When using a manual hydraulic forklift, it is necessary to strictly follow safety regulations to avoid personal injury, equipment damage, or cargo damage. The following is a detailed classification explanation of key precautions:

1、 Pre operation inspection: prevent problems before they occur

Equipment integrity check

Forks: Check for cracks, deformation, or severe wear (if the wear on the fork tip exceeds 10% of the original size, it needs to be replaced).

Wheel set: Remove debris (such as loose threads and plastic sheets) from the wheel groove, test steering flexibility, and ensure that the wheels are not stuck or loose.

Hydraulic system: Check whether the hydraulic cylinder leaks and whether the oil level is within the range of the scale (insufficient oil can cause weak lifting or jamming).

Handle and Chain: Confirm that the handle is securely connected and the chain is not broken or excessively stretched (chain breakage may cause the fork to suddenly fall).

Environmental Assessment

Ground conditions: Avoid potholes, slopes (prohibited when the slope is greater than 2%), or slippery ground to prevent forklifts from tipping over.

Space limitation: Ensure that the work area is free of obstacles (such as low door frames and hanging objects), and reserve sufficient height for forklift lifting (usually 20cm or more higher than the cargo).

Fire and explosion prevention: In oil depots, chemical warehouses, and other places, confirm that forklifts do not pose a risk of static electricity generation (such as hydraulic oil that meets explosion-proof standards).

2、 Standardization in operation: equal emphasis on safety and efficiency

Load management

Overloading is strictly prohibited: The rated load is usually 1-3 tons, and overloading can cause damage to the hydraulic system or deformation of the forks (such as handling 3.5 tons of goods, which may cause the forks to bend more than 5 °).

Uniform distribution: The center of gravity of the goods should be located at the center of the fork to avoid overloading (overloading exceeding 10% may cause overturning).

Size restriction: The length of the fork must cover at least 2/3 of the bottom of the cargo, and it is prohibited to use short forks to transport long items (such as using a 1.2-meter fork to transport a 2-meter-long steel pipe).

action control

Slow lifting: The lifting/lowering speed of the fork should be ≤ 0.1m/s to avoid rapid operation causing the goods to tilt or hydraulic oil to splash.

Smooth movement: Driving speed ≤ 3km/h (approximately walking speed), sudden acceleration, sudden braking, or sudden turning are prohibited (turning radius must be ≥ 1.5 meters).

No empty sliding: When the forklift is empty, it is necessary to press and lift it appropriately to avoid sparks or wear caused by friction between the front wheel support frame and the ground.

Personnel protection

Maintain distance: During operation, no part of the body should be placed under the fork, near mechanical lifting components, or behind the cargo (to prevent the cargo from slipping and injuring).

No personnel allowed: Forklifts are only used for transporting goods, and it is strictly prohibited for personnel to stand or ride on them (forklifts without safety protection devices can easily cause falls when carrying people).

Wear protective equipment: Operators need to wear safety helmets, anti slip shoes, and reflective vests, and also wear earplugs in noisy environments (such as construction sites).

3、 Special scenario response: targeted risk prevention

Slope operation

No uphill handling: If you need to pass through a slope, it must be unloaded and the fork arm must face downhill (to prevent the forklift from losing control due to the sliding of goods).

Fixed goods: When parking on a slope, wooden wedges or blocks should be used to secure the wheels to prevent the forklift from sliding.

low-temperature environment

Preheat hydraulic system: Before operating in an environment below -10 ℃, it is necessary to press the lifting fork multiple times to raise the hydraulic oil temperature to the normal working temperature (to avoid high oil viscosity causing operation jamming).

Anti slip measures: Install anti-skid chains on the wheelset or choose a rubber tire forklift (compared to nylon wheels, rubber wheels have stronger grip at low temperatures).

Fire and explosion prevention places

Disable electric assistance: It is strictly prohibited to install electric lifting devices on forklifts (electric components may generate sparks).

Regular cleaning: After daily work, use anti-static cloth to wipe the forklift to avoid the accumulation of oil stains that may cause static fires.

4、 Emergency response: rapid response to reduce losses

Cargo dumping

Immediate Evacuation: Operators must quickly evacuate to a safe area (at least 3 meters away) and must not attempt to straighten the cargo with their hands.

Warning signs: Set up warning signs around the dumping area to prevent other personnel from approaching.

Hydraulic system Failure

Slow pressure relief: If the hydraulic cylinder leaks or stalls, the handle should be slowly lifted to the "pressure relief" position to avoid the fork suddenly falling.

Do not forcefully operate: Do not use a hammer to strike the hydraulic cylinder or forcefully pull the handle to prevent further damage to the components.

Forklift rollover

Grasp the steering wheel tightly: If the forklift overturns due to unbalanced load or sharp turns, the operator needs to grip the handle tightly and fall to the ground with the forklift (to avoid being crushed by the forklift).

Check for injury: Immediately inspect oneself and surrounding personnel for any injuries after flipping over, and call the emergency number.

5、 Maintenance and upkeep: Extend equipment lifespan

Daily cleaning

Clean up oil stains: Use a dry cloth to wipe the forks, wheels, and hydraulic cylinders to prevent oil stains from corroding metal parts.

Drainage treatment: If the forklift is used in a humid environment, it is necessary to regularly drain the accumulated water in the hydraulic cylinder (to avoid oil emulsification).

monthly inspection

Replace hydraulic oil: According to the frequency of use, replace the hydraulic oil every 3-6 months (it is recommended to use ISO VG32 or VG46 anti-wear hydraulic oil).

Lubricating wheel set: Apply lithium based grease to the axle to reduce wear and noise.

Annual maintenance

Fork strength test: Entrust a professional organization to test the bending fatigue strength of the fork (to ensure compliance with ISO 5057 standard).

Hydraulic system sealing inspection: Confirm through pressure testing that the hydraulic cylinder has no leakage (leakage rate should be ≤ 5ml/min).

6、 Training and Certification: Enhancing Operational Skills

Theoretical training

Learning standards: Master national standards such as "Safety Operating Procedures for Manual Hydraulic Forklifts" (GB/T 3805-2008).

Case analysis: Learn the consequences of overloading, uneven loading, sharp turns and other violations through accident videos.

Practical assessment

Simulation scenario: Set up slopes, narrow passages, and other scenarios in the training venue to assess the emergency response capabilities of operators.

Assessment criteria: The entire process of cargo handling, lifting, and parking must be completed within 3 minutes without any violations.

Recurrent training

Annual refresher training: Operators are required to participate in at least 4 hours of safety refresher training each year to update their operational knowledge and skills.

New equipment training: If a company introduces a new type of forklift (such as ultra-low height or stainless steel material), it needs to conduct equipment characteristic training separately.

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