Forklift Maintenance Plan. Maintenance and repair of forklifts

Maintenance is required to keep equipment in good working order. For this, in addition to major repairs, regular maintenance is required. For forklifts The time and scope of maintenance work is determined in accordance with the operating hours.

An additional advantage of regular maintenance, in addition to increasing its full service life, is the ability to timely detect minor faults and carry out appropriate repairs. Undoubtedly, this is much less expensive than major renovation as with financial side, and from the point of view of saving time.

There are several types of maintenance for warehouse forklifts:

• daily maintenance;
• scheduled maintenance;
• seasonal service;
• maintenance of special equipment when placing it for storage periods;
• maintenance of forklifts when removing them from long-term storage.

Urgent equipment repair!

The technician will arrive on the day of your request. Accurate diagnosis. Prompt troubleshooting.

Spare parts in stock

A large selection of spare parts is in stock, so we can repair equipment on the day you call

Repair of any complexity

We carry out repairs of any complexity and will tell you how to prevent breakdowns in the future.

Quality assurance

Our specialists are professionals and have more than 10 years of experience. We do only high-quality repairs!

Forklift maintenance costs

List of works	TO 1	TO 2	TO 3	TO 4	TO 5	TO 6	TO 7	TO 8	TO 9	TO 10
Price for diesel forklifts:	RUB 3,800	RUB 2,350	11,000 rub.	15,300 rub.	11,000 rub.	RUB 27,360	11,000 rub.	15,300 rub.	11,000 rub.	RUB 29,360
Diagnostics of main units	+	+	+	+	+	+	+	+	+	+
Changing the engine oil	+		+	+	+	+	+	+	+	+
Replacing the oil filter			+	+	+	+	+	+	+	+
Replacing the air filter*			+	+	+	+	+	+	+	+
Changing the oil in the box				+		+		+		+
Replacing the fuel filter*				+		+		+		+
Changing hydraulic oil						+				+
Changing the oil in the drive axle						+				+
Replacing antifreeze										+
Replacing spark plugs**										+
Loader Lubrication										+
Price for gas and gasoline forklifts:	3,200 rub.	1,950 rub.	8,900 rub.	RUB 13,260	8,900 rub.	RUB 25,260	8,900 rub.	RUB 13,260	8,900 rub.	RUR 27,260

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When to carry out maintenance

• At the end of each working day, an inspection of equipment is required;
• TO-1 is carried out after operating the equipment for 100 hours or more. Technical fluids can be replaced, components can be lubricated, and all mechanisms can be adjusted;
• TO-2 is carried out after operating the forklift for 250-300 hours. Within this scope, work is carried out in accordance with TO-1, fuel and air filters are additionally changed;
• regular seasonal maintenance of loaders involves performing maintenance work 2, as well as additionally changing the oil in the gearbox and hydraulic system;
• Annual maintenance of forklifts involves, first of all, the replacement of technical fluids and lubricants.

Forklift service

During the operation of a forklift, oil and other working fluids are used up and need to be renewed. In addition, the loader is a complex system with a large number of units and components, and the integrity of each of them ensures the uninterrupted operation of this type of warehouse equipment.

During maintenance, the working fluids are replaced, along with the filters, and all components of the forklift are checked.

The type of maintenance varies depending on the scope of work performed. Based on how many engine hours the loader operates, the type of required maintenance is determined.

Please note that the materials used during maintenance are of no small importance. The specialists of our company take the choice with full responsibility Supplies and operating fluids.

GaratKar LLC provides a full range of maintenance and repair work for forklifts of all popular brands.

TO category:

Port handling machines

Maintenance and the concept of forklift repair

The design of forklifts is characterized by the use of standard automotive components, low voltage DC electrical equipment and positive displacement hydraulic drives.

Maintenance and repair of the chassis and mechanical power transmission of loaders in terms of the scope of work and technology for their implementation are close to the corresponding work on cars.

Run-in of loaders. The service life of a forklift depends largely on strict adherence to the break-in period after receiving the forklift from the manufacturer. Run-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 the rubbing parts. When running in forklifts, the engine is also run in at the same time. internal combustion, and when running in electric forklifts, training charge-discharge cycles of the battery are performed.

