Precautions for operation:
1. Only trained drivers with driving licenses can drive;
2. Before and after repairing or operating the control device, if any defect is found, check the alarm;
3. The specified load shall not be exceeded during handling. The fork must be fully inserted under the goods and the goods shall be evenly placed on the fork. It is not allowed to pick the goods with the tip of a single fork;
4. Start, turn, drive, brake and stop smoothly, and slow down when turning on wet or smooth roads;
5. When loading, lower the goods and tilt the gantry backward;
6. Be careful when driving on the ramp. When driving on more than one tenth of the ramp, drive forward on the uphill and backward on the downhill. Do not turn up or down the slope. Do not load and unload when the forklift is driving;
7. When driving, pay attention to pedestrians, obstacles and potholes, and pay attention to the gap above the forklift;
8. No one is allowed to stand on the fork and no one is allowed to carry people on the vehicle;
9. No one is allowed to stand or walk under the fork;
10. It is not allowed to operate vehicles and accessories from positions other than the driver's seat;
11. Do not handle goods that are not fixed or loosely stacked, and handle goods with large size carefully;
12. For high gantry forklifts with a lifting height greater than 3m, pay attention to the falling of goods above, and take protective measures if necessary; During operation, the gantry shall be tilted back as much as possible and tilted back and forth within the minimum range;
13. When refueling, the driver shall not be on the vehicle and turn off the engine. When checking the liquid level of battery or oil tank, do not ignite;
14. When leaving the vehicle, lower the fork to the ground, place the gear handle in the neutral position, turn off the engine and disconnect the power supply, pull the hand brake well, and cushion the wheels with cushion blocks when parking on the ramp.
Forklift maintenance:
Regular maintenance measures shall be taken to make the forklift work normally and reliably and give full play to the potential capacity of the forklift. Technical maintenance measures are generally:
1. Daily maintenance, after each shift.
2. For level-1 technical maintenance, after working for 100 hours, the one shift system is equivalent to 2 weeks.
3. After 500 hours of secondary technical maintenance, one shift is equivalent to one quarter
1、 Routine maintenance
1. Clean the dirt, dirt and dirt on the forklift. The key parts are: fork frame and gantry slide, generator and starter, battery electrode fork column, water tank and air filter.
2. Check the fastening of all parts, focusing on: fork support, lifting chain tension screw, wheel screw, wheel fixing pin, brake and steering gear screw.
3. Check the reliability and flexibility of the steering gear.
4. Check the leakage, focusing on: each pipe joint, diesel tank, engine oil tank, brake pump, lifting cylinder, tilt cylinder, water tank, water pump, engine oil pan, torque converter, transmission, drive axle, main reducer, hydraulic steering gear and steering cylinder.
5. Tire pressure inspection: if it is insufficient, it shall be supplemented to the specified value to confirm that there is no air leakage. Check whether the ground and side of the tire are damaged and whether the rim is deformed.
6. Inspection of brake fluid and water volume: check whether the brake fluid is within the scale range and whether air is mixed in the brake pipeline. When adding brake fluid, prevent dust and water from mixing in. When adding water to the water tank, use clean tap water. If antifreeze is used, add the same antifreeze. When the water temperature is higher than 70 ℃, do not open the water tank cover. When opening the cover, pad a thin cloth and do not screw the water tank cover with gloves.
7. Inspection of engine oil quantity, hydraulic oil and electrolyte: first pull out the oil dipstick, wipe the head of the dipstick, insert it, and then pull it out to check whether the oil level is between the two graduation marks. The oil level in the working oil tank shall be between two scale marks; If there is too little oil, air will be mixed in the pipeline, and too much oil will overflow from the cover plate. Battery electrolyte should also be between the upper and lower scale lines. If it is insufficient, distilled water should be added to the top line.
8. Brake pedal, inching pedal, clutch pedal and hand brake inspection: step on each pedal to check whether there is abnormal retardation or jamming. The force of the hand brake handle shall be less than 300N, and it is confirmed that the hand brake is safe and reliable.
9. Inspection of belt, horn, light, instrument, etc.: check whether the belt tightness meets the requirements, there is no adjustment allowance or damage, and there are cracks, which must be replaced; The horn, light and instrument shall be normal and effective.
