Internal combustion forklifts are prone to many failures. The most common failures are generator failure, generator does not generate electricity (not charging), charging voltage is too high and charging voltage is too low. When the engine is running normally, the ammeter always indicates discharge and charge and the indicator light is on, indicating that the power system is faulty and should be repaired in time. Today, the editor will introduce to you the common troubleshooting tricks of internal combustion forklifts.
1. The generator does not generate electricity
Symptoms:
When the engine is running above the medium speed, the ammeter shows discharge or charge and the indicator light is on.
cause of issue:
1) The fan drive belt is too loose, slipping or broken.
2) The charging circuit is disconnected, grounded or short-circuited, that is, the circuit from the generator armature terminal to the ignition switch is blocked.
3) The regulating voltage of the regulator is too low, the magnetizing coil and resistance are ablated and damaged, and the primary and secondary contacts are ablated and dirty.
4) The insulation of the brush is damaged, and the spring force is too weak; the brush is stuck in the frame, and the contact with the collector ring is poor.
5) The diode is broken down, short-circuited or disconnected; the connection between the diode and the stator winding is loose or broken.
6) The insulation of the generator armature and the magnetic field terminal is damaged or the contact is poor.
7) The collector ring insulation is broken down.
8) Stator and rotor winding open circuit, short circuit or grounding.
9) The rotor claws are loose.
10) The final high-power tube of the crystal voltage regulator is open circuit, thereby cutting off the circuit of the excitation current of the alternator, causing the generator not to generate electricity.
The charging current is too large. In the case of sufficient battery power, the battery is still charged with a charging current of more than 10A for a long time. Excessive charging current will cause overcharging of the battery, excessive consumption of electrolyte, overheating of the ignition coil, easy ablation of the distributor contacts, easy burnout of the bulb, and overheating of the generator.
Second, the charging current is too large
Symptoms:
When the car is running at a low speed, the ammeter shows no charging; when the car is at a medium speed or above or the battery is out of power, the charging current is small.
cause of issue:
1) The charging line is in bad contact.
2) The fan drive belt is slipping or too loose.
3) Regulator adjustment voltage is too low, contact ablation, dirt, poor contact.
4) Individual diodes are damaged.
5) The collector ring is dirty, and the contact between the brush and the collector ring is poor.
6) Poor connection, short circuit or open circuit of a certain phase of the stator winding.
Troubleshooting and troubleshooting:
1) Check whether the fan drive belt is too loose or slipping, and whether the wire is loose and leads to poor contact.
2) Check the engine: remove the lead wires of the armature and the magnetic field connection post, connect the two leads of the test lamp to the armature and the magnetic field connection post respectively, and make the engine run. If the brightness of the test lamp increases with the speed, it means that the generator is good; otherwise, it means that there is a fault inside the generator. You should check whether the brush is worn too much, whether there is oil on the collector ring, whether the contact between the brush and the collector ring is good, and whether the brush is in good condition. Whether the movement on the frame is stuck, whether the diode is damaged, whether there is an open circuit or short circuit in the stator winding.
3) Check the regulator: first open the regulator cover, use an insulator to block the air gap, and make the delivery machine run at a medium speed. If the ammeter indicates high current charging, it means that the adjustment voltage is too low, and the spring tension should be increased to ensure Increase regulation voltage. At the same time, you should also check whether the contacts are oily, ablated, whether the resistance is open circuit, loose connection, poor contact, etc.
3. Unstable charging failure
Symptoms:
When the engine is running stably at a medium speed or above, the pointer of the ammeter swings, and the charging is intermittent, which is very unstable.
cause of issue:
1) The fan drive belt is slipping.
2) The wire connection of the charging circuit is loose or in poor contact.
3) The collector ring is dirty and has poor contact with the brush.
4) The brush is worn too much or the spring pressure is too small.
5) The contacts of the regulator are ablated, oxidized, the spring of the contact arm is too soft, or the additional resistance is unreliable.
Troubleshooting and troubleshooting:
1) Check whether the tightness of the fan drive belt is appropriate, and check the connection between the charging circuit wires segment by segment.
2) Let the engine rotate at a speed slightly higher than the idle speed, remove the regulator cover for inspection, and use a screwdriver to lap the first-level contact. If the pointer of the electric wave meter is stable, it means that the first-level contact is not in good contact. The spring tension is not adjusted properly or the attached resistor is not working well.
3) If the pointer of the ammeter only swings in the high-speed range, it means that the secondary contacts are ablated, dirty or in poor contact, or the air gap is not adjusted properly, which should be ruled out.
4) Check the contact between the brush and the collector ring and the internal connection of the generator.
