Flowchart for Judging "Self-Inspection / Professional Handling" of Electric Forklift Faults

(Core Logic: Safety First → Basic Screening → Classified Judgment, Avoiding Risks of Unauthorized Operation)

Step 1: After a Fault Occurs, First Perform "Pre-Safety Operations" (Mandatory)

1. Immediately park the forklift in a flat, obstacle-free, and pedestrian-free area.
2. Pull the parking brake tightly; if there is cargo, unload it stably first.
3. For electrical faults (e.g., smoke, alarms), additionally turn off the main battery switch.
4. Confirm personal safety (no risk of oil leakage or electric leakage) before starting the judgment.

Step 2: Proceed to "Basic Self-Inspection" Judgment (Screen Step-by-Step According to the Following Branches)

Branch 1: Can the Fault Cause Be Located Through "Visual Inspection"?

• Judgment Criterion: The cause can be identified only by observing / checking external conditions, without disassembling any components.▶ Yes (Examples: Instrument shows "battery red zone" → battery dead; hydraulic oil below the scale line → insufficient oil level; charging plug not disconnected → failure to start)→ Execute "Self-Inspection Handling": Perform basic operations such as charging, refilling hydraulic oil, and reconnecting the plug. After operation, test whether the fault is eliminated.▶ No (Examples: Forklift fails to start but the instrument shows no abnormality; fork lifting jams and no external cause is found)→ Proceed to "Branch 2".

Branch 2: Can Normal Operation Be Restored Through "Restart / Simple Reset"?

• Judgment Criterion: Restoration can be attempted only through "restarting the power supply" or "no-load operation reset", without using tools.▶ Yes (Examples: Jamming during driving → returns to normal after turning off the power and restarting; tilting jams → returns to normal after repeatedly pulling the tilting handle under no-load to release air)→ Execute "Self-Inspection Handling": After restoration, test 3 times (driving, lifting, braking). If no abnormality is confirmed, continue using (record the fault time).▶ No (Examples: Still fails to start after restart; fault recurs after reset)→ Proceed to "Branch 3".

Branch 3: Is It "Obvious Damage to External Wearable Parts" (Only Need to Judge the Position, Do Not ｒｅｐｌａｃｅ by Yourself)?

• Judgment Criterion: The damaged part is visible to the naked eye, and no disassembly of the internal structure is required.▶ Yes (Examples: Tire punctured with an obvious hole; anti-slip pad on the fork falls off; loose horn wire)→ Execute "Self-Inspection Recording": Only mark the position of the damaged part and inform maintenance personnel (do not ｒｅｐｌａｃｅ the tire / connect wires by yourself).▶ No (Examples: Internal abnormal noise, oil cylinder leakage, no response from the brake pedal)→ Directly proceed to "Step 3: Professional Handling Judgment".

Step 3: "Professional Handling" Judgment (If Any Condition Is Met, Immediately Stop Self-Inspection and Contact Maintenance Personnel)

Scenario 1: Fault Involving "Core Safety Components"?

• Includes: Brake failure (no resistance when stepping on the pedal / parking brake cannot hold), stuck / deviated steering (ineffective after adjusting tire pressure), sudden loss of control during driving (failure of acceleration / deceleration).
• Conclusion: Immediately prohibit operation, hang the "Fault Out of Service" sign, and contact professional personnel.

Scenario 2: Fault Involving "Complex Electrical Components"?

• Includes: Motor smoking / abnormal noise, controller displaying fault codes (e.g., E01/E02), burnt smell from battery terminals, smell of burnt wires.
• Conclusion: Turn off the main battery switch, stay away from the forklift, and contact professional personnel (do not touch high-voltage components).

Scenario 3: Fault Involving "Hydraulic System Sealing / Pressure"?

• Includes: Oil leakage / dripping at the oil cylinder joint (not low oil level), slow fork lifting (still ineffective after refilling oil), failure of the tilting oil cylinder to reset.
• Conclusion: Prohibit operating the hydraulic handle to prevent hydraulic oil splashing, and contact professional personnel.

Scenario 4: Fault Is "Recurring" or "Cause Unidentifiable"?

• Includes: The same fault occurs ≥2 times a day (e.g., automatic shutdown after startup), vague fault symptoms (e.g., abnormal noise but unlocatable position).
• Conclusion: Record fault details (time, symptoms), stop using the forklift, and contact professional personnel to conduct inspection with diagnostic equipment.

Notes

1. Self-inspection handling is only applicable to basic faults with "no safety risks and no disassembly operations"; faults beyond this scope shall all be classified as professional handling.
2. After handling any fault, it is necessary to record the "fault phenomenon, handling method, and result" to facilitate subsequent prevention.