Although manual hydraulic forklifts have a simple structure, they are prone to shortened equipment life and even safety accidents due to excessive wear, hydraulic system failure, or structural damage in specific usage scenarios or improper operation. The following are three common situations of easy damage and their cause analysis:

1、 Overloading or unbalanced load operation

Phenomenon: fork deformation, hydraulic cylinder leakage, chain breakage, and frame bending.

reason:

Overloading:

The rated load of manual hydraulic forklifts is usually 1-3 tons. If they are overloaded for a long time (such as handling goods weighing more than 20% of their rated weight), it can cause the hydraulic cylinder seal ring to rupture due to excessive pressure, leading to oil leakage.

Overloading can also cause excessive bending stress on the forks, leading to cracks or even fractures at the base or middle of the forks.

Unbalanced load:

Uneven placement of goods on two forks (such as excessive load on one side) can cause the center of gravity of the forklift to shift, increasing the force on one fork. Long term uneven load can cause deformation of the forks or distortion of the frame.

When the load is unbalanced, the uneven force on both sides of the hydraulic cylinder may accelerate the wear of the seals, leading to the failure of the hydraulic system.

Case: During the handling of heavy equipment in a warehouse, the forklift's rated load was not checked, resulting in the sudden breakage of the fork during lifting and damage to the goods due to falling.

2、 Poor environment or improper maintenance

Phenomenon: Hydraulic system jamming, increased wheel wear, and rusting of metal components.

reason:

Hydraulic system contamination:

If the hydraulic oil is not regularly replaced or the specified model (such as HM46 anti-wear hydraulic oil) is not used, impurities (such as metal particles and dust) may be mixed in the oil, causing the hydraulic pump or control valve to get stuck and affecting the flexibility of the fork lifting.

Long term use of inferior hydraulic oil can accelerate the aging of sealing rings and cause leaks.

Lack of lubrication in the wheelset:

If the bearings of the casters (load-bearing wheels and steering wheels) are not regularly lubricated, it can lead to increased rotational resistance and even jamming.

After working in muddy or humid environments, if the debris on the wheel set (such as ropes and plastic bags) is not cleaned up in a timely manner, it will cause the wheels to become tangled or sway, accelerating wear and tear.

Corrosion of metal components:

Forklifts parked in open or humid environments for a long time are prone to rusting of metal parts such as frames and forks, which reduces their structural strength.

Case: A logistics center failed to regularly clean the entanglement on the forklift wheel set, resulting in the steering wheel getting stuck. The forklift lost control and crashed into the shelf while turning.

3、 Violation of regulations or rough use

Phenomenon: The hydraulic cylinder piston rod is bent, the fork surface is scratched, and the control handle is broken.

reason:

Emergency stop or acceleration:

Sudden sudden braking or rapid start-up during transportation can cause the cargo to impact the fork due to inertia, resulting in scratches or deformation on the fork surface.

During emergency stop, the hydraulic cylinder piston rod may bend due to instantaneous high pressure, affecting the sealing performance.

Impact of falling goods:

Directly dropping goods from a height onto a forklift, or forcibly pulling out the pallet before the fork has fully descended, can cause dents or cracks on the surface of the fork.

Falling impact may also damage the one-way valve inside the hydraulic cylinder, causing the fork to be unable to maintain a lifted state.

Excessive force on the operating handle:

Excessive force when pressing the handle may cause the hydraulic pump plunger to bend or the control valve to be damaged.

Long term violent operation can also accelerate the wear and tear of the handle connection, leading to the risk of breakage.

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