Walkie 101 20000 Up MM

Maintenance Manual
Model 101 Walkie Pallet Truck

Serial No.: 101-00-20000 and up
PDMM-0100 Issued: 5/21/01

PDMM-0100B Revised: 3/14/03
Raymond is a trademark of The Raymond Corporation. All other brand and product names are
trademarks or registered trademarks of their respective companies.
© Copyright The Raymond Corporation 2001.
All Rights Reserved.
Raymond® Walkie Pallet Truck Maintenance Manual Page Revision Record
Page Revision Record

This page is a record of the revision of all pages in this manual. Whenever a page is revised, this
section is updated and included in the revision.
Pages can be revised due to technical or non-technical changes.
• Technical changes are identified by a vertical line (change bar) in the left margin adjacent to the
change.
• Non-technical changes, such as typographical/grammatical corrections, paragraph
renumbering, repagination and so on, are not identified with a change bar.
All pages affected by changes are identified with "Revised: mm/dd/yy" in the footer of the page.
Document Revision History

• PDMM-0100 . . . . . . . . . . . . . . Original Issue, dated 5/21/01
• *PDMM-0100B . . . . . . . . . . . . . Revision B, dated 3/14/03
* Denotes revision is posted on the Raymond iNet.
List of Pages
Cover ......................3/14/03
iii ............................3/14/03
iv ............................3/14/03
1-1 thru 1-6 ............5/21/01
1-7 ..........................3/14/03
1-8 ..........................3/14/03
1-9 ..........................3/14/03
1-10 thru 1-12 ........5/21/01
2-1 thru 2-16 ..........5/21/01
3-1 thru 3-3 ............5/21/01
3-4 ..........................3/14/03
3-5 thru 3-8 ............5/21/01
4-1 thru 4-8 ............5/21/01
5-1 thru 5-14 ..........5/21/01
5-15 ........................3/14/03
5-16 ........................3/14/03
5-17 thru 5-70 ........5/21/01
6-1 ..........................5/21/01
6-2 ..........................3/14/03
6-3 thru 6-68 ..........5/21/01
6-69 ........................3/14/03
6-70 thru 6-84 ........5/21/01
A-1 thru A-16..........5/21/01
I-1 thru I-4..............3/14/03
PDMM-0100B Revised: 3/14/03 iii

Page Revision Record Raymond® Walkie Pallet Truck Maintenance Manual
Page Revision Record
This page intentionally left blank.
iv PDMM-0100B Revised: 3/14/03

Raymond® Walkie Pallet Truck Maintenance Manual How to Use This Manual
How to Use This Manual

1:snHow To Use This Manual
1:
PDMM-0100 Issued: 5/21/01 1-1

How to Use This Manual Raymond® Walkie Pallet Truck Maintenance Manual
Map of the Manual
Map of the Manual
How to Use This

Manual
Map of the Manual
Manual Design
Safety
Page Revision
Record
Vehicle
Systems
Specifications
Overview
Table of Contents
General System
Data
Scheduled
Start Page
Maintenance
Theory of
Operations
Trouble Electrical &

Shooting Hydraulic T.S.
Guidelines
Definitions
Component
Alphabetical List
Procedures
of Component
Procedures
Fault Codes
Component
Location Photos
Appendix
Programmable
Maintenance Tool
Index Troubleshooting
Charts
map.wmf
1-2 PDMM-0100 Issued: 5/21/01

Manual Design
Manual Design
The Raymond® Walkie Pallet Truck
Maintenance Manual is designed with the
following objectives in mind:
• Provide technical coverage for expected
levels of user expertise
• Anticipate your needs and reduce your
decisions regarding maintenance
• Reduce page flipping through a “one-stop
shopping” approach
The two-line running page header at the top of

each page tells you the following:
• Name of the manual
(Raymond® Walkie Pallet Truck
Maintenance Manual)
• Current chapter title
(example: this page How to Use This
Manual)
• Current topic
(example: this page Manual Design)
We suggest you get in the habit of turning to the

START page first when you use this manual.
PDMM-0100 Issued: 5/21/01 1-3

Manual Design
The START page asks a few simple questions to

guide you to the proper chapter.
• How to Use This Manual explains the
manual format and design and contains the
Table of Contents and START page.
• Safety explains warning and caution notes,
general safety rules and safety rules for
batteries, static, jacking, and welding.
• Systems Overview includes truck
specifications and theory of operation
information.
• Scheduled Maintenance outlines the
recommended schedule of preventive
services to keep your truck working most
efficiently.
• Troubleshooting is a set of “decision-tree”
charts designed to take you from a
symptom to a specific sequence of tests in
order to isolate a failing component.
• TS1: START TROUBLESHOOTING on
page 5-27 will guide you to the
individual troubleshooting symptom
chart you need.
• Once you are familiar with the
symptoms listed, you may instead find
the symptom chart from the List of
Troubleshooting Charts on page 5-25.
• When you complete a troubleshooting
procedure, be sure to follow the steps in
the END1: End of Troubleshooting
Procedure on page 5-30.
• Component Procedures gives step-by-step
procedures for testing, removal,
installation, and adjustment of individual
truck components. Components are listed
in an order which considers:
• Frequency of attention
• Physical attachment (example: brake
must be removed before drive motor)
• Functional relation (example: drive
motor and drive unit components are
grouped together)
1-4 PDMM-0100 Issued: 5/21/01

Manual Design
To find a component procedure, you may

use one of three methods:
• Look up the component name. See List
of Component Procedures on page 6-2.
• Find the component. See Component
Locator Photos on page 6-5.
• Look up the component name in the
Index on page I-1.
• Appendix contains reference information
such as torque values, lubricants and
schematics.
• Index lists subjects alphabetically.
PDMM-0100 Issued: 5/21/01 1-5

Manual Design
1-6 PDMM-0100 Issued: 5/21/01

Raymond® Walkie Pallet Truck Maintenance Manual How To Use This Manual
Table of Contents
Table of Contents
Page Revision Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Map of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Manual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
START Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Jacking Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Tie-down for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Truck Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Vehicle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
General System Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Special TPDMM-0100Bools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Every Two Months or 250 Operating Hours. . . . . . . . . . . . . . . . 4-4
Annually or Every 1500 Operating Hours . . . . . . . . . . . . . . . . . 4-6
Grease Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
PDMM-0100B Revised: Draft 1-7

How To Use This Manual Raymond® Walkie Pallet Truck Maintenance Manual
Table of Contents
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
How to Use This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Electrical Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . 5-3
Hydraulic Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . 5-6
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Electrical Connector Locator Chart . . . . . . . . . . . . . . . . . . . . . 5-12
Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Programmable Maintenance Tool (PMT) . . . . . . . . . . . . . . . . . . 5-15
List of Troubleshooting Charts. . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Troubleshooting Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

List of Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Component Locator Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Tractor Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Power Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Diodes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Switches (General). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Control Handle Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Main ON/OFF Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Brake (Deadman) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Lift-Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Hydraulic Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Motor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
1-8 PDMM-0100B Revised: Draft

Table of Contents
Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Motors, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
Drive Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70
Adjusting Hydraulic Pump Pressure Relief Valve . . . . . . . . . . . 6-72
Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81
Cold Storage Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Lubrication Equivalency Chart . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Torque Chart - Standard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Torque Chart - Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
PDMM-0100B Revised: Draft 1-9

Table of Contents
1-10 PDMM-0100 Issued: 5/21/01

START Page
START Page
START: Why are you here?
To review Go to Chapter 2
safety Yes "Safety"
precautions?
No
To examine
Go to Chapter 3
specifications
Yes "Systems Overview"
or theory of
operations?
No
To do Go to Chapter 4
scheduled Yes "Scheduled Maintenance"
maintenance?
No
Go to Chapter 5
To troubleshoot Yes "Troubleshooting"
a problem?
List of Troubleshooting Charts

No
Go to Chart START Troubleshooting

START-2
startpg1.wmf
PDMM-0100 Issued: 5/21/01 1-11

START Page
START-2
To test,
inspect, adjust,
Go to Chapter 6
remove/install a Yes
"Component Procedures"
component?
Alphabetical List of
No
Component Procedures
Component Locator
To find
Go to Chapter 7
general reference Yes
"Appendix"
information?
No
To locate an Go to the Index

object or Yes
procedure by
name?
startpg2.wmf
1-12 PDMM-0100 Issued: 5/21/01

Raymond® Walkie Pallet Truck Maintenance Manual Safety
Safety 2:
PDMM-0100 Issued: 5/21/01 2-1

Safety Raymond® Walkie Pallet Truck Maintenance Manual
Definitions
Definitions
Throughout this manual, you will see two kinds
of safety reminders:
! WARNING
Warning means a potentially
hazardous situation exists that, if not
avoided, could result in death or
serious injury.
! CAUTION
Caution means a potentially
hazardous situation exists that, if not
avoided, could result in minor or
moderate injury or in damage to the
truck or nearby objects.
2-2 PDMM-0100 Issued: 5/21/01

General Safety
General Safety
Do NOT operate or work on this truck unless

you are trained, qualified and authorized to do
so and have read the Owner/Operator Manual.
1864 002.eps
Know the truck’s controls and what they do.
Do NOT operate this truck if it needs repair or if

it is in any way unsafe.
1808 002.eps
Operate this truck only from the operator’s

position.
1808 003.eps
PDMM-0100 Issued: 5/21/01 2-3

General Safety
Before working on this truck, always turn the

key switch to OFF and disconnect the truck’s
battery connector (unless this manual tells you
otherwise).
1808 004.eps
Do NOT wear watches, rings, or jewelry when

working on this truck.
1864 067.eps
Follow the scheduled lubrication, maintenance

and inspection steps.
schedmnt.eps
Follow exactly the safety and repair instructions

in this manual. Don’t take “shortcuts.”
2-4 PDMM-0100 Issued: 5/21/01

General Safety
Do NOT use an open flame near the truck.
23L6S012.eps
Do NOT use gasoline or other flammable liquids

for cleaning parts.
Clean up any hydraulic fluid, oil or grease that

has leaked or spilled on the floor.
spills.eps
Always park this truck indoors.
1808 005.eps
PDMM-0100 Issued: 5/21/01 2-5

General Safety
Do NOT park this truck in a cold storage area

overnight.
Do NOT wash this truck with a hose.
Do NOT add to or modify this truck until you

contact your local Raymond Dealer to receive
written manufacturer approval.
2-6 PDMM-0100 Issued: 5/21/01

Battery Safety
Battery Safety
! WARNING
As a battery is being charged, an
explosive gas mixture forms within
and around each cell. If the area is
not properly ventilated, this
explosive gas can remain in or
around the battery for several hours
after charging. Be sure there are no
open flames or sparks in the
charging area. An open flame or
spark can ignite this gas, resulting in
serious damage or injury.
! WARNING
Battery electrolyte is a solution of
sulfuric acid and water. Battery acid
causes burns. Should any electrolyte
come in contact with your clothing or
skin, flush the area immediately with
cold water. Should the solution get
on your face or in your eyes, flush
the area with cold water and get
medical help immediately.
Wear personal protective equipment to protect

eyes, face and skin when checking, handling or
filling batteries. This equipment includes
goggles or face shield, rubber gloves (with or
without arm shields) and a rubber apron.
25L6SO16.eps
Make sure a shower and eyewash station are

nearby in case there is an accident.
04G6S059.eps
PDMM-0100 Issued: 5/21/01 2-7

Battery Safety
A battery gives off explosive gases. NEVER

smoke, use an open flame, or use anything that
gives off sparks near a battery.
23L6S012.eps
Keep the charging area well-ventilated to avoid

hydrogen gas concentration.
04G6S058.eps
Turn the key switch OFF before disconnecting

the battery from the truck at the battery
connector. Do NOT break live circuits at the
battery terminals. A spark often occurs at the
point where a live circuit is broken.
Do NOT lay tools or metal objects on top of the

battery. A short circuit or explosion could
result.
04G6S057.eps
Keep batteries clean. Corrosion causes shorts

to the frame and possibly sparks.
2-8 PDMM-0100 Issued: 5/21/01

Battery Safety
Keep plugs, terminals, cables and receptacles in

good condition to avoid shorts and sparks.
27Y7S013.tif
Vent Hole
Keep filler plugs firmly in place at all times
except when the electrolyte level is checked,
when water is added to the cells or when the
specific gravity is checked.
Make sure the vent holes in the filler plugs are
open to allow the gas to escape from the cells.
09G6S047.tif
Do NOT allow cleaning solution, dirt or any

foreign matter to enter the cells.
Make sure you install the correct size battery. A

smaller or lighter weight battery could seriously
affect truck stability. See the truck’s spec plate
for more information.
PDMM-0100 Issued: 5/21/01 2-9

Battery Safety
Never plug a battery charger into the truck’s

battery connector. Plug the battery charger only
into the battery connector from the battery.
1808 006.eps
Follow the charging procedures in the Battery

Instruction Manual and in the Battery Charger
Instruction Manual.
25L6S014.eps
2-10 PDMM-0100 Issued: 5/21/01

Jacking Safety
Jacking Safety
Sometimes you may need to jack the truck off
the floor to perform maintenance procedures.
When doing so, observe the proper safety
precautions:
1. Lower the forks completely. Remove any
load.
2. Place all controls in neutral.
3. Block the wheels to prevent movement of
the vehicle.
4. Disconnect the battery connector.
5. Place the jack under the designated jacking
points.
! WARNING
Use extreme care whenever the
truck is jacked up. Keep hands and
feet clear from vehicle while jacking
the truck. After the truck is jacked,
place solid blocks beneath it to
support it. DO NOT rely on the jack
alone to support the truck.
Fork Section
1. Using the lift button, raise the forks to
maximum height.
2. Block the fork section as shown in
Figure 2-1. The tractor section will remain
on the floor.
3. Lower the forks onto blocks.
4. Turn the key switch OFF and disconnect
the battery connector.
27Y7S068.tif
Figure 2-1: Blocking the Fork Section
PDMM-0100 Issued: 5/21/01 2-11

Jacking Safety
Tractor Section
1. Place the jack in the designated jacking
position.
2. Jack one side of the truck so that the drive
tire is off the floor no more than 1 in.
(25.4 mm).
3. Block that side of the truck in place.
4. Jack the other side of the truck level with
the first side.
5. Block that side of the truck in place.
NOTE: After working on a vehicle, test all
controls and functions to assure proper
operation.
2-12 PDMM-0100 Issued: 5/21/01

Tie-down for Transport
Tie-down for Transport

To transport your Raymond Walkie Pallet Truck
in an over-the-road vehicle or rail car, follow
these steps:
1. Lower the forks and locate the truck in the
center of the transport vehicle.
2. Using a suitable lifting device, remove the
battery. See “Battery” on page 6-8.
3. Position the adjustable chain over and
through the battery compartment.
4. Position an additional adjustable chain over
and through the battery compartment.
5. Position the chain ends of one chain toward
the front of the vehicle bed and the chain
ends of the other chain to the back of the
vehicle bed and draw taut. See Figure 2-2.
NOTE: This will secure the truck to the vehicle 1808 007.eps
bed and prevent tip-over and forward or Figure 2-2: Tie-Down for Transport
backward movement.
6. Secure the battery according to the battery
manufacturer’s instructions. If equipped,
remove the battery cover or storage tray
from the top of the battery and store
separately.
PDMM-0100 Issued: 5/21/01 2-13

Towing
Towing
To safely tow a Raymond Walkie Pallet Truck:
1. Lower the forks and remove any load.
3. Using a suitable towing vehicle, lift the
tractor end of the truck until the drive tire
is no more than 1 in. (25.4 mm) off the
floor.
4. Tow the truck slowly in the tractor-first
direction.
2-14 PDMM-0100 Issued: 5/21/01

Welding Safety
Welding Safety
! WARNING
Flame cutting or welding on painted
surfaces may produce potentially
harmful fumes, smoke and vapors.
Prior to performing flame cutting or
welding operations, it is
recommended that the coating be
removed in the vicinity where the
operation(s) will be performed.
Coating removal may be by

mechanical methods, chemical
methods or a combination of
methods. Flame cutting and/or
welding operations should be carried
out only in well ventilated areas
using local exhaust if necessary.
Before working on this truck, make sure that:

• Fire protection equipment is nearby.
• You know where the nearest eyewash
station is.
• Disconnect the battery before you attempt
to inspect, service or repair the lift truck.
Discharge residual charge in the motor
controller by connecting a load across the
controllers B+ and B- (such as a contactor
04GSO59.eps
coil or by pressing the horn button).
• Check for shorts to frame as described on
page 5-5. If any shorts are detected, remove
them before you proceed with the welding
operation.
• Clean the area to be welded.
• Protect all truck components from heat,
weld spatter and debris.
• Attach the ground cable as close to the weld
area as possible.
1808 004.EPS
PDMM-0100 Issued: 5/21/01 2-15

Welding Safety
• Do not perform any welding operations

near the electrical components.
• If welding must be done near the battery
compartment, remove the battery from the
truck.
• When you are finished welding, perform all
ground tests and electrical inspections
before the vehicle is operated.
2-16 PDMM-0100 Issued: 5/21/01

Raymond® Walkie Pallet Truck Maintenance Manual Systems Overview
Systems Overview 3:
PDMM-0100 Issued: 5/21/01 3-1

Systems Overview Raymond® Walkie Pallet Truck Maintenance Manual
Truck Model Identification
Truck Model Identification
1581 001.tif
Figure 3-1: Model 101 Walkie Pallet Truck
Vehicle Specifications
! WARNING
The total weight of the load must
include the pallet and the container
or the device holding the load.
Category Model 101

Maximum Load Capacity 4,500 lb (2,041 kg)
Upright Height 50.8 in. (129.1 cm)
Overall Length (Handle Raised) up to 81.8 in. (207.8 cm)
Overall Width 30.0 in. (76.2 cm)
Maximum Lift Height 9.25 in. (23.5 cm)
Regular Speed, Maximum 3.9 mph (6.3 kph)
Stopping Distance 6 ft. (1.83 m)
Battery Compartment Width 9.0 in. (22.8 cm)
Battery Voltage 24 volts
Minimum Battery Weight 200 lb (91 kg)
Maximum Battery Weight 660 lb (299 kg)
Truck Weight Without Battery 800 lb (362 kg)
Wheel: Drive 10.5 x 5 in. Rubber
Wheel: Load 3.25 x 5 in. Polyurethane (2)
3-2 PDMM-0100 Issued: 5/21/01

General System Data

3:snSystems Overview
General System Data
Gauge
Console
Battery
Control
Handle Load
Wheels
Fork
Section
Drive Unit
Figure 3-1: Model 101 General System Data
PDMM-0100 Issued: 5/21/01 3-3

Special Tools
Special Tools
Programmable Maintenance
Tool
The optional Programmable Maintenance Tool
(PMT) (P/N 950-185/002) allows you to test,
program (or configure) and diagnose the motor
controller in the truck.
The PMT is powered by the host controller
through the four-pin connector located at the
bottom of the controller.
27y7s021.tif
Figure 3-2: Programmable Maintenance Tool
3-4 PDMM-0100B Revised: 3/14/03

Theory of Operation
3:snSystems Overview
Theory of Operation
Lift/Lower
The lift/lower system consists of an electrically
operated hydraulic pump assembly and related
components.
The hydraulic pump assembly consists of a
positive displacement rotary gear pump with
reservoir mounted to an adapter. A DC electric
motor is mounted to the opposite side of the
pump adapter. An adjustable relief valve, check
valve, and a solenoid operated lowering valve
are located within the adapter.
With the forks elevated, the normally closed
solenoid valve and the check valve prevent
hydraulic fluid from returning to the reservoir.
Lift
When the battery is plugged in, the Main
ON/OFF switch is ON, the key switch is ON,
and the lift button is pressed:
• Lift switch (SW12) closes.
• Lift pump contactor (M2) closes, applying
B+ to the lift motor causing the lift pump to
operate.
• Hydraulic fluid is drawn through the 100
micron screen in the reservoir into the lift
pump.
• As the pump rotates, oil is forced out the
pressure port through the lift hose to the
lift cylinder. Oil cannot return to the
reservoir because of the closed pressure
relief valve and closed lowering solenoid
valve (SOL).
• Hydraulic pressure in the lift cylinder raises
the forks.
Lift cutout switch (SW10) will interrupt
power to the lift motor when the forks reach
a preset lift limit.
PDMM-0100 Issued: 5/21/01 3-5

Directional/Speed Control
• When the lift switch is open, the pump

contactor coil is de-energized. This stops
the lift motor and pump. The forks are held
in position by hydraulic fluid trapped in the
cylinder by the check valve, the static
position of the relief valve, and the closed
lowering solenoid (SOL).
The relief valve will open if the hydraulic
pressure exceeds the preset limit.
Lower
When the battery is connected, the Main
ON/OFF switch is ON, the key switch is ON and
the lower button is pressed:
• Lower switch (SW11) is closed, applying B+
to the lowering solenoid (SOL).
• Lowering solenoid opens.
• Hydraulic fluid in the lift cylinder returns to
the hydraulic reservoir through the
lowering valve and the flow control valve.
• The forks lower.
The following descriptions assume the battery is
charged and connected, the Main ON/OFF
switch (SW13) is ON, and the key switch (SW1)
is ON.
The control handle must be in the proper
position to close the brake (deadman) switch
(SW2) and release the brake. See “Brake
(Deadman) Switch” on page 5-7. When the
brake (deadman) switch is closed, main
contactor (M1) is energized.
NOTE: When the control handle is released and
the deadman switch opened, the main
contactor (M1) will remain energized for
several seconds before de-energizing.
Forward
When the twist grip/butterfly control is rotated
in the forward direction (tractor first) from
neutral:
• Forward directional switch (SW3) is closed
and B+ voltage is applied to PMC-12 of the
motor controller.
3-6 PDMM-0100 Issued: 5/21/01

• The resistance across the throttle

potentiometer (VR-4 to VR-2) increases
from zero ohms to a maximum of 6.5K
ohms. Throttle input voltage is then
generated at PMC-6 with respect to PMC-7.
• Once the throttle input voltage is above the
neutral band threshold the motor controller
begins to provide current flow through the
drive motor armature at M-. It also provides
current flow through the field windings in
the proper polarity at S1 and S2.
• The drive wheel begins to rotate in forward
direction at a speed proportional to throttle
input.
Reverse
When the twist grip/butterfly control is rotated
in the reverse direction (forks first) from
neutral:
• Reverse directional switch (SW4) is closed
and B+ voltage is applied to PMC-11 of the
motor controller.
• The resistance across the throttle
potentiometer (VR-4 to VR-2) increases
from zero ohms to a maximum of 6.5K
ohms. Throttle input voltage is then
generated at PMC-6 with respect to PMC-7.
• Once the throttle input voltage is above the
neutral band threshold the motor controller
begins to provide current flow through the
drive motor armature at M-. It also provides
current flow through the field windings in
the proper polarity (S1 and S2).
• The drive wheel begins to rotate in reverse
direction at a speed proportional to throttle
input.
Emergency Reverse
If the emergency reverse switch (belly button
switch) (SW7) is closed with the control handle
lowered (SW2 closed) in travel mode, the control
system will provide an immediate, rapid
acceleration in the reverse (forks-first) direction:
• Emergency reverse switch (SW7) is closed
applying B+ voltage to PMC-13.
• Travel inputs (VR, SW3, SW4) are ignored.
PDMM-0100 Issued: 5/21/01 3-7

Motor Controller
• The polarity of the field voltage at S1 and S2

is reversed by the motor controller.
• The motor controller provides maximum
torque immediately after the emergency
reverse switch is closed and current limit is
automatically set to the higher plugging
value (approximately 300 Amps).
• Maximum reverse travel will continue until
the emergency reverse switch is released.
Once the emergency reverse switch is activated,
the motor controller inhibits the forward
direction. To reset the truck for normal travel,
the handle must be cycled to “brake applied”
position (SW2 open). Turning the key switch
OFF and then ON will also reset the motor
controller.
Motor Controller
The basic functions of the motor controller
include:
• The direction control section controls the
drive motor direction by manipulating the
drive motor field polarity according to the
directional switch inputs (SW3, SW4).
• The throttle control section controls the
drive motor speed and torque by monitoring
relative position change of the wiper in the
travel potentiometer with respect to the
static neutral position. Variable motor
speed is accomplished by separate control
of field and armature currents.
• The emergency reverse circuitry controls
the override of the directional travel control.
• Controls main contactor (M1) operation.
• The diagnostics section continuously
monitors the travel circuits for fault
conditions and responds appropriately,
shutting down travel in some cases.
3-8 PDMM-0100 Issued: 5/21/01

Raymond® Walkie Pallet Truck Maintenance Manual Scheduled Maintenance
Scheduled Maintenance 4:
PDMM-0100 Issued: 5/21/01 4-1

Scheduled Maintenance Raymond® Walkie Pallet Truck Maintenance Manual
Maintenance Guidelines
Maintenance Guidelines
Following a regularly scheduled maintenance
program:
• Promotes maximum truck performance
• Prolongs truck life
• Reduces costly down time
• Avoids unnecessary repairs
Scheduled maintenance includes:
• Lubrication
• Cleaning
• Inspection
• Service
Perform all of the scheduled checks and
maintenance during the suggested intervals.
The intervals given in this guide are based on
normal operating conditions. When operating
under abnormal or severe conditions, perform
these services more often as required to keep
the unit in good operating condition.
See “Lubrication Equivalency Chart” on page
A-2. Refer to the manufacturer’s supplements
for components not listed on the following
pages.
4-2 PDMM-0100 Issued: 5/21/01

Daily
Daily
Perform the daily checks and report any faults
or abnormal conditions to your supervisor.
Item Daily or Eight Hour Checklist
Check cleanliness and exterior condition. See “Battery

Exterior Cleaning” on page 6-9.
Check the charge.
Check the weight.
Battery Check the connector. Make sure all powered functions shut
down when disconnected.
Make sure the battery is properly installed.
Check the “free play” of the battery. Make sure the battery
does not move more than 0.5 in. (12.7 mm).
Check that the horn operates when you press the horn
button. (Battery must be connected and the Main ON/OFF
switch must be ON.)
Check the speed and directional controls.
General Operation Check the steering operation.
Check the lifting and lowering functions.
Check the operation of the emergency reverse button.
Note any unusual noise during operation, and report it to
your supervisor or maintenance personnel.
Verify the drive motor does not run while the brake is
applied.
Brake
Check that the control handle returns to the vertical
position when released.
Warning/Safety/Operational decals must be in place and

Decals legible. Notify your local authorized Raymond Dealer if any
decal is defective.
Hydraulic System Check for oil leaks.
Check the condition of the drive wheel and load wheels.

