed or cracked, and whether the welding seam of the fork frame is intact; Ensure that the fork length is equal to or greater than the pallet length to prevent overloading.

Braking and steering: Test brake sensitivity (do not slide on the handbrake ramp test), check the flexibility of the steering wheel.

Environmental adaptability inspection

Ground conditions: Avoid using on muddy, bumpy, or sloping ground to prevent forklifts from tipping over or forks from breaking.

Channel planning: Ensure that the width of the work channel is ≥ forklift width+50cm to avoid collisions with goods and equipment.

2、 Operating standards: Safe and efficient, extending lifespan

Load management

Overloading is strictly prohibited: The rated load of manual hydraulic forklifts is usually 1.6-3.0 tons. Overloading can cause the forks to bend, hydraulic cylinders to burst, or the entire vehicle to overturn.

Uniformly distributed load: The center of gravity of the goods should be centered to avoid uneven loading; Use straps or pallets to secure loose goods and prevent them from scattering during transportation.

Prohibition of single fork operation: Using a single fork may cause the fork frame to break or overturn due to uneven stress.

Lifting and handling actions

Slow lifting fork: When pressing/unloading, operate the handle at a constant speed to avoid rapid lifting causing the goods to slip or hydraulic impact.

Low speed driving: Transport speed ≤ 3km/h (adult walking speed), slow down to ≤ 1.5km/h when turning to prevent centrifugal rollover.

High load and low load: When handling large and heavy goods, the fork should be lowered to the lowest position (≤ 20cm above the ground) to reduce the height of the center of gravity.

Special scenario operation

Slope operation: It is prohibited to load and unload goods on slopes (slope>5%); If necessary, the operator should stand on the side of the forklift to prevent inertia from losing control.

Eye obstruction: If the goods obstruct the line of sight, reverse driving or be guided by others to avoid collision.

No high-altitude throwing: It is strictly prohibited to throw goods from a height onto a forklift to prevent deformation of the fork or damage to the goods.

3、 Maintenance and upkeep: Regular maintenance and preventive measures

routine maintenance

Cleaning and lubrication: Clean the forklift after daily work, remove oil stains from the forks and axles; Add lubricating grease to the axle, chain and other parts.

Tightening inspection: Check if the axle nuts and fork bolts are loose and tighten them in a timely manner.

Hydraulic oil management: Check the oil quality every 3 months and filter or replace it if necessary; Use a dedicated filter when refueling to prevent impurities from entering.

regular maintenance

250 hour maintenance: Clean the hydraulic oil filter screen and check for metal powder (if too much, it indicates wear on the hydraulic cylinder or pump).

500 hour maintenance: Replace the hydraulic oil filter element and check the viscosity of the hydraulic oil (if it is lower than the standard value, it needs to be replaced).

1000 hour maintenance: comprehensive replacement of hydraulic oil, cleaning of oil tank; Check the straightness of the fork (deviation ≤ 1% is qualified).

7000-10000 hour overhaul: Disassemble hydraulic pump and motor, replace seals and worn parts.

Fault handling

Hydraulic system malfunction: If the fork cannot lift, check if the hydraulic oil is sufficient, if the filter element is clogged, and if the hydraulic cylinder seal is aging.

Mechanical failure: If the wheel is stuck, check whether the bearing is damaged and whether the axle is bent; If the fork is deformed, it needs to be replaced immediately.

Electrical faults (such as electric hydraulic forklifts): Check the battery level and wiring for looseness to avoid short circuits.

4、 Safety taboos: Do not touch the red line

personnel security

Do not stand under the fork: No part of the body is allowed to enter between the fork and the ground, whether empty or loaded.

No manned driving: Hydraulic forklifts are designed as cargo handling tools and personnel are strictly prohibited from riding on them.

Prohibited work with obstructed vision: If the goods obstruct the view, it must be reversed or guided by others.

Equipment safety

Do not allow heavy load to stand still: Long term parking under heavy load can cause aging of hydraulic cylinder seals, and it is necessary to relieve pressure or place the goods on the ground.

Prohibition of rough operation: Avoid sudden stops, sharp turns, and sudden directional changes to reduce impact damage to hydraulic systems and mechanical structures.

Prohibited from operating with illness: If the forklift has faults such as oil leakage, abnormal noise, or fork deformation, it must be immediately stopped and repaired.

5、 Skills for improving operational efficiency

Optimize the placement of goods: Move commonly used goods closer to the work site to reduce the distance traveled by forklifts.

Reasonably plan the path: avoid narrow passages and reduce the number of forklift turns.

Two handed joystick: improves control stability and reduces one handed fatigue.

Prepare for parking in advance: Observe the parking position during the transportation process to reduce repeated adjustments.

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