Forklifts play an important role in the daily operations of businesses. The continuous and efficient operation of these valuable equipments is critical for uninterrupted workflow. The engine is like the heart of a forklift and naturally undergoes wear and tear over time. Regular maintenance and timely overhaul of the forklift engine are important to extend the life of the vehicle and reduce operational costs.
In this blog post, we will discuss when and why a forklift engine overhaul is necessary, the details of the overhaul process, and ERA Forklift’s expertise and solutions in this area.
How is a Forklift Engine Overhauled?
Engine Removal
Before starting the overhaul process, the forklift engine is removed from the vehicle. This is necessary for a more detailed examination and repair of the engine.
Cleaning and Inspection
Once the engine is removed, all parts are cleaned. This cleaning process removes dirt, oil, and other deposits from the internal and external surfaces of the engine. Then, all parts of the engine are examined in detail. During this examination, worn, damaged, or parts that need to be replaced are identified.
Part Replacement or Repair
Damaged or worn parts identified during the inspection are replaced with new or refurbished parts. This may include internal engine components like pistons, rings, valves, bearings, and gaskets.
Reassembly
After all parts are repaired or replaced, the engine is reassembled. During this stage, it is ensured that all parts are correctly placed and tightened with appropriate torque values.
Testing and Adjustment
After the engine is reassembled, various tests are conducted to check its performance and functionality. During these tests, the engine’s settings are adjusted to ensure it operates efficiently.
Installation and Final Checks
After all tests and adjustments, the engine is reinstalled in the forklift. Once the engine is mounted, final tests are conducted to check the overall performance of the forklift.
Since each forklift model and engine type can vary, these general steps can be adapted for a specific model or engine type. Moreover, due to the complexity of the overhaul process, these types of operations are usually carried out by experienced technicians or service centers.
When is a Diesel Forklift Engine Overhaul Necessary?
Long Usage Time
Natural wear and tear occur due to prolonged use of the engine. After a certain operating time, the engine may need an overhaul.
Irregular Performance or Power Loss
Reduction in engine power, irregular operation, or unexpected stops are signs that the engine may be worn out to the point where it requires an overhaul.
Excessive Oil Consumption or Leakage
Excessive oil consumption or oil leaks indicate that the internal parts may be worn and need replacement.
Abnormal Sounds
Strange noises (metallic sounds, squeaks, etc.) while the engine is running can indicate the presence of worn or damaged parts.
Decreased Fuel Efficiency
A decrease in the engine’s fuel efficiency can also be a sign of wear or adjustment issues.
Increased Smoke Emissions
Excessive smoke from the exhaust, especially if it is black or blue, indicates problems with combustion inside the engine.
Periodic Maintenance Schedule
In some forklifts, engine overhaul is recommended as part of the periodic maintenance schedule set by the manufacturer. This is a preventive measure to extend the life of the engine and prevent major breakdowns.
Post-Accident or Damage
If the forklift has been in an accident or there has been significant damage to the engine area, it is important to assess the condition of the engine and overhaul it if necessary.
The need for forklift engine overhaul, especially under heavy operating conditions, may arise more frequently. Therefore, the intensity of use and working environment of the forklift are also factors that influence the necessity for overhaul.
ERA Forklift’s Expertise in Diesel Engine Overhaul
At ERA Forklift, we offer expert services for the overhaul of diesel forklift engines of all brands, including Hyster, Linde, Toyota, Asimato, Heli, and others. Contact us to ensure your forklifts operate longer, more reliably, and more efficiently. Our professional service team will assess the condition of your forklift engines and provide customized solutions.
Contact Us
ERA Forklift serves as an authorized service and dealer for Hyster (TSM Global) on the European side of Istanbul.
Contact us for more information about our authorized Hyster forklift services:
If you are looking for a quality, fast, and reliable service for the overhaul of your diesel forklift engines, ERA Forklift is always at your side.