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Maintenance of diesel forklifts

Author : Hitop

Update time : 2021-03-03 16:32:10

When the diesel engine of the forklift cannot be started?
cause of issue:
Failure of the fuel supply system
1. There is gas in the fuel system
Elimination method: Use the oil pump to remove the air in the system, and check whether the system is leaking.
2. There is blockage in the fuel system
Remedy: disassemble and clean
3. The oil pump does not supply or intermittently supply oil
Remedy: check and repair
4. Poor fuel injection from the fuel injection pump
Remedy: check the spray condition of the injector
5. The fuel supply advance angle is incorrect
Remedy: Check the wear of the plunger and delivery valve of the fuel injection pump and whether the delivery valve spring is broken.
6. The intake air valve is not open or the oil cut-off handle is in the oil cut-off position
Remedy: Open the air intake damper or put the oil cut-off handle in the oil supply position.

Insufficient pressure
1. The piston is badly worn
Remedy: replace the piston ring
2. Piston ring cementation
Elimination method: remove the glue
3. Valve leakage
Remedy: the valve spring is broken or the elasticity is reduced, the valve clearance is improper, and the valve cone is not tightly sealed. Take corresponding measures.
4. Low temperature at the end of compression
Remedy: The outside temperature is low, take preheating and other methods to solve it.

The failure of the electrical system
1. Insufficient battery power
Remedy: Recharge to meet the specified requirements
2. Poor electrical connection
Remedy: Check whether the wiring is correct and reliable
3. Poor contact between the starter motor brush and the commutator
Remedy: repair or replace the brush and clean the surface of the commutator with fine sandpaper, and blow off the dust
4. Insufficient torque and slippage of the starter clutch disc
Remedy: add spacers and adjust

For forklifts with harsh operating environments, high strength, and long continuous use, special attention must be paid to the maintenance and temperature monitoring of forklift components. It is recommended to pay special attention to the following points:
1. Frequently check whether the bolts of the battery cell, motor and electronic control parts are loose. The vibration intensity of the forklift is relatively high. The bolts in these parts are often loose after a period of use, and these parts are often high-current working for a long time, and the parts where the bolts are loose will become very hot and easy to burn.

2. Check the heat dissipation measures of the motor and the electric control, and often remove dust from the motor housing and the position of the electric control heat dissipation base plate. The accumulation of dust, especially oily dust, on the motor and electronic control will greatly reduce the heat dissipation capacity of the motor and electronic control. As summer is approaching, a thorough cleaning of the motor housing and the electronic control heat dissipation base plate is required. In addition, for those designs with inadequate heat dissipation measures, additional heat dissipation measures should be considered, such as installing a high-power cooling fan on the motor or the position of the electronic control board. For motors or electronic controls that use a cooling fan to dissipate heat, it is necessary to frequently remove dust from the cooling fan to prevent the cooling fan from being stuck and damaged by accumulated dust and debris, which will affect the heat dissipation of the motor and the electronic control.

3. The electrolyte level and density of the battery need to be checked frequently. Most of the lead-acid batteries currently on the market are liquid-filled. Before each charge, check whether the liquid level of each monomer is normal, clean the surface of the battery, and add distilled water immediately after charging (note that ordinary tap water or mineral water must not be used).

4. Frequently check whether the hydraulic control switch and potentiometer signal are reset well. Some forklift hydraulic joystick switches and potentiometers will not reset after a period of use. This situation will cause the oil pump motor to continue to run at high speed and fail to stop even if the hydraulic action is not operated. Causes the oil pump motor and the oil pump electric control to overheat and burn.

Pay attention to the following points in daily work: do maintenance and prevention in advance, make a maintenance plan (3 months, according to the degree of use of the forklift model), regularly check the oil level, regularly clean, and reserve consumable parts.

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