In order to ensure the stable operation of
forklift equipment, it is crucial to fully understand its failure
characteristics in different use stages and seasonal conditions. This article
centers on the common problems of forklift trucks in the early stage, normal
use period, near overhaul period and seasonal changes to systematically sort
out, and help users to improve the level of equipment management.
I. Failure characteristics in the early stage of use
Forklift trucks in the early stage of use,
usually in the period of going together, have a relatively high,
and gradually decline with time. Failures at this stage are
mostly caused by unstable manufacturing or maintenance quality, as well as
break-in problems caused by improper operation. Typical performance includes
loose bolts, pipe fittings or fall off, oil circuit system due to residual
metal chips or casting sand clogging caused by hydraulic parts strained oil
leakage, adjusting the gap or pressure changes so that the equipment can not
meet the normal performance requirements, and even leakage of oil, water, gas, and other phenomena. If the equipment quality is reliable and properly
operated, can effectively reduce the initial failure rate.
Ⅱ. The normal use of the stage of failure characteristics
When the forklift completes the go-along
and enters the stable operation stage, as long as the maintenance and operation
are carried out following the norms, the failure rate is usually low,
and the overall operation curve tends to be stable. Failures at this stage are
mostly episodic, hidden, and difficult to find during routine
inspections. Most of the problems are caused by accidental factors, such as
improper operation, inadequate maintenance or abnormal wear and tear of local
parts. Overall, the performance of the equipment is more reliable, and maintenance
should focus on preventive inspection and condition monitoring.
Ⅲ. Close to the overhaul period of failure characteristics
With the increase of service life, the forklift
gradually enters the pre-major repair period, the wear and tear of
equipment components is obvious, and the technical condition gradually
deteriorates. The typical characteristic of this stage is frequent and wide
range of faults, often involving multiple systems. Common problems include leakage
of the pipeline due to aging of seals, damage of friction parts due to poor
lubrication, and reduced response of hydraulic and braking systems. At this
stage, it is recommended that enterprises combine the intensity of use,
the development of overhaul plans, timely replacement of aging parts, to
prevent sudden equipment shutdowns affecting operations.
Ⅳ. Failure differences in different seasons
Seasonal changes also have a significant
impact on forklift operation. Especially in winter, the low temperature
environment will significantly increase the failure rate. Common problems such
as poor fuel atomization leading to start-up difficulties, oil solidification
caused by oil blockage, poor lubricant fluidity to accelerate the wear and tear
of machine parts, battery capacity decline affecting the normal operation of
the start-up and electronic control system, and hydraulic transmission efficiency
decline. In contrast, the failure rate in summer is relatively low, but the
high temperature may also cause overheating of the engine, electrical
components aging and other problems, so the cleaning and ventilation of the
cooling system should not be ignored.
Forklift failure performance in different times and seasons has obvious rules. Scientific control of the operation cycle, combined with seasonal characteristics to adjust the maintenance strategy, is to protecting the key to efficient and safe operation of the equipment. It is recommended that managers strengthen daily inspection, regular maintenance and fault prediction to enhance the efficiency of forklifts and prolong the life of the whole machine.
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