What are the regulations regarding forklift maintenance quotas?

Maintenance quotas can be divided into three parts: preventive maintenance system, maintenance and repair quotas, and the formulation of forklift repair plans.

1. Preventive maintenance system

Preventive maintenance is the foundation for the effective use of forklifts. This maintenance system is composed of some interrelated regulations and norms. The maintenance and repair it stipulates are carried out in a planned manner and are conducted when the forklift can still prevent unexpected malfunctions.

If unplanned repairs (referred to as post-event repairs or fault repairs) are carried out when forklifts break down or their performance drops below the qualified level, there may often be frequent unexpected failures caused by technical issues. This will lead to prolonged downtime, cause significant losses to production, and also add additional difficulties and cost consumption to the repair work. Therefore, the methods of post-repair and post-maintenance are no longer adopted now.

The daily maintenance of each shift is carried out by the operators of that shift before the shift. The basic task is to conduct an external inspection of the entire machine or each component to ensure that no faults occur during the shift's operation. Add fuel and lubricating materials, as well as electrolyte, cooling water and brake fluid, etc. If daily maintenance is done well, the safety and technical requirements during the working process can basically be met.

The preventive maintenance system also stipulates two types of regular maintenance based on the differences in operation volume and running time: first-level maintenance (first maintenance) and second-level maintenance (second maintenance). The purpose of regular maintenance is to maintain good condition or the rated working capacity between two adjacent regular maintenance sessions.

Repair is the entire technical process of eliminating faults caused by surface wear of parts, part deformation, fit damage and other reasons during the production process. It can be classified into major overhauls and major overhauls based on the workload.

Item repair is a targeted repair carried out based on the actual technical condition of the forklift to ensure its working capacity. The project involves replacing and restoring individual components and making adjustments.

A major overhaul is to repair the damage of machine parts and restore their rated working capacity. A major overhaul involves replacing or repairing any component, including the main parts, and making adjustments to repair the damage of the machine parts and restore their service life.

2 Quota for maintenance and repair

The quota is determined based on the continuous working time between forklift maintenance and repair, and all preventive measures of the preventive maintenance system (i.e., daily maintenance, first maintenance, second maintenance, item repair and major repair) are implemented in a timely manner. Forklifts can only be reused after undergoing the prescribed maintenance and repairs.

When formulating the quota for preventive maintenance, it is necessary to take into account the frequency of forklift usage. Due to the varying operation volumes of forklifts, there are different degrees of wear and tear. The repair of wear and tear is related to different preventive workloads. Therefore, the intervals between maintenance and repair should ensure that forklifts, especially those with high annual operation volumes, are in a state of rated working capacity.

The intervals between forklift maintenance and repair are shown in Table 2-10. The characteristics of the working duration (maintenance period) of forklifts between maintenance periods are not related to the intensity of the operation. After completing a certain amount of work (kt) or having been in operation for a certain period of time (month or year), the forklift undergoes itemized and major overhauls