When the forklift cannot start or works abnormally, a systematic investigation should be carried out based on specific symptoms (such as engine failure, hydraulic system failure, electrical faults, etc.). The following are solutions for different types of faults:

1、 The engine cannot start

1. Insufficient starting speed

reason:

Insufficient battery power or loose wiring.

Fuel pipeline air resistance or filter blockage.

The high viscosity of winter engine oil leads to increased resistance.

Solution:

Check the battery voltage and charge or replace it if necessary; Tighten the wiring terminals.

Clean the fuel filter and exhaust the air in the pipeline.

Replace the low-temperature suitable engine oil (such as 10W-30).

2. Fuel supply system malfunction

reason:

The fuel tank is empty, the fuel transfer pump is malfunctioning, or the fuel injection pump plunger is worn.

Water or air in diesel enters the fuel circuit.

Solution:

Add fuel and check the pressure of the fuel transfer pump.

Drain the accumulated water at the bottom of the fuel tank and loosen the air release screw of the fuel injection pump to release air.

Replace the worn fuel injection pump plunger or nozzle.

3. Insufficient compression pressure

reason:

Loose cylinder head bolts and damaged cylinder gasket.

The wear of the piston ring and cylinder wall leads to air leakage.

Solution:

Re tighten the cylinder head bolts and replace the cylinder gasket.

Check the cylinder pressure and replace the piston ring or boring cylinder if necessary.

2、 Hydraulic system failure

1. The gantry cannot be lifted or tilted

reason:

Insufficient hydraulic oil or oil contamination.

Multi way valve overflow valve blockage or hydraulic pump malfunction.

Solution:

Add hydraulic oil to the mark and replace the contaminated oil.

Clean the multi way valve overflow valve and check the hydraulic pump pressure (normally 15-20MPa).

2. Forks automatically descend

reason:

Aging of oil cylinder seals or hydraulic oil leakage.

The pressure drop is caused by the leakage inside the multi way valve.

Solution:

Replace the oil cylinder seal and check if the oil pipe joint is loose.

Repair the multi way valve and replace the worn valve core.

3、 Electrical system malfunction

1. Electric forklift cannot start

reason:

Insufficient battery power or wiring malfunction.

The controller or motor is damaged.

Solution:

Use a multimeter to check the battery voltage (normally ≥ 24V), charge or replace the battery.

Check the input and output signals of the controller, replace the faulty motor or contactor.

2. Abnormal lighting and signal

reason:

The light bulb is burnt out or the circuit is short circuited.

Poor switch contact.

Solution:

Replace the light bulb and check if the insulation layer of the circuit is damaged.

Clean the switch contacts and replace the switch assembly if necessary.

4、 Steering and braking system malfunction

1. Heavy or malfunctioning steering

reason:

Internal leakage of steering cylinder or malfunction of steering pump.

Worn steering knuckles or insufficient tire pressure.

Solution:

Check the sealing of the steering cylinder and replace the worn pump body.

Adjust the clearance between the steering knuckles and replenish the tire pressure to the standard value.

2. Brake failure or dragging

reason:

The return oil hole of the brake master cylinder is blocked or the brake shoes are worn.

There is air or brake fluid leakage in the brake pipeline.

Solution:

Clean the return oil hole of the brake master cylinder and replace the worn brake shoes.

Drain the air from the brake pipeline and check the brake fluid level.

5、 Other common faults

1. Engine overheating

reason:

Insufficient coolant or clogged radiator.

Fan belt breakage or water pump malfunction.

Solution:

Add coolant and clean the dust on the surface of the radiator.

Replace the fan belt or water pump assembly.

2. Abnormal smoke emission from the exhaust pipe

reason:

White smoke: There is water in the diesel or the cylinder gasket is damaged.

Black smoke: Poor atomization of the fuel injector or insufficient intake.

Blue smoke: Engine oil entering the combustion chamber (such as worn valve guides).

Solution:

Drain the accumulated water in the fuel tank and replace the cylinder gasket.

Clean or replace the fuel injector, and check the air filter.

Replace the valve guide seal ring and check for oil leakage in the turbocharger.

6、 Suggestions for troubleshooting process

Observation phenomenon: Record the environment (such as temperature, load), sound, odor, etc. at the time of the fault occurrence.

Preliminary inspection: Check vulnerable parts such as batteries, oil, lights, etc.

System testing: Use tools such as pressure gauges and multimeters to test hydraulic/electrical system parameters.

Component replacement: Conduct replacement testing on suspected faulty components (such as fuel injectors and motors).

Professional maintenance: If unable to solve the problem on your own, contact the manufacturer or professional maintenance personnel.

The main equipment produced by Hebei Makita: stage electric hoist, electric chian hoist, wire rope electric hoist，Hand chain hoist, lever hoist, pneumatic hoist and other lifting equipment