Before starting the break-in, you should test the operating movements of the loader without a working load. During the break-in period, especially on the first trips, carefully monitor the operation of all components and mechanisms, checking the condition of the fasteners, the tightness of the systems, smooth and quiet operation, and heating. The duration of running in 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%.

Loader maintenance. It is carried out in the forms of routine (daily) and preventive (periodic) maintenance.

Routine (daily) maintenance of forklifts in terms of volume and range of work is usually divided into daily (before starting work) and weekly, i.e. after approximately 50 working hours. Periodic maintenance of these machines is performed every 200-250 working hours, i.e. almost monthly.

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, all fasteners are carefully checked and tightened, especially bolted ones, since the drive (front) axle of loaders is not sprung and these connections weaken to a greater extent than in transport vehicles with spring suspension. The following is also carried out: checking the condition of pipelines and high-pressure hoses, tightening seals; checking the condition of the forklift carriage bearings, springs and parts of the balance beam suspension; adding oil to the drive axle gearboxes; checking the condition of electrical wiring; listening to the engine; draining sludge and cleaning filters.

Preventative (monthly) maintenance is scheduled for the next weekly maintenance and consists, in addition to weekly work, mainly of checking and adjustment work.

On electric forklifts, tightening is carried out at this frequency. contact connections, cleaning contact surfaces of contactors, checking the amount of pressing and failure of contactors, cleaning contact segments and fingers of controllers, checking the condition of electric motor commutators. The condition and value of the insulation resistance is also checked.

During weekly and monthly maintenance of forklifts, in addition to the basic mandatory work listed above, work is usually performed “as needed,” including the replacement of wearing parts and minor repairs.

Loaders are lubricated in accordance with factory instructions and lubrication charts.

For carburetor internal combustion engines of forklifts, in addition to performing shift maintenance work, periodic maintenance is performed at intervals of 50, 100 and 1000 working hours.

Chassis. Wear of wheels and steering and cases of breakage of forklift springs largely depend on the condition of the surfaces of warehouse sites, roads and crossings over railways and crane tracks.

Repair of worn truck tires in operational conditions is usually not carried out. Metal wheel tires are rubberized at rubber products factories.

Adjustment of tapered roller bearings of wheel hubs is carried out according to general rules adjustment of such units. After adjusting the bearings, monitor the temperature of the wheel hubs during the first hours of operation of the loader. When the hubs heat up, the adjustment should be repeated.

The springs of the rear balancer suspension of the steered wheels quite often fail. Depending on local conditions and the nature of the damage, they are replaced as a whole or repaired by replacing individual sheets.

Steering. Adjusting the steering consists of eliminating play and gaps formed in the steering rod joints and the steering gear engagement. Play in the joints of the rods is eliminated by tightening the movable crackers. The steering mechanism is adjusted by selecting gaps in its engagement. A characteristic feature of electric forklifts is the gearing of the steering mechanism, while for auto-loaders it is a worm gear.

With a worm steering mechanism, adjustment of the engagement of the roller and the worm is made by removing or adding the required number of shims to change the size a. In this case, the bipod rod should be disconnected, and the bipod shaft should be installed in the middle position. In addition, the axial play of the tapered bearings of the worm is adjusted using gaskets. After these adjustments, the force required to turn the steering mechanism should be within 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 forklifts with a lifting capacity of 3000 kg more often includes hydraulic boosters that reduce the force on the steering wheel. The amplifier is a hydraulic follow-up mechanism, which combines a spool device ( leading link) and hydraulic power cylinder (driven link).

A hydraulic booster with a collapsible cylinder is shown in Fig. 3. The steel pipe of the power cylinder is located between the body and the cover. The body and cover are tightened with studs and connected by a pipe. The housing houses the spool mechanism for controlling the power cylinder. The rod head is attached through a ball pin to a console welded to the loader chassis frame, and the eye of the power cylinder is attached through a rod to the steering linkage lever. The ball pin is connected to the bipod rod of the steering mechanism. The spool device consists of a sleeve, fixedly fixed in the body, and a spool, the shank of which is connected to a ball pin, clamped between two crackers in a sliding cup by a rigid spring. Overcoming the resistance of the spring, the ball pin can move along the cylinder axis together with the sliding glass by a small amount (2-3 mm) from its average position. In this case, the spool will move by the same amount and in the same direction relative to the sleeve. While moving, the spool connects the cavities of the power cylinder with the injection 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 drain.

