The daily maintenance of the forklift is a necessary process for the forklift to continue to use. The maintenance of the forklift is divided into four categories, namely daily maintenance, first-level maintenance, second-level maintenance, and third-level maintenance. Daily maintenance is carried out every day, usually after 50 hours of work, first-level maintenance, after every 200 hours of work, second-level maintenance, after every 600 hours of work, third-level maintenance. Only in this way can the service life of the forklift be extended.
Forklift maintenance:
In order to make the forklift work normally and reliably, and exert the potential of the forklift, regular maintenance measures are required. Technical maintenance measures are generally:
1. Daily maintenance, after every shift.
2. First-level technical maintenance. After 100 hours of cumulative work, one shift is equivalent to 2 weeks.
3. 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, mud and dirt on the forklift. The key parts are: fork and gantry slides, generator and starter, battery electrode fork column, water tank, and air filter.
2. Check the tightening of each part, the key points are: fork frame support, lifting chain tensioning screw, wheel screw, wheel fixing pin, brake, steering gear screw.
3. Check the reliability and flexibility of the steering gear.
4.Check the leakage situation, the key points are: each pipe joint, diesel tank, engine oil tank, brake pump, lifting cylinder, tilt cylinder, water tank, water pump, engine oil pan, torque converter, transmission, drive axle, main deceleration Controller, hydraulic steering gear, steering cylinder.
5. Tire pressure check: Insufficient should be added to the specified value to confirm no air leakage. Check the tire ground surface and side for damage, and whether the rim is deformed.
6. Brake fluid, water volume check: check whether the brake fluid is within the scale range, and check whether air is mixed into the brake pipeline. When adding brake fluid, prevent dust and water from entering. 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 ° C, do not open the water tank cover. When opening the cover, cushion a thin cloth, and do not use gloves to twist the water tank cover.
7. Check the engine oil, hydraulic oil and electrolyte: first pull out the oil scale, wipe the ruler and insert it before pulling 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 graduation marks; too little oil, air will be mixed into the pipeline, too much will overflow from the cover. The electrolyte of the battery should also be between the upper and lower scale lines. If it is insufficient, add distilled water to the top line.
8. Brake pedal, inching pedal, clutch pedal, hand brake check: 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, confirm that the hand brake is safe and reliable.
9. Check the belt, horn, lighting, instrument, etc .: Check whether the belt tightness is in accordance with the regulations, there is no adjustment margin or damage or crack, it must be replaced; the horn, lighting, instrument should be normal and effective.
10. Remove the oil filter sediment.
2. First-class technical maintenance
According to the "daily maintenance" project, and add the following work.
1. Check the cylinder pressure or vacuum.
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 gear 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 installation of the generator and the starter motor is firm, and whether the terminals are clean and firm, and check the carbon brush and commutator for wear.
9. Check the tightness of the fan belt.
10. Check whether the wheels are firmly installed, whether the tire pressure meets the requirements, and remove the sundries embedded in the tread.
11. The parts are disassembled due to maintenance work. When reassembling, a forklift truck road test is required.
(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 if the diesel oil inlet filter is clogged and damaged, and clean or replace the filter.
3. Second-level technical maintenance
In addition to maintaining each item according to the first-level technology, the following tasks are added:
1. Clean all oil tanks, filter screens and pipelines, and check for corrosion and cracking. After cleaning, do not use fiber yarn or fabric to wipe.
2. Clean the torque converter, gearbox, check parts for wear and replace with new oil.
3. Check the bearing of the transmission shaft, and change the direction of the universal joint cross shaft if necessary.
4. Check the tightening condition of each part of the drive axle and whether there is oil leakage, and clear the air holes. Dismantle and inspect the main reducer, differential, wheel reducer, adjust the axial clearance of the bearing, 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 vertical and horizontal tie rods and the joints of the steering arm.
11. Dismantle the tires, remove the rust and paint the rims, check the inner and outer tires and pads, change positions and inflate as required.
12. Check the connection and tightening of the hand brake mechanism and 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 cleaning rollers and the attachments are reliable, and add welding if necessary.
16. Dismantle and inspect the lifting cylinder, tilt cylinder and steering cylinder, and replace the worn seals.
17. Check each instrument sensor, fuse and various switches, and adjust if necessary.
Fourth, the whole vehicle lubrication
For a new forklift or a forklift that has been out of work for a long time, within two weeks of starting use, for the bearings that should be lubricated, when lubricating, the new oil should be used to squeeze out all the old oil and lubricate it more than two times. The following points:
1. Before lubricating, remove the dirt on the oil cap, oil plug and oil nozzle to prevent the dirt from falling into the mechanism.
2. When injecting lubricant with a grease gun, it should be infused until the parts of each component combine to extrude the lubricant.
3. Seasonal lubricants (motor oil, etc.) should be replaced in summer or winter.
