Full Daily Maintenance Plan for Forklift Stability (Directly Implementable)

The core of daily maintenance for forklift stability lies in closed-loop management of key components according to inspection cycles, standardized operation, regular calibration, and environmental control, forming a closed-loop system of Inspection - Maintenance - Documentation - Improvement. Below is a modular, executable, and systematic plan.

I. Daily Inspection (Mandatory, Performed by Operators, Signed for Confirmation)

To be completed before daily operations, focusing on identifying critical hazards affecting stability. Inspection records must be filed and retained.

Inspection Item	Inspection Standard	Maintenance/Disposal Action
Vehicle Posture & Ground Contact	No body tilting; normal ground contact of tires, outriggers and counterweights without suspension	Adjust immediately; if outriggers/counterweights are loose, take the forklift out of service and report for repair
Tires & Wheel Hubs	Tire pressure complies with the original manufacturer’s manual (different pressures for unloaded/loaded conditions); no bulges, cuts or excessive wear on tire treads; no wheel hub deformation or loose bolts	Inflate or deflate tires to standard pressure; replace tires if wear/damage exceeds limits; tighten wheel hub bolts according to torque standards
Counterweights	No loose or broken fixing bolts; no cracks or displacement of counterweights	Re-tighten bolts to the original manufacturer’s torque specification; if cracks or displacement occur, take the forklift out of service and report for repair
Mast & Chains	No mast deformation or cracks; consistent chain tension without chain breakage, tooth skipping or excessive wear; no jamming of rollers/sliders	Tighten chains to standard tension; apply lubricating grease or replace components if jamming or excessive wear is detected
Tilt Cylinders & Seals	No leakage (no oil stains); smooth tilting movement without jamming or drifting	If leakage or drifting occurs, take the forklift out of service and report for repair; clean the cylinder surface daily to prevent dust ingress
Steering System	Flexible steering without jamming or excessive play; no steering wheel deviation	If jamming or excessive play is found, inspect steering tie rods and bearings, and apply lubricating grease or report for repair if necessary
Braking System	Normal brake pedal travel without excessive free play; effective parking brake without rolling	Adjust pedal travel; if parking brake fails, take the forklift out of service and report for repair

II. Weekly/Shift Maintenance (Performed by Teams, Supervised by Equipment Officers)

Hydraulic System Maintenance

1. Check hydraulic oil level (follow manual standards for cold/hot states). Low oil level can cause loss of control of mast/tilting movements; replenish with the same type of hydraulic oil—mixing different types is strictly prohibited.
2. Inspect hydraulic oil pipes and joints for leakage; ensure hydraulic filters are not clogged (clean filter surfaces weekly and replace according to the scheduled cycle).
3. Test mast lifting/lowering and forward/backward tilting movements to confirm no shaking or drifting (tests required for both unloaded and loaded conditions).

Lubrication Maintenance

In accordance with the lubrication point list (original manufacturer’s manual), apply lubricating grease to key parts such as mast rollers, chains, steering joints and outrigger pins (select grease suitable for working conditions, e.g., low-temperature/high-temperature type).

Load Center Distance Verification

Confirm the load center distance on the forklift nameplate; strictly prohibit overloading and eccentric loading operations. Check fork spacing to ensure the cargo center of gravity is within the load center distance.

III. Monthly/Quarterly In-Depth Maintenance (Performed by the Equipment Department, Conducted by Professional Personnel)

Calibration and Testing of Key Stability Components

1. Forks: Inspect forks for deformation, cracks and wear; calibrate fork levelness (measured with a level, correction required if deviation exceeds limits). For forklifts with adjustable fork spacing, ensure uniform spacing.
2. Lateral Stability Test: On a flat, hard surface, test the vehicle’s lateral tipping limit under unloaded and rated load conditions (over-limit testing is strictly prohibited). If the tipping angle is abnormal, inspect counterweights, masts and tires.
3. Lifting Stability Test: Lift the rated load to the maximum height, test for forward tilting tendency and mast shaking. If abnormalities are detected, inspect tilt cylinders, counterweights and load center distance.

Battery/Counterweight System (Special for Electric Forklifts)

1. Ensure counterweights and battery packs of electric forklifts are securely fixed; no battery displacement or leakage. Inspect battery fixing bolts and re-tighten them according to torque specifications.
2. Maintain normal electrolyte level for lead-acid batteries (no drying out); keep battery surfaces clean to prevent corrosion.

Tightening and Anti-Corrosion

1. Conduct a comprehensive inspection of bolts on key parts such as the vehicle body, mast and counterweights, and re-tighten them according to the original manufacturer’s torque standards.
2. Apply anti-rust agent to rust-prone parts (e.g., outriggers, chains, wheel hubs) after cleaning and drying.

IV. Operation and Environmental Control (The "Soft Line of Defense" for Stability Maintenance, Implemented by All Personnel)

Standardized Driving Operations (Directly Affect Stability, Must Be Fully Trained)

1. Strictly prohibit speeding, sharp turns and sudden braking, especially when carrying heavy loads, operating at high lifting heights, or on slippery/tilted roads.
2. Ramp Operations: Drive forward when ascending ramps and reverse when descending ramps. Strictly prohibit steering, gear shifting and parking on ramps (if parking is necessary under special circumstances, the parking brake must be engaged and wheel chocks installed).
3. Load Control: The cargo center of gravity must be within the load center distance; overloading and eccentric loading are strictly prohibited. When stacking or retrieving goods, tilt the mast slightly forward/backward to avoid cargo shaking.

Working Environment Control

1. Operation Site: The ground shall be flat, free of potholes, oil stains and accumulated water; the slope shall not exceed the maximum allowable slope of the forklift (usually ≤5%).
2. Parking Area: Must park on a flat, hard surface, engage the parking brake, shift to neutral and install wheel chocks. Strictly prohibit parking on ramps, edges or soft ground.

Personnel and Training

1. Operators must hold valid certificates to work and receive regular special training on stability (including inspection, operation and emergency disposal).
2. New employees or transferred employees must pass practical assessment before being allowed to work independently.

V. Abnormal Disposal and Closed-Loop Improvement (Key Link to Prevent Hazard Escalation)

Immediate Out-of-Service Conditions (Stop Operations Immediately If Any of the Following Occurs)

1. Vehicle body tilting, counterweight displacement/cracking, severe tire damage
2. Mast/chain jamming, hydraulic system leakage, braking/steering failure
3. Failed stability tests (e.g., abnormal lateral tilting or forward tilting tendency)

Closed-Loop Process

Discover hazards → Take the forklift out of service immediately → Report to the equipment department → Repair/calibrate → Acceptance inspection and approval → Document and file records → Analyze hazard causes (e.g., human operation error, component aging) → Formulate improvement measures (e.g., strengthen training, shorten inspection cycles)

VI. Supplementary: Special Maintenance for Electric Forklift Stability

1. Battery Packs: Regularly inspect battery fixing devices to prevent center-of-gravity shift caused by battery displacement. When replacing batteries, use only original manufacturer-matched battery packs (complying with weight and size requirements).
2. Electronic Control System: Check electronic control parameters related to stability (e.g., tilt speed limit, lifting speed limit) to ensure compliance with original factory settings; unauthorized modification is strictly prohibited.
3. Regenerative Braking: Test the normal operation of the regenerative braking function to avoid stability impacts caused by braking failure.