Loader refers to equipment that is used for unloading and loading works and has the ability to move around, grab cargo, raise or lower it, stack it or place it on racks.

The design of a forklift depends on its purpose. Most of all, the industry produces universal machines that are used in various fields National economy. They can handle loads of varying volumes and weights. There are special loaders that are used to move strictly defined cargo or are used in special conditions work performed, for example, in mines.

A forklift, which is mounted on a mast or carriage, is mainly used to transport goods on special pallets. Loading equipment can be three-legged or four-legged. A machine with three support points is much more maneuverable than its four-support counterpart, but it is less stable in the transverse direction, which does not allow it to be used for moving large loads.

Loaders are equipped with engines internal combustion or are produced on electric traction. Electric forklifts are mainly used for work in warehouses or on sites with high-quality coverage. Equipment with diesel or gasoline engines is designed to work in outdoor conditions and has high load capacity.

The first forklifts appeared almost a hundred years ago in America, this is primarily due to the economic boom in industry. Rapid development industry, the emergence of ports and railway communications, and an increase in cargo flows contributed to the mechanization of loading and unloading operations.

Of course, the first models were significantly different from modern loaders, but in 1923 the device forklifts began to resemble modern analogues.

First World War contributed to the development loading equipment only accelerated, and the Second World War pushed the design idea even further, since it was necessary to unload a large amount of cargo in a short period of time.

The USA at that time was the main leader in the production of loading equipment, as the countries were recovering from the war and could not become competitors in this industry. Over time, Europe and Japan caught up with America and began to create loaders of better quality than American cars.

Japanese companies used to break into the loading equipment market additional options, that is, they completed their own loaders additional equipment. It was confusing market prices almost by a third. Nowadays manufacturers pay great attention not only to technical aspects, but also on appearance loaders.

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Construction loader - This is a type of self-propelled lifting equipment of intermittent action. Its main working body is lifting mechanism with an installed bucket, forks, or other load-handling device. The main purpose is lifting, moving, loading or unloading, and storing medium-sized cargo. It is able to combine the above operations to increase labor productivity, which also depends on the maneuverability and skill of the operator.

A loader, like a crane, is a lifting equipment, but, unlike it, it is capable of transporting cargo over long distances. He is capable of serving warehouses, construction sites, perform work in cramped conditions, for example, unloading boxcars, or storing goods on racks. Autonomous movement and work, high mobility and ergonomics make it a universal machine capable of performing cargo transportation tasks on a construction site. Functionality loader are expanded due to the presence of a large number of load-handling devices and other equipment.

There is the following classification of loaders:

By maximum load capacity:

Low load capacity 1 - 4 t;

Average load capacity 4 - 10 t;

High load capacity 10 - 16 t;

Ultra-high load capacity - from 16 tons and above.

Based on the type of lifting device, construction forklifts are divided into three types:

1. . Its lifting device is a mast, consisting of several sections inserted into one, a hydraulic cylinder and a carriage. It moves up and down the mast, raising and lowering the load, and a load-handling member is attached to it.

2. . Lifting device represents space frame, fixed at one end to the horizontal shaft of the front part of the machine, a lifting hydraulic cylinder is installed in the middle, and a load-handling device is installed at the other end. There are two designs front loader: with a front lever mechanism and with the possibility of rear unloading of the load-handling body.

3. . Its load-handling device is installed on a telescopic boom. It is attached to the frame on a shaft, and can be lowered and raised using a hydraulic cylinder. Depending on the design, it can be with a rotating or non-rotating boom.

According to the location of the lifting device:

A) frontal - the lifting mechanism is located in front of the loader. It is most widespread due to its functionality.

B) side – the load lifting mechanism is located on the side. Performs specific tasks when servicing warehouses with narrow passages and long cargo. Basically, it is equipped with a fork lifting device.

By main type power unit:

Petrol / gas;

Electrical;

Diesel / gas-diesel.

By chassis type:

Tracked loader (can be equipped with both rubber and iron tracks);

A wheel loader, in turn, is divided into two categories according to the type of wheels installed and their number:

Type of wheels: chamber-pneumatic, non-puncture-super-elastic and bandages made of solid rubber tape;

Number of wheels: three-wheeled, four-wheeled, six or more wheels.

