Drive Tire Pressing

Misalignment of the tire and hub while the tire is being pressed onto the hub can cause damage to the hub. For this reason, chamfers have been provided on the outside edge of the hub and on the end of the inside diameter of the tire’s metal insert. The chamfers help to center the hub and tire during the pressing operation and reduce the possibility of misalignment. To prevent damage, install the hub on the circular ram with its chamfered side up.

1.Check the inside surface of the metal insert on the new tire. Remove any scaling or rust with sandpaper. Clean the inside of the metal insert and lubricate it with a soap solution.

2.Place a circular ram on the press table. See Figure7-42 . The length of the ram must be longer than the width of the old tire to permit complete removal of the old tire. The outside diameter of the ram must be small enough to fit loosely in the insert of the tire but must be large enough to rest squarely on the flat surface on the outer edge of the hub.

smaller in diameter than the inside diameter of the tire insert and the same thickness as the depth of the recess) to obtain the correct amount of recession.

4.Position the hub assembly with the old tire on the top of the circular ram so the outside of the wheel is positioned upward. The outside edge of the hub has a chamfer to help guide the new tire onto the wheel. The chamfered edge must always be the leading edge when you press a tire onto the hub.

5.Center the hub assembl y on top of the ram and make sure that they mate squarely.

6.Apply grease to the inside of the tire rim.

7.Position the new tire with its chamfered insert facing the hub. Align the new tire and the hub so that they are concentric.

8.Begin pressing the new tire onto the hub and the old tire off the wheel. Run the press slowly for the first few inches of travel, because this is the critical stage of the operation. If the tire begins to cock to one side, stop the press and realign the tire. A sharp jar with a soft-headed mallet will usually realign the tire on the hub.

9.If the new tire does not press on with a minimum of 5 tons (68,947 kPa) pressure, try pressing a different new tire. If the tire still does not press on, replace the hub and tire assembly.

10.Release the press. Remove the wheel, tire assembly, and the old tire from the press table. Wipe off any grease. Inspect the wheel and tire assembly.

3.If the outside edge of the hub is not flush with the edge of the metal insert in the old tire, measure how far the hub is recessed inside the tire. Place the new tire in the same position the old tire was installed on the hub. You can use a spacer (slightly

Publication: 1089040, Issued: 08 Apr 2016 7-35

Section 7.Component Procedures

Model 9600/9700 Swing-Reach ® Lift Truck

Brake Drive and Brake

Brake Inspection

1.Turn the key switch OFF and disconnect the battery connector.

2.Open the motor compartment door.

3.Check air gap between the armature and armature plate near all three spacers. See Figure7-43. If air gap exceeds 0.040 in. (1mm), replace the brake pads. See “Pad Replacement” .

Figure 7-43.Checking Brake Air Gap

Brake Removal

1.Turn the key switch OFF and disconnect the battery connector.

2.Block the drive tire to prevent movement.

3.Raise tractor compartment top cover and remove rear cover.

4.Note the location of cable ties securing the motor cable bundle to the cable bracket. Cut cable ties to free the cables from the bracket. Remove the cable bracket.

5.Disconnect brake armature lead connection.

6.Loosen one of the locking bolts and obtain a spacer approx. 0.005 to 0.015 in. (0.12to 0.38 mm) thicker than the

7-36 measured total air gap (non-energized). Insert spacer between the armature plate and the coil body. Tighten the locking bolt just enough to prevent rotation of the motor shaft.

7.Remove the retaining nut and washer from the motor shaft. See Figure7-43.

8.Remove the three brake mounting bolts.

9.Use a brake puller to remove the brake assembly from the motor.

Pad Replacement

1.Install the brake release bolts. NOTE: Do not overtighten the brake release bolts.

2.Turn the brake assembly over and remove the three bolts securing the adapter plate. See Figure7-44.

Publication: 1089040, Issued: 08 Apr 2016

Model 9600/9700 Swing-Reach ® Lift Truck Section 7.Component Procedures

Drive and Brake Brake

Brake Installation

1.Correctly position brake assembly on motor, making sure the keyways on the motor shaft and carrier are correctly aligned.

2.Gently tap the carrier flange onto motor shaft until seated.

3.Apply thread-locking compound (P/N1013829) and install the three brake mounting bolts. Torque to 15 ft. lb. (20.3Nm).

4.Remove brake release bolts and install in their storage locations.

5.Install adapter plate. Torque adapter plate bolts to 6ft.lb. (8.6 Nm).

NOTE: Leave the brake release bolts installed for reassembly to motor.

Coil Replacement

1.If installed, carefully remove the brake release bolts. Separate the coil from the armature plate.

NOTE: The brake release bolts are under tension from the springs inside the coil body.

2.With the coil inverted, make sure all eight springs are inserted into the cavities.

NOTE: On coils with ten spring cavities, the two empty cavities must be 180° apart.

3.Place the thin washer shaped spacer over the springs.

4.Note the orientation and place the inverted armature plate on the coil directly over the spacer.

