Braking system common faults and approach

The first two rounds of the brake can not analyze the reasons for failure are:
1, the gap between the two brake lines or brake ranging blockage, the gap between the two brake adjustment or dredge pipeline;
2, there is oil in the brake drum or brake shoes distorted, approach is to remove oil or repair, replacement brake shoes;
3, there is air in the brake lines, is the way to deal with exclusion of air brake lines.

Second, the hand brake failure, this may be due to the hand brake cable slack approach to treatment is to adjust the hand brake wire tightness.

Third, Zhidongshiling, analysis of failure are:
1, the diesel engine partsbrake drum and brake shoe gap is too large, is the way to deal with the gap modulation of the brake drum and brake shoes;
2, the brake master cylinder fluid out of the valve failure, maintenance approach is out of the valve;
3, excessive brake lining wear, friction plate approach is better;
4, the contact surface is not enough friction plate, friction plate approach is repaired.


Steering system common faults and approach:

First, the steering gear oil spills, analyze the reasons for failure are:
1, each steering joints (body, every dish, stator, rotor) oil spill, this treatment approach is to replace the seals, cleaning steering, sturdy bolt joints or better;
2, the journal of the relief valve seals or damaged, this approach is relatively simple, the journal is a better place and seals at the relief valve;
3. Limit bolt washers at uneven way this situation was handled better polished washer or gasket.

Second, steering failure, analyze the reasons for failure are:
1 piece of battery powered forklift broken steering spring break or deform steering pin, it may be broken or deformed coupling opening, this approach is better spring, pin, coupling;
2, valve failure, the approach is to clean safety valve, replace the spring;
3, steering cylinder leakage is too large, the approach is to replace the seals or cylinder.

Forklift truck hoisting system maintenance and repair

Forklift truck hoisting system is a device for loading and unloading work directly forklift truck, cargo unloading, stacking and ultimately by its completion, so it is the most important part of the forklift truck. Often need to strengthen the conservation and use, in order to maintain a good technical condition of it.

Disassembly and assembly and adjustment

The inner, outer door frame. battery forklift trucks‍ truck hoisting system between each main component, have relative motion. Wherein the inner and the outer door frame composed of a kinematic pair, fork frame and inner frame composed of a kinematic pair. In order to improve the motion accuracy of kinematic pair, the decrease of the friction between the moving member, reducing vibration and noise, improve the lateral stability of vehicle unloading goods fork, both inside and outside the door frames and forks on both side roller adjusting shim. Through the shim adjustment, so that a gap between the cargo fork frame side roller and an inner door frame, door frame gaps between the roller and the inner and outer door frame, if the relative motion freely, the gap value is not greater than 1mm. When the gap between the roller or coincidence type gantry clearance exceeds the specified by the design, roller to be adjusted or replaced, to ensure that the clearance of rolling or sliding, reduce the impact sound, to prevent the goods from sliding out of the goods fork. The door frame section flange size (thickness) reduced by more than LMM or the whole door frame combined lateral dimensions (width direction of the vehicle) is greater than a specified size more than 2.5mm, the emergence of the door frame deformation and warpage, are required to replace the door frame, in order to ensure the safe use.

The guide pulley and the lifting chain. Chain assembly, two chain tensioning force should be equal, load as evenly as possible, not to have the distortion phenomenon, the two sprocket after installation, flexible rotation. The pairing of the two forks, fork length should be approximately equal thickness. Two fork vertical section and horizontal section angle should be consistent. Two fork mounted on a fork, a plane on which should be kept in the same plane. The adjustment of the maximum length of heavy chain should be in the fork to the maximum lift height (i.e., lifting oil cylinder piston rises to an upper limit) when, after the adjustment of the hoisting chain should not be too tight, usually at the height of LM, with 5ON force on the chain, the deflection of 2Omm maximum as qualified. Each maintenance, dealing with inner and outer door frame channel steel and the chain sprocket grease, to ensure good lubrication, reducing friction of kinematic pair. In the wide field of vision in the hoisting system, the two lift cylinder (cylinder) stroke should be equal, the oil inlet pipe of each should be smooth. Two cylinder plunger rod end should also contact with the inner door frame, a sprocket support.

