Diesel Forklift Operating Procedures
1. Diesel forklifts are special equipment. Drivers must undergo professional training, pass the relevant department's examination, and obtain a special operation certificate before operating the forklift. Operating without a certificate is strictly prohibited.
2. Driving under the influence of alcohol or while fatigued is strictly prohibited. While operating the forklift, drivers must not engage in any activities that could impede safe forklift operation, such as eating, using a mobile phone, or engaging in idle conversation.
3. Drivers must wear personal protective equipment (PPE) when operating the forklift. When getting on and off the forklift, jumping is prohibited; drivers must hold onto the handles and place their feet on the platform. It is strictly forbidden to enter the cab while holding the steering wheel or control levers. It is strictly forbidden to place any part of the body into the mast mechanism or between the mast and the forklift body.
4. Before starting the vehicle, you must check that the forklift's fuel tank capacity meets the specified requirements, check for leaks in the fuel lines, water lines, exhaust pipe, and all accessories, check the tightness of the wheel bolts and the tire pressure to the specified values, check the flexibility and reliability of the steering and braking systems, check for any short circuits or loose connections in the electrical wiring, and ensure that the horn, turn signals, brake lights, and all instruments are functioning properly. The diesel forklift must be in good working order before operation.
5. When starting the forklift with a load, the driver should first ensure that the load is stable and secure. Start slowly and smoothly. When loading and unloading, i.e., from the initial loading of the forks to the stable loading and vice versa, the brakes must be activated. No one is allowed within a 1-meter radius of the forks when the forklift is lifting or lowering goods.
6. No one is allowed to get on or off the forklift while it is in operation, and standing on the forks is strictly prohibited. If there are people ahead, honk the horn to indicate your route. When turning, crossing, or at narrow intersections, proceed with caution and slow down, and honk the horn in preparation for stopping. When entering or leaving the work site or while driving, be aware of overhead obstacles and avoid sharp turns and sudden braking except in emergencies.
7. When unloaded, the forks should be 0.05-0.15 meters off the ground. When loaded, the load should not be more than 0.5 meters off the ground, and the lifting mast must be tilted back to its maximum limit.
8. When driving an empty forklift uphill, reverse while moving the forks forward while moving downhill. When driving a loaded forklift uphill, move the forks forward while moving the forks backward while moving downhill. Coasting in neutral is strictly prohibited when going downhill. U-turns are never allowed on a slope.
9. The load on the forklift must not obstruct the driver's view. If the view is obstructed, the forklift should be reversed slowly. When encountering an uphill slope, reversing is prohibited; one person should be present to direct the forks to move upwards.
10. Speeding, overloading, and uneven loading are strictly prohibited. Regardless of whether unloaded or heavily loaded, the forklift speed must be controlled below 5 km/h. On good roads, the weight of finished 名媛直播 or raw materials transported by a diesel forklift must not exceed its rated weight. In poor road conditions, the load should be appropriately reduced, and the speed should be decreased.
11. During operation, goods must not be raised for long distances (height must not exceed 0.5 meters); it is forbidden to use the forks to overturn pallets or to unload goods by using braking inertia; it is forbidden to directly shovel and transport hazardous materials; it is forbidden to operate with a single fork; it is forbidden to use inertia to load or unload goods; it is forbidden to use the forks to carry personnel during operation; after the forks are raised, it is strictly forbidden for anyone to stand under the forks or to perform maintenance work; it is forbidden to use damaged or deformed pallets to carry goods.
12. During operation, if any suspicious noise or abnormal phenomenon is detected, the forklift must be stopped immediately for inspection and immediate action taken to resolve the issue. Operation must not continue until the fault has been rectified. Repairing or disassembling parts while the forklift is running is strictly prohibited.
13. When parking, the forks should be lowered to the lowest position, the steering lever should be in neutral, the parking brake should be engaged, the ignition switch turned off, and the key removed. The forklift must not be parked in emergency exits, near entrances/exits, or next to fire-fighting facilities. Avoid parking the forklift on slopes whenever possible. If unavoidable, use reliable objects to block the wheels, engage the handbrake, and turn off the engine.
14. After parking, goods must not be left suspended in the air. After unloading, the forks should be lowered to the normal driving position before driving.
15. After each use, the diesel forklift must be parked in the designated location.
16. Violation of these regulations resulting in personal injury, company property damage, or damage to the company's reputation may be subject to penalties ranging from warnings, fines, compensation, dismissal, to referral to judicial authorities, depending on the severity of the violation.
Diesel Forklift Maintenance Requirements
1. Scope
This procedure specifies the maintenance steps, requirements, and precautions for diesel forklifts. Regular maintenance and inspection are essential for the forklift to function properly.
2. 250-Hour Vehicle Inspection and Maintenance
(1) Clean and lubricate the steering axle. Thoroughly clean the steering axle with water or a cold cleaner.
(2) Lubricate the mast and tilt cylinder support. Inject grease through the tilt cylinder grease inlet at the mast bracket. Inject grease through the mast support grease inlet at the frame until fresh grease seeps from the bearings.
(3) Check the condition and tightness of electrical wires, terminals, and connectors.
(4) Check the tightness and wear of all hydraulic system connections; tighten or replace as necessary.
(5) Inject grease into the guide wheel grease inlet and the fork carriage grease inlet until fresh grease seeps from the forklift.
(6) Lubricate the piston rod after each forklift cleaning.
3. Vehicle 500-Hour Inspection and Maintenance
(1) Inspect the condition and tightness of the mast and lifting chain. Thoroughly clean the mast guides and lifting chain. Inspect the condition and wear of the lifting chain, paying particular attention to the sprocket area and checking the chain retaining pins. Replace any damaged ones immediately.
