Section 7. Component Procedures
Model 9600/9700 Swing-Reach ® Lift Truck
Motors
Electrical Components
7. While gently pulling the scale outward, slowly pull the paper strip in the direction that the commutator normally rotates. 8. When the paper strip begins to move freely, the spring scale will read the spring brush tension. 9. Refer to Table 7-6 for correct spring tension. Table 7-6.
Minimum Brush Length and Spring Tension
4. With minimal pressure, run the stone back and forth across the commutator until it is polished. Do not pass stone over the ends of the commutator segments. 5. Thoroughly blow out the motor with compressed air. 6. Inspect commutator. Reinstall the brush or armature and cover. 7. Check operation.
Motor
Min. Brush Length
Spring Tension
AC Motor Service
Load Handler
0.62 in. (15.7 mm)
40 to 65 oz. (1134 to 1842 grams)
Temperature Sensor Replacement
Steer
0.50 in. (13 mm)
32 to 40 oz. (907 to 1134 grams)
10. Repeat steps 3 thru 9 for the remaining brushes.
Polishing the Commutator NOTE: Use a narrow masking tape (1/2 to 3/4 in. wide) and wrap the stone in a spiral configuration, leaving only enough stone exposed to make contact with the commutator. As the length of the stone becomes shorter with use, peel back and remove portions of the tape.
Make sure loose clothing is tied back. Do not wear jewelry. Wear insulated gloves. 1. If the motor has 4 or more brushes, remove an accessible brush from the motor with the motor still installed in the truck. If the motor only has 2 brushes or the commutator is not accessible with the stone, the armature must be installed in a lathe or replaced. If so, go to step 4. 2. Activate the motor. 3. With the motor turning, carefully insert the commutator stone into the brush box area.
7-54
Traction Motor 1. Turn the key switch OFF and disconnect the battery connector. 2. Remove the brake assembly. 3. Disconnect the temperature sensor connector. 4. Disconnect motor power cables. Note locations for reassembly later. 5. Remove the terminal board. 6. Remove the four bolts that secure the top end bell to the bottom end bell. 7. Remove the top end bell using a puller. 8. Cut the bad temperature sensor cable. 9. Install new temperature sensor with high temperature silicone P/N 1110785/716. Mount the sensor close to the location of the original. Secure the cable with a cable tie to one of the power leads for stress relief. 10. Reinstall the top end bell. 11. Reinstall the four bolts that secure the top end bell to the bottom end bell. 12. Reinstall the brake assembly. 13. Connect the new temperature sensor cable. 14. Install the terminal board and reconnect power cables. Torque motor cable securing nuts to 18 ft. lb. (24 Nm). 15. Reconnect the battery connector and turn the key switch ON.
Publication: 1089040, Issued: 08 Apr 2016
