Preventive maintenance and repair system - maintenance operations
The system of preventive maintenance and repair is a complex of organizational and technical measures carried out in a planned manner. Activities are developed and implemented in accordance with the recommendations of manufacturers and include preventive inspectionsmaintenance, repairs.
In the process of using the machines, the following are carried out: shift maintenance (EO) performed before, during and after work shift; scheduled maintenance (TO), performed in a planned manner through certain periods established by manufacturers; seasonal maintenance (SO) carried out twice a year in preparation for May for operation in the following season.
There are two types of scheduled repairs: current (T) and major (K). Maintenance must ensure the operability of the machine until the next scheduled repair, overhaul and serviceability of the machine for a time equal to or close to its full resource. The frequency of performing a particular type of maintenance or repair is measured by the operating hours of the machine per hour. The operating time is determined according to the readings of the counters installed on the magician or according to the records of shift time. To account for shift time, a log of operating hours is kept. The frequency, complexity and duration of maintenance and repairs of loaders are given in the Recommendations for the organization of maintenance and repair of construction machines.
The owner organization develops a schedule for the maintenance and repair of the loader on its balance sheet. Maintenance and repair work is carried out in accordance with the instructions contained in the Operating Instructions of the machine manufacturer.
Maintenance operations carried out in this order. Shift maintenance (EO) (performed by the driver) includes operations to prepare the machine for work, maintenance, return to the parking lot (garage).
In the process of preparing for work, the driver inspects the loader, checks the completeness and condition of the tool. Before starting the engine, it controls the level and quality of oil in the crankcase, the presence of fuel in the tank, coolant in the radiator, working fluid in the hydraulic tank; also checks the fastening of the wheels, the condition of the tires and the pressure in them, the tension of the fan and generator drive belts. If necessary, work is carried out to eliminate leaks and refuel systems.
After starting and warming up the engine, check the serviceability of the instrumentation, the operation of the working equipment, the running gear and the hydraulic drive, the serviceability of the brakes and steering.
Upon returning to the parking lot, they clean and inspect the loader, eliminate malfunctions and lubricate parts and mechanisms.
The first maintenance (TO-1) is carried out by a specialized team with the involvement of a driver in a special area and, in addition to the SW operations, includes a number of additional checks and adjustments on the engine, working equipment, chassis. In the process of TO-1, all the fastening connections of the loader are checked and the steering, brake and clutch control are adjusted. Inspect all pipeline connections, assess the condition of the sleeves. Drain sediment from the fuel filter. They control how the stud nuts on the cylinder head are tightened, whether the carburetor control drive works well, and adjust the power steering.
The second maintenance (TO-2) includes the entire scope of work of the EO and TO-1 and additionally the following work: checking, cleaning candles; regulation of gaps between electrodes; cleaning and adjusting the carburetor; checking and cleaning the contacts of the breaker; checking and adjusting clearances between valves and pushers; disassembly of the fuel sump;
washing the mesh and filter element, wheel bearings; lubricant change; bearing regulation; cleaning of brake mechanisms and checking their technical condition; adjustment of clearances in the steering; adjustment of valves in the hydraulic system;
adjusting the tension of the hoist chains; checking the condition of the brushes and the generator collector; cleaning the battery terminal; tightening the bolts and nuts securing the mechanisms to the frame.
Seasonal maintenance (SO) is carried out twice a year - in spring and autumn, and includes the work provided for by TO-2, and additional ones: flushing the cooling system and filling it with seasonal liquid; flushing the fuel tank and fuel lines; seasonal change of lubricant and working fluid, checking the density of the electrolyte and bringing it to normal; cleaning and lubricating the handbrake elements.
The composition of operations and maintenance for each specific machine model is determined by the tool.
To Category:
Port handling machines
Maintenance and the concept of forklift repair
The design of the forklifts is characterized by the use of typical automotive components, low voltage direct current electrical equipment and positive displacement hydraulic drives.
The maintenance and repair of the chassis and power transmission of loaders in terms of the scope of work and the technology for their implementation are close to the corresponding work on cars.
