Piler Fork Overtravel

Fork extension has exceeded its maximum allowed travel distance, triggering a safety stop.

Probable Causes (ranked)

• Fork extend limit switch failed or wiring broken
• Hydraulic valve sticking — fork continues extending after command removed
• PLC output stuck ON due to relay welding
• Limit switch actuator bent or misaligned
• Encoder on fork drive giving incorrect feedback

Fix Steps

1. 1 Verify fork extend limit switch operation manually — actuate by hand, watch PLC input LED
2. 2 Check hydraulic directional valve — use manual override to test
3. 3 Inspect PLC output module — check for welded relay contacts with multimeter
4. 4 Realign or replace limit switch actuator bracket
5. 5 Test fork drive encoder separately to confirm counts match actual travel

Suggested Replacement Parts

Parts matched to fault category: Limit Switch

Prices are estimates. Verify part numbers match your equipment before ordering.

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