Rice. 2. Worm gear steering mechanism

Rice. 3. Hydraulic power steering

The position of the hydraulic booster in the kinematic steering chain 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 acting through the rod on the power steering spool and moving 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) cylinder cavity with the discharge line, and the channel located on the other side of the piston - with drain line. Oil pressure moves the cylinder along the spool, turning the loader wheels. A similar picture will occur when turning the steering wheel 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 place the sleeve relative to the spool in a neutral position, therefore, the rotation of the steered wheels will stop. Thus, the power steering cylinder “monitors” the movements of the spool all the time and accurately repeats them. The movement of the cylinder is transmitted through a rod to the steering linkage lever, due to which the wheels turn.

To protect the hydraulic steering drive from overload, a safety valve is used, usually mounted in the power steering spool housing. The operation of the valve is to release oil into the drain line when the pressure rises above the permissible level.

Rice. 4. Diagram of power steering (the steering column and bipod are 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 forklift. The valve is adjusted (on forklifts 4043 and 4045) to a maximum pressure of 50 kg/cm2 at 1600-2000 rpm of the engine crankshaft and oil temperature of 30-50 °C.

Maintenance of the hydraulic booster consists of lubricating the ball pins, periodically checking the cleanliness of the rod and external oil leaks through connections and seals. A normally operating hydraulic booster should provide a force on the steering wheel of no more than 2-3 kg, regardless of road conditions.

If the normal operation of the hydraulic steering drive is disrupted (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 is retained. In this case, the rods act as links in the kinematic steering chain, transmitting force from the steering wheel to the steering wheels of the car, and oil flows from one cavity of the amplifier cylinder to another through an emergency ball valve.

Brakes. Loaders have operational hydraulic brakes driven by a pedal only on the front (drive) wheels. Forklifts also have a manual locking brake mounted on the flange of the secondary shaft of the gearbox. Electric forklifts use an operational brake as a holding brake, for which the pedal is equipped with a latch.

Adjustment of hydraulic brakes is carried out as the friction linings on the pads 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 can be adjusted.

The gap between the pads and the brake drum is adjusted by turning the eccentric supports of the pads. It is necessary to pay attention to the uniformity of adjustment of all pads and 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. This replacement is usually carried out when turning brake drums. In these cases, the initial installation of the pads should be done using a feeler gauge. 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 master cylinder piston pusher 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 when moving.

If air gets into the brake system normal operation brakes are broken. Due to the compressibility of 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 cylinder. The wheel brakes are pumped one at a time.

General indicator technical condition Hydraulic brakes of loaders can be served by the pedal stroke, which, when you press it with your foot until full braking, should be about half the full stroke.

Hydraulic drive. Raising the carriage and tilting the forklift frame, as well as the movement of lifting and auxiliary devices loaders are usually carried out using a volumetric hydraulic drive.

Only specific issues are discussed and specified below. technical operation hydraulic drive of loaders.

Operational adjustments of the hydraulic system of loaders include adjustment of safety and overflow valves of hydraulic distributors. Hydraulic distributors are used that have either one of these valves or both.

The safety valve of the hydraulic distributor limits the maximum value and the overflow value of the working oil pressure entering the cylinders, and, consequently, the force they develop. The safety valve is usually adjusted 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. Pump motor switching contacts

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 forks of the forklift 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 readings of the pressure gauge. (If the hydraulic distributor has both valves, then the safety valve is adjusted first when the overflow is closed, and then the overflow.)

For electric forklifts, the timing of turning on the hydraulic pump electric motor is periodically adjusted. Signs of the need for such adjustment are increased noise in the pump, uneven and insufficient speed of lifting the load and other problems in the operation of the hydraulic drive caused by insufficient opening of the hydraulic distributor channels for the passage of oil when the pump electric motor is turned on. This adjustment is made by moving the pressure bars that engage the electrical contacts. The bar engages contact when the forks are lifted, and the bars - when the Frame is tilted forward and backward, respectively.