Breaking in loaders. The service life of a forklift largely depends on the strict observance of the rules of the break-in period after receiving the loader from the manufacturer. Running-in is carried out in order to check the operation of all components and systems of the machine, as well as for better running-in of rubbing parts. During the run-in of forklifts, the internal combustion engine is also run-in, and during the run-in of electric forklifts, training charge-discharge cycles of the battery are performed.
Before starting the break-in, you should try out the working movements of the loader without a work load. During the break-in period, especially during the first trips, they carefully monitor the operation of all components and mechanisms, checking the condition of the fasteners, the tightness of the systems, the smoothness and noiselessness of operation, heating. The running-in duration of a new loader is at least 50 hours, and its rated load capacity should be used during this period by no more than 50-75%.
Forklift maintenance. It is produced in the forms of current (daily) and preventive (periodic) maintenance.
The current (daily) maintenance of loaders in terms of scope and range of work is usually divided into shifts (before starting work) and weekly, that is, after about 50 working hours. Periodic maintenance of these machines is carried out after 200-250 working hours, i.e. almost monthly.
Every shift maintenance includes work on washing and cleaning the machine, checking the condition and operation of the steering, brakes, hydraulic drive, internal combustion engine; checking (charging or changing) traction batteries; refueling the car.
During weekly maintenance, a thorough check and tightening of all fasteners, especially bolts, is carried out, since the drive (front) axle of loaders is not sprung and these connections weaken to a greater extent than for transport vehicles with spring suspension. The following are also performed: checking the condition of pipelines and high-pressure hoses, tightening seals; checking the condition of the bearings of the forklift carriage, springs and parts of the balancing suspension; adding oil to the drive axle gearboxes; checking the condition of the wiring; listening to the engine; sludge drain and filter cleaning.
Preventive (monthly) maintenance is timed to coincide with the next weekly maintenance and consists, in addition to weekly work, mainly in inspection and adjustment work.
On electric forklifts, with this frequency, tightening of contact connections, cleaning of contact surfaces of contactors, checking the magnitude of pressing and dropping of contactors, cleaning contact segments and fingers of controllers, checking the condition of collectors of electric motors. The condition and value of the insulation resistance is also checked.
During weekly and monthly maintenance of loaders, in addition to the basic mandatory work listed above, “on demand” work is usually performed, including the replacement of wearing parts and minor repairs.
Loaders are lubricated in accordance with factory instructions and lubrication charts.
For carburettor internal combustion engines of forklifts, in addition to performing work on shift maintenance, periodic technical maintenance is performed at intervals of 50, 100 and 1000 working hours.
Chassis. Wear of wheels and steering and cases of breakage of loader springs largely depend on the condition of coatings of storage areas, roads and crossings over railways and crane tracks.
Worn-out trucks are usually not repaired in an operational environment. Metal wheel tires are rubberized at the factories of rubber products.
Adjustment of roller tapered bearings of wheel hubs is carried out according to general rules adjusting such units. After adjusting the bearings, during the first hours of operation of the loader, the temperature of the wheel hubs is monitored. If the hubs become hot, the adjustment should be repeated.
The springs of the rear balancing suspension of the steered wheels often fail. Depending on local conditions and the nature of the damage, they are replaced as a set or repaired by replacing individual sheets.
Steering. Steering adjustment is to eliminate the backlash and gaps formed in the steering rod joints and the engagement of the steering mechanism. The play in the hinges of the rods is eliminated by tightening the moving crackers. The steering mechanism is adjusted by sampling the gaps in its engagement. Typical for electric forklifts is the gearing of the steering mechanism, for forklifts - worm gear.
For a worm steering gear, the engagement of the roller and the worm is adjusted by removing or adding the required number of shims to change the size a. In this case, the bipod rod must be disconnected, and the bipod shaft is set in the middle position. In addition, the axial play of the worm tapered bearings is regulated by means of gaskets. After these adjustments, the force required to turn the steering gear should be in the range of 1.5-2.5 kg, and the angle of rotation of the bipod from the middle position in each direction should be at least 42 °.
