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How do forklift manufacturers solve the lighting problem of forklifts

How do forklift manufacturers solve the lighting problem of forklifts

  • 2021-12-27
Forklift is a tool we often use in our daily work, and our daily maintenance is very important. Of course, some minor problems will inevitably occur in normal times. Today, Hifoune Forklift will take you to learn about the troubleshooting methods of the forklift lighting equipment.
No matter what type of forklift we are, the forklift lights are prone to failures. So what are the main aspects of common forklift failures: the lights are not bright, the lights are dim, the lights are flickering, and the safety device is sounding.
The reasons for the above-mentioned failures are generally: burning filament, loose wire, poor grounding, open circuit or short circuit; excessive adjustment of charging voltage and failure of various switches, etc.
During the inspection, the open circuit or short circuit can be found, and then the fault can be eliminated. If the bulb burns out frequently, it is mostly caused by the generator voltage being too high, and the regulator can be adjusted. Judging the above faults should be performed when the battery has sufficient power and other electrical equipment is working normally.
1 Diagnose with light test method, fire test method and power short-circuit method
The lights do not turn on, and the horn does not sound. It should be checked whether the fuse is automatically opened. If it does not open, there is an open circuit in the wire of the battery and the fuse, or the connector is loose and the fuse is damaged, which should be found and eliminated. If the safety device jumps, it jumps again after a while after pressing it, indicating that there is a ground.
The lights are dim and the lights are red. Check the battery capacity, the tightness and contact of the wire joints, whether the grounding is good, whether the reflector or lamp glass is stained, whether the wiring head is firm, whether there is a broken wire insulation, and whether the bulb has been used for a long time and the tungsten wire has evaporated and turned black.
The light relay is not working properly. Check for the following faults: wrong wiring, short circuit, open circuit, contact burnt or loose wiring, core gap is too large or too small, the spring is too hard or too soft, making the contact bad. Repair according to technical specifications if necessary.
The bimetal fuse is in poor contact or is disconnected. When running at night, the headlights, small lights, and rear lights sometimes disappear, sometimes bright and sometimes dark, indicating instrument lights sometimes disappear, and the horn does not sound when parking. The bimetal fuse is connected to the circuit through two contacts. Once the contacts are loose, ablated or poorly connected, electrical equipment will work poorly. In case of this phenomenon, check the contact of the bimetallic fuse to see if it gets hot by touching it with your hands. Use another wire to connect the two terminals of the fuse (i.e. short-circuit the fuse) to temporarily eliminate the fault or replace it with a new one.
2 Checking steps for light failure
Check insurance. Most forklifts are equipped with fuse boxes. During the inspection, it is necessary not only to check whether the fuse is blown, but also to find out the reason for the blow. If the fuse of a lamp blows frequently or when the lamp is turned on, it is mostly because the lamp circuit has a short circuit. When checking, remove the connection on the lamp, connect one end of the wire to the fuse box, and connect the other end to the live wire of the lamp to test. If the brightness of the light is normal and the fuse is intact, it indicates that there is a short circuit in the connecting wire between the fuse box and the light. If the fuse is normal and there is normal voltage, proceed to the next inspection.
Check the bulb. Whether the bulb filament is burnt can usually be confirmed by visual inspection. If the bulb becomes black or the filament is burnt, replace with a new bulb. If the bulb filament is frequently burnt, it is mostly caused by the damage of the generator regulator and the excessively high output voltage. In this regard, a voltmeter can be used to check. If the generator output voltage is too high, it means that the regulator is damaged.
Check the grounding. If the fuse and the bulb are normal, and the bulb live wire has normal voltage, check whether the ground wire is open or has poor contact. Connect one end of the wire to the ground end of the bulb, and the other end to the frame or the negative electrode of the battery to test. If the light brightness is normal, it can be judged as poor grounding. At the same time, check whether the lamp holder is oxidized, rusted, and has poor contact. This point should be paid special attention.
Check the wiring. Forklift lighting systems are usually equipped with control devices, such as light relays and dimming switches in the forklift lighting system. Therefore, during inspection, if both the far and near lights of the headlamp are not bright, check whether the dimmer switch socket is loose and whether the light relay can conduct the light circuit. If the visual inspection cannot be confirmed, the fault location can be determined by the method of wire short-circuiting, that is, the white wire terminal of the light relay is short-circuited with the blue wire terminal with the wire. If there is a sound, it means that the light relay is normal, and most of the fault lies in the dimmer switch or the light switch.
Hope the above description is helpful to you. If you have other better opinions, you are welcome to communicate with us.

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