Diesel Forklift Inspection & Repair Guide
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Th7
Th7
Diesel Forklift Inspection & Repair Guide
🔧 I. General Inspection of Diesel Forklift
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Visual Check
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Check for oil leaks (engine oil, gearbox oil, hydraulic oil).
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Inspect tires, forks, lifting chains, and mast.
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Check fuel tank, exhaust pipe, and engine noise.
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Engine Check
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Check engine oil level (using dipstick).
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Inspect air filter – replace if too dirty.
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Check oil and fuel filters.
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Inspect belts and fuel lines.
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Cooling System Check
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Check radiator (water level, leaks, scaling).
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Check radiator fan operation.
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Hydraulic System Check
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Check hydraulic oil level.
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Look for leaks at valves, hoses, or lift cylinders.
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Test lifting, lowering, and tilting functions.
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Brake & Steering System Check
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Check brake fluid, brake pedal condition.
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Check steering responsiveness and power assist.
🔍 II. Common Issues & Fixes
| Issue | Cause | Solution |
|---|---|---|
| Hard to start | Dirty fuel filter, weak glow plug, weak injection pump | Replace filter, check glow plug and pump |
| Engine runs but weak power | Clogged air filter, weak pump, thin oil | Clean filter, change oil, check pump |
| Weak or no lifting | Low hydraulic oil, faulty pump | Refill oil, repair or replace pump |
| Overheating | Low coolant, dirty radiator | Add coolant, clean radiator |
| Oil leaks | Cracked hose, loose connectors | Replace hose, tighten fittings |
🛠️ III. Suggested Maintenance Schedule
| Item | Frequency |
|---|---|
| Engine oil change | Every 250 working hrs |
| Oil and fuel filter replacement | Every 500 working hrs |
| Air filter & belt inspection | Every 100 working hrs |
| Hydraulic oil inspection | Weekly |
| Radiator water inspection | Daily |
| General maintenance | Every 1000 hrs or 6 mo |