Rice. 1. Gear steering mechanism
The steering system of forklift trucks with a carrying capacity of 3t more commonly includes hydraulic boosters that reduce the force on the steering wheel. The amplifier is a hydraulic follow-up mechanism in which a spool device (leading link) and a hydraulic power cylinder (slave link) are combined.
The hydraulic booster with a collapsible cylinder is shown in fig. 3. Steel pipe the power cylinder is located between the body and the cover. The body and cover are pulled together with studs and connected by a branch pipe. The body houses the spool mechanism for controlling the power cylinder. The head of the rod through the ball pin is attached to the console welded to the frame of the loader chassis, and the lug of the power cylinder is attached through the rod to the steering linkage lever. The ball pin is connected to the rod of the bipod of the steering mechanism. The spool device consists of a sleeve fixed motionlessly in the body, and a spool, the shank of which is connected to a ball pin clamped between two crackers in a sliding glass by a rigid spring. Overcoming the resistance of the spring, the ball pin can move along the axis of the cylinder together with the sliding glass by a small amount (2-3 mm) from its middle position. In this case, the spool will move relative to the sleeve by the same amount and in the same direction. Moving, the spool connects the cavities of the power cylinder with the discharge and drain channels so that the movement of the cylinder relative to the piston occurs in the same direction as the displacement of the spool. In the neutral position, the spool is held by a spring. In this case, the oil pumped by the pump has a free passage to the drain.
Rice. 2. Worm gear steering mechanism
Rice. 3. Hydraulic power steering
The position of the hydraulic booster in the steering kinematic circuit is shown in fig. 5. The moment created by the driver on the steering column is converted by the steering mechanism and bipod into a force that acts through the rod on the hydraulic booster spool and moves it.
When the steering wheel is turned, for example, to the left, the bipod rod with the ball pin, and with it the spool, will move forward, connecting the channel of the front (left in Fig. 3) cavity of the cylinder with the discharge line, and the channel located on the other side of the piston with drain line. The oil pressure moves the cylinder following the spool to turn the loader wheels. A similar picture will be when the steering wheel is turned to the right.
As soon as the movement of the steering wheel stops, the spool will stop and the cylinder, having caught up with it, will put the sleeve relative to the spool in a neutral position, therefore, the rotation of the steered wheels will stop. Thus, the hydraulic booster cylinder “follows” the movements of the spool all the time and exactly repeats them. The movement of the cylinder is transmitted through the rod to the steering linkage lever, due to which the wheels turn.
To protect the steering hydraulic drive from overload, a safety valve is used, usually mounted in the hydraulic booster spool housing. The operation of the valve is to drain oil into the drain line when the pressure rises above the allowable one.
Rice. 4. Scheme of steering with hydraulic booster (steering column and bipod conventionally depicted in a horizontal plane)
Inspection, adjustment of the safety valve and replacement of its spring can be done without removing the hydraulic booster from the lift truck. The valve is adjusted (on lift trucks 4043 and 4045) for a maximum pressure of 50 kg / cm2 at 1600-2000 rpm of the engine crankshaft and an oil temperature of 30-50 ° C.
Care of the hydraulic booster consists in lubricating the ball pins, periodic review stem cleanliness and external oil leaks through connections and glands. A normally working hydraulic booster should provide a steering wheel force of no more than 2-3 kg, regardless of road conditions.
In the event of a malfunction of the hydraulic steering drive (malfunction of the hydraulic pump, breakage of the safety valve spring, etc.), as well as when the forklift engine is not running, the ability to control the machine remains. In this case, the rods act as links in the kinematic steering chain, transmitting force from the steering wheel to the steered wheels of the machine, and the oil flows from one cavity of the booster cylinder to another through the emergency ball valve.
Brakes. Loaders have operational hydraulic brakes driven by a pedal only on the front (driving) wheels. Forklift trucks also have a manual holding brake mounted on the flange of the output shaft of the gearbox. For electric forklifts, an operational brake is used as a holding brake, for which its pedal is equipped with a latch.
Adjustment of hydraulic brakes is carried out as the friction linings on the shoes wear out, when the gaps between the linings and the brake drums increase, which also increases the brake pedal travel. In addition, if necessary, the free play of the brake pedal is adjusted.
