How to determine whether the core components of a forklift need maintenance?

I. Power System: Engine/Battery (Electric Forklifts) - The "Heart" of Forklifts The power system is the core of forklift operation. Its failure can directly lead to the forklift being unable to start or having insufficient power. The following signals need to be closely watched: 1 Abnormal sounds/vibrations of internal combustion forklifts (engines) : A "tap-tap-tap" abnormal sound occurs when starting (possibly due to excessive valve clearance or fuel injector failure). During operation, there is a "knocking sound" (wear between the piston and the cylinder wall, fuel grade mismatch). There is severe vibration at idle (loose engine bracket, unbalanced flywheel). Performance degradation: Weak acceleration, reduced power when climbing slopes (possibly due to clogged air filter, dirty fuel filter element, insufficient fuel pump pressure); The fuel consumption suddenly increased (due to poor atomization of the fuel injectors, carbon deposits on the throttle body, and decreased cylinder sealing performance). Appearance/Liquid abnormality: Oil leakage (aging of the oil pan gasket, poor sealing of the oil dipstick), observe whether there are organic oil stains on the ground; The color of the engine oil is abnormal (normally light yellow/dark brown. If it is black with impurities, emulsified and turned white, it is necessary to check whether water has entered or if it has been excessively worn). Abnormal exhaust color (black smoke: incomplete combustion; blue smoke: oil burning; white smoke: coolant entering the cylinder or low-temperature atomization). 2. electric forklift (battery/motor) battery abnormality: The charging time is significantly prolonged, but the driving range is greatly reduced (battery capacity has declined, and the voltage of a single cell battery is lower than 1.7V and requires maintenance). The battery casing is bulging and leaking (electrolyte leakage may cause a short circuit and the machine needs to be stopped immediately for inspection). The temperature is too high during charging (exceeding 45℃, which may be due to charger failure or sulfation of the battery plates). Motor abnormality: During operation, the motor emits a "buzzing" abnormal sound or strange smell (winding short circuit, bearing wear); The motor housing is overheating (normal operating temperature ≤60℃; if it exceeds, it may be due to excessive load or poor heat dissipation). The forklift has a jerking start (motor carbon brush wear, controller failure).

September 23, 2025