Anyone ever heard of this problem? The direction contacts pull in like they're supposed to when the direction lever is moved into forward or reverse. One of the problems is that there is no forward movement, I checked the contact surfaces and they look like new. Take a bit of emery cloth and polish the surface and away it goes. Operator drives for a day and tells me that it occasionally doesn't move forward even though the contactor pulls in.
Today, a day later, it quits again. I checked everything and then gave the contacts a little polish and away it goes. I've checked that there is spring pressure for the reverse contactor tips that are the double acting style and it seems fine. The moving contact armature doesn't bottom out until after the contact tips make contact.
It almost seems that the contact surfaces are being covered or coated with something that is non-conductive but they are the second set and the work environment is clean and dry.
Any thoughts or has anyone run into this problem before?
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Thanks for the replies and suggestions. I'm going to drop by there tomorrow and have another look. Just wondering if it may be worthwhile to replace the factory contactors with a set of EV100 300amp direction contactors. From what I understand, new contact tips seem to work for a few months. A Toyota tech has told me that the 6 series electrics had a few problems and were dropped in favour of the 7 series pretty quickly.
I'll keep working on the problem...............
hi sleepy wheel Check the brake pads and brake disc ,has been known for filings from brake disc to get into contact and affect contact operation ,especially when pads are low.
I have come across similar contactor related problems but not in this specific truck.
However if the problem is happening on the same contactor tips the ideal thing to do would be to swap the motor cables around off the back of the contactor and then see if the fault then swaps over to the other contactor or remains on the same contactor.
If it remains on the same contactor irrespective whether it goes forward or backwards then there is a good chance its a contactor problem. On the other hand if the problem then transfers across to the other contactor its most likely going to be a motor related problem.
Its just unusual to have the problem occur in forward only if its a coating issue on the tips. You would have expected other tips to be affected.
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