The clearance between the shoes and the brake drum is adjusted by turning the eccentric supports of the shoes. It is necessary to pay attention to the uniformity of the adjustment of all blocks and to make adjustments on unheated drums. If adjustment by turning the eccentric pad supports does not give a satisfactory result, the brake pads (or just the brake linings) are replaced. Such a replacement is usually carried out when turning brake drums. In these cases, the initial installation of the pads should be done on the probe. The gap between the pad lining and the drum should be within 0.15-0.25 mm.
The free play of the brake pedal is adjusted by changing the length of the piston pusher of the main brake cylinder so that the gap between the pusher and the piston is 2-3 mm, which corresponds to a pedal free play of 10-15 mm. Adjusting the free play of the brake pedal is necessary to prevent spontaneous braking of the loader while driving.
If air enters the brake system, the normal operation of the brakes is disrupted. Due to the compressibility of the air, the brake pedal springs and its travel increases. Air is removed from the brake system by pumping it with brake fluid using the master brake cylinder. The wheel brakes are bled one by one.
A general indicator of the technical condition of the hydraulic brakes of loaders can be the pedal travel, which, when pressed with your foot until full braking, should be about half of the full travel.
Hydraulic drive. Raising the carriage and tilting the frame of the forklift, as well as the movement of the load gripping and auxiliary devices of the loaders, are usually carried out using a volumetric hydraulic drive.
Below, only specific issues of the technical operation of the hydraulic drive of loaders are considered and specified.
The operational adjustments of the hydraulic system of loaders include the adjustment of safety and overflow valves of hydraulic distributors. The hydraulic distributors having both one of these valves, and both are applied.
The safety valve of the hydraulic distributor limits the value of the maximum, and the overflow value of the working pressure of the oil entering the cylinders, and, consequently, the force developed by them. The safety valve is usually regulated by 110-115%, and the overflow valve by 95-100% of the operating pressure of the pump. After adjustment, the valves must be sealed.
Rice. 5. Contacts for turning on the pump motor
In the latter case, a tee with a pressure gauge is installed in the pressure line in front of the distributor, after which the pump is started and the forklift forks are raised to failure (or the frame is tilted to any extreme position). In this case, all the oil supplied by the pump will flow through the valve and it can be adjusted to the required pressure according to the pressure gauge. (If the hydraulic distributor has both valves, then the safety valve is adjusted first with the overflow blocked, and then the overflow.)
For electric forklifts, the moments of turning on the hydraulic pump electric motor are periodically adjusted. Signs of the need for such adjustment are increased noise in the pump, uneven and insufficient lifting speed and other malfunctions in the operation of the hydraulic drive caused by insufficient opening of the channels of the hydraulic distributor for the passage of oil when the pump motor is turned on. This adjustment is made by moving the push bars that include the electrical contacts. The bar engages contact when the forks are lifted, and the bars engage contact when the Frame is tilted forward and backward respectively.
Of the main components of the hydraulic system of loaders in ports, piston and plunger cylinders of the fork lift and frame tilt mechanism are usually repaired, and sometimes gear and vane hydraulic pumps are repaired. As a rule, hydraulic equipment (spool valves, hydraulic boosters, etc.) is not repaired in port workshops, and worn-out and damaged hydraulic equipment is replaced with a new one.
The quality of repair and assembly of loader power cylinders must be checked by static pressure. Cylinders are tested for strength, density and idle pressure by the working oil of the hydraulic system at its temperature of 30-50 °C.
The strength and density test is carried out at double working pressure for 5 minutes. At the same time, oil leakage from the cylinder through seals and welding points is not allowed.
The passage of oil from one working cavity to another is checked at operating pressure and is allowed no more than 5 cm3 / min for cylinders with a diameter of up to 100 mm and 10 cm3!min For cylinders with a diameter of more than 100 mm.
Idling of the cylinder should occur freely at an oil pressure of no more than 10-12% of the working pressure, which indicates the absence of distortions and tightening of the seals.
Forklift hydraulic systems use gear and vane pumps. Typically, loader pumps have some margin of performance, and therefore, with little wear, the decrease in the volumetric efficiency of the pump caused by it is not reflected in the operation of the machine.
