Power Train
Testing And Adjusting
Troubleshooting
Visual Checks
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
ÒProblemsÓ and ÒProbable CausesÓ.
Checks During Operation
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.
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.
To prevent personal injury, never use air pressure
that is more than 205 kPa (30 psi), and wear
protective clothing and a face shield.
NOTICE
To prevent damage to electrical components, make
sure the air line is equipped with a water filter when
they are cleaned with air.
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.
Do not operate the drive motors without a load,
as too much speed may cause damage to the
motor and injury to personnel.
Problem 1: Drive Motor Will Not Operate.
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.
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.
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).
WARNING
WARNING
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