5.Assemble the armature and coil: a.Using a clamp, mate the armature plate to the coil, make sure the thin washer is correctly aligned. b.Install the brake release bolts through the coil and armature plate and tighten.

6.Install carrier, pads, and adapter plate. Torque adapter plate bolts to 6ft.lb. (8.6Nm).

5.Loosen one of the retainer bolts and insert a 0.030 to 0.040 in. (0.76 to 1 mm) spacer between the armature plate and coil body. Tighten the retainer bolt just enough to prevent rotation of the motor shaft as the retaining nut is being torqued.

6.Install retaining nut and a new washer to motor shaft. Torque retaining nut to 120ft. lb. (163 Nm).

7.Loosen the retainer bolt and remove the spacer.

8.Attach the motor cable bracket. Apply thread-locking compound (P/N1013829) to the bolts and torque to 6ft.lb. (8.6 Nm).

9.Attach the cable bundle to the cable bracket with cable ties and connect the brake armature lead connector.

10.Unblock the drive tire. Reconnect the battery connector and turn the key switch ON.

11.Make sure brake operates correctly and traction motor rotates without interference to motor cables.

NOTE: When the truck is stationary, pressing and releasing the deadman pedal should cause the brake to release and engage. When the truck is traveling, the brake should remain released (coil energized) until the truck speed reaches 0.5 mph (0.8 km/h).

Publication: 1089040, Issued: 08 Apr 2016 7-37

Publication: 1089040, Issued: 08 Apr 2016

Section 7.Component Procedures

Model 9600/9700 Swing-Reach ® Lift Truck

Battery ProceduresElectrical Components

Battery Procedures

Before working on the battery, review “Battery Safety” on page2-5. Batteries for this lift truck weigh between 2900 and 3700 lb. (1317 to 1680 kg). Use extreme care during replacement. Use a suitable battery moving device or hoist for lifting. DO NOT extend a battery more than 1/3 of its length outside the battery compartment without being attached to a battery-moving device.

Battery Connector/Cables Inspection

1.Turn the key switch OFF and disconnect the battery connector.

2.Check the battery connector for damaged cables.

3.Check to see if battery cables are pulling out of the connector.

4.Check the cables at the battery terminals. Connections should be tight, with no corrosion.

5.Look inside the connector. Check all internal contacts for damage, dirt, or corrosion. Do not use a metal object to clean the connector.

NOTE: Some degreasers and parts cleaners cause the connector shell to disintegrate. Avoid contacting battery connectors with solvents.

Removal, Replacement, and Installation

The cables to either half of the connector have a lip on their forward end. This lip snaps over a spring-loaded retainer that is part of the connector.

NOTE: When replacing battery cable ends, remove only one end at a time from the connector, to avoid the cable ends touching and causing a short circuit.

7-40

DO NOT allow the metal cable end to touch the battery. Use insulated tools and avoid contact with battery case or cable ends.

1.To remove a cable from the connector, push the retainer down while pulling the battery cable towards the rear and out of the connector. See Figure7-46 and Figure7-47

Battery Exterior Cleaning

1.Read, understand, and follow procedures, recommendations and specifications in the

Publication: 1089040, Issued: 08 Apr 2016 battery and battery charger manufacturer’s manuals.

2.Wear personal protective equipment. See “Battery Safety” on page2-5.

3.Turn the key switch OFF and disconnect the battery connector. Remove the battery from the lift truck.

4.Inspect the battery cables to make sure they are not frayed or loose. Inspect the battery connector to make sure there is no foreign material inside the connector. Make sure the filler plugs are tight and the vent holes in the filler plugs are open.

7.Use a brush with flexible bristles to clean the entire top of the battery with the soda solution. Wait until all foaming stops, indicating that the battery exterior is neutralized.

8.Rinse the battery with clean water.

9.Dry the battery completely before reinstalling it.

10.Reinstall the battery in the lift truck, using a suitable battery moving device. Reconnect the battery connector.

Testing, Charging, and Maintenance

For information on testing, charging, and maintaining your lift truc k battery, consult the battery manufacturer’s specifications and instruction manual.

NOTE: Never plug the battery charger into the lift truck. This severely damages the lift truck’s electrical system. Plug the charger only into the connector from the battery.

Battery State-of-Charge

5.Keep the top of the battery clean and dry. Corrosion, dust, and moisture provide a conducting path to short-circuit cells or create shorts to ground.

NOTE: DO NOT clean the top of the battery with the soda solution while it is installed in the lift truck. Water can seep into the electrical components and cause serious damage.

6.Wash dirty batteries (or any that have had electrolyte spilled on them) with a solution of 1 lb. (0.45 kg) of baking soda added to 0.5 gal. (1.9 liters) of hot water.

Battery State-of-Charge (BSOC) is a feature that monitors and remembers the charge level of the battery connected to the lift truck and prevents excessive discharging of that battery. Operating a lift truck using a discharged battery can damage both the battery and the electrical components of the lift truck. See page5-4 for a detailed description of how BSOC works and the procedure for setting BSOC Cutout.