Daily maintenance and maintenance of forklifts
To make the forklift work normally and reliably, and to give full play to the potential of the forklift, regular maintenance measures must be taken. Technical maintenance measures are generally:
1. Routine maintenance: after each shift.
2. Level 1 technical maintenance: After 100 hours of cumulative work, one shift is equivalent to 2 weeks.
3. Secondary technical maintenance: After 500 hours of accumulated work, one shift is equivalent to one quarter.
1. Routine maintenance:
1. Clean the dirt, soil and dirt on the forklift, the key parts are: fork frame and mast slide, generator and starter, battery electrode fork column, water tank, air filter.
2. Check the tightness of each part, focusing on: fork frame support, lifting chain tightening screws, wheel screws, wheel fixing pins, brakes, and steering gear screws.
3. Check the reliability and flexibility of the foot brake and steering gear.
4. Check for leakage, focusing on: various pipe joints, diesel tank, oil tank, brake pump, lift cylinder, tilt cylinder, water tank, water pump, engine oil pan, torque converter, transmission, drive axle, main reduction gear , Hydraulic steering gear, steering cylinder.
5. Remove the sediment from the oil filter.
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. Parts are disassembled due to maintenance work, and the forklift road test shall be carried out after reassembly.
(1) 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.
(2) Listen to whether the engine is running under acceleration, deceleration, heavy load or no load, and whether there is any abnormal noise.
(3) After the road test for a period of mileage, check the brakes, 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 filter screen at the oil inlet of the diesel tank is blocked or damaged, and clean or replace the filter screen.
3. Secondary technical maintenance:
In addition to maintaining the items according to the first-level technology, 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, add or replace lubricating oil.
5. Disassemble, inspect, adjust and lubricate the front and rear wheel hubs, and perform half-shaft shifting.
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, 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, and check 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 for charging.
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.
Fourth, the whole car lubrication
For a new forklift or a forklift that has stopped working for a long time, within two weeks of starting to use, for bearings that should be lubricated, when lubricating, use new oil to squeeze out all the old oil and lubricate it more than twice, and pay attention The following points:
1. Before lubrication, the dirt on the oil cap, the oil plug and the nozzle should be removed to prevent the dirt from falling into the mechanism.
2. When injecting lubricant with a grease gun, it should be injected until the lubricant is extruded at the joint of each part.
3. Seasonal lubricants (oil, etc.) should be replaced in summer or winter.
