To prevent damage to hydraulic forklifts, it is necessary to establish a systematic protection mechanism from five aspects: operating standards, maintenance, environmental management, component protection, and personnel training. Specific measures are as follows:

1、 Standardize operational behavior to avoid human damage

load control

Overloading is strictly prohibited: Each forklift is marked with its rated load capacity (such as 2-5 tons for manual forklifts). Overloading can cause deformation of the frame, high hydraulic system pressure, and even cause oil pipe bursts.

Uniformly distributed load: The center of gravity of the goods should be placed in the center, and the length of the fork should completely cover the bottom of the pallet to prevent overloading that may cause the forklift to tip over or the fork to break.

Prohibition of single fork operation: Single fork loading can accelerate fork wear due to uneven stress, increasing the risk of fracture.

Motion Control

Gentle operation of hydraulic rod: Rapid lifting or tilting of the fork can generate hydraulic shock, damaging the cylinder seal or valve body. For example, the lifting action should last for 2-3 seconds to avoid sudden stops and starts.

Prohibit 'hitting the ground ox': using a fork to strike the ground or hard objects, which can directly cause the fork to bend, the axle to deform, or the hydraulic system to leak oil.

Passing through obstacles at low speeds: When encountering potholes or thresholds while driving, the speed should be reduced to below 1km/h to prevent the frame from twisting or the tires from bursting.

Special scenario operation

Slope operation: It is prohibited to load or unload goods or turn on slopes with a slope greater than 5%; If you need to park on a slope, you must tighten the handbrake and secure the wheels with wedges.

Wet and slippery ground: When driving on oily or waterlogged ground, the speed should be reduced by 50% and sudden braking should be avoided to prevent tire slippage and rollover.

2、 Strengthen maintenance and prevent hidden faults

routine inspection

Hydraulic system: Check the oil level daily (the oil level should be between the upper and lower limits of the oil gauge in the cold state), the oil quality (transparent and non emulsified), and check whether there is oil leakage in the oil pipe joints and cylinder piston rods.

Wheel system: Clean the ropes, plastic bags and other foreign objects wrapped in the wheel groove, check the tire wear (if the tread depth is less than 1.6mm, it needs to be replaced) and the lubrication of the wheel hub bearings.

Safety device: Test the brake pedal travel (usually 20-30mm), handbrake tension (to be able to secure a fully loaded forklift), and ensure that the horn and lighting functions are normal.

regular maintenance

Every 200 hours: Clean the hydraulic oil radiator, replace the air filter element (shortened to 100 hours if there is high dust in the environment), and check the chain tension (manually adjust the upper and lower clearance to 2-3mm).

Every 500 hours: Replace the hydraulic oil filter element (accuracy ≥ 10 μ m), check the water content of the brake oil (replace if it exceeds 3%), and adjust the clutch free stroke (usually 10-15mm).

Every 1000 hours: replace the hydraulic oil completely (using L-HM 46 anti-wear hydraulic oil), empty the air in the oil circuit (achieved by extending and retracting the oil cylinder three times throughout its full stroke), and check for cracks in the fork welds.

Long term suspension management

When the forklift is not in use for more than one week, it is necessary to lower the forklift to the lowest position without load, disconnect the power (electric forklift) or close the oil valve (manual forklift), and store it in a dry and ventilated place to avoid moisture and corrosion of the hydraulic system.

3、 Optimize the work environment and reduce external damage

Channel planning

The width of the main channel should be ≥ forklift width+1.2m (such as a 2m wide forklift requiring a 3.2m channel), and the width of the aisle between shelves should be ≥ 2.5m to ensure sufficient turning radius.

The ground flatness error should be less than 5mm/m, and the slope should be less than 2% to avoid parts loosening due to bumps during forklift operation.

environmental control

High temperature environment: When working in places with a temperature greater than 40 ℃, it is necessary to shorten the continuous working time of the hydraulic system (rest for 15 minutes every 2 hours) to prevent excessive oil temperature (normal oil temperature is 50-80 ℃).

Low temperature environment: Before working in places with a temperature below -10 ℃, the hydraulic system needs to be preheated (run without load for 5-10 minutes) and low-temperature hydraulic oil (such as L-HV type) should be used.

Corrosive environment: When used in chemical, salt spray and other places, it is necessary to apply anti rust paint to metal parts and install corrosion-resistant seals on hydraulic systems.

Isolation in hazardous areas

Set up warning signs (such as "speed limit 5km/h" and "no parking") in the forklift operation area, and delineate pedestrian and vehicle passages to avoid collisions caused by mixed traffic.

4、 Strengthen component protection and extend service life

Forklift protection

Install a rubber sleeve at the front end of the fork to prevent scratches or deformation when handling metal goods.

Regularly check the levelness of the forks (the height difference between the front ends of the two forks is ≤ 5mm). If it exceeds the tolerance, adjust the connecting rod or replace the forks.

Hydraulic system protection

Apply anti rust grease on the surface of the oil cylinder piston rod to prevent erosion by rainwater or corrosive liquids.

Install hydraulic oil return filter (accuracy ≥ 25 μ m) to intercept impurities such as metal powder and reduce valve body wear.

Electrical system protection

Electric forklifts need to regularly clean the dust on the motor cooling fan to prevent overheating and burning; Apply conductive paste to the wiring terminals to prevent oxidation and poor contact.

5、 Enhance personnel skills and strengthen safety awareness

Operation Training

New employees are required to receive more than 40 hours of practical training to master the structural principles, fault phenomena, and emergency handling of forklifts (such as immediately closing the oil pump valve when the oil pipe bursts).

Regular refresher training (once every six months), updating safety operation standards (such as the requirements of the new national standard GB/T 36507-2018).

Assessment mechanism

Establish a qualification certificate system for operation, and those who fail theoretical exams (covering hydraulic principles, safety regulations) and practical assessments (such as hill start and emergency braking) are prohibited from taking up their posts.

Implement the "one vehicle, one person" responsibility system, link forklift maintenance records with operator performance, and force standardized operations.

emergency drill

Organize an emergency drill for forklift malfunctions once a quarter, simulating scenarios such as oil pipe leaks and brake failures, and training operators to complete actions such as stopping, warning, and evacuation within 30 seconds.

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