7.1.2.1. Forklift device
Rice. 7.12. Forklifts:
A with front loader;
b with side lift
A forklift is a universal self-propelled lifting and transport machine designed for loading, unloading and transporting various goods over short distances. The loader mainly works with piece and packaged goods; it can also be used to transport bulk cargo.The forklift consists of lifting equipment and a pneumatic wheel chassis.
Depending on the location of the working equipment on the chassis, there are forklifts with a front load lifter (Fig. 7.12, a) and with a side loader (Fig. 7.12, b).
lifting equipment includes a forklift 2 and a load-handling device - forks 1. Front-end loaders transport cargo on forklifts, with a side loader - on platform 5; The forklift in this case serves to load the cargo onto the platform and unload it.
Instead of forks, another load-handling device can be installed on the forklift, for example, an boom with a grab for loading loose and lumpy materials.
All elements of the forklift drive (power plant, transmission, control system) and running gear are borrowed from mass-produced trucks. They differ only in the layout of the units and the frame.
Undercarriage of a forklift(Fig. 7.13) contains a frame 9, on which the engine 7, units and power transmission systems and a running gear are installed - drive axle 4 and axle 10 with steered wheels.
Rice. 7.13. Forklift
The wheels of the undercarriage form four supports of the forklift and provide it with a stable position, its movement and maneuvering on the site under its own power.Drive axle 4 is rigidly attached to frame 9, and axle 10 with steerable wheels is hinged, with the possibility of lateral swing of the axle. Articulated suspension allows you to keep the contact of all wheels when driving on uneven ground and evenly distribute the load on the steered wheels.
7.1.2.2. Forklift working equipment
Forklift is designed to capture the load, lifting it to the required height, lowering it and stacking it.
The main parts of the forklift (Fig. 7.14) are the sliding frame of the lifting mechanism and the carriage with forks.
The sliding frame of the forklift consists of an outer fixed frame and an inner movable frame.
The outer frame 1 is a structure consisting of two vertical guides and upper and lower crossbars. A plate with a ball joint 16 is welded to the lower cross member for attaching the lifting cylinder 5. In the lower part, trunnions are welded to the frame, pivotally connecting the outer frame of the forklift with frame 2 of the loader chassis. In the middle part of the outer frame, two brackets 3 are welded, connecting the frame with tilt cylinders 4.
The inner frame 6 of the forklift consists of two vertical rails interconnected by crossbars. Two cheeks 7 are attached to the upper crossbar, to which a traverse 8 fixed on the plunger of the lifting cylinder 5 is attached with rollers 9 for cargo chains 10.
Rice. 7.14. Forklift
The lifting mechanism includes a plunger cylinder 5, a traverse 8 with rollers 9 and chains 10. One end is attached to the brackets of the carriage chain, and the other to the bracket of the lifting cylinder housing.When the cylinder is turned on, the plunger begins to extend and move the inner frame through the traverse 8. The inner frame moves relative to the outer frame at a speed equal speed extension of the plunger, and the carriage relative to the outer frame moves at twice the speed and at the end of the plunger stroke, it is on top of the inner frame.
The carriage is lowered by its own weight.
To tilt the load lifter, two hydraulic cylinders 4 are used, the bodies of which are pivotally attached to the brackets of the chassis frame, and the rods are attached to the lugs on the outer frame of the load lifter. They tilt the forklift forward or backward by 3° and 10°, respectively.
To install lifting devices (forks) - the sliding frame of the forklift is equipped with a carriage suspended from the frame on two leaf chains.
Rice. 7.15. Carriages: a with rigid fastening of pickups;
b with articulated tiebacks
Carriage with rigid fastening of pickups(Fig. 7.15, a) consists of the upper and lower plates 1, interconnected by racks 2, to which the axles 3 of the rollers 4 are welded.The rollers move along the guides of the inner frame.
Slots are made in the top plate for fixing the forks. The forks have upper 8 and lower 9 hooks, bracket 10 and spring-loaded latch 7.
In a carriage with articulated pickups(Fig. 7.15, b) axles 12 are used, and brackets 13 are used to fix them. In addition, side rollers 14 are made on a separate bracket 15.
Interchangeable lifting devices are designed to increase the productivity of the loader when working with loads of certain shapes and sizes, such as drums, rolls, bales, bulk and lumpy materials. Interchangeable lifting devices are also used to perform specific loading and unloading and installation operations, for example, when unloading containers. Up to 40 types of load handling devices are used for forklifts.
Fork extensions used for loading and unloading operations and stacking packaged goods with low bulk density, for example, in light and food industries.
blockless arrows Designed to handle bulky, irregularly shaped loads. A blockless boom is called an arrow in which a cargo hook with a constant or variable reach is located on the cantilever part. Blockless arrows are used when it is necessary to lift the load to a great height.
Rice. 7.16. blockless boom
standard design
A blockless boom of a typical design (Fig. 7.16) consists of a cantilever part made of two channels 9 connected by crossbars 10, a supporting part with uprights 14, braces 11, a transverse bar 12 with hooks 13 for hanging onto the forklift carriage and a lower crossbar 15.Hook 1 (shown disassembled in Fig. 7.16; hook assembly 7) is hung on the boom in socket 8.
To rearrange the hook from one position to another, it is necessary to turn the traverse 90° around its axis and, lifting it up together with the hook, remove the traverse trunnions from the guide slots of sockets 8.
A blockless boom with a variable, smoothly changing reach and a hydraulic drive for moving the hook is shown in fig. 7.17.
