To prevent damage to manual forklifts used on ships due to fatigue and improper operation, a systematic prevention plan needs to be developed from five dimensions: operating standards, maintenance, environmental adaptation, personnel management, and equipment selection. Specific measures are as follows:

1、 Standardize operating procedures to reduce equipment fatigue

load control

Strict load limit: According to the rated load indicated on the forklift nameplate (usually 1-5 tons), overloading the transportation of goods is prohibited to avoid damage to the hydraulic system caused by overpressure.

Uniform distribution: The center of gravity of the goods should be aligned with the centerline of the forklift to prevent frame distortion or axle breakage caused by unbalanced loading.

Avoid impact: Maintain a constant speed during transportation, and prohibit sudden acceleration, braking, or pulling of the handle to reduce damage to bearings and chains caused by mechanical impact.

Optimization of operating posture

Human resource allocation: When carrying heavy objects, operators should keep their backs straight and use their leg strength to push the forklift, avoiding excessive stress on the waist that may cause fatigue or sprains.

Handle control: When pressing, the downward angle of the handle should not exceed 45 ° to prevent the hydraulic cylinder sealing ring from failing due to excessive compression.

scene adaptation

Slope operation: When using in the inclined area of the ship deck, the cargo should be lowered to the lowest height and personnel should be arranged to assist in stabilizing from the side to prevent forklifts from tipping over.

Narrow space: Plan the transportation path in advance to avoid frequent turning that may cause tire wear or frame deformation.

2、 Strengthen maintenance and prolong equipment lifespan

Daily checklist

Hydraulic system: Check the hydraulic oil level (the oil level should be between the upper and lower limits of the oil gauge), and ensure that there are no leaks in the oil pipes. If the oil is cloudy or has bubbles, replace it immediately.

Tire and wheel hub: Confirm that the tire pressure meets the standard (usually 0.6-0.8MPa), check the tightening of the wheel hub bolts to prevent looseness and wheel axle fracture.

Structural components: Check for cracks or deformations in the fork and frame, with a focus on checking if the welds (such as the connection between the robotic arm and the vehicle body) are secure.

Regular maintenance plan

Weekly maintenance: Clean the surface oil stains of the equipment, lubricate the moving parts such as chains and pulleys, and reduce friction losses.

Monthly maintenance: check the sealing of the hydraulic cylinder and replace the aging sealing ring; Check the sensitivity of the braking system and adjust the brake pad clearance.

Annual overhaul: Disassemble and inspect key components such as the frame and fork, conduct stress testing, and replace high-strength steel components if necessary.

Corrosion protection

Coating protection: Spray anti rust paint on the metal surface of the forklift, with a focus on protecting the frame, forks, and other easily corroded parts.

Salt spray treatment: The ship environment has high salt content. After each use, rinse the equipment with fresh water and apply rust proof oil (such as WD-40).

3、 Optimize the work environment and reduce equipment wear and tear

Deck anti-skid treatment

Lay anti-skid pads or spray anti-skid agents on the forklift's driving path to reduce excessive wear caused by tire slippage.

When working on rainy days, suspend the use of manual forklifts or switch to electric anti-skid models.

temperature control

Low temperature environment: In cold sea areas (such as the Arctic route), use low-temperature hydraulic oil (such as HV46) to prevent hydraulic system failure caused by oil solidification.

High temperature environment: Avoid prolonged exposure to sunlight, and if necessary, install a cooling fan for the hydraulic system to prevent excessive oil temperature.

Ventilation and Lighting

When working in the cargo hold, ensure good ventilation to avoid the accumulation of harmful gases generated by the evaporation of hydraulic oil.

Adequate lighting is required for night work to prevent operators from hitting goods or equipment due to unclear visibility.

4、 Strengthen personnel training and enhance operational skills

Theoretical training

Equipment structure: Explain the hydraulic principle, braking system, and safety device working mechanism of manual forklifts.

Risk identification: Train on the hazards of overloading, overloading, emergency stop and other violations, and strengthen safety awareness through case analysis.

Regulatory standards: Study the safety regulations of the International Maritime Organization (IMO) and the ship's affiliated companies regarding the use of manual forklifts.

Practical training

Simulation scenario: Practice high difficulty operations such as ramp handling and narrow channel turning on the ship simulation deck.

Emergency response: Train on emergency measures for hydraulic system leaks, brake failures, and other unexpected situations (such as emergency pressure relief and using wooden wedges to secure forklifts).

Assessment and certification: After passing theoretical exams and practical assessments, an operating license will be issued, and skills will be regularly updated through retraining.

5、 Select compatible equipment to match ship requirements

lightweight design

Choose aluminum alloy or high-strength plastic material forklifts to reduce their own weight (20% -30% lighter than traditional steel forklifts) and lower operator fatigue.

Anti corrosion model

Purchase all stainless steel forklifts or galvanize key components such as forks and hydraulic cylinders to adapt to high salt spray environments on ships.

Modular structure

Choose components such as forks and wheelsets that can be quickly disassembled to facilitate local replacement and maintenance, reducing downtime.

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