(2) Adjust the lifting chain length. After a period of operation, the lifting chain will stretch. Therefore, the left and right chain lengths must be checked and adjusted.
(3) Apply chain spray to the guide surface and between the chains to improve lubrication.
(4) Drain the engine oil. The engine should only be changed when it is at operating temperature.
(5) Replace the engine oil filter. Apply a small amount of oil to the new filter gasket, screw the filter in by hand until the seal is engaged, and then tighten it half a turn.
(6) Add engine oil. After adding new oil and replacing the filter, test run the engine. During trial operation, observe the oil pressure warning light and check the sealing of the drain plug and filter.
(7) Check the coolant. The cooling system should be filled with a mixture of water and antifreeze year-round to prevent sedimentation, frost, oxidation, and increased boiling point. The antifreeze and water content should be 40% and 60%, respectively.
(8) Check the connection between the drive axle and the engine, the bracket, the counterweight, the overhead guard, the steering axle, and the tightness of the drive axle.
(9) Check and lubricate the pedal mechanism, the linkage mechanism for driving operation, and the engine control mechanism. If necessary, apply a small amount of oil to the pedal journals and fork joints.
(10) Check the drive belts of the generator and fan. Damaged or loose belts will affect cooling performance. The belt tension is 355N. There are two methods to check the belt: one is to check with a gauge, and the other is to check by pressing with your fingers.
(11) Replace the fuel filter and clean the radiator and hydraulic oil cooler. 4. Vehicle 1000-Hour Inspection and Maintenance
(1) Replace the air filter element and check the negative pressure switch (at least every 12 months or after 5 cleanings). When installing the filter element, be careful not to damage it and ensure the correct installation position.
(2) Check the condition and tightness of the engine mounts. The engine mounts should not be subjected to heavy pressure. The frequency of mount maintenance varies depending on the working environment.
(3) Check the sealing of the intake and exhaust pipes.
(4) Check the sealing of the hydraulic system, drive axle, pumps, valves, and pipes.
(5) Replace the pressure filter. When replacing, lower the mast and use a special wrench to loosen the filter seat on the left side of the gearbox, then unscrew the filter by hand. Fill the new filter with hydraulic oil and apply oil to the seals. During test run, check the sealing of the filter contact surfaces.
(6) Replace the suction filter. During replacement, the filter element should be slowly pulled out so that the oil can flow back into the tank. Perform a test run and check the filter cover's seal.
(7) Replace the vent filter. Unscrew the hydraulic tank vent filter, remove the oil level indicator from the filter, and install it on the new filter. If the working environment is harsh, it is necessary to replace the filter earlier.
(8) Check the wheel-side reducer oil level. To check this, the forks must be fully lowered, and the oil level of both wheel-side reducers must be checked. Approximately 2.0 liters of oil should be added to each side.
(9) Check the parking brake. Drive the fully loaded forklift onto a 15% slope, depress the brake pedal, lock the parking brake lever, and stop the engine. The forklift should be unable to move at this point.
5. Vehicle 2000-Hour Inspection and Maintenance
(1) Replace the generator and fan V-belts. Check using the finger pressure method: Press down on the belt with your thumb to check its tension. The belt should sink about 10mm between the pulleys. If the tension is insufficient, tighten the belt. After running the engine for about 15 to 20 minutes, retighten the belt.
(2) Check the fuel injectors. Special tools are required for checking and adjusting the fuel injectors. Injector pressure standard: 300 bar.
(3) Check and adjust valve clearance. Valve clearance can be checked when the engine is warm from a cold state. Valve clearance refers to the clearance between the rocker arm and the valve. If the engine runs smoothly and reaches maximum power, the valve clearance is correctly adjusted. Valve clearance standard: Intake valve 0.20mm, Exhaust valve 0.45mm.
6. Vehicle 3000-hour inspection and maintenance
(1) Change hydraulic oil. When changing the hydraulic oil, the forks must be fully lowered and the hydraulic oil in the vehicle drained. Total oil volume: 39L.
(2) Check the connection between the drive axle and the engine. Remove the base plate and tighten all bolts to 64 Nm. The drive axle is mounted on the intermediate housing with 8 M10 bolts. The intermediate housing is mounted on the engine with 9 M10 bolts.
(3) Lubricate the mast and tilt cylinder support. Inject grease through the tilt cylinder grease inlet at the mast bracket. Inject grease through the mast support grease inlet at the frame until fresh grease seeps from the bearings.
(4) Check the condition and tightness of the mast and lifting chain. Thoroughly clean the mast guide grooves and lifting chain. Check the condition and wear of the lifting chain, paying particular attention to the sprocket area and the chain retaining pins. Replace any damaged ones immediately.
(5) Replace the engine oil filter. Apply a small amount of oil to the new filter gasket, screw the filter in by hand until the seal is engaged, then tighten half a turn.
(6) Replace the air filter element and check the negative pressure switch (at least every 12 months or after 5 cleanings). When installing the filter element, be careful not to damage it and ensure it is installed correctly.
(7) Replace the suction filter. During replacement, slowly pull out the filter element so that the oil can flow back into the tank. Test run and check the filter cover seal.
(8) Replace the vent filter. Unscrew the hydraulic tank vent filter, remove the oil level indicator from the filter, and install it on the new filter. If the working environment is harsh, it is necessary to replace the filter earlier.
(9) Check the parking brake. Drive the fully loaded forklift onto a 15% slope, depress the brake pedal, lock the parking brake lever, and stop the engine. The forklift should be unable to move at this point.
(10) Check the coolant. The cooling system should be filled with a mixture of water and antifreeze year-round. To prevent precipitation, condensation, oxidation, and boiling point elevation. The antifreeze and water content is 40% and 60%, respectively.
(1) Replace the fuel filter and clean the radiator and hydraulic oil cooler.