Rice. 7.17. Blockless boom with hydraulic
hook travel drive
Between the channels, relying on their lower shelves, the carriage 1 with the hook 2 moves. The hydraulic cylinder 6 and the articulated linkage 4 serve to move the carriage. linkage axis 5.When the rod is extended from the cylinder, the leverage, lengthening, moves the carriage with the load hook forward. When the rod is pulled inward, the linkage folds up and the hook moves back.
By adjusting the extension of the rod, you can install the hook anywhere on the cantilever of the boom.
Rice. 7.18. Frameless bucket
Frameless bucket(Fig. 7.18) is made with brackets 3 and 15 for attaching it to the loader carriage.Hydraulic cylinder 4 is attached to the bracket 3 with the help of axis 2, and brackets 8 are attached to brackets 15 on axles 11, which, in turn, are attached to the carriage. Cylinder 4 is fixed between the carriage posts using axle 5.
Pincer grip(Fig. 7.19) is designed for work with round wood and board packages. The capture consists of a frame 6, on which the upper 2 and lower 3 paws with forks are hinged.
The upper paw is driven by a hydraulic cylinder 9, the lower paw - by two hydraulic cylinders 4. The gripper ensures the fork 1 tilts down when picking up the load and up when transporting it.
Boom with grapple and hook(Fig. 7.20) is mounted on a forklift and is a three-dimensional metal structure.
Rice. 7.20. Boom with clamshell
fixture and hook
In the middle part, the boom is hinged to the brackets 4 mounted on the carriage 3, in the tail - with the help of rods 1 to the forklift.Traverse with hook 5 is attached to the front of the boom. Beam 7 with hydraulic cylinders 8 is attached to the boom on chains 6, on which a double-jaw grab 10 is suspended by means of rods 9 and rods of hydraulic cylinders. The jaws of the grab are driven by hydraulic cylinders 8.
Rice. 4.19. Pincer grip
Rice. 7.21. Swivel carriages:
A with pitchforks; b with clamp
Swivel carriages are designed to rotate the load when stacking. On the rotary part 1 of the carriage, a fork 2 (Fig. 7.21, a) or a side clamp 3 (Fig. 7.21, b) are mounted, which is driven by a separate hydraulic cylinder 4.Single and multi-pin grips designed for securing piece cargo in the form of bandages, coils of wire, tires (single-pin), as well as for the transportation of piece cargo in the form of barrels, rolls, bags (multi-pin). The grippers are attached to the carriage in the same way as a blockless boom is attached.
Universal forklifts consist of the same units for their purpose as electric forklifts, and differ from the latter in type power plant And technical parameters. You can read them at the beginning of the article. Forklift trucks equipped with a set of interchangeable load gripping devices can also perform various cargo operations with piece, bulk, lumpy, timber and other cargo.
Forklifts have a common constructive scheme including chassis 9 on pneumatic wheels, engine internal combustion 7, transmissions, hydraulic drives, forklift 3, steering axle 8, drive axle 11, carriage 2, forks 1, control panel 10, driver's seat 6, steering wheel 5 and guardrail 4.
Forklifts are widely used automotive units, assemblies and parts. Forklifts with a front-mounted forklift usually have a front axle that is driven and a rear axle that is steered.
are arranged similarly to small-sized ones, but have big sizes, carrying capacity.
Designed for loading and unloading and transport operations with long loads and large-capacity containers. They allow you to reload and transport long loads in narrow aisles, which is impossible with conventional universal (front-end) loaders.
It is irrational to use the latter for transporting long loads, since this can lead to a loss of lateral stability of the loader and, in addition, will require wide passages. The front axle of the loader is controlled, the rear axle is driven.
Single bucket loaders called self-propelled loading and unloading machines with the main working body in the form of a bucket installed at the end of the lifting boom.
Single-bucket loaders are mainly used for loading bulk and lumpy materials into vehicles. Loaders are sometimes used to unload bulk materials from covered railway wagons.
The main type of loaders are tractors and tractors equipped with mounted working equipment on caterpillar or pneumatic wheels. The working equipment forms a set of beams and levers hinged on the frame of the machine, carrying the bucket. Replacing the bucket with special grippers makes it possible to use these machines for processing piece goods, including timber, cargo and turns them into universal loaders.
loaders have high permeability and provide great traction.
The scheme of a single-bucket loader with pressure action with rear unloading is shown in the figure.
A bucket with a capacity of 2.8 m3 is mounted on a lifting frame made in the form of a portal hinged to support legs mounted on the tractor to mount the loader equipment. The frame covers the crawler trucks from the outside. A channel beam is welded to the bottom of the bucket, having trunnions at the ends, by which the bucket is connected to two (right and left) symmetrical systems of drive levers and an arrow, each of which consists of a fork traction, a figured lever and the main lever, which is freely planted on the trunnions of the support frame and is pivotally connected to the hydraulic cylinder rod and figured intermediate lever, the lower part of which is pivotally connected to the lifting boom. A buffer is provided to protect the oil tank from possible shocks, and skis are provided to protect the lever frame of the bucket from abrasion.
When the cylinder rods are extended, the levers mounted on the boom (gantry) of the loader turn, the boom rises, and the bucket turns.
When moving the bucket over the tractor (middle position), it takes a horizontal position and then acquires a reverse slope. The bucket is unloaded from the side opposite to scooping.
Loader capacity 4 t, unloading height 2.6…3.4 m, unloading angle 25…45°.
A scoop loader with front unloading and a rigid frame has a portal on the chassis in front of the cab that carries loading equipment: a shaped curved boom with two levers. articulated rods -
pushers with a rotary bucket, and two pairs of hydraulic piston cylinders double-acting and performing lifting-lowering of the boom and rotation of the bucket in the longitudinal and vertical planes. The bucket boom is equipped with skis for resting on the ground when scooping up the load.
