Common failures in electric forklifts

Damage problems in electric forklifts and remedies

Nowadays, society is increasingly demanding on environmental protection issues. Energy-saving, low-noise, and non-polluting electric forklifts are motor vehicles that meet the above needs. The process of using electric forklifts is also inevitable for damage, which, if not corrected in time, will lead to many troubles for businesses. With many years of technical translation. The team of electric forklift maintenance engineers of Samcovina Joint Stock Company has synthesized some common troubleshooting methods of electric forklifts, hoping to solve the problem for everyone.

Currently in the electric forklift segment in Vietnam market, the main electric forklift brands are Toyota, Linde, Hyster, TCM, Komatsu, Hyudai, etc. The electric forklifts of this brand will be equipped with a device display device, when the electric forklift fails, the operator must first check the error code displayed on the display screen on the vehicle (electric forklift has the system checks itself when a fault occurs, the display will show the Cause of the fault usually appears as a code), or check the flashing fault light, then check the vehicle’s manual to find the nearest range true of the error cause. The hydraulic system and the walking system of the electric forklift are two relatively independent and interconnected systems, which control the hydraulic motor and the walking motor, respectively.

The most common errors that are most likely to occur are as follows:
The connection plug of the battery and electric forklift distribution box is loose.

Repair method: Direct repair or replacement

The fuse in the electric forklift’s electrical distribution box has blown.

Repair method: Direct replacement

The battery terminals are loose, poor contact leads to the wrong power.

Repair method: Tighten or replace terminal block

The battery does not store power or does not have enough capacity.

Maintenance method: First check if the charger can work and charge normally, and then evaluate whether the battery itself is damaged.

The gear lever does not reset or operates without response.

Repair method: Replace micro switch or multi-way valve

Weak lifting, emergency stop, pressure relief, lifting in the wrong position.

Repair method: First check whether the hydraulic motor and hydraulic pump are working properly, then check whether the hydraulic oil tank is lacking oil, the hydraulic oil filter is clogged, at the end Also check to see if the oil cylinder is leaking.

Car can’t move

Maintenance method: first check whether the motor for the moving part is working properly, if it is working normally, the transmission must be checked.

Walking motor does not work when powered

Maintenance method: Check whether the walking motor is burnt out, whether the housing is connected, the brushes are worn, and the motor bearings are not stuck.

Motion motor is not powered

Maintenance method: First check the power supply, main contactor, controller, accelerator, reversing contactor, bypass contactor, regenerative contactor, current sensor, motor- module, diode, computer board, etc.

The forklift cannot be started and the display is unresponsive.

Repair method: Check the power supply, key switch and main contactor are energized, then check if the main board is normal, then to the starter board, the monitor plug is broken liquid, etc.

Hydraulic system not working properly

Repair method: First check if the hydraulic motor is working properly, then check the module, module board, main board, multi-way valve, hydraulic gear pump, etc.

Steering system not working properly

Maintenance method: First check whether the steering oil pump is working properly, then check the direction encoder, power steering cylinder, then check the steering main board, fuse, steering switch, direction sensor , steering worm system, rudder ball head and tie rod for loose and falling out, check for damage to triple disc and bearing, steering joint and steering pin, needle roller bearing, face bearing flat, etc. damaged or not, etc.

Besides, there are many other causes of damage in electric forklifts. Above, we only list common cases, the above sharing will hopefully help someone to quickly fix the damage in the electric forklift they are using.

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