Remove any steel chips and foreign material to prevent
Wheels/Tires damage to the wheels.
Check for gouging and chunking of the surface. If damaged,
report to your supervisor or maintenance personnel.
PDMM-0100 Issued: 5/21/01 4-3

Every Two Months or 250 Operating Hours
Every Two Months or

250 Operating Hours
Perform daily checks plus the following:
Item Every Two Months or Every 250 Hours
Lubricate all grease fittings. See “Grease Fittings” on page

Grease Fittings
4-7.
Check the lift limit switch for lift motor cut-out. Adjust if
Forks
necessary.
Lubrication Points Lubricate all levers, shafts and linkage points.
Check the lift cylinder for leaks. Replace cylinder if

Lift Cylinder
necessary. See “Hydraulic Cylinder” on page 6-74.
Check for proper fluid level with the forks fully lowered -
within 1 in. (25.4 mm) of filler plug. Add fluid if necessary.
See “Lubrication Equivalency Chart” on page A-2.
Check hydraulic connections and mountings.
Hydraulic System
Check the tightness of the pump and motor hardware.
Check hoses, tubes and fittings for leaks. Replace hoses or
seals. Clean the fill/vent plug. See “Hydraulic Unit” on
page 6-77.
Check for loose hardware. Tighten if necessary.

General Check the tightness of the drive unit mounting bolts.
Tighten if necessary.
Visually inspect all cables for damage. Replace if necessary.

See “Power Cables” on page 6-16.
Electrical System
Check for electrical shorts to frame. See “Checking for
Shorts from Battery to Truck Frame” on page 5-4.
Check the tightness of the retaining nut on the drive wheel

Drive Wheel
mounting. Tighten to 250 ft. lbs. (339.2 Nm).
Check for oil leaks. If leaks are found, check the oil level. If
the oil level is low, determine the cause. See “Drive Unit”
Drive Unit on page 6-57.
Check and lubricate the transmission pivot bearing. See
Figure 4-2.
Check the condition of brushes, springs and holders.

Check that the brush length exceeds the minimum length.
Motor Brushes
Drive motor - 0.62 in. (15.7 mm)
Hydraulic pump motor - 0.5 in. (12.7 mm)
Brake (Deadman) Check adjustment. See “Brake (Deadman) Switch” on page

Switch 6-27.
Check and lubricate the load wheel bearings and linkage.

Load Wheel
See “Grease Fittings” on page 4-7.
4-4 PDMM-0100 Issued: 5/21/01

Every Two Months or 250 Operating Hours
Item Every Two Months or Every 250 Hours
Check the brake shoes for wear. Replace if necessary. See

Brake
“Brake” on page 6-43.
Clean the battery and the truck. See “Battery Exterior

Battery System
Cleaning” on page 6-9.
PDMM-0100 Issued: 5/21/01 4-5

Annually or Every 1500 Operating Hours
Annually or Every 1500

Operating Hours
Perform the Every Two Month checks plus the
following:
Item Annually or Every 1500 Hours
Change the oil in the drive housing.

Drive Housing
See “Drive Housing Lubrication” on page 6-62.
4-6 PDMM-0100 Issued: 5/21/01

Grease Fittings
Grease Fittings
665 044.tif
Figure 4-1: Load Wheel Axle (Cold Storage and

Lubrication Package Option Only)
1665 045.tif
Figure 4-2: Pivot Bearing (Standard)
Figure 4-3: Pull-Rod (Cold Storage and Lubrication

Package Option Only)
PDMM-0100 Issued: 5/21/01 4-7

Grease Fittings
Figure 4-4: Load Wheel Fork (Cold Storage and

Lubrication Package Option Only)
Figure 4-5: Lower-Link (Cold Storage and Lubrication

Figure 4-6: Rear Pull-Rod (Cold Storage and Lubrication

4-8 PDMM-0100 Issued: 5/21/01

Raymond® Walkie Pallet Truck Maintenance Manual Troubleshooting
Troubleshooting 5:
PDMM-0100 Issued: 5/21/01 5-1

Troubleshooting Raymond® Walkie Pallet Truck Maintenance Manual
How to Use This Chapter
How to Use This Chapter

This chapter uses a set of “decision-tree” charts
designed to take you from a symptom to a
specific sequence of tests in order to isolate a
failing component.
• Use the TS1: START TROUBLESHOOTING
on page 5-27 to guide you to the individual
symptom chart you need.
• Once you’re familiar with the symptoms
listed, you may instead simply look up the
symptom chart from the List of
Troubleshooting Charts on page 5-25.
As you work with a troubleshooting symptom
chart, you may be instructed to test various
electrical connector pins.
Every time you complete a troubleshooting
procedure, be sure to follow the steps in the
END1: End of Troubleshooting Procedure on
page 5-30.
If the troubleshooting symptom charts do not
isolate the problem, or if the symptoms are not
consistent or repeatable, go to GEN1: General
Troubleshooting on page 5-28. This chart will
help you approach the problem in a systematic
and logical manner.
Each chart begins with an oval-shaped symbol
containing the title and symptom. Charts are
identified as H for Hydraulic and T for Travel.
The logic generally flows top to bottom and left
to right. A symbol shaped like a baseball home
plate means the chart is continued on another
page (either a continuation of the current chart,
or a different chart). Continuation charts have a
suffix number added. A continuation chart
begins with a circle-shaped symbol containing
the chart number and suffix.
For example, look at Chart H-3 on
page 5-38. One logic path is continued on Chart
H-3-2, which is the next page. Another logic
path from Chart H-3 goes to the END1: End of
Troubleshooting Procedure on page 5-30.
5-2 PDMM-0100 Issued: 5/21/01

Electrical Troubleshooting Guidelines
Electrical
Troubleshooting
Guidelines
Many problems are caused by a faulty or dirty
battery. Make sure the battery is clean. Check
the electrolyte level and state-of-charge. See
“Battery” on page 6-8. Be sure to block the
truck whenever a troubleshooting procedure
requires turning the key switch ON. This will
avoid accidents caused by unexpected truck
travel.
! CAUTION
Unless otherwise directed, disconnect
the battery connector when you
check electrical circuits or
components with an ohmmeter.
Electrical current can damage the
ohmmeter.
Save time and trouble by looking for simple

causes first.
Visually inspect all wiring and electrical
components for:
• Loose connections or connectors
• Loose or broken terminals
• Damaged terminals, blocks, or strips.
• Broken wiring and shorted conditions
(especially those that are close to metal
edges or surfaces)
Use an ohmmeter to check for wiring continuity
and shorts.
For information on pin, connector, and harness
connections, see “Wiring Harness” on page 6-17
and see “Electrical Connector Locator Chart” on
page 5-12.
PDMM-0100 Issued: 5/21/01 5-3

Checking for Shorts from Battery to Truck Frame
Checking for Shorts from

Battery to Truck Frame
2. Use a voltmeter set on a 50 volt DC scale.
3. Attach the voltmeter leads as follows:
• Negative (-) lead to an unpainted,
grounded surface on the truck frame
• Positive (+) lead to the positive battery
terminal,
4. The voltmeter should show no more than 3
volts.
5. Now attach the voltmeter leads as follows:
• Negative (-) lead to the negative battery 1665 051.TIF
terminal Figure 5-1: Battery Shorts to Frame, testing
• Positive (+) lead to an unpainted,
grounded surface on the truck frame
6. The voltmeter should show no more than 3
volts.
7. If you get more than a three volt reading in
Step 4 or 6:
a. Remove the battery from the truck. See
“Battery” on page 6-8.
b. Thoroughly clean the battery. See
“Battery Exterior Cleaning” on page 6-9.
c. Reinstall the battery.
d. Repeat steps 2 through 6 to see if this
has eliminated the problem.
e. If excessive voltage is still found, have
the battery checked for internal leakage.
5-4 PDMM-0100 Issued: 5/21/01

Checking for Shorts from Components to Truck
Checking for Shorts from

Components to Truck Frame
2. Use an ohmmeter and measure the
resistance to an unpainted, grounded
surface on the frame at B+, B-, and all
fuses. See Figure 5-2.
A resistance reading of less than 1000
ohms indicates a serious short to frame. If
this condition exists, locate the source of
low resistance or short to frame using
step 6. Do not continue until this condition
is corrected.
3. Remove the battery from the truck. See
“Battery” on page 6-8. 1665 052.tif
Figure 5-2: Component Shorts to Frame, testing

4. Connect the battery lead to the truck.
5. Use an ammeter to measure the leakage
current to an unpainted, grounded surface
on the frame at B+, B-, all fuses and all
motors. If the current is less than 0.001
ampere (1mA), the truck system passes. If
the current exceeds 1mA, go to step 6.
6. To find the cause of the low resistance,
disconnect the power cables from each
motor or major sub-assembly one at a time,
to determine if that item is causing the low
resistance.
PDMM-0100 Issued: 5/21/01 5-5

Hydraulic Troubleshooting Guidelines
Hydraulic
Troubleshooting
Guidelines
When you check voltage at solenoids, make
sure hydraulic lines and components are fully
installed.
Use an ohmmeter to check for wiring continuity
to solenoids. Use an ammeter to check for
proper current to solenoids and contactor coils
(refer to specific component tests).
! CAUTION
ohmmeter.
Visually inspect all hydraulic lines and

components for:
• Leaking connections or connectors
• Loose or broken fittings
• Damaged tubing, hoses, vents, or seals
5-6 PDMM-0100 Issued: 5/21/01

Definitions
Definitions
Acceleration Rate
The time required for the controller to increase
from 0% to 100% duty cycle (PWM) when a
continuous 100% throttle request is applied.
Acceleration rate is an adjustable parameter
within program mode. See “Motor Controller
Parameter Settings (User Access Only)” on page
5-21.
Brake (Deadman) Switch

The switch (also known as deadman switch)
10
(SW2) that must be closed to allow truck travel.
The switch is activated by the control handle
position. The switch acts to protect against
travel while the brake is applied. The handle
must be positioned between 10° of vertical and 10
10° of horizontal in order for the brake
(deadman) switch to be closed, allowing travel. 1820 001.EPS
See Figure 5-3. Figure 5-3: Brake (Deadman) Switch and Brake Actuation
Continuity
A continuous and uninterrupted path between
two or more locations in an electrical circuit,
typically having a resistance of less than 1 ohm.
Creep Speed
Creep speed is activated when a direction is
first selected. It is the speed at the minimum
throttle setting (minimum PWM). See “Pulse
Width Modulation” on page 5-9. The output
maintains creep speed until the throttle is
rotated out of the throttle minimum setting
(10% of throttle). Creep speed is adjustable
from 0–10% PWM duty cycle. The factory
default value is 0%.
Current Limiting
A protective function of the motor controller
which prevents excessive current levels from
damaging drive components. The controller has
adjustable current limit parameters for the
drive current, brake (plugging) current, field
current maximum, and field current minimum.
PDMM-0100 Issued: 5/21/01 5-7

Definitions
Emergency Reverse
Emergency Reverse is activated when the
emergency reverse switch (“Belly Button”
switch) is pressed while the brake is released
and the keyswitch (SW1) is ON. After the “Belly
Button” (BB) switch is released, normal
controller operation is not resumed until
neutral (no direction) is selected or until the
brake is cycled (brake, then brake release).
However, repeatedly pressing the BB switch will
reactivate the emergency reverse function each
time.
Fault Codes
The motor controller provides fault information
by flashing fault codes via the status LED built
into the controller cover. See “Fault Codes” on
page 5-13.
High Pedal Disable (HPD)

The HPD feature prevents the truck from being
started while the throttle is applied. The motor
controller can be programmed to have HPD
based on either the brake (deadman) switch or
key switch input. The Model 101 is Type “1”
(only key switch input required prior to 25%
throttle).
Neutral Braking
The automatic process by which the drive motor
creates torque opposite to the direction of travel
when the throttle is returned to neutral with the
control arm in travel position. This is a
programmable parameter (Neutral Braking). See
“Motor Controller Parameter Settings (User
Access Only)” on page 5-21.
Open Circuit
A lack of a continuous path between two or
more electrical connections. Usually greater
than one megohm resistance.
5-8 PDMM-0100 Issued: 5/21/01

Overtemperature (Motor Controller)

Overtemperature of the motor controller is
185°F (85°C) and above. At overtemperature the
drive current limit is linearly decreased from
full set current down to zero.
NOTE: Plugging strength is not decreased at
any overtemperature level.
Overvoltage Cutoff
Overvoltage protection resets the internal
microprocessor, zeros out the pulse width
modulation, and shuts down the controller.
Controller operation resumes when the voltage
is brought within the acceptable range. The
cutoff voltage and re-enable voltage are set at
the factory and are not adjustable.
Plugging (Plug Braking)

The process by which the drive motor creates
torque opposite to the direction of travel
proportional to the throttle command opposing
the current travel direction. The braking
(plugging) current limit is a programmable
parameter and is normally set higher than the
drive current limit. This parameter is factory
preset and not user adjustable.
Pulse Width Modulation

Pulse Width Modulation (PWM), also called
“chopping,” controls the speed of the motor by
switching the battery voltage applied to the
motor on and off very quickly.
Ramp Shape
The ramp shape (acceleration) is the
relationship between the speed/directional
control rotation and truck response (PWM
output). It is adjustable (throttle map
parameter) so you can provide the proper feel
for each truck.
Ramp shape number refers to the PWM output
at half throttle, as a percentage of its full range.
PDMM-0100 Issued: 5/21/01 5-9

Sequencing Delay
Sequencing delay allows the brake (deadman)
switch to be momentarily opened within a set
time (sequency delay), thus preventing
inadvertent activation of high pedal disable
(HPD) or static return to off (SRO). See “Static
Return To Off (SRO)” on page 5-11 or High
Pedal Disable (HPD) on page 5-8. This feature
is useful in applications where the brake
(deadman) switch may bounce or be
momentarily cycled during operation.
Short Circuit or “Short”

A short circuit is an unspecified path in a
circuit that provides unwanted full or partial
continuity between two or more locations in an
electrical circuit.
Example: Two insulated wires are physically
next to each other and the insulation has been
worn off each of the wires. Because the
conductors inside each wire are now touching
each other, there is a short circuit.
Example: A power cable from the battery to a
junction post in the truck has had the
insulation worn away. Because the wire
conductors are touching the tractor frame,
there is a short circuit of the battery cable.
Speed Limiting
The controller can limit the maximum speed:
• “Max speed” parameter limits the maximum
PWM for both directions of travel. This is a
programmable parameter. See “Motor
Controller Parameter Settings (User Access
Only)” on page 5-21.
5-10 PDMM-0100 Issued: 5/21/01

Static Return To Off (SRO)
Static Return To Off (SRO)

The SRO feature prevents the truck from being
started (direction selected) prior to the release of
the brake (brake [deadman] switch closed). SRO
checks sequencing of the brake (deadman)
switch input and KSI relative to the direction
input. The brake (deadman) switch must be
activated before the speed/directional control is
rotated. If a direction is selected before or
simultaneously (within 50 milliseconds) with
the brake input, the motor controller will not
command travel.
Tractor
The body section of the truck that contains the
motors, drive unit, controls, and handle.
Undertemperature
When the controller is operating at less than
-25°C (-13°F), current limit is reduced to about
one-half of the set current resulting in reduced
travel speed.
Undervoltage Cutback
Undervoltage protection automatically disables
the controller output if the battery voltage is
detected below the undervoltage point at
startup, or when the battery voltage is pulled
below the undervoltage point by an external
load. The undervoltage cutback point is set at
the factory and is not adjustable.
PDMM-0100 Issued: 5/21/01 5-11

Electrical Connector Locator Chart
Electrical Connector
Locator Chart
Refer also to electrical schematics located in the
Appendix and wiring harness component
procedures.
Connector Function or Routing Location

PMC1 Connector on motor controller Motor controller
JP2 Handle functions In control handle
JP3 Travel functions (C.S. only) In control handle
JP6 Travel functions In control handle
JP9 Meters (Options) By key switch
JPS1 Splice for brake switch circuits In control handle
Table 5-1: Electrical Connector Locator Chart
5-12 PDMM-0100 Issued: 5/21/01

Fault Codes
Fault Codes
An internal microcontroller automatically
checks the function of the motor controller.
When this microcontroller detects a fault, it
signals the appropriate fault code through the
LED on the bottom of the motor controller.
Under normal operation, the LED flashes a
single flash at approximately one flash every
five seconds. A two-digit flash code signals a
fault has been detected by the microcontroller.
Correct faults by following the Troubleshooting
Charts beginning on page 5-21.
Fault Code Explanation / Possible Cause

LED off No power or defective controller
Solid on Defective motor controller
Single flash ¤ Controller operational, normal operation, no faults
1, 1 ¤ ¤ Current sensor error: Motor controller malfunction
1, 2 ¤ ¤¤ Hardware fail-safe error: motor controller malfunction
1, 3 ¤ ¤¤¤ Internal M- short to B-: Motor controller malfunction
1, 4 ¤ ¤¤¤¤ Static Return to Off (SRO) fault: Improper sequence of key
switch, interlock, or direction inputs. Wrong SRO type
selected. Interlock or direction switch circuit open. Sequence
delay too short.
2, 1 ¤¤ ¤ Potentiometer (Pot) wiper circuit fault: Pot wiper wire open. Pot
wiper wire shorted to B- or B+. Bad throttle pot.
2, 2 ¤¤ ¤¤ Emergency reverse wiring fault: Belly button wire open. Belly
button check wire open.
2, 3 ¤¤ ¤¤¤ High-Pedal-Disable (HPD) fault: Improper sequencing of key
switch, brake switch and throttle inputs. Wrong HPD type
selected. Misadjusted throttle pot. Sequencing delay too short.
2, 4 ¤¤ ¤¤¤¤ Pot low fault: Pot wiper wire open. Pot wire shorted to B- or B+.
3, 1 ¤¤¤ ¤ Contactor driver output overcurrent or field winding shorted:
Main contactor coil shorted. Field winding shorted.
3, 2 ¤¤¤ ¤¤ Main contactor welded: Main contactor stuck closed. Main
contactor driver shorted.
3, 3 ¤¤¤ ¤¤¤ Motor field winding open: Field winding open. Field connection
open.
3, 4 ¤¤¤ ¤¤¤¤ Missing contactor: Main contactor coil open. Wire to main
contactor coil open or shorted to B-.
PDMM-0100 Issued: 5/21/01 5-13

Fault Codes
Fault Code Explanation / Possible Cause

4, 1 ¤¤¤¤ ¤ Low Battery Voltage: Low battery voltage (less than 16 V).
Corroded or loose battery terminal. Loose controller terminal.
4, 2 ¤¤¤¤ ¤¤ Overvoltage: High battery voltage (greater than 29 V). Vehicle
operating with charger attached.
4, 3 ¤¤¤¤ ¤¤¤ Overtemperature or undertemperature cutback: Temperature
greater than 185°F (85°C) or less than -13°F (-25°C). Excessive
load on vehicle. Operation in extreme environments.
4, 4 ¤¤¤¤ ¤¤¤¤ Mode 2 or Mode 4 selected at start-up: Mode switch(es) shorted
to B+. Mode switch(es) taped or “tied” down.
Table 5-2: Fault Codes
5-14 PDMM-0100 Issued: 5/21/01

Programmable Maintenance Tool (PMT)

5:snTroubleshooting
Programmable
Maintenance Tool (PMT)
The optional Programmable Maintenance Tool
allows you to test and diagnose the motor
controller in this walkie pallet truck. See
“Programmable Maintenance Tool” on page 3-4.
The PMT is powered by the host controller
through a four-pin connector at the bottom of
the controller. See Figure 5-4.
When the PMT is first plugged into the
controller, the PMT displays the controller’s
model number, date of manufacture, and
software revision code. Following this initial
display, the PMT displays a prompt for further
instruction.
NOTE: Follow the prompt at the top of the PMT
screen, not the blinking icon, to choose
the desired menu item.
The operating modes are Program, Test,
Diagnostics, Special Program and Special
Diagnostics.
The programmer is operated via an 8-key
Connector
keypad. The three top keys select the three
standard operating modes (Program, Test,
Diagnostics), two keys scroll the display up and
down, and two keys change the value of
selected parameters. The eighth key, the More
Info key, is used to display further information
about selected items within any of the three
standard modes. In addition, when pressed
together with the Program or the Diagnostics
key, the More Info key selects the Special
Program mode or the Special Diagnostics mode.
1665 037.tif
When one of the menu keys is pressed, the LED Figure 5-4: Connecting PMT to Motor Controller
at the corner of the key lights up, identifying
the mode of operation. Four lines of a menu are
displayed at a time in the LCD display window.
The item at the top of the display window is the
selected item. To select an item, scroll within
the menu until the desired item is positioned at
the top of the display window. In Program
mode, the selected item is highlighted by a
flashing arrow.
PDMM-0100B Revised: 3/14/03 5-15

Diagnostics Modes
Diagnostics Modes
The PMT is used to access the diagnostic
history file of the motor controller.
The PMT can display all of the faults the
controller has recorded since the diagnostic
history file was last cleared. The faults may be
intermittent, caused by loose wires, or caused
by operator error.
For example, a contactor fault may be caused
by loose wires; carefully check contactor wiring.
A High Pedal Disable (HPD) or overtemperature
fault may be caused by operator habit or
overloading.
In Diagnostics mode, currently active faults
detected by the controller are displayed.
In Special Diagnostics mode, the controller
diagnostic history file is displayed. This field
includes a list of all faults observed and
recorded by the controller since the history was
last cleared.
NOTE: Each fault is listed only once, regardless
of the number of times it occurred.
Diagnostics Mode Access

1. Turn the key switch OFF.
2. Remove the tractor cover.
3. Connect the PMT to the motor controller.
4. Turn the key switch ON.
5. Access the Diagnostics mode by pressing
the Diagnostics key to display the currently
active faults detected by the controller. See
Table 5-4 on page 5-19.
6. Press the More Info key when in the
Diagnostics mode to display additional
information about the selected item.
Special Diagnostics Mode Access

5-16 PDMM-0100B Revised: 3/14/03

Test Mode
5:snTroubleshooting
5. Hold the More Info key, then press the

Diagnostics key. See Table 5-4 on page
5-19.
6. Scroll through the line items using either
Scroll Display key. When the item you want
is the top line on the display, press the
More Info key to display additional
information about the selected item.
Clear
After you have diagnosed and corrected the
problem, you should clear the diagnostic
history file. This allows the motor controller to
accumulate a new file of faults. By checking the
new history file at a later date, you can easily
determine whether the problem was completely
fixed.
1. Hold the More Info key, then press the
Program key. Release both keys after you
enter the Special Program mode.
2. Scroll through the modes using the Scroll
Display keys until “CLEAR DIAG HIST” is
the top line in the display.
3. Press the More Info key again. Follow the
PMT on-screen instructions to acknowledge
or cancel.
4. Press the Change Value Up scroll key to
clear the diagnostic history. Press the
Change Value Down key to cancel.
NOTE: “CLEAR DIAG HIST” also resets the
maximum and minimum temperatures
listed in the Test Menu.
Test Mode
Real-time status information is displayed in
Test mode for various inputs, outputs,
temperature, etc. This information can be
helpful in troubleshooting many problems and
is useful for checking out the operation of the
controller during initial installation.
In the Test mode, the item of interest does not
need to be the top item on the list; it only needs
to be among the four items visible in the
window.
NOTE: Test items may be viewed while
operating the truck.
PDMM-0100 Issued: 5/21/01 5-17

Test Mode
Access
5. Press the Test key on the PMT. See
Table 5-3.
Scroll Display key. When the item you want
is the top line on the display, press the
More Info key for a full screen display of
additional information about the selected
item.
Test Mode
Display Explanation
THROTTLE% Throttle reading, in percent of full throttle
ARM CURRENT Motor armature current, in amps
FIELD CURRENT Motor field current, in amps
ARM PWM Armature duty cycle (PWM) - applied as %
FIELD PWM Motor field duty cycle (PWM) - applied as %
BATT VOLTAGE Battery voltage (B+ and B- connection) at key switch input
CAP VOLTAGE Voltage of controller B+ (bus bar)
HEAT SINK TEMP Heat sink temperature - °C
FORWARD INPUT Forward switch: on/off
REVERSE INPUT Reverse switch: on/off
MODE Controller operating mode: 1 to 4
INTRLCK INPUT Interlock (brake/deadman) switch: on/off
PEDAL INPUT (not used)
EMR REV INPUT Emergency reverse switch: on/off
MOTOR RPM (not used)
MAIN CONT Main contactor: on/off
AUX CONT (not used)
REV OUTPUT (not used)
BRAKE OUTPUT (not used)
FAULT 1 OUTPUT (not used)
FAULT 2 OUTPUT (not used)
CONTROL STATE (not used)
MODSEL 1 Mode select 1 switch: on/off
MODSEL 2 Mode select 2 switch: on/off
Table 5-3: Test Mode Menu
5-18 PDMM-0100 Issued: 5/21/01

