Diesel vs. Electric Forklift Maintenance Frequency

The maintenance frequency of diesel forklifts is significantly higher than that of electric forklifts. The core difference stems from the complexity of their power systems. Specific frequencies are divided based on operating hours and component types, as follows:

Maintenance Frequency for Diesel Forklifts

• Routine Maintenance: Conducted every 500 hours. Key tasks include replacing engine oil, oil filters, air filters, and fuel filters, as well as checking the hydraulic oil level and sealing.
• Key Component Maintenance:
  • Transmission & Drive Axle: Check oil every 1,000 hours; ｒｅｐｌａｃｅ gear oil every 2,000 hours.
  • Engine: Inspect spark plugs and fuel injectors every 1,500 hours; perform a major overhaul every 15,000 hours.
  • Brake System: Check brake pad thickness and brake fluid every 800 hours; ｒｅｐｌａｃｅ brake fluid every 1,500 hours.
• Environment Adaptation Adjustment: For outdoor/heavy-duty operations (e.g., ports, construction sites), reduce maintenance intervals by 20%-30%.

Maintenance Frequency for Electric Forklifts (Lithium-Ion vs. Lead-Acid)

1. Lithium-Ion Electric Forklifts

• Routine Maintenance: Conducted every 1,000 hours. Tasks include cleaning the battery surface, checking the tightness of circuit connectors, and testing battery voltage and the cooling system.
• Key Component Maintenance:
  • Lithium-Ion Battery: Test capacity degradation every 2,000 hours; perform a comprehensive inspection every 5 years (no regular replacement required).
  • Motor & Controller: Check insulation and operating temperature every 3,000 hours; no mandatory replacement cycle.
  • Hydraulic System: Check oil and seals every 1,500 hours; ｒｅｐｌａｃｅ hydraulic oil every 3,000 hours.

2. Lead-Acid Electric Forklifts

• Routine Maintenance: Conducted every 300 hours. Tasks include refilling electrolyte (except for maintenance-free lead-acid batteries), cleaning battery terminals to prevent sulfation, and checking circuit connections.
• Key Component Maintenance:
  • Lead-Acid Battery: Test capacity every 800 hours; ｒｅｐｌａｃｅ directly every 1.5-2 years (when the cycle life expires).
  • Motor & Hydraulic System: Same as lithium-ion models; inspection and maintenance every 3,000 hours.

Key Factors Affecting Maintenance Frequency

• Operation Intensity: For daily operation ≥12 hours (high-frequency, heavy-duty), reduce maintenance intervals for all models by 30%-40%.
• Environmental Conditions: In outdoor, humid, or dusty environments, increase filter replacement frequency for diesel forklifts and enhance circuit inspection frequency for electric forklifts.
• Brand & Service Life: For old diesel forklifts (in use for over 5 years), double the maintenance frequency; for electric forklifts, increase inspection frequency after battery degradation.