SPECIFICATIONS

Vehicle Systems Testing And Adjusting
The key switch, seat switch, control valve switch,
and the line contactor must be closed for the
hydraulic pump motor to operate.
3. Not enough voltage. High resistance in battery
cells or cables.
Charge the battery or make a replacement of the
battery.
Check all the cells for one or more that has
defects.
Check the specific gravity of each cell. The
maximum density difference from the highest to
lowest cell must not be more than .020 SG
(specific gravity).
Check cable terminals for tight fit at battery ter-
minal and control panel connectors. Check for
broken inner wires in cables.
4. Brushes are worn.
Disconnect the battery and discharge the capacitors
(HEAD CAP). Inspect the pump motor commutator
for burnt marks or scoring (scratches).
Make corrections or make a repair of the arma-
ture commutator, replace the brushes as neces-
sary.
See Armature Commutator Inspection and Brush
Inspection in Testing And Adjusting.
Make reference to Problem: Pump Motor
Overheat (Too Much Heat).
Check for opens in the field coil.
Test coils according to procedures in Testing And
Adjusting. If there are opens, make a replacement
of the coils.
5. Check for short or open circuit in the armature or
between armature and field.
Loose field winding pole pieces.
Check poles for damaged insulation, repair or
replace damaged insulators.
Failed armature bar insulation or armature bar
connector open. Repair or rebuild the insulation,
make a replacement of the armature.
NOTE: If armature opens caused commutator bar
pitting or burnt areas, armature will need replace-
ment. Heat from the arcing causes the hardened
copper commutator bars to be annealed (soft). Just
machining (turned to a lesser diameter) of the
commutator will not correct the problem from
occurring again. The armature must be replaced.
Opens in the armature bar connections must be
found and soldered (repaired).
7. Lift and drive system operation not correct.
See troubleshooting section of the MicroController
Control System module.
Problem 2: Neither traction or hydraulic will last
through a complete normal work period.
Probable cause:
1. Too small a battery installed in the lift truck.
Study and question the use of the lift truck in its
complete working conditions, select and purchase
appropriate capacity of battery regarding work
hours.
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.
3. Battery Discharge Indicator (BDI) lift interrupter
circuit which protects the battery, shuts off the
hydraulic motor circuit too soon.
See Battery Discharge Indicator Operation
Adjustment and Troubleshooting in the
MicroController Control System module.
4. Battery charge interval is too long or charged
battery cooling time is too short. This causes
excessive (too much) cell temperatures which
decreases the capacity of the battery to supply the
rated ampere hours.
Decrease the battery work duration before a
change.
Increase the battery cooling time after a charge
before it is put to use.
5. Battery has one or more defective cells which can
result in much less than the rated capacity and
ability of the battery.
Test and locate the defective cells. Replace the
defective cell(s).
Battery cells are connected in series, one bad
cell causes a high resistance in series with the
other cells. This slows down the speed of the
motor as the cell resistance increases. This can
occur with the other cell almost fully charged.
6. Hydraulic system draws too much battery power
because of lifting and tilting arrangements or
hydraulic controls 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 (if available).
Check the mast for restriction during operation.
Remove quick disconnects and install fittings
with lesser resistances to oil flow.
Check for defective hydraulic control valve, the
pilot operated relief valve.
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