The maintenance methods of electric forklifts require a multi - dimensional approach combining daily inspections, regular maintenance, and special maintenance of key components. The specific operations are as follows:
I. Daily Maintenance (Daily/Per Shift)
Battery System Inspection
- Check the electrolyte level (for lead - acid batteries, add distilled water; lithium batteries are maintenance - free).
- Make sure to let the battery rest for 30 minutes after charging before use to avoid overcharging and overdischarging.
- Clean the battery surface and apply Vaseline to the terminals to prevent oxidation.
Mechanical Component Inspection
- Inspect tire wear and air pressure (the pressure of solid tires is 5 - 7 kg/cm²).
- Check the tightness of the chain (the sagging amount should be ≤ 20 mm) and the sensitivity of the braking system.
- Ensure that the lights, warning devices, and steering system are functioning properly.
Cleaning and Safety
- Clean the dirt on the forklift body, especially in areas prone to dust accumulation such as the fork frame and door frame slideway.
- Before operation, check the brakes, steering, and lighting systems. Report any abnormalities for repair immediately.
II. Regular Maintenance (Based on Operating Hours)
50 - Hour Maintenance
- Replace the hydraulic oil filter. Check the door frame clearance and chain tension.
- Supplement the specific gravity of the battery electrolyte and check for loose electrical control connectors.
250 - Hour Maintenance
- Replace the hydraulic oil (ISO VG32 standard) and gearbox oil.
- Check the drive axle oil level, brake fluid, and tire air pressure.
- Remove dirt from the battery, and measure the thickness of the brake pads.
500 - Hour Maintenance
- Replace the gear oil and brake fluid. Inspect the brake drum wear.
- Clean the brake master cylinder. Check the steering axle limit and bolt fastening.
- Replace the hydraulic gearbox oil filter. Test the motor carbon brushes.
Annual Overhaul
- Detect door frame deformation, balance weight fastening, and safety device functions.
- Replace the drive axle gear oil. Unblock the air holes and radiator.
III. Special Maintenance of Key Components
Battery Maintenance
- Perform a deep discharge once a month (not less than 20% of the battery capacity).
- The charging cycle is 4 - 6 hours. Avoid high - temperature/low - temperature environments (≤ 50°C).
- Keep the electrolyte density at 1.28 g/cm³. Do not use tap water for supplementation.
Hydraulic System
- Replace the hydraulic oil every 500 hours and check for oil pipe leaks.
- Regularly test the lifting speed and the sealing of the tilt cylinder.
Electrical System
- Clean the controller heat sink once a month and check the insulation of the wiring.
- Check and replace the motor carbon brushes every 2000 hours. Keep the battery charger well - ventilated.
IV. Operating Specifications and Emergency Handling
Operating Specifications
- Do not exceed 80% of the rated load. Drive at a low speed on slopes.
- Disconnect the negative terminal of the battery if the forklift will not be used for a long time to avoid self - discharge.
- Observe before reversing. Sound the horn when turning and give way to oncoming vehicles.
Emergency Handling
- Stop the forklift immediately and report for repair in case of a malfunction. Do not operate with problems.
- Use a fire extinguisher to put out a fire and call the police in case of a fire.
V. Maintenance Records and Tools
- Establish a maintenance file (date/project/replaced parts).
- Equip with a testing tool kit including a multimeter, hydraulic pressure gauge, etc.
- Complete each maintenance within 2 hours to ensure efficiency.
Through systematic maintenance, the failure rate of electric forklifts can be reduced by 40%, and their service life can be extended by more than 30%. It is recommended to give priority to brands that offer a 3 - year battery warranty and conduct regular professional inspections.
