How to maintain the forklift
Aug 11 , 2021
The daily maintenance of the forklift is a necessary process for the continuous use of the forklift. The maintenance of the forklift is divided into four categories, namely, daily maintenance, primary maintenance, secondary maintenance, and tertiary maintenance. Daily maintenance must be carried out every day, usually after every 50 hours of work, the first level of maintenance is carried out, after every 200 hours of work, the second level of maintenance is carried out, and after every 600 hours of work, the third level of maintenance is carried out. In this way, the service life of the forklift can be prolonged.

Forklift maintenance:

To make the forklift work normally and reliably, and to play the potential of the forklift, it is necessary to have regular maintenance measures. Technical maintenance measures are generally:

1. Daily maintenance, after each shift.

2. Level 1 technical maintenance. After 100 hours of accumulated work, one shift is equivalent to 2 weeks.

3. Secondary technical maintenance, after 500 hours of cumulative work, one shift is equivalent to one quarter

1. Routine maintenance

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

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

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

4. Check the leakage situation, focusing on: various pipe joints, diesel tanks, oil tanks, brake pumps, lifting cylinders, tilt cylinders, water tanks, water pumps, engine oil pans, torque converters, transmissions, drive axles, main reduction gears , Hydraulic steering gear, steering cylinder.

5. Tire pressure check: Insufficiency should be added to the specified value to confirm that there is no air leakage. Check whether the tire contact surface and sides are damaged, and whether the rim is deformed.

6. Check the brake fluid and water volume: check whether the brake fluid is within the scale range, and check whether air is mixed in the brake pipeline. When adding brake fluid, prevent dust and water from mixing. When adding water to the water tank, use clean tap water. If antifreeze is used, the same antifreeze should be added. When the water temperature is higher than 70℃, do not open the water tank cover. When opening the cover, put a thin cloth on it and do not twist the water tank cover with gloves.

7. Engine oil quantity, hydraulic oil, electrolyte check: first pull out the oil dipstick, clean the dipstick head, insert it and then pull it out to check whether the oil level is between the two scale lines. The oil level in the working oil tank should be between the two scale lines; if there is too little oil, air will be mixed in the pipeline, and too much will overflow from the cover. The battery electrolyte should also be between the upper and lower scale lines. If it is insufficient, add distilled water to the top line.

8. Check the brake pedal, micro-motion pedal, clutch pedal, and hand brake: depress each pedal to check whether there is abnormal sluggishness or jamming. The force of the hand brake handle should be less than 300N, confirm that the hand brake is safe and reliable.

9. Inspection of belts, horns, lights, meters, etc.: Check whether the belt tightness meets the requirements, there is no adjustment margin or breakage and cracks, which must be replaced; the horns, lights, and meters should be normal and effective.

10. Remove the sediment from the oil filter.

2. Level 1 technical maintenance

In accordance with the "daily maintenance" project, and add the following work.

1. Check the cylinder pressure or vacuum degree.

2. Check and adjust the valve clearance.

3. Check whether the thermostat is working properly.

4. Check whether the multi-way reversing valve, lifting cylinder, tilt cylinder, steering cylinder and gear pump work normally.

5. Check whether the shifting work of the transmission is normal.

6. Check and adjust the gap between the brake pads of the hand and foot brakes and the brake drum.

7. Replace the oil in the oil pan, check whether the crankcase ventilation pipe is intact, and clean the oil filter and diesel filter element.

8. Check whether the generator and starter motor are installed firmly, and whether the wiring head is clean and firm, and check whether the carbon brush and commutator are worn.

9. Check the tightness of the fan belt.

10. Check whether the wheel is installed firmly, whether the tire pressure meets the requirements, and remove the sundries embedded in the tread.

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

(1) The braking performance under different degrees should be free from deviation or snaking. On steep slopes, after the hand brake is tightened, it can stop reliably.

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

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

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

12. Check whether the filter screen at the oil inlet of the diesel tank is blocked or damaged, and clean or replace the filter screen.

Three, secondary technical maintenance

In addition to maintaining the items according to the first-level technical maintenance, the following tasks are added:

1. Clean each fuel tank, filter screen and pipeline, and check for corrosion and cracking. Do not wipe with fiber yarn or cloth after cleaning.

2. Clean the torque converter, gearbox, check the wear of parts, and replace with new oil.

3. Check the bearing of the drive shaft and change the direction of the universal joint cross shaft if necessary.

4. Check the tightness of each part of the drive axle and whether there is oil leakage, and dredge the air holes. Disassemble and inspect the main reducer, differential, and wheel reducer, adjust the bearing axial clearance, and add or replace lubricating oil.

5. Disassemble, inspect, adjust and lubricate the front and rear wheel hubs, and perform semi-shaft transposition.

6. Clean the brake and adjust the gap between the brake drum and the brake shoe friction plate.

7. Clean the steering gear and check the amount of free rotation of the steering wheel.

8. Disassemble and clean the gear oil pump, pay attention to check the wear of gears, housings and bearings.

9. Disassemble the multi-way valve, check the gap between the valve stem and the valve body, and do not disassemble the safety valve if it is not necessary.

10. Check the steering knuckle for damage and cracks, the coordination of the kingpin of the steering axle and the steering knuckle, and check the wear of the joints of the vertical and horizontal rods and the steering arm.

11. Disassemble the tires, remove rust and paint on the rims, check the inner and outer tires and cushion belts, change positions and inflate according to regulations.

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

13. Check the battery electro-hydraulic specific gravity. If it does not meet the requirements, it must be removed for charging.

14. Clean the water tank and oil radiator.

15. Check whether the shelf and frame are deformed, the rollers for disassembly and washing, and the attachments are reliably fixed, and if necessary, add welding firmly.

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

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

Fourth, the whole car lubrication

For a new forklift or a forklift that has stopped working for a long time, within two weeks of starting to use, for bearings that should be lubricated, when lubricating, use new oil to squeeze out all the old oil and lubricate it more than twice, and pay attention The following points:

1. Before lubrication, the dirt on the oil cap, the oil plug and the oil nozzle should be removed to prevent the dirt from falling into the mechanism.

2. When injecting lubricant with a grease gun, it should be injected until the parts of each component are combined to extrude the lubricant.

3. Seasonal lubricants (oil, etc.) should be replaced in summer or winter.

Tags : forklift
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