The common faults of diesel forklifts are concentrated in three categories: starting, power, and braking/steering. Prioritize checking the basic systems of fuel, circuit, and hydraulics, and most faults can be solved quickly.
I. Difficult Starting (Most Common)
Core Causes: Poor fuel supply, dead battery, and faulty preheating system.Solutions:- Check the fuel quantity and ensure there is no blockage or air leakage in the fuel line (focus on the filter element and fuel pipe joints).
- Measure the battery voltage (normal voltage ≥ 12V). Recharge or ｒｅｐｌａｃｅ the battery if it is dead, and clean the battery terminals.
- When starting a cold engine, confirm that the glow plugs work normally (they should feel hot after being powered on) and ｒｅｐｌａｃｅ them if damaged.
II. Insufficient Power (Weak Driving/Lifting)
Core Causes: Blocked fuel line, excessive engine load, and abnormal air intake system.Solutions:- ｒｅｐｌａｃｅ the fuel filter element and air filter element, and clean the carbon deposits on the fuel injectors.
- Check if the lifting system is overloaded and if the forks are stuck. Reduce the load and lubricate the guide rails.
- Check if the turbocharger (if equipped) has air leakage and if the air intake pipe is damaged.
III. Abnormal Braking/Steering
Core Causes: Insufficient hydraulic oil, worn braking components, and stuck steering mechanism.Solutions:- Replenish the brake fluid/steering hydraulic oil, check for leaks in the pipeline, and ｒｅｐｌａｃｅ the aged sealing rings.
- If the braking force is weak, check the thickness of the brake pads (ｒｅｐｌａｃｅ if less than 3mm) and adjust the brake clearance.
- If the steering is heavy, lubricate the steering knuckles and tie rods, and check if the steering pump pressure is normal.