Fork. As the installation size hook and a fork between the standardization, linked to various attachments are the same and fork. So the plate fork frame can be conveniently replaced attachments. In order to make the fork or attachments from the fork frame is on or off, when the fork is provided with a file Shelves, can use the middle lower plate gap disassembly fork. In order to make the fork or attachments on the positioning frame and fork fork to adjust the spacing, can use a plurality of positioning upper plate symmetrical hole and a positioning groove, the positioning pin positioning by fork upper with spring. When the fork is hinged type, fork frame made of a sliding rod type, in the fork is arranged in the frame around the two round shaft, one on each circular sleeve fork, fork can slide on a round shaft, to adjust distance between the two forks, assembly and disassembly fork, need to be circular shaft next, fork is used card pin on the circular shaft.

Fork. The installation should pay attention to the selection of Lpg Gas Forklift Truck‍. The pairing of the two forks, fork length should be approximately equal thickness. The angle between the two fork vertical section and horizontal section should also be consistent, fork mounted on a fork, two forks on the plane should be kept in the same plane, should not be high and low dislocation phenomenon.‍

Forklift common system failures and approaches

Forklift use battery, diesel, propane and other industrial power for industrial energy forklift, currently more common mobile forklift are: electric forklifts, electric forklift trucks (the industry is generally divided into all-electric forklift trucks, semi-electric stacker) , electric cars, propane forklifts, diesel forklifts, etc., to the individual needs and design and production, such as reach trucks, gas powered forklift attachments (attachment of meaning is based on specific market needs to be redesigned for the forks manufactured to meet customer demand, the current common attachments such as dump, Paper clips, clamps drums, tires fixture, wooden clip and so on, the design is very flexible), etc., these are
all maneuvering the truck category. Tactical Truck class commonly used systems are: drive systems, lifting systems, hydraulic systems, braking systems, steering systems, the general failure of love on these five systems, systems approach common faults.

Drive system common faults and approach:
First, the clutch does not slip or separation, analyze the reasons for failure are:
1, the friction plate on top of the sticky oil or lining is damaged, this treatment approach is to clean or replace the friction plate friction plate;
2, combined with the state of the release bearing pressure in the release lever on top of this treatment approach is to adjust shorter cylinder pushrod assembly;
3, release bearing too much free travel, this treatment approach is to transfer cylinder assembly in the long putter;

4, the oil in the air, this approach is to drain the oil inside the air;
Second, the gearbox abnormal sound, analyze causes are:
1, excessive gear wear or bearing damage, this treatment approach is to replace the gear or replacement of bearings;

2, there is debris inside the gearbox, way to deal is to exclude debris.
Lifting system common faults and approach:First, the time is not synchronized gantry tilt, analyze the reasons for the failure is due to inconsistent or two tilt cylinder stroke cylinder bore size of the pipe joints closure due to the inconsistent, way to deal with the adjustable tilt cylinder 2 stroke and replace
with the same closure hole connector.
Second, the load can not lift the door frame, this is because the multi-way valve overflow
hole plug, multi-way valve by removing the overflow hole debris on it.
Third, the electric forklift trucks mast fell too fast, this is because the inlet valve speed does not work, the only limiting valve repair it.
Fourth, the fork mast down automatically, this is because of lack of hydraulic oil cylinder caused by the maintenance approach to multi-valve, add hydraulic oil.

Forklift truck hoisting system repair

Ask heavy system technology. Door frame should be no cracks, defects should not affect the strength, rigidity, deformation amount shall not exceed the allowable value of design. The door frame generally use the overlapping structure. Inside and outside the door frame should be with a good, flexible slide, no blocking phenomenon.

The guide pulley rack should be installed in the correct and reliable. The pulley and the pulley shaft should be free of cracks and defects, wheel groove wear amount shall not exceed the original design thickness of 10%, and the guide pulley rack with appropriate, flexible and reliable rotation to make the pulley. Chain specifications should be consistent with design requirements. Chain plate and the shaft should be no cracks and deformation, and maintain a flexible and reliable transmission.