Test Mode
The table below lists possible messages you

may see displayed when the PMT is operating in
either the Diagnostics or the Special
Diagnostics mode. See “Diagnostics Modes” on
page 5-16.
Diagnostics and Special Diagnostics List
Display Explanation
NO KNOWN FAULTS No known faults occurred
ANTI-TIEDOWN Improper mode select switch input at start-up
ARM SENSOR See Fault Code 1,3: Defective motor controller
BB WIRING CHECK BB wiring check failed (Emergency Reverse)
CONT DRVR CHECK Contactor driver overcurrent; shorted M1 coil
FIELD OPEN See Fault Code 1,3: Motor field winding open
FLD SENSOR See Fault Code 1,3: Defective motor controller
HPD High-pedal-disable (HPD) activated
HW FAILSAFE 1 Power-On self-test fault (defective controller)
HW FAILSAFE 2 External watchdog fault
HW FAILSAFE 3 External watchdog fault
LOW BATTERY VOLTAGE Battery voltage too low (less than 16 volts)
M- SHORTED (M-) terminal shorted to B-
MAIN CONT DNC Main contactor did not close
MAIN CONT WELDED Main contactor welded
MISSING CONTACTOR Open M1 contactor circuit
OVERVOLTAGE Battery voltage too high (greater than 29V)
PRECHARGE FAULT Internal capacitors did not charge properly
SRO Static-return-to-off (SRO) activated
THERMAL CUTBACK Thermal cutback due to temperature (over/under)
THROTTLE FAULT 1 Throttle wiper input fault
THROTTLE FAULT 2 Throttle low input fault
Table 5-4: Diagnostics and Special Diagnostics List
PDMM-0100 Issued: 5/21/01 5-19

Program Mode
Program Mode
In the Program mode, all the adjustable
parameters and features of the controller are
displayed (four at a time), along with their
present settings. All changes occur in “real
time”; the parameters can be changed while the
truck is in operation.
5. Press the Program key to enter Program
mode. See Table 5-1 on page 5-21.
6. Press either Scroll Display key until the
parameter you want is the top line of the
display (with the flashing arrow).
7. Press either Change Value key until the
setting you want is displayed. The
parameter is now set at the value you
selected.
8. If the display stops changing and you want
to go further, press the More Info key. If the
display shows “Min Limit” or “Max Limit,”
you have reached the factory set limit for
that parameter.
NOTE: The parameter may depend on another
parameter. If so, the display will show
this information. Changing the related
parameter may allow you to change the
setting further.
To find definitions of each parameter, see
“Definitions” on page 5-7.
5-20 PDMM-0100 Issued: 5/21/01

Program Mode
Default
Parameter Range Description
Setting
(M1) Neutral 0-100% 0% % Automatic plug (brake) current when

Brake throttle is returned to neutral.
Quick Start 0-2 0 Controls how output (PWM) will respond to

rate of throttle change.
(M1) Accel 0-3 seconds 1.0 second Time to reach full output (PWM) from zero
Rate output in M1 (high speed, PMC-3 on) mode.
(M1) Max 40-100% 96% Maximum speed (PWM duty factor) in M1

Speed (high speed) mode.
Table 5-1: Motor Controller Parameter Settings (User Access Only)
! CAUTION
While adjustment of these parameters is possible, settings at values other

than those listed above will produce improper and unauthorized operational
characteristics.
PDMM-0100 Issued: 5/21/01 5-21

Special Program Mode

Special Program mode allows you to perform a
variety of tasks. Table 5-2 on page 5-22 shows
the line items in Special Program mode. To
distinguish between the Program and Special
Program modes, look at the menu items in the
display (See “Program Mode” on page 5-20.)
Access
5. Press and hold the More Info key; then
press the Program key. See Table 5-2 on
page 5-22.
Scroll Display key until the item you want
to change is the top line on the display.
Press the More Info key again to find out
how to make the adjustment.
7. Press either Change Value key until you
reach the value you want.
Display Explanation
RESET ALL SETTINGS Revert to default settings. See Table 5-1 on page 5-21.
CONT SETTINGS→ PROG Save controller settings in PMT. See “Cloning” on page 5-23.
PROG SETTINGS→ CONT Load programming settings in controller.
CLEAR DIAG HISTORY Clear diagnostic history memory.
CONTRAST ADJUSTMENT Adjust display contrast.
LANGUAGE SELECTION Select displayed language.
PROGRAMMER INFO Display PMT information.
CONTROLLER INFO Display controller info.
Table 5-2: Special Program Modes
5-22 PDMM-0100 Issued: 5/21/01

Cloning
Cloning
Using the PMT, you can copy or “clone”
parameters and options from one motor
controller to another. Cloning only works
between controllers with the same model
number and software version.
Copy Parameters
1. Turn the key switch OFF. Remove tractor
cover.
2. Connect the PMT to the motor controller
you want to clone. See Figure 5-4.
4. Press and hold the More Info key, then
press the Program key. Release both keys
after you enter Special Program mode.
Display keys until
“CONT SETTINGS PROG”
is the top line in the display.
6. Press the More Info key again. The PMT will
prompt you to acknowledge (save controller
settings in PMT) or cancel.
Enter Parameters
1. Disconnect the PMT from the motor
controller that you used to “clone”
parameters.
2. Turn the key switch OFF. Remove the
tractor cover.
3. Connect the PMT to the motor controller
you want to program.
5. Press and hold the More Info key, and press
the Program key. Release both keys after
you enter Special Program mode.
Display keys until
“PROG SETTINGS CONT”
is the top line in the display.
7. Press the More Info key again. The PMT will
prompt you to acknowledge (load
programming settings in controller) or
cancel.
PDMM-0100 Issued: 5/21/01 5-23

Cloning
5-24 PDMM-0100 Issued: 5/21/01


5:snTroubleshooting

TS1: START TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
GEN1: General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
MISC: Miscellaneous Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
END1: End of Troubleshooting Procedure. . . . . . . . . . . . . . . . . . . . . 5-30
Hydraulic Charts
H-1: No Lift, Lift Motor Does Not Run, Travel is OK . . . . . . . . . . . . . 5-31
H-2: No Lift or Slow Lift, Lift Motor Does Run. . . . . . . . . . . . . . . . . . 5-36
H-3: No Lower, Lift and Travel OK . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Travel Charts
T-1: No Travel, Lift/Lower OK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
T-2: No Travel in Either Direction. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
T-3: No Travel in Either Direction, Lift/Lower OK . . . . . . . . . . . . . . . 5-46
T-4: No Travel, Lift/Lower OK, Fault Code 1,2 . . . . . . . . . . . . . . . . . 5-47
T-5: No Travel, Main Contactor Does Not Close,
Motor Controller Fault Code 3,4 . . . . . . . . . . . . . . . . . . . . . . . 5-48
T-6: No Travel, Main Contactor Does Close,
Motor Controller Fault Codes 2,1 or 2,4 (or both) . . . . . . . . . . 5-49
T-7: Slow Travel, Lift/Lower OK, No Fault Code . . . . . . . . . . . . . . . . 5-51
T-8: No Emergency Release, Travel/Lift/Lower OK . . . . . . . . . . . . . . 5-55
T-9: Slow Travel, Lift/Lower OK. Fault Code 2,2 . . . . . . . . . . . . . . . . 5-56
T-11: No Travel. Fault Code 4,2.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
T-12: Slow or No Travel. Fault Code 4,1 . . . . . . . . . . . . . . . . . . . . . . 5-58
T-13: Slow or No Travel. Fault Code 4,3 . . . . . . . . . . . . . . . . . . . . . . 5-60
T-14: No Travel. Fault Code 1,4. SRO . . . . . . . . . . . . . . . . . . . . . . . . 5-63
T-15: No Travel, Fault Code 2,3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
T-17: Plugging Does Not Operate Properly . . . . . . . . . . . . . . . . . . . . 5-67
T-18: Truck Does Not Accelerate Properly. . . . . . . . . . . . . . . . . . . . . 5-68
Wiring Charts
W-1: Truck Functions Partially. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
PDMM-0100 Issued: 5/21/01 5-25

Wiring Charts
5-26 PDMM-0100 Issued: 5/21/01

Troubleshooting Flowcharts
5:snTroubleshooting
Troubleshooting
Flowcharts
TS1: START TROUBLESHOOTING
TS1: START TROUBLESHOOTING
Are travel Are hydraulic

No No
functions OK? functions OK?
Yes
Go to Chart Go to Chart
Yes T-1 GEN1
Are hydraulic
No
functions OK?
Yes
MISC H-1
TS-1.wmf
PDMM-0100 Issued: 5/21/01 5-27

GEN1: General Troubleshooting
GEN1: General Troubleshooting
Gather as much
information as you Eliminate unlikely
What is the problem?
can about the causes.
problem.
Where did it happen?
When did it happen?
Select and prioritize

What functions are affected? the most likely
causes.
What conditions trigger the problem?
Check each likely

Talk directly to the
cause, using the tests
operator or foreman.
in this manual.
Check all other truck

Operate the truck functions before
yourself. returning the truck to
service.
Using the schematics

if necessary, identify
all components which
could cause the
problem.
Gen1.wmf
5-28 PDMM-0100 Issued: 5/21/01

MISC: Miscellaneous Problems
MISC: Miscellaneous Problems Not Covered By Other

Charts
Is a wiring
problem No
suspected?
Yes
W-1 GEN1
misc.wmf
PDMM-0100 Issued: 5/21/01 5-29

END1: End of Troubleshooting Procedure
END1: End of Troubleshooting Procedure
Operate the truck as it

Make sure ALL wires, was being operated
hoses, and cables that when the problem
you removed have been occurred. Verify the
re-attached correctly. problem does not recur.
Have the driver operate

Make sure all panels are the truck. Verify the
properly reinstalled. problem does not
recur.
Make sure any

component that was Fill out any required
drained has been forms.
refilled with the
correct level of fluid.
This is especially
If you contacted Raymond important if the
Create the same
Field Service to discuss solution you
conditions that occurred
the problem, call them found is not in
when the problem first
again to let them know the
happened.
what fixed the problem. troubleshooting
chart.
End of Troubleshooting
End1.wmf
5-30 PDMM-0100 Issued: 5/21/01

H-1: No Lift, Lift Motor Does Not Run, Travel is OK
1 H-1: No Lift, Lift Motor Does Not Run,

Travel is OK.
With key switch on,

cycle the lift switch.
Listen to/feel the
pump contactor.
With key switch on

and lift switch
Does
depressed, measure
contactor
No voltage between
energize
pump contactor coil
(click)?
M2-X and M2-Y
terminals.
Is B+ voltage
Yes
present?
Yes
No
Replace pump
With battery plugged contactor
in, measure voltage
between B- and
With key switch off and battery
CB1-2. disconnected, check for
continuity and wiring shorts
Go to Chart between:
END1
Yes
Pump contactor coil M2-Y to B-
Pump contactor M2-X to lift
cut-out switch
Lift cut-out switch to JP2-4
JP2-4 to control handle lift
Replace/Reset switch SW12-4
Is B+ voltage
No Circuit Breaker Control handle lift switch
present?
CB1. SW12-3 to JP2-2
JP2-2 to keyswitch (SW1)
Yes
Go to Chart Go to Chart Go to Chart

H-1-2 END1 H-1-4
H-1-1a.wmf
PDMM-0100 Issued: 5/21/01 5-31

H-1-2
With key switch off and
battery disconnected,
check for continuity and
wiring shorts between
FU1-2 to circuit breaker
CB-1; circuit breaker
With key switch on
CB-1 to pump contactor;
and lift switch
pump contactor to pump
depressed, measure
motor.
voltage across B- and
lift pump motor MP-1
terminal.
Is circuit Replace circuit

No
breaker OK? breaker.
No
Is B+ present?
Yes Go to Chart
End1
Yes
With key switch off

and battery
disconnected, check
lift motor brushes. No Repair or replace.
Are cables OK?
Yes
Go to Chart
End1
No Replace pump
Are brushes OK? Replace brushes.
contactor.
Yes

H-1-3 End1 End1
H-1-2a.wmf
5-32 PDMM-0100 Issued: 5/21/01

H-1-3
Test pump motor.

See Component
Procedures.
Is motor OK? No Replace motor.
Yes
With key switch off

and battery
disconnected, remove Go to Chart
motor from pump. END1
See Component
Procedures. Turn
pump shaft with
hand.
Does pump run

No Replace pump.
freely?
Yes
Verify the problem still

exists. Repeat H-1. If Go to Chart Go to Chart
you return here, go to GEN1 END1
General
Troubleshooting.
H-1-3a.wmf
PDMM-0100 Issued: 5/21/01 5-33

H-1-4
Is wiring OK? No Repair or replace.
Yes Yes
With key switch off

and battery
disconnected, check Go to Chart
for continuity in END1
control handle lift
switch.
Are switch(es)
No Repair or replace.
OK?
Yes
With forks lowered,

key switch off,
battery disconnected Go to Chart
and lift cut-out End1
switch closed check
for continuity in lift
cut-out switch.
Go to Chart
H-1-5
H-1-4a.wmf
5-34 PDMM-0100 Issued: 5/21/01

H-1-5
Is switch OK? No Repair or replace.
Yes Yes
With key switch off,

battery disconnected Go to Chart
and wires removed, END1
measure resistance of
pump contactor coil.
Is
it approximately No Replace contactor.
16 ohms?
Yes

exists. Repeat H-1. If Go to Chart
you return here, go to END1
General
Troubleshooting.
Go to Chart
GEN1
H-1-5a.wmfL
PDMM-0100 Issued: 5/21/01 5-35

H-2: No Lift or Slow Lift, Lift Motor Does Run
H-2: No Lift or Slow Lift,

Lift Motor Does Run
Check for any Check hydraulic

Check the battery. mechanical binding pressure. See relief
See Component in lift cylinder valve settings in
Procedures. linkages and major Component
leaks. Procedures.
No
Replace or recharge Is there binding Is pressure

Is battery OK? No
the battery. or major leaks? correct?
No
Yes
Yes Yes
With key switch off

and battery Verify that the problem
disconnected, check Go to Chart still exists. Repeat H-2.
the lift motor and END1 Repair. If you return here, go to
brushes. See General
Component Troubleshooting.
Procedures.
Yes
Is motor OK? No Repair or replace. END1 GEN1
Yes
END1 H-2-2
H-2-1a.wmf
5-36 PDMM-0100 Issued: 5/21/01

H-2-2

battery disconnected, and
Adjust lift pressure.
forks lowered, remove
See Component
pressure relief valve and
Procedures.
check for signs of damage
or contamination.
No
Was problem
Can you get the
Is relief valve OK? No caused by No Replace valve.
correct pressure?
contamination?
Yes Yes Yes

Flush system. Go to Chart
exists. Repeat H-2. If
Replace hydraulic END1
you return here, go to Replace pump.
fluid. See Component
General
Procedures.
Troubleshooting.
Was Go to Chart
contamination END1
No
found in
pump?
Go to Chart
GEN1
Yes
Go to Chart
Flush system. END1
Replace hydraulic
fluid. See Component
procedures.
Go to Chart
END1
H-2-2a.wmf
PDMM-0100 Issued: 5/21/01 5-37

H-3: No Lower, Lift and Travel OK
H-3: No Lower,
Lift and Travel OK.
With battery connected

and key switch ON, cycle
the lower switch and
listen to/feel the lower With battery connected,
solenoid. key switch ON, while
pressing lower switch,
measure voltage across
No lower solenoid: SOL1-X to
SOL1-Y.
Does solenoid
energize With key switch OFF and battery
(click)? disconnected, check for continuity and
wiring shorts between:
Is B+ present? No SOL1-Y to B-
SOL1-X to JP2-5
JP2-5 to LOWER SWITCH-SW11-4
Yes LOWER SWITCH-SW11-3 to JP2-2
JP2-2 to KEY SWITCH-IGN
Yes
With key switch OFF and

loosen, but DO NOT
REMOVE, the high
pressure line at the
hydraulic pump
assembly. Allow forks to
slowly lower. Have rags
and drain pan ready to
catch fluid. Yes
Repair mechanical With key switch OFF Go to Chart

binding in lift and battery END1
Do forks lower? No cylinders or fork disconnected, while
mechanism. See pressing switch, check
Component for continuity across
Procedures. lower switch.
Yes
Go to Chart
H-3-2 Go to Chart Go to Chart
END1 H-3-3
H-3-1a.wmf
5-38 PDMM-0100 Issued: 5/21/01

H-3-2
Allow forks to
completely lower.
Remove and inspect
solenoid valve for
free movement and
for signs of
contamination.
Is there free Is solenoid valve Replace solenoid

No restricted due to No
movement? valve.
contamination?
Yes Yes
Clean solenoid valve.

Remove
Replace or repair contamination. Flush
pump assembly. hydraulic system,
clean filter and install
new fluid.
Go to Chart
END1
H-3-2a.wmf
PDMM-0100 Issued: 5/21/01 5-39

H-3-3
Is switch OK? No Replace switch.
Yes

exists. Repeat H-3. If Go to Chart
you return here, go to END1
General
Troubleshooting.
Go to Chart
GEN1
H-3-3a.wmf
5-40 PDMM-0100 Issued: 5/21/01

T-1: No Travel, Lift/Lower OK
T-1: No Travel, Lift/Lower OK. Main Contactor Does Not Close.

Motor Controller LED is Flashing Once Every 2 Seconds.
Check the battery.

See Component
Procedures.
Charge or replace the

battery.
Is the battery
No
OK?
Go to Chart
END1
Yes
Are
Check the battery terminals and
terminals and quick quick disconnect No Repair or replace.
disconnect plug. plug
OK?
Yes
Go to Chart
With key OFF, battery END1
disconnected and control
handle in operating
position, disconnect wires
at brake switch. Check for
continuity at brake switch
SW2-C to SW2-NO.
PMT 1 can be used here. 1
Programmable
See PMT section in
Maintenance Tool
Troubleshooting.
Go to Chart
T-1-2
T-1-1a.wmf
PDMM-0100 Issued: 5/21/01 5-41

T-1-2
Repair, replace, or With key off and battery disconnected, check for
adjust brake continuity and wiring shorts between:
Is there
No switch SW2 SW1-BAT on key switch (switch closed/on) to SW2-C
continuity?
or mechanical SW2-NO to PMC-15
actuator.
Yes
With battery connected,

key switch on, and
brake switch closed,
Go to Chart
check for B+ at Repair or replace as
END1 Is the wiring OK? No
PMC-15. necessary.
PMT1 can be used
here. See PMT section
in Troubleshooting.
1
Programmable
Maintenance Tool
Go to Chart
Is there B+ at
No END1
PMC-15? Yes
Yes

Go to Chart exists. Repeat T-1. If
T-1-3 you return here, go to
General
Troubleshooting.
Go to Chart
GEN1
T-1-2a.wmf
5-42 PDMM-0100 Issued: 5/21/01

T-1-3
With truck jacked and

blocked, battery plugged
in, key switch on and
handle in travel position:
measure voltage at PMC- 1 Programmable
12 (with reference to B-)
Maintenance Tool
while rotating throttle in
forward direction.
PMT1 can be used here.
See PMT section in
Troubleshooting. With key switch off and battery
disconnected, check for continuity and
SW2-NO to JPS-1
JPS-1 to JP6-1
JP6-1 to FWD SW (SW3-C)
FWD SW (SW3)-C to REV SW (SW4)-C
Is B+ present? No
FWD SW (SW3)-NO to JP6-2
JP6-2 to PMC-12
REV SW (SW4)-NO to JP6-3
JP6-3 to PMC-11
Yes
Replace motor
controller.
Yes

END1 T-1-4 END1
T-1-3a.wmf
PDMM-0100 Issued: 5/21/01 5-43

T-1-4
With key switch off, battery

disconnected and FWD and REV
switches closed, check for
continuity between:
FWD SW-C to FWD SW NO (SW3)
REV SW-C to REV SW NO (SW4)
Are switches OK? No Replace switches.
Yes
Verify the problem still Go to Chart

exists. Repeat T-1. If you END1
return here, go to General
Troubleshooting.
Go to Chart
GEN1
T-1-4a.wmf
5-44 PDMM-0100 Issued: 5/21/01

T-2: No Travel in Either Direction
T-2: No Travel in Either Direction, Lift/Lower OK.

Motor Controller Fault Code 3,1.

remove connector PMC
from motor controller.
Measure resistance in Repair or replace
Is wiring OK? No
wiring harness between: wiring.
PMC-16 to PMC-4
battery disconnected, remove
connector PMC and check for
Yes
Go to Chart
between:
END1
Is resistance
PMC-4 to M1-Y Disconnect and
approximately No
PMC-16 to M1-X measure resistance
30 ohms?
SW1-IGN to M1-X of main contactor
coil.
Programmable Maintenance
Yes Tool can be used here. See
PMT section in
Troubleshooting.
With key switch off
and battery Is resistance
disconnected, approximately No Replace coil
remove wires S1 30 ohms?
and S2 at motor
controller. Measure
resistance in wiring
harness between S1 Yes
and S2. Go to Chart
Remove wires at S1 and
Verify the problem still END1
S2 at motor. Measure
exists. Repeat T-2. If
resistance between S1
you return here, go to
and S2 of motor.
No General
Troubleshooting.
Is resistance less
than 1.0 ohms?
Go to Chart Yes
Is resistance less GEN1
Yes
than 1.0 ohms?
Replace motor
controller. Repair or
replace wiring
With S1 & S2 wires
disconnected from
No
motor controller, check
Go to Chart Is wiring OK?
continuity and for
END1
Go to Chart
S1 (motor) to S1 (PMC)
END1
S2 (motor) to S2 (PMC)
T-2-1a.wmf
PDMM-0100 Issued: 5/21/01 5-45

T-3: No Travel in Either Direction, Lift/Lower OK
T-3: No Travel in Either Direction, Lift/Lower OK.


disconnect drive motor
cable at motor controller
terminal M-. Connect
battery, turn key
switch on.
Is Test motor. See

code 1,3 still No Component
displayed? Procedures.
Yes
Replace motor
Is motor OK? No Repair or replace.
controller.
Yes
Verify the problem

Go to Chart still exists. Repeat Go to Chart
END1 T-3. If you return END1
here, go to General
Troubleshooting.
Go to Chart
GEN1
T-3.wmf
5-46 PDMM-0100 Issued: 5/21/01

T-4: No Travel, Lift/Lower OK, Fault Code 1,2
T-4:No Travel in Either Direction, Lift/Lower OK.

Motor Controller Fault Code 1,2
Replace motor
controller.
Go to Chart
END1
T-4.wmf
PDMM-0100 Issued: 5/21/01 5-47

T-5: No Travel, Main Contactor Does Not Close, Motor Controller Fault Code 3,4
T-5: No Travel, Main Contactor Does Not Close.


Measure resistance of
main contactor coil.
Measure resistance in
wiring harness between:
PMC-16 to PMC-4

Are Are
No check for continuity and Replace coil.
there approx. there approx. No
30 ohms? 30 ohms?
PMC-16 to M1-X
PMC-4 to M1-Y
SW1-IGN to M1-X
Yes Yes
Verify the problem

still exists. Repeat Go to Chart
Replace motor END1
T-5. If the problem
controller.
still exists, go to
General
Troubleshooting.
Go to Chart
Go to Chart
END1
Is wiring OK? No Repair or replace. END1
Yes
Go to Chart
END1
T-5-1a.wmf
5-48 PDMM-0100 Issued: 5/21/01

T-6: No Travel, Main Contactor Does Close, Motor Controller Fault Codes 2,1 or 2,4 (or both)
T-6: No Travel, Main Contactor DOES Close.

Motor Controller Fault Codes 2,1 or 2,4 (or Both).

Measure resistance
between PMC-7 to PMC-6
while slowly rotating
throttle in both directions. 1 Programmable
Maintenance Tool
See PMT section in
Troubleshooting.

disconnected, check for
Does
resistance increase
between:
from 0-6K ohms in No
PMC-6 to JP6-4
each
JP6-4 to VR-2
direction?
VR-4 to JP6-5
JP6-5 to PMC-7
Yes

and PMC
disconnected: verify
PMC-6 and PMC-7 are
not shorted to B+, B-,
frame, or each other.
Is wiring OK? No Repair wires.
Yes
Yes

Replace motor END1 T-6-2 END1
controller.
Go to Chart
END1
T-6-1a.wmf
PDMM-0100 Issued: 5/21/01 5-49

T-6-2

disconnect JP6. Re-test
potentiometer resistance
between VR-4 and VR-2.
Does
resistance increase
from 0-6K ohms in No Replace throttle
each potentiometer.
direction?
Yes
Verify the problem

still exists. Repeat Go to Chart
T-6. If you return END1
here, go to General
Troubleshooting.
Go to Chart
END1
T-6-2a.wmf
5-50 PDMM-0100 Issued: 5/21/01

T-7: Slow Travel, Lift/Lower OK, No Fault Code
T-7: Slow Travel, Lift/Lower OK.

No Fault Codes.
Verify battery is Charge or replace

Is battery OK? No
charged. battery.
Yes
Verify programming of the

motor controller has not
changed using the Go to Chart
programmable END1
maintenance tool. See the
motor controller section in
Component Procedures.
Reset the controller

to parameters
Has described in Has travel
programming Yes Component returned to
changed? Procedures. Use the normal?
Programmable
Maintenance Tool
No
No
Yes
Test mode select inputs.
With battery connected
and key switch ON,
measure battery voltage Go to Chart
between: END1
B+ and PMC-9
B+ and PMC-14
to verify truck is operating
in the proper mode.
Programmable
Maintenance Tool can be
used here.
Go to Chart
T-7-2
T-7-1a.wmf
PDMM-0100 Issued: 5/21/01 5-51

T-7-2
With key switch OFF

and battery discon-
nected, remove PMC
No connector from motor
controller. Check for
continuity and wiring
Is B+ present shorts between: Are wiring and No Repair or replace.
in both cases? PMC-9 and B- switch OK?
PMC-14 and B-
PMC-16 and B+
using wiring diagram
Yes (schematic).
Yes
battery unplugged, remove
connector PMC from motor Verify the problem
controller. Measure resistance Go to Chart
still exists. Repeat T-
between PMC-7 to PMC-6 while END1
7. If you return here,
slowly rotating throttle in both go to General
directions. Troubleshooting.
See PMT section in
check for continuity and
Troubleshooting
PMC-6 to JP6-4
No JP6-4 to VR-2
VR-4 to JP6-5 Go to Chart
Does JP6-5 to PMC-7 GEN1
resistance increase
from 0-6K ohms in
each direction?

