I. Preface
1.1 Purpose and Importance
Forklifts are indispensable equipment in industrial production and warehousing logistics. Their efficient operation and safe use are directly related to production efficiency and the safety of the working environment. Through regular maintenance, equipment failures can be prevented, equipment life can be extended, and operational safety can be ensured. This manual aims to provide a systematic and comprehensive forklift maintenance guide to help users establish an effective maintenance system.
1.2 Scope of Application
This manual is applicable to electric forklifts, internal combustion forklifts and other special forklifts. It is applicable to the maintenance of forklifts in various environments such as industrial production, warehousing, and logistics.
1.3 Basic Principles of Maintenance
Preventive maintenance is the main method, and fault repair is the auxiliary method.
Strictly follow the maintenance manual and technical requirements provided by the manufacturer.

Regular inspection, timely record, and timely processing.

II. Overall Strategy of Maintenance
2.1 Preventive Maintenance and Fault Maintenance
Preventive Maintenance
Regularly inspect and maintain forklifts to prevent failures. Including daily inspection, regular maintenance and preventive replacement of wearing parts.
Fault maintenance
After a fault occurs, repair and replace parts in time to restore the forklift to normal working condition.
2.2 Maintenance cycle setting
Daily maintenance: before and after daily use.
Level 1 maintenance: after every 50 working hours or after the engine has been running for 150 hours. For internal combustion forklifts with less than 150 working hours per year, level 1 maintenance is performed once a year.
Level 2 maintenance: after every 200 working hours, or every 450 hours.
Level 3 maintenance: after every 600 working hours.
2.3 Personnel and responsibilities
Operator: responsible for daily inspection and simple maintenance.
Maintenance personnel: responsible for detailed inspection and maintenance every week, month, quarter and year.

Manager: supervise the implementation of the maintenance plan and ensure record and file management.

III. Daily maintenance
3.1 Inspection and operation steps
Before and after operation, conduct a brief inspection to ensure that all indicators are normal.
Inspection of hydraulic oil, battery power, tires and wheels, brake system, operating controls and safety devices.
3.2 Hydraulic oil inspection
Check whether the hydraulic oil level is within the normal range and add if necessary.
Check whether the hydraulic oil is leaking and deal with the leakage problem in time.
3.3 Battery power check
Ensure that the battery is fully charged and check whether the battery connection is firm.
Check whether the battery shell is damaged or leaking, and replace the battery if necessary.
3.4 Tire and wheel hub inspection
Check whether the tire is worn or damaged and ensure that the air pressure is normal.
Check whether the wheel hub is loose and ensure that the tire is tight.
3.5 Brake system inspection
Check the wear of the brake pads to ensure that the brakes are sensitive.
Check whether the brake fluid level is normal and add it if necessary.
3.6 Operation control and safety device inspection
Check whether each operation control is flexible and whether the safety device is effective.
Check whether the alarm system and lights are normal to ensure safe operation.
3.7 Recording and feedback
Record daily inspection results and feedback problems found.
Keep detailed daily maintenance records for subsequent analysis and improvement.
Fault warning and evaluation function of forklift management system
Fault warning: The forklift management system (FMS) can detect potential fault signs in advance and issue warnings by real-time monitoring of various operating parameters of the forklift, such as engine status, oil pressure, water temperature, battery power, etc. Maintenance personnel can intervene before a failure occurs, avoiding greater damage and reducing downtime.
Health assessment: FMS can assess the overall health of the forklift and predict which parts may soon reach the critical point of maintenance or replacement based on operating data and historical records, so as to arrange maintenance plans in advance.