The gear frame wheel frame should be intact, no cracks, and the portal frame with good, can in the door frame, a flexible sliding smoothly without jamming phenomenon. Surface of the guide wheel frame beam should be flat, smooth, stable and reliable to fork lateral movement. Fork should have sufficient strength and rigidity, and the guide wheel frame beam with good. Attachments shall be fitted with a protective frame of general framework of flat steel, and to maintain the integrity and no distortion. The door frame and the tilt cylinder and the frame shall be connected firmly, with a good, reliable lock, flexible rotation.

The door frame can not have deformation and welding sparks, door frame and the door frame, with the frame and the inner frame is relatively smooth ascending and descending. The door frame and the roller clearance shall not be greater than 1.5mm, the sliding good without jamming. Roller rotation should be recorded live, roller and shaft should be no cracks, defects, wheel groove wear amount shall not be greater than the size of the original 1O%. Two hoisting chain tension should be uniform, no distortion, end the connection is firm; the chain pin shaft and the clearance of bearing holes shall not be too large. Sprocket rotation should be flexible, groove depth of no more than the original size of the 0.5mm; the gear frame shall have serious deformation, weld the welding phenomenon.

Fork surface shall not have cracks, each weld shall not have sparks. The fork root angle of not more than 93 degrees, the thickness shall not be less than the size of the original 90%; the left and the right fork tip height shall not exceed the fork length of horizontal section 3%; fork positioning should be reliable, a bearing surface and a positioning fork hook surface without obvious defects; fork and genus clearance with frame should not be too large, and move smoothly.

Wear and tear parts and maintenance. In the use of forklift, fork of the dangerous section of common upper elbow and fork and the vertical sections of the hook on the vertical portion of welding in the vertical section near the lower part, dangerous position is extremely easy to produce fracture. In particular, forklift truck manufacturers‍ drivers often illegal operation, used alone side fork front-end lifting or sharp pick goods on the ground, leading to the fork or fork sharp bending deformation, even (cargo overloaded) vertical section of root and broken consequences will cause serious economic loss.

Maintenance of the common fork of forklift truck. According to the national standard, the fork usage should be checked annually; used in the harsh conditions of forklift need more frequent inspections, to detect any defect or permanent deformation, take the relevant technical measures, so as to eliminate the hidden trouble of safety. For inspection by the professional and technical personnel of electric forklift trucks‍ fork fork produces, found signs of impede the safe use of the failure and obvious deformation of any defect, must stop, and only after rigorous repair, and after test acceptance qualified rear can use.

Fork the surface crack (especially the fork root, hook, hook and under vertical segment junction), once found, the height difference between the two fork tip, more than the length of horizontal section 3%, fork must stop using. Use must also ensure the positioning pin in well maintenance and normal condition in situ, if any fault, fork must stop before the good repair. Should be regularly checked thoroughly wear degree fork horizontal section and vertical section, especially the fork root, if the thickness is reduced to the original 90% should also stop using. The hook on the support surface fork and positioning hook under the surface wear, the backlog and other local deformation, increased gap between the fork and the fork, must repair before use.

In the absence of conditions, fork breakage is best replaced with new parts, not allowed to improvise to use, even if the fork after repair welding, only through the strict technical standard test, to achieve the original specification requirements, can be put into use.‍

Forklift Safety belts

1. You can not arbitrarily change the structure and working principle of seat belts, making it safer and more effective protection of the driver.

2. The truck has encountered serious collision, tumbling and other events, you must replace the new belt.

3. Because outside of normal chemical action, such as the sun and rain to the truck seat belt damage, cracked, aging or soft distortion, it must be replaced with new forklift seat belts.

4. forklift safety connection with metal and warp, bend, break, rust or age, you must replace the safety.

5. truck seat belt performance when using poor does not automatically retract, not emergency self-locking buckle safety belts are not tight when these trucks, etc. must be replaced in order to maintain normal security role to play.