According to the maximum height to which it is possible to lift the load, they are divided into two groups:

Up to 4 meters;

Above 4 meters.

A modern loader consists of a self-propelled chassis with the following components installed on it:

hydromechanical lift with replaceable working parts, counterweight, internal combustion engine or electric motor, transmission, chassis, operator's cabin with controls and hydraulic system.

Fork (mast) lifting mechanism consists of a main frame attached to the frame of the forklift at an articulated joint, and with the help of a hydraulic cylinder the angle of its inclination changes forward to 8° and backward to 15°. The main frame of the mast carries a movable frame, which is raised or lowered when the central hydraulic cylinder operates. At the top of the mast there are two sprockets, through which chains are thrown. They are connected at one end to the fixed main frame of the lifting mechanism, and at the other to a carriage with a gripping device.

The forklift can be equipped lifting mast following construction:

Duplex or two-section;

Mast - duplex with the possibility of free movement of the carriage - the design is similar to a duplex, an additional third cylinder is installed, which increases the free lifting height (lifting the lifting carriage, without moving the second section of the mast);

Triplex or three-section - all structures of this type are equipped freewheeling carriages.

Loaders with a duplex freewheel or triplex mast design, and having a maximum mast height of 2.2 m, are called: “car loader”. The triplex mast is capable of lifting loads to the highest height compared to other types. This type of equipment is used to move containerized cargo on pallets in production or in a warehouse.

Let's take a look at one of the most common linkage lift devices, the Z-type arrangement. At the front end of the boom, on a swivel joint, a front bucket is attached. It has the ability to change the inclination using a hydro-mechanical mechanism consisting of one or two hydraulic cylinders and levers attached to the bucket. The hydraulic cylinders themselves rest on the frame and are mounted on hinges. In such a mechanism, the fulcrum of the lever is located between the points of application of forces, this creates increased force on the edge of the bucket. Rubber seals on the hinge joints of the linkages and booms reliably hold the lubricant and prevent moisture, dirt and dust from penetrating inside. This increases the durability of the hinge joints and reduces the labor costs for their maintenance.

Telescopic loader equipped with a multi-section telescope boom. The boom length is increased by extending the sections using an internal hydraulic cylinder. A lever mechanism with a hydraulic cylinder is installed at the end of the boom to change the angle of inclination of the load-handling member.

The telescopic boom loader consists of base chassis With chassis and a rotating platform installed on it. The boom itself, the operator's cabin, the power unit, the counterweight, and the hydraulic system are mounted on it. The fixed boom, together with the rest of the loader equipment, is installed on the running chassis of the special equipment. The advantage of a telescopic boom loader is the incomparable maximum height lifting load ( average among existing models- 18 m) and high lifting capacity (the most common models lift about 5 tons).

Diesel and gasoline engines known for their reliability, ease of execution and maintainability. But they are almost impossible to operate indoors due to the exhaust gases emitted, and high level noise. The situation can be corrected by installing an expensive cleaning filter.

The gas engine is structurally similar to gasoline engine. Not only is it more economical in terms of fuel costs, but it also has lower emissions. Loader with gas engine can work freely in a poorly ventilated building. Equipped with replaceable cylinders with a capacity of 27 to 50 liters.

A loader with an electric motor is designed for indoor use. Such cars are profitable due to the lowest fuel cost, low level noise and absence of gaseous emissions into the atmosphere. But they cannot be used at low temperatures - rechargeable batteries have a limited resource and are very expensive.

Information instruments and controls are located in the operator's cabin. Due to the danger of operating the machine, special safety requirements for the driver are established for the cab. It must be strong enough to withstand the fall of a forklift or load. In the case of working with bulk cargo, it must protect the operator from dust or the possibility of injury from solid fractions. The cabin must have a heating or air conditioning system to operate in hot or cold climates, respectively.

