A logistics center reported that a Linde E20C electric forklift would suddenly cut power and stop while driving. The operator had to restart the machine multiple times an hour.
The technician connected the "Service Handheld Tool" to read the fault codes. The code indicated "Brake Pedal Switch Failure." Linde forklifts have a safety logic: if the brake pedal is pressed even slightly, the traction motor is disabled.
He removed the "Brake Pedal Switch" (located under the floor plate). He tested the continuity. The "Normally Open" contact was burnt and had high resistance. When the forklift drove over a bump, the vibration caused the brake pedal linkage to move slightly. The faulty switch sent a false signal to the controller, thinking the operator was braking, triggering the power cut.
Additionally, he checked the "Accelerator Potentiometer" (Hall effect sensor). The sensor output voltage was jittery (fluctuating). The wiper arm inside the sensor was worn. This caused the controller to receive erratic speed commands. The controller detected the inconsistency between the brake signal and the accelerator signal and triggered a safety shutdown.
The repair involved replacing the brake pedal switch and the accelerator pedal sensor unit. He also adjusted the brake pedal return spring to ensure it fully released after braking. The controller was recalibrated to recognize the new pedal sensors. The forklift then operated smoothly without interruption.