6. If installing a Off road forklifts when using seat belts, the thickness not less than 1.5 mm, a width of not less than 50 mm, it is best to replace the seat belt with the requirements of the emergency self-locking function.

The main reason for the forklift rust corrosion

Most factories forklift is an indispensable tool for the production of labor, of course, also be loss tool. Corrosion is the truck which consumed the culprit, now have to analyze the main reason for rust corrosion in the end what?

Forklift corrosion not only related to the environment and also its structure.

Forklift can be divided into internal combustion battery powered forklift and electric forklifts. Most internal combustion forklifts used in ports, terminals and mining sites, the use of the environment is bad, especially in ports and the chemical industry, by the subtropical, humid tropics, maritime environment and industrial emissions, the combined effects of dust, causing corrosion damage Forklift Parts corrosion is more serious; and battery forklift mostly used in warehouses and other indoor places, small changes in the environment, the corrosion caused by environmental factors is relatively light.

Stress generated inside the truck corrosive environments such as high temperatures generated by the engine and sulfur, chlorine ions and other combustion gas, generated mist battery, leakage, work of vibration, generated by the impact, friction, etc. caused by collision damage is caused by partial the main reason for corrosion damage all terrain forklifts Parts.

The main mechanism of metal corrosion is the original metal is converted to a metal oxide, resulting in structural parts or components to rust, damage can not be repaired or scrapped. The paint, rubber, fiberglass and other non-metallic materials aging, mainly after comprehensive environmental action by, the material structure of polymer pyrolysis, degradation, dissolution, and other physical and chemical changes, resulting in the appearance and performance. Forklift design itself visible structure, materials, processes and protective measures directly determine the corrosion resistance of the truck.

Forklift working device repair

Lpg Forklift Trucks‍ Chains and pulleys in maintenance, there shall be no crack and deformation of the chain sheet, need to be flexible rotation. Every 20 section chain elongation does not exceed the specified value (8mm). Wear chain pins shall not be more than the original diameter 5%, there shall be no serious bending, fatigue crack and corrosion. If more than the allowable situation, should be replaced. If pulley surface appears uneven wear, two pulley diameter difference is greater than 0.2mm, the pulley surface appear step or indentation, the influence of the chain in normal operation. Should be replaced.

The main, side roller in maintenance, inspection of main, side roller wear marks should be uniform. The wear limit along the diameter direction, main roller 1.Omm, side roller is 0.5mm. Or should be replaced. The inner, outer door frame in maintenance, inner, outer door frame requirements of flat, in length not straightness shall not exceed 1mm, limits the use of 3mm. Otherwise, should be repaired. Magnaflux, striking method to check for cracks. If have, should repair. Check that the deformation or distortion. When the bending deformation in the length range is more than 1.5mm, the transverse width difference is more than 1.5mm, more than 2.Omm of the bending deformation of an inner door frame roof, should be corrected. When the overall deformation is serious, the guide mouth size exceeds the limit of wear, should be scrapped. Inside and outside the door frame side rails on each side wear steps up to 2mm, should replace the rail or dressing after use.

The working device is assembled on the check and adjustment, first check and adjustment of the inner and outer door frame before and after the gap. Match and use of gap of roller 1mm following assembly. When assembling, the get fit clearance, operation lifting handle, so that the inner door frame, running, to run smoothly, roller rotation freedom, even; two is the inspection and adjustment of inner and outer door frame around the gap. According to the required size, adjust the installation position of the lateral roller with method of the pad, to ensure the clearance of the roller and the inner and outer door frame channel steel wall is worth to meet (the inner door frame top position is 0.1-1.Omm, the lowest position for the inner door frame 0.1-1.5mm); three is the fork frame around the gap adjustment, and inside, the outer door frame around the same gap adjustment, only the gap value everywhere are 0.1-1.Omm. All the good, the lifting fork, door frame, see whether smooth action. Decrease from the maximum height, inner door frame together with the requirements of air fork free fall. Otherwise, should be re adjusted; four is the lifting chain adjustment. Lifting chain is too long, lifting height is not up to the requirements; too short will cause serious accident fork out of an inner door frame channel steel; the two chain loose a tight, causing a chain of overload and eccentric load, causing a fork and an inner door frame movement is not smooth, not flexible. Therefore, must adjust the two chain. The method is: will the rough terrain forklift trucks‍ parked in the flat field, the door frame in a vertical state, the fork fell to the ground, a lifting oil cylinder piston (Zhu Sai) to the next check point. Installed on the chain, two chain end and fork is connected, and a lock. The chain around the pulley, and the other end of the lifting oil cylinder body flange or the door frame beam is connected with the hinge bolts and adjusting the length of the chain. Finger at 1000mm from the ground, to 49N for the quasi according to the chain, the chain moving distance is below 20mm, in the same way, adjust the other chain. The two chain after a good tune, lifting fork and then check the tightness, two chain length should be consistent.‍