Repaired, as well as new pumps, before installing them on a loader, must be tested to verify their operability and volumetric efficiency. Pumps in operation must also be periodically tested to check their technical condition. The test can be done with a flow meter or a measuring tank test rig.
A test stand with a measuring tank is shown in fig. 6. At the beginning of the test, turn on the electric motor and allow the pump under test to pump oil to the drain into the supply tank by closing the valve and opening the valve until the oil temperature reaches 40 °C.
Rice. 6. Test bench for hydraulic pumps
Then, having adjusted the throttle according to the pressure gauge so that the pump operates at a pressure of 15-20 atm, the oil is pumped into a measuring tank and, by measuring the tank filling time, the actual pump performance is determined. During the pump test, the absence of oil leakage through the seal is checked. The operation of the pump should not be accompanied by noise and knocking, the oil should not quickly heat up and emulsify.
After the repair of the hydraulic system of the loader, its general test is carried out. Before testing the hydraulic system, it is necessary to remove air from it and test the operation of the pump and hydraulic distributor separately. To remove air from the system that accumulates in the upper part of the lift cylinders, slightly unscrew the plug that closes the air outlet, operate the lift cylinder several times to its full stroke until oil appears from under the plug, then wrap the plug. If required, replenish the supply tank with oil.
After testing all movements in idle, they begin to test them under a working (rated) load. The tightness test of the system is carried out in the positions of the fork and frame of the forklift, at which the loads on the rods and plungers of the power cylinders will be maximum. In this case, no oil leakage should be observed through the pipeline connections and the seals of the rods and plungers of the cylinders and pump shafts. The magnitude of internal leaks is judged by the magnitude of the displacement of the rods and plungers of the power cylinders under rated load with the valve spools closed. In this case, the forks (cargo carriage) should not fall by more than 2 mm / min when tested for 5 minutes, and the frame of the forklift should not tilt by more than 3 ° for 10 minutes.
The value of oil pressure in the hydraulic system is measured (by pressure gauge) when it is idling and under rated load. The pressure in the system during idle operation should not exceed 12-15%, and under load - 110% of the value of the passport pressure. abnormal high pressure in the system indicates high mechanical resistance, which can be caused by inaccurate assembly of units, misalignment of guides, jamming of rollers, strong clamping of lip seals and oil seals, etc.
Rice. 7. Scheme of skew of the movable frame of the forklift relative to the fixed one
When testing the hydraulic system, the speed of working movements (comparison with passport ones) and their smoothness are monitored.
Forklift. The wear of the guides of the telescopic frame of loaders is not always given sufficient attention, especially since it is able to work with large wear of the guides. However, this wear can, in some cases, cause accelerated wear on one of the loader's most difficult-to-repair components, the lift hydraulic cylinder.
As can be seen from fig. 7, the piston of the cylinder is rigidly connected by a rod to the movable part of the telescopic frame, while the cylinder itself is rigidly connected to the fixed part of it. The piston rod can be located strictly along the axis of the cylinder only if there is no mutual shift in the horizontal direction or distortion of the movable and fixed parts of the telescopic frame.
The load lifted by the forks of the loader creates a moment that contributes to the mutual distortion of the parts of the telescopic frame, which acquires the greatest value when the forks are raised and the clearances are increased. As a result, with a large wear of the frame guides, the rod warps by a value of b relative to the cylinder and the piston begins to touch the cylinder walls with its metal parts. In this case, not only wear of the cylinder occurs, but scoring on its surface can also occur. Therefore, for loaders (for which the gaps in the guides are adjustable), the gaps should be checked and adjusted periodically, and in other cases, when the first signs of the piston body touching the cylinder walls, it is necessary to replace the worn guides with new ones.
A forklift is a complex device consisting of many mechanisms and systems that require constant monitoring and timely maintenance. Every working day of a forklift operator should begin with a visual inspection of the equipment. First of all, they inspect the nodes that directly affect the safety of the work. They check the integrity and cleanliness of external lighting devices, the presence of defects on tires and rims, make sure that there are no smudges of working fluids, check the condition of the load lift chains, the presence and level of brake fluid. Sitting in the operator's seat, they check the operation of the lights and the sound signal, the brake pedal. A more detailed inspection and maintenance of loaders is carried out by service specialists in accordance with the maintenance schedule established by the equipment manufacturer.
