1, Common faults and maintenance of new energy electric forklifts
Electric forklifts are environmentally friendly and energy-saving, and have been increasingly used in the storage field in recent years. However, some faults are inevitable during the use of electric forklifts. Here are some common faults and their maintenance methods:
1. Battery malfunction
(1) Decreased battery capacity: Check if the battery needs to be replaced, and replace aging batteries in a timely manner based on their usage time and cycle times.
(2) The battery cannot be charged: Check if the connection between the charger and the battery is good, and eliminate the connection fault; Check if the charger is working properly. If not, replace the charger.
(3) Battery self discharge: Check if there is any leakage in the battery, and replace it if there is leakage.
2. Motor malfunction
(1) Motor cannot start: Check if the power supply circuit of the motor is normal and eliminate the circuit fault; Check if the motor is overheated. If it is overheated, stop the machine for cooling.
(2) Motor has abnormal noise: Check whether the motor bearings are worn, and replace the bearings if they are worn; Check if there are any foreign objects inside the motor, and clean them if there are any.
(3) Unstable motor speed: Check if the motor power supply voltage is stable. If it is unstable, rule out the power supply fault; Check for poor coil contact in the motor, and repair the wiring if necessary.
3. Control system malfunction
(1) Controller malfunction: Check for circuit short circuits or other issues with the controller. If so, repair or replace the controller.
(2) Malfunction of control lever: Check if the connection of the control lever is good. If the connection is poor, repair it; Check if the control lever is damaged, and replace it if damaged.
(3) Display screen malfunction: Check if the power supply of the display screen is normal. If not, repair the power issue; Check if the display screen is damaged, and replace it if damaged.
4. Driving malfunction
(1) Slow driving speed: It may be due to insufficient motor power, damaged transmission chain between motor and tire, etc. The motor and transmission chain can be inspected and repaired or replaced.
(2) Unstable operation: This may be due to uneven tire pressure, tire damage, or significant differences between the front and rear wheels. You can check and replace the tires.
(3) Abnormal steering: It may be due to damage to the steering gear, insufficient hydraulic oil in the steering system, or insufficient friction between the tires and the ground. The steering gear and hydraulic system can be checked while adjusting the friction between the tires and the ground.
5. Hydraulic system malfunction
(1) Hydraulic oil leakage: It may be caused by aging or damage to the sealing ring, and the corresponding sealing components can be replaced.
(2) Insufficient hydraulic oil: It is necessary to add hydraulic oil in a timely manner and ensure its adequacy.
(3) Hydraulic pump noise is loud: It may be caused by damage or wear of the internal components of the hydraulic pump. The internal components of the hydraulic pump can be replaced.
6. Other faults
(1) Excessive noise: It may be due to uneven tire pressure, loose suspension system, or damaged bearings. Relevant components need to be inspected, repaired, or replaced.
(2) System malfunction alarm: It may be due to circuit failure or loss of sensor signal, and the problem needs to be checked and resolved.
2, What should be noted when repairing electric forklifts
As a common logistics handling equipment, electric forklifts are widely used in warehouses, factories, and logistics centers. If used for a long time or maintained improperly, various faults and problems may occur. When repairing electric forklifts, the following points should be noted:
1. To carry out maintenance operations effectively and reliably, prescribed tools and specialized tools should be used for maintenance. Maintenance tools should be arranged in order, regularly inspected, and used correctly.
2. When it is necessary to lift an electric forklift for maintenance, the vehicle should be parked on a level ground and the front and rear wheels should be in a braking state. Use a jack to hold the support point tightly against the axle and frame, lift the vehicle and perform the maintenance operation.
3. Before carrying out maintenance work, the grounding wire should be removed from the battery to reduce the risk of wire damage and burnout caused by short circuits.
4. Before maintenance, cover the body, seats, and floor with protective covers to prevent damage and contamination.
5. To ensure both correct and smooth reassembly operations, disassembled parts should be neatly grouped and stored. Before inspection and reassembly, the parts should be cleaned, and the rotating and sliding surfaces of the parts must be lubricated with oil or grease.
6. When repairing hydraulic systems and other dust-proof components, please use clean tools in a clean and dust-proof area.
7. Before inspecting or welding electrical system components, make sure to remove the leads from the battery terminals. (First remove the negative pole, then remove the positive pole.)
8. Use a stopper to block the equipment and fork frame during maintenance.
9. Maintenance work should be carried out in a well ventilated room (workshop), and attention should be paid to safe maintenance.
10. After the maintenance work is completed, it is necessary to conduct a final inspection for any missing maintenance items.