The specific application of the loader and its purpose determines the design suspension. In particular, important parameter is the number of wheels. Three-wheel models have two drive wheels and a single or double wheel. This design copes well with work in narrow spaces where maneuverability is required. The disadvantage of a three-wheel loader is its reduced load capacity and operation only on flat surfaces, due to less stability. Four-legged models have other advantages and disadvantages. They are not as maneuverable, but are capable of lifting larger loads, and can be used outdoors and travel long distances on bumpy roads.

When purchasing a loader, the owner should think about what kind of surface the equipment will drive on. Suitable for moving on uneven surfaces pneumatic tires with good shock-absorbing properties. They will protect the suspension units from rapid wear. For driving on smooth surfaces with small, hard particles, you can use expensive, wear-resistant super-elastic tires. Because of low profile they have almost no shock absorption, and quickly wear out the chassis fasteners. Common solid rubber tires can also be used on slightly uneven paved roads. They have balanced characteristics, price-reliability ratio, and will satisfy any practical owner small loader.

To grab cargo, loaders are equipped with more than just simple forks or buckets various sizes. Modern technology can be equipped with complex devices, ranging from clamshell, double-bucket grips to a mini excavator or hydraulic hole drill. Forklift manufacturers offer very a wide range of attachments. They satisfy needs in any field: construction, agriculture and forestry, area cleaning, etc. The picture shows only some samples of equipment.

7.1.2.1. Construction of forklifts

Rice. 7.12.

Forklifts: A

with front load lifter; b

with side load lifter

A forklift is a universal self-propelled lifting and transport machine designed for loading, unloading and transporting various cargo over short distances. The loader mainly works with piece and packaged cargo; it can also be used for transporting bulk cargo.

The forklift consists of lifting equipment and a pneumatic undercarriage.

Depending on the location of the working equipment on the chassis, a distinction is made between forklifts with a front load lift (Fig. 7.12, a) and with a side load lift (Fig. 7.12, b). Lifting equipment

includes a forklift 2 and a load-handling device - forks 1. Front-end forklifts transport cargo on forks, with a side loader - on platform 5; In this case, the forklift serves to load cargo onto the platform and unload it.

Instead of forks, a forklift can be equipped with another load-handling device, for example, a boom with a grab for loading bulk and lump materials.

All forklift drive elements (power plant, transmission, control system) and chassis are borrowed from commercially produced trucks. They differ only in the layout of the units and the frame. Forklift chassis (Fig. 7.13) contains a frame 9 on which the engine 7, units and systems are installed power transmission

and the running gear – drive axle 4 and axle 10 with steered wheels.

The wheels of the running device form four supports of the forklift and provide it with a stable position, its movement and maneuvering around the site under its own power.

The drive axle 4 is rigidly attached to the frame 9, and the axle 10 with steered wheels is hinged, with the possibility of transverse swing of the axle. The articulated suspension allows you to maintain contact of all wheels when moving on an area with uneven surfaces and evenly distribute the load on the steered wheels.

7.1.2.2. Forklift working equipment

Forklift designed to grab a load, lift it to the required height, lower it and stack 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 an upper and lower cross member. A plate with a ball heel 16 is welded to the lower cross member for fastening the lift cylinder 5. In the lower part, axles are welded to the frame, pivotally connecting the outer frame of the forklift with the frame 2 of the forklift chassis. In the middle part of the outer frame, two brackets 3 are welded, connecting the frame with the tilt cylinders 4.

The internal frame 6 of the forklift consists of two vertical guides connected to each other by crossbars. Two cheeks 7 are attached to the upper cross member, to which is attached a cross-beam 8 fixed to the plunger of the lift cylinder 5 with rollers 9 for load 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 carriage chain brackets, and the other to the lift cylinder housing bracket.

When the cylinder is turned on, the plunger begins to extend and move the internal frame through the traverse 8. The inner frame relative to the outer one moves at a speed equal speed the plunger extends, and the carriage moves relative to the outer frame at double speed and at the end of the plunger stroke it ends up on the top of the inner frame.

The carriage lowers under its own weight.