For lift trucks, the service interval is on average about 250 hours, or once every one and a half to two months. The main work with an operating time of 250 m / h is the replacement of oil and an oil filter in the engine forklift, replacing the fuel filter, checking the coolant level, checking the contamination of the air filter and, if necessary, purging it.
For electric forklifts, due to the absence of an internal combustion engine, the maintenance interval is approximately 500 m / h, but daily battery maintenance and maintenance work is added.
With an operating time of 500 m / h, or once every three months, the work on servicing the internal combustion engine is supplemented by work on lubricating the controlled axle and lifting device, checking the oil level in the gearbox and drive axle.
During semi-annual maintenance, or every 1000 m / h, in addition to the above works, work is added to change the oil in the gearbox and drive axle, and replace the air filter.
The largest maintenance is an annual maintenance, with an operating time of 2000 m / h. All planned works included in the maintenance of 250 m / h, 500 m / h, 1000 m / h are carried out. In addition to these works, a complete replacement of hydraulic oil and hydraulic filters, replacement of brake fluid is carried out.
Further, the maintenance cycle is repeated again.
This article gives a general idea of forklift maintenance. A detailed list of equipment maintenance work is indicated in the service and repair manual.
Forklifts play an extremely important role in the handling of heavy loads at warehouse terminals, construction sites and other sites that require the rapid movement of goods and materials. It is not surprising that when warehouses are busy, the load on machines is enormous, which leads to a sharp decrease in the life cycle transportation products. But after all, a frequent change of equipment leads to serious expenses that not every company can afford. So does it make sense to change technique like seasonal gloves? Isn't it better to approach the issue wisely and organize the correct and high-quality maintenance that will double the life of the machine?
Specialists of the NTK Forklift company, which supplies Russian market forklifts such worldwide famous brands, how Atlet, Manitou and Maximal, gave some advice on how to increase the life of a forklift of one of these brands. 
It is known that the disease is easier to prevent by taking care of preventive measures than to treat its advanced form. It will be cheaper and painless for the entire body system. It is the same with a forklift, so maintenance should first of all be of a preventive nature, that is, to prevent premature failure of the machine. has many advantages:
The wear rate of parts is reduced due to the timely replacement of lubricants;
. the occurrence of malfunctions is prevented due to their timely detection and elimination;
. reduced repair costs and losses from truck downtime;
. ensures that the loader is always ready for work.
Operating experience shows that in the absence of proper maintenance service life of loaders is reduced by about half and the cost of operation increases by 40%. The terms of maintenance are usually indicated in the manual for the loader, they can be changed, but it is forbidden to exceed the permissible limits by more than 10%.
So the first loader maintenance should be carried out after one month or after 200 hours from the moment it was put into operation. Further, periodic maintenance should be carried out at least once every six months according to the following schedules:
1) once every six months - for loaders that operate less than 600 engine hours over the specified period;
2) for actively working loaders - the passage of maintenance on the operating time of every 600 hours.
For trucks operating in difficult conditions (heavy dirt, dust, etc.), the maintenance interval must be shortened. The timeliness of maintenance of loaders is taken into account when considering warranty cases.
Carrying out maintenance it is necessary to plan in advance in order to replace the forklift with another forklift during the service period or to reschedule loading operations for another time.
Main types technical work are considered:
Control - inspection of the working units of the loader, mechanisms and control systems;
. lubricating - timely topping up of oils and lubricants in the mechanisms intended for this;
. adjusting - adjustment of control systems. This factor determines the likelihood of an accident occurring.
An important factor in maintenance is diagnosing, i.e., determining the actual state of the mechanisms and systems of the loader. Based on the results of the diagnosis, it is necessary to start repairing the units and assemblies that have shown insufficient for the normal functioning.
As you know, any machine requires timely regular maintenance. Special equipment, in particular loaders, is no exception here.
