COMMON FAULTS IN STACKER FORKLIFTS

Here are common faults found in stacker forklifts, especially in semi-electric and full-electric models:

🔧 Lifting System Faults

• Cannot lift/lower: Caused by hydraulic oil leakage, weak pump, or damaged control valve.

• Slow or jerky lifting: Dirty oil filter, air in hydraulic cylinder, or damaged seal.

• Lifts then drops down: Faulty load-holding valve or oil leakage in the cylinder.

🔋 Electrical System Faults (Electric Forklifts)

• Controller board error: Due to moisture, short circuit, or software malfunction.

• Motor not working: Faulty motor, contactor, or damaged control circuit.

• Battery drains quickly: Battery degradation, damaged cells, or improper charging.

• Unable to charge battery: Faulty charger, loose charging port, or damaged BMS (Battery Management System).

⚙️ Mechanical Faults

• Jammed wheels or forks: Dirt buildup, worn wheels, or misaligned axle.

• Strange noise during operation: Lack of lubrication or worn bearings.

• Forks bent or misaligned: Caused by overloading or strong impact.

💡 Sensor & Safety Faults

• Incorrect height sensor reading: Dirty, damaged, or misaligned sensor.

• Horn or warning lights not working: Broken wire, faulty switch, or bulb failure.

• Unable to start: Faulty safety switch or incorrect operation position.

📌 Maintenance Recommendations

• Check and replace hydraulic oil every 3-6 months.

• Charge the battery properly, avoid deep discharge.

• Lubricate friction points every 1-2 months.

• Inspect sensors and electronic boards every 6 months.