Forklift Safety belts

1. You can not arbitrarily change the structure and working principle of seat belts, making it safer and more effective protection of the driver.

2. The truck has encountered serious collision, tumbling and other events, you must replace the new belt.

3. Because outside of normal chemical action, such as the sun and rain to the truck seat belt damage, cracked, aging or soft distortion, it must be replaced with new Lpg Gas Forklift seat belts.

4. forklift safety connection with metal and warp, bend, break, rust or age, you must replace the safety.

5. truck seat belt performance when using poor does not automatically retract, not emergency self-locking buckle safety belts are not tight when these trucks, etc. must be replaced in order to maintain normal security role to play.

6. If installing a forklift when using seat belts, the thickness not less than 1.5 mm, a width of not less than 50 mm, it is best to replace the seat belt with the requirements of the emergency self-locking function.

Use and maintenance of electric forklift hand while

Routine maintenance, class after work. 2, the level of technical maintenance, accumulated 100 hours of work, a group working system is equivalent to two weeks. 3, two technical maintenance, accumulated 500 hours, the equivalent of a quarter of a group working system. First, a routine maintenance, cleaning the truck dirt, mud and dirt Egypt, key positions are: YTO forklift frame and door frame slide, generator and starter, battery electrodes fork columns, tanks, air filter. 2, check all parts of fastening, focusing on: Fork supporting, lifting chain tensioning screw, wheel bolts, wheel fixed pin, brakes, steering screws. 3, check the foot brake, steering reliability, flexibility. 4. Check for leaks, focusing on: all fittings, diesel tank, sump, pump the brake, lift cylinders, tilt cylinders, tanks, pumps, engine oil pan, torque converter, transmission, drive axle, the main reduction , hydraulic steering, steering cylinder. 5, put the oil filter to precipitate.
Second, a technical maintenance in accordance with the "routine maintenance" project, and add the following work. 1, check the cylinder pressure or vacuum. 2. Check and adjust valve clearance. 3, check the thermostat is working properly. 4. Check the multi-valve, lift cylinders, tilt cylinders, steering gear if the fuel tank and pump is working properly. 5. Check the transmission's shift work properly. 6. Check and adjust the hand, foot brake, brake pads and brake drum clearance. 7, the replacement of the oil sump, check the crankcase ventilation takeover is intact, clean oil filter and fuel filter element.
8. Check the generator and starter motor is firmly installed, and lugs are clean firm, check brushes and commutator for wear. 9. Check the fan belt tightness. 10. Check the wheel is firmly installed, meets the requirement if the tire pressure, and clear debris embedded in the tread. 11, due to maintenance work and dismantled parts, when re-assembled to conduct the truck road test. (1) braking performance under varying degrees, there should be no deviation, hunting. On the steep slopes, after the hand brake tension, can reliably stop. (2) to listen to the engine under acceleration, deceleration, reload or load operation, etc., there is no unusual sounds. (3) road test some mileage, check brakes, transmission, front axle, gear pumps at the presence of overheating. (4) YTO rough terrain forklift lifting speed is normal, with or without shaking. 12, check the diesel tank of fuel filter has blocked imports of damage, and clean or replace the filter.
Three, two technical maintenance and except a technical maintenance projects, and add the following: 1, cleaning the tank, filters and piping, and check for corrosion, cracking collision case, after cleaning may not be used with fiber the yarn, cloth wipe. 2, cleaning torque converter, transmission, inspect parts for wear, replace with new oil. 3, check the drive shaft bearing, depending on the need to exchange universal joint cross-axis direction. 4. Check the drive axle fastening ministries and whether leakage, and clear pores. Dismantling the main gear, differential, wheel reducer, adjust the bearing axial clearance, add or replace oil. 5, dismantling, adjustment and lubrication of the front and rear wheels, axle were transposed. 6, cleaning brakes, adjust the clearance between the brake drum and brake shoe lining between. 7, cleaning liberal amount of rotation steering, check the steering wheel. 8, disassembly and cleaning gear pumps, pay attention to check the wear of the gear housing and bearing 9, demolition multi-way valve, the stem and the valve clearance check, do not open the safety valve, if not necessary. 10, check for damage and cracks knuckles, steering axle kingpin with the situation with the knuckle, dismantling the vertical and horizontal rod and steering arm joints wear. 11, removing a tire on the rim rust paint, check the tires and tubes and flaps, transposition accordance with the provisions inflated. 12. Check the connections are tight hand brake parts, adjusting the hand brake lever and foot brake pedal stroke work. 13. Check the battery electro-hydraulic proportion, as inconsistent with the requirements, the charge must be removed. 14, clean water tank and oil cooler. 15, check the shelves, frame without deformation, washable wheel, each accessory is reliable fixed, restocking weld if necessary. 16, dismantling the lifting cylinders, tilt cylinders and steering cylinder, replace worn seals. 17, check the instrument sensors, fuses and various switches, make adjustments if necessary. Fourth, the whole car or truck lubrication new truck stops working after a long time, within two weeks at the start of use, should be lubricated bearings for when lubrication, Chen should take advantage of new oil will all the oil out, and lubricate twice above, and should pay attention to the following points: 1, should be removed before lubricating oil cap, oil drain plug and nozzle above the dirt, dirt to avoid falling into the house. 2, with the grease gun lubricant injection pressure, injection pressure to be part of the components of the combination of the extrusion lubricant so far. 3, should be replaced in the summer or winter seasonal lubricant (oil, etc.).