Forklifts and special purpose equipment in general are whole system important nodes that interact with each other, and if at least one of them fails, this can cause a breakdown in the rest of the components of the entire system. As a rule, if you do not resort to timely technical care of equipment, then all its main components wear out much faster, sometimes without even recouping the costs spent on acquiring such equipment. How to ensure the smooth operation of forklifts and extend the life of equipment? We will talk about this below.
Today, it is not at all uncommon that unscrupulous sellers and manufacturers of special equipment are constantly trying not only to avoid timely service, but also to save on replacement parts, offering consumers low-quality, in other words, not original consumables. It is natural in such situations that loaders now and then begin to break down and break down, and this happens even when the equipment is initially in excellent condition. Due to untimely maintenance of loaders, attachments, the main equipment control systems, and even the engine itself can fail.
What to do to ensure that the equipment serves for a long time without breakdowns and costly repairs?
Have your own master repairmen in the staff, as well as special equipment that is necessary for the maintenance and service of loaders. If the fleet of forklifts is small, accordingly, many will say that to keep individual workers and purchase optional equipment to care for the equipment will be expensive. The way it is. In this case, it is best to conclude an agreement with special company, which in the future will be engaged in the maintenance of equipment.
Modern service companies able to solve a complex of important tasks in the maintenance of loaders. They do not only timely diagnostics of machines, but are also able to identify future problems at an early stage, that is, problems that may arise in the near future and quickly eliminate them by professionally setting up all equipment components, timely repairs or replacing consumables. Among other things, in such centers, as a rule, free consultations are also given to owners of loaders on the correct operation of machines and their attachments, which also allows you to avoid a number of breakdowns and at the same time increase the productivity of equipment and reduce maintenance costs.
The services of professionals today also require costs, however, as practice shows, these costs always pay off, and therefore, receiving high-quality timely service maintenance loaders, their owner does not lose absolutely anything, he only acquires reliable and stable machines in his garage.
Attention! There are also such moments when the replacement of certain parts or consumables by specialists of service centers is carried out free of charge. To find out what kind of repairs can be made by employees of specialized centers for free, it is important for the owner of the loader to carefully study the contractual conditions and warranty obligations of the company selling such equipment. In the event that the loaders were operated for their intended purpose and with the fulfillment of all the conditions recommended by the manufacturer, but due to the fault of the manufacturer, in the end, some breakdowns nevertheless occurred, they will be eliminated in service center is free.
Types of forklift maintenance
It is worth knowing that depending on the manufacturer and type of loader, the order of scheduled maintenance activities may vary slightly. Everything here will depend, first of all, on the recommendations of the manufacturer of the equipment. Meanwhile, as a rule, several types of maintenance in all cases remain unchanged. It:
Daily maintenance of equipment;
- scheduled maintenance loaders;
- seasonal service machines;
- maintenance of special equipment during its storage period;
- maintenance of loaders when removing them from long-term storage.
Daily maintenance of loading and unloading equipment.
The frequency of such maintenance is from 8 to 10 hours, that is, every time after a working day. Such maintenance of the equipment is carried out by the operator himself and includes an inspection of the loader (checking for external damage, checking the general condition of the machine and its working units) and preparing the equipment for the next period of operation.
If, while carrying out a shift check of the loader, the operator detects leaks, lack of fuel or any other inconsistencies, he must eliminate them immediately before the next work on the loader.
Before starting work, immediately after the engine has warmed up, the operator must daily check the operation of:
- measuring devices;
- undercarriage of the loader;
- controlling expendable materials appliances;
- attachments;
- hydraulic system;
- brake system;
- steering.
After the work has been done and the loader has been placed in the garage, the specialist working on the equipment is obliged to inspect the machine, clean it of debris, eliminate the detected malfunctions and lubricate all the main components of the equipment.
Scheduled forklift maintenance.
Such maintenance is of several types:
- TO-1;
- TO-2.
The first version of such maintenance is also carried out after about 100 hours of operation of the equipment, and the second after 500 hours.
Scheduled maintenance of loaders is carried out by specialists with the participation of the operator working on the equipment in the process. Monthly TO-1 includes:
- additional check of the engine and its tuning;
- checking attachments and running gear of the loader;
- checking all the fastening connections available on the equipment;
- checking pipeline connection points;
- checking the assembly of the brake system, steering and clutch;
- draining the sediment from the fuel filter.