Yes
Turn key switch OFF, jack

and block truck. With key
switch ON and handle in
operating position, measure Yes
voltage at B+ of motor
controller (with reference to
M-) of motor controller with Repair or replace
throttle ON. throttle 1Programmable
potentiometer
Maintenance Tool
assembly. Yes
Go to Chart END 1 END 1
T-7-3
T-7-2a.wmf
5-52 PDMM-0100 Issued: 5/21/01

T-7-3
Does voltage
increase from 2 volts Replace motor
No
to B+ in each controller.
direction?
Yes
With key switch off

and battery
disconnected, check Go to Chart
the drive motor END1
brushes. See
Component
Procedures.
Are brushes OK? No Replace the brushes.
Yes
With key switch off, Go to Chart

test drive motor. See END1
Component
Procedures.
Go to Chart
T-7-4
T-7-3a.wmf
PDMM-0100 Issued: 5/21/01 5-53

T-7-4
Go to Chart
Is drive motor Replace or repair END1
No
OK? drive motor.
Yes
With truck jacked

and blocked, key
switch off and battery
With key switch off, Remove drive motor
disconnected, release
remove brake drum. from drive unit. See
the brake by pulling
See Component Component
the handle down into
Procedures. Procedures.
the operating
position. Turn the
brake drum by hand.
No No
Does the
brake release; Does the Does the
will the drum armature shaft armature shaft No
turn freely by turn freely? turn freely?
hand?
Yes Yes
Yes
Do load wheels spin No

freely?
Yes
Repair or Repair,
replace load Repair or Repair or
adjust, or
Verify the problem replace the replace drive
wheel replace the
still exists. Repeat T- drive unit. motor.
assembly brake.
7. If you return here,
go to General
Troubleshooting.
GEN1 END1
T-7-4a.wmf
5-54 PDMM-0100 Issued: 5/21/01

T-8: No Emergency Release, Travel/Lift/Lower OK
T-8: No Emergency Reverse, Travel/Lift/Lower OK.

No Motor Controller Fault Codes.
With truck jacked and blocked, With key switch off, battery
battery connected, key switch on disconnected and PMC
and handle in travel position; disconnected; check for
measure voltage at PMC-13 (with continuity of emergency reverse
reference to B-) while pushing switch (SW7) between:
emergency reverse switch. C (Common) and NO (Normally
1
PMT can be used here. See PMT Open) while holding switch
section in Troubleshooting. closed.
Is B+ present? No Is switch OK? No Replace switch.
Yes

Yes disconnected, check for continuity
and wiring shorts between:
SW2 (Brake)-NO to JPS-1 Go to Chart
JPS-1 to JP6-6 END1
JP6-6 to SW7 (Emergency Reverse)-C
Replace motor SW7-NO to JP6-7
controller. JP6-7 to PMC-13
Is wiring
OK?
Go to Chart
END1
Yes
1 Programmable
Maintenance Tool Go to Chart
exists. Repeat T-8. If you
END1
return here, go to General
Troubleshooting.
Go to Chart
GEN1
T-8-1a.wmf
PDMM-0100 Issued: 5/21/01 5-55

T-9: Slow Travel, Lift/Lower OK. Fault Code 2,2
T-9: Slow Travel, Lift/Lower OK. Speed Limited to 15%. Motor

Controller Fault Code 2,2 (Emergency Reverse Wiring Fault).

Measure resistance
between:
PMC-10 to PMC-13.
1
See PMT section in Programmable
Troubleshooting. Maintenance Tool
With key switch off, battery

disconnected and PMC disconnected,
check for continuity and wiring shorts
between:
Is there
No PMC-10 to JP6-8
continuity?
JP6-8 to SW7 (Emergency Reverse)-NO
JP6-7 to SW7 (Emergency Reverse)-NO
JP6-7 to PMC-13.
Yes
Replace motor
Is wiring OK? No Repair wiring.
controller.
Yes
Verify the problem

Go to Chart still exists. Repeat Go to Chart
END1 T-9. If you return END1
here, go to General
Troubleshooting.
Go to Chart
GEN1
T-9-1a.wmf
5-56 PDMM-0100 Issued: 5/21/01

T-11: No Travel. Fault Code 4,2.
T-11: No Travel. Motor Controller Fault Code 4,2 -

Excessive Battery Voltage (>29 Volts)
Verify the correct

battery is installed in
Is
truck. 1
battery charger Programmable
No PMT 1 can be used
plugged into Maintenance Tool
here. See PMT
truck?
section in
Troubleshooting.
Yes
Never plug charger

into truck.
Disconnect charger
immediately to Is correct battery Replace with correct
No
prevent further (24V) installed? battery.
damage. Only plug
specified battery into
truck.
Yes
Go to Chart
END1 Replace motor
controller.
END1 END1
T-11-1a.wmf
PDMM-0100 Issued: 5/21/01 5-57

T-12: Slow or No Travel. Fault Code 4,1
T-12: Slow or No Travel

Motor Controller Fault Code 4,1 - Low Battery Voltage (< 16 Volts).
Check the battery.

See Component
Procedures.
Replace or recharge
Is battery OK? No
battery.
Yes
Check the battery Go to Chart

terminals and quick END1
disconnect plug.
Are
terminals and
connectors
OK?
Yes
T-12-2 END1
T-12-1a.wmf
5-58 PDMM-0100 Issued: 5/21/01

T-12-
2
With key switch OFF and battery

disconnected, check for
between:
B-BAT to Motor Controller B-
B+BAT to Circuit Breaker CB1-1
CB1-1 to CB1-2
CB1-2 to Main Contactor M1-1
M1-1 to M1-2 1 Programmable
M1-2 to Motor Controller B+ Maintenance Tool
1
PMT can be used here. See PMT
section in Troubleshooting.
Are wires, fuses

and main No Repair or replace.
contactor
OK?
Yes
With key switch ON and battery Go to Chart

connected, while attempting END1
travel, measure voltage between
B- and:
CB1-1, CB-1-2, M1-1, M1-2, MD-
A1, motor controller B+
Is voltage equal Repair or replace

No faulty wiring or
to B+ (within
1.0 volt)? connector.
Yes
Replace motor
controller. Go to Chart
END1
T-12-2a.wmf
PDMM-0100 Issued: 5/21/01 5-59

T-13: Slow or No Travel. Fault Code 4,3
T-13: Slow or No Travel.

Motor Controller Fault Code 4,3 - Thermal Cutback.
Check the battery.

See Component
Procedures.
Replace or recharge
Is battery OK? No
battery.
Yes
Check for free Go to Chart

movement or END1
mechanical binding
of load wheels.
Do wheels
turn No Repair or replace.
freely?
Yes
T-13-2 END1
T-13-1a.wmf
5-60 PDMM-0100 Issued: 5/21/01

T-13-
2
With truck jacked

and blocked, key
switch off and battery
With key off, remove
disconnected, release
brake drum. See
the brake by pulling
Component
the handle down into
Procedures.
the operating
position. Turn the
brake drum by hand.
No
Does the Remove the drive

Does the
brake release; will motor from the drive
armature shaft No
the drum turn freely unit. See Component
turn freely?
by hand? Procedures.
Yes Yes
Go to Chart
Repair, adjust, or Does the Repair or replace the
T-13-3 No
replace the brake. armature shaft drive motor.
turn freely?
Yes
END1 Repair or replace the END1
drive unit.
Go to Chart
END1
T-13-2a.wmf
PDMM-0100 Issued: 5/21/01 5-61

T-13-
3
Check mounting of
Is truck
motor controller. It
overloaded or
should be mounted
operated under
No securely and in
conditions extreme
contact with the
for its intended
electrical panel (which
purpose?
acts as a heatsink).
Yes
Allow the motor

Operate and load
controller to cool
within specifications.
down and re-test the
truck.
Is controller
Go to Chart mounted
No Repair.
END1 correctly?
Yes
Replace motor
controller. Go to Chart
END1
Go to Chart
END1
T-13-3a.wmf
5-62 PDMM-0100 Issued: 5/21/01

T-14: No Travel. Fault Code 1,4. SRO
T-14: No Travel. Motor Controller Fault Code 1,4 -

Static Return To Off (SRO).
Condition: Directional inputs

The handle must be (Forward and/or Reverse) were
moved to the operating active prior to the handle being
position before the
lowered (brake switch closing).
throttle is rotated.
Was proper
Lower handle, then
sequence No
apply throttle.
followed?
Yes
Go to Chart
With key switch on and END1
battery plugged in,
measure voltage at:
PMC-12 and PMC-11
(with reference to B-).
1
PMT 1 can be used here. Programmable
See PMT section in Maintenance Tool
Troubleshooting.
Is B+ present? No
Replace
motor
Yes controller
T-14-2 END1
T-14-1a.wmf
PDMM-0100 Issued: 5/21/01 5-63

T-14-
2
Check directional switches

SW3, SW4 for shorted tips.
Are switches Repair or replace

No switches.
OK?
Yes
The motor controller is receiving a direction command on

Pin PMC-12 or PMC-11, before the handle is lowered. Go to Chart
With key switch off, battery disconnected and PMC END1
disconnected from motor controller, check for continuity
PMC-11 to JP6-3
JP6-3 to SW4 (Reverse)-NO
PMC-12 to JP6-2
JP6-2 to SW3 (Forward)-NO
Yes
Replace motor
controller.
END1 END1
T-14-2a.wmf
5-64 PDMM-0100 Issued: 5/21/01

T-15: No Travel, Fault Code 2,3
T-15: No Travel,
Motor Controller Fault Code 2,3 - High Pedal Disable.
Condition: Throttle circuit

was active prior to the
handle being lowered (brake
The handle must be switch closing).
moved to the
operating position
before the throttle
is rotated.
Was proper
Lower handle, then
sequence No
apply throttle.
followed?
Yes
Test and adjust throttle

potentiometer.
See Component Go to Chart
Procedures. END1
Programmable
Maintenance Tool can be
used here. See PMT
section in
Troubleshooting.
Adjust or replace
Is throttle throttle
potentiometer No potentiometer.
OK? See Component
Procedures.
Yes
T-15-2 END1
T-15-1a.wmf
PDMM-0100 Issued: 5/21/01 5-65

T-15-
2

disconnected, and PMC
disconnected from motor
controller, check for continuity
PMC-6 to JP6-4
JP6-4 to VR-2
VR-4 to JP6-5
JP6-5 to PMC-7.
Yes
Go to Chart
Replace motor END1
controller.
Go to Chart
END1
T-15-2a.wmf
5-66 PDMM-0100 Issued: 5/21/01

T-17: Plugging Does Not Operate Properly
T-17: Plugging Does Not Operate Properly.

Truck Travels OK in Forward and Reverse.

check brushes
and motor.
See Component
Procedures.
Are brushes and Repair or replace

No
motor OK? as necessary.
Yes
Go to Chart
END1
Replace the motor

controller.
Go to Chart
END1
T-18.wmf
PDMM-0100 Issued: 5/21/01 5-67

T-18: Truck Does Not Accelerate Properly
T-18: Truck Does Not Accelerate Properly.
With key switch off

and battery
disconnected, check
for mechanical
Check to see the reason for slow
battery is charged. acceleration.
(Dragging brake,
defective wheel
bearing, bad load
wheel, etc.)
Is there a
Is battery Charge or replace
No mechanical Yes Repair as required.
charged? battery.
problem?
No
Yes
Connect battery, turn key

With key switch off switch on and connect
and battery PMT1 to motor controller.
disconnected, check Go to Chart Use the PMT to adjust Go to Chart
throttle potentiometer END1 "ACCELERATION RATE" END1
adjustment. See to maximum. See
Component Component Procedures.
Procedures. Drive truck and note
results.
1
Programmable
Maintenance Tool
Is it adjusted Adjust throttle Is acceleration

No Yes Return to service.
properly? potentiometer. OK?
No
Go to Chart
END1
Yes Go to Chart Go to Chart

T-18-2 END1
T-18-1a.wmf
5-68 PDMM-0100 Issued: 5/21/01

T-18
-2
With key switch off

and battery
disconnected, check
motor and brushes.
See Component
Procedures.
Repair or replace
motor. See
Is motor OK? No
Component
Procedures.
Yes
Go to Chart
END1
Replace motor
controller.
Go to Chart
END1
T-18-2a.wmf
PDMM-0100 Issued: 5/21/01 5-69

W-1: Truck Functions Partially.
W-1: Truck Functions Partially. Some

Functions Do Not Work When Commanded.
Visually check the

wiring in the handle
and where the wiring Are wires OK? No
leaves the handle and
is over the brake.
Look for damage to
the wiring.
Yes
Use a DVM and

Does the wiring check for continuity
No
look OK? of wires per the
schematic.
Yes
Use a DVM and

check for continuity
Are continuity
of wires in the handle Repair or replace
measurements No
per the schematic. wires as required.
OK?
Yes
Are the
Verify problem still
continuity Repair or replace
No exists. Repeat W-1.
measurements wires as required.
If you return here, go
OK?
to General
Troubleshooting.
Yes
Visually check the

Go to Chart
wiring and
END1
connectors in the
area of the HCC Go to Chart Go to Chart
hydraulic control GEN1 END1
W-1-1a.wmf
5-70 PDMM-0100 Issued: 5/21/01

Raymond® Walkie Pallet Truck Maintenance Manual Component Procedures
Component Procedures 6:
PDMM-0100 Issued: 5/21/01 6-1

Component Procedures Raymond® Walkie Pallet Truck Maintenance Manual
List of Component Procedures
B H
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

Adding Water . . . . . . . . . . . . . . . . . . 6-13 Hydraulic Components
Charging . . . . . . . . . . . . . . . . . . . . . . 6-10 Adjustments . . . . . . . . . . . . . . . . . . . . 6-69
Exterior Cleaning . . . . . . . . . . . . . . . . 6-9 Cylinder . . . . . . . . . . . . . . . . . . . . . . . 6-74
Maintenance Free . . . . . . . . . . . . . . . 6-15 Fluid . . . . . . . . . . . . . . . . . . . . . . . . . 6-70
Multiple Packs . . . . . . . . . . . . . . . . . . 6-8 Hydraulic Unit . . . . . . . . . . . . . . . . . . 6-77
Specific Gravity . . . . . . . . . . . . . . . . . 6-14 Filter Screen . . . . . . . . . . . . . . . . . 6-79
Storage . . . . . . . . . . . . . . . . . . . . . . . 6-15 Pump . . . . . . . . . . . . . . . . . . . . . . 6-80
Voltage Check . . . . . . . . . . . . . . . . . . 6-15 Relief Valve Adjustment . . . . . . . . 6-72
Battery Pack Reservoir . . . . . . . . . . . . . . . . . . . 6-78
Multiple . . . . . . . . . . . . . . . . . . . . . . . 6-8 Solenoid . . . . . . . . . . . . . . . . . . . . 6-30
Single . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Suction Tube . . . . . . . . . . . . . . . . 6-79
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Brake (Deadman) Switch . . . . . . . . . . . . . 6-27 L
C Lift Limit Switch . . . . . . . . . . . . . . . . . . . . 6-29

Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . 6-81
Circuit Breaker . . . . . . . . . . . . . . . . . . . . 6-21 Load Wheel
Contactors . . . . . . . . . . . . . . . . . . . . . . . 6-42 Pull Rod Adjustment . . . . . . . . . . . . . . 6-68
Cover, Tractor . . . . . . . . . . . . . . . . . . . . . . 6-7 Load Wheels . . . . . . . . . . . . . . . . . . . . . . . 6-67
Lubrication
D Drive Housing . . . . . . . . . . . . . . . . . . 6-62
Deadman Switch . . . . . . . . . . . . . . . . . . . 6-27 M

Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . 6-57 Motor Controller . . . . . . . . . . . . . . . . . . . . 6-38
Drive Wheel . . . . . . . . . . . . . . . . . . . . . . 6-64 Motors
Brush Spring Tension . . . . . . . . . . . . . 6-47
E Brushes . . . . . . . . . . . . . . . . . . . . . . . 6-45
Commutator . . . . . . . . . . . . . . . . . . . . 6-48
Emergency Reverse Check . . . . . . . . . . . 6-39 Drive . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
General . . . . . . . . . . . . . . . . . . . . . . . 6-45
F Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81
Tests . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
P
G
Power Cables . . . . . . . . . . . . . . . . . . . . . . 6-16
Gauges . . . . . . . . . . . . . . . . . . . . . ..... 6-31 Pump, Hydraulic . . . . . . . . . . . . . . . . . . . 6-80
Hour Meter . . . . . . . . . . . . . . . ..... 6-31
Hour/Battery Discharge Meter ..... 6-32 S
Gear Oil . . . . . . . . . . . . . . . . . . . . ..... 6-62 Switches
Brake . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Control Handle . . . . . . . . . . . . . . . . . . 6-23
Deadman . . . . . . . . . . . . . . . . . . . . . . 6-27
General . . . . . . . . . . . . . . . . . . . . . . . 6-22
6-2 PDMM-0100B Revised: Draft

Key Switch . . . . . . . . . . . . . . . . . . . . 6-26

Lift Limit . . . . . . . . . . . . . . . . . . . . . . 6-29
Main ON/OFF . . . . . . . . . . . . . . . . . . 6-25
Wheels
Drive . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Load . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
Wiring Harness . . . . . . . . . . . . . . . . . . . . 6-17
PDMM-0100 Issued: 5/21/01 6-3

6-4 PDMM-0100 Issued: 5/21/01

Component Locator Photos

6:snComponent Procedures
Main ON/OFF Main

Key Switch Battery Connector Hydraulic Cylinder
Switch Contactor
page 6-26 (rear view) page 6-74
page 6-25 page 6-42
page 6-8
Motor Fill/Vent
Controller Plug
page 6-38 page 6-70
Hydraulic
Horn Reservoir
page 6-37 page 6-78
Drive Unit
page 6-57
Figure 6-1: Tractor Interior
PDMM-0100 Issued: 5/21/01 6-5

Relief Valve
Lift Motor
page 6-72
page 6-81
Fill/Vent Plug
page 6-70
Lift-Limit Switch
page 6-29
Hydraulic
Reservoir
page 6-78
1665 033.tif
Figure 6-2: Hydraulic Components
6-6 PDMM-0100 Issued: 5/21/01

Tractor Cover
Tractor Cover
Removal
To remove the tractor cover, unscrew the two
captive screws on top of the cover and lift the
cover slightly outward and upward away from
the truck.
Installation
To install the cover, slide it back into the
original position, and screw the two captive
screws in on top of the cover.
PDMM-0100 Issued: 5/21/01 6-7

Battery
Battery
! CAUTION
Before working on the battery, see
“Battery Safety” on page 2-7.
Batteries may weigh more than 500
pounds. Use extreme care during
replacement. Use a suitable battery
replacement device or hoist for
lifting.
The Model 101 may be equipped with either a

multiple battery pack, single battery or a
maintenance free battery and charger.
Multiple Battery Pack

Removal
1. After the truck is stopped and the handle is
returned to the full up position, turn the
key switch OFF.
2. Disconnect the battery connector located at
the top of the tractor cover. Remove the
battery cover.
3. To gain access to the lower two batteries,
lift up on one of the top battery frames.
4. As the frame is lifted, swing the battery
toward the center of the forks.
5. The cables may now be disconnected from
the battery terminals and the batteries may
be serviced or replaced if necessary. See
Figure 6-3.
Installation
1. Position the fully charged and tested
batteries in the battery pack.
2. Reconnect the battery cables to the battery
terminals in accordance with the battery
wiring hookup shown on the decal in the
battery frame.
1790 001.eps
3. Reconnect the battery connector, reinstall Figure 6-3: Battery Wiring Hookup
the battery cover, turn the key switch ON,
and test the operation of the pallet truck.
6-8 PDMM-0100 Issued: 5/21/01

Battery
Single Battery Pack (Optional)

Removal
2. Disconnect the battery connector located at
the top of tractor cover.
3. Position the battery replacement device
above the battery and attach to the battery
manufacturer’s designated lift points. See
Figure 6-4.
4. Remove the battery with the lifting device.
5. Place the discharged battery on the
charging stand.
Installation
1. With a fully charged and tested battery on
the lifting device, position the lifting device
in accordance with the manufacturer’s
recommendations.
2. Position the battery in the compartment. Be 27Y7S134.tif
sure the battery has no more that 0.50 in. Figure 6-4: Battery with Hoist
(12.7 mm) of “free play” movement in the
battery compartment.
3. Move the lifting device from the area.
4. Reconnect the battery connector, turn the
key switch ON, and test the operation of the
truck.
Battery Exterior Cleaning

1. Inspect the battery.
a. Make sure the cables are not frayed or Cable
loose.
Vent Hole
b. Make sure there is no foreign material
inside the connector.
c. Make sure the filler plugs are tight and
the vent holes in the filler plugs are
open. See Figure 6-5.
2. Keep the top of the battery clean and dry.
Corrosion, dust, and moisture provide a
conducting path to short-circuit cells or
create grounds. Filler Plug
09g6s047.tif
Figure 6-5: Battery Filler Plugs and Vent Holes
PDMM-0100 Issued: 5/21/01 6-9

Battery
! CAUTION
Do not clean the top of the battery
with the soda solution while it is
installed in the truck. Water would
seep into the electrical compartments
and cause serious damage.
a. Disconnect the battery connector, and

remove the battery from the truck before
you clean it.
b. Tighten the battery filler plugs.
c. 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 1/2 gal (1.9 liters) of hot water.
d. 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.
e. Rinse the battery with clean water.
f. Dry the battery completely before re-
installing it.
g. Apply a thin coat of petroleum jelly to
the battery posts and cable terminals.
Charging
To charge a battery, direct current is passed
through the battery cells in the direction
opposite to that of discharge. Charging time is
5% to 20% longer than discharge time.
The most important element in battery service
and prolonging battery life is proper charging.
Make sure you follow the proper method for
each application, following the battery and
battery charger manufacturers’ instructions.
Figure 6-6: Multiple Battery (Swing-Out) Pack Charger
6-10 PDMM-0100 Issued: 5/21/01

Battery
! CAUTION
The vent holes in the filler plugs must
be open to allow hydrogen gas to
escape from the cells. When you
charge the battery, make sure the
polarity connections are correct. The
positive lead of the charger must be
connected to the positive terminal,
and the negative lead must be
connected to the negative terminal.
1. Familiarize yourself with the following:

• Charging rate, starting rate, and finish
rate
• Time available for charge
• Overheating, excessive gassing, or
overcharging
• Variations between cell voltage
2. Battery performance varies depending on
the type of application. If you use more
than one truck, one battery, and one
charger, keep the same batteries and
charger assigned to each truck. This makes
it easier to diagnose any battery or charging
problem.
3. Consult your battery and battery charger
manufacturer’s manual for specific
charging procedures.
4. Wear personal protective equipment, see
5. Turn the key switch OFF, disconnect the
battery, and remove the battery from the
truck.
6. Inspect the battery.
7. Check the electrolyte level in each cell.
Electrolyte should cover the top of the
battery plates. If electrolyte level is below
the plates, add just enough water to cover
the plates. See “Adding Water” on
page 6-13. Do not fill to level yet.
Electrolyte level will rise during charging.
PDMM-0100 Issued: 5/21/01 6-11

Battery
8. Using a hydrometer, measure and record

the specific gravity of each cell. See
“Specific Gravity” on page 6-14.
9. Check and record the voltage of each cell.
10. To get the maximum use out of each
battery, recharge only when effectively
discharged. Routinely recharging batteries
when only partially discharged will
decrease battery life. At maximum
recommended discharge, the specific
gravity should read 1.140-1.160 or less.
11. Ensure that the filler plugs are clean and
the vent holes are open. Tighten all filler
plugs.
! CAUTION
NEVER plug the battery charger into
the truck. This will severely damage
the truck’s electrical system. Plug the
charger ONLY into the connector
from the battery.
12. Charge the battery, following specific

instructions in your battery and battery
charger manufacturer’s manual.
13. Using a hydrometer, check the specific
gravity of each cell. No amount of charging
will increase battery capacity or raise
specific gravity above its fully charged level
(specific gravity 1.280 to 1.300).
14. If, after charging, the electrolyte level is
below the fill port, add water to bring it to
the fill level. See “Adding Water” on
page 6-13. Do not overfill the cells or
allow electrolyte to spill onto the battery
case.
In general, a lead-acid battery may be charged
at any rate in amperes that does not cause
excessive gassing or produce electrolyte
temperatures above 110° F (43° C).
Temperatures of 120° F (49°C) are allowed only
for short periods of time.
6-12 PDMM-0100 Issued: 5/21/01

Adding Water
Adding Water
Water must be added to battery cells
periodically. Frequency and quantity depend on
the water level above the plates and the amount
of gassing during charge.
Guidelines:
• Wear personal protective equipment, see
“Battery Safety” on page 2-7. Use only
distilled water or water approved by the
battery manufacturer.
• Before charging, make sure battery plates
are covered with electrolyte. Add water, if
necessary, only to cover plates.
• Electrolyte level rises during charging. To
avoid overflow, add water to fill port, if
necessary, after charging, and after
hydrometer and voltmeter readings are
taken.
• Keep the outside of the battery case clean
and dry.
PDMM-0100 Issued: 5/21/01 6-13

Adding Water
Specific Gravity
Specific gravity readings for lead acid batteries
with electrolyte temperatures at 80° F (27° C)
vary with the state-of-charge as follows:
Charge Specific Gravity
100% 1.280-1.300
75% 1.250-1.260
50% 1.200-1.210
25% 1.150-1.160
0% 1.080
Most industrial deep-cell discharge batteries

are considered discharged when 20% of the
charge remains (specific gravity 1.140).
NOTE: Maintenance-free batteries do not
require specific gravity checks.
Procedure:
1. Wear personal protective equipment. See
2. Insert the nozzle of the hydrometer into the
battery cell and draw enough electrolyte
into the tube to permit the float to ride free.
3. Leave the hydrometer nozzle in the battery
and read the specific gravity of the cell.
4. If there is not enough electrolyte in the
battery to get a hydrometer reading:
• Add just enough water to cover the
battery plates
• Charge the battery, then take readings
5. Record the specific gravity reading on the
battery chart.
6-14 PDMM-0100 Issued: 5/21/01