They are designed with swivel boom within 120 ... 180 ″, This allows for side unloading.
Scheme articulated shovel loader shown in the figure.
All components and assemblies of the loader are mounted on an articulated frame containing the front 5 and rear 3 semi-frames interconnected by a vertical articulated device 4. This provides a change in the direction of the loader by turning the semi-frames relative to each other, increasing maneuverability and reducing the duration of its working cycle. Rigidly connected to the front frame 5 front axle 6. The rear axle 1 is suspended from the semi-frame 3 by means of a horizontal articulated device. This balancing suspension rear axle allows it to turn in a vertical plane when running wheels on an uneven surface pavement or when driving over rough terrain.
The result is a constant grip of the wheels with the road, and the frame gets rid of twisting deformations. Both axles have the same unified design and are leading axles with the ability to disable the rear axle in transport mode.
The main working body of the loader is a bucket 8 of a tipping type with a capacity of 1.5 m3. It is hinged on the outer end of the lifting boom 7 and is connected by a lever system 9 to two hydraulic cylinders 10 of its rotation.
The inner end of the boom is pivotally mounted on the front half-frame. By turning relative to the hinge, the boom is raised and lowered, driven by two hydraulic cylinders. The housings of the hydraulic cylinders for turning the bucket and lifting the boom are hinged on the racks of the front half-frame.
Loader power unit - diesel four stroke engine with a capacity of 135 liters. With. The engine is mounted on the rear half-frame 3 and is started from the cabin 11.
consists of portal 1, based on pneumatic wheels 2. Diesel engine 3 and gearbox are installed on the upper platform of the loader, which can capture, lift and transport the container. It provides two-tier stacking of containers, their loading and unloading from the automobile rolling stock. dimensions: width 4.6 m, height 7.4 m. Minimum turning radius 9 m. Lifting speed 8 m/min, movement with load 25 km/h, weight 25 tons.
They provide not only transportation, but also stacking of containers in 2 ... 3 tiers. To move the container, they run into it with their portal 1, grab it with a special grip 2 (spreader) and lift it to the required height.
Some straddle carriers can grab a container from a railway platform (car) with a spreader 3 and transport it to a storage place. In some loaders, all 4 wheels are driven, and they can turn 90 °, which ensures the movement of the loader in all directions without turning.
They serve to move in open warehouses mainly lumber and other long loads, formed in packages or stacked in bundles, and containers.
Loaders can work on the planned sites with a hard surface. The load is placed between the right and left running wheels. Chassis - unsprung. Chassis contains four wheels with pneumatic tires, of which the front ones are steered, and the rear ones are driven. Energy source - automotive carbureted engine. The loader is equipped with four forks that can be rotated by 90° in the horizontal plane, located in pairs on the left and right sides. After picking up the load, the forks are raised to the transport position. The load lifter allows the load handling device to be lowered 2 m below its supporting surface.
It is intended for mechanization of loading onto railway open rolling stock, cars and trailers (semi-trailers) for them, as well as unloading from them packaged cargoes formed in packages and moved in separate units and long cargoes, mainly timber. The loader is used in open warehouses with a hard, even surface.
The machine is unsprung, the front wheels are driven, the rear wheels are steered, the energy source is a carburetor engine 1 with a power of 84.5 kW. The forklift is made in the form of an articulated arm 5 with a mechanism for maintaining a constant position of the forks. The boom is raised and lowered by a plunger hydraulic cylinder 4. Two double-acting piston hydraulic cylinders are installed on the boom: changes in the inclination of the grip (forks) in the longitudinal direction 7 and closing (opening) 6 of the upper jaw. To increase the longitudinal stability of the loader, there are two front retractable supports 3. The counterweight 2 can be extended back beyond the outline of the machine in transport position.
consists of an arrow 2, on which the jaw b and the rotary jaw 3 are rigidly fixed.
A pack of wood is captured by the pressure movement of the entire machine forward when turning the jaw 3 upwards. Jaw 6 serves as a stop to which the forest is pressed by the lower jaw, and after lifting, transferring the handle through the tractor - a guide for the mass of forest rolling down. The rotation of the jaw relative to the boom is carried out by hydraulic cylinders 7 using roller chains and sprockets 5 near the axis of rotation 4. The handles are raised by hydraulic cylinders 9, while the balancers I rotate relative to the frame 10 rigidly connected to the tractor body. Shields 8 and 11 are used to protect the loader cab and tractor mechanisms from destruction in the event of a possible fall of the load.
The forklift is a special warehouse equipment designed for loading and unloading operations, transportation and warehousing of various cargoes. The loader device is a well-coordinated system, including a mass of components and additional equipment. What components are included in the forklift device, how does it work?
Loader design
Rich is being issued today the lineup forklifts. Design different models may differ.
But, for the most part general device forklift requires the following components and assemblies:
- engine;
- rechargeable batteries (relevant for electric models);
- chassis;
- tires;
- brake mechanisms;
- lifting device;
- control system;
- hanging equipment.
Let us analyze in more detail the functional purpose and features of the key components of the forklift type device.
Engine
Most main element forklift devices (diesel or electric) - a power unit, it is also an engine. Today, forklifts are produced, equipped with one of two types of engines: electric or internal combustion (ICE). The latter, in turn, are divided into diesel, gasoline and gas. Some manufacturers offer models with hybrid power units, which allows you to work on different types fuel. Most loaders used in European countries, equipped with gas or electric motors. This is due to the economy and environmental friendliness of this technique.
