Daily maintenance, after every shift.
1. First-level technical maintenance. After a total of 100 hours of work, one shift system is equivalent to 2 weeks.
2. Second-level technical maintenance. After 500 hours of cumulative work, one shift system is equivalent to one quarter.
1. Routine maintenance
1. Clean the dirt, soil and dirt on the forklift. The key parts are: fork and gantry slide, generator and starter, battery electrode fork column, water tank, air filter.
2. Check the tightening of each part, the focus is: fork frame support, lifting chain tensioning screws, wheel screws, wheel fixing pins, brakes, steering gear screws.
3. Check the reliability and flexibility of the foot brake and steering gear.
4. Check the leakage, the main points are: each pipe joint, diesel tank, engine oil tank, brake pump, lifting cylinder, tilting cylinder, water tank, water pump, engine oil pan, torque converter, transmission, drive axle, main deceleration Device, hydraulic steering gear, steering cylinder.
5. Remove the oil filter sediment.
Second, the first-level technical maintenance is carried out according to the "daily maintenance" project, and the following work is added.
1. Check cylinder pressure or vacuum degree.
2. Check and adjust the valve clearance.
3. Check whether the thermostat works normally.
4. Check whether the multi-directional valve, lifting cylinder, tilting cylinder, steering cylinder and gear pump work normally.
5. Check whether the shifting 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 connection 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 terminal 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 truck road test is required after reassembly.
(1) The braking performance at different levels should be free from deviations and snaking. On a steep slope, after the hand brake is tightened, it can stop reliably.
(2) Listen for abnormal sound when the engine is running under acceleration, deceleration, heavy load or no load.
(3) After a period of road test, check the brake, 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 diesel oil inlet filter is clogged and damaged, and clean or replace the filter.
Third, the second-level technical maintenance In addition to the first-level technical maintenance items, and add the following work:
1. Clean the fuel tanks, filters and pipelines, and check them for corrosion and cracks. After cleaning, do not use fiber yarns or fabrics to wipe.
2. Clean the torque converter, gearbox, check parts for wear and replace with new oil.
3. Check the drive shaft bearing and change the direction of the universal joint cross shaft as needed.
4. Check the tightening condition of each part of the drive axle and whether there is oil leakage, and clear the air holes. Disassemble and inspect the main reducer, differential, and wheel reducer, adjust the axial clearance of the bearing, and add or replace the lubricant.
5. Dismantle, inspect, adjust and lubricate the front and rear wheels, and perform half-shaft transposition.
6. Clean the brake and adjust the gap between the brake drum and 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, housing 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 the steering knuckle for damage and cracks, the cooperation between the steering axle master pin and the steering knuckle, and dismantle and inspect the wear of the joints of the crossbar and steering arm.
11. Disassemble the tire, remove the rust and paint the rim, check the inner and outer tires and the cushion belt, change the position and inflate according to the regulations.
12. Check the connection and tightening of the hand brake mechanism, adjust the working stroke of the hand brake lever and foot brake pedal.
13. Check the battery's 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 the frame are deformed, whether the disassembly and washing rollers and the attachments are reliable, and if necessary, add welding firmly.
16. Dismantle and inspect the lifting cylinder, tilting cylinder and steering cylinder, and replace the worn seals.
17. Check each instrument sensor, fuse and various switches, and adjust if necessary.
4. Lubricate the new forklift truck or the forklift truck after a long-term shutdown. Within two weeks of starting use, for the bearings that should be lubricated, when lubricating, the new oil should be used to squeeze out the old oil and lubricate it twice. Above, at the same time should pay attention to the following points:
1. Remove the dirt on the oil cap, oil plug and grease nipple before lubrication to prevent the dirt from falling into the mechanism.
2. When injecting the lubricant with a grease gun, it should be infused until the parts are extruded with lubricant.
3. Seasonal lubricants (motor oil, etc.) should be replaced in summer or winter.
