How to Properly Maintain an Electric Forklift
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Proper maintenance of an electric forklift is crucial to extend its lifespan, ensure optimal performance, and minimize breakdowns during operation. Here’s a detailed guide by category:
🔧 1. Daily Maintenance (Before or After Shifts)
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Check battery water level (for lead-acid batteries): Ensure proper water level. Only refill with distilled water after full charging.
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Check lithium battery charge level: Make sure the battery is charged if needed. Avoid letting it drop below 20%.
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Check tires: Look for wear, cracks, or improper pressure (for pneumatic tires).
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Check brakes and horn: Ensure brakes are working properly; horn and signal lights are clear.
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Check for hydraulic oil leaks: If oil spots are found under the forklift, inspect the cylinders and hoses.
🛠 2. Periodic Maintenance (Based on Operating Hours)
| Operating Hours | Maintenance Tasks |
|---|---|
| Every 250 hours | – Clean the entire forklift, especially motor and battery areas – Retighten bolts and screws – Lubricate lift chains and moving joints |
| Every 500 hours | – Replace hydraulic oil – Clean or replace hydraulic oil filter – Inspect drive and lift motors |
| Every 1000 hours | – Inspect electrical system, circuit boards, sensors – Check battery condition (charging/discharging, wear) – Adjust brake and lifting systems |
| Every 2000 hours | – Inspect control system and main circuit board – Replace worn parts: carbon brushes, bearings, wheels if necessary |
⚡ 3. Battery Charging and Usage Notes
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Charge in a well-ventilated area (lead-acid): Prevent hydrogen gas buildup which may cause explosions.
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Avoid intermittent charging (lead-acid): Always complete the full charge cycle to extend battery life.
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For lithium batteries: Fast charging and intermittent charging are allowed; no water refilling or frequent cleaning needed.
📌 4. Things to Avoid
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Do not use high-pressure washers near motors or circuit boards.
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Do not overload or exceed safe lifting height.
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Avoid frequent deep discharging of the battery.
Need a maintenance checklist? I can provide a weekly/monthly/quarterly checklist template for you or your technicians.