To tilt the forklift, two hydraulic cylinders 4 are used, the bodies of which are pivotally attached to the chassis frame brackets, and the rods are attached to the eyes on the outer frame of the forklift. They allow the forklift to tilt forward or backward at an angle of 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 plate chains.

Rice. 7.15. Carriages: a with rigid fastening of grabbers;

with front load lifter; with hinged support arms

Carriage with rigid fastening of grabbers(Fig. 7.15, a) consists of upper and lower plates 1, connected to each other by racks 2, to which axles 3 of rollers 4 are welded.

The rollers move along the guides of the inner frame.

The top plate has slots for fixing the forks. The forks have upper 8 and lower 9 hooks, a bracket 10 and a spring-loaded lock 7.

In a carriage with hinged mounts(Fig. 7.15, b) axles 12 are used, and brackets 13 are used to fix them. In addition, the side rollers 14 are made on a separate bracket 15.

Replaceable lifting devices designed to increase the performance of the loader when working with loads of a certain shape and size, such as barrels, rolls, bales, bulk and lump materials. Replaceable load-handling devices are also used to perform specific loading, 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 the light and food industries.

Blockless arrows Designed to handle bulky, irregularly shaped loads. A blockless boom is a boom in which the load hook, which has a constant or variable reach, is located on the cantilever part. Blockless booms are used when it is necessary to lift a load to a greater height.

Rice. 7.16. Blockless boom

standard design

A blockless boom of a standard design (Fig. 7.16) consists of a cantilever part made of two channels 9 connected by cross members 10, a support part with racks 14, braces 11, a transverse bar 12 with hooks 13 for hanging on the forklift carriage and a lower cross member 15.

Hook 1 (shown disassembled in Fig. 7.16; assembled hook 7) is hung on the boom in socket 8.

To move the hook from one position to another, it is necessary to rotate the traverse 90° around its axis and, lifting it up together with the hook, remove the traverse pins from the guide grooves of the 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 movement drive

Between the channels, resting on their lower flanges, carriage 1 with hook 2 moves. To move the carriage, a hydraulic cylinder 6 and an articulated lever transmission 4 are used. The bottom of the cylinder is mounted on axis 8, and the head of the rod is connected to the lever transmission by axis 5.

When the rod extends from the cylinder, the lever transmission, lengthening, moves the carriage with the load hook forward. When the rod is pulled inward, the linkage folds and the hook moves back.

By adjusting the amount of extension of the rod, you can install the hook anywhere in the console part 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.

A hydraulic cylinder 4 is attached to the bracket 3 using an axis 2, and brackets 8 are attached to the brackets 15 on the axes 11, which, in turn, are attached to the carriage. Cylinder 4 is secured between the carriage posts using axis 5.

Pincer grip(Fig. 7.19) is designed for working with round timber and packages of boards. The gripper consists of a frame 6, on which the upper 2 and lower 3 arms with forks are hinged.

The upper paw is driven by a hydraulic cylinder 9, the lower one by two hydraulic cylinders 4. The grip ensures that the forks 1 are tilted down when picking up the load and up when transporting it.

Boom with grab device and hook(Fig. 7.20) is installed on a forklift and is a spatial metal structure.

Rice. 7.20. Boom with grab

fixture and hook

In the middle part, the boom is hingedly attached to brackets 4 installed on the carriage 3, in the tail part - with the help of rods 1 to the forklift.

The crossbar with hook 5 is attached to the front part of the boom. A beam 7 with hydraulic cylinders 8 is attached to the boom on chains 6, on which a two-jaw grab 10 is suspended by means of rods 9 and hydraulic cylinder rods. The jaws of the grab are driven by hydraulic cylinders 8.

Rice. 4.19. Pincer grip

Rice. 7.21. Rotary carriages:

Forklifts: with a pitchfork; b with clamp

Rotary carriages designed to rotate the load when stacking. On the rotating part 1 of the carriage, forks 2 (Fig. 7.21, a) or a side clamp 3 (Fig. 7.21, b), which is driven by a separate hydraulic cylinder 4, are mounted.

