The starting of a diesel forklift is achieved by connecting the power supply to the starter with a key switch, and the starter rotates to drive the engine. The common reasons for forklift startup failures are as follows.

I. Starting motor idling

When starting a forklift, there is only a sound of the starting motor idling, and the engine does not rotate or cannot be started. This type of fault is usually checked in the following aspects:

Check if the magnetic switch of the starting motor is damaged.

Troubleshooting method: Repair or replace the starter magnetic switch.

Check if the one-way engagement mechanism of the forklift starting motor is slipping.

Troubleshooting method: Repair or replace the starter fork.

Troubleshooting method: Repair or replace the one-way meshing device of the starting motor.

Check if the forklift inside the starting motor is loose or worn.

Troubleshooting method: Replace or repair the fork inside the starter motor.

Check: The shock absorber spring of the starter is damaged.

Troubleshooting method: Replace the shock absorber spring of the starting motor.

II. Insufficient starter power for electric forklifts

When starting a forklift, both the starting motor and engine rotate, but the starting machine runs slowly and weakly, making it unable to start. This type of malfunction is usually checked in the following aspects:

Check if the voltage of the battery is sufficient

Troubleshooting method: Charge or replace the forklift battery with a new one.

Check if the starting motor has sufficient battery capacity, whether the cable is heating up, and whether the copper heads on both sides of the cable are loose.

Troubleshooting method: Tighten the copper heads on both sides of the cable and replace the cable with a thicker cross-section.

Check whether the internal bearings of the starting motor are worn or too loose, and whether there is any friction between the rotor and stator.

Troubleshooting method: Replace the bearings of the starting motor and add lubricating grease.

Check whether the carbon brush of the starting motor is worn too much, and whether the copper head surface of the rotor is burned or dirty.

Troubleshooting method: Replace the carbon brush of the starting motor and clean the copper head of the processed rotor.

III. Abnormal startup sound

When the forklift starts, it hears a scream of friction between the rotating iron and the iron, but the engine does not turn. This type of malfunction is usually checked in the following aspects:

Check for wear or single tooth damage on the gear of the forklift starting motor.

Troubleshooting method: Repair the one-way gear of the forklift starting motor or replace it with a new gear.

Check for wear or single tooth damage on the flywheel ring gear of the engine motor.

Troubleshooting method: Replace the flywheel ring gear of the engine motor.

Check whether the bearings and copper heads of the starting motor are worn or loose, and whether there is friction between the rotor and stator.

Troubleshooting method: Repair the starting motor and replace the bearing or copper head.

Inspection: After the forklift is started, the starting motor gear and engine flywheel gear are not loosened, the starting motor gear cannot return to its original position, the gear surface is rough and meshing is too tight, the driving device is stuck on the starting motor armature shaft, and the electromagnetic switch contacts are sintered.

Troubleshooting method: Repair the forklift starter motor, replace the return spring of the starter motor, replace the gears, and replace the contacts.

IV. No response during startup

There is no response from the forklift starter when twisting the forklift key. This type of malfunction is usually checked in the following aspects:

Check if the starting battery of the forklift has voltage and if the battery pile head is loose.

Troubleshooting method: Charge or replace the battery with a new one, and screw the battery cable pile firmly.

Check for poor contact or open circuit in the forklift circuit and key thinking switch.