Often, forklift manufacturers use engines from third party manufacturers. So, most often, forklifts are equipped with engines from Nissan or GM.
Let's analyze a few of the most popular models engines of these manufacturers and their characteristics:
The electrical circuit of the loader is the basis of the equipment control system. This is a complex of electronic components, including microprocessors, controllers and other parts, providing automatic or semi-automatic control of all forklift units, and, above all, the engine.
lifting device
Device forklift truck any model necessarily implies the presence of a special unit responsible for lifting the load. Standard-type loaders produced today are capable of lifting loads by 8 m. There are also specialized high-altitude cranes, the maximum lifting height of which reaches 18 m. Lifting loads to a considerable height is associated with a lot of dangers. To reduce risks, manufacturers install special systems on their equipment that protect against vibration and level the effect of the unevenness of the site on which the loader operates. Due to this, the weight of the mast is reduced, its structure becomes more rigid and durable.
Loading units have masts that lift loads by means of special hydraulic cylinders. The loader's hydraulic circuit ensures smooth lifting and high security during machine operation. Models with retractable masts do not have a unit that is responsible for tilting the mast, since the center of gravity of these units shifts so much that the tilt would simply lead to a rollover. These models of loaders are equipped with tilting forks.
Tires
Forklifts can be used in the most different conditions. The machines are used both in warehouses with a flat floor and in open areas, sometimes without any coating at all, which is especially important for construction sites. In manufacturing plants, there are often metal chips on the floor, on which forklifts have to move.
Therefore, various types of tires are used, selected based on the conditions of use:
- pneumatic;
- bandage;
- superelastic.
Pneumatic tires are similar in design to automobile tires, but reinforced with additional cord layers. Allows the use of loading equipment on various surfaces. Can be used on hard ground snow covered surface. A layer of air provides smoothing of irregularities, which has a positive effect on the service life of the transmission system.
Bandage tires are made from special material containing rubber, and a metal inner ring. Designed for use on flat surfaces. They have excellent strength, can be subjected to significant loads.
Superelastic tires are a combination of the two options discussed above. If necessary, they can be replaced with pneumatic ones. The design of such tires involves the presence of 3 layers of a substance containing rubber. The inner layer is designed to fix the tire on a steel disc rim. The middle layer performs a shock-absorbing function. The last layer can have a pattern. If there is no pattern, the use of such tires is allowed only on hard, even surfaces.
Most modern loaders use tires from the manufacturers SOLIDEAL (Belgium, produces all types of tires) or Advance (China, the main specialization is the manufacture of superelastic tires).
WITH.
L- loader length;
B – loader width;
H 1 is the height of the loader.
Load lifting speed;
Movement speed;
maneuverability.
12. Maneuverability determines the completeness of the use of the area of the premises and depends on the turning radius and overall dimensions of the loader.
The device of loaders (the main parts of the working equipment and running gear).
The loader consists of two main parts:
1. Working equipment.
2. Chassis.
The composition of the working equipment:
1. Lifting device (fork grip, single pin grip, multi pin grip, cargo boom, bucket, side grip.
2. Forklift.
Running gear composition:
3. Cabin. 7. Frame.
4. Engine. 8. Transmission.
5. Counterweight. 9. Driving wheels.
6. Steerable wheels.
Working equipment is designed to perform cargo operations with various cargoes.
The internal combustion engine is the source of energy.
The transmission is the power transmission that connects the engine to the drive wheels.
The counterweight ensures the stability of the loader when working with loads.
The principle of operation of the forklift.
When the rods of the lifting cylinders are extended, the inner frame is extended relative to the outer frame. Simultaneously with the inner frame, the rollers rise, on which the chains roll, raising the carriage.
As a load gripping device, a fork, bucket, cargo boom, clamps, grips can be used.
Types of gears, their purpose. Gear ratio in cylindrical gears.
A gear train is a pair of toothed gears in mesh. Gears are cylindrical, bevel and worm.
The gear train is characterized by the gear ratio i
i \u003d Z 2 / Z 1 \u003d n 1 / n 2
The gear ratio is the ratio of the number of teeth Z 2 of the driven gear to the number of teeth Z 1 of the drive gear. It shows how many times the torque on the driven shaft or its speed (n) changes.
Principle of operation.
When the steering wheel is turned, the front longitudinal link 3 moves the distributor spool 5. The working fluid is directed to the corresponding cavity of the hydraulic cylinder, which acts on the rear longitudinal link 6. This link turns the pendulum lever 7, which is connected transverse rods 8 with pivot pins 9.
hydraulic steering.
In this type of steering, there is no mechanical connection between the steering column and the wheels. The hydraulic steering on the loaders is combined into one hydraulic system with the hydraulic drive of the working equipment.
Compound:
1. Steering column. 4. Hydraulic cylinder.
2. Hydrowheel. 5. Traction.
3. Pipelines. 6. Ball joint.
The hydraulic steering is:
Directing device - works as a distributor;
Dosing device - skips a certain amount working fluid at a certain steering angle.
Principle of operation.
When the steering wheel is turned, the working fluid through the distributor enters one of the cavities of the hydraulic cylinder 4 located on the beam of the controlled axle. The rods of the hydraulic cylinder through the rod 5 are connected with the pivot pins. Steering wheels are fixed to the pivot pins.
The main malfunction of the steering is the increased free play of the steering wheel (backlash). The reasons for the increased backlash can be:
Wear of ball joints;
Deterioration of the steering mechanism;
Loose fasteners;
Air entering the system.
Purpose of the worm gear.
Parking brake operation.
The brake is turned on by moving the handle 5. The handle pulls the cable 4 and turns the lever 1, which, with the help of a spacer bar, pushes the pads apart, pressing them against the brake drums.
The brake is released by returning the handle while pressing the button 6. excluding spontaneous movement of the handle.
When the efficiency of the parking brake decreases, the mechanism must be adjusted by turning the adjusting screw 7, which changes the length of the cable.
Purpose, types and frequency of maintenance. The content of the daily Maintenance.
The maintenance system provides:
Reduced intensive wear of parts;
Fault prevention;
Extension of the service life;
Constant readiness of a loader for work.
A. External examination.
1. Check whether the faults found during the last shift have been eliminated.
2. Check for leaks of oil, fuel and other fluids (Fig.1).
3. Check the reliability of the wheels and the serviceability of the tires (Fig. 2).
4. Check the air pressure in the pneumatic tires (Fig. 3).
5. Inspect the cab guard (Fig. 4).
6. Inspect the working equipment for cracks and deformations (Fig.5).
7. Inspect the condition of the load chains and check their tension (Fig.6,7).
Fig.1 2 Fig. 3 Fig. 4
Rice. 5 Fig. 6 Fig. 7
B. Inspection of units and systems.
1. Check the hydraulic fluid level (Fig. 1).
2. Check the brake fluid level (Fig. 2).
3. Check the operation of the brake pedal (Fig. 3).
4. Check the operation of the devices and control lamps control panel.
5. Check fuel level.
Rice. 1 Fig. 2 Fig. 3
D. Checking the operation of the loader.
1. Start and warm up the engine.
2. Check the motor for condition and noise (Fig. 1).
3. Check the free play of the steering wheel (Fig. 2).
4. Check the operation of the light signaling (Fig. 3).
5. Check the operation of the sound signal (Fig. 4).
6. Check the operation of the forklift. 5).
7. Check the brakes and steering while driving (Fig.3).
Rice. 1 Fig. 2 Fig. 3
Rice. 4 Fig. 5 Fig. 6
18. Production instruction on labor protection for the driver of the loader. Main sections.
Safety requirements before starting work.
The use of overalls and safety shoes during work;
Preparing the loader for work;
The procedure for the driver to start the engine.
This section displays next questions:
Security measures during unloading and loading of cargo;
Limiting speeds of movement on the territory of the enterprise;
Requirements for goods to be moved;
Safety measures during unloading and loading of railway wagons;
What actions are prohibited for a forklift driver;
Safety measures during unloading and loading of vans with a check-in to the body.
Safety requirements in emergency situations.
This section displays the following questions:
Actions of the driver in case of loss of stability of the loader;
Actions of the driver in the event of a fire;
Actions of the driver in the event of an accident or an accident.
Safety requirements at the end of work.
This section displays the following questions:
Rules for parking a forklift;
Work carried out on the loader at the end of work.
Safety requirements during work.
1. When moving a forklift through the territory of a construction site or enterprise, the driver must:
a) make sure before starting to move that there are no people in the way of movement, as well as machines and mechanisms, and give warning signal;
b) when driving in crowded places, their possible appearance (passages, exits from the premises), reduce speed and give an audible signal;
c) comply with the established Vehicle speed of movement on the construction site and the territory of the enterprise;
d) do not leave the loader cab when the engine is running;
e) avoid sudden braking on wet and icy roads;
f) give a sound signal at the entrance and exit from the premises, as well as at intersections with limited visibility.
2. When performing loading and unloading and transport operations, the driver must:
a) when approaching the place of loading (unloading), reduce speed;
b) transport cargo at a height of 200-300mm from the road level;
c) approach the vehicle for loading and unloading operations only after it has stopped and the engine has been turned off;
d) move bulky cargo that obscures the visibility of the route, in reverse or front, but only accompanied by a specially designated person.
3. When loading or stacking soil and bulk materials, the driver must:
a) load the material along the entire front of the stack or face;
b) clean the bucket from adhering soil or material in the lowered position with a shovel or scraper;
c) when stacking bulk materials, stop the loader at a distance of at least 1.0 m from the edge of the slope.
4. When operating a loader equipped with a fork, the driver must:
a) before starting work, check the presence of a gap under the load for the free passage of the fork;
b) place the load evenly along the entire length of the fork, resting it against the backs of the forks by tilting the load back at an angle of 10-15 ° during the capture.
It is forbidden to transport the load, which is on the forks, in an unstable position.
5. Troubleshooting, inspection, adjustment of the unit should be carried out with the engine stopped, lowered to the ground or the working body installed on reliable stands, the brake is applied and the gear lever is in the neutral position.
6. If necessary, travel on locality and on highways, the driver must:
a) bring the working body to the transport position;
b) determine the condition of the route, find out the possibility of overcoming slopes, rises, fords and artificial structures;
c) keep the gear engaged when driving downhill;
d) move through railways only in designated places on solid flooring;
e) when the loader is stopped, apply the parking brake;
f) leaving the loader cab for carriageway roads, make sure that there is no traffic in the passing and opposite directions;
g) use a rigid hitch when transporting loaders in tow or when towing other machines;
h) follow the rules of the road.
7. The driver is obliged to carry out loading and unloading operations in the security zone of the existing overhead power line under the direct supervision of the engineering and technical worker responsible for the safe performance of work, with the written permission of the organization - the owner of the power transmission line and obtaining a work permit that determines safe conditions works.
8. In winter time Drivers are prohibited from:
a) heat the engine with an open flame;
b) work on a loader with a defective cabin heating device;
c) carry out work lying under the loader without the use of an insulated mat.
9. When working at night, the illumination of the work area should be provided by external light sources. The use of headlights by the driver is allowed as an additional source of light.
Requirement for safety in emergency situations.
1. The driver is obliged to stop working in the following cases:
a) in the event of malfunctions that can cause an accident:
The presence of cracks or deformations in the metal structures of the loader;
Leak detection in the power system, lubrication, cooling, hydraulic drive;
Drop in tire pressure;
The presence of crackling, rattle and other signs of malfunction of the hydraulic system or engine;
Malfunctions of the parking or service brake;
Load handling device failure.
b) under adverse weather conditions:
Poor visibility (fog, snowfall, rain);
Icing of the roadway (platform).
c) when you feel unwell.
2. in the event of a fire on the loader:
Call the fire brigade immediately;
Start extinguishing the fire with available means (fire extinguisher, sand, felt mat, tarpaulin).
3. in case of an accident or an accident:
Provide first aid to the injured;
Report the incident to the supervisor.
Safety requirements at the end of work.
At the end of the work, the driver must:
1. Park the forklift in accordance with the following requirements:
Apply the parking brake;
Lower the working body to the ground or place it on a stand;
Bring the control levers to the neutral position;
Stop the engine.
2. Clean the loader undercarriage and work equipment.
3. Report all noticed malfunctions in the operation of the loader to the work manager or the person responsible for maintaining the machine in good condition and make an entry in the log.
It is forbidden to lift and move the following loads:
Loads in an unstable position;
Safety requirements for warehousing.
Warehousing of goods is carried out in closed warehouses and in open areas. Loads are installed on racks or in stacks. Warehousing of goods should be carried out according to technological maps.
Technological maps are made in the form of a warehouse plan, a storage site, on which the following should be indicated:
Locations of cargo stacks;
Dimensions of passages for loaders;
Vehicle access roads;
Passages of people.
Aisle sizes.
The width of the aisles depends on the turning radius of the forklift, the dimensions of the goods being transported and the stacking angle.
By reducing the stacking angle from 90º to 45º, the aisle width can be reduced by 40%.
The width of the central passages in closed warehouses for two-way traffic of loaders must be at least 3 m.
Stack height.
The height of the stacks depends on the properties of the cargo and the means of packaging. For example, stacked goods on pallets and box pallets can be installed 4 tiers high.
According to the conditions of stability, the height of the stack should not exceed the size of the smaller side of the base of the load more than:
For non-separable containers - 6 times;
For collapsible containers - 4.5 times.
Stacking device.
Oversized and heavy loads are stacked in one row.
Palletized loads should be stacked on top of each other. To improve stability, the topmost row should be placed with a checkerboard offset. The distance between pallets in a stack is at least 50mm (Fig. 1).
Cylindrical weights must be installed on horizontal spacers with stops (Fig. 2).
Rice. 1 Fig. 2
Cylindrical weights can be installed in a pyramid using stops, no more than 3m high (Fig. 3).
Packets of lumber in stacks must be separated by spacers - wooden blocks with a section of 100x100mm. The height of the stacks when stacking by loaders is not more than 7 m (Fig. 4).
Rice. 3 Fig. 4
Locations of stacks.
It is prohibited to lay loads close to the walls of buildings, columns. When placing loads, the following minimum indents must be observed (Fig. 5):
From the walls - 1m;
From heating devices - 0.2 m;
From light sources - 0.5 m.
Placement of cargo should be carried out at a distance of at least 1 m from the edge of the slope of trenches or pits (Fig. 6).
Cargo located near railway and crane rail tracks must be located from the rail head:
Not closer than 2m with a stack height of 1.2m;
With a higher stack height - no closer than 2.5 m (Fig. 7).
Rice. 5 Fig. 6 Fig. 7
Requirements for goods to be moved.
Weight of cargo.
The loader can be represented as a scale balanced with respect to the tipping edge - the axis of the front wheels.
When the mass of the load exceeds the capacity of the forklift, the common center of gravity crosses the tipping edge and the balance is disturbed.
The location of the cargo.
The balance of the scales is disturbed if the load is removed from the tipping edge.
For removing common center gravity of the loader and the load from the tipping edge (increasing the stability of the loader), the load on the forks must be placed in compliance with the following requirements:
Place the load close to the back of the forks, and tilt the forklift back until it stops (this position is called TRANSPORT);
The center of gravity of the load must be located on the longitudinal axis of the loader;
The load must not protrude beyond the forks by more than 1/3 of the overall dimension.
Lifting height.
To increase the stability of an object, its center of gravity should be located as low as possible to the supporting surface. It is clear that object 1 is much more difficult to drop than object 2.
With an increase in the lifting height of the load, the stability of the loader decreases.
Site slope
When the loader is working on a site with a slope, the centers of gravity of the load and the loader are shifted to the side. Especially dangerous is the high lifting of the load, in which the center of gravity can shift beyond the limits of stability.
To ensure stability, the site must meet certain requirements:
During unloading and loading operations, the slope of the site should not exceed more than 3 °;
movement is allowed on the site with a slope, no more than indicated in the technical specifications on this loader, with the transport position of the load, with which the movement to the ascent with the load is only forward, and the descent is only in reverse.
Centrifugal force.
Centrifugal force is the force of inertia acting when a body moves in a circle. Centrifugal force is generated when the forklift moves around corners.
When the loader turns, its wheels move in the direction of turn, and the center of gravity of the loader continues to move by inertia in forward direction. In this case, the centrifugal force Fц acts on the loader, causing the moment of capsizing. Value centrifugal force and the moment of overturning depend on the speed of movement and the turning radius. The driver must slow down when cornering to avoid tipping the truck and dropping the load.
Inertia when braking.
