4. Control panel operation not correct: See the MicroController System Operation module. These can cause transistors to become defective, control panel failure or drive fuse to go bad. 5. Brushes are worn: Inspect the drive motor commutator for burnt marks or scoring (scratches). Make corrections or make a repair of the armature commutator and replace the brushes as necessary. See Armature Commutator Inspection and Brush Inspection in Testing And Adjusting. Make reference to Problem: Sparks At The Commutator And/Or Rapid Brush Wear. Problem 3: Neither traction or hydraulic will last through a complete normal work period. Probable Cause: 1. Too small a battery equipped in the lift truck:
Use a larger battery for the complete work cycle and normal work period. 2. Battery not being fully charged or equalized during the battery charging operation: Check the battery cells for an equalization charge (a charge to make the specific gravity the same in all cells). Check the battery charger for defects. 6. Check for opens in the field coils: Test coils according to procedures in Testing And Adjusting. If there are opens, make a replacement of the field assembly. 7. Check for a short circuit in the armature windings: Loose field winding pole pieces, make the necessary corrections. Field armature bar insulation. Repair or rebuild the insulation or make a replacement of the armature. 3.
Battery change interval is too long or changed battery cooling time is too short. This decreases the capacity and the ability of the battery: Decrease the battery work duration before a change. Increase the battery cooling time after a charge before it is put to use. 8. Static return to off circuit actuated: If the static return to off is actuated, the control will not start again until the accelerator is released and the directional control lever is returned to neutral. 4. Battery has one or more defective cells which results in less than the rated capacity and ability of the battery: Replace the battery. 5.
Traction system draws (make a consumption of) too much battery power because of traction system faults. Operation of the duty cycle (complete working cycle) condition is not correct: Check the brake adjustment according to the procedures in Testing And Adjusting in the Vehicle Systems module, Check the mechanical components such as wheel bearings, axles, etc., for corrections to eliminate the faults. Change to a tire with less friction. Problem 2: Traction will not operate through a normal work period, but hydraulic operation is normal. Probable Cause: 1. Brakes have a defect, cause a resistance (lack of free movement). Heat increases, which causes the motor to stall:
Check the brake adjustment according to the procedures in Testing And Adjusting in the Vehicle Systems module. 6. Hydraulic system draws too much battery power because of lifting and tilting arrangements, or hydraulic conditions are not correct for the duty cycle: Decrease hydraulic relief valve setting to the capacity that only will be used. Change to a smaller hydraulic pump. Check the mast for restriction during operation. 2. Too much heat in MicroController control panel because: a. Extra heavy traction loads. Decrease the duty cycle load. b. Faulty thermal switch. See the MicroController System Operation module. c. Too high current limit (C/L) setting.
Lower the setting on the C/L adjustments. 7. Lift truck working more than the capacity of its design with no available power after one work shift: Have available an extra (exchange) battery. Decrease the speed and work load required to complete the work shift. Power Train Testing And Adjusting 10