Voltage Check
Voltage Check
Take a voltage check on each cell after
performing the specific gravity check on page
6-14. Connect the leads of a voltmeter to the
positive and negative terminals of each cell.
Voltage readings will vary with the state of
charge:
Charge Voltage Reading
100% 2.14
75% 2.07
50% 1.95
25% 1.80
Record the voltage reading for each cell on the

battery maintenance chart. There should be a
difference of no more than 0.2 volt between
cells.
Maintenance-Free Batteries
The truck may be equipped with a
maintenance-free battery and charger, in which
case, the specific gravity need not be checked.
See Figure 6-7. Please follow manufacturer’s
recommendations for service of these batteries.
A maintenance-free battery still requires some
care. The battery should be kept clean and dry
and may be washed to remove any accumulated
foreign matter. See “Battery Exterior Cleaning”
on page 6-9.
1665 030.tif
Storage Figure 6-7: Maintenance-Free Battery Charger
Before you store a battery, make sure the

electrolyte is at the proper level in all the cells,
the filler plugs are tight, and the battery is fully
charged.
Store the battery in a clean, cool, dry location
away from radiators and other sources of heat.
Check the electrolyte level and the specific
gravity every 30 days during storage. Whenever
the specific gravity is less than 1.230, charge
the battery.
PDMM-0100 Issued: 5/21/01 6-15

Power Cables
Power Cables
Power cables should be checked for damage,
including:
• Evidence of overheating
• Burned spots in the cable
• Nicks in the insulation
• Damaged or overheated terminal lugs
• Damaged mounting hardware or brackets
Repair or replace damaged cables or mounting
hardware as necessary.
Power cables are marked on the terminal lug
with the location where they belong. If the
marking is missing or is not readable, remark
the cable with the correct information.
The terminal lugs should be crimped tightly and
securely on the wire. Replace the lug if
overheating is evident and repair or replace
faulty connectors as necessary.
6-16 PDMM-0100 Issued: 5/21/01

Wiring Harness
Wiring Harness
All wires in the harness are marked every 1 to
1.5 in. (2.54 to 3.81 cm) with a wire
identification number. These numbers
correspond to wire identification given in the
schematic. See “Schematics” on page A-9.
Terminology
The term “connector JPx” means a mated
connector consisting of two connector halves.
One half contains male connectors, or pins (P);
the other half contains female connectors, or
jacks (J).
When you disconnect a mated JP connector,
you will have two connector halves. The
individual connector halves are designated by
“Jx” and “Px.”
For example, connector JP2 is the mated
connector in the control handle. J2 represents
the jack connections. P2 represents the pin
connections.
To locate electrical connectors on the truck
refer to the electrical schematic located in the
Appendix or see “Electrical Connector Locator
Chart” on page 5-12.
PDMM-0100 Issued: 5/21/01 6-17

Wiring Harness
Inspection
Whenever working on the truck, use care
around wiring harnesses.
• Do not pull on wires.
• Carefully mate and unmate all connectors.
• Do not pry apart connectors with
unspecified tools.
• Examine and maintain any added materials
used to dress or protect the wire. This
includes spiral wrap, brackets, cable ties,
fasteners, flexible conduit, etc.
• Check harness wires for abrasions,
scrapes, nicks in the wire, damage from
overheating or burns, or other general
insulation damage.
• Replace terminations with exposed wire
visible at the connectors. Damaged
terminations, exposed wires, or damaged
connectors can cause operational failure of
the truck.
During troubleshooting and repairs, it is
sometimes necessary to unmate a connector,
move a harness, cut a cable tie, or remove the
wire from a bracket. Note carefully the location
of the wire and all protective or securing
attachments before moving the harness.
After repair, return or replace all protective
and/or securing hardware to its original
condition. Protective materials are necessary to
provide reliable performance of the interconnect
system.
In addition to the wire identification number
printed every 1 to 1.5 in. (2.54 to 3.81 cm) on
the wire, there should be a wire marker at each
termination. If the marker is missing or
unreadable, remark the wire to allow easier
identification.
NOTE: It is normal to find unused connectors
for uninstalled options that have had
heat shrink applied over them and have
been strapped to the harness.
6-18 PDMM-0100 Issued: 5/21/01

Diodes
Diodes
Test
Check diodes with a digital multimeter or use a
Simpson 260 multimeter or its equivalent. Use
the diode testing feature on the digital
multimeter. Use the RX1 ohm scale on the
Simpson 260 multimeter.
! CAUTION
ohmmeter.
Replace the entire assembly if defective diodes

are found.
Positive lead (+) Anode Cathode

Negative lead (-) Cathode Anode
Simpson 260 8–30 Ohms Infinity
Multimeter
Reading
Digital Multimeter 0.3–1.0 V Infinity
Reading
PDMM-0100 Issued: 5/21/01 6-19

Fuses
Fuses
Test/Inspection
Examine the fuse for signs of overheating,
discoloration, cracking, or other physical
damage. Replace the fuse if you find damage.
See Figure 6-8.
To test a fuse, remove it or isolate it from the
electrical circuit. Do this by removing the fuse
from the truck or by removing all the Circuit Breaker
CB1
connections from one side of the fuse.
Use an ohmmeter set to Rx1 scale and measure
the resistance across the fuse. The resistance
should be less than 1 ohm. Fuse FU1
1665 031.tif
Figure 6-8: Fuse/Circuit Breaker Location
6-20 PDMM-0100 Issued: 5/21/01

Circuit Breaker
Circuit Breaker
Under extreme operating conditions the current
demand on the battery may exceed the rating
for the main circuit breaker and force it open.
This will cause the truck to become inoperable
until the circuit breaker automatically resets
itself.
Test/Inspection
Examine the circuit breaker for signs of
overheating, discoloration, or other physical
damage. See Figure 6-8. Replace the circuit
breaker if you find damage.
To test a circuit breaker, remove it or isolate it
from the electrical circuit and allow it to cool (or
reset itself). Do this by removing the circuit
breaker from the truck or by removing all the
connections from one side.
Use an ohmmeter set to Rx1 scale and measure
the resistance across the circuit breaker. The
resistance should be less than 1 ohm.
PDMM-0100 Issued: 5/21/01 6-21

Switches (General)
Switches (General)
Refer to the electrical schematic in the

Appendix to identify the electrical circuit
location of the switch.
Test/Inspection
Examine the switch for signs of arcing,
overheating, discoloration, cracking, or other
physical damage. Replace the switch if you see
such damage.
To test a switch, isolate it from the electrical
circuit. Do this by removing all the connections
from the switch, making sure all wires are
labeled and identified for reconnection.
Use an ohmmeter set to a low resistance scale
to measure the resistance across the switch. In
a closed position, the switch should be less
than 1 ohm. In an open position, the switch
should show a resistance greater than 10
megohms.
6-22 PDMM-0100 Issued: 5/21/01

Control Handle Switches

Removal
2. From the underside, remove the four socket
head cap screws from the handle cover
assembly. See Figure 6-9.
NOTE: There are two different lengths of
screws; note the location of different Screws
screws for installation later.
1479 004.tif
Figure 6-9: Control Handle Cover Assembly
3. For access to the horn, lift and lower

switches, remove the travel potentiometer
bracket, directional switch bracket, and
emergency reverse switch bracket covering
Emergency
these switches. Identify wire placement. See Reverse
Figure 6-10. Switch
4. Carefully remove the directional switch
operating assembly.
Directional Switch
Operating Assembly
Directional
Switches
Travel
Potentiometer
Bracket
Directional
Switch
Bracket
1479 009.tif
Figure 6-10: Control Handle Switches
PDMM-0100 Issued: 5/21/01 6-23

5. Remove the switch mounting plate and

switches.
6. Remove the switch mounting nut and
washer, noting the position of the washer.
7. Unplug the connector.
Installation
Directional
1. Reattach the horn, lift, and lower switches Switches
with washers and mounting nuts to the
switch plate.
2. Reinstall the switch mounting plate and
switches on the control handle.
Travel
3. Mount the emergency reverse switch Potentiometer
bracket in the handle. Secure the assembly Bracket
with the two screws used to hold the switch
assembly to the control handle.
4. Connect the wires.
5. Reinstall the travel potentiometer bracket
and directional switch bracket. Reattach
the wiring. 1479 009.tif
6. Reinstall the directional switch operating Figure 6-11: Accessing Directional Switches
assembly.
7. Reattach the handle cover assembly.
NOTE: These four screws are not the same
length. Make sure you put the proper
length screw in the right location.
8. Reconnect the battery connector and turn
the key switch ON.
9. Test the control handle switch function.
Adjust the throttle potentiometer setting as
required.
6-24 PDMM-0100 Issued: 5/21/01

Main ON/OFF Switch
Main ON/OFF Switch

A Main ON/OFF switch (SW13) is provided on
the gauge console. See Figure 6-12. In the OFF Main ON/OFF Gauge Console
Switch
position (O), battery power to all control
functions is interrupted. In the ON position (I),
battery potential is provided to all control
functions via the key switch.
Inspection
1. With the battery plugged in and the Main
ON/OFF switch in the ON position, battery
voltage B+ should be present on both
terminals of the switch.
2. Test the Main ON/OFF switch with an
ohmmeter after disconnecting the battery
and removing the wires from the switch
terminals.
In the OFF position, the ohmmeter should 1581 004.tif
read greater than 1 megohm, and in the ON Figure 6-12: Main ON/OFF Switch Location
position, the ohmmeter should read less
than 1 ohm. If not, replace the switch.
Removal
3. Remove the gauge console from the
electrical panel.
4. Disconnect the wires from the switch.
5. Remove the Main ON/OFF switch.
Installation
1. Install the new Main ON/OFF switch.
2. Connect the wires to the new Main ON/OFF
switch terminals.
3. Re-install gauge console onto electrical
panel.
4. Reconnect the battery connector and check
operation.
5. Install the tractor cover.
PDMM-0100 Issued: 5/21/01 6-25

Key Switch
Key Switch
A two-position (ON/OFF) key switch (SW1),
located on the gauge console, energizes all truck
control functions when in the ON position,
provided the Main ON/OFF switch is in the ON
position. See Figure 6-13.
Inspection
2. With the battery plugged in and the key
switch ON, battery voltage B+ should be
present on both terminals of the switch.
3. Test the key switch with an ohmmeter after
turning it OFF, disconnecting the battery
Key Switch
and removing the wires from the switch
terminals.
In the OFF position, the ohmmeter should
read greater than 1 megohm, and in the ON
position, the ohmmeter should read less
than 1 ohm. If not, replace the switch.
Removal
3. Remove gauge console from electrical panel.
4. Remove the mounting nut from the stem of
the key switch.
1581 004.tif
5. Disconnect the wires from the key switch. Figure 6-13: Key Switch Location
6. Remove the key switch.
Installation
1. Install the new key switch and tighten the
locking nut.
2. Connect the wires to the new key switch
terminals.
3. Re-install the gauge console onto the
electrical panel
4. Reconnect the battery connector and check
operation.
6-26 PDMM-0100 Issued: 5/21/01


Adjustment
The brake (deadman) switch (SW2) is located Brake (Deadman)
near the brake drum, at the side of the drive Switch
motor. See Figure 6-14.
1. Turn the key switch to OFF and disconnect
! WARNING
Use extreme care whenever the 1581 007.tif
truck is jacked up. Keep hands and Figure 6-14: Brake (Deadman) Switch
DO NOT rely on the jack alone to
support the truck. For details, see
“Jacking Safety” on page 2-11.
2. Jack the truck and block the frame.

3. Remove the drive unit cover.
4. Loosen the two (2) screws holding the
switch on the bracket. Slide the switch to
the left as far as possible. See Figure 6-15. Brake (Deadman) Switch
5. Slide the switch back to the right until the

switch “clicks”. Move the switch to the left
(approximately 1/32 in. [0.7 mm]) until it
“clicks” again. Retighten the screws.
6. Check that the brake arm makes solid
contact with the switch lever.
7. Check that the switch “clicks” near the
middle of the cam arm movement. The
brake switch should operate within 10 Screws
degrees of the full up or down handle
position. Be sure the switch does not 1581 008.tif
bottom out when fully compressed. Figure 6-15: Brake (Deadman) Switch Inactive, Brake ON
PDMM-0100 Issued: 5/21/01 6-27

8. Install the drive unit cover and torque to

35 ft. lbs. (49 Nm).
9. Remove the blocks, connect the battery
connector and turn the key switch ON.
10. Test the operation of the truck.
Removal
1. Lower the forks completely.
3. Remove the drive unit cover.
4. Disconnect the wires on the deadman
switch.
5. Remove the screws holding the deadman
switch on the mounting bracket.
Figure 6-16: Brake (Deadman) Switch Active, Brake OFF
6. Remove the deadman switch.
Installation
1. Mount the deadman switch to the mounting
bracket.
2. Connect the wires to the deadman switch.
the key switch ON.
4. Test drive the truck.
5. Adjust the switch if necessary. See “Brake
(Deadman) Switch” on page 6-27.
7. Install the drive unit cover.
8. Reconnect the battery connector.
6-28 PDMM-0100 Issued: 5/21/01

Lift-Limit Switch
Lift-Limit Switch
When the forks are fully raised, the lift-limit
switch (SW10) turns the hydraulic pump motor Lift-Limit Switch
off. This keeps the pump from trying to extend
the lift cylinder beyond its maximum travel. See
Figure 6-17.
Adjustment
1. Raise the forks until they reach their fully
raised position. If the lift-limit switch does
not shut the pump down when the lift
cylinder reaches its upper limit, the relief
valve on the hydraulic pump will make a
high-pitched squeal, indicating that the 1581 014.tif
relief valve is opening. Figure 6-17: Lift-Limit Switch

the battery.
3. Loosen the bolt and slide the switch bracket
up or down to activate (cut power off) when
the lift is 1/2 to 1 in. (12.7 to 25.4 mm)
before its fully raised position.
4. Tighten the bolt.
5. Reconnect the battery and turn the key
switch ON. Lower the forks and then raise
them until they reach their fully raised
position. The lift-limit switch should cut
power off to the pump when the lift cylinder
reaches 1/2 to 1 in. (12.7 to 25.4 mm)
before its fully raised position.
PDMM-0100 Issued: 5/21/01 6-29

Hydraulic Solenoid
Hydraulic Solenoid
Removal
1. Make sure that the forks are fully lowered.
2. Turn the key switch to OFF. Disconnect the
battery connector.
3. Remove the two wires from the terminals on
the solenoid.
4. Remove the nut holding the solenoid coil to
the solenoid valve.
5. Lift the solenoid coil off the solenoid valve.
6. Remove the solenoid valve from the
manifold.
Installation
1. Inspect the seat where the solenoid seals
against the manifold. The sealing surface
should be completely clean and free from
any nicks or damage.
Hydraulic Solenoid
2. Inspect the O-ring for any damage. If the Release Valve
O-ring is damaged or deformed in any way,
replace it.
3. Thread the solenoid valve into the manifold.
Torque the solenoid valve to 144-180 in. lbs
(16-20 Nm).
4. Install the solenoid coil onto the solenoid
valve and tighten the nut. Torque the nut to
48-60 in. lbs (5-7 Nm).
1665 033.tif
5. Connect the wires to the terminals. Figure 6-18: Hydraulic Solenoid
the key switch ON. Test the functions of the
truck.
7. Turn the key switch OFF. Disconnect the
battery.
6-30 PDMM-0100 Issued: 5/21/01

Gauges
Gauges
The Model 101 comes standard with an hour
meter. A combination hour meter/battery
discharge meter is optional.
Hour Meter
When the battery is connected, this meter
shows the number of hours. The digital quartz
“hour glass” icon flashes and the counter
increases when the brake (deadman) switch is
closed.
Inspection
If the numbers do not illuminate when the
battery is plugged in, use a voltmeter to check
for B+ at pin 1 on the back of the gauge (with
respect to pin 2, B-). If voltage is not present,
use the schematic in the Appendix and trace B+
and B- to the source (battery).
If the meter does not log hours, verify that B+ is
present on pin 3 when the brake (deadman)
switch is closed (the handle is in drive position).
If voltage is not present, use the schematic in
the Appendix and trace B+ to the source (brake
(deadman) switch).
If the required voltages are present (as outlined
above) and no other problems are found,
replace the hour meter.
Removal
electrical panel.
4. Remove wires from the back of the gauge
and make careful note of their orientation.
5. Remove the mounting nuts (2) and slide off
the gauge mounting bracket.
6. Remove the gauge by lifting through the top
of the gauge console.
PDMM-0100 Issued: 5/21/01 6-31

Gauges
Installation
1. Place the new gauge in the mounting hole.
2. Replace the gauge bracket, install the nuts,
and tighten them securely.
3. Connect the wires to the proper terminals.
4. Re-install the gauge console on the
electrical panel.
5. Reconnect the battery connector and test
operation.
Combination Hour/Battery
Discharge Meter
Hour Meter
When power is applied, the meter’s digital
quartz “hour glass” icon flashes and counter
increases. The meter logs hours when the brake
(deadman) switch is closed.
Battery Discharge Meter

The battery discharge meter measures the
battery state-of-charge when the key switch is
ON.
When the battery is fully and properly charged,
the green bar closest to 1 is lit. As the battery
loses its charge, a green or yellow bar moves
closer to 0. Two red bars begin flashing when
the battery is almost fully discharged.
Inspection
If the displays do not illuminate when the key
switch is ON, use the voltmeter to check for B+
at pin 6 on the back of the gauge (with respect
to pin 2, B-). If the voltage is not present, use
the schematic in the Appendix and trace B+ and
B- to the source (battery via key switch).
If the point does not move when the key switch
is ON, use the voltmeter to check for B+ at pin 5
on the back of gauge (with respect to pin 2, B-).
If the voltage is not present, use the schematic
in the Appendix and trace B+ and B- to the
source (battery via FU1).
6-32 PDMM-0100 Issued: 5/21/01

Gauges
If the meter does not log hours, verify that B+ is

present on pin 3 when the brake (deadman)
switch is closed (handle is in drive position). If
the voltage is not present, use the schematic in
the Appendix and trace B+ to the source (brake
(deadman) switch.
If the required voltages are present (as outlined
above) and no other problems are found,
replace the gauge.
! CAUTION
If the battery is replaced with
another battery that is not fully
charged (i.e., the gauge does not
reset its indication to a full charge
state) the display may provide
wrong information for the battery
state-of-charge.
Removal
electrical panel.
4. Remove the wires from the back of the
gauge and make careful note of their
orientation.
5. Remove the mounting nuts and slide off the
mounting bracket.
6. Remove the gauge by lifting through the top
of the gauge console.
Installation
1. Place the new gauge in the mounting hole.
2. Replace the bracket, install the nuts, and
tighten them securely.
3. Connect wires to the proper terminals.
4. Re-install the gauge console on the
electrical panel.
operation.
PDMM-0100 Issued: 5/21/01 6-33

Control Handle
Control Handle
The control handle is designed so that some
repairs can be made without removing the
entire handle. Wiring harness connectors in the
handle can be disconnected to allow the head
unit to be removed for bench repair.
Head Unit Removal

Control
1. Turn the key switch OFF and disconnect Handle
the battery connector. Bottom
Cover
2. Remove the four hex head cap screws that
secure the control handle bottom cover. See
Tie Plate
Figure 6-19.
3. Remove the four hex head cap screws
securing the lower control handle cover. See 1479 004.tif
Figure 6-20. Figure 6-19: Control Handle Cover Removal
4. Disconnect the wiring harness connectors.
See Figure 6-20. Note the position of cable
ties holding the harness. When
reassembling, attach new cable ties in the
same locations.
securing the tie plate.
6. Remove the four hex head cap screws,
washers, and nuts (two in front and one on Lower Control
each side of the handle) that secure the Handle Cover
head unit to the handle. The head is now Removed
loose and may be removed from the handle. Harnesses
Head Unit Reassembly

1. Install the head unit to the handle with the
four hex head cap screws, washers, and
nuts removed previously.
2. Install the tie plate with the four hex head
cap screws removed previously.
1581 002.tif
Figure 6-20: Control Handle Harnesses
6-34 PDMM-0100 Issued: 5/21/01

Control Handle
3. Connect the wiring harness connectors and

install new cable ties where previously
located.
NOTE: If the truck is a Cold Storage Unit, apply
an ample amount of sealing compound
(P/N 990-564) where wires enter plugs
or receptacles. The amount applied
should be enough to prevent moisture
from entering the connector. Disconnect
connectors to apply compound both
internally and externally. Avoid sealing
compound on pin contact area.
4. Install the lower control handle cover with
the four hex head cap screws removed
previously.
5. Install the control handle bottom cover with
the four hex head cap screws removed
previously.
6. Connect the battery connector and turn the
key switch ON.
Control Handle Stem Removal

securing the lower control handle cover.
3. Disconnect the wiring harness connectors.
See Figure 6-20. Note the position of cable
ties holding harnesses and cables. When
reassembling, attach new cable ties in the
same locations.
! CAUTION
Before removing the chain master
link in the next step, make sure you
are holding the handle. When the
master link is removed, the handle
will fall.
4. Pull the handle down to operating range.

Insert a wire or punch through a chain link
close to the handle (or use a pair of locking
pliers to grasp the chain close to the
handle).
PDMM-0100 Issued: 5/21/01 6-35

Control Handle
5. Release the handle to relieve tension on the
chain and the anchor.
6. Disconnect the handle return chain at the
master link located near the transmission
case. See Figure 6-21.
7. Remove any remaining cable ties and pull
the wiring harness out the bottom of the
handle.
8. Remove the motor side cover. Remove the
cotter pin retaining bolt and cotter pin and
slide the pivot pin out. See Figure 6-22.
9. Carefully remove the handle.
Master Link
Control Handle Stem Reassembly

1. During reassembly, be certain that the 1581 010.tif
brake release cam on the handle pivot pin Figure 6-21: Detaching Handle
is in the correct position before installing
the cotter pin.
2. Slide in the handle pivot pin through the Cotter Pin
lower control handle assembly and reinstall Retaining Bolt
the cotter pin and retaining bolt.
3. Raise the handle and reconnect the handle
return spring at the chain master link
located near the transmission case.
4. Pull handle down to operating range and
remove the wire, punch or pliers installed
earlier.
Cotter Pin
5. Thread the handle harnesses through the
handle base.
6. Reattach the control handle head unit if Figure 6-22: Removal of Handle Pivot Pin
removed.
7. Reconnect the handle harness connectors.
Install the cable ties in their original
locations on the handle harness and drive
motor cables.
8. Install the control handle cover.
9. Install the motor side cover.
key switch ON.
6-36 PDMM-0100 Issued: 5/21/01

Horn
Horn
The horn can be sounded regardless of key
switch position, provided the Main ON/OFF
switch is in the ON position.
Removal
Horn
3. Disconnect the two wires from the horn.
See Figure 6-23.
4. Remove the horn mounting bolt. 1665 031.tif
Figure 6-23: Horn Location
Installation
1. Attach the horn to the electrical panel and
tighten the mounting bolt.
2. Attach the two wires.
operation.
PDMM-0100 Issued: 5/21/01 6-37

Motor Controller
Motor Controller
! CAUTION
Do not open the controller. Opening
the controller could damage it and
will void the warranty.
Cleaning
Motor
1. Turn the key switch OFF and disconnect Controller
2. Remove the tractor cover. 1665 031.tif
Figure 6-24: Motor Controller Location

3. Discharge the capacitors in the controller
by connecting a load (such as a contactor
coil or a horn) across the controller’s B+
and B- terminals.
4. Clean the controller with a moist rag. Allow
it to dry before connecting the battery.
5. Make sure the power cable connections are
tight. Avoid stressing the cable connections
and putting strain on internal components.
Removal
1. Turn the key switch OFF and disconnect Motor
the battery connector. Controller
3. Discharge the capacitors in the controller PMC
by connecting a load (such as a contactor Connector
coil or a horn) across the controller’s B+
and B- terminals.
4. Push the locking tab and disconnect the
PMC connector (control wires) from the
motor controller. See Figure 6-25.
5. Disconnect the three power cables
(terminals B+, B- and M-) on the motor
controller. Avoid stressing the power cable 1665 031.tif
connections. Disconnect wiring harness Figure 6-25: Motor Controller Connections

connectors (terminals S1 and S2).
6. Remove the three hex head cap screws
securing the motor controller to the
electrical panel. Remove the controller.
6-38 PDMM-0100 Issued: 5/21/01

Emergency Reverse Check
Installation
NOTE: All motor controllers are preset to
factory default specifications.
1. Secure the motor controller to the electrical
panel with the three previously removed
hex head cap screws.
2. Reconnect the three power cables
(terminals B+, B- and M-) on the motor
controller. Torque screws to 12 ft. lbs. (16.3
Nm) maximum. Avoid stressing the cable
connections and putting strain on internal
components.
3. Connect the PMC connector (control wires)
and wiring harness connectors (terminals
S1 and S2) to the motor controller.
key switch ON.
5. Test operation of the truck.
Emergency Reverse Check

A wire connected directly between the motor
controller and the emergency reverse switch
can detect a broken wire.
The emergency reverse check output wire
periodically pulses the emergency reverse
circuit to check for continuity. If there is no
continuity, the motor controller limits the
vehicle to 15% speed and indicates Fault Code
2, 2. (See “Fault Codes” on page 5-13.)
PDMM-0100 Issued: 5/21/01 6-39

Throttle Potentiometer Adjustment
Throttle Potentiometer
Adjustment
The throttle is a two wire resistive throttle that
connects the pot wiper pin (PMC-6) and the pot
low pin (PMC-7). Zero speed corresponds to 0
ohm and full speed corresponds to 6.5K ohm.
! WARNING
the truck. After the truck is jacked, Control
Handle
DO NOT rely on the jack alone to Bottom
support the truck. For details, see Cover
2. Jack and block the truck.

