What Are The Maintenance Items for Diesel Forklift Truck ?
Oct 11 , 2021

Diesel forklift truck maintenance mainly includes daily maintenance, primary maintenance and secondary maintenance. The maintenance period is:

1. Daily maintenance, after each shift;

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

3. Two-level technical maintenance. After 500 hours of accumulated work, one shift is equivalent to one quarter.

The following is the specific maintenance content of each item.

1. Daily maintenance

(1). Check the amount of oil in the crankcase of the forklift engine and the space filter box, the amount of fuel in the fuel tank and the amount of cooling water in the radiator, and add as required when insufficient;

(2). Check the height of the electrolysis page in the forklift battery, add it as needed, and keep the cover air hole unobstructed, and the pole and the wire joint are tightly and firmly connected;

(3). Check the freelance stroke and work reliability of the hydraulic brake and hand brake of the forklift, and add brake fluid and exhaust the air in the system as necessary;

(4). Check the tire pressure of the forklift and remove the debris embedded in the tire pattern;

(5). Check the amount of working oil in the oil tank of the vehicle hydraulic system and whether there is any leakage in the pipelines, joints, etc.;

(6). Check the water level of the water tank;

(7). Check the working conditions of instruments, lights, speakers, etc.;

(8). Check for leakage, focusing on: various pipe joints, diesel tanks, oil tanks, brake pumps, lifting cylinders, tilting cylinders, water tanks, water pumps, engine oil pans, torque converters, transmissions, drive axles, main reduction gears Steering gear, hydraulic steering gear, steering cylinder;

(9). After the above-mentioned changes are checked, start the forklift engine, check the operation of the forklift engine, and check whether the transmission system, brake system, and hydraulic lifting systems are working properly.

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 works normally;

(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, whether the wiring head is clean and firm, and 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.

A. 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.

B. Listen to whether the engine is running under acceleration, deceleration, heavy load or no load, and whether there is any abnormal noise.

C. After a certain mileage of the road test, check whether there is overheating at the brake, transmission, front axle housing, and gear pump.

D. Whether the lifting speed of the fork frame is normal and whether there is tremor.

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

3. 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. After cleaning, do not wipe with fiber yarn or cloth.

(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 shifting.

(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 free rotation of the steering wheel.

(8). Disassemble and clean the gear oil pump, pay attention to check the wear of gears, shells 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, disassemble and inspect 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 tightness 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 and charged.

(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 meter, and adjust if necessary.

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