10. Drain the oil filter sediment.
2、 Primary technical maintenance
Carry out according to the "routine maintenance" project, and add the following work.
1. Check the cylinder pressure or vacuum.
2. Check and adjust the valve clearance.
3. Check whether the thermostat works normally.
4. Check whether the multi-way directional valve, lifting cylinder, tilt cylinder, steering cylinder and gear pump work normally.
5. Check whether the transmission shifts normally.
6. Check and adjust the clearance between the brake pad and brake drum of hand and foot brakes.
7. Replace the oil in the oil pan, check whether the crankcase ventilation pipe is intact, and clean the oil filter and diesel filter element.
8. Check whether the generator and starter motor are firmly installed, whether they are clean and firm with the connector, and whether the carbon brush and commutator are worn.
9. Check the tightness of the fan belt.
10. Check whether the wheel is firmly installed, whether the tire pressure meets the requirements, and remove the sundries embedded in the tread.
11. If the parts are disassembled due to maintenance work, the forklift road test shall be carried out after reassembly.
(1) The braking performance under different degrees shall be free from deviation and snaking. On steep slopes, it can stop reliably after the hand brake is tightened.
(2) Listen for abnormal sound when the engine is running under acceleration, deceleration, heavy load or no load.
(3) After the road test for a certain mileage, check whether there is overheating at the brake, transmission, front axle housing and gear pump.
(4) Whether the lifting speed of the fork frame is normal and whether it trembles.
12. Check whether the filter screen at the oil inlet of the diesel tank is blocked or damaged, and clean or replace the filter screen.
3、 Secondary technical maintenance
In addition to the first level technical maintenance of each item, the following work is added:
1. Clean each oil tank, filter screen and pipeline, and check whether there is corrosion and crack. After cleaning, it is not allowed to wipe with gauze with fiber and cloth.
2. Clean the torque converter and gearbox, check the wear of parts and replace with new oil.
3. Check the transmission shaft bearing and change the direction of the cardan spider as necessary.
4. Check the fastening of each part of the drive axle and whether there is oil leakage, and dredge the air hole. Disassemble and inspect the main reducer, differential and wheel reducer, adjust the axial clearance of bearings, and add or replace lubricating oil.
5. Disassemble, inspect, adjust and lubricate the front and rear hubs, and carry out half shaft transposition.
6. Clean the brake and adjust the clearance between the brake drum and the brake shoe friction plate.
7. Clean the steering gear and check the free rotation of the steering wheel.
8. Disassemble and clean the gear oil pump, and pay attention to the wear of gear, shell and bearing.
9. Disassemble the multi-way valve, check the clearance between the valve rod and the valve body, and do not disassemble the safety valve if necessary.
10. Check the steering knuckle for damage and cracks, the fit between the steering axle kingpin and the steering knuckle, and disassemble and check the wear of the vertical and horizontal tie rods and the joints of the steering arm.
11. Remove the tire, rust and paint the rim, check the inner and outer tires and cushion belt, transpose and inflate according to the regulations.
12. Check the connection and fastening of hand brake parts, and adjust the working stroke of hand brake lever and foot brake pedal.
13. Check the electro-hydraulic specific gravity of the battery. If it does not meet the requirements, it must be removed for charging.
14. Clean the water tank and oil radiator.
15. Check whether the shelf and frame are deformed, whether the rollers and accessories are fixed reliably, and add welding if necessary.
16. Dismantle and inspect the lifting cylinder, tilt cylinder and steering cylinder, and replace the worn seals.
17. Check each instrument sensor, fuse and various switches, and adjust them if necessary.
4、 Whole vehicle lubrication
For new forklifts or forklifts that have stopped working for a long time, within two weeks after starting to use, for bearings that should be lubricated, new oil should be used to squeeze out all the old oil and lubricate it more than twice. At the same time, pay attention to the following points:
1. Before lubrication, remove the dirt on the oil cover, oil plug and oil nozzle to prevent the dirt from falling into the mechanism.
2. When injecting lubricant with grease gun, it shall be injected until the parts of each component combine to extrude lubricant.
3. Seasonal lubricants (oil, etc.) should be replaced in summer or winter.
