Model 9600/9700 Swing-Reach ® Lift Truck

Section 4.Scheduled Maintenance

Fork Inspection

If there is greater than 10% wear of the fork arm, the fork has at least a 20% reduction in capacity.

NOTE: The caliper is designed to measure forks up to 4 in. (100 mm). It is not to be used on full or lumber tapered forks. For these forks, you must know the original fork blade thickness and take a measurement of the fork arm thickness. If the difference in the measurement exceeds 10% of the original thickness, the fork must be removed from service.

3.Measure 2 in. (50 mm) out from the heel of the fork.

4.Place the caliper over the flanks of the fork arm blade at this 2 in. (50 mm) point. See Figure4-12.

Fork Hooks

1.Remove the forks from the carriage.

2.Determine the fork mounting class.

a.Measure the height of the carriage or the distance between the hooks. See Figure4-13.

5.If the inside teeth of the caliper hit the fork, there is <10% wear. If the inside teeth pass freely over the fork arm, there is >10% wear and the fork must be removed from service.

b.Compare this measurement to the table below.

3.Locate the correct extruded edge on the caliper for the fork mounting class. See Figure4-14.

Publication: 1089040, Issued: 08 Apr 2016

Section 4.Scheduled Maintenance

Model 9600/9700 Swing-Reach ® Lift Truck

4.Slide the extruded edge up into the fork pocket. See Figure4-14.

5.If the caliper’s extruded edge completely slides up into the fork pocket, remove the fork from service. See Figure4-14.

6.Compare the measurement to the maximum allowable deflection calculated in step 1.

7.Verify the measurement taken in step 3 is still the same. Without moving the fork eye, pull the right fork tip outward as far as possible.

8.Measure the distance between the inside edges of the forks at the same locations used in step 3.

9.Compare the measurement to the maximum allowable deflection calculated in step 1.

Repeat the procedure for the left fork. If any of the measurements exceed the maximum allowable deflection, the fork eye tube should be checked for “oval distortion”, and micro cracks in the wall or in the welds attaching the fork eye to the fork. If “oval distortion” and/or cracks are found, the fork must be removed from service.

Markings

Fork Eye Inspection

Perform the following procedure to inspect forks on trucks that use a fork bar inserted through a round fork eye to connect the forks to the carriage.

Fork Inspection 4-18

1.Measure the length of the fork blade. Multiply the length of the fork blade by 0.04.

Example: if you are checking a 42 in. fork; 42 x 0.04 = 1.68 (1 11/16 in.)

This is the maximum allowable deflection at the tip of the fork, in either direction horizontally.

2.Move both forks 2 in. inward from the carriage on the fork bar so the carriage does not interfere with fork movement.

3.Measure the distance between the inside edges of the forks at the tips.

4.Without moving the fork eye, push the right fork tip inward as far as possible.

5.Measure the distance between the inside edges of the forks at the same locations used in step 3.

Make sure the fork’s marking (individual load rating) is legible (typically located on side of fork). If fork marking is not legible, remove the fork from service.

Publication: 1089040, Issued: 08 Apr 2016

Section 5.Troubleshooting

Model 9600/9700 Swing-Reach ® Lift Truck

Electrical Troubleshooting

General Block the lift truck so that the drive tire is off the floor whenever a troubleshooting procedure requires turning the key switch ON. This prevents accidents caused by unexpected lift truck travel.

Electrical Troubleshooting 5-2

Unless otherwise directed, disconnect the battery connector when you check electrical circuits or components with an ohmmeter. Electrical current can damage an ohmmeter.

Before removing a power amplifier, discharge the amplifier’s internal capacitor by jumpering the + and –terminals with a 100 ohm 25W resistor.

•Many problems can be caused by a dirty battery. Make sure the battery is clean.

•Save time and trouble by looking for simple causes first.

•Use a Digital MultiMeter (DMM) such as a Fluke meter, for all measurements. Analog meters can give inaccurate readings and load down sensitive electronic circuits enough to cause failure. Make sure meter cables are connected to the correct meter jacks and that the correct function and scale are selected.

•Printed circuit boards are conformal coated. Make sure meter leads make a good electrical connection with test points.

•When measuring voltage, connect the positive meter lead to the connector or probe point marked (+) in the test. Connect the negative meter lead to the connector or probe point marked (–).

•Whenever measuring resistance, turn the key switch OFF and disconnect the battery connector. Battery current can damage an ohmmeter. Isolate the component from the circuit.

•Before replacing an electrical component, disconnect and clean all jack/pin connectors on the component(s) with contact cleaner (P/N 996-600/CC2). Reconnect and retest truck.

Shorts to Frame

“Shorts to frame” is an industry term for unintentional current leakage paths between normally isolated electrical circuits and their metal enclosures.

Shorts to frame may be metallic connections, such as a wire conductor contacting metal through worn insulation. More often, shorts to frame are resistive “leakage” paths caused by contamination and/or moisture.

These leakage paths can result in unwanted electrical noise on the metallic lift truck structure and can cause incorrect operation.

Shorts to frame are caused by:

•Accumulation of dirt

•Battery electrolyte leakage

•Motor brush dust

•Motor brush leads touching the housing

•Breakdown in insulation

•Bare wires

•Pinched wiring harness

•Incorrect mounting of circuit cards

Shorts to frame can occur at numerous locations on a lift truck, including:

•Batteries

•Motors

•Cables, wiring, and harnesses

•Heatsinks

•Bus bars

•Solenoids

Publication: 1089040, Issued: 08 Apr 2016