Of the main components of the hydraulic system of loaders in port conditions, the piston and plunger cylinders of the fork lifting and tilting mechanism are usually repaired, and sometimes gear and blade hydraulic pumps are repaired. Repair of hydraulic equipment (spool valves, hydraulic boosters, etc.) in port workshops, as a rule, is not carried out, and worn out and damaged hydraulic equipment is replaced with new ones.

The quality of repair and assembly of forklift power cylinders must be checked by static pressure. The cylinders are tested for strength, density and idle pressure with hydraulic system working oil at a temperature of 30-50 °C.

The test for strength and density is carried out at double the working pressure for 5 minutes. In this case, oil leakage from the cylinder through the seals and welding points is not allowed.

Oil flow 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 over 100 mm.

The cylinder should idle freely at an oil pressure of no more than 10-12% of the operating pressure, which indicates the absence of distortions and overtightening of the seals.

Forklift hydraulic systems use gear and vane pumps. Typically, loader pumps have some capacity reserve, and therefore, with slight wear, the resulting decrease in volumetric efficiency of the pump does not affect the operation of the machine.

Repaired as well as new pumps must be tested to check their functionality and volumetric efficiency before being installed on a loader. Pumps in use must also be tested periodically to check their technical condition. The test can be done using a flow meter or a test bench with a measuring tank.

A test bench with a measuring tank is shown in Fig. 6. At the beginning of the tests, turn on the electric motor and allow the test pump to pump oil to drain into the supply tank, closing the tap and opening the tap, until the oil temperature reaches 40 °C.

Rice. 6. Hydraulic pump test bench

Then, having adjusted the throttle according to the readings of 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 time of filling the tank, the actual performance of the pump is determined. During testing of the pump, it is checked that there is no oil leakage through the seal. The operation of the pump should not be accompanied by noise or knocking, and the oil should not quickly heat up and emulsify.

After repairing the hydraulic system of the loader, a 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 covering the air release hole, operate the lift cylinder several times to the full length of its stroke until oil appears from under the plug, then tighten the plug. If required, top up the supply tank with oil.

After testing all movements idle, they begin testing them under working (nominal) load. The system tightness test is carried out in the positions of the forks and the forklift frame, at which the loads on the rods and plungers of the power cylinders will be maximum. In this case, there should be no oil leakage through pipeline connections and seals of rods and plungers of cylinders and pump shafts. The magnitude of internal leaks is judged by the amount of movement of the rods and plungers of the power cylinders under rated load with the valve spools closed. In this case, the forks (load carriage) should not lower by more than 2 mm/min when tested for 5 minutes, and the forklift frame should not tilt more than 3° within 10 minutes.

The amount of oil pressure in the hydraulic system is measured (using a pressure gauge) when it is running idle and under rated load. The pressure in the system during idle operation should not exceed 12-15%, and under load - 110% of the nameplate pressure. Abnormal high pressure in the system indicates high mechanical resistance, which can be caused by inaccurate assembly of components, misalignment of guides, jamming of rollers, strong clamping of lip seals and oil seals, etc.

Rice. 7. Scheme of the skew of the movable frame of the forklift relative to the stationary one

When testing the hydraulic system, the speed of working movements is monitored (compared with the passport speeds) and their smoothness.

Forklift. The wear of the guides of the telescopic frame of loaders is not always given enough attention, especially since it is capable of operating with large wear on the guides. However, this wear can in some cases cause accelerated wear on one of the most difficult parts of a forklift to repair - the lift hydraulic cylinder.

As can be seen from Fig. 7, the cylinder piston is rigidly connected by a rod to the movable part of the telescopic frame, while the cylinder itself is rigidly connected to its stationary part. The piston rod can be positioned strictly along the cylinder axis only if there is no mutual shift in the horizontal direction or misalignment of the movable and stationary parts of the telescopic frame.

The load lifted by the forks of the loader creates a moment that contributes to the mutual misalignment of parts of the telescopic frame, which becomes greatest when the forks are raised and the clearances are increased. As a result, with great wear of the frame guides, the rod warps by an amount 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 scuffing on its surface can also occur. Therefore, for loaders (in which the gaps in the guides are adjustable), the gaps should be periodically checked and adjusted, and in other cases, when the first signs of the piston body touching the cylinder walls appear, it is necessary to replace the worn guides with new ones.

