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, first-level maintenance, second-level maintenance, and third-level maintenance. Routine maintenance is carried out every day. Usually, the first-level maintenance is performed after every 50 hours of work, the second-level maintenance is performed after every 200 hours of work, and the third-level maintenance is performed after every 600 hours of work. Only in this way can the service life of the forklift be extended.
Forklift maintenance:
To make the forklift work normally and reliably, and to develop the potential capacity of the forklift, regular maintenance measures are required. Technical maintenance measures generally include:
1. Routine maintenance, after each shift.
2. For first-level technical maintenance, after accumulatively working 100 hours, the working system of one shift is equivalent to 2 weeks.
3. Secondary technical maintenance, after accumulatively working 500 hours, one shift is equivalent to one quarter
1. Routine maintenance
1. Clean the dirt, mud and dirt on the forklift. The key parts are: fork frame and mast slide, generator and starter, battery electrode fork column, water tank, and air filter.
2. Check the fastening of each part, focusing on: fork frame support, lifting chain tensioning 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 tank, oil tank, brake pump, lifting cylinder, tilting cylinder, water tank, water pump, engine oil pan, torque converter, transmission, drive axle, main speed reducer Device, hydraulic steering gear, steering cylinder.
5. Tire pressure check: If the tire is insufficient, it should be supplemented to the specified value to confirm that there is no air leakage. Check whether the tire contact surface and side are damaged, and whether the rim is deformed.
6. Check the amount of brake fluid and water: Check whether the brake fluid is within the range of the scale, and check whether air is mixed into 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, it should be filled with the same antifreeze. When the water temperature is higher than 70°C, 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. Check the engine oil level, hydraulic oil, and electrolyte: first pull out the oil dipstick, wipe the dipstick, 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 if there is too much oil, it will overflow from the cover plate. 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. Inspection of brake pedal, inching pedal, clutch pedal, and hand brake: step on each pedal to check whether there is abnormal slowness or jamming. The force of the hand brake handle should be less than 300N to confirm that the hand brake is safe and reliable.
9. Inspection of belts, horns, lights, instruments, etc.: Check whether the tightness of the belts meets the regulations, if there is no adjustment margin or if there are cracks in damage, they must be replaced; horns, lights, and instruments should be normal and effective.
10. Remove the sediment from the oil filter.
Second, the first level of technical maintenance
Follow the "daily maintenance" item, and add the following work.
1. Check cylinder pressure or vacuum.
2. Check and adjust the valve clearance.
3. Check whether the thermostat works normally.
4. Check whether the multi-way reversing valve, lifting cylinder, tilting cylinder, steering cylinder and gear pump are working normally.
5. Check whether the gear shifting of the transmission works normally.
6. Check and adjust the gap between the brake disc and the brake drum of the hand and foot brakes.
7. Replace the engine 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 installation of generator and starter motor is firm, whether the connection 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 firmly installed, whether the tire pressure meets the requirements, and remove debris embedded in the tread.
11. Parts and components are dismantled due to maintenance work, and a forklift road test must be carried out after reassembly.
(1) Braking performance at different levels, there should be no deviation or snaking. On steep slopes, after the hand brake is tightened, it can stop reliably.
(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 certain mileage of the road test, check whether the brake, transmission, front axle housing, and gear pump are overheated.
(4) Whether the lifting speed of the fork frame is normal and whether there is vibration.
12. Check whether the oil inlet filter screen of the diesel tank is blocked or damaged, and clean or replace the filter screen.
Three, two technical maintenance
In addition to maintaining each item according to the first-level technology, the following tasks are added:
1. Clean the oil tanks, filter screens and pipelines, and check for corrosion and cracks. After cleaning, do not wipe with yarn or cloth with fibers.
2. Clean the torque converter and gearbox, check the wear of parts, and replace with new oil.
3. Check the transmission shaft bearing, and change the direction of the cross shaft of the universal joint if necessary.
4. Check the fastening condition of each part of the drive axle and whether there is oil leakage, and dredge the air hole. Disassemble and inspect the main reducer, differential, and wheel reducer, adjust the axial clearance of the bearing, and add or replace lubricating oil.
5. Disassemble, adjust and lubricate the front and rear hubs, and transpose the half shafts.
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 the gears, casing 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 unless necessary.
10. Check whether the steering knuckle is damaged or cracked, the coordination between the kingpin of the steering bridge and the steering knuckle, and the wear of the joints of the longitudinal and horizontal tie rods and the steering arm.
11. Remove the tires, derust and paint the rims, check the inner and outer tires and pads, replace them and inflate them according to regulations.
12. Check the connection and fastening of the hand brake parts, and adjust the working stroke of the hand brake lever and foot brake pedal.
13. Check the electro-hydraulic specific gravity of the battery. 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 shelves and frames are deformed, remove and wash the rollers, and whether the attachments are fixed reliably, and add welding if necessary.
16. Disassemble and inspect the lifting cylinder, tilting cylinder and steering cylinder, and replace the worn seals.
17. Check all instrument sensors, fuses and various switches, and adjust them if necessary.
Fourth, the whole vehicle lubrication
For a new forklift or a forklift that has stopped working for a long time, within two weeks of starting to use, for the bearings that should be lubricated, when lubricating, use new oil to squeeze out all the old oil and lubricate it more than twice. At the same time, pay attention to The following points:
1. Before lubricating, the dirt on the oil cap, oil plug and oil nipple should be removed to prevent the dirt from falling into the mechanism.
2. When injecting the lubricant with a grease gun, it should be injected until the parts of each component are combined to squeeze out the lubricant.
3. Seasonal lubricants (oil, etc.) should be replaced in summer or winter.