3. Disconnect the handle harness connector
JP6 at the bottom end of the handle prior to
1479 004.tif
adjustment. This will ensure that feedback
Figure 6-26: Control Handle Switch Cover Removal
from other circuitry in the truck will not
affect the ohmmeter readings.
4. Remove the four hex head cap screws that
secure the control handle bottom cover.
Remove the cover to access the throttle
potentiometer. See Figure 6-26.
5. To electrically center the potentiometer, the
throttle must be in the neutral position.
Loosen the nut on the potentiometer shaft.
See Figure 6-27.
Body
6. Connect the ohmmeter to pins VR-2 and
VR-4. Measure the potentiometer
resistance while rotating the potentiometer
body until the ohmmeter reads as close to
‘0’ ohms as possible. Retighten the
potentiometer shaft nut.
Shaft
Cam
NOTE: While performing the next step, hold the
cam while rotating the Directional/
Nut
Speed Control Handle to prevent the
assembly from coming out of the control
handle assembly.
1479 009.tif
7. With the ohmmeter still connected to pins
Figure 6-27: Throttle Potentiometer Components
VR-2 and VR-4, verify that the forward and
reverse throttle positions are equal by
6-40 PDMM-0100 Issued: 5/21/01

Throttle Potentiometer Adjustment
rotating the Directional/Speed Control

Handle fully in both directions. Record the
maximum resistance value in both
directions. In either direction the resistance
value should be 6.5K ± 500 ohms. In
addition, the difference between the two
readings must be 300 ohms or less.
Maximum Variation Example
Handle Position Resistance (Ohms)
Fully clockwise 6,500
Fully counter-clockwise 6,200
8. To determine the ideal potentiometer

position, add the previously recorded
readings in Step 7 and divide that result in
half. (See example below.) Loosen the
potentiometer nut (1/2 turn) so that the
potentiometer will move in the bracket
when you apply force with your finger.
Example:
6,500 ohms CW + 6,200 ohms CCW =
12,700 ohms
12,700 ÷ 2 = 6,350 ohms (ideal maximum
resistance value setting)
9. Rotate the throttle control fully in one
direction. Move the potentiometer body
until the ideal maximum resistance value is
obtained. Once the potentiometer is
electrically centered, tighten the
potentiometer shaft nut securely to prevent
the pot from moving in the bracket.
10. Reattach the switch cover to the control
handle with the four screws previously
removed.
12. Test the truck’s operation.
14. Jack and remove the blocks from
underneath the truck. See “Jacking Safety”
on page 2-11.
PDMM-0100 Issued: 5/21/01 6-41

Contactors
Contactors
Removal
3. Disconnect the wires from the X and Y
terminals on the contactor coils. See
Figure 6-28. Bus Bar
4. Remove the nuts securing the bus bar and

cables to the contactor. Note the location for
assembly later. See Figure 6-28.
5. Remove the two screws holding the X and Y
contactor assembly to the electrical panel. Terminals
Installation
1. Secure the contactor to the electrical panel
with the two screws removed earlier.
2. Secure the bus bar and cable to the 1665 038.tif
contactor with the nuts. Figure 6-28: Disconnecting Main Contactor
3. Connect the wires to the X and Y terminals.

key switch ON.
6-42 PDMM-0100 Issued: 5/21/01

Brake
Brake
! CAUTION
Allow the brake to cool completely
before servicing.
Brake Shoe Adjustment

Brake Rod
Linkage
! WARNING
DO NOT rely on the jack alone to Brake
support the truck. See “Jacking Application
Spring Brake Release
Safety” on page 2-11.
Cam

3. Remove the drive motor cover.
4. Fully raise the control handle and remove 1581 009.tif
the brake application spring. This will allow Figure 6-33: Brake Adjustment, location
the brake to release. See Figure 6-33.
5. Lower the control handle into the operating
range so that the brake linkage bearing is
on top of the brake release cam.
6. Adjust the brake rod linkage to the clevis so
that the clevis pin just goes in the brake
lever. See Figure 6-34. Brake
Adjusting Rod
7. Reinstall the spring and test braking
ability.
NOTE: Use a maximum rated load when you
measure the stopping distance. The
truck should stop within approximately
6 feet (1.83 meters).
Brake
8. If the brake is inadequate, then shorten the Lever
brake rod linkage to the clevis to get Brake Application
adequate braking. This establishes the Spring
braking force on the brake shoes.
1665 053.tif
Figure 6-34: Brake Adjustment, close-up
PDMM-0100 Issued: 5/21/01 6-43

Brake Shoe Adjustment
NOTE: The brake drum may be removed and

the brake lever moved one “spline” to
compensate for brake wear.
Removal

2. Remove the drive motor cover. M12-1.75 Nut
3. Fully raise the control handle and remove

the brake application spring. Disconnect
the clevis from the brake lever.
4. Loosen the nut and remove the brake
drum.
5. Remove the springs and remove the brake
shoes.
6. Remove the screws holding the brake
assembly to the drive motor assembly.
1581 009.tif
7. Remove the brake assembly.
Figure 6-35: Brake Removal
NOTE: By lifting one brake shoe of the brake
assembly at a time, the mounting screws
can be removed without disassembling
the brake assembly.
Installation
NOTE: During reassembly, the brake lever
should be checked to see that it is set at Shoes
60° and that the brake drum nut is
torqued to 75 ft lbs (105 Nm). Brake
1. Install the brake assembly to the drive Lever
motor. Apply thread-locking compound
P/N 990-536 to mounting screws and Springs
torque to 11 ft lbs (15 Nm). Screws
2. Install the brake drum and secure with the
locking nut.
3. Install the brake adjusting rod assembly.
4. Install the clevis pin holding the lever.
5. Reinstall the brake application spring. 1665 055.tif
Figure 6-36: Brake Installation

6. Adjust the brake. See “Brake Shoe
Adjustment” on page 6-43.
7. Install the drive motor cover.
8. Reconnect the battery connector. Turn the
key switch ON and test-operate the truck.
6-44 PDMM-0100 Issued: 5/21/01

Motors, General
Motors, General
Drive Motor Brushes

Inspection
Conduct a partial inspection of the drive motor
after every 1,000 hours of truck operation. If
you work in an abnormally severe or caustic
environment or if you have a rigorous duty
cycle, inspect the motor more frequently.
Set up and rigidly adhere to a strict inspection
schedule to obtain the maximum efficiency
from the electrical equipment.
Each partial inspection of the motor should
include the following:
1. Inspect the brushes for wear and for proper
contact with the commutator. Record the
level of wear on the brushes. This history
will give you an indication of whether a
brush should be changed or if it can wait
MTRBRUSH.tif
until the next inspection. Refer to page 6-47
for acceptable brush length and general Figure 6-37: Drive Motor Brush, Typical Location
motor information.
NOTE: Overloading a unit is ultimately reflected
in the motor and brush wear; therefore,
you must take this into account when
considering brush replacement.
2. Check brush spring tension. See “Drive
Motor Brush Spring Tension” on page 6-47.
3. Clean brushes and holders. Wipe the
commutator with a dry, lint-free cloth. DO
NOT USE lubricants of any kind on or
around the commutator.
4. Check brush holders for solid connection to
the mounting support. Tighten the
mounting screws as necessary.
5. Check the cap screws holding the brush
cross connectors to the brush holder body.
6. Make sure the motor terminals are secured
tightly to the motor frame. Be careful not to
strip the threads or crush the insulating
parts.
PDMM-0100 Issued: 5/21/01 6-45

Motors, General
7. Check all the cap screws around the frame

for tightness.
8. Keep the outside frame of the motor clean
and free from dirt. Maintain a free air
passage around the motor to permit heat
radiation.
Replacement
If one brush needs replacement, always replace
the entire set of brushes.
Use only genuine Raymond brushes. Using
another type of brush could damage the
commutator or cause excessive brush wear.
If the end of the brush is not already contoured
to fit the commutator, use the following
procedure to seat the brush to the commutator:
NOTE: If the motor commutator is not
accessible, form the brush contour
using a brush seating stone.
1. Move the motor brush springs out of your
way.
2. Wrap a piece of 00 sandpaper around the
commutator. DO NOT use emery cloth to
seat brushes.
3. Move the brushes back down in their
holders so that the face of the brushes
matches the curve of the commutator.
4. Remove the sandpaper.
5. Blow any dust out of the motor with clean,
compressed air at a maximum of 30 psi
(207 kPa).
6-46 PDMM-0100 Issued: 5/21/01

Motors, General
Drive Motor Brush Spring Tension

Inspection
3. Slide the brush up slightly in its holder.
4. Insert a paper strip between the brush face
and the commutator.
5. Place a small leather loop around the coil
spring for the brush. If the brush spring
has a loop at the brush, hook the spring
scale directly to the spring.
6. Attach a 5 lbs (2.27 kg) spring scale to the leather
loop
leather loop. coil spring
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. Paper
9. Refer to the table below for proper spring

tension.
TENSION.tif
Figure 6-38: Motor Brush Spring Tension Inspection

Minimum
Spring
Motor Brush
Tension
Length
Drive 0.62 in. 20 oz min

Motor (15.7 mm) (568 grams)
10. Repeat steps 3 through 9 for the remaining

brushes.
PDMM-0100 Issued: 5/21/01 6-47

Motors, General
Commutator
Inspection
Mica Segments
The commutator should be inspected for
surface condition and high mica. Most
armatures have the mica undercut. If the
armature on your motor does not, do not
attempt to cut it. See Figure 6-39.
The commutator must be smooth and clean to NORMAL
provide maximum brush wear. When UNDERCUT
High Mica
commutators are not properly maintained,
carbon dust can collect in the grooves between
the segments. This can lead to a short circuit in
the armature.
Good commutation will be indicated by a dark HIGH MICA
brown polished commutator and an evenly
polished brush wearing surface. 1881 003.tif
Figure 6-39: Mica Inspection

If the commutator appears rough, pitted, or has
signs of burning or heavy arcing between the
commutator bars, the motor should be removed
for servicing.
Servicing
Servicing a motor for an abnormal commutator
surface condition and high mica or mica
undercutting requires special equipment at a
motor rebuilding facility. Do not attempt to
service the motor yourself.
6-48 PDMM-0100 Issued: 5/21/01

Terminal Nuts
Terminal Nuts
Whenever you disconnect and reconnect any Terminal
Stud
power leads to a motor, always tighten the
motor cable securing nuts with a torque wrench
to prevent over-tightening them and damaging Motor
Cable Flat
the motor. Use a second wrench on the stud Securing Washer
terminal securing nut to avoid twisting the Nut
stud. Check these torques each time you check Fiber
Washer
motor brushes.
Stud
Motor
Motor Cable Stud Terminal Terminal
Stud Size Housing
Securing Nut Securing Nut Securing
Nut
3/8 in. 100-120 in. lbs 140-160 in. lbs
(M10) (11.2-13.6 Nm) (15.8-18.1 Nm)
CABLENUT.eps
5/16 in. 90-110 in. lbs 110-140 in. lbs
(M8) (10.2-12.4 Nm) (12.4-15.8 Nm) Figure 6-40: Motor Terminal Nuts
1/4 in. 40-50 in. lbs 50-60 in. lbs
(M6) (4.5-5.6 Nm) (5.6-6.8 Nm)
Electric Motor Tests

Motor Types
See Figure 6-41.
• A shunt-wound or separately-excited motor, Shunt-Wound or Separately-Excited Drive
such as the drive motor, has four external
connections: two armature (A) and two
field (E). E2 (S2)
• A series-wound motor, such as the lift

motor, has only two external connections
because the armature and field windings
E1 (S1)
are connected internally.
Series-Wound Lift Motor

Open Circuit Motor Test
An open circuit is one in which the electrical
circuit within the motor has been broken. This
can be caused by:
• Bad brushes or brush springs
• A broken wire in the field or armature
winding
• A loose or bad connection
Dschem.eps
Figure 6-41: Motor Circuits
PDMM-0100 Issued: 5/21/01 6-49

Refer to Figure 6-41 for the following procedure:

1. Isolate the motor from the truck circuit by
removing the power cables. Use two
wrenches to avoid twisting the terminal
stud.
2. With the motor at room temperature,
connect the leads of a digital ohmmeter
between the individual circuits in the
motor.
3. Observe the following measurements:
Acceptable Unacceptable
Motor Terminals Resistance Resistance
Readings Readings
Traction Armature A1 to A2 0.01–0.10 ohms Greater than

(Drive) 0.10 ohms
Field E1 to E2 0.1–1.0 ohms Greater than

(S1 to S2) 1.0 ohms
Lift A to S 0.020–0.030 ohms Greater than

0.1 ohms
Measure all readings at room temperature.
Table 6-2: Motor Resistance Readings
4. If the meter indicates high resistance in the

armature, check the condition of the
brushes before replacing the motor.
5. If an open circuit is found in a series-
wound motor, the motor must be
disassembled by a motor rebuilding facility
to isolate the problem to the field or
armature circuit.
Grounded Motor Test

In a grounded motor, an electrical circuit exists
between the current-carrying conductors and
the motor housing. This can be caused either by
direct contact or through conductive foreign
material.
The ground may be caused by:
• Insulation breakdown
• Brush leads touching the motor housing
• Build-up of carbon dust or other materials
6-50 PDMM-0100 Issued: 5/21/01

To test a motor for grounds:

Isolate the motor from the truck circuit by
removing the power cables. Use two wrenches
to avoid twisting the terminal studs.
Attach one lead of a digital ohmmeter to a motor
terminal and the other lead to an unpainted
surface of the motor housing. Set the ohmmeter
to the highest scale.
If the ohmmeter reads resistance of less than
100,000 ohms, the motor is grounded. Clean,
repair or replace the motor as necessary.
Short-Circuited Winding
A short-circuited winding is one in which the
insulation on the field or armature has broken
down at two or more points. The breakdown
creates a low resistance path, allowing current
to flow from one turn of the coil to another
adjacent coil turn, without actually flowing
through the coil wire. The result is a decrease in
total resistance of the motor winding and an
increase in the current flow. The severity of the
short circuit depends on its location.
A shorted motor may be indicated by:
• Slow or sluggish operation
• Running faster than normal
• Overheating
• Blowing a power fuse
• Severe burning or discoloring on one or two
commutator segments every 90° of rotation
These symptoms can be caused by problems
other than the motor itself:
• Brake too tight or dragging
• Wheel bearings too tight
• Faulty transmission
• Binding in an attached pump
Testing a motor for short-circuited windings
requires special equipment at a motor
rebuilding facility.
PDMM-0100 Issued: 5/21/01 6-51

Short Circuited Armature

A short circuit in the armature will cause
heating, which will probably result in burning
of:
• The armature coil
• Brush wires
• Commutator segments
Visual inspection may reveal these conditions.
Positive determination of a short-circuited
armature requires special equipment at a motor
rebuilding facility.
6-52 PDMM-0100 Issued: 5/21/01

Drive Motor
Drive Motor
Removal
NOTE: While it is not necessary to remove the
drive tire to remove the drive motor, it
makes removing/installing the motor a
lot easier with the tire off.
3. Disconnect the brake (deadman) switch and
remove the mounting bracket from the
case.
4. Remove the brake assembly. See “Brake” on
page 6-43.
5. Disconnect the power cables from the drive
motor, noting their proper position. Use two
wrenches to avoid twisting the motor stud.
6. Remove the four hex head bolts securing
the motor to the drive unit.
7. Remove the motor from the drive unit.
Brush Replacement
1. Lift out the drive motor from the drive unit
mounting location.
2. Remove any shields around the motor end
cover to expose the brushes.
3. Lift the spring off the brush, pull the brush
out of the holder.
4. Follow the brush replacement instructions.
See “Drive Motor Brushes” on page 6-45.
5. Replace the shields around the motor end
removed in step 2.
Motor Disassembly
1. Remove the pinion gear lock nut and pinion
gear from the motor armature shaft.
2. Remove and discard the old O-ring.
3. Remove the four screws holding the brush
end bell to the field housing.
4. Separate the end bell from the field
housing. The armature will come out with
the end bell.
PDMM-0100 Issued: 5/21/01 6-53

Drive Motor
5. To remove the end bell from the armature,

remove the snap ring that holds the bearing
in the end bell. If needed, press off the
bearing and replace.
Installation
1. Thoroughly clean all parts with solvent or
other non-corrosive cleaning fluid. Air dry
all parts. The O-ring on the drive end of
motor should be replaced at this time with
a new O-ring.
NOTE: Install the drive motor in a dirt-free area.
2. Install the brake assembly by lifting one
brake shoe at a time and attach with two (2)
hex head cap screws. Apply thread-locking
compound (P/N 990-536) and torque to 25
to 30 ft lbs (35 to 42 Nm).
3. Position the brake actuating lever. See
“Brake Shoe Adjustment” on page 6-43.
4. Install the brake drum and the lock nut.
5. Install the pinion gear and the lock nut on
the armature shaft. Place a wrench on both
lock nuts and torque to 75 ft lbs (105 Nm).
6. Install a new O-ring on the motor drive end.
NOTE: Always make sure that the O-ring has
been lubricated with petroleum jelly
before reinstalling.
NOTE: When reinstalling the drive motor the
power cables must be kept to the back
side of the gear housing or the motor will
not go into the gear case.
7. Slide the drive motor in the gear case and
work it around until the motor lines up
with the cluster gear.
8. Install the four hex head cap screws and
torque to 35 ft lbs (49 Nm).
9. Attach the power cables with four hex head
bolts. Torque to 60 to 84 in. lbs
(6.8 to 9.5 Nm). Use a second wrench on
the stud terminal securing nut to avoid
twisting the motor stud. See “Terminal
Nuts” on page 6-49.
10. Reattach the brake (deadman) switch and
wires as described on page 6-27.
6-54 PDMM-0100 Issued: 5/21/01

Drive Motor
11. Reattach the brake linkage and spring and

adjust as necessary.
12. Install the control handle. See “Control
Handle” on page 6-34.
13. Install the drive tire, if removed. Torque nut
to 250 ft lbs (339 Nm).
14. Install the drive motor cover. Torque screws
to 35 ft lbs (49 Nm).
15. Before testing operation, move the handle
from extreme left to right and down into
operating position and back several times.
Check for any wire and cable interference.
Repair or adjust as necessary.
PDMM-0100 Issued: 5/21/01 6-55

Drive Motor
6-56 PDMM-0100 Issued: 5/21/01

Drive Unit
Drive Unit
Removal
1. Lower the forks, turn the key switch OFF
and disconnect the battery connector.
! WARNING
place solid blocks beneath it to Pivot Bearing
Retaining Nut
alone to support the truck. For 1665 045.tif
details, see “Jacking Safety” on Figure 6-42: Pivot Bearing Retaining Nut
page 2-11.

Drain Screw Fill/Level Plug
4. Disconnect the control wiring harness and
power cables from the electrical panel.
5. Remove the control handle. See “Control
6. Remove the pivot bearing retaining nut. See
Figure 6-42.
! WARNING
Transmission assembly may fall free 1665 039.tif
from mounting after nut is removed. Figure 6-43: Drive Unit Fill Plug
7. Remove the transmission assembly by

lowering through the pivot-frame mount.
8. Feed the control wiring harness and power
cables through the transmission pivot
mount.
9. Remove the drive unit drain screw (lower
cover screw). See Figure 6-43. Allow the
gear oil to drain.
PDMM-0100 Issued: 5/21/01 6-57

Drive Unit
Disassembly
1. After draining the gear case lubricant,
thoroughly clean the outside with solvent or
other non-corrosive cleaning fluid. Air dry
all parts, and proceed with disassembly of
transmission.
2. Remove the drive wheel. See “Drive Wheel”
on page 6-64.
3. Remove the drive motor. See “Drive Motor”
on page 6-53.
4. Remove the 14 hex head cap screws
securing the gear case cover. Remove the
gear case cover.
5. Block the transmission with the gear case
side down. Allow room for the gears to drop
between the blocks.
6. Press the drive axle through the collar and
bearing. The gear/axle and the cluster gear
will come out together.
7. Remove the old bearings and races from the
gears and case. Clean the transmission
case, making sure that the vent hole
located in the upper corner is free of
obstructions.
6-58 PDMM-0100 Issued: 5/21/01

Drive Unit
9
1
14
2
22
20
3
21
5 17
18 15
27 10
25 19
11
7
12 16
13
W08175b.eps
Figure 6-44: Drive Unit, Cross-Sectional View
Legend:
1 Housing, Gearbox 15 Screw
2 Cover, Gearbox Motor 16 Seal
3 Cover, Gearbox 17 Bearing, Bronze
4 Pinion, Drive 1st Stage 18 Bearing, Sealed
5 Gear Set, 2nd Stage 19 Locknut, Output Shaft
7 Gear Set, Output 20 Locknut, DC Motor
9 Sleeve 21 Key, Woodruff
10 Spacer, Output Shaft 22 O-Ring, Motor
11 Pin, Dowel 23 Hub, Wheel (not shown)
12 Plug, Fill/Level 25 Key, Input
13 Bearing Set, Cup & Cone 26 Key, Output (not shown)
14 Screw 27 Ring, Retaining
PDMM-0100 Issued: 5/21/01 6-59

Drive Unit
Assembly
1. Install the new bearings [18] on the cluster
gear [5].
2. Install the new bearing [13] on the drive
axle [7].
3. Place the case in a fabricated assembly
base and press the new bearing cups [13] in
the transmission case.
4. Position the transmission on the work
bench with the gear case side up. Place the
drive axle [7] and cluster gear [5] in the case
as a unit with the gears meshed. Because of
the gear size and bearing tolerances, the
gear set and bearing cannot be installed
separately.
5. Use P/N 990-411 on the mating surface
and install the drive unit gear case cover
[3]. Be sure that the two dowel pins [11] are
in the case to position the cover. Torque the
cover bolts to 30 ft lbs (42 Nm).
6. Reposition the transmission case so that it
rests on the gear case cover.
7. Temporarily install the drive motor in the
transmission case using only two bolts to
hold the motor in place.
8. Install the outer drive axle bearing cone [13]
and retaining collar [13]:
a. Place the bearing cone over the shaft.
Use a standard 1-14 nut and bearing
installation tool to push the bearing on
the drive axle. At this time the bearing
will not seat on the shoulder of drive
axle. Remove the nut and pusher.
b. Install the drive axle seal [16] in the
transmission case.
c. Install the bearing collar in the drive
axle. Use a bearing installation tool
and nut to press the collar on the
shaft. This should also press the
bearing down, seating it on the
shoulder. Turn axle shaft while
torquing nut to 250 ft lbs (339 Nm).
Control the drive axle turning by
holding the brake lever on the drive
motor.
6-60 PDMM-0100 Issued: 5/21/01

Installation
Installation
! CAUTION
Be sure the key switch is OFF and the
battery connector is disconnected
before you begin.
1. Install the drive motor. See “Drive Motor” on

page 6-53.
2. Install the bearing cups in the frame. Install
a Nilos ring over the pivot tube on the top of
the transmission assembly and install the
bearing cone.
3. Feed the wire harness and power cables
through the pivot tube.
4. Reinstall the drive unit assembly through
the pivot frame while feeding the harness
and cables through the pivot frame mount.
Install the bearing cone and Nilos ring.
5. Liberally grease the top and bottom bearing
cones on the pivot bearing.
6. Unblock and lower the truck.
7. While tightening the drive unit locking nut,
rotate the drive unit to simulate the
steering action. Continue to tighten the nut
until the nut is snug and the drive unit will
not rotate. Back the nut off 1/4 turn and
move steering. If the steering feels free, lock
the nut with thread-locking compound
P/N 990-536. If the steering still feels snug,
back the nut off another 1/4 turn before
applying thread-locking compound.
8. Install the control handle. See “Control
9. Reconnect the wiring harness.
10. Ensure the drive unit is filled to the proper
level with gear oil. Install the fill/level plug.
12. Install the battery, reconnect the battery
connector and the turn key switch ON.
13. Check the controls for proper operation.
PDMM-0100 Issued: 5/21/01 6-61

Drive Housing Lubrication

Gear Oil Level
1. Remove the fill/level plug. See Figure 6-45.
Fill/Level Plug
2. Check the oil level. When the truck is level, Drain Screw
the oil should be up to the bottom of the
plug opening.
3. If necessary, add the specified oil through
the plug opening, but do not overfill.
4. Install the fill/level plug securely.
Changing Gear Oil

1. Remove the drain screw (lower cover screw)
from the bottom of the gear housing cover 1665 039.tif
and allow the oil to drain. See Figure 6-45. Figure 6-45: Drive Unit Fill/Drain Plugs
2. After the oil has drained completely, flush
the housing with a suitable solvent and
allow it to drain.
3. Install the drain screw.
4. Fill the drive housing with the specified
gear oil through the fill/level plug opening
in the cover of the transmission. The drive
housing will hold 0.8 qts (0.75 liter) of gear
oil. Do not overfill.
6-62 PDMM-0100 Issued: 5/21/01

Drive Axle Seal

Replace the drive axle seal without removing
the gear case cover by doing the following:
Removal
! WARNING
place solid blocks beneath it to
alone to support the truck. For
details, see “Jacking Safety” on
page 2-11.

