Remote-controlled forklifts are an important part of modern warehousing and logistics equipment, widely used due to their flexibility and high efficiency. However, ensuring their safety and long-term stable operation is crucial during use and maintenance. This article introduces the safety operating procedures and maintenance of remote-controlled forklifts.
1.1 Pre-Operation Inspection
Battery Power: Before each operation, check the forklift's battery power to ensure it is sufficient, avoiding sudden shutdowns during operation.
Equipment Appearance: Inspect the forklift's appearance, especially the forks, tires, and drive system, ensuring there are no damaged or loose parts, no obvious deformation or cracks, and confirming that tire wear is within safe limits.
Remote Control Function Check: Ensure the remote control functions properly, all buttons respond normally, and it is properly paired with the forklift. If the remote control signal is weak or it cannot be operated, the batteries must be replaced immediately or the fault must be diagnosed.
Function Test: Test the stability of the remote control signal connection, check the sensitivity of the emergency stop button, and verify that the hydraulic lifting system's working pressure is normal.
Environmental Assessment: Remove obstacles from the work area, ensure the ground's load-bearing capacity and flatness meet requirements, and set up clear safety warning signs.
1.2 Safety Measures During Operation
Adhere to Load Limits: When loading, ensure the forks are fully inserted into the pallet and the center of gravity is centered and stable. Strictly adhere to the forklift's maximum load limit; overloading will not only affect the forklift's efficiency but may also lead to equipment damage or accidents.
Smooth Driving: When operating a remote-controlled forklift, avoid sharp turns, rapid acceleration, or sudden braking to ensure the forklift's stability, especially when stacking items at a height. Maintain a constant speed, slow down before turning, and sound the horn when passing through narrow passages. Never carry passengers while operating the forklift.
Operate Within Line of Sight: Ensure the forklift is always within the operator's line of sight and avoid operating in environments with many obstacles. Avoid standing in front of or to the side of the forklift; maintain a safe distance and avoid signal obstruction or interference to prevent collisions.
1.3 Safety Environment of the Workplace
Obstacle Removal: Before operation, ensure the work area is free of obstructions to avoid operational errors or equipment damage caused by obstacles.
Maintain Appropriate Speed: In the work environment, especially in narrow passages and areas with high stacks of goods, avoid high-speed driving and remain vigilant at all times.
Warning Signs: Ensure there are clear warning signs in the warehouse or work area to remind operators to pay attention to safety, especially in high-risk areas.
1.4 Special Operating Scenarios
Working at Heights: When raised above 2 meters, safety belts must be worn, and the lifting platform must be securely locked.
Operating on Slopes: Always keep the forks pointing upwards on the slope. Turning or stopping on slopes is strictly prohibited.
Night Operations: All lighting equipment must be turned on, and operators must wear reflective vests.
2.1 Daily Maintenance and Inspection
Cleaning: Clean the forklift surface daily, removing oil and dust, paying special attention to the cleaning and protection of electrical components.
Battery Maintenance: Regularly check the battery electrolyte level and battery terminals to ensure there is no corrosion or loosening. Regularly charge the battery to avoid over-discharge.
Tightening Inspection: Thoroughly inspect the tightness of bolts and nuts, paying particular attention to the fork carriage and mast connections.
Hydraulic System Inspection: Regularly check the hydraulic system oil level and ensure the hydraulic oil is clean and meets standards. Check for leaks in oil lines and cylinders.
Drive System Inspection: Regularly inspect the wear of the motor, transmission, tires, and steering system. Lubricate moving parts promptly to reduce friction and extend service life.
2.2 Regular Maintenance
Brake System: Test braking performance, check and adjust brake pad clearance to ensure stable braking function.
Tire Inspection and Replacement: Regularly check tire wear, especially the grip and wear uniformity of forklift tires. Replace tires with cracks, bulges, or severe wear immediately.
Motor and Electronic Control System: Regularly inspect the motor brushes and terminals to prevent malfunctions caused by poor contact. Regularly clean the cooling fan of the electronic control system to ensure proper heat dissipation.
2.3 Annual Comprehensive Inspection
Battery Charging System Inspection: Regularly inspect the forklift's bearings, chains, gears, and other transmission systems, adding lubricating oil as needed to prevent friction and malfunctions due to insufficient lubrication.
Hydraulic System: Check for leaks in the oil lines and clean the hydraulic oil tank breather.
2.4 Troubleshooting and Repair
Common Fault Diagnosis: Check the charger's output voltage and current to ensure the charging system is functioning correctly. Perform battery capacity testing if necessary to ensure optimal battery performance.
Remote Control System Inspection: Conduct a professional inspection of the remote control system annually to ensure the stability of the wireless signal and the effectiveness of remote control. When replacing remote control batteries, ensure the use of original factory batteries to avoid operational issues caused by battery problems.
Key Component Replacement: Replace wear-prone parts such as hydraulic seals and drive belts according to usage time.
2.5 Troubleshooting and Repair
Common Fault Diagnosis: Common faults in remote-controlled forklifts include insufficient battery power, electronic control system malfunctions, and drive system abnormalities. Operators should possess basic troubleshooting skills and contact professional maintenance personnel promptly when encountering complex problems.
Basic Fault Diagnosis Regular Maintenance Records: Maintenance personnel should establish detailed maintenance records, documenting each inspection and repair to ensure the forklift's operational status is traceable.
3.1 Personnel Training System
Establish a tiered training system. New employees must pass both theoretical and practical assessments before operating independently. Regularly organize safety drills to strengthen emergency response capabilities.
3.2 Technical File Management
Improve the maintenance records for each forklift, including daily inspection checklists, maintenance schedules, and repair records, providing data support for equipment lifecycle management.
3.3 Intelligent Management
Introduce an IoT monitoring system to collect operational data in real time. Use big data analysis to predict potential faults and achieve preventative maintenance.
While remote-controlled forklifts improve work efficiency, strict adherence to safety operating procedures and maintenance measures is crucial for long-term stable operation. Operators should always maintain high vigilance, conduct regular safety checks, and promptly identify and address problems. Maintenance personnel need to regularly perform comprehensive inspections and maintenance on the forklifts to ensure the equipment operates in an efficient and safe condition.
Scientific and standardized safe operation and systematic maintenance are key to ensuring the safe and efficient operation of remote-controlled forklifts. By establishing a sound management system, strengthening personnel training, and improving maintenance records, the efficiency of equipment use can be significantly improved, the service life extended, and a strong guarantee for safe production in enterprises can be provided. Through reasonable use and maintenance, remote-controlled forklifts can better serve enterprises, reduce failure rates, and extend their service life.