TO category:

Loaders

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System of scheduled preventive maintenance and repair of forklifts

Ensuring reliability and durability depends not only on improving the quality of design and manufacture of forklifts, but also on rational organization their operation. Without proper maintenance, the service life of forklifts is reduced by approximately half and the cost of operation increases by 40%. Maintenance (MOT) of forklifts, according to the purpose and specifics of the implementation, can be divided into the following types.

Run-in under production conditions is carried out to break in the rubbing parts, at which their normal operation becomes possible. All new and repaired loaders that have not been tested at the factory (in workshops) are subject to running-in under production conditions. The running-in procedure is indicated in the operating instructions.

Monthly maintenance (MS) consists of inspecting the loaders, wiping them down, refilling them with fuel, lubricant, electrolyte, and coolant. Daily maintenance is performed before starting work, between shifts, and after work during long stops.

Periodic maintenance is the main link in the planned preventive system. Its purpose is to reduce the wear rate of parts, identify and prevent failures and malfunctions by timely performance of inspection, lubrication, fastening, adjustment and other work. Compliance with the rules of periodic maintenance extends the service life of forklifts between repairs, reduces fuel and lubricant consumption, and allows for timely detection and elimination of the causes of malfunctions. Periodic types of maintenance must be carried out without fail and within the time limits strictly established by the rules.

Seasonal maintenance (SM) is carried out 2 times a year to prepare the loader for operation in cold and warm seasons. It is advisable to combine it with TO-2 or with another type of repair. During CO, all the work provided for by TO-2 is performed, and additionally the following.

On forklifts, the engine cooling system is flushed to remove scale and sediment from it, and in the fall, if possible, the system is filled with antifreeze liquid (antifreeze). Flush the fuel tank and fuel lines. On auto- and electric forklifts, seasonal lubrication is performed in accordance with the lubrication chart and the working fluid in the hydraulic system is changed. Check the density of the battery electrolyte and, if necessary, adjust it to the norm for a given period of the year according to the instructions for caring for batteries. Clean the handbrake, parts of the release and adjustment mechanisms from dirt; The supporting surfaces of the ends of the brake pads are lubricated with a thin layer of grease. Once a year in the spring, the oil radiator hoses are checked and the entire system is blown through them to eliminate possible blockages in the hoses and radiator.

Maintenance of forklifts during storage includes preservation, maintenance in a state of preservation and removal from preservation. Conservation involves work to protect parts from moisture, dust, temperature, relieve stress from them within limits that ensure the preservation of the performance qualities of forklifts and their components, and also helps to reduce loss of performance and maintain the quality of forklifts during non-working periods.

Maintenance(TP) eliminates (prevents) failures and malfunctions of forklifts in the immediate vicinity of their place of operation using relatively simple mobile equipment or in workshops (garages). The need for routine repairs is most often identified during shift maintenance and during operation. Depending on the nature of the failures, inspection and diagnostic, disassembly and assembly, plumbing, electrical, welding, mechanical, tire repair, painting and other works are performed in various combinations

Typically, routine repairs come down to partial disassembly of the loader with the replacement of faulty parts, assemblies, mechanisms and assemblies with serviceable ones. During the assembly process, associated components, mechanisms and assemblies are adjusted. The assembled loader is subjected to running-in and additional adjustment. During routine repairs of units, individual worn or damaged parts are replaced or restored. Only basic components and parts (metal structures, body, frame, base, crankcase, etc.) are not replaced or restored. All other smaller parts are attached to the basic parts.

The purpose of a major overhaul is complete or partial restoration. the original qualities of the loader or its parts that have failed. During a major overhaul, loader units are completely disassembled, all parts are inspected and sorted (defective) into usable, in need of repair, or unusable. Overhauled loaders and units are assembled from repaired, new, and parts recognized as suitable during inspection and sorting. During a major overhaul, the same types of work are performed as during a current one, and, in addition, they often perform work to restore the size, shape, quality of surfaces of parts, as well as the manufacture of parts, running-in and testing of repaired units and assemblies. Technological process overhaul of loaders involves the use various equipment, installations, stands, devices, tools, as well as the labor of qualified engineers and workers. Taking this into account, major repairs are carried out at specialized repair enterprises. At the same time, loaders and units submitted for repair and accepted for repair must comply with approved technical conditions.

