Summary of Common Malfunctions of Electric Forklifts (Latest Version in 2025)

1、 Hydraulic system malfunction

1.1 Slow lifting speed/unable to lift

Phenomenon: The fork lifts slowly or cannot lift at all.

reason:

Insufficient hydraulic oil or too thin oil quality.

The oil filter is clogged and the oil circuit is not smooth.

Hydraulic pump wear or aging of seals leading to internal leakage.

Improper pressure adjustment of the multi way valve.

Solution:

Add hydraulic oil to the specified level and replace the excess oil.

Clean or replace the oil filter.

Repair or replace hydraulic pumps and seals.

Adjust the pressure of the multi way valve to the standard value (usually 12-15MPa).

1.2 Fork vibration

Phenomenon: The fork shakes significantly during the lifting process.

reason:

Air enters the lifting cylinder.

Excessive wear of the inner door frame, fork frame rollers, and bearings.

The tension of the two lifting chains is uneven.

Solution:

Remove the air inside the oil cylinder (through the exhaust screw).

Replace worn rollers and bearings.

Adjust the tension of the chain to be uniform (sagging ≤ 20mm).

2、 Electrical system malfunction

2.1 Battery Failure

Phenomenon:

The battery is not fully charged or rapidly depleted.

The forklift suddenly loses its forward/reverse function and has no response when lifting.

Forklifts move at unpredictable speeds with each thrust.

reason:

Battery aging or sulfation.

Abnormal charger voltage or poor circuit contact.

Impurities or local short circuits mixed into the electrolyte.

Solution:

Perform balanced charging on lead-acid batteries and inspect the BMS system for lithium batteries.

Adjust the output voltage of the charger to the standard range and repair the contact points of the circuit.

Replace the electrolyte and eliminate the short circuit fault.

2.2 Controller Failure

Phenomenon: Forklift operation is out of control and the speed is abnormal.

reason:

Internal components of the controller are damaged or the circuit is short circuited.

Micro switch is damaged or has poor contact.

Solution:

Replace damaged controller components or the entire controller.

Repair or replace the micro switch, clean the contact points.

3、 Steering system malfunction

3.1 Heavy steering

Phenomenon: The steering wheel is difficult to turn and the steering is not flexible.

reason:

Insufficient hydraulic oil flow or blocked oil circuit.

The steering cylinder is leaking and the seals are aging.

The steering gear is worn or has excessive clearance.

Solution:

Check the hydraulic system pressure and clean the oil circuit.

Replace the seal of the steering cylinder.

Adjust or replace the steering gear and adjust the side clearance to 0.1-0.2mm.

4、 Brake system malfunction

4.1 Brake Failure

Phenomenon: Stepping on the brake pedal to the bottom has no braking effect.

reason:

Brake circuit open circuit or traction motor controller malfunction.

The brake friction plate is excessively worn and the clearance is too large.

Solution:

Check and repair the brake circuit, replace the controller.

Adjust the brake clearance to the standard value (usually 1-2mm).

4.2 Unilateral braking

Phenomenon: When braking, the vehicle deviates to one side.

reason:

The pressure of the brakes on both sides is uneven or there is a significant difference in the degree of wear of the friction plates.

The brake oil circuit is blocked or leaking.

Solution:

Adjust the brake pressure on both sides to balance.

Clean the brake oil circuit and replace the leaking seals.

5、 Drive system malfunction

5.1 Driving fatigue

Phenomenon: The forklift accelerates slowly and its climbing ability decreases.

reason:

The motor carbon brush is severely worn or the controller is malfunctioning.

Tight chains lead to increased transmission resistance.

Poor lubrication of bearings and excessive frictional resistance.

Solution:

Replace the motor carbon brush, repair or replace the controller.

Adjust the tightness of the chain to an appropriate range.

Supplement bearing grease and replace damaged bearings.

5.2 Wheel hub oil slinging

Phenomenon: Lubricating oil leaks from the hub area.

reason:

The wheel hub seal is aging or damaged.

Excessive bearing clearance leads to oil seal failure.

Solution:

Replace the wheel hub seal.

Adjust the bearing clearance to the standard value and replace the damaged bearing.

6、 Door frame and chain issues

6.1 Unstable lifting of forks

Phenomenon: During the lifting process of the fork, there may be shaking or jamming.

reason:

Insufficient lubrication or deformation of the door frame guide rail.

The severe wear of the roller leads to poor movement.

Solution:

Add lubricating grease to the door frame guide rail and correct the deformed guide rail.

Replace the worn rollers.

6.2 Uneven chain tension

Phenomenon: The tightness of the two lifting chains is inconsistent.

reason:

The elongation of the chain varies after long-term use.

Failure to ensure even tension between the two chains during installation or adjustment.

Solution:

Adjust the tightness of the two chains to be consistent (sag ≤ 20mm).

Regularly check and adjust the chain tension, and replace excessively stretched chains if necessary.

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