Common faults of forklifts can be summarized into the following core categories and handling directions. By combining fault symptoms with maintenance strategies, equipment lifespan can be effectively extended:

1. Engine system malfunction

Difficulty in starting

Low-temperature startup issues: In winter, engine oil viscosity increases, battery capacity decreases, and diesel atomization is poor. It is necessary to preheat the diesel, check the cylinder tightness, and compression pressure.

Oil circuit fault: The oil tank is empty, the filter is clogged, the oil pipe is leaking, or the connector is loose. It is necessary to clean the oil circuit and remove the air.

Circuit fault: Battery power shortage, poor line contact, starter motor damage. It is necessary to check the battery status and line connections.

Insufficient power

Intake system: The air filter is clogged, leading to insufficient air intake. It needs to be cleaned or the filter element needs to be replaced.

Fuel system: The injector needle valve has poor sealing and the injection pressure is too low. It is necessary to adjust the injection timing or replace the injector.

Abnormal exhaust: emitting black smoke (indicating poor air intake or incomplete fuel combustion), emitting blue smoke (indicating engine oil burning), emitting white smoke (indicating water in the diesel or a leaking cylinder head), requiring targeted troubleshooting.

II. Hydraulic system failure

Problem with the lifting mechanism

The tilt of the gantry is not synchronized: the travel of the tilt cylinder is inconsistent or the throttle holes in the oil pipes are of different sizes. It is necessary to adjust the cylinder travel or replace the connector.

Failure to lift with no load: The overflow hole of the multi-way valve is blocked, and debris needs to be cleared.

Fork automatic lowering: insufficient hydraulic oil in the cylinder or sealing failure of the multi-way valve. It is necessary to repair the multi-way valve and add hydraulic oil.

Hydraulic oil leakage

Seal aging: The seals at the joints of the oil cylinder and pipeline are worn, and it is necessary to replace the seals and tighten the joints.

Hydraulic pump failure: The pump body is worn or the bearing is damaged, requiring maintenance or replacement of the hydraulic pump.

III. Electrical system malfunction

Startup and charging issues

Battery failure: Battery aging and excessive charging and discharging cycles lead to shortened lifespan. Regularly check the battery voltage and replace the aged battery.

Circuit fault: Loose wiring, poor contact, or aged wiring. It is necessary to reconnect the wiring and replace the aged wiring harness.

Lighting and signal malfunction

Bulb damage: Headlights, turn signals, and other bulbs are burned out and need to be replaced.

Switch fault: The light control switch or horn switch is damaged and requires replacement of the switch assembly.

IV. Braking system failure

brake failure

The clearance between the brake drum and the brake shoe is too large: it needs to be adjusted to the standard value (usually not less than 0.25cm).

Failure of the brake master cylinder: The inlet and outlet valves are damaged or there is brake fluid leakage. It is necessary to repair the master cylinder and replace the seals.

Friction plate wear: The brake shoe is insufficiently thick or unevenly worn. It is necessary to replace the friction plate and adjust the brake.

The hand brake is malfunctioning

Wire slack: The stretching of the hand brake wire has resulted in a decrease in braking force, and the tightness of the wire needs to be adjusted.

V. Steering system fault

The steering is not flexible

Steering shaft issues: If the steering shaft makes abnormal noises, is misaligned, or is loose, it is necessary to inspect the steering shaft connections and tighten the bolts.

Steering gear failure: gear wear or bearing damage, requiring replacement of the gear or bearing assembly.

Heavy steering

Hydraulic power assist failure: The steering power assist pump is damaged or the oil circuit is blocked. It is necessary to repair the power assist pump and clean the oil circuit.

VI. Transmission system failure

Clutch slipping

Oil contamination on friction plate: Oil contamination on the friction plate reduces the friction force. It is necessary to clean the friction plate and inspect the oil seal.

Failure of the release bearing: The free travel of the release bearing is too large or it is pressed against the release lever. It is necessary to adjust the length of the push rod or replace the bearing.

Abnormal noise from the gearbox

Gear wear: The gears or bearings inside the gearbox are damaged, requiring replacement of the worn parts and removal of debris.

Air in oil circuit: Air has entered the transmission system's oil circuit. It is necessary to remove the air and inspect the oil seal.

VII. Cooling system failure

Engine at high temperature

Water pump damage: The water pump bearing is worn or the seal is not tight. It is necessary to replace the water pump and check the coolant circulation.

Scale buildup in the water tank: The radiator of the water tank is blocked, leading to a decrease in cooling efficiency. It is necessary to clean the water tank and replace the coolant.

Thermostat failure: The thermostat is stuck, causing poor circulation of the coolant. It is necessary to replace the thermostat and check the fan belt.

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