Overhaul of loaders is carried out using two methods: individual, in which the main parts, components, and assemblies after their repair are installed on the same loader; aggregate-type, in which the restoration of the rides is carried out by replacing entire units with new ones or pre-repaired ones from revolving fund. The aggregate method of repairing lift trucks is the most progressive, it allows you to minimize machine downtime, labor intensity and cost of repairs, improve the quality of repair work and mechanize operations to restore parts, assemblies and assemblies.

The formation of the structure of the repair cycle (the number of periodic repairs, their type and alternation) should reflect the connection between the reliability indicators of the loader and the potential durability of its components and elements. The current instructions for carrying out preventive maintenance SN 207-68 for loaders recommend the structure of the repair cycle shown in Fig. 10.1. Existing standards for the duration of operation of loaders between repairs do not depend on the load intensity, which is explained by the lack of a scientifically based system for regulating operating modes.

Rice. 10.1. Structure of the repair cycle of a forklift of the fourth group of operating modes

It is necessary to agree on the duration of periods between repairs in accordance with the classification of forklifts by operating modes. The solution to the issue can be achieved by serial production by industry of six modifications of loaders in accordance with the mentioned classification. This procedure is adopted for some types of hoisting and transport machines, for example, overhead cranes, gantry cranes, jib cranes, etc.; release of one modification of loaders for all operating modes. With both methods, the overhaul periods of the loader and its elements should depend on the load, and their specific duration will be determined by the basic operating modes adopted during the design. When producing six modifications for each of them, the overhaul period must correspond to the load spectrum, i.e., four variants of overhaul periods.

When focusing on the production of one modification for the entire matrix of classification of loaders by operating modes, for the base model, four variants of overhaul periods are also saved in accordance with the load spectra, and for the remaining five modifications, the overhaul periods will be reduced by 2 times if the modification is located to the right of the base one, or increase by 2 times if the modification is to the left of the base one, i.e. the number of repair periods in use classes will increase or decrease exponentially with a denominator of 2. Serial production of modifications various types Each manufacturer selects loaders taking into account the existing manufacturing technology and the annual volume of mass production.

Using the structure of the repair cycle, you can easily find the frequency of maintenance TO-1, TO-2 and routine repairs TP under changing load classes.

Based on these standards, the estimated need for the loader for preventive measures for the planned period is determined, the volume of major repairs is established, the necessary repair base and contingent are justified work force related to keeping forklifts in good technical condition.

The main purpose of maintenance is to reduce the wear rate of parts, prevent malfunctions, extend the service life of forklifts, ensure their constant readiness for work, increase reliability and safety of operation.

The operating instructions for loading and unloading machines provide for the following work.

Preventive Maintenance System - Maintenance Operations

The system of planned preventative maintenance and repair is a complex of organizational and technical measures carried out as planned. Activities are developed and carried out in accordance with the recommendations of manufacturers and include preventive inspections

maintenance, repairs.

During the use of machines, the following is carried out: monthly maintenance (MS), performed before, during and after work shift; scheduled maintenance (MRO), performed as planned at certain periods established by the manufacturers; seasonal maintenance (SO), performed twice a year in preparation for operation in the subsequent season.

Planned repairs are divided into two types: current (T) and capital (K). Current repairs should ensure the operability of the machine until the next scheduled repair; major repairs should ensure the serviceability of the machine for a time equal to or close to its full service life. The frequency of performing a particular type of maintenance or repair is measured by the machine's operating hours per hour. The operating time is determined by the readings of counters installed on the mag or by shift time recording data. To record shift time, an operating hours log is kept. The frequency, complexity and duration of maintenance and repairs of forklifts are given in the Recommendations for organizing the maintenance and repair of construction machines.

The owner organization develops a maintenance and repair schedule for 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 sequence. Shift maintenance (MS) (performed by the driver) includes operations to prepare the machine for work, maintenance, and 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 tools. Before starting the engine, controls the level and quality of oil in the engine 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 their pressure, 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 chassis and hydraulic drive, the serviceability of the brakes and steering.

Upon returning to the parking lot, the loader is cleaned and inspected, faults are eliminated and parts and mechanisms are lubricated.

