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Reasons and troubleshooting methods for electric forklift walking faults

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Published by NEWTON February 02,2024

New Newton electric forklift

New Newton electric forklifts and electric stackers have trouble shooting during operation. The problem with the running circuit is manifested as the phenomenon of not running, and the problem of not running should be focused on three aspects: operating circuit, control circuit, and main circuit. The operation circuit mainly solves the problem of whether the reversing contactor can be closed, while the control circuit mainly solves the problem of whether there is a control signal of thyristor; The main circuit is to solve the problem of whether the running motor can be powered on; In addition, there are also faults where vehicles cannot enter at full speed.
Inspection of operating circuit faults for New Newton electric forklifts and electric stackers. The operating circuit mainly includes power switch, seat or handle switch brake switch, start switch, contactor coil, etc. When checking, the first step is to determine whether there is a sound of the contactor's engagement. If there is a sound of engagement, it indicates that the operating circuit is working normally. If there is no sound of engagement, it indicates that the operating circuit is faulty. When encountering a malfunction in the operating circuit, the first thing to check is whether the control fuse is burned out, and whether the seat or handle switch is fully closed. Some vehicles cannot be started after long-term use, and the seat or handle switch cannot be closed, which will prevent the entire vehicle from starting. After confirming the reliable connection of the seat or handle switch, the direction switch can be turned to another direction for testing. If there is a sound of engagement, it indicates that the contactor coil is faulty or the direction switch has poor contact. If there is still no sound of engagement, it indicates that it is not a problem with the contactor coil. It is necessary to check whether the brake switch is closed, and whether the starting switch and power switch have good contact. If there are no faults in the above parts, it is possible that the circuit of the contactor coil is disconnected due to an internal fault in the control circuit board, and the contactor cannot be energized. If it is a fault with the control circuit board, it is usually repaired by the manufacturer.

New Newton electric forklift

New Newton electric forklift and electric stacker control circuit fault inspection. When there is no malfunction in the operating circuit, if the vehicle still cannot run, the control circuit should be checked. The inspection of the control circuit should focus on checking whether the control pulses of the VS1, VS2, and VS3 thyristors are present. When checking, check with the three pulse output terminals of the control circuit board as the boundary, and use the DC voltage range of a multimeter to check if there is a voltage signal at the output terminal. If there is a signal indicating that the internal circuit is normal, further inspection should be conducted to see if the external circuit is soldered off or loose; If there is no signal or the signal is too weak, the internal circuit is faulty and the control board can only be replaced. If the control pulse is normal, the accelerator should be checked for signal output or if the interface between the accelerator and the control board is well connected.

Circuit inspection for the owner of the new Newton electric forklift and electric stacker. While ensuring that there are no faults in the first two sets of circuits, the main circuit should be checked when the vehicle is still not running. The main circuit inspection should first check whether the main fuse is burnt out, and then focus on checking whether the three thyristors are damaged or whether the capacitor C is damaged, and whether the contactor contacts are burned or mechanically stuck; Is the freewheeling diodes VD1 and VD2 in good condition? Is the wiring of the motor reliable. In addition, the governor is also equipped with some sensors. When these sensors fail, in order to protect the governor, the governor will cut off the output and cannot run. Therefore, in the absence of any faults in the above circuits, it is also necessary to check whether the temperature sensors, current sensors, etc. are working properly. Moreover, because the governor is equipped with a temperature protection device, when the governor temperature is too high, the governor will also cut off the output and cannot run. When the temperature drops, restart the vehicle. If the temperature protection phenomenon occurs in a short time or just after the vehicle is started, check whether the temperature sensor or temperature measuring circuit is faulty.

New Newton electric forklift

New Newton electric forklift and electric stacker full speed circuit inspection. When the vehicle cannot enter full speed driving, the first thing to check is whether there is a short circuit or open circuit in the coil of the full speed contactor, and whether the contacts of the contactor can be closed. When checking the normal operation of the full speed contactor, it should be checked whether the accelerator can output the maximum value specified in the manual. If the maximum value cannot be reached, the microprocessor will not issue a connection command to the full speed contactor coil. If the cause of the normal malfunction of the accelerator output signal is in the control board circuit, the control board should be replaced at this time.

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