1、 Printed copies are uncontrolled. Page 1 of 10 INDUSTRIAL TRUCKS 1.0 PURPOSE: The purpose of this Standard is to promote safety through design, construction, application, operation, and maintenance of basic Industrial Vehicles. In this standard, Section 2.0 - Section 4.0 references the requirements
2、of Industrial Vehicles in North America and Section 5.0 - Section 8.0 references the requirements in Europe. This Standard may be used by governmental authorities desiring to formulate safety rules and regulations. NORTH AMERICA STANDARD 2.0 SCOPE: “Industrial Vehicle“ as referred to in this standar
3、d includes alL vehicles referenced in the Powered Material Handling Vehicles (PMHV) Operators Manual/Handbook. Specifically: Fork Lift Trucks (Sit-down and Stand-up/Stackers), Walking-Rider Trucks, Tow Tractors, Personnel Carriers, Burden Carriers, and Order Pickers. Floor Cleaning Equipment (Indoor
4、/Outdoor), Personnel Lifts, Mobile Cranes, Construction Equipment and other miscellaneous industrial equipment should use the Manufacturers maintenance schedule/menu or local/ Governmental regulations. Any unit that is a rental unit must be serviced by the rental personnel. Repairs on rental units a
5、re the responsibility of the rental agency. Ford personnel are NOT to repair rental vehicles. 2.1 REFERENCES: American National Standards Institute (ANSI): B56.1 Low Lift and High Lift Trucks B56.5 Guided Industrial Vehicles B56.6 Rough Terrain Forklift Trucks B56.7 Industrial Crane Trucks B56.8 Per
6、sonnel and Burden Carriers B56.9 Operator Controlled Industrial Tow Tractors B56.11.3 Load Handling Symbols for Powered Industrial Trucks B56.11.4 Hook-Type Forks and Fork Carriers B56.11.5 Measurement of Sound Emitted by Low Lift, High Lift and Rough Terrain Powered Industrial Trucks Standard Numbe
7、r w-ZA1 Issue Date: 20000204 Global Manufacturing Standards Rev: Printed copies are uncontrolled. Page 2 of 10 American Society of Testing Materials (ASTM) E 709 Standard Practice for Magnetic Particle Examination. Automotive Industry Action Group (AIAG M-6), Optimum Shipping and Receiving Handbook
8、NFPA-58 Standard for Storage and Handling of Liquified Petroleum Gases NFPA-505 Fire Safety Standard for Powered Industrial Trucks UL 558 Standard for Safety for Internal Combustion-Engine-Powered Industrial Trucks UL 583 Standard for Safety for Electric Powered Industrial Trucks Canadian Transport
9、Commission (CTC) Industrial Truck Association Standards (ITA) National Electric Manufacturers Association Standard (NEMA) Occupational Safety and Health Administration Standards (OSHA) The Tire and Rim Association Standards (TRA) 2.2 COMPLIANCE: All trucks shall comply with the latest edition of the
10、 referenced Standards where applicable. In those instances where Ford standards exceed the requirements of the referenced standards, Ford standards shall apply. It shall be the responsibility of the supplier to determine that all standards are met or request a waiver of requirements as may be necess
11、ary. Any waiver shall be recorded and approved by persons designated by Advanced Manufacturing Engineering - Packaging Engineering (AME-PE). All truck suppliers shall re-submit for approval new or present model trucks which have been significantly changed (such as mast, carriage, transmission, engin
12、e, electric components, brakes, dimensional changes, etc.) from current approved models. 3.0 TECHNICAL CONTENT: 3.1 NAME PLATES AND IDENTIFICATION 3.1.1 NAME PLATES: Shall be metal or durable plastic tags stamped, embossed, or engraved in accordance with ANSI-B56 and OSHA 1910.178 (b)(c), U.S. Dept.
13、 of Labor. 3.1.2 EQUIPMENT IDENTIFICATION: Truck shall be identified by unit number (maximum 5 characters) provided by requisitioning activity. Truck shall be labeled with unit number on each side of the mast or chassis with 3 inch tall letters of contrasting color to background. 3.1.3 TRAILER UNLOA
14、DING IDENTIFICATION: Trucks exceeding 8,000 lbs basic lifting capacity (at a 24 inch load center) shall be identified as unacceptable for use in loading and unloading conventional over-the-road trailers. Identification shall consist of letters “HD“ in contrasting color, 8 inches x 3 inches in size o
15、n each side of the chassis. NOTE: Trucks with 8,000 lbs basic lifting capacity need not be labeled in this manner. Standard Number w-ZA1 Issue Date: 20000204 Global Manufacturing Standards Rev: Printed copies are uncontrolled. Page 3 of 10 3.2 STEERING CONTROL - RIDER TYPE TRUCKS: The use of spinner
16、 knobs is prohibited unless approved by the original equipment manufacturer or his designated representative. Personnel and burden carriers require automotive-type steering (tiller steering is not allowed) with a conventional steering wheel. 3.3 LIFT, TILT, ATTACHMENT CONTROLS: A multi-functional co
17、ntrol lever is not acceptable. 3.4 LIGHTS: 3.4.1 All rider-type trucks shall be equipped with manually adjustable headlight(s) and tail-stop light(s). 3.4.2 All lights shall be 12 VDC. 3.4.3 Headlights to be keyswitch operated so that lights are “ON“ when keyswitch is “ON“. 3.4.4 Mounting location s
18、hall be manufacturers standard location. 3.4.5 FORK LIFT TRUCKS (SIT-DOWN AND STAND-UP) ONLY shall be equipped with rear drive lights, operated when the keyswitch is “ON“ and the direction control is in “REVERSE“. 3.5 PAINT: The standard paint and color used by the manufacturer shall be acceptable.
