1. Battery system maintenance (core focus)
Electrolyte management
Lead-acid battery: Check the electrolyte level daily, add distilled water when it is 10-15mm below the plate (tap water/purified water is prohibited).
Lithium battery: Maintenance-free, but avoid high temperature (>40°C) and low temperature (<0°C) environments.
Charging specifications
Charge when the remaining power is 20%, avoid deep discharge; deep discharge once a month to 20% to activate the battery. After charging, let it stand for 30 minutes before use. Long-term disuse requires recharging once a month.
Anti-oxidation measures
Apply vaseline to the battery terminals for corrosion protection and keep the surface dry. Disconnect the connection with the chopper during charging to prevent overvoltage damage.
2. Mechanical component maintenance
Daily inspection
Tires: Keep the pressure of pneumatic tires at 5-7 kg/cm², remove foreign matter on the tread; check for wear and cracks on solid tires.
Chain: droop ≤ 20mm, lubricate and prevent rust.
Braking system: test sensitivity, brake fluid level must be between MAX-MIN.
Regular lubrication
Gantry guide rails and steering bearings are lubricated weekly; wheel hub bearings are greased monthly.
Hydraulic system
Hydraulic oil is replaced every 500 hours (ISO VG32 is recommended), oil temperature ≤ 60°C; filter element is replaced synchronously every 500 hours. Check the sealing of the oil cylinder, and replace the sealing ring in time if oil leaks.
3. Electrical system maintenance
Controller and motor
Clean the controller heat sink every month to prevent dust accumulation and overheating.
Motor carbon brushes are checked and replaced every 2000 hours to avoid motor damage.
Line protection
Check the aging of the wiring harness insulation layer and the waterproof seal of the connector (especially the charging port).
Regularly test the line insulation resistance (≥1MΩ) with a multimeter.
4. Operation Specifications and Safety
Load control: Load ≤ 80% of rated load, speed limit on slopes to prevent rollover.
Avoid impact operation: sudden acceleration/sudden braking is prohibited, and steering is prohibited during driving (to prevent gear damage).
Gantry operation: lifting/tilting movements are smooth; the gantry needs to be tilted backward when carrying cargo (to prevent cargo from sliding).
5. Professional maintenance cycle table
Daily maintenance:
Daily, battery level, tire pressure, light/alarm test, hydraulic oil level, chain tightness
First-level maintenance: 250 hours, full vehicle fastener inspection, brake pad thickness measurement, hydraulic system leakage detection
Second-level maintenance: 1000 hours, hydraulic oil filter replacement, circuit insulation test, steering system calibration
Annual inspection: 2000 hours, gantry deformation detection, safety device verification, gearbox oil replacement, hydraulic pressure 12–15MPa
6. Safety and record management
Before maintenance: Disconnect the power supply and wear insulating gloves.
Archive Records: Create a maintenance log (date/item/replaced parts) to track the number of battery charging cycles.
Fault Warning: Immediately shut down when the dashboard alarm sounds, common problems such as low voltage (need to stop driving) and abnormal noise (check gears/chains).
