How to troubleshoot electric tugger failure? Correct steps

Why Check for Faults

Checking electric tugger failures from time to time is essential in improving equipment efficiency and extending its service life. On the one hand, the electric tuggers by GYPOT are well known in the market, and they operate well; on the other hand, the best equipment can have failures. Therefore, regular inspections and maintenance can help detect the problem on time and prevent failures, avoid production interruptions, and financial losses.

Comparing the annual failure rate on GYPOT with other brands, it will be less than 3%, while the average in the industry is about 5%. From the data, it is clear that while the products of GYPOT are more reliable than other brands, there should still be regular inspections and maintenance. For instance, the inspection of the logistics company was not carried out regularly, which contributed to the high rate of failures reaching 7%. It refers to the fact that the expenses on operations were increasing, and work efficiency was decreasing.

Troubleshooting Steps

Checking Power and Battery

Firstly, check the power connection and battery level of a gypot electric tugger. According to GYPOT technical support department, 30% of failures occur due to the lack of battery power or unstable connection. After using the tugger, the battery should be charged over 80%. For example, Amazon’s warehouse center faced 30% of equipment downtime due to low battery power, and timely battery charging reduced this time by 20%.

Besides, battery aging is a frequent problem. GYPOT batteries can serve for 600 charge-discharge cycles, but if the vehicle is used frequently, this number may be reduced. Thus, it is essential to carry out quarterly battery verifying and testing. If the aging is observed, it should be changed because otherwise the vehicle’s failures will continuously occur due to the battery.

Checking the Control Panel

Press each button to confirm its response. If the control panel lights do not turn on, the circuit board may be faulty. GYPOT electric tuggers are designed with dustproof and waterproof features, but regular checks for burnt or shorted circuit boards are still necessary. General Electric (GE) reports that 15% of equipment failures are related to control panel issues, and monthly inspections and circuit board replacements when necessary have reduced failure rates by 12%.

Control panel connections also need to be checked to ensure they are not loose or damaged. Connection issues can lead to button malfunctions or unstable control signals. Monthly routine checks of the connections to ensure all contact points are secure can effectively reduce control system failures.

Checking Motor Status

The motor is one of the core components of the GYPOT electric tugger. Does it make any unusual noises during operation? Gently turn the motor shaft by hand to check for smoothness. GYPOT motors are designed with excellent cooling systems, but overheating still needs to be prevented. Boeing's data shows that 20% of electric tugger failures are due to motor overheating, and adding cooling equipment and regularly cleaning the motor has reduced motor failure rates by 15%.

Dust accumulation inside the motor can also affect its operating efficiency. Monthly internal motor cleaning to ensure it is dust-free can extend the motor's lifespan. Compressed air can be used if necessary to clean the motor's interior and prevent dust buildup from affecting cooling.

Checking the Drive System

Confirm if the gears and belts in the drive system are worn or broken. Drive systems of GYPOT are designed for high durability, but regular inspection and maintenance are still essential. For instance, Walmart’s logistics center checked its failure rate from 8% to 2% by conducting monthly drive system inspection. Replacements will be made if the gears and belts are worn. In addition, people must keep an eye on the tension of the drive belt. Drive systems are very sensitive to slack and tensile;, if the belt is too loose or too tight, it cannot function normally. Hence, monthly inspections should be conducted.

Checking Tires and Wheels

The status of tires and wheels directly affects the use of electric tuggers. The GYPOT electric tuggers are equipped with high-wear-resistant tires, yet checking tires every quarter for wear is still necessary. According to data from JD Logistics, quarterly tire check replacing worn-out wheels helped reduce the failure rate of the equipment by 40%. The stability of the equipment can be ensured by checking that the tire pressure is normal and if it is not, worn tires need to be replaced promptly.

At the same time, labor must be made so that the wheels are not caught. The application of a lubricant to the wheels in every quarter avoids increase friction and wear, ensuring the smoothness of the electric tract during use.

Daily Maintenance Tips

Regularly clean GYPOT electric tuggers, especially the motor and drive system, once a month. Removing dust and debris prevents them from affecting equipment efficiency. Using a clean soft cloth and an appropriate amount of cleaner effectively removes surface dirt and keeps the equipment clean.

Maintain sufficient battery power, charge promptly after each use, and avoid keeping the battery at a low power state for a long time. Immediately charge after each use to ensure the battery power always stays above 80%, extending the battery's lifespan.

Check tire wear conditions once a quarter to ensure normal tire pressure and promptly replace worn tires. Conduct comprehensive tire checks every quarter to ensure no cracks or severe wear. If problems are found, immediately replace with new tires to ensure safe driving.

Lubricate key parts once every three months to reduce wear and extend the equipment's lifespan. Use appropriate lubricating oil to lubricate key parts such as gears and bearings, ensuring smooth operation of all parts and reducing wear caused by friction.