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I'm the one who takes care of the trucks and batteries, so the batteries are taken fairly good care of. The operators using the deadman as a regular brake is a possibility. I keep an eye out. Thanks for your help.
We've had trouble with the coils getting weak when they get hot, causing the brake to drag.
How well does your customer maintain the battery? low voltage + heavy use = hot coils
We generally replace the entire unit, we have one customer who runs 24/7 with bad battery maint. he buys a lot of brakes!
One other thing to consider are the operators stepping off the deadman to stop the truck?
Have you checked that the drive shaft on the motor is straight. I had one a while ago, similar issue, and eventually found that at some point the drive motor had had the top of the shaft slightly bent, causing the brakes to never stay in adjustment.
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