A logistics center reported that a Linde E16 electric forklift would suddenly lose drive power when accelerating up a ramp. The steering and hydraulics would continue to work. The fault was intermittent and happened more frequently on hot days.
The technician connected the Linde diagnostic tool and found a fault code for "Traction Motor Current Limit Exceeded." The traction motor cables were inspected. The main power connector for the traction motor (located near the drive axle) was found to be heavily corroded with green oxidation on the pins.
Under high load (climbing a ramp), the corrosion created high resistance, causing the connector to heat up and drop voltage. The controller detected the voltage drop and shut down the drive to protect the motor.
Additionally, the traction motor brushes were checked. One brush was worn down to the limit, causing intermittent contact with the commutator. This further contributed to the resistance and current fluctuations.
The repair involved cutting off the corroded connector and installing a new, sealed waterproof connector. The motor brushes were replaced as a set, and the commutator was cleaned with a commutator stone to remove carbon buildup. The forklift regained full power and the intermittent shutdowns ceased.