diesel engine parts spare parts market demand will greatly promote the spare parts

 In recent years, global production and sales growth year after year forklift truck in China's market size. China's economy has accelerated steadily for the better development of the logistics industry, rough terrain forklift for sale industry growth of China's industrial vehicles best sub-sectors, and has been unprecedented attention. By the end of 2012, the Chinese market has reached 1.5 million truck fleet units. The presence of a large number of trucks, diesel forklift trucks will bring strong demand for its accessories.Forklift spare parts in China has become a major truck production and sales market. Major foreign famous brand forklifts targeting this opportunity to invest and set up factories in China have, which will undoubtedly bring a huge opportunity for forklift parts supplier. Spare parts business because of the growing market demand and higher profits become a new profit growth point of the manufacturers to pursue. Therefore, within a short period of time, the rise of a large number of major Chinese brands supporting forklift spare parts manufacturers. They superior equipment and technology, management greatly enhance China's forklift spare parts cost, maximize the overall prosperity of China led the forklift parts market.

2 Ton Diesel Forklift driver of the vehicle before the job should censor overweight chain

 door frame, fork or without injury, bolts are secure; check whether you need refueling, lubricants, four-wheel rough terrain forklift truck check the startup, operation, and braking performance; Also check the lights, sound signals are complete and valid, then start to confirm normal operation; after starting the engine, listen to the engine running, check the status of each instrument instruction.2.5 tons Diesel forklift trucks 2 Ton Diesel Forklift driver of the vehicle before the job should censor overweight chain, door frame, fork or without injury, All Terrain Forklift bolts are secure; check whether you need refueling, lubricants, check the startup, operation, and braking performance; Also check the lights, sound signals are complete and valid, then start to confirm normal operation; after starting the engine, listen to the engine running, check the status of each instrument instruction.