Inspection and testing methods for electric forklifts after installation

1、 Installation confirmation and file verification

1. Basic information verification

Nameplate and certificate of conformity: Confirm that the forklift nameplate information (manufacturer, model, self weight, load capacity) is consistent with the certificate of conformity and purchase contract.

Configuration verification: Check whether the height of the door frame, motor model, fork size, etc. meet the contract requirements.

CE certification and standard compliance: Verify whether the forklift has passed the EU CE certification (if applicable), confirm compliance with EN ISO 3691-1 standards and local safety regulations (such as OSHA).

2. Match the packing list with the physical item

Component integrity: Check all components (including instructions, warranty cards, spare parts) against the packing list to ensure that there are no missing or damaged parts.

Appearance inspection: Check the body for deformation, cracks, fork bending (≤ 3 °), cracks, and the firmness of accessory connections.

2、 Mechanical system inspection

1. Walking and hydraulic system

Tire inspection:

Air pressure: Front wheel 6-8 bar, rear wheel 4-6 bar.

Tire wear: residual pattern ≥ 40%, no damage or bulges.

Braking system: Brake within 3 meters of no load, steering force detection (steering wheel free angle ≤ 15 °).

Hydraulic system:

Chain tension: sag ≤ 20mm.

Lifting speed: The full load lifting time meets the calibration value ± 10%, without any jamming or leakage.

2. Steering and structural safety

Steering performance: Verify steering sensitivity, with no abnormal resistance or noise.

Door frame deformation: Use a laser rangefinder to detect the deformation of the door frame (standard value ≤ 2mm/m).

Protective structure: Confirm that the operating platform protective structure (ROPS/FOPS) complies with ISO 6055 standard.

3、 Electrical system inspection

1. Battery and Charging System

Lead acid battery:

Electrolyte level: within the scale line, add distilled water when insufficient.

Electrode pile head: free from oxidation and corrosion, with firmly connected wires.

Lithium battery:

Electricity level: ≥ 80%, with no loose or corroded connections.

Charging safety: Verify the compatibility of the charger, test the charging process (lead-acid batteries need to neutralize acid mist, lithium batteries use dedicated fire extinguishers).

2. Electrical safety and signaling

Emergency power-off switch (E-stop): When pressed, the device immediately shuts off and functions normally.

Lighting and Signal:

Headlight illumination ≥ 200lux (5m distance).

The sound pressure level of the horn is ≥ 93dB (A), and the turn signals, brake lights, and reversing lights are effective.

Cables and interfaces: Check that cables, plugs, and sockets are not damaged, aged, or exposed.

4、 Functional and Performance Testing

1. Dynamic testing

No load operation: Conduct a 3-minute trial run to test the braking, steering, and lifting functions, and the motor produces no abnormal noise.

Full load test:

Driving stability: flat road ≤ 10km/h, turning/ramp ≤ 5km/h, no overload or off load.

Ramp driving: Do not shift gears when going uphill, disable neutral coasting when going downhill, verify the effectiveness of engine/motor braking.

Reverse test: When the goods obstruct the line of sight, reverse the vehicle and verify the effectiveness of the reverse image or radar.

2. Special scenario verification

Load handling: When handling goods that are too long, too wide, or too high, warning signs or dedicated personnel should be used for guidance.

Dangerous goods: Use explosion-proof forklifts when handling flammable and explosive materials, in compliance with relevant transportation regulations.

5、 Verification of safety devices

1. Operation Protection System (OPS)

Driver departure detection: Verify the automatic power-off function when leaving the seat.

Emergency reverse braking: When encountering obstacles, brake within 0.5 seconds without delay.

2. Intelligent system diagnosis

Motor temperature rise: Download CAN bus data and analyze continuous working temperature rise (≤ 85 ℃).

Fault code: Diagnose and record the fault code to ensure there are no unresolved abnormalities.

6、 Environmental and Maintenance Verification

1. Cleaning and sealing

Vehicle cleanliness: No oil stains, no accumulated water or debris in the battery compartment, and good sealing.

Ventilation requirements: The charging area should be well ventilated and equipped with dry powder fire extinguishers (lithium batteries) or carbon dioxide fire extinguishers (lead-acid batteries).

2. Maintenance records and training

Digital archives: Establish a point inspection app to record data, including battery maintenance (monthly capacity testing), transmission device (changing lubricating oil every 500 hours), etc.

Operator training: Ensure certified personnel are on duty, familiar with safety regulations (such as prohibiting passengers and speeding), and the management conducts regular spot checks on implementation.

7、 Compliance and documentation

1. Acceptance report

Standard compliance: According to EN ISO 3691-1, OSHA 1910.178 and other standards, fill in the acceptance report and sign it.

Warranty commitment: Clearly define the warranty period (e.g. 1 year), record spare parts supply and response time (on-site within 24 hours).

2. Emergency response

Battery leakage: Wear protective equipment, neutralize with baking soda, and clean up.

Mechanical malfunction: When the brake fails, press the E-stop button and contact maintenance personnel for assistance.

The main equipment produced by Hebei Makita: stage electric hoist, electric chian hoist, wire rope electric hoist，Hand chain hoist, lever hoist, pneumatic hoist and other lifting equipment