The break-in period, also known as the running-in period, refers to the initial operating hours of a new forklift. During this phase, internal combustion forklifts exhibit characteristics such as rough machining surfaces, poor lubrication efficiency, accelerated wear, and loosened fasteners. To prevent premature damage and ensure optimal performance, mandatory maintenance must be carried out as per break-in period guidelines.

For internal combustion forklifts, the mandatory maintenance schedule begins after 50 hours of operation, with specific tasks divided into three phases: early-stage, mid-term, and late-stage maintenance.

1. Early-Stage Maintenance (Pre-Use Inspection & Preparation)

Performed before operating the forklift for the first time, this phase ensures that all components are in optimal condition.

• Clean the entire forklift.
• Inspect and tighten all external bolts, nuts, pipe joints, clamps, and safety lock mechanisms.
• Check for oil or coolant leaks.
• Verify fluid levels: engine oil, gear oil, hydraulic oil, and coolant.
• Lubricate all designated lubrication points.
• Check tire pressure and wheel hub bearing tightness.
• Inspect front wheel alignment, steering angle, and steering system connections.
• Check and adjust the free travel of the clutch and brake pedals, as well as the travel of the parking brake lever. Verify braking efficiency.
• Inspect and adjust V-belt tension.
• Check forklift battery: electrolyte level, density, and load voltage.
• Test all instruments, lights, signals, switches, and accessories.
• Verify the stroke of the hydraulic system’s control levers and cylinders.
• Inspect and adjust the tension of the lifting chain.
• Check the mast and fork assembly for proper operation.

2. Mid-Term Maintenance (After 25 Hours of Operation)

• Inspect and tighten cylinder head bolts and intake/exhaust manifold fasteners.
• Check and adjust valve clearance.
• Lubricate all lubrication points.
• Replace the engine oil.
• Inspect hydraulic system components (lift, tilt, and steering cylinders) for leaks and seal integrity.

3. Late-Stage Maintenance (After 50 Hours of Operation)

• Thoroughly clean the forklift.
• Remove the engine speed limiter (for gasoline/diesel models).
• Clean the engine lubrication system, replace the engine oil and filter, and service the ventilation system.
• Flush and replace fluids in the transmission, torque converter, drive axle, steering system, and hydraulic system, and clean all oil filters.