Electric forklift maintenance troubleshooting and maintenance methods May 16 , 2022
With the continuous increase of the use time of the electric forklift and the influence of various factors such as the environment and the driver's operation during use, the forklift mechanism and various parts will be naturally loosened or worn to varying degrees, as well as the accumulation of fouling. and mechanical damage. Improper use and maintenance will also cause serious abnormal wear and tear, so that the normal cooperation relationship of electric forklift accessories is destroyed. In addition, deformation of parts, natural corrosion, loosening of fasteners and incorrect adjustment of relevant parts will destroy the original technical state of electric forklift machinery. When the technical state deteriorates to a certain extent, there will be a certain degree of abnormal phenomenon or some spare parts will lose their ability to work, so that the machine cannot continue to work. This phenomenon is called mechanical failure. When the mechanical parts of the electric forklift fail, find out the location and cause of the failure by analyzing, judging and taking necessary methods, and remove it, and quickly restore the intact technical condition, which is called electric forklift maintenance and troubleshooting.
Reasons for abnormal sound of electric forklift and maintenance methods:
1. The screws of the fasteners are loose, the guide wheels and rollers of the car body are severely worn, and the gap is too large.
2. The wear gap between the chain and the pin shaft of the chain piece is too large, or the gap between the upper and lower staples of the fork and the fork beam is too large.
3. Check whether the conflict between the guide wheel, the roller and the gantry is too large. Whether the cooperation gap between the fork and the fork frame beam is too large, these factors will cause abnormal sound when the electric forklift is in use.
4. Check whether the tire screws are loose, whether the bearing is damaged, etc.
5. The forklift gear pump fails, such as air entering the pump from the oil suction pipe or seal, the resistance of the oil suction pipe is too large, or even partially blocked. Gear pump accuracy is not high. The pump and the coupling are not coaxial. The solution is to add lubricating oil to the connection. If the abnormal noise decreases, it means leakage, tighten the joint or directly replace the sealing ring; if there is no change, check the gear accuracy, carry out research and adjustment, and replace the gear if necessary. Finally, check the coaxiality between the pump and the coupling, pay attention to the difference between the working state and the static state, and adjust according to the technical requirements.
There are many reasons for the abnormal sound of the forklift. Forklift maintenance personnel should drive the forklift into the parking lot facility to conduct a special investigation to find the cause. Only in this way can the cause of the abnormal sound of the forklift be solved from the source, and the fault can be solved directly.
Electric forklift working device and hydraulic system failure and maintenance method
1. The main reasons for the vibration during lifting are: there is air in the lifting cylinder, oil leakage in the hydraulic system, large and small rollers of the inner mast fork and
Excessive wear of the gantry bearing, uneven tension of the two lifting chains, etc.
2. The lifting speed is too slow or cannot be lifted. The main reasons are the lack of oil in the fuel tank, the blockage of the oil filter, the failure of the safety valve, the high temperature of the hydraulic oil, the too thin of the hydraulic oil, the oil leakage of the hydraulic pipeline, the damage of the hydraulic pump and so on. The abnormal noise when the gantry is lowered is generally due to damage or aging of the shockproof rubber. The maintenance method is to first check whether there is oil leakage in each joint, each component gasket and the inside of the structure. If there is, replace it; bleed the system, if it still cannot be eliminated, disassemble and inspect the lifting hydraulic cylinder, gear pump and If the working condition of the safety valve fails, repair or replacement is required.
3. Lifting and jumping, the gantry is jumping when lifting. The reason for the failure is that there is air in the lifting hydraulic cylinder; the performance of the gear pump is poor; the reversing valve of the forklift is inflexible; the oil is not clean. The maintenance method is to first loosen the bleed plug on the hoisting hydraulic cylinder to release the air in the hoisting cylinder; check the cleanliness of the oil. If the jumping still cannot be removed, check the working condition of the reversing valve and gear pump, if they are not working well, they should be repaired or replaced.
Other faults and maintenance methods
1. The main reasons for free sliding too fast when there is a load are: oil leakage in pipelines and joints, or serious wear of the valve hole slide valve stem or sealing ring of the multi-way valve.
Internal leakage, hoisting cylinder piston oil seal wear, internal leakage and so on.
2. The front and rear tire screws are loose, the wheel hub bearing is damaged, the rear axle plane bearing and needle roller bearing are damaged, etc., there will be abnormal conditions during driving work.
3. Abnormalities in all parts of the whole vehicle should be eliminated one by one, and after a test drive inspection finds problems, reasonable maintenance and treatment should be carried out to solve the problem.
4. Braking deviation. The reason for this failure is that the braking force of the left and right wheels is unbalanced, which makes the forklift bias to one side when braking. When braking, which side is grabbing forward, it is necessary to check the braking gap or master cylinder condition of which side. The deviation is irregular, suddenly left and right, if the brake is to the left and then to the right, you should check the braking condition of the left wheel first, otherwise, check the right wheel. Finally, there is oil on the brake shoe pads or the brake drum.
5. Oil leakage (including external leakage and internal leakage). The oil leakage of the master cylinder and wheel cylinder is mostly due to the leakage of the leather cup and aprons due to wear and tear due to the excessive use time. If the brake pedal feels very light, it is generally because the master cylinder cup is worn out and oil leaks. Oil leakage; if the brake shoe is too thin or the brake clearance is too large, when the brake pedal is pressed hard, the wheel cylinder cup will turn over and cause oil leakage.
6. Excessive consumption of forklift brake fluid.
1) Check whether there is oil leakage in each pipeline.
2) The brake spool valve cup in the shift control valve of the forklift transmission leaks oil, and the brake fluid enters the transmission. At this time, the smell of the brake fluid can be smelled from the transmission oil quantity inspection hole.
3) The poor sealing of the piston cup, sealing ring or piston push rod sealing ring and control valve cup of the vacuum booster booster cylinder will cause excessive consumption of brake fluid.
7. It is very laborious to step on the brake pedal. Cause of failure: The master cylinder cup or the master cylinder piston seal is swollen. The copper tube between the master cylinder and the supercharger is deformed or flattened, which makes the inner hole smaller and the oil flow is not smooth. The copper tube leading to the wheel cylinder is deformed, resulting in a smaller hole diameter and poor oil flow. The sealing ring of the control cylinder swells, and the brake fluid deteriorates and becomes too viscous to make the fluidity worse.

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