The first maintenance (TO-1) is carried out by a specialized team with the involvement of a driver in a special area and includes, in addition to EO operations, a number of additional checks and adjustments for the engine, working equipment, and chassis. During the TO-1 process, all fastening connections of the loader are checked and the steering, brake and clutch controls are adjusted. Inspect all pipeline connections and assess the condition of the hoses. Drain sediment from the fuel filter. Check 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 EO and TO-1 and additionally following works: checking, cleaning spark plugs; regulation of gaps between electrodes; cleaning and adjusting the carburetor; checking and cleaning the breaker contacts; checking and adjusting the gaps between valves and pushers; dismantling the fuel sump;

washing the mesh and filter element, wheel bearings; replacement of lubricant; bearing adjustment; cleaning brake mechanisms and checking their technical condition; adjustment of clearances in the steering; setting valves in the hydraulic system;

adjusting the tension of lift chains; checking the condition of the generator brushes and commutator; cleaning the battery terminals; tightening bolts and nuts securing mechanisms to the frame.

Seasonal maintenance (MS) is carried out twice a year - in spring and autumn and includes work provided for by TO-2 and additional: flushing the cooling system and refilling it with seasonal fluid; 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 hand brake elements.

The scope of operations and maintenance for each specific machine model is determined by the tool.

The SST company provides after-sales service for forklifts in Moscow. Data vehicles They are complex units, the functioning of which depends on the stability of a large number of components and mechanisms. To ensure their uninterrupted operation, timely service is required, which can only be provided by experienced and professional specialists.

	TO-2 (200 m/h), semi-annual maintenance (1200 m/h), annual maintenance (2400 m/h)	200m/h	1200m/h	2400m/h
	List of works performed
1	Checking and, if necessary, adjusting valve clearances		x	x
2				x
3	Replacing the coolant in the radiator, checking the radiator cap, cooling system hoses, and checking that the radiator is not damaged			x
4	Replacing the air filter element	x	x	x
5	Replacing the fuel filter	x	x	x
6	Blowing the air filter housing, the outer surface of the radiator, and the engine compartment	x	x	x
7	Checking and, if necessary, adjusting engine idle speed	x	x	x
8	Checking the condition and adjusting the tension of the fan and (or) generator belt	x	x	x
9	Check and, if necessary, adjust the tension of the forklift chains, lubricate the chains, lubricate the forklift frames	x	x	x
10	Replacing the oil and filter in the gas turbine engine, checking the operation of the gas turbine distributor, checking the low speed valve of the gas turbine engine, inspecting for leaks			x
11	Changing the oil in the gas turbine engine, checking the operation of the gas engine distributor, checking the low speed valve of the gas engine, inspecting for leaks		x
12	Checking the condition of the wheels, checking for play, adjusting if necessary in the wheel bearings, tightening the wheel fastenings	x	x	x
13	Checking the serviceability of the steering, adjustment (if possible without replacing the controls), checking the condition of the pivot and ball joints	x	x	x
14	Lubrication of components and parts through grease nipples	x	x	x
15	Check and, if necessary, adjust the free play of the brake pedal and handbrake; checking the effectiveness of the service and parking brake systems; checking the tightness of the service brake system	x	x
16	Replacing the brake fluid, checking and, if necessary, adjusting the free play of the brake pedal and handbrake; checking the effectiveness of the service and parking brake systems; checking the tightness of the service brake system			x
17	Checking and tightening the lift and tilt cylinders and inspecting for leaks	x	x	x
18	Checking the operation of the hydraulic distributor and its drive, inspecting for leaks	x	x	x
19	Checking the operation of the hydraulic system pump, inspecting for leaks	x	x	x
20	Changing the oil in the hydraulic system tank with replacing the oil filter			x
21	Changing the oil in the hydraulic system tank		x
22	Checking and, if necessary, tightening the connections of the hydraulic system RVD	x	x	x
23	Checking the level and density of the electrolyte in the battery, the condition of the battery terminals, cleaning and lubricating them if necessary	x	x	x
24	Changing the oil in the crankcase or drive axle gearboxes, inspecting for oil leaks			x
25	Checking the level and quality of oil in the crankcase or drive axle gearboxes, inspecting for oil leaks		x
26	Replacing spark plugs	x	x	x
27	Checking and, if necessary, adjusting the ignition timing, checking the condition of the breaker cover, distributor runner	x	x	x
	Cost of work	from 4000	from 5500	from 8000
Materials
1	Oil filter HDP			280
2	Engine oil filter	470	470	470
3	Fuel filter	535	535	535
4	Hydraulic return filter			1470
5	Air filter element	545	545	545
6	Semi-synthetic motor oil 8l.	2940	2940	2940
7	Flushing oil 7l.	900	900	900
8	Engine oil ATF Dexron-III 8l.		2940	2940
9	Hydraulic oil HLP 32 4 l.		6400	6400
10	Antifreeze WEGO G11 (green) 10 kg			1110
11	Grease "Elite-X" EP2 tube cartridge	400	400	400
12	Brake fluid LUXE DOT-4 0.5 l			120
13	Lubricant for chains and open gears 200	590	590	590
14	Transmission oil GL-5-5l.			1200
	Cost of consumables	6380	15720	19900
	x - replacement, check (if necessary)
	The cost of a 2.5 ton machine increases by 755 rubles.