When braking, the drive wheels stop moving, and the load and loader continue to move under the influence of inertia. This violates longitudinal stability loader. The action of the inertia force increases with an increase in the height of the load and sudden braking.
Conclusion: transport the load at the transport height and brake the loader smoothly.
Induction training.
This type The training is conducted by an occupational safety engineer. It is recommended that the agenda include the following:
1) general information about the enterprise and characteristics production;
2) the main provisions of labor protection legislation:
Employment contract, work time and rest time, labor protection for women and persons under 18 years of age, compensation and benefits for working conditions;
Internal labor regulations and liability for violation of these rules;
Organization of work on labor protection in production and carrying out state, departmental supervision and control;
3) general rules behavior of people working in the enterprise;
4) the main dangerous and harmful production factors characteristic of the enterprise:
Methods and means used at the enterprise to prevent injuries and occupational diseases:
Basic rules of labor safety for the prevention of injuries;
5) basic requirements for sanitation and personal hygiene;
6) the procedure and norms for the issuance of funds personal protection, terms of wear and rules for their use;
7) circumstances and causes of typical accidents that occurred at work;
8) the procedure for investigating accidents and occupational diseases;
9) ways and means of preventing accidents and fires, actions of personnel in case of their occurrence;
10) actions of employees in case of accidents, first aid to victims.
An entry in the journal is made about the conduct of the introductory briefing with the obligatory signature of the instructed and instructing.
Target coaching.
Target briefing is carried out when performing the most dangerous or previously unperformed work.
Loading and unloading works.
1. Before starting work, receive instructions from the manufacturer of works on the features of the cargo, the technology of work and safety measures.
2. Perform work with concentration, without being distracted. Do not lean out over the cab rails while driving.
3. Observe the established driving speeds:
On roads on the territory of the enterprise - 10 km / h;
Indoors - 5 km/h;
When turning, driving around the corners of buildings, crossing railway tracks, at intersections and in narrow places, no more than 3 km/h.
The mass of which exceeds the maximum load capacity of the loader or does not correspond to the load capacity schedule;
Loads in an unstable position;
Clamped, crushed, frozen loads;
Oversized cargo of unknown weight.
5. Manual stacking of cargo on a pallet is carried out only after the pallet is placed on the site.
6. Movement with bulky cargo, closing the forward view, it is necessary to carry out in reverse or forward, but at the commands of the signalman.
7. Move at least 1m away from places where people work;
8. Carrying people on the forklift is prohibited.
9. Lifting people to a height using a forklift is prohibited.
Safety requirements for loading and unloading goods in railway wagons, on platforms.
1. Open the car door.
2. Check the serviceability of the bridge and the reliability of its fastening.
3. Inspect the floor of the car and make sure there are no breaks in the floor.
4. Make sure that the car is braked.
5. Make sure the opposite door is closed.
6. Load the cargo first from one side of the car to the middle, and then from the other side.
7. Gaps between packages and longitudinal walls of the car and adjacent packages 50-60mm.
The order of slinging cargo.
1. Hook the load only in accordance with the slinging scheme, use, if necessary, quickdraws.
2. The hook must be free to go into the mouth of the loop.
3. The load is slinged for all the loops provided for by the project for lifting.
4. The branches of the slings must have the same tension, and the angle between them must not exceed 90°.
5. The sling is superimposed without knots and twists.
6. The unused ends of the multi-branch sling are fixed so that when moving the load they do not touch objects that meet on the way.
It is forbidden:
- hang the load on one horn of a two-horned hook;
Drive the hook into the mounting loop;
Correct the branches of the sling in the throat of the hook with blows.
Loader driving on a slope.
When driving a forklift on a site with a slope, the following requirements must be observed:
Keep the gear engaged when driving downhill;
Move on the rise with a load only forward;
Move downhill with a load only in reverse;
The slope of the platform must not exceed the value specified in the technical specifications for this loader (maximum value is approximately 14°-16º);
Driving across the slope is prohibited.
Principle of operation.
The principle of operation is based on the displacement of carbon dioxide by excess pressure. When the locking and starting device is opened, CO 2 flows through the siphon tube to the socket and from a liquefied state passes into a solid (snow-like) state. The temperature drops sharply (up to -70°C). Carbon dioxide, falling on a burning substance, isolates it from oxygen.
With fractures, burns.
When receiving a chemical burn, you must:
1. Acid:
Rinse the affected area under running cold water for 15-20 minutes;
Treat the affected area with a 3-5% alkaline solution;
2. Alkaline:
Rinse the affected area under running cold water for 15-20 minutes;
Treat the affected area with a 3-5% acid solution;
Apply an aseptic bandage;
summon ambulance or send to the hospital.
When receiving a thermal burn:
The principle of operation of the starting system.
When the key is turned in the ignition lock 4, the corresponding contacts are closed. Electricity flows through the winding of the coil 5 of the traction relay and the armature 6 moves to the left. In this case, the armature, using the lever 7, moves the movable gear 8 into engagement with the ring gear 9 of the flywheel.
At the same time, moving contact 3 closes fixed contacts 2 of starter 1. Current great strength is supplied from the battery to the starter, which, using gear 8, rotates crankshaft engine and starts it.
The traction relay is switched on with a characteristic click that the driver hears. If, after turning on the traction relay, the starter does not rotate the crankshaft, then one of the malfunctions has occurred:
Discharged battery;
Starter defective;
Contacts are oxidized.
Possible malfunctions.
Supply system diesel engine intended for:
Purification of fuel and air;
Fuel supply to the cylinders;
Removal of exhaust gases.
