Troubleshooting WARNING Visual Checks If an electrical failure or an overload of the motor is present, personnel must not breathe the toxic fumes which are a product of the burnt insulation. All power must be disconnected from the motor before any inspection is made to find the failure. The area around the motor must be well ventilated (air flow) and the motor is to be cooled before any repair work is done. Water must not be used on any electric equipment because of the danger of electrical shock. If fire is present, disconnect the electrical power and use a carbon dioxide extinguisher to put the flame out. Make a visual inspection of the truck to check for problems.
Operate the truck in each direction. Make a note of the noises that are not normal and find their source. If the operation is not correct, make reference to the Check List During Operation for TProblemsУ and TProbable CausesУ. Checks During Operation Do not operate the drive motors without a load, as too much speed may cause damage to the motor and injury to personnel. Drive Motor Before an analysis is made of any electric drive motor problem, always make reference to the Troubleshooting section of the MicroController System Operation module. Problem 1: Drive Motor Will Not Operate. WARNING Probable Cause: 1.
Switch not closed (battery connector, key switch, seat switch, direction switch or parking brake switch): Close the switch. If it still does not operate, test for power to the control panel and power flow through each switch with a voltmeter. The lift truck can move suddenly. Battery voltage and high amperage are present. Injury to personnel or damage to the lift truck is possible. Safely lift both drive wheels off the floor. Put wood blocks or jack stands of the correct capacity under the frame so the drive wheels are free to turn. During any test or operation check, keep away from the drive wheels.
The head capacitor (HEAD CAP) will have to be discharged before any contact with the control panel is made. Disconnect the battery and discharge the HEAD CAP. Rings, watches and other metallic objects should be removed from hands and arms when troubleshooting the MicroController control system. 2. Bad connection. Fuse bad: Check battery connections. Check connections at battery connector. Check fuses, drive and logics. Replace fuse if bad. Check the Drive motor and control panel for possible reasons for a bad fuse. Some causes are: a. Operate during too heavy transistor load, too high current limit (C/L). b. Operate in stall conditions. c.
Possible short circuit in drive motor, see Probable Causes 5, 6 and 7. To prevent personal injury, never use air pressure that is more than 205 kPa (30 psi), and wear protective clothing and a face shield. 3. Low battery voltage: Check battery terminal voltage. If too low, charge the battery. Check all the cells for one or more that have defects. Check the specific gravity of each cell. The maximum density difference from the highest to the lowest cell must not be more than. 020 SG (specific gravity). NOTICE To prevent damage to electrical components, make sure the air line is equipped with a water filter when they are cleaned with air. Power Train Testing And Adjusting 9