Comprehensive guide for protection and inspection methods of electric forklifts

1、 Protection methods

1. Battery system protection

Lead acid battery maintenance:

Regularly replenish distilled water to avoid low electrolyte levels.

Perform monthly capacity testing to ensure the health status of the battery.

Avoid overcharging or overdischarging, and charge immediately when the remaining battery level is below 20%.

Lithium battery maintenance:

Avoid extreme temperatures (below -10 ℃ or above 45 ℃), and replenish electricity once a month when it is not in use for a long time.

Use original or certified chargers, and do not mix chargers of different specifications.

Charging safety:

The charging area should be well ventilated and kept away from open flames and static electricity.

Wear protective equipment (face mask, goggles, rubber gloves) and remove metal jewelry before charging.

2. Electrical system protection

Circuit and controller:

Quarterly testing of electrical circuit insulation and investigation of controller and contactor contact oxidation.

Clean electrical components to avoid dust accumulation and short circuits.

Lighting and Signal:

Regularly test the functions of turn signals, headlights, and reverse buzzer to ensure that the warning devices are functioning properly.

3. Maintenance of mechanical components

Lubrication management:

Inject oil every 250 hours to lubricate the guide rails, bearings, and chains of the gantry.

Use specialized lubricants to prevent oil from deteriorating and causing wear.

Braking and steering system:

Check the brake pad thickness (≥ 5mm) and brake fluid level every 500 hours.

Check the pressure of the steering system and replace the aging oil seal or sealing ring.

Wheel hub and tire:

Tighten the wheel hub bolts using a torque wrench to the standard torque (e.g. 200-250Nm for M16 bolts).

Check tire wear (remaining pattern ≥ 40%), and maintain a front tire pressure of 6-8 bar and a rear tire pressure of 4-6 bar when inflating the tires.

4. Maintenance of hydraulic system

Oil management:

Replace hydraulic oil every six months and check the cleanliness of the oil (filter or replace if necessary).

Check for oil pipe leakage and aging of sealing rings, and replace components in a timely manner.

Pumps and valves:

Test the hydraulic pump pressure (usually 16.5MPa) and check the sealing of the control valve.

Clean the hydraulic system filter element to avoid blockage that may cause slow lifting speed or shaking.

5. Safety device management

Emergency power-off function:

Press the E-Stop button to confirm that the vehicle is immediately powered off and all actions stop.

OPS protection system:

Verify the sensitivity of the operation protection system to ensure automatic alarm and restriction of actions in case of overload or abnormality.

Door frame and fork inspection:

Check for cracks and deformations in the fork (replacement is required if the thickness is ≤ 90% of the original), and ensure that the lifting/tilting action of the gantry is smooth without any abnormal noise.

2、 Inspection method

1. Daily inspection (operator)

Pre start check:

Instrument panel self-test (no fault light), battery level remains in the range of 20% -90%.

The fork has no cracks or deformations, and the depth of insertion into the pallet is sufficient. The horizontal bending of the fork is ≤ 3 °.

Dynamic testing:

No load braking test (braking within 3m), steering force detection (steering wheel free angle ≤ 15 °).

The hydraulic lifting speed meets the calibration value (full load lifting time ± 10%).

Environmental adaptability confirmation:

Lighting system (headlight illumination ≥ 200lux/5m), warning device (horn sound pressure level ≥ 93dB).

Tire pressure (solid tire hardness ≥ 85 Shore A), remove foreign objects from the tread.

2. Regular inspections (by the management)

Power system:

Check battery capacity monthly and replace gearbox oil every 500 hours.

Check the wear of the motor carbon brush (not exceeding 1/3 of the original length) and clean the dust at the heat dissipation port.

transmission:

Check the transmission oil level and quality, and replace the lubricating oil every 500 hours.

Structural components:

Use a laser rangefinder to detect the deformation of the gantry (standard value ≤ 2mm/m) and evaluate the tire wear marks.

Intelligent system:

Download CAN bus data, analyze motor temperature rise curve (continuous operation ≤ 85 ℃), and record diagnostic fault codes.

3. Special inspection

Hydraulic system malfunction:

Check for insufficient oil, clogged oil filters, and worn oil pumps, and promptly replenish or replace components.

Electrical system malfunction:

Check for battery aging, abnormal charger voltage, poor or short circuit connections in the circuit.

Steering system malfunction:

Detect insufficient hydraulic oil flow, internal leakage of steering cylinder, and wear of steering gear.

Brake system malfunction:

Check for brake pad wear, oil circuit blockage, and improper brake clearance.

3、 Operating standards

1. Start and Drive

Wear a seat belt, adjust the seat to the appropriate position, and confirm the surrounding safety before starting the key.

Control the driving speed within the factory to ≤ 5km/h, and sound the horn to slow down in narrow areas.

Place the goods in the center with the forks 300mm off the ground to avoid sharp turns or sudden braking.

2. Cargo handling

The depth of inserting the fork into the pallet is sufficient, and overloading is prohibited (load capacity ≤ 90% of rated value).

Maintain stability when lifting and lowering goods to avoid uneven force on the gantry causing shaking.

3. Maintenance after operation

Standardized parking: Place the fork on the ground, turn off the power and remove the key, and park in the designated area.

Clean the vehicle body, check the tires and hydraulic system, and record maintenance details.

4. Charging management

Follow OSHA standards: Charge in designated areas, avoid open flames, and connect clips correctly (positive first, negative later).

Check the electrolyte level before charging, and add distilled water to the safe level after charging.

4、 Emergency response

Abnormal findings: Immediately stop the machine, report for repair, and record the fault symptoms (such as abnormal noise and oil leakage).

Battery accident: If the battery heats up or electrolyte overflows during charging, turn off the charger and ventilate.

Emergency power outage: Press the E-Stop button to cut off the power and hang a "fault" sign.

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