During the long-term operation of BYD electric forklifts, the controller walking failure is a relatively common problem, mainly manifested as weak walking, driving deviation, and inability to start walking. When encountering such faults, maintenance personnel need to conduct a systematic investigation first: first check the vehicle power system to confirm whether the battery voltage is in the normal range, and whether the wiring terminals are loose or oxidized; then check whether the wiring of the walking motor is in good condition to rule out the possibility of failure of the motor itself; if there is no abnormality in the above links, then check the signal output and internal circuit of the controller through professional equipment to determine whether the electronic control assembly needs to be replaced.
Before replacing the electronic control assembly, it is necessary to make full preparations: first, prepare suitable special disassembly and assembly tools, such as insulating wrenches, multimeters, wiring markers, etc.; second, confirm that the model and parameters of the new electronic control assembly are fully matched with the original equipment to avoid subsequent failures due to non-compliance with specifications; third, disconnect the total power supply of the vehicle in advance and take insulation protection measures to prevent the risk of electric shock during maintenance.
The disassembly and assembly process should strictly follow the main points of the specification: when disassembling the old assembly, first use a marker to clearly mark the position and number of each wiring to avoid subsequent wiring confusion; remove the fixing bolts in turn, carefully remove the old assembly, and pay attention to avoid pulling the surrounding pipelines and sensors; when installing the new assembly, follow the corresponding wiring marks to ensure that each wiring is firm and not loose, and then tighten and fix it evenly with bolts to ensure that the assembly installation position is flat and stable.
After the replacement is completed, comprehensive debugging and testing are required: first, power-on test to check whether the controller indicator light is on normally and whether there is an error code; then carry out no-load walking test to observe whether the forklift is walking smoothly, with or without deviation, stuck phenomenon; then carry out load test to verify whether the walking power returns to normal; finally, match relevant parameters through professional equipment to ensure that the electronic control assembly and other components of the vehicle operate in harmony.
In addition, after the maintenance is completed, follow-up maintenance tips are required: regularly check the terminals and heat dissipation of the electronic control assembly to keep the surrounding area clean and free of debris; avoid frequent sudden acceleration and sudden braking of the forklift in daily operations to reduce the controller load; if walking abnormalities occur again, stop the machine in time for investigation to avoid the expansion of the fault.