Single and multi-pin grippers designed for securing piece goods in the form of bandages, coils of wire, tires (single-pin), as well as for transporting piece goods in the form of barrels, rolls, bags (multi-pin). The grips are attached to the carriage in the same way as a blockless boom.

Most forklift models come standard with a servo brake. Devices with high load capacity are equipped disc brakes with oil baths. The parts and mechanisms of such a system wear out slowly, which reduces maintenance costs.

Control cabin

The need for a separate operator's cabin was not immediately realized. It was only after several accidents involving injuries from falling loads that manufacturers began to develop special frame structures that provide operator protection and comfort.

Modern forklifts are equipped with a comfortable cabin, equipped with sound insulation and a safety system. A special safety grid protects against the danger of falling loads. Armchair with seat belt will prevent serious consequences for the operator in the event of a collision or rollover of the forklift.

The cabin can be open or closed. The difference is that the former are equipped with a roof with a steel lattice and are used mainly inside warehouses. The closure can be used outside even in winter time(most models have heating).

Some loaders have cabs equipped with computer system control, which requires the “driver” to have skills in working with complex equipment.

Attachments

Attachments are a set of additional accessories for a loader that expand the scope of its application. Buying them is much cheaper than purchasing a separate type of equipment for highly specialized tasks. We list the most common options:

• Forks. Designed to work with “non-palletized” cargo, that is, those that are difficult to move using pallets. For example, rolls or barrels.
• Lateral shift device (side shifter). Allows you to reduce maneuvers to a minimum when moving with loads. Relevant when the loader is operating in a confined space.
• Buckets. Used for transporting and lifting bulk materials.
• Dumps. Necessary for clearing the area or road surface from the snow.
• Road brushes. An effective product for cleaning streets and premises.
• Drilling equipment. An ordinary forklift can be turned into a machine that can drill a small hole, for example, to install a light pole outside a warehouse.

Results

The technical characteristics of the forklift depend on the specifics of the device given above components. Having an understanding of the main elements, mechanisms and structural features of loading equipment, you will be able to purchase equipment that best suits your tasks.

An integral attribute of any modern logistics company are forklifts. Particularly common electric forklifts. They are quite versatile and can be used in any conditions. Unlike gas and diesel models, their operation is much cheaper. Among the areas of application of this technology are various warehouses with food or any other products. But they also found themselves wide application in small production premises, port and aviation terminals where it is impossible to operate gas and diesel equipment due to the presence of exhaust gases.

Loaders are basic warehouse equipment that greatly facilitates maintenance and handling of various loads. It uses a pitchfork as its main tool. But in addition to them, the loader can be equipped with other grips, depending on the type of cargo. So, along with forks, traverses, hooks, retractable forks, and pushers can be used.

Types of equipment

Three-wheeled electric forklifts and four-wheeled counterparts can be distinguished. The first, based on their characteristics, have a load capacity of up to two tons. They are equipped with a special steerable axle that swings around a longitudinal axis.

The steered wheel can rotate around its axis vertically at an angle of no more than 90 degrees. This allows the turning radius to be significantly reduced. Due to this, the loader has high maneuverability, which is so necessary in narrow warehouse spaces.

Four Wheel Loader: Features

Despite all the advantages three-wheeled models, four-wheeled vehicles are more common. This type of equipment can be seen in most warehouses, workshops, and factories. These are more universal models, which, unlike their three-wheeled counterparts, have a greater load capacity. They are also quite maneuverable. Of course, this maneuverability cannot be compared with three-wheeled counterparts, but these models have separate drive to the drive wheels.

Among the most popular and popular models are units with a carrying capacity from 0.25 to five tons. More powerful equipment is also used - up to ten tons or more.

Frame

The main element in the design of a loader is the frame. It is fixed and rests on the front, as well as rear axle. In this case, the front axle is the drive axle, and the rear axle is the steered axle. The controlled part is connected to the loader frame using springs.

There is a hydraulic cylinder on the drive axle. It provides the ability to attach an articulated lift to the frame. The hydraulic lift itself consists of two frames - an outer one and a movable inner one. The last part of the structure can move relative to the main one in a vertical plane. The main frame may have a slight slope - often no more than five degrees. The frame can be tilted both forward and backward. In this case, the backward tilt can be performed no more than ten degrees. This design of an electric forklift makes it easier to grab loads using forks. By tilting backwards, the stability of the loader is improved when moving with loads.