The composition of the power system:
1. Fuel tank. 4. Filter fine cleaning.
2. Filter coarse cleaning. 5. High pressure fuel pump.
3. Booster pump. 6. Nozzles.
The operation of the power system.
Fuel from the fuel tank through the coarse filter enters the booster pump. The booster pump is used before starting the engine to fill the fuel supply system, and after starting the engine, it supplies fuel through the fine filter to fuel pump high pressure (TNVD) at a pressure of 0.8 kgf / cm 2.
The injection pump delivers fuel through injectors to the cylinders under high pressure at strictly defined times. The amount of incoming fuel is determined by the position of the cut-off screw channel of the plunger relative to the bypass channel of the sleeve.
The injectors are designed to inject fuel into the cylinders, spray it finely and form a fuel jet. Fuel is injected into the cylinders at the end of the 2nd stroke - the compression stroke and ignites spontaneously.
Malfunctions of the power system.
48. The engine does not start or does not develop full power.
No fuel in fuel tank;
Air enters the fuel supply system;
Clogged fuel filters;
Reduced fuel injection pressure;
Seized fuel pump rail.
2. Smoky exhaust gases (black smoke).
Insufficient air supply;
The atomizer needle is stuck or the nozzle atomizer holes are coked;
Fuel advance angle set incorrectly.
Appointment of loaders, their main technical characteristics.
The loader is self-propelled lifting machine designed for loading and unloading operations and transporting goods over short distances.
Technical characteristics of the loader.
1. The rated load capacity is the maximum allowable weight for lifting and transporting that the truck is designed for.
2. Distance from the back of the fork to the center of gravity of the load WITH. This distance is not a constant value and depends on the length of the forks and the overall dimensions of the load. Forklift load capacity vs. distance C shows the load capacity chart.
3. Lift height H is the distance from the parking level to the upper surfaces of the forks in the up position.
4. Overall dimensions of the loader:
L- loader length;
B – loader width;
H 1 is the height of the loader.
5. Free lift height H 2 is the amount of fork lift without increasing overall height. Forklifts with a low free lift height cannot work in rooms with low ceilings, wagons.
6. Ground clearance h is the distance from the lowest point of the truck to the parking level.
Stability loaders have low ground clearance.
7. Turning radius R is the smallest radius of the area required to turn the loader.
8. Tilt angles of the forklift:
α - forward tilt angle to facilitate the capture of the load on the forks (3 ° - 5 °);
β – angle of inclination back to increase stability when transporting cargo (8°-12º).
9. Load lifting speed (0.25m/s - 0.45m/s).
10. Movement Speed ( top speed traffic on roads in the territory of the enterprise is 10 km/h).
11. Productivity is the amount of cargo moved by a forklift in a certain time.
Performance depends on:
loader capacity;
Load lifting speed;
Movement speed;
maneuverability.
12. Maneuverability determines the completeness of the use of the site
Forklift mast types: FV, FFV, TFV or Duplex, Triplex, Quadroplex. The principle of operation and purpose of the forklift
There are several types of forklift masts:
. Duplex is a two-section mast with standard free play.
. Duplex is a two-section mast with special free play.
. Triplex - a three-section mast.
. Quadroplex is a four-section mast.
At different manufacturers For loaders, the types of masts in the specifications are designated differently, but this does not change the essence. But in a professional environment most widespread has the following forklift markings:
FV - two-section mast
FFV - two-section free swing mast
TFV - three-section free lift mast
For example, Japanese Nissan loaders have mast markings as follows: 2W, 2F, 3F. Where the number indicates the number of sections, and the letter F indicates the presence of a special freewheel at the forklift.
Duplex mast with standard free lift
This type of mast has two sections and two lifting cylinders located on the sides. With such a mast, the forks rise to a height of 150 mm from the ground, and then the inner section of the mast begins to extend, thereby increasing the height of the loader. The lifting heights of such masts range from 3.0 m to 5.0 m. The standard lifting height for loaders is 3.0 m.
The kinematic diagram of a standard duplex mast is as follows.
duplex mast with special free play
When the lift lever is pressed, the hydraulic cylinders begin to move upwards at the loader and raise the inner section of the mast on which the blocks (polyspast system) are located with chains attached to the carriage. Thanks to this, the load carriage with the forks also begins to rise.
duplex mast with special free play
The mast consists of two sections, like the standard one, but in hydraulic diagram one more special freewheel cylinder is added, which is located in the middle of the mast. Its function is to raise the carriage with forks without changing the building height of the forklift, and only then the inner section of the mast is extended using two side lifting cylinders. The most common lifting heights for these forklifts range from 3.0 m to 3.3 m.
The kinematic diagram of this forklift is as follows. 
First, the central cylinder with the block rises and with it the forks. The main lift cylinders then begin to operate and extend the inner mast section.
Triplex mast
Unlike its predecessors, the mast already has three sections. For forklifts and electric forklifts, these masts always have a special free play by default.
The triplex mast according to the kinematic scheme combines the first two masts.
First, the freewheel cylinder works, then the main lifting cylinders that lift the second mast section, and that, through the system of blocks, pulls up the third mast section with the carriage and forks.
Four-section mast Quadroplex
This is the result of the genius of the load handling engineers on the forklifts. The mast already consists of four sections. The range of lifting heights is 6.0 m - 8.0 m. It is used very rarely by some manufacturers on loaders with a carrying capacity of 2.0 to 3.5 tons. These include GROS and HYUNDAI.
single section simplex mast
The simplex mast has only one section, so it does not have side lift cylinders, but only a central cylinder, which is both a freewheel cylinder and a main lift cylinder. Clear representatives and owners of such masts are hydraulic stackers with a lifting height of 1.6 m.
