Precautions for Manual Hydraulic Forklifts at Different Stages of Use

Manual hydraulic forklifts are essential for material handling in warehouses, factories, and logistics centers. To ensure safety, efficiency, and longevity, operators must follow specific precautions at each stage of use—before operation, during operation, and after operation. Below is a detailed breakdown of key precautions:

I. Pre-Operation Precautions

1. Visual Inspection

Check for visible damage:

Inspect the forks, mast, wheels, and frame for cracks, bends, or excessive wear.

Ensure no loose bolts or nuts are present.

Examine hydraulic components:

Look for oil leaks in the oil cylinder, hoses, and valve body.

Check hydraulic oil levels (refer to the manufacturer’s guidelines; typically, the oil should be at the mid-point of the sight glass).

Verify steering and mobility:

Ensure the steering wheel turns smoothly without excessive resistance.

Check that wheels rotate freely and are not obstructed.

2. Functional Testing

Test lifting and lowering:

Pump the handle a few times to ensure the forks rise and descend smoothly.

Check for abnormal noises (e.g., grinding, hissing) during operation.

Inspect brakes (if applicable):

Some manual forklifts have parking brakes; test them to ensure they hold securely.

Check safety features:

Ensure overload protection (if equipped) is functional.

Verify that the fork tilt mechanism (if present) operates correctly.

3. Environmental Assessment

Clear the workspace:

Remove obstacles, debris, or slippery substances from the operating area.

Evaluate ground conditions:

Avoid uneven, sloped, or soft surfaces that could cause instability.

Check load compatibility:

Ensure the load fits within the fork dimensions and does not exceed the rated capacity (usually marked on the forklift).

II. During-Operation Precautions

1. Safe Loading Practices

Center the load:

Position the load evenly on both forks to prevent tipping.

Avoid overhanging loads that could shift during movement.

Do not exceed capacity:

Refer to the forklift’s load chart; overloading can cause structural failure or loss of control.

Secure unstable loads:

Use straps or shrink wrap if the load is loose or prone to shifting.

2. Proper Handling Techniques

Maintain a stable speed:

Move slowly, especially when turning or navigating corners.

Avoid sudden stops or jerky movements that could destabilize the load.

Keep forks low:

Lower the forks to a safe height (just above the ground) when moving to improve stability.

Use the neutral position:

When stationary, place the handle in the neutral position to prevent accidental movement.

3. Navigation and Awareness

Watch for obstacles:

Keep a clear view of the path ahead and use a spotter if visibility is limited.

Avoid pedestrians:

Sound the horn at intersections or blind spots.

Never allow riders on the forklift.

Stay clear of edges:

Keep a safe distance from dock edges, ramps, or elevated platforms.

4. Hydraulic System Care

Pump smoothly:

Avoid excessive force when pumping the handle to prevent hydraulic system damage.

Do not hold the release valve open:

Releasing pressure too quickly can cause the load to drop suddenly.

Listen for abnormalities:

Stop operation immediately if you hear unusual noises (e.g., air in the system, grinding gears).

III. Post-Operation Precautions

1. Proper Shutdown Procedures

Lower the forks completely:

Reduce the forks to the ground to prevent tripping hazards and relieve hydraulic pressure.

Engage the parking brake (if applicable):

Ensure the forklift is securely parked.

Store the handle correctly:

Place the handle in the neutral position to avoid accidental activation.

2. Cleaning and Maintenance

Remove debris:

Clean the forks, wheels, and frame to prevent dirt buildup that could affect performance.

Check for new damage:

Inspect the forklift for any issues that may have occurred during operation.

Report maintenance needs:

Notify supervisors of any repairs or replacements required (e.g., worn seals, damaged forks).

3. Storage Guidelines

Park in a designated area:

Store the forklift in a dry, level location away from traffic.

Protect from weather:

Use covers if the forklift will be exposed to rain, snow, or extreme temperatures.

Charge batteries (if electric-assisted):

If the forklift has an electric component, recharge it as needed.

IV. Additional Safety Tips

Operator training:

Ensure all operators are certified and familiar with the specific forklift model.

Regular maintenance:

Schedule periodic inspections by a qualified technician to check hydraulic fluid, seals, and structural integrity.

Use personal protective equipment (PPE):

Operators should wear steel-toed boots, gloves, and high-visibility vests.

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