The protection and maintenance of manual forklifts need to be carried out from four dimensions: daily inspection, operation specification inspection, regular maintenance, and professional in-depth maintenance. The specific methods are as follows:

1、 Daily check: "Five step troubleshooting method" before daily use

Hydraulic system testing

Oil leakage inspection: Observe whether there are oil stains at the hydraulic cylinder and oil pipe joints. If a leak is found, stop immediately and replace the seals.

Oil level confirmation: When the fork is lowered to the lowest position, check whether the hydraulic oil level is about 50mm above the flat surface of the oil tank (refer to the standard value). If it is insufficient, add hydraulic oil of the same model.

Empty load test: Repeatedly lift and lower the fork 3-5 times to confirm that there is no jamming, abnormal noise, or automatic sliding phenomenon.

Structural safety inspection

Fork status: Use a ruler to measure whether the fork is deformed (allowable deviation ≤ 1% length), check for cracks or excessive wear (thickness wear exceeding 10% needs to be replaced).

Chain integrity: Check the tension of the chain, pull the middle section of the chain upwards by hand, and the vertical displacement should be ≤ 20mm, otherwise it needs to be adjusted or replaced.

Wheel set flexibility: manually rotate the wheels to confirm that there is no jamming or deviation, and the tire pressure should meet the standard (such as polyurethane wheel pressure of 0.2-0.3MPa).

Control system verification

Handle operation: Test whether the handle lifting and center locking functions are sensitive, and whether the brake device can effectively brake within 1 meter.

Safety device: Check if the overload protection valve (automatically releases pressure when the pressure exceeds 1.65MPa) is working properly.

Appearance and environmental inspection

Structural damage: visually inspect the frame and fork frame for deformation or weld cracking.

Cleanliness: Remove foreign objects (such as wrapped packaging tape and iron filings) from the forks and wheelsets to prevent them from falling off and injuring people during operation.

2、 Operation specification inspection: the "six no's principle" in use

Do not overload: The weight of the goods must not exceed the rated load of the forklift (usually 2-5 tons), and the length of the fork must be ≥ the length of the pallet.

Non unbalanced loading: The center of gravity of the goods should be located at the center of the two forks to avoid tipping over caused by single fork operation or center of gravity deviation.

Not driving at high speed: driving speed ≤ 3 kilometers per hour, slowing down to within 1.5 kilometers per hour when turning.

Do not stand still on a slope: It is strictly prohibited to lift goods on a slope for a long time to prevent damage to the hydraulic cylinder or the goods from slipping off.

Work without obstruction of vision: If the goods obstruct the view, reverse the vehicle or assign a commanding personnel.

No passengers/sliding: It is prohibited for personnel to stand on the fork or use the slope to slide freely.

3、 Regular maintenance: staged "three-level maintenance system"

First level maintenance (every 250 hours)

Lubrication tightening: Apply lubricating grease to the axle, nut, chain and other parts, tighten the cylinder head bolts and wheel nuts.

Component cleaning: Use high-pressure air to blow clean the air filter (if it is too dirty, it needs to be replaced), clean the fork frame and door frame slide.

Oil change: Change the engine oil and oil filter, fill the brake fluid to the mark.

Secondary maintenance (every 500 hours)

Deep cleaning: Drain the water separator and clean the radiator, replace the hydraulic filter.

Performance test: Test the chain lifting tension (to reach 1.5 times the rated load), adjust the valve clearance.

Replacement of vulnerable parts: Replace spark plugs (check motor carbon brushes for electric forklifts) and fuel filters.

Level 3 maintenance (every 2000 hours)

System overhaul: Replace coolant, distribution belts, and sealing gaskets, clean or replace internal ventilation filters.

Bearing maintenance: Replace the wheel bearing grease, check the transmission filter and oil.

Hydraulic system maintenance: Conduct a comprehensive inspection of hydraulic cylinders and oil pipes, and replace aging seals.

4、 Professional in-depth maintenance: annual "full body physical examination"

Structural strength testing: Use ultrasonic flaw detector to check whether there are cracks in the welds of the fork frame and door frame.

Hydraulic system pressure test: Check whether the system pressure meets the standard through a pressure gauge (such as a standard value of 16MPa, with an allowable deviation of ± 5%).

Electrical system insulation test: Use a megohmmeter to measure the insulation resistance of the motor and controller (should be ≥ 1M Ω) to prevent leakage.

Safety device verification: Entrust a third-party organization to verify the sensitivity of safety devices such as overload protection valves and speed limiters.

The main equipment produced by Hebei Makita: stage electric hoist, electric chian hoist, wire rope electric hoist，Hand chain hoist, lever hoist, pneumatic hoist and other lifting equipment