In busy logistics warehouses and industrial plants, electric forklifts are like steel giants, frequently moving all kinds of heavy objects and efficiently completing the tasks of loading, unloading and stacking goods. Deep within the electrical system of electric forklifts, the DC contactor 260A/72V (large size) silently plays a crucial role. It is like a loyal “guardian” of the power core, ensuring the stable operation of the forklifts.

Lao Zhang is an experienced forklift driver. He has been operating electric forklifts for many years and knows the performance of the vehicles like the back of his hand. One day, the factory where Lao Zhang worked received a batch of urgent goods that needed to be moved into the warehouse. He started the electric forklift as usual. However, when he was moving the first pallet of goods, he noticed something abnormal. When he operated the forklift to lift the goods, he clearly felt that the power was insufficient. The sound of the motor running became dull and intermittent, and the movements of the forklift became slow and difficult.

Lao Zhang’s heart sank. He immediately realized that there might be a serious malfunction in the electrical system of the forklift. Relying on his years of accumulated experience, his eyes quickly locked onto the DC contactor 260A/72V (large size). He stopped the forklift and, after ensuring safety, opened the electrical control box of the forklift and found the relatively large but vital DC contactor.

After careful inspection, Lao Zhang found that the contacts of the contactor had serious ablation phenomena, and some of the contacts had even stuck together. This was because during the long-term and frequent process of the electric forklift moving heavy objects, it was necessary to control the on-off of large currents through the contactor to drive the powerful motor to operate. Long hours of high-load work made the contacts gradually heat up and wear out under the impact of large currents, eventually leading to ablation and adhesion, which seriously affected the normal transmission of current and caused the motor to be unable to obtain a stable and sufficient power supply.

Lao Zhang knew very well that if this problem couldn’t be fixed in time, it would not only delay the progress of goods handling but also might cause more serious damage to the entire electrical system of the forklift and even affect the production and operation of the factory. He immediately informed the maintenance department of the factory.

The maintenance personnel quickly arrived at the scene. First, they conducted a comprehensive inspection and evaluation of the DC contactor. Then, using professional tools, they carefully disassembled the contactor, carefully cleaned and separated the ablated and adhered contacts, and replaced the seriously damaged contact parts. During the repair process, the maintenance personnel explained to Lao Zhang, “This DC contactor 260A/72V (large size) is a key hub in the electrical system of electric forklifts. It has to withstand a large current as high as 260A and a voltage of 72V, precisely controlling the start, stop and operation of the motor. Once it malfunctions, the power of the forklift will be greatly reduced, or it may even completely lose its working ability. When operating the forklift usually, try to avoid excessive overloading and frequent rapid start and stop operations as much as possible, so as to reduce the damage to the contactor and extend its service life.”

After the maintenance personnel’s professional and meticulous repair, the DC contactor resumed its normal working state. Lao Zhang restarted the forklift and felt the return of the powerful, stable and smooth power. His worry immediately dissipated. He sincerely said to the maintenance personnel, “Thanks to your timely repair. Otherwise, this job couldn’t be done. This DC contactor is really the core ‘guardian’ of the forklift!” The maintenance personnel smiled and replied, “It’s all what we should do. However, don’t be sloppy with daily maintenance in the future.”

Since then, Lao Zhang has been more cautious and careful when operating the electric forklift. He strictly abides by the operating procedures and regularly cooperates with the maintenance personnel to inspect and maintain the electrical system of the forklift, especially paying attention to the working state of the DC contactor 260A/72V (large size). Because he deeply understands that this seemingly insignificant component is actually the key to ensuring the efficient and stable operation of electric forklifts and an important support for the smooth progress of logistics and production operations.