As for TO-2, it includes a set of the same actions as for TO-1, plus:
- inspection and cleaning of blockages in the electrical wiring of the loader;
- cleaning and checking spark plugs;
- cleaning and tuning the carburetor;
- clearing blockages between valves and pushers;
- bearing adjustment;
- replacement of liquid consumables (oils and other lubricants);
- washing the filters and the sump of the fuel system;
- checking and adjusting the hydraulic system;
- inspection of the generator brushes;
- collector inspection;
- cleaning the battery terminals;
- inspection and testing of the brake system;
- setting the exact tension in the chain mechanisms;
- steering adjustment;
- checking all bolted and nut connections at the points of attachment of the main assembly of the mechanism.
Seasonal maintenance of forklifts.
Seasonal maintenance of forklifts takes place twice every 12 months, as a rule, during the transitions from winter to summer and from summer to winter seasons, that is, in autumn and spring.
Seasonal maintenance includes absolutely all the activities described above, and in addition to them:
- flushing the cooling system;
- flushing of fuel lines and fuel tank of the loader;
- change or refueling of liquid in the cooling system;
- complete change of working fluids and lubricants;
- electrolyte density control;
- lubrication of the handbrake system.
Maintenance of loaders during storage.
Maintenance during storage of equipment includes the following activities:
- washing, drying and delivery to the place of storage of the loader;
- cleaning equipment from dirt and cargo residues;
- assessment of the technical condition of the loader and, if necessary, elimination of visible faults;
- checking the paintwork and, if chips and scratches are found, their elimination;
- checking the tightness of the main components of the hydraulic system;
- degreasing and coating with special lubricant to protect hinges, unpainted parts of the loader, all threaded joints, rubbing and protruding surfaces of equipment from moisture and dust;
- control of the correct placement of the loader in the garage;
- checking the completeness of equipment.
At the time of storage of the equipment, it is necessary to carry out maintenance every two months of storage indoors and every month if the loader is stored in an open area, that is, in other words, on the street.
Maintenance of loading and unloading equipment when removing it from storage.
When the equipment, after storage, should again go into operation, the operator is obliged to prepare it for these works, and for this he:
- mounts attachments removed before storage of the loader;
- carries out additional assembly of all special hauls of equipment;
- Performs adjustments of existing equipment.
Types of repair of loading and unloading machines.
As in any other case, when servicing forklifts, repairs are usually divided into 2 types:
- capital (bringing equipment into working condition when the components important for this work are completely worn out);
- current (ensures the operability of the loader after scheduled repairs).
Safety precautions for forklift repair and maintenance.
- Under no circumstances should persons who do not have special knowledge and skills in working with special vehicles, as well as knowledge of safety precautions, be allowed to repair and maintain loaders.
- At the time of maintenance and repair of loaders, the engine of the equipment must not be left on.
- When repairing equipment, the forks or other attachments must be in the lowered state, and the loader itself must be set to the hand brake and be in first gear.
- It is forbidden to repair equipment with a raised jack or jacks.
- Before repairing the bridges of equipment and operations, there must be stands under the bucket beam.
- Do not remove tires while there is air in them.
- When inspecting the battery, make sure that the electrolyte does not get on the skin or in the eyes. This may cause a burn.
- First, when preparing the electrolyte, water is poured, and then acid, in the reverse order, pouring liquids in this case is prohibited by safety regulations.
The schedule for the maintenance of forklifts and carrying out repair work is planned by the owner of the equipment based on the manufacturer's instructions for a particular model and type of forklift.
Among other things, maintenance periods for loading and unloading machines can also be determined based on the actual operating time of the equipment. These data are specified according to the readings of special meters installed in the loader or according to the data of a special log, in which the operating hours of special vehicles in engine hours should be recorded.
Timely service maintenance of loaders allows their owners to do without serious breakdowns and, accordingly, major repairs of machines for as long as possible. In addition to this, these measures, carried out on time, make it possible to increase the life of the equipment and attachments used in the work.
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