Daily maintenance, after each shift.
1. For level-1 technical maintenance, after working for 100 hours, the one shift system is equivalent to 2 weeks.
2. After 500 hours of secondary technical maintenance, the one shift system is equivalent to one quarter.
1、 Routine maintenance
1. Clean the dirt, dirt and dirt on the forklift. The key parts are: fork frame and gantry slide, generator and starter, battery electrode fork column, water tank and air filter.
2. Check the fastening of all parts, focusing on: fork support, lifting chain tension screw, wheel screw, wheel fixing pin, brake and steering gear screw.
3. Check the reliability and flexibility of foot brake and steering gear.
4. Check the leakage, focusing on: 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 reducer, hydraulic steering gear and steering cylinder.
5. Drain the oil filter sediment.
2、 The first level technical maintenance shall be carried out according to the "daily maintenance" project, and the following work shall be added.
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-way directional valve, lifting cylinder, tilt cylinder, steering cylinder and gear pump work normally.
5. Check whether the transmission shifts normally.
6. Check and adjust the clearance between the brake pad and brake drum of hand and foot brakes.
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 firmly installed, whether they are clean and firm with the connector, and 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 the sundries embedded in the tread.
11. If the parts are disassembled due to maintenance work, the forklift road test shall be carried out after reassembly.
(1) The braking performance under different degrees shall be free from deviation and snaking. On steep slopes, it can stop reliably after the hand brake is tightened.
(2) Listen for abnormal sound when the engine is running under acceleration, deceleration, heavy load or no load.
(3) After the road test for a certain mileage, check whether there is overheating at the brake, transmission, front axle housing and gear pump.
(4) Whether the lifting speed of the fork frame is normal and whether it trembles.
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.
3、 In addition to the items of level-1 technical maintenance, the following work is added for level-2 technical maintenance:
1. Clean each oil tank, filter screen and pipeline, and check whether there is corrosion and crack. After cleaning, it is not allowed to wipe with gauze with fiber and cloth.
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 cardan spider as necessary.
4. Check the fastening 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 bearings, and add or replace lubricating oil.
5. Disassemble, inspect, adjust and lubricate the front and rear hubs, and carry out half shaft transposition.
6. Clean the brake and adjust the clearance 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, and pay attention to the wear of gear, shell and bearing.
9. Disassemble the multi-way valve, check the clearance between the valve rod and the valve body, and do not disassemble the safety valve if necessary.
10. Check the steering knuckle for damage and cracks, the fit between the steering axle kingpin and the steering knuckle, and disassemble and check the wear of the vertical and horizontal tie rods and the joints of the steering arm.
11. Remove the tire, rust and paint the rim, check the inner and outer tires and cushion belt, transpose and inflate according to the regulations.
12. Check the connection and fastening of hand brake parts, and adjust the working stroke of 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 for charging.
14. Clean the water tank and oil radiator.
15. Check whether the shelf and frame are deformed, whether the rollers and accessories are fixed reliably, 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 them if necessary.
4、 For new forklifts or forklifts that have stopped working for a long time, within two weeks after starting to use, for the bearings that should be lubricated, all the old oil should be squeezed out with new oil and lubricated more than twice. At the same time, pay attention to the following points:
1. Before lubrication, remove the dirt on the oil cover, oil plug and oil nozzle to prevent the dirt from falling into the mechanism.
2. When injecting lubricant with grease gun, it shall be injected until the parts of each component combine to extrude lubricant.
3. Seasonal lubricants (oil, etc.) should be replaced in summer or winter.