19、3.6 SPEED CONTROL: A tamper-proof speed control set to limit travel speed to MAXIMUM of eight miles per hour, except for special purpose vehicles used exclusively outside. (This does not relax posted speed limits on Ford property). NOTE: Tamper-proof controls are defined as those that cannot be adju
20、sted, even with the use of hand tools. 3.7 FUEL SYSTEMS 3.7.1 LIQUID PROPANE GAS (LPG) TRUCKS: Shall be equipped with Closed Loop / Lean-Burn Carburetion system to minimize pollutants in exhaust emissions. Trucks which utilize DOT type cylinders require a LPG tank mounting bracket with a minimum of
21、two retaining straps and locating stud. 3.7.2 ELECTRIC POWERED TRUCKS: Battery, compartment, and connector shall conform to Ford ZA2 battery standard. Battery retaining device shall be equipped with an interlock device to interrupt power to the drive control circuitry when batteryis not secured. 3.8
22、 POWER: Shall be sufficient to permit riding type trucks to climb a 15% grade with rated capacity load and give normal service life operating intermittently on 6% grades. Standard Number w-ZA1 Issue Date: 20000204 Global Manufacturing Standards Rev: Printed copies are uncontrolled. Page 4 of 10 Walk
23、ing type trucks shall have sufficient power to climb a 10% grade with rated capacity load at a minimum of 1 mile per hour, and give normal service life operating intermittently on 6% grades. Walking type trucks shall have a maximum travel speed without load on level concrete of 3.5 mph. Drive motors
24、 shall incorporate thermal overload protection. 3.9 ELECTRIC CIRCUITS, IDENTIFICATION AND DIAGRAM: All wires shall be identified at each termination by marking with a number or color coded to correspond with wiring diagram. This diagram, showing part numbers, shall be included in the Parts and Servi
25、ce Manual. 3.10 BATTERY DISCHARGE INDICATOR: Shall be preset for lift interrupt at 80 percent battery discharge with indicator light. 3.11 OPERATORS SAFETY GUARDS: 3.11.1 OPERATOR SAFETY DOORS: All rear entry stand up riding stacker and reach trucks shall be equipped with a full height safety door.
26、The door must open outward with spring hinges to hold the door in the normally closed position. (Side entry vehicles do not require safety doors.) 3.11.2 SAFETY HAND GUARD FOR CONTROLS - WALKING-TYPE TRUCKS: The steering control handle shall be equipped with large diameter rubber discs mounted on th
27、e handle ends or a sheet metal pocket (180 degrees) enclosed on both ends to protect the fingers. No control buttons are to be located in the handle ends. 3.11.3 REAR-VIEW MIRRORS: The use of rear-view mirrors is prohibited. On vehicles used exclusively outside, side-view mirrors are allowed. 3.12 S
28、ERVICE MANUAL, PARTS CATALOG, OWNERS/OPERATORS MANUAL: Two complete service manuals and parts catalogs covering the truck and all attachments shall be provided with each new truck series, serial number series or model type. Both sets shall be delivered to the maintenance / engineering activity when
29、the truck is delivered. All new units shall be equipped with an owners/operators manual. Owners / operators manual shall include detailed instructions for towing disabled equipment for each specific model. 3.13 TIRE AND WHEEL OVERHANG REQUIREMENTS: Cushion tires must be mounted flush with the wheel
30、on one side. 3.14 EVALUATION AND APPROVAL: Prior to the purchase or lease of industrial trucks, it is required that the vehicle be approved by AME-PE. Once approval has been granted, all vehicles of that model will remain approved until changes are made by the manufacturer. Under special circumstanc
31、es, such as product failure in the field, this approval may be withdrawn. Standard Number w-ZA1 Issue Date: 20000204 Global Manufacturing Standards Rev: Printed copies are uncontrolled. Page 5 of 10 3.14.1 FIELD EVALUATION: The manufacturer shall submit a request for approval of a vehicle by field e
32、valuation to AME-PE prior to any sale. A vehicle of the type, model and design shall be delivered to a designated Ford location for a 90 day field evaluation on a no-charge consignment basis. The Ford field evaluation location shall furnish AME-PE Staff a report of field valuation results for approv
33、al and addition as an approved source/model. Major component changes to existing approved trucks, such as mast, carriage, transmission, engine, electric components, brakes, dimensional changes, etc., require Ford evaluation and approval prior to sale. 3.15.1 WARRANTY: Industrial Lifting Trucks (Fork
34、 trucks, stackers, and order pickers) shall be under the manufacturers warranty for a minimum of one year with unlimited operating hours. Industrial Trucks without Lift (Tows, personnel and burden carriers) shall be under manufacturers warranty for a minimum of two years or 6,000 operating hours. Ma