Maintenance Features

Like any equipment, a forklift can fail. This happens either due to wear of parts, or due to improper operation, or due to lack of repair. To prevent spending on major repairs, we recommend that you perform timely maintenance on your forklifts. As part of maintenance, a number of activities are carried out, the task of which is to maintain the performance of warehouse equipment. Our service specialists can perform diagnostics both in our workshop and directly at your facility. Regular maintenance of components and mechanisms is a guarantee that the equipment will last much longer.

When to carry out maintenance

For forklift maintenance, prices in our service start from 4,000 rubles. The final cost depends on the scope of work performed on a particular loader. In any case, the vehicle should be serviced at a certain frequency, which will increase its service life and functionality:

• At the end of each working day, an inspection of equipment is required;
• TO-1 is carried out after operating the equipment for 100 hours or more. Technical fluids can be replaced, components can be lubricated, and all mechanisms can be adjusted;
• TO-2 is carried out after operating the forklift for 250-300 hours. Within this scope, work is carried out in accordance with TO-1, fuel and air filters are additionally changed;
• regular seasonal maintenance of loaders involves performing maintenance work 2, as well as additionally changing the oil in the gearbox and hydraulic system;
• Annual maintenance of forklifts involves, first of all, the replacement of technical fluids and lubricants.

In each specific case, the cost of maintenance work varies. Our service center equipped with everything necessary. We service forklifts of different brands: Komatsu, Toyota, Nissan, Mitsubishi, Yale, TCM.

Why is it important to perform maintenance on time?

Special equipment can withstand high levels of load. However, it is very important to carry out timely maintenance and repairs to keep the units in working order. When performing maintenance, you can immediately see problems with the engine, transmission, pump drives or final drive and prevent them from developing into more serious problems. It is almost impossible to carry out maintenance of forklifts on your own, so it is easier and more reliable to contact a specialized center. The advantages of this solution are obvious:

• diagnostics of the equipment will be carried out using special equipment, after which its condition will be determined;
• problems related to the technical side are identified in a timely and professional manner;
• Only on the equipment can the functions of the forklift be configured;
• As part of the inspection, technical fluids and consumables are replaced;
• If any malfunctions are suddenly discovered, repairs are carried out and components are replaced.

In addition, only at the service center you can get advice from experienced specialists.

How we are working

Our service center specialists will perform maintenance on domestic and foreign-made loaders. All work is carried out using professional equipment, so we can cope with repair work of any complexity. If necessary, we can conclude a contract with you for the maintenance of forklifts and front-end loaders. By contacting us, you receive the following benefits:

• Our warehouse always has a large selection of spare parts and consumables, so we eliminate breakdowns as quickly as possible;
• our staff are qualified specialists who have been working in this field for more than 10 years;
• in our work we use specialized tools and equipment;
• You can contact us in any emergency situations, warranty or non-warranty.

To find out what the prices for forklift maintenance will be, call our service center. We will perform a thorough diagnosis and then select options to solve problems if any are identified. We perform scheduled and urgent maintenance - call for details!