Controls

As governing bodies of this warehouse equipment a steering column equipped with hand brake, various levers, switches in the form of keys, joysticks.

Counterweight

Every electric forklift has a counterweight. It is installed on the rear of the machine.

The main task of the counterweight is to provide the equipment with maximum stability when it is necessary to work with fairly large and very heavy loads.

Power point

The power unit in these machines is used Electrical engine. Torque is transmitted to the front drive axle. The engine is bolted securely to a flange located on a steel casting of the drive axle housing. A bevel gear is installed at the end of the motor shaft using a key connection. It meshes with a gear, which is secured to the differential housing with rivets. The differential housing is mounted on two bearings. Inside the differential there are two bevel gears with shanks, as well as two satellites. They both sit on the same finger.

There is a hole with splines in the gear shank - the axle shaft is inserted into it. At the other end of the axle shaft (also on splines) a gear is fixed - it has internal teeth. It is connected to a massive cast iron wheel using rivets.

When the operator turns on the electric motor of an electric forklift, the torque is transmitted through several gears to the driving pair of wheels. The wheels are mounted on tapered roller bearings, securely mounted on a fixed axle. This axle is pressed into the axle housing. The bearings are hidden under a cast iron cover. The brake discs are mounted on the side flanges front axle. A double-row spherical bearing is used as a support for the drive shaft in many models. It is installed in a fixed disk.

Power supply

The battery for a forklift is the most important part of this unit. Can act as a battery Various types batteries, as well as a three-phase current network (AC and DC). The most widely used batteries are those consisting of several batteries. Their number can reach several dozen. The batteries used are acid or alkaline, depending on the forklift manufacturer. But it is the alkaline elements that are more applicable. In addition to batteries for the loader, alternating current, connected via a cable, can be used as a power source. This is a flexible cable, the length of which is 20-30 meters.

The best models of electric forklifts

The most the best models those that are issued are considered Japanese companies. They all have different characteristics and suitable for different types operation.

Nichiyu FB-75

This loader has excellent speed characteristics. He is able to type quickly desired speed. Also this model handles slopes and other uneven surfaces well. He, unlike others similar models, has a high degree of electrical safety. All electrical power parts are located inside. Therefore, you can operate this equipment even during rain.

IN basic configuration there is a mast with a “soft landing” function, electric amplifier steering wheel, motor alternating current, batteries, recovery system, "wet" brake system, optics and turn signals.

"Amkodor-12"

This model is suitable for small spaces. There is a built-in battery, and the mast allows you to lift loads to a height of up to six meters. An unloaded forklift can reach speeds of up to 15 kilometers per hour. The model is comfortable, economical, easy to use, and highly maintainable.

EP-103

Japanese electric forklifts are not always available to everyone. And then you have to choose among domestic models. The EP-103 model is considered one of the best. These units are manufactured in Yekaterinburg at the ZIK plant. This is a well-balanced technique that has a low cost. EP is easy to maintain. The characteristics of this machine fully meet all consumer needs. Its carrying capacity is 1000 kilograms. The EP-103 electric forklift can lift loads to a height of up to three meters. The speed of movement is nine kilometers per hour. The engine has a power of 3.55 kW.

Maintenance and repair

Maintenance work includes caring for battery. In order for the machine to operate efficiently, economically and for a long time, you should not allow deep discharges and sulfation. It is necessary to periodically service the engine - the commutator assembly is especially delicate. Repairing electric forklifts can be quite expensive, but proper care it won't be needed.

It is also necessary to periodically check the tightness of the bolts, the condition of the oil in the hydraulic system, lubricate the main components, inflate pneumatic wheels, change lubricants in bridges.

If the unit fails, it is better to diagnose and repair it in service centers. If this is Japanese equipment, then the forklift cannot be repaired by electricians, which are required in any production. Repair of imported electric forklifts must be carried out by appropriate specialists.