Here are some common problems and maintenance methods for electric forklifts:
Battery Problems
The battery cannot be charged.
Reasons: Charger failure, loose or damaged battery connection cables, battery aging, poor contact of the charging socket.
Maintenance methods: Check whether the charger is working properly, and you can replace the charger for testing; check the battery connection cables to ensure they are firmly connected, and replace them if they are damaged; if the battery is aging, consider replacing it with a new one; clean the charging socket to ensure good contact.
The battery's endurance capacity decreases.
Reasons: The battery has not been deeply charged and discharged for a long time, the battery plates are sulfated, the operating environment temperature is too low, and the load is too large.
Maintenance methods: Perform several deep charging and discharging operations on the battery to activate the battery plates; use desulfurization equipment to repair the battery; use the forklift in a suitable environmental temperature and avoid operating at too low a temperature; arrange the load reasonably to avoid overloading.
Motor Problems
The motor does not rotate.
Reasons: Short circuit or open circuit of the motor winding, controller failure, blown fuse, loose motor connection cables.
Maintenance methods: Use a multimeter to check the motor winding. If there is a short circuit or open circuit, repair or replace the motor; check whether there are fault codes in the controller. If so, repair or replace the controller according to the instruction manual; replace the blown fuse; tighten the motor connection cables.
The motor has insufficient power.
Reasons: Wear of the motor bearings, the motor rotor rubbing against the stator, too low power supply voltage, improper parameter setting of the controller.
Maintenance methods: Replace the worn motor bearings; check the clearance between the motor rotor and the stator. If there is a rubbing phenomenon, repair or replace the relevant components; check the power supply voltage to ensure that it is stable within the specified range; reset the controller parameters and adjust them to appropriate values.
Hydraulic System Problems
The lifting speed is slow.
Reasons: Insufficient hydraulic oil, oil pump failure, too low setting pressure of the safety valve, blocked oil pipe.
Maintenance methods: Check the hydraulic oil level and add hydraulic oil if it is insufficient; check whether the oil pump is working properly and replace it if there is a fault; adjust the pressure of the safety valve to make it reach the specified value; clean the blocked oil pipe.
There is a stutter when the fork descends.
Reasons: Air in the hydraulic cylinder, wear of the fork guide wheels, contamination of the hydraulic oil.
Maintenance methods: Perform an air exhaust operation on the hydraulic cylinder to expel the internal air; check the fork guide wheels and replace them if they are severely worn; replace the contaminated hydraulic oil and clean the hydraulic system filter.
Brake System Problems
The brakes fail.
Reasons: Severe wear of the brake pads, brake fluid leakage, blocked brake pipeline, excessive travel of the brake pedal.
Maintenance methods: Replace the worn brake pads; check the brake fluid level and pipeline. If there is a leakage, repair the leakage point and add brake fluid; clean the blocked brake pipeline; adjust the travel of the brake pedal to make it meet the specified requirements.
The brakes pull to one side.
Reasons: Uneven wear of the brake pads on the left and right sides, inaccurate wheel alignment, failure of the brake cylinder.
Maintenance methods: Replace the unevenly worn brake pads to make the wear degree of the brake pads on both sides consistent; check and adjust the wheel alignment parameters; check the brake cylinder and repair or replace it if there is a fault.
Electrical System Problems
The lights do not turn on.
Reasons: Damaged light bulbs, blown fuses, failure of the light switch, open circuit of the wiring.
Maintenance methods: Replace the damaged light bulbs; check and replace the blown fuses; check the light switch and replace it if there is a fault; use a multimeter to check the wiring and repair the open circuit.
The horn does not sound.
Reasons: Fault of the horn itself, damage to the horn button, failure of the relay, poor contact of the wiring.
Maintenance methods: Replace the horn; check the horn button and replace it if it is damaged; check the relay and replace it if there is a fault; check the wiring to ensure that all connection points are in good contact.