35、jor components on all trucks, such as the engine and drive train, shall have a warranty for a minimum of three years with unlimited operating hours. 4.0 INSPECTIONS: 4.1 PREVENTATIVE MAINTENANCE (EXCLUDING PRE-SHIFT INSPECTIONS PERFORMED BY OPERATOR): Inspection intervals and procedures shall be per
36、formed as recommended by the original equipment manufacturer. 4.2 INSPECTION AND REPAIR OF INDUSTRIAL TRUCK FORKS: 4.2.1 GENERAL INFORMATION: Any fork which shows a defect shall be removed from service and shall not be returned to service unless it has been satisfactorily repaired by an approved rep
37、air source. Any repairs required on forks shall be performed only by the original fork manufacturer or a qualified approved source in accordance with the manufacturers recommendations (Positioning locks may be repaired by qualified plant maintenance personnel). 4.2.2 INSPECTION REQUIREMENTS: Forks i
38、n use shall be inspected at intervals of not more than 12 months (for single shift operation) or whenever any defect or permanent deformation is detected. A visual fork inspection shall be performed carefully by trained personnel with the aim of detecting any damage, failure, deformation, etc., whic
39、h might impair safe use. Any fork which shows a defect shall be removed from service, and shall not be returned to service unless it has been satisfactorily repaired in accordance with the manufacturers recommendations by a qualified approved source. Standard Number w-ZA1 Issue Date: 20000204 Global
40、 Manufacturing Standards Rev: Printed copies are uncontrolled. Page 6 of 10 4.2.3 SURFACE CRACKS: Forks should be thoroughly cleaned and examined visually for cracks, giving special attention to the heel and welds attaching all mounting components to the fork blank. The inspection shall include any
41、special mounting mechanisms of the fork blank to the fork carrier including bolt type mounting and forged upper mounting arrangements for hook or shaft type carriages. Forks shall be removed from service if cracks are found. 4.2.4 STRAIGHTNESS OF BLADE AND SHANK: The straightness of the upper face o
42、f the blade and the front face of the shank should be checked. Any fork with a deviation from straightness that exceeds 0.5 percent of the length of the blade and/or height of the shank shall be removed from service. 4.2.5 FORK ANGLE: The angle between the upper face of the blade and the load (front
43、) face of the shank shall be checked. Any fork with a deviation of more than 3 degrees from the original specification shall be removed from service. 4.2.6 DIFFERENCE IN HEIGHT OF FORK TIPS: The difference in height of one set of forks when mounted on the fork carrier should be checked. The maximum
44、allowable difference in tip heights shall not exceed 3 percent of the length of the blade. Replace one or both forks if the difference on the fork tip height exceeds the maximum allowable difference. 4.2.7 POSITIONING LOCK: The positioning lock should be checked for proper operation. If any defect i
45、s found, the fork shall be removed from service. 4.2.8 WEAR: The fork blade and shank should be checked for wear, giving special attention to the vicinity of the heel. If the thickness is reduced to 90 percent or less of the original thickness, the fork shall be removed from service. (EXAMPLE: A for
46、k with 1-3/4 inch nominal thickness shall be removed from service when the worn thickness is less than 1-9/16 inch.) Fork hooks (when provided) should be checked. The support face of the top hook and the retaining faces of both hooks should be checked for wear, crushing, and other local deformations
47、. IF any defect is found such that the clearance between the fork and the fork carrier becomes excessive, the fork shall be removed from service. 4.3. MAGNETIC PARTICLE INSPECTION: A magnetic particle inspection of forks shall be performed any time it is considered necessary based on visual inspecti
48、on and must be performed at intervals not to exceed 24 months or 4,000 operating hours, whichever occurs first. The magnetic particle inspection is to be performed only by qualified certified technicians from approved certification services. Standard Number w-ZA1 Issue Date: 20000204 Global Manufact
49、uring Standards Rev: Printed copies are uncontrolled. Page 7 of 10 EUROPE STANDARD 5.0 SCOPE: This manufacturing standard shall apply to all Industrial Trucks with motive power. Industrial Trucks covered by this Standard are Powered Platform Trucks, Tractors (Tow Trucks, Mini Tugs), Fork Lift Trucks (Counter-balanced, Reach, and Straddle trucks), Powered Pallet Trucks, Driverless Trucks. Ford Manufacturing Standards are available for specific types of vehicles and must be conformed to accordingly. 6.0 REQUIREMENTS: All vehicl
