The protection and inspection of hydraulic forklifts need to be comprehensively implemented from four dimensions: daily maintenance, regular maintenance, professional testing, and operating standards. The specific methods are as follows:

1、 Daily maintenance: the core of basic protection

Cleaning and anti-corrosion

Clean the surface dust and oil stains of the forklift after daily homework, with a focus on cleaning components such as forks, chains, and oil cylinders to prevent dirt accumulation and wear or corrosion.

Avoid long-term exposure of forklifts to damp, acidic, and alkaline environments. When storing, choose a dry and ventilated place to prevent metal parts from rusting.

Hydraulic system inspection

Oil level and quality: Check the hydraulic oil level daily to ensure it is within the specified range; Observe the color of the oil and replace it immediately if it becomes cloudy or contains impurities.

Leakage investigation: Check for leaks in hydraulic pipelines, joints, and cylinders, and promptly repair or replace seals if leaks are found.

Air removal: After replacing hydraulic oil or seals, it is necessary to use the "air strike" operation (place the control lever at a low position and swing the handle more than ten times) to remove air from the system and avoid component damage caused by cavitation.

Tire and braking system

Tire inspection: Daily check whether the tire pressure is normal, whether there is any damage or foreign object embedded on the surface, and promptly clean the debris in the pattern.

Braking test: Test the braking performance before operation to ensure that the braking is sensitive and reliable; Adjust the brake pedal stroke to the specified range (usually 10-15cm).

Forks and door frames

Check whether the fork is deformed, cracked or worn, whether the door frame is lifted smoothly, and whether there is any jamming or abnormal noise.

When the fork is loaded, it needs to be fully inserted into the bottom of the cargo, and the insertion depth should not be less than the center distance of the load (usually 500mm or 600mm).

2、 Regular maintenance: the key to preventive maintenance

Lubrication and fastening

Lubrication cycle: Lubricate moving parts such as chains, door frame guides, rollers, etc. every 200 hours to reduce wear.

Tightening inspection: Every 500 hours, check whether the connecting bolts of each component are loose, especially the key parts such as the drive wheel and fork.

Deep maintenance of hydraulic system

Filter replacement: Replace the hydraulic oil filter every 500 hours to prevent impurities from entering the system.

Oil replacement: Replace the hydraulic oil every 1000 hours and clean the hydraulic oil tank and filter; If working at high temperatures for a long time, it is necessary to change the oil in advance.

Oil seal inspection: Check the oil cylinder piston sealing ring every 2000 hours, and replace the oil seal if it is severely worn.

Electrical system maintenance

Battery inspection (electric forklift): Check the electrolyte level of the battery every 500 hours, and add distilled water if it is insufficient; Clean the surface of the battery to prevent short circuits.

Line inspection: Check the wires and plugs for damage or looseness every 1000 hours to ensure good insulation of the electrical system.

Transmission system maintenance

Gear oil replacement: Replace the gearbox oil every 2000 hours and check the lubrication of the rotating bearings.

Brake system adjustment: Check the wear of brake pads every 1000 hours and replace them if necessary; Adjust the free travel of the brake pedal.

3、 Professional testing: Ensuring safety performance

Annual comprehensive inspection

Power system: detect engine operating conditions (internal combustion forklift) or motor performance (electric forklift).

Hydraulic system: Use a digital hydraulic tester to measure pressure and flow rate to ensure good sealing of the lifting and tilting cylinders.

Braking performance: Measure the braking distance and deceleration through a braking performance tester to ensure compliance with standards (such as braking distance not exceeding 20% of the standard value).

Deformation degree of the gantry: Use a laser centering instrument to detect the verticality of the gantry, with a resolution of 0.01mm/m.

load test

Overload test: When the hydraulic oil temperature is 40-50 ℃, load 1.25 times the rated load to test the strength of the gantry, and there should be no permanent deformation after the test.

Fork sliding amount: Lift the fork to a height of 2 meters under full load, close the distribution valve, and measure the sliding amount 10 minutes later. The standard value is usually ≤ 10mm.

stability test

Longitudinal stability: The front wheels of the forklift are mounted on the weighing platform, and the rear wheels are lifted to achieve a longitudinal inclination angle of 15 °. The front axle load is measured, and the center of mass height is calculated to ensure compliance with design requirements.

Lateral stability: Through load curve verification, ensure that the forklift does not tip over under turning or lateral force.

4、 Operating standards: the fundamental basis for extending lifespan

Gentle homework

Avoid rough handling, reduce impact loads, and prevent component damage or oil pipe rupture caused by sudden increase in hydraulic system pressure.

temperature control

The working temperature of the hydraulic system is controlled at 30-80 ℃. If the oil temperature is too high, it will reduce the viscosity of the oil, causing leakage and wear.

Load management

Overloading is strictly prohibited, and the weight of a single transport must not exceed the rated load (usually manual hydraulic forklifts ≤ 1 ton, electric forklifts ≤ 3 tons).

The center of gravity of the goods should be centered to avoid deformation or overturning of the gantry caused by unbalanced loading.

Slope operation

When going uphill, the vehicle should move forward, and when going downhill, the vehicle should move backward (with the fork facing downhill). It is strictly prohibited to slide in neutral.

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