The sudden interruption of hydraulic forklift operation during use may be caused by hydraulic system failure, electrical system failure, mechanical component failure, improper operation, or environmental factors. The specific reasons and analysis are as follows:

1、 Hydraulic system malfunction

Hydraulic oil problem:

Insufficient hydraulic oil: Hydraulic oil is the power source for the operation of hydraulic forklifts. If the oil level is insufficient, it will cause insufficient system pressure and prevent the forklift from operating normally.

Hydraulic oil contamination: Impurities, moisture, or air mixed into hydraulic oil can reduce its performance, leading to unstable system pressure or component damage. For example, impurities may block the throttle hole, increase the resistance of the slide valve, and slow the response of the mechanism.

Excessive hydraulic oil temperature: Excessive hydraulic oil temperature can lead to a decrease in oil viscosity, reduced lubrication performance, accelerated component wear, and even system failure. Excessive oil temperature may be caused by insufficient oil quantity, poor oil quality, oil pump intake, or internal system leaks.

Hydraulic pump malfunction:

Wear and tear of hydraulic pump: The hydraulic pump is the core component of the hydraulic system. If it is severely worn, it can lead to insufficient pressure or inability to generate pressure, making the forklift unable to operate normally.

Hydraulic pump intake: Hydraulic pump intake can cause unstable system pressure and even cause forklift stalling. The intake may be caused by aging seals, ruptured oil pipes, or internal leaks in the oil pump.

Hydraulic valve malfunction:

Overflow valve malfunction: The overflow valve is used to control the maximum pressure of the hydraulic system. If the malfunction occurs, it may cause the system pressure to be too high or too low, affecting the normal operation of the forklift.

Fault in directional valve: The directional valve is used to control the flow of hydraulic oil. If the fault occurs, it may cause the forklift to operate abnormally or fail to operate.

Hydraulic cylinder malfunction:

Internal leakage of hydraulic cylinder: Internal leakage of hydraulic cylinder can cause a decrease in system pressure, resulting in slow or ineffective forklift operation. Leakage may be caused by aging seals, scratches on piston rods, or wear on cylinder barrels.

Inconsistent stroke of hydraulic cylinder: If the stroke of two tilting cylinders is inconsistent, it may cause the gantry to tilt out of sync, affecting the stability of the forklift.

2、 Electrical system malfunction

Power issue:

Insufficient battery power: Insufficient battery power can cause the forklift to fail to start or experience sudden interruptions during operation.

Poor contact of power switch: Poor contact of power switch may cause interruption of forklift circuit and prevent normal operation.

Electrical component malfunction:

Fuse blowing: Fuses are used to protect circuits, and if blown, they may cause interruptions in the forklift circuit.

Contactor failure: The contactor is used to control the on/off of the circuit. If the fault occurs, it may cause the forklift to fail to start or suddenly interrupt during operation.

3、 Mechanical component failure

Transmission component malfunction:

Clutch slippage: Clutch slippage may cause interruption of forklift power transmission and prevent normal operation.

Gearbox malfunction: Worn gears or damaged bearings inside the gearbox may cause abnormal or interrupted forklift operation.

Brake component malfunction:

Brake stuck: Brake stuck may cause the forklift to malfunction or stop.

Brake fluid leakage: Brake fluid leakage can cause brake system failure and affect forklift safety.

4、 Improper operation or environmental factors

Improper operation:

Overloading operation: Overloading operation can cause forklift components to bear excessive loads, accelerate wear or damage.

Sudden braking or sharp turning: Sudden braking or sharp turning may cause excessive force on forklift components, leading to malfunctions.

Environmental factors:

High temperature environment: High temperature environment can cause hydraulic oil temperature to rise, performance to decline, and lead to system failures.

Damp environment: A damp environment may cause electrical components to become damp and short-circuit, leading to circuit failures.

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