Diesel forklift maintenance cycle and maintenance items
Sep 27 , 2021

The maintenance cycle of diesel forklift trucks is daily maintenance, that is, the maintenance inspection before starting the diesel forklift truck every day. The first-level maintenance time is 150 hours of cumulative operation of the engine. If the annual working time is less than 150 hours, the first-level maintenance shall be carried out once a year. The second level of diesel forklift truck maintenance time is 450 hours. For three forklifts with less than 450 hours of work, the second level of maintenance is carried out every three years.

Details of maintenance items for diesel forklift trucks are as follows:

   One, daily maintenance

  Daily maintenance is the cleaning, inspection and debugging of the diesel forklift truck by the driver of each shift. It is a daily maintenance item with cleaning and fastening as the main item, and it is an important basis for forklift maintenance. The main tasks are: removing dirt, dirt and dust on the diesel forklift truck: checking and adding engine cooling water, lubricating oil and fuel: draining the cooling system at low temperatures (without antifreeze): checking the fastening of each part of the diesel forklift truck. The details of the daily maintenance of the diesel forklift truck are as follows:

  1. Clean the dirt, soil and dust on the diesel forklift truck. The key parts are the fork frame and mast slide, generator and starter, battery electrode column, water tank, and air filter.

  2. Check the fastening of each part, focusing on the support of the fork frame, lifting chain tensioning screws, wheel screws, wheel fixing pins, brakes, and steering gear screws.

  3. Check the reliability and flexibility of the foot brake and steering gear.

4. Check for leakage, focusing on all pipe joints, diesel tanks, engine oil tanks, brake pumps, lifting cylinders, tilt cylinders, water tanks, water pumps, engine oil pans, hydraulic torque converters, transmissions, drive axles, and main Reducer, hydraulic steering gear, steering cylinder.

  5. Remove the sediment from the oil filter.

  6. Check the working conditions of instruments, lights, buzzers, etc.

  7. After the above inspections are completed, start the engine, check the operation of the engine, and check whether the transmission system, braking system, and hydraulic lifting system work normally.

  Second, first-level branch maintenance

  The first-level branch maintenance is a regular project centered on cleaning, tightening, and lubrication. In addition to other tasks required for daily maintenance, the main tasks are to add and replace lubricating oil (grease) to the specified parts, and to carefully inspect, debug and partially replace the easily worn parts of the diesel forklift truck. The main contents of the first-level technical maintenance of diesel forklift trucks are as follows:

   1. Check the cylinder pressure or vacuum degree: check and adjust the valve clearance: check whether the thermostat is working properly.

   2. Check whether the multi-way pumping reversing valve, lifting cylinder, tilting cylinder, steering cylinder and gear pump are working properly.

   3. Check whether the shifting work of the transmission is normal: check and adjust the gap between the brake pads of the hand and foot brakes and the brake drum.

   4. Change the oil in the oil pan, check whether the crankcase ventilation pipe is intact, and clean the oil filter of the washing machine and the filter element of the diesel filter.

  5. Check whether the installation of the generator and starter is firm, whether the terminals are clean and firm, and check the wear of the brushes and commutators.

   6. Check the tightness of the fan drive belt.

   7. Check whether the installation of the wheel is firm, whether the tire pressure meets the requirements, and remove the sundries embedded in the tire.

   8. The parts are disassembled due to maintenance work, and the road test of the diesel forklift truck shall be carried out after reassembly.

  1) Test the braking performance under different degrees, and there should be no deviation. On steep slopes, the hand brake can stop reliably after being tightened.

   2) Listen to whether there is any abnormal sound when the engine is running under acceleration, deceleration, heavy load or no load.

  3) After a period of road test, check the brakes, transmission, front axle housing, and gear pump for overheating.

  4) Check whether the lifting speed of the fork frame is normal and whether there is tremor.

   9. Check whether the filter screen of the diesel pump oil inlet is blocked or damaged, and clean or replace the filter screen.

   Third and second level maintenance

   Secondary maintenance is maintenance repair. In addition to completing the work content specified in the first-level maintenance, the second-level maintenance should focus on the local disintegration inspection according to the natural wear rule of the parts, the faults or precursors found during operation, and the general parts that have exceeded the limit. Repair or replacement to eliminate the partial failure of the diesel forklift truck caused by the natural wear of the parts or due to improper maintenance and operation, so that the diesel forklift truck is in a normal technical state. It is mainly an item of inspection, adjustment, and prevention, mainly for partial disassembly, inspection, cleaning, oil change, summer repair or replacement of vulnerable parts that exceed the limit. In addition to maintaining the items according to the first-level technology, the following tasks should be added:

1. Clean the fuel tanks, filters and pipelines, and check for corrosion and cracks. Do not wipe with fiber gauze after cleaning: clean the torque converter and gearbox, check the wear of the parts, and replace them with new ones. Oil.

2. Check the bearing of the drive shaft, and change the direction of the universal joint cross shaft as needed: check the fastening of the drive components and whether there is oil leakage, clear the air holes: disassemble the main reducer, differential, and adjust the shaft of the bearing Add or replace lubricating oil to the gap.

  3. Disassemble, inspect, adjust and lubricate the front and rear wheel hubs, and perform semi-shaft transposition. Clean the brake and adjust the gap between the brake drum and the brake shoe friction plate: clean the steering gear and check the free rotation of the steering wheel.

  4. Disassemble and clean the gear oil pump, pay attention to check the wear of gears, shells and bearings: disassemble the multi-way valve, check the gap between the valve stem and the valve body, and do not disassemble the relief valve if you are unintentional.

5. Check the steering knuckle for damage and cracks, check the fit between the kingpin of the steering axle and the steering knuckle, disassemble and inspect the joints of the longitudinal, tie rod and steering arm: remove the tires, remove rust and paint the rim , Check the inner and outer tires and cushion belt, change the position and inflate according to the regulations.

   6. Check the connection and tightening of the hand brake components, and adjust the working stroke of the hand brake lever and foot brake pedal.

   7. Check the battery electro-hydraulic density. If it does not meet the requirements, it must be removed for charging: clean the water tank and the oil radiator.

   8. Check whether the shelf and frame are deformed: Remove and wash the roller: Check whether the fixing of each accessory is reliable, and if necessary, add and weld it firmly.

   9. Disassemble and inspect the lifting cylinder, tilt cylinder and steering cylinder, and replace the worn seals.

   10. Check the sensors, fuses and various switches of each instrument, and adjust if necessary.

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