3. Remove the drive unit fill plug and drain
screw and allow gear oil to drain.
5. Remove the nut holding the drive tire to the
drive axle.
6. Remove the drive tire by hand or if wheel is
stubborn, use three bolts from the drive
motor cover and thread in hub to push
drive tire off drive axle.
7. Remove the axle seal with a seal puller. Do
not damage the sealing surface or
mounting bore.
Installation
1. Install the new oil seal.
2. Reinstall the drive tire. Torque the drive tire
retaining nut to 250 ft lbs (339 Nm).
3. Install the drive motor cover. Torque screws
to 35 ft lbs (49 Nm).
4. Replace the drain screw. Replace the gear
oil and replace the fill plug.
PDMM-0100 Issued: 5/21/01 6-63

Drive Wheel
Removal
! WARNING
the truck. After the truck is jacked, Drive Wheel
place solid blocks beneath it to Locking Nut
alone to support the truck. For
details, see “Jacking Safety” on
page 2-11.
2. Jack and block the truck under the tractor

frame.
3. Remove the locking nut holding the drive
wheel to the drive axle. See Figure 6-46.
1581 007.tif
4. Remove the drive wheel by hand or if Figure 6-46: Drive Wheel Locking Nut
necessary use three bolts from the side
cover over the drive wheel and thread in the
hub to push the drive wheel off the drive
axle.
5. Press the drive tire from the wheel hub.
6-64 PDMM-0100 Issued: 5/21/01

Cushion Tire Replacement

Any 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 pressing and to reduce
the possibility of misalignment.
! CAUTION
To prevent damage, the hub must be
installed on the circular ram with the
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.
2. Place a circular ram on the press table. See
Figure 6-47. The length of the ram must be
longer than the width of the old tire to allow
complete removal of the old tire. The
tire.pcx
outside diameter of the ram must be small
enough to fit loosely in the insert of the tire Figure 6-47: Cushion Tire Replacement
but must be large enough to rest squarely
on the flat surface on the outer edge of the
hub.
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. The new tire must be placed
in the same position the old tire was
installed on the hub. You can use a spacer
(slightly smaller in diameter that the inside
diameter of the tire insert and the same
thickness as the depth of the recess) to
obtain the proper amount of recession.
4. Position the hub assembly with the old tire
on 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
a tire is pressed onto the hub.
PDMM-0100 Issued: 5/21/01 6-65

5. Center the hub assembly on top of the ram

and make sure they mate squarely.
6. Position the new tire with its chamfered
insert facing the hub. Align the new tire and
the hub so they are concentric.
7. 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, stop the
press immediately and realign the tire. Use
a soft-headed mallet to realign the tire on
the hub.
NOTE: If the new tire does not press on with a
minimum pressure of 5 tons
(68,947 kPa), replace the hub.
8. Release the press. Remove the wheel, tire
assembly and the old tire from the press
table. Inspect the wheel and tire assembly.
9. Install the wheel and tire assembly on the
drive axle of the truck. Torque the drive
retaining nut to 250 ft lbs (339 Nm).
6-66 PDMM-0100 Issued: 5/21/01

Load Wheels
Load Wheels
Replacement
1. Lift the forks to maximum height and block
them. See “Jacking Safety” on page 2-11.
Axle Set
2. Remove the axle set screw. See Figure 6-48. Screw
27y7s173.tif
Figure 6-48: Removing Set Screw

3. Drive the axle out of the load arm casting
with a hammer and brass drift pin. See
Figure 6-49.
4. Push the wheel out. See Figure 6-50.
5. If the bearings are to be reused, insert a
brass drift pin into each end of the load
wheel and knock the bearings out.
6. Install the bearings in the load wheel with
the shields facing out.
27y7s174.tif
Figure 6-49: Removing Axle from Load Arm Casting

7. Place the new load wheel upright on a flat
surface. Position the bearing over the load
wheel. Place a flat metal plate over the
bearing, and hammer the bearing in place
with a plastic mallet. Make sure the bearing
is fully seated in the load wheel.
8. Align the wheel with the holes in the load
arm casting.
9. Drive the axle through the load arm casting
and wheel. Align the "dimple" in the axle Wheel
with the set screw hole. Axle
10. Install and tighten the set screw.
11. Lubricate the grease fittings if necessary.
27y7s175.tif
Figure 6-50: Removed Load Wheel and Components
PDMM-0100 Issued: 5/21/01 6-67

Load Wheel Pull Rod
Load Wheel Pull Rod

Removal and Replacement
NOTE: It may be easier to work with the truck
upside down. Remove the battery before
turning the truck over. Some oil may
leak from the hydraulic reservoir.
1. Extend the load wheel forks and remove the
shaft connecting the wheel fork to the pull
rod.
2. Remove the pivot pin locking bolt and drive
the pivot pin out with a brass drift pin.
3. With the lower links out of the lift frame
channels, the links can be separated and
the pull rod removed from the link pin.
Each link has one set screw at opposite
ends. The link can be pulled apart without
removing any other setscrews.
4. Press new bushings in the pull rods, if
necessary.
5. Reassemble the pull rods on the lower links
and press the links together so they will fit
in the frame channel.
6. Reinstall the pivot shaft and the retaining
bolt in the lower links.
7. Reconnect the pull rod to the wheel fork.
8. Place the truck upright and install the
battery. Connect the battery. Check the
reservoir fluid level. Test the operation of
the lift frame.
Carrier Frame Linkage

The bushings on the upper links can be
replaced by removing the links from one side at
a time and pressing in new bushings.
1. To separate the lift and carrier frames,
remove all electric connections before
removing the links.
2. Remove linkages and lift the lift frame off
the carrier frame.
6-68 PDMM-0100 Issued: 5/21/01

Hydraulic Components
Hydraulic Components
General Guidelines
To prolong the life of your Raymond Walkie
Pallet Truck, adhere to the following guidelines:
• Keep all fittings and connections tight to
prevent leaks. Be careful not to over-tighten
brass fittings or they may become damaged
or distorted.
• Before you remove any component from the
hydraulic system, wash the component and
surrounding area with cleaning solvent to
prevent foreign matter from entering the
system. Cap and plug all openings
immediately.
• Whenever you remove a fitting with a pipe
thread, use a sealing compound on the
outside of the threads before you reinstall
the fitting. (Never use Teflon® tape.) Make
sure all parts are clean.
• When you install a hose assembly, make
sure that it is not twisted when the fittings
are tightened. Always use two wrenches on
a swivel-type fitting—one to hold the fitting
and the other to tighten the hose.
Adjustments
The only adjustment on the frame is a pair of
lowered height stops. These stops consist of
bolts with jam-nuts fitted on the frame just
above the transmission assembly on either side
of the lifting cylinder. The bolts should be
adjusted so that when the truck is fully
lowered, the bolt heads stop against the
transmission frame evenly and both pallet forks
are of equal distance from the floor.
PDMM-0100B Revised: 3/14/03 6-69

Hydraulic Fluid
Hydraulic Fluid
Motor
Proper Level
To prevent air from entering the lines, the fluid Lift Motor
level (with the forks fully lowered) should be Solenoid
filled and visible to within 1 in. (2.54 cm) below
the fill port elbow. See Figure 6-51. Add the
specified fluid if necessary. See “Lubrication
Equivalency Chart” on page A-2.
Changing Fluid Adapter Body

(Pump)
Store and handle the hydraulic fluid with
extreme care to prevent moisture and foreign
matter from entering the hydraulic system.
Contaminated hydraulic fluid is the major
cause of hydraulic system failures. Any service
equipment, such as containers, funnels and
hand pumps, should be kept clean at all times.
Cover them when not in use. Solenoid
Release
1. Lower the forks. Valve Relief Valve
the battery connector. Fill/Vent
Reservoir Plug
Filler Port
1665 033.tif
Figure 6-51: Hydraulic Unit
6-70 PDMM-0100 Issued: 5/21/01

Changing Fluid
1:snChanging Fluid
4. Remove the lift cylinder hose from the

fitting at the hydraulic pump. Lift Motor Solenoid
See Figure 6-52.
5. Connect a drain hose (high pressure) to the
open fitting on the pump and tighten. (A
pressure gauge hose is acceptable.) Place
the hose in a waste fluid container.
! WARNING
Fluid will be under pressure and may
spray or splash. Point hose away
from your body and hold firmly in Lift Cylinder
Hose Adapter Body
waste fluid container. (Pump)
1665 040.tif
6. Connect the battery connector and turn the Figure 6-52: Hydraulic Connections
key switch ON.
7. Run the hydraulic pump by pressing the lift
button until all the hydraulic fluid is
pumped from the system.
9. Remove the drain hose and reconnect the
lift cylinder hose.
10. Remove the vent plug and fill the reservoir
to within 1 in. (2.54 cm) below the filler port
elbow with the recommended hydraulic
fluid. See “Torque Chart - Standard” on
page A-3. Replace the vent plug.
11. Connect the battery and turn the key
switch ON.
12. Raise and lower the forks several times to
purge air from the system.
14. Dispose of the waste fluid properly.
PDMM-0100 Issued: 5/21/01 6-71

Adjusting Hydraulic Pump Pressure Relief Valve
Adjusting Hydraulic
Pump Pressure Relief
Valve
The hydraulic system is protected by a relief
valve located in the adapter body.
See Figure 6-51. The relief valve is set by the
manufacturer to open at a specified pressure.
Relief Valve Settings
Pressure Settings
Truck
Capacity
PSI kPa
4,500 lb
3,200 22,063
(2,041 kg)
Table 6-3: Truck Pressure Levels
Check Setting Hydmtrpm.tif
Figure 6-53: Checking Relief Valve Pressure

1. Attach a jumper wire across the terminals
of the lift-limit switch so the switch will not
shut the pump down when the forks reach
their upper limit.
2. Retract the lift cylinder completely. Turn
the key switch OFF. Remove the 90° elbow.
Install a female run tee with a 1/8 in. NPT
0 to 3,500 psi (0 to 24131 kPa) pressure
gauge in place of the elbow.
See Figure 6-53.
3. Turn the key switch ON. Leave the control
handle in the neutral (vertical) position.
4. Press the lift button and observe the
indicator on the pressure gauge. When the
forks reach the upper lift limit, the pump
will make a high pitched squeal indicating
that the relief valve is opening.
5. If the relief valve opens at a lower or higher
pressure than the specified pressure,
adjust the relief valve as follows:
a. Remove the hex cap covering the relief
valve adjustment screw.
See Figure 6-51.
6-72 PDMM-0100 Issued: 5/21/01

Adjusting Hydraulic Pump Pressure Relief Valve
b. As you depress the lift button, turn the

adjusting screw inward to increase the
pressure setting or outward to decrease
the pressure setting.
c. Check the indicator on the pressure
gauge. After the relief valve is properly
set, release the lift button.
d. Reinstall the hex cap.
e. Check the relief valve setting.
f. Lower the forks completely. Turn the
key switch OFF.
g. Remove the pressure gauge. Replace the
elbow.
h. Turn the key switch ON. Raise the forks.
Inspect all hoses and fittings for leaks.
i. Adjust the lift-limit switch to shut down
the pump when the forks reach their
upper limit. See “Lift-Limit Switch” on
page 6-29.
PDMM-0100 Issued: 5/21/01 6-73

Hydraulic Cylinder
Hydraulic Cylinder
Fluid leakage indicates that the seal is worn.
Replace the seal, wiper, and retaining ring (Seal
Kit P/N 939-028) when fluid leakage becomes
excessive.
Cylinder Removal
2. Turn the key switch ON. Leave the control
handle in the neutral (vertical) position.
3. Press the lift button and raise the forks to Hydraulic
maximum height and block them. See Line
4. Lower the forks onto the blocking to release
pressure on the hydraulic cylinder.
Manually press down on the cylinder after
the forks come to rest on the blocking to
disengage the cylinder from the tractor
frame.
1665 041.tif
Figure 6-54: Removing Hydraulic Line from Cylinder

! WARNING
Hot oil under pressure may be
present. Be certain truck is safely
blocked and pressure is released.
6. Thoroughly clean the outside of the cylinder

before removing the hydraulic hose.
Remove the hose from the cylinder. Cap
and plug the fittings. See Figure 6-54.
NOTE: Be prepared to catch hydraulic fluid
under the hydraulic cylinder in a
suitable container.
7. Lift the cylinder up and out of the tractor
frame. Some spillage of hydraulic oil may
occur.
6-74 PDMM-0100 Issued: 5/21/01

Hydraulic Cylinder
Cylinder Disassembly
1. Thoroughly clean the outside of the
cylinder.
2. Pull the rod out until the end of the rod and Inlet Port
the retaining ring can be seen through the
inlet port. See Figure 6-55.
3. Insert a screwdriver into the inlet port and
slide the retaining ring into the deep groove
in the piston rod assembly. Barrel
4. Remove the rod assembly from the barrel. Wiper
5. Remove the retaining ring from the piston Seal

rod.
Snap Ring Rod
6. Remove the wiper and seal from inside the
barrel assembly. Figure 6-55: Hydraulic Cylinder Disassembly
Cylinder Inspection
1. Thoroughly clean all parts and remove all
nicks and burrs with emery cloth.
2. Inspect the inside surface of the barrel
assembly for excessive wear or scoring.
3. Inspect the outside surface of the rod for
nicks, scratches, or scoring.
Cylinder Assembly
1. Make sure all parts are cleaned and dried
thoroughly. Metal parts should be lightly
oiled before reassembly.
2. Install new seal in the barrel. Install new
wiper in the barrel with lips facing inward.
3. Install new retaining ring in deep groove of
the piston rod end.
4. Oil outside of piston rod and carefully
insert rod into barrel.
5. Push rod into barrel until the retaining ring
can be seen through the inlet port.
6. Insert a screwdriver into the inlet port and
slide the retaining ring into the lock
position.
7. Extend rod to full out position to make sure
the retaining ring is locked in place.
PDMM-0100 Issued: 5/21/01 6-75

Installation
Installation
1. Place the new cylinder into position in the
tractor frame.
NOTE: To prevent air from filling the cylinder,
install the cylinder with the rod
retracted.
2. Connect the hydraulic hose.
the key switch ON.
4. Press the lift button to extend the cylinder.
5. Check the hydraulic reservoir fluid level. If
necessary, add fluid. See “Lubrication
Equivalency Chart” on page A-2.
6. Remove the blocking. Lift and lower the
forks several times. Look for leakage
around the fittings and cylinder seal.
7. Recheck the hydraulic reservoir fluid level.
If necessary, add fluid.
6-76 PDMM-0100 Issued: 5/21/01

Hydraulic Unit
Hydraulic Unit
Draining and cleaning the hydraulic reservoir is
important to control the accumulation of
condensation and contamination which can
damage the hydraulic system.
Pump Motor
Condensation is caused by the repeated heating
and cooling of hydraulic fluid during normal
operation. Contaminants include dirt, rust,
scaling and products of fluid deterioration.
Adapter Body
(Pump)
Removal
The hydraulic pump and motor assembly must
be removed from the truck in order to separate
the pump from the motor.
Vent
1. Lower the forks completely. Plug
the battery. Remove the tractor cover.
3. Remove and tag all wires and cables
Hydraulic
connected to the pump motor.
Reservoir
See Figure 6-56.
4. Remove and cap the hydraulic line from the
hydraulic unit. Disconnect the solenoid 1665 040.tif
control. Figure 6-56: Hydraulic Unit
5. Remove the bolts that secure the hydraulic
unit mounting bracket to the tractor frame.
6. Remove the hydraulic unit from the truck.
Installation
1. Install the hydraulic unit on the tractor
frame and secure with the previously
removed screws.
2. Install the hydraulic line on the hydraulic
unit.
3. Fill the reservoir with the specified
hydraulic fluid. See “Lubrication
Equivalency Chart” on page A-2. Use a
funnel with a flexible neck. Fill the reservoir
to within 1 in. (2.54 cm) below the filler
plug elbow. See Figure 6-56. Use up to
1.58 qts (1.5 liters).
4. Install the vent plug. See Figure 6-56.
5. Connect all wires and cables to the pump
motor. Connect the battery.
PDMM-0100 Issued: 5/21/01 6-77

Hydraulic Reservoir
6. Raise and lower the forks. Check all hoses

and fittings for leaks.
7. Lower the forks.
8. Check the hydraulic fluid level in the
reservoir.
Hydraulic Reservoir
Removal
Cap
1. Remove the hydraulic unit from the truck. Screws (4)
See “Removal” on page 6-77.
2. Remove the four cap screws that connect
the hydraulic reservoir to the adapter
housing. See Figure 6-57.
3. Tap the reservoir lightly to loosen. Wiggle
the reservoir sideways while pulling up at
the same time to remove.
4. Remove the reservoir and properly dispose
27y7s154.tif
of the old hydraulic fluid. See Figure 6-58.
Figure 6-57: Adapter Cap Screws
5. After the fluid has drained, flush the inside
of the reservoir with a suitable cleaning
solvent.
6. Dry the inside of the reservoir with clean,
dry compressed air. Reservoir
Installation
1. Inspect the reservoir O-ring and the inside
leading edge for defects and replace if
necessary.
2. Lubricate the O-ring (with applicable
hydraulic fluid) and install the O-ring. See
Figure 6-58.
3. Carefully install the reservoir on the
adapter housing and secure with four (4) O-ring
cap screws. 27y7s156.tif
4. Install hydraulic unit in the truck. See Figure 6-58: Removed Reservoir
“Installation” on page 6-77.
6-78 PDMM-0100 Issued: 5/21/01

Filter Screen and Suction Tube
Filter Screen and Suction Tube

1. Remove the reservoir. See “Hydraulic
Reservoir” on page 6-78. Filter
Screen
2. With the pump assembly inverted, push the
spring clip toward the pump housing. See
Figure 6-59.
3. Grasp the suction tube with the filter
screen and pull out of pump housing.
4. Clean the filter screen at the bottom of the
suction tube with a suitable solvent. See
Figure 6-60. Suction
Tube Pump
5. From the pump side, blow dry with clean, Housing
dry compressed air.
Spring
Clip
27y7s157.tif
Figure 6-59: Pump Housing Components
Installation
1. Inspect the filter screen and tube for defects
Filter
and replace if necessary. Screen
2. Lubricate the pump end of the suction tube
with hydraulic fluid.
3. Push the spring clip toward the pump
housing and insert the suction tube
through the spring clip and into the pump
housing until it stops. See Figure 6-59.
Suction
4. If necessary, rotate the suction tube so that Tube
the filter screen is toward the center line of
the pump.
27y7s158.tif
5. Install the hydraulic reservoir. See
Figure 6-60: Cleaning Filter Screen
“Hydraulic Reservoir” on page 6-78.
PDMM-0100 Issued: 5/21/01 6-79

Hydraulic Pump
Hydraulic Pump
Adapter Pump
Removal Body
1. Remove the hydraulic unit from the truck

and place on a clean bench for
disassembly. See “Hydraulic Unit” on page
6-77.
2. Remove the reservoir to gain access to the
pump. See “Hydraulic Reservoir” on page
6-78.
3. Grasp the suction tube with the filter Mounting
screen and pull out of the pump housing. Bolts (8)
See Figure 6-61. 27y7s159.tif
Figure 6-61: Pump and Adapter Body

4. Remove the eight pump mounting bolts.
Remove the pump from the adapter body.
Installation
1. Stand the motor assembly on end, with the
adapter body facing up.
2. Lubricate the O-ring and install on the
3. Insert the pump drive coupling onto the
end of the motor armature shaft and fill the
cavity with lubricant (P/N 990-638).
4. Align the splines on the motor drive and
pump shaft. Gently push the pump pilot on
the adapter.
5. Secure the pump with the eight pump
mounting bolts and torque to 10 to 12 ft lbs
(13.5 to 16.3 Nm).
6. Check the inlet screen for clogging. Clean
with a suitable solvent. Insert the inlet tube
into the pump.
7. Install the reservoir. See “Hydraulic
Reservoir” on page 6-78.
6-80 PDMM-0100 Issued: 5/21/01

Lift Motor
Lift Motor
General Data
Brush Replacement Replace brushes when they have worn to the minimum length of
1/2 in. (12.70 mm).
Spring Tension Adjust the spring tension of new brushes to 32 to 40 oz (908.8 to

1136 gms).
Removal
1. Remove the hydraulic unit from the truck.
See “Hydraulic Unit” on page 6-77.
2. Remove the two bolts from the end plate
that attach the motor to the adapter body.
See Figure 6-62.
3. Separate the motor and the adapter body.
See Figure 6-63.
4. Remove the solenoid from the side of the
motor housing to be reused.
See Figure 6-63.
27y7s160.tif
Figure 6-62: Bolts Securing Motor to Adapter
Pump Drive
Coupling Solenoid
Mounting
Bolts (2)
27y7s161.tif
Figure 6-63: Separated Reservoir and Motor
PDMM-0100 Issued: 5/21/01 6-81

Installation
Installation
1. Stand the pump assembly on end, with the
2. Set aside the pump drive coupling to be
reused. See Figure 6-64.
NOTE: The coupling is the mechanical
connection between the pump shaft and
the electric motor armature shaft. It may
have been removed with the motor.
3. Insert the pump drive coupling onto the
end of the pump shaft and fill coupling
cavity with lubricant (P/N 990-638). See
Figure 6-64.
4. Rotate the pump or motor shafts to make 27y7s162.tif
sure the motor shaft fits correctly into the Figure 6-64: Coupling Cavity
coupling.
5. Install the new motor onto the adapter
body. Rotate further if necessary until the
motor contacts the adapter body.
NOTE: There is an indexing pin on the end of
the motor housing that fits into a hole in
the adapter body to make sure the motor
mounting screws align with the threaded
holes in the adapter body.
See Figure 6-65.
27y7s165.tif
Figure 6-65: Indexing Pin

6. Insert the screws into the motor end plate,
through the motor and into the adapter
body. See Figure 6-66.
7. Make sure the motor is mating flush with
the adapter body and torque screws to
6.3 to 7.4 ft lbs (8.5 to 10 Nm) maximum.
8. Install the solenoid.
9. Install the hydraulic unit. See “Hydraulic
Unit” on page 6-77.
27y7s160.tif
Figure 6-66: Securing the Motor and Adapter Body
6-82 PDMM-0100 Issued: 5/21/01

Cold Storage Conditioning
Cold Storage
Conditioning
New Raymond Walkie Pallet Trucks to be used
in a cold storage environment are equipped at
the factory with cold storage components for
Cooler and Freezer applications.
! CAUTION
When a truck is to be installed in a
cold storage environment, change
the fluid in the hydraulic reservoir
and the drive unit according to the
following items.
Classes of Cold Storage

Raymond Walkie Pallet Trucks can be
conditioned for two classes of cold storage:
Cooler
• Environment where temperatures fluctuate
from 20°F (-7°C) to 70°F (21°C) in a
continuous duty cycle.
• Application where the truck goes in and out
of the freezer for short periods of time.
Freezer
• Environment where temperatures fluctuate
from -20°F (-29°C) to 40°F (4°C).
• Application where truck operates
continuously in a temperature of -20°F
(-29°C).
For a listing of the recommended fluids see
“Torque Chart - Standard” on page A-3.
PDMM-0100 Issued: 5/21/01 6-83

Classes of Cold Storage
6-84 PDMM-0100 Issued: 5/21/01

Raymond® Walkie Pallet Truck Maintenance Manual Appendix
Appendix A:
PDMM-0100 Issued: 5/21/01 A-1

Appendix Raymond® Walkie Pallet Truck Maintenance Manual
Lubrication Equivalency Chart
Lubrication Equivalency Chart
Approved Raymond Lubricants
Where Used Type Specification Raymond Part Number
Drive Unit Gear Case Gear 80W - 90 Gear Oil 990-610/04

(above +30°F/-1°C) Lubricant API Service GL-5 (1 quart/0.9 liter)
990-610/03
(5 gal./18.9 liters)
Drive Unit Gear Case Oil 10W-30 Motor Oil 990-603/04

(below +30°F/-1°C) API Service CE,CD,CC,SG,SF (1 quart/0.9 liter)
(cold storage) 990-603/03 (5 gal./18.9
liters)
Hydraulic Reservoir Hydraulic ISO 46 990-616/04

(non-cold storage Fluid (1 quart/0.9 liter)
trucks) 990-616/01
(+50°F to +120°F) (1 gal./3.8 liters)
(+10°C to +49°C) 990-616/02
(2 gal./7.6 liters)
990-616/03
Hydraulic Reservoir Hydraulic MIL-H-5606A/B 990-618/TX1

(-20°F to 0°F) Fluid (1 gal./3.785 liters)
(-29°C to -18°C) 990-618/01
Hydraulic Reservoir Hydraulic ISO 32 990-617/01

(-20°F to +70°F) Fluid (1 gal./3.785 liters)
(-29°C to +21°C) 990-617/03
Hydraulic Reservoir Hydraulic 10W-30 Motor Oil 990-615/01

(for high performance/ Fluid API Service CE,CD,CC,SG,SF (1 gal./3.785 liters)
high temperature 990-615/03
applications) (1 gal./3.785 liters)
Bearings, etc. Grease NLGI Grade 2 990-620/01

(10 cartridges per case)
990-620/02
Bearings, etc. Grease NLGI 2 990-652/001 (Spray)

(Cold Storage) with 990-652/002 (Cartridge)
Teflon
Figure A-1: Lubrication Equivalency Chart
A-2 PDMM-0100 Issued: 5/21/01

Torque Chart - Standard
Torque Chart - Standard

Grade
Identification None
Marking
SAE Grade 2 Bolts SAE Grade 5 Bolts SAE Grade 8 Bolts
Tightening Torque Tightening Torque Tightening Torque
Size
Dry Oiled* Dry Oiled* Dry Oiled*
in. lbs. in. lbs. in. lbs. in. lbs. in. lbs. in. lbs.
4-40 5 4 8 6 12 9
4-48 6 5 9 7 13 10
6-32 10 8 16 12 23 17
8-32 19 14 30 22 41 31
8-36 20 15 31 23 43 32
10-24 27 21 43 32 60 45
10-32 31 23 49 38 68 51
1/4-20 66 49 96 75 144 108
1/4-28 76 56 120 86 168 120
ft. lbs. ft. lbs. ft. lbs. ft. lbs. ft. lbs. ft. lbs.
5/16-18 11 8 17 13 25 18
5/16-24 12 9 19 14 25 20
3/8-16 20 15 30 23 45 35
3/8-24 23 17 35 25 50 35
7/16-14 30 24 50 35 70 55
7/16-20 35 25 55 40 80 60
1/2-13 50 35 75 55 110 80
1/2-20 55 40 90 65 120 90
9/16-12 70 55 110 80 150 110
9/16-18 80 60 120 90 170 130
5/8-11 100 75 150 110 220 170
5/8-18 110 85 170 130 240 180
3/4-10 175 130 260 200 380 280
3/4-16 195 145 300 220 420 320
7/8-9 165 125 430 320 600 460
7/8-14 185 140 470 350 660 500
1-8 250 190 640 480 900 680
1-12 270 200 700 530 1000 740
1 1/8-7 350 270 800 600 1280 960
1 1/8-12 400 300 880 660 1440 1080
1 1/4-7 500 380 1120 840 1820 1360
1 1/4-12 550 420 1240 920 2000 1500
1 3/8-6 660 490 1460 1100 2380 1780
1 3/8-12 740 560 1680 1260 2720 2040
1 1/2-6 870 650 1940 1460 3160 2360
1 1/2-12 980 730 2200 1640 3560 2660
Figure A-2: Torque Chart - Standard
*NOTE: Use “oiled” values for bolts with thread-locking compound.
PDMM-0100 Issued: 5/21/01 A-3

Torque Chart - Metric
Torque Chart - Metric

Ferrous Metric Bolts
(The grade rating is stamped on the head of the bolt.)
Grade 8.8 Grade 10.9
Diameter
Torque (with bolts oiled*) Torque (with bolts oiled*)
(in millimeters)
Newton-meters Foot-pounds Newton-meters Foot-pounds
6 8.6 6 12 9
8 21 15 29 21
10 42 30 58 43
12 72 55 101 75
16 174 130 245 181
20 340 255 475 350
24 580 435 820 605
Figure A-3: Torque Chart - Ferrous Metric
Metric Bolts, Coarse Thread
Diameter Torque (with bolts oiled*)

(in millimeters) Newton-meters Foot-pounds
3 0.5 4.4
3.5 0.79 7.0
4 1.2 10.6
5 2.2 19.4
6 3.9 34.5
8 9 79.6
10 17 150
Figure A-4: Torque Chart - Non-Ferrous Metric
A-4 PDMM-0100 Issued: 5/21/01

Decimal Equivalent Chart

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
1/64 .016 .02 .397
1/32 .031 .03 .794
3/64 .047 .05 1.191
1/16 .062 .06 1.587
5/64 .078 .08 1.984
3/32 .094 .09 2.381
7/64 .109 .11 2.778
1/8 .125 .12 3.175
9/64 .141 .14 3.572
5/32 .156 .16 3.969
11/64 .172 .17 4.366
3/16 .188 .19 4.762
13/64 .203 .20 5.159
7/32 .219 .22 5.556
15/64 .234 .23 5.593
1/4 .250 .25 6.350
17/64 .266 .27 6.747
9/32 .281 .28 7.144
19/64 .297 .30 7.540
5/16 .312 .31 7.937
21/64 .328 .33 8.334
11/32 .344 .34 8.731
23/64 .359 .36 9.128
3/8 .375 .38 9.525
25/64 .391 .39 9.922
13/32 .406 .41 10.319
27/64 .422 .42 10.716
7/16 .438 .44 11.112
29/64 .453 .45 11.509
15/32 .469 .47 11.906
31/64 .484 .48 12.303
1/2 .500 .50 12.700
Figure A-5: Decimal Equivalent Chart
PDMM-0100 Issued: 5/21/01 A-5

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
33/64 .516 .52 13.097
17/32 .531 .53 13.494
35/64 .547 .55 13.891
9/16 .562 .56 14.288
37/64 .578 .58 14.684
19/32 .594 .59 15.081
39/64 .609 .61 15.478
5/8 .625 .62 15.875
41/64 .641 .64 16.272
21/32 .665 .66 16.669
43/64 .672 .67 17.065
11/16 .688 .69 17.462
45/64 .703 .70 17.859
23/32 .719 .72 18.256
47/64 .734 .73 18.653
3/4 .750 .75 19.050
49/64 .766 .77 19.447
25/32 .781 .78 19.844
51/64 .797 .80 20.241
13/16 .812 .81 20.637
53/64 .828 .83 21.034
27/32 .844 .84 21.431
55/64 .859 .86 21.828
7/8 .875 .88 22.225
57/64 .891 .89 22.622
29/32 .906 .91 23.019
59/64 .922 .92 23.416
15/16 .938 .94 23.812
61/64 .953 .95 24.209
31/32 .969 .97 24.606
63/64 .984 .98 25.003
1.000 1.00 25.400
Figure A-5: Decimal Equivalent Chart
A-6 PDMM-0100 Issued: 5/21/01

Standard/Metric Conversions
Standard/Metric
Conversions
To Convert... Multiply...
Inches to Millimeters Inches x 25.4
Millimeters to Inches Millimeters x 0.039
Inches to Centimeters Inches x 2.54
Centimeters to Inches Centimeters x 0.394
Feet to Meters Feet x 0.305
Meters to Feet Meters x 3.281
Yards to Meters Yards x 0.914
Meters to Yards Meters x 1.094
Miles to Kilometers Miles x 1.609
Kilometers to Miles Kilometers x 0.621
Square Inches to Square Centimeters Square Inches x 6.452
Square Centimeters to Square Inches Square Centimeters x 0.155
Square Feet to Square Meters Square Feet x 0.093
Square Meters to Square Feet Square Meters x 10.753
Square Yards to Square Meters Square Yards x 0.836
Square Meters to Square Yards Square Meters x 1.196
Pints to Liters Pints x 0.473
Liters to Pints Liters x 2.113
Quarts to Liters Quarts x 0.946
Liters to Quarts Liters x 1.057
Gallons to Liters Gallons x 3.785
Liters to Gallons Liters x 0.26
Ounces to Grams Ounces x 28.35

Figure A-6: Standard/Metric Conversions
PDMM-0100 Issued: 5/21/01 A-7

Standard/Metric Conversions
To Convert... Multiply...
Grams to Ounces Ounces x 0.035
Ounces to kilograms Ounces x 0.028
Kilograms to ounces Kilograms x 35.27
Pounds to Kilograms Pounds x 0.454
Kilograms to pounds Kilograms x 2.2
Pounds per Square Inch to Kilo pascals Pounds per Square Inch x 6.894
Kilo pascals to Pounds per Square Inch Kilo pascals x 0.145
Inch Pounds (in. lbs.) to Newton Meters (Nm) Inch Pounds x 0.113
Newton Meters (Nm) to Inch Pounds (in. lbs.) Newton Meters x 8.85
Foot Pounds (ft. lbs.) to Newton Meters (Nm) Foot Pounds x 1.3568
Newton Meters (Nm) to Foot Pounds (ft. lbs.) Newton Meters x 0.737
Miles per hour to kilometers per hour Miles per hour x 0.6214
Kilometers per hour to miles per hour Kilometers per hour x 1.609
Fahrenheit to Celsius (°F - 32) x 0.555
Celsius to Fahrenheit (°C x 1.8) + 32

Figure A-6: Standard/Metric Conversions
A-8 PDMM-0100 Issued: 5/21/01

Schematics
A Appendix
Schematics
PDMM-0100 Issued: 5/21/01 A-9

Schematics
Model 101 Electrical Control Std.
28 26 27
SW13
1 2
FU1 BAT IGN 6
1 15A SW1
CB1 KEY 7
80A IGN 6 C NO
2 SW2
BRAKE
6
-1 M1-X
M2 M1 M1
-2 M1-Y
24
JP6-5 VR-2
19 VR-4
LIFT
MP MOTOR
ARMATURE
JP6-4
9
JP6-2
2
B+
LIFT JP6-3
MOTOR 3
FIELD
JP6-7
11A
11B
2
4 JP6-8
V
B
A
T
T
E
R
Y B+
A1
B-
DRIVE MD
MOTOR DRIVE
ARMATURE MOTOR
FIELD
A2
M- S1 S2
KSI 6
PLUG PMC-16
DIODE MODE SELECT 1
PMC-14
MAIN CONTACTOR 24
PMC-4
BRAKE 7
PMC-15
POT LOW 19
PMC-7
POT WIPER 9
PMC-6
FWD 2
PMC-12
REV 3
PMC-11
EMERGENCY REVERSE 11A
PMC-13
EMERGENCY REVERSE CHECK 11B
PMC-10
MODE SELECT 2 13
MOTOR PMC-9
CONTROLLER
B-
13 13
REFER TO PAGE A-14 FOR COMPONENT LEGEND

W06785aa.eps
Figure A-7: Standard Model 101 Electrical Schematic
A-10 PDMM-0100 Issued: 5/21/01

Schematics
Model 101 Electrical Control Std. (Cont.)F
METER OPTIONS CONNECTOR

J9-5
J9-6
J9-3
J9-2
JPS-1
13
7 7 27 6
JP6-1 JP6-6 JP2-2

JP2-1
SW9 SW11 SW12

SW3 C SW4 C SW7 C 3 3 3
NO NO NO
4 4 4
TRACTOR FORKS BELLY HORN LOWER LIFT
FIRST FIRST BUTTON
HANDLE ASSEMBLY
JP2-3 JP2-5 JP2-4
8 4 5
SW10
5
C
LIFT
CUT-OUT
H2(POS)
NC
17
SOL-X M2-X
8 4 17
SOL M2
13 13
13
SOL-Y M2-Y
H1(NEG)
13 13 13
W06785ab.eps
Standard Model 101 Electrical Schematic - continued
PDMM-0100 Issued: 5/21/01 A-11

Schematics
Model 101 Electrical ContrModel 101
28 26 27
SW13
1 2
FU2 BAT IGN 6
1 15A SW1
CB1 KEY 7
80A IGN 6 C NO
2 SW2
BRAKE
6
-1 M1-X
M2 M1 M1
-2 M1-Y
24
19 JP3-1 VR-4 VR-2

LIFT
MP MOTOR
ARMATURE
9 JP6-4
JP6-2
2
B+
LIFT JP6-3
MOTOR 3
FIELD
JP3-3
11A
11B
2 JP3-4
4
V
B
A
T
T
E
R
Y B+
A1
B-
DRIVE 6
MD DRIVE
MOTOR
ARMATURE MOTOR
FIELD
A2
M- S1 S2
KSI 6
PLUG PMC-16
DIODE MODE SELECT 1
PMC-14
MAIN CONTACTOR 24
PMC-4
BRAKE 7
PMC-15
POT LOW 19
PMC-7
POT WIPER 9
PMC-6
FWD 2
PMC-12
REV 3
PMC-11
EMERGENCY REVERSE 11A
PMC-13
EMERGENCY REVERSE CHECK 11B
MOTOR PMC-10
CONTROLLER MODE SELECT 2 13
PMC-9
B-
13 13

W06785cc.eps
Figure A-8: Cold Storage (CS) Model 101 Electrical Schematic
A-12 PDMM-0100 Issued: 5/21/01

Schematics
METER OPTIONS CONNECTOR

J9-5
J9-6
J9-3
J9-2
JPS-1
13
7 7 27 6
JP6-1 JP3-2 JP2-2

JP2-1
SW9 SW11 SW12

SW3 C SW4 C SW7 C 3 3 3
NO NO NO 2
4 4 4
TRACTOR FORKS BELLY HORN LOWER LIFT HTR1
FIRST FIRST BUTTON HEATER
1
HANDLE ASSEMBLY
JP2-3 JP2-5 JP2-4 JP2-6
8 4 5 13
6 6 6 6
2 2 2 2 6
HTR2 HTR3 HTR4 HTR5 1 CR1

HEATER HEATER HEATER HEATER SW10
1 1 1 1 5
C
LIFT
2 4 CUT-OUT
H2(POS)
NC
0 17
12
22 22
SOL-X M2-X
13
8 4 17
13 13 13 13 12
SOL M2
13 13
THERMO 13
SOL-Y M2-Y
H1(NEG)
13 13 13 13 13
W06785cd.eps
Cold Storage (CS) Model 101 Electrical Schematic - continued
PDMM-0100 Issued: 5/21/01 A-13

Schematics
FU1-2 B+ BATTERY 27 FU1-2 B+ BATTERY 27

SW1-IGN KEYSWITCH 6
SW2-NO BRAKE SWITCH 7 SW2-NO BRAKE SWITCH 7
M2-X M2-X
M2 M2
HOUR METER OPTION HOUR/DISCHARGE
M2-Y M2-Y
METER OPTION
COMMON (BNEG) 13 COMMON (BNEG) 13
METER METER
OPTIONS OPTIONS
CONNECTOR CONNECTOR
7 6
J9-3 J9-6
13 13
J9-2 J9-2
27
J9-5
1 2
1 2
27
J9-5 5 6
4 3 7
J9-3 3 4
COMPONENT LEGEND
CB CIRCUIT BREAKER 80 AMPS M1 CONTACTOR MAIN HTR1 HEATER IN HANDLE (C.S. ONLY) PMC1 CONNECTOR ON MOTOR CONTROLLER
FU1 FUSE CONTROL CIRCUIT 15 AMPS M2 CONTACTOR PUMP HTR2 BRAKE SWITCH HEATER (C.S. ONLY)
MD MOTOR DRIVE HTR3 LIFT SOLENOID HEATER (C.S. ONLY) SOL SOLENOID LOWER
MP MOTOR PUMP HTR4 LIFT LIMIT SWITCH HEATER (C.S. ONLY) SW1 KEYSWITCH
HTR5 CONTROLLER HEATER (C.S. ONLY) SW2 BRAKE SWITCH
JP2 CONNECTOR IN HANDLE FOR FUNCTIONS SW3 TRACTOR FIRST SWITCH
CR1 HEATER RELAY (C.S. ONLY)
JP3 CONNECTOR IN HANDLE FOR TRAVEL (C.S. ONLY) SW4 FORKS FIRST SWITCH
THERMO CONTROLLER THERMOSTAT (C.S. ONLY) SW7 BELLY BUTTON SWITCH
JP6 CONNECTOR IN HANDLE FOR TRAVEL
JP9 TERMINAL CONNECTIONS FOR METER OPTION SW9 HORN SWITCH
JPS-1 SPLICE CONNECTION IN HANDLE FOR BRAKE SW10 LIFT LIMIT SWITCH
SW11 LOWER SWITCH
SW12 LIFT SWITCH
SW13 MAIN ON/OFF SWITCH
VR THROTTLE POTENTIOMETER
W06785a3.eps
Figure A-9: Model 101 Options Electrical Schematic
A-14 PDMM-0100 Issued: 5/21/01

Schematics
Hydraulic Schematic
1881 002.eps
Lift
Solenoid Cylinder
Valve
Check
Valve Pressure
Relief
Valve
2000
PSI
M 097
Flow Control
Motor Pump
2.0
GPM
Filter
Reservoir
Figure A-10: Model 101 Hydraulic Schematic
PDMM-0100 Issued: 5/21/01 A-15

Schematics
A-16 PDMM-0100 Issued: 5/21/01

Raymond® Walkie Pallet Truck Maintenance Manual Index
Index 2:
PDMM-0100B Revised: Draft I-1

Index Raymond® Walkie Pallet Truck Maintenance Manual
A E
Acceleration Rate . . . . . . . . . . . . . . . . .5-7 Electrical Connector Locator Chart . . . 5-12

Adjustments Electrical Troubleshooting . . . . . . . . . . 5-3
Lift-Limit Switch . . . . . . . . . . . . . . 6-29 Emergency Reverse . . . . . . . . . . . . . . . 5-8
Lowered Height Stops . . . . . . . . . . 6-69 Emergency Reverse Check . . . . . . . . . 6-39
Equivalent Chart, Decimal . . . . . . . . . . A-5
B
F
Battery . . . . . . . . . . . . . . . . . . . . . . . . .6-8
Adding Water . . . . . . . . . . . . . . . . 6-13 Fault Codes . . . . . . . . . . . . . . . . .5-8, 5-13
Charging . . . . . . . . . . . . . . . . . . . . 6-10 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Exterior Cleaning . . . . . . . . . . . . . .6-9
Maintenance Free . . . . . . . . . . . . . 6-15 G
Maintenance-Free . . . . . . . . . . . . . 6-15
Multiple Packs . . . . . . . . . . . . . . . .6-8 Gauges . . . . . . . . . . . . . . . . . . . . . . . 6-31
Specific Gravity . . . . . . . . . . . . . . . 6-14 Combination Hour/Battery Discharge Meter
Storage . . . . . . . . . . . . . . . . . . . . . 6-15 6-32
Voltage Check . . . . . . . . . . . . . . . . 6-15 Hour Meter . . . . . . . . . . . . . . . . . . 6-31
Battery Pack Hour/Battery Discharge Meter . . . 6-32
Multiple . . . . . . . . . . . . . . . . . . . . .6-8 Gear Oil . . . . . . . . . . . . . . . . . . . . . . . 6-62
Single . . . . . . . . . . . . . . . . . . . . . . .6-9
Brake . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Brake (Deadman) Switch . . . . . . . 5-7, 6-27 H
High Pedal Disable (HPD) . . . . . . . . . . . 5-8

C
Horn . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Hour Meter . . . . . . . . . . . . . . . . . . . . 6-31
Cables, Power . . . . . . . . . . . . . . . . . . . 6-16 Hour/Battery Discharge Meter . . . . . . 6-32
Checks Hydraulic Components
Shorts to Frame . . . . . . . . . . . 5-4, 5-5 Adjustments . . . . . . . . . . . . . . . . . 6-69
Circuit Breaker . . . . . . . . . . . . . . . . . . 6-21 Cylinder . . . . . . . . . . . . . . . . . . . . 6-74
Cloning . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Assembly . . . . . . . . . . . . . . . . 6-75
Component Locator Photos . . . . . . . . . .6-5 Diassembly . . . . . . . . . . . . . . . 6-75
Connector Locator Chart . . . . . . . . . . . 5-12 Inspection . . . . . . . . . . . . . . . . 6-75
Contactors . . . . . . . . . . . . . . . . . . . . . 6-42 Installation . . . . . . . . . . . . . . . 6-76
Control Handle . . . . . . . . . . . . . . . . . . 6-34 Removal . . . . . . . . . . . . . . . . . 6-74
Switches . . . . . . . . . . . . . . . . . . . . 6-23 Fluid . . . . . . . . . . . . . . . . . . . . . . 6-70
Conversions, Standard/Metric . . . . . . .A-7 Changing . . . . . . . . . . . . . . . . 6-70
Cover, Tractor . . . . . . . . . . . . . . . . . . . .6-7 Level . . . . . . . . . . . . . . . . . . . . 6-70
Creep Speed . . . . . . . . . . . . . . . . . . . . .5-7 Hydraulic Unit . . . . . . . . . . . . . . . 6-77
Current Limiting . . . . . . . . . . . . . . . . . .5-7 Filter Screen . . . . . . . . . . . . . . 6-79
Installation . . . . . . . . . . . . . . . 6-77
D Pump . . . . . . . . . . . . . . . . . . . 6-80
Relief Valve Adjustment . . . . . 6-72
Deadman Switch . . . . . . . . . . . . . . . . . 6-27 Removal . . . . . . . . . . . . . . . . . 6-77
Decimal Equivalent Chart . . . . . . . . . . .A-5 Reservoir . . . . . . . . . . . . . . . . 6-78
Definitions . . . . . . . . . . . . . . . . . . . . . .5-7 Solenoid . . . . . . . . . . . . . . . . . 6-30
Diodes . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Suction Tube . . . . . . . . . . . . . 6-79
Drive Unit . . . . . . . . . . . . . . . . . . . . . . 6-57 Troubleshooting . . . . . . . . . . . . . . . 5-6
Drive Wheel . . . . . . . . . . . . . . . . . . . . 6-64
I-2 PDMM-0100B Revised: Draft

Raymond® Walkie Pallet Truck Maintenance Manual Index
K O
Key Switch . . . . . . . . . . . . . . . . . . . . 6-26 Operation

Directional/Speed Control . . . . . . . 3-6
L Lift/Lower . . . . . . . . . . . . . . . . . . . . 3-5
Motor Controller . . . . . . . . . . . . . . . 3-8
Overvoltage Cutoff . . . . . . . . . . . . . . . . 5-9
Lift Limit Switch . . . . . . . . . . . . . . . . 6-29
Lift Motor . . . . . . . . . . . . . . . . . . . . . 6-81
Lift-Limit Switch . . . . . . . . . . . . . . . . 6-29 P
Adjustment . . . . . . . . . . . . . . . . . 6-29
Load Wheel Page Revision Record . . . . . . . . . . . . . . . iii
Pull Rod Adjustment . . . . . . . . . . 6-68 Plugging . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Load Wheels . . . . . . . . . . . . . . . . . . . 6-67 Power Cables . . . . . . . . . . . . . . . . . . . 6-16
Lowered Height Stop Adjustment . . . . 6-69 Programmable Maintenance Tool . . . . . 3-4
Lubrication Pulse Width Modulation . . . . . . . . . . . . 5-9
Drive Housing . . . . . . . . . . . . . . . 6-62 Pump, Hydraulic . . . . . . . . . . . . . . . . 6-80
Equivalency Chart . . . . . . . . . . . . . A-3
Lubrication Equivalency Chart . . . . . . A-2 R
M Ramp Shape . . . . . . . . . . . . . . . . . . . . . 5-9
Main ON/OFF Switch . . . . . . . . . . . . 6-25 S

Maintenance
Annually/Every 1500 Hours . . . . . 4-6
Safety
Daily . . . . . . . . . . . . . . . . . . . . . . . 4-3
Battery . . . . . . . . . . . . . . . . . . . . . . 2-7
Every Two Months/250 Hours . . . . 4-4
General . . . . . . . . . . . . . . . . . . . . . . 2-3
Grease Fittings . . . . . . . . . . . . . . . 4-7
Towing . . . . . . . . . . . . . . . . . . . . . 2-14
Maintenance-Free Battery . . . . . . . . . 6-15
Transport . . . . . . . . . . . . . . . . . . . 2-13
Map, Navigating the Manual . . . . . . . . 1-2
Welding . . . . . . . . . . . . . . . . . . . . 2-15
Metric Conversions . . . . . . . . . . . . . . . A-7
Sequencing Delay . . . . . . . . . . . . . . . . 5-10
Motor Controller . . . . . . . . . . . . . 3-8, 6-38
Shorts from Frame . . . . . . . . . . . . . . . . 5-5
Overtemperature . . . . . . . . . . . . . . 5-9
Shorts to Frame . . . . . . . . . . . . . . . . . . 5-4
Undertemperature . . . . . . . . . . . . 5-11
Specific Gravity . . . . . . . . . . . . . . . . . 6-14
Motors
Specifications . . . . . . . . . . . . . . . . . . . . 3-2
Brush Spring Tension . . . . . . . . . 6-47
Speed Limiting . . . . . . . . . . . . . . . . . . 5-10
Brushes . . . . . . . . . . . . . . . . . . . . 6-45
Switches
Commutator . . . . . . . . . . . . . . . . 6-48
Brake . . . . . . . . . . . . . . . . . . . . . . 6-27
Drive . . . . . . . . . . . . . . . . . . . . . . 6-53
Brake (Deadman) . . . . . . . . . . . . . 6-27
General . . . . . . . . . . . . . . . . . . . . 6-45
Control Handle . . . . . . . . . . . . . . . 6-23
Lift . . . . . . . . . . . . . . . . . . . . . . . 6-81
Deadman . . . . . . . . . . . . . . . . . . . 6-27
Tests . . . . . . . . . . . . . . . . . . . . . . 6-49
General . . . . . . . . . . . . . . . . . . . . . 6-22
Key . . . . . . . . . . . . . . . . . . . . . . . . 6-26
N Key Switch . . . . . . . . . . . . . . . . . . 6-26
Lift Limit . . . . . . . . . . . . . . . . . . . . 6-29
Neutral Braking . . . . . . . . . . . . . . . . . 5-8 Lift-Limit . . . . . . . . . . . . . . . . . . . 6-29
Main ON/OFF . . . . . . . . . . . . . . . . 6-25
Test/Inspection . . . . . . . . . . . . . . 6-22
PDMM-0100B Revised: Draft I-3

Index Raymond® Walkie Pallet Truck Maintenance Manual
Throttle Potentiometer Adjustment . . . 6-40

Torque Chart
Metric . . . . . . . . . . . . . . . . . . . . . . .A-4
Standard . . . . . . . . . . . . . . . . . . . . .A-3
Tractor Cover
Installation . . . . . . . . . . . . . . . . . . .6-7
Removal . . . . . . . . . . . . . . . . . . . . .6-7
Troubleshooting
Electrical . . . . . . . . . . . . . . . . . . . . .5-3
Hydraulic . . . . . . . . . . . . . . . . . . . .5-6
Voltage Check . . . . . . . . . . . . . . . . . . . 6-15
Wheels
Drive . . . . . . . . . . . . . . . . . . . . . . . 6-64
Load . . . . . . . . . . . . . . . . . . . . . . . 6-67
Wiring
Harness . . . . . . . . . . . . . . . . . . . . 6-17
Inspection . . . . . . . . . . . . . . . . 6-18
Terminology . . . . . . . . . . . . . . . 6-17
Power Cables . . . . . . . . . . . . . . . . . 6-16
Wiring Harness . . . . . . . . . . . . . . . . . . 6-17
I-4 PDMM-0100B Revised: Draft

Walkie 101 20000 Up MM

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Walkie 101 20000 Up MM

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Maintenance Manual

Model 101 Walkie Pallet Truck

PDMM-0100 Issued: 5/21/01

Page Revision Record

Document Revision History

PDMM-0100B Revised: 3/14/03 iii

Page Revision Record

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iv PDMM-0100B Revised: 3/14/03

How to Use This Manual

PDMM-0100 Issued: 5/21/01 1-1

Map of the Manual

Map of the Manual

How to Use This

Trouble Electrical &

1-2 PDMM-0100 Issued: 5/21/01

The two-line running page header at the top of

We suggest you get in the habit of turning to the

PDMM-0100 Issued: 5/21/01 1-3

The START page asks a few simple questions to

1-4 PDMM-0100 Issued: 5/21/01

To find a component procