CPD 1-5 ton battery forklift core system fault analysis

5.1 CPD battery counterbalance forklift transmission system CPD battery counterbalance forklift is too loud gear noise when driving Possible causes: First, the gap between the gears is too large; second, excessive wear of gear gears; Third, the oil level in the gearbox is in a low state. Elimination method: For the problem of excessive gear clearance, it can be adjusted; If the gear gear is over-worn, the worn gear needs to be replaced in time; When the transmission fluid level is low, check the oil level and refuel. Obvious noise when changing the driving direction Possible causes: on the one hand, the gear clearance is too large; On the other hand, there is a problem of excessive wear on the gear gear. Elimination method: adjust the gear clearance when it is too large; If the gear gear is over-worn, it needs to be replaced with a new gear.

5.2 Steering system CPD battery counterbalance forklift cannot achieve turning action Possible causes: including auxiliary motor stopping work, oil pump damage or failure, steering gear jamming, hose joint blockage, steering gear failure, etc. Elimination method: When the auxiliary motor is not working, check whether the power wiring is normal, and replace it if necessary; The oil pump is damaged or faulty and needs to be replaced directly; The steering gear should be checked and replaced in severe cases; Hose joints need to be checked and cleaned; If the steering gear fails, it will be checked and updated according to the actual situation. The steering operation is heavy Possible causes: the system pressure is too low; abnormal oil circuit throttle valve; the piston rod of the steering cylinder is bent; the wear of the gear pump is serious; The steering cylinder leaks too much. Elimination method: The steering gear pressure can be adjusted if the system pressure is too low; abnormal oil circuit throttle valve needs to be repaired; the bending piston rod of the steering cylinder should be replaced in time; The gear pump is seriously worn and needs to be replaced with a new gear pump; If the steering cylinder leaks too much oil, replace the seal. Forklift snake-shaped driving phenomenon Possible causes: first, the internal leakage of the steering gear is too large; Second, the ball head is too loose. Elimination method: The internal leakage of the steering gear is too large and needs to be replaced; The ball head is too loose and can be solved by adjustment, and if the adjustment is ineffective, it can be replaced.

5.3 CPD battery counterbalance forklift brake system poor braking effect Possible causes: there is oil leakage problem in the brake system; gas is present inside the pipe; the brake shoe clearance is not adjusted; the brakes overheated; Improper pedal adjustment. Elimination method: Brake system oil leakage needs to be repaired for sealing; The gas in the pipeline should be exhausted; If the brake shoe clearance is not adjusted, it needs to be readjusted; Brake overheating needs to investigate the cause and deal with it properly; If the pedal is not properly adjusted, it will be adjusted. Noise during brake operation Possible causes: The friction surface becomes hard due to the adhesion of impurities; the bottom plate is deformed or the fixing bolts are loose; Brake shoes have deformation problems or improper installation; friction plates are worn; Loose wheel bearings.

Elimination method: The friction surface can be repaired or directly replaced due to impurities; If the bottom plate is deformed or the bolt is loose, the bottom plate needs to be repaired or replaced, and the fastening bolts need to be repaired; Brake shoes should be repaired or reinstalled if they are deformed or improperly installed; if the friction plate is worn, replace it with a new friction plate; Loose wheel bearings need to be repaired and tightened. Poor handbrake function Possible causes: First, the cable length is inconsistent; Second, the handle is not adjusted in place. Elimination method: The cable length is different, and the cable can be adjusted or replaced; If the handle is not adjusted in place, the adjustment operation will be performed.

5.4 No oil or insufficient oil in the hydraulic system Possible causes: there is an air leakage problem at the line or connection; The oil level in the fuel tank is low; Excessive oil impurities leading to clogging of the oil filter; the gear pump is severely worn; The gear pump seal is damaged. Elimination method: air leakage at the line or connection needs to be repaired for sealing; The fuel tank should be checked and refueled when the fuel level is low; The oil filter is clogged and the oil and filter need to be replaced. The gear pump is seriously worn and should be replaced; If the gear pump seal ring is damaged, it should be inspected and replaced with a new seal. Weak lifting or inability to lift Possible causes: Severe wear of the gear pump; insufficient system pressure; Excessive wear of multi-way valves and stems; there is leakage in the lifting cylinder; The safety valve does not return to its position. Elimination method: The gear pump is seriously worn and needs to be replaced; The pressure of the safety valve can be adjusted when the system pressure is insufficient; The multi-way valve and valve stem are too worn and need to be replaced or installed with a new valve stem. The leakage of the lifting cylinder needs to replace the sealing ring; The safety valve does not return to its position and needs to be overhauled.

5.5 Electrical system No voltage when turning on the key switch Possible causes: Poor contact with the key switch; the line is disconnected; poor joint contact; Loose battery connectors. Elimination method: The key switch needs to be replaced if it is in poor contact; the line should be reconnected if it is disconnected; Poor contact of the joint needs to be replaced or repaired; If the battery connector is loose, tighten the connecting bolt. Stepping on the forklift accelerator pedal The vehicle does not drive Possible causes: the line is disconnected; poor joint contact; the directional switch is faulty; Drive components fail. Elimination method: the line is disconnected and reconnected; Replacement or repair of the joint with poor contact; Directional switch failure needs to be replaced or repaired; Failure of drive components should be checked or replaced. The motor does not run at high speed during lifting Possible causes: the contactor coil is broken or disconnected; the lifting switch is not working properly; the line is disconnected; poor joint contact; The main contacts of the contactor are burned out. Troubleshooting method: contactor coil problems need to replace contacts; If the lifting switch is not working properly, it should be maintained or replaced; the line is disconnected and reconnected; Replacement or repair of poor contact joints; If the contactor main contact is burned out, the main contact is replaced. Auxiliary motor running at high speed for a long time Possible cause: The lift switch is not working properly. Elimination method: repair the lifting switch. Lights not working properly Possible causes: blown fuse; poor joint contact; Bulb damage. Elimination method: Replace the fuse in time if it is blown out; Replacement or repair of the joint with poor contact; If the bulb is damaged, replace it with a new one. 

The horn does not sound
Possible causes: poor joint contact; Poor contact between horn switches; Damaged horns.
Elimination method: replacement or repair of poor contact of the joint; Speaker switch is repaired for poor contact; If the horn is damaged, it will be replaced.The horn kept ringingPossible cause: Horn switch contacts sticking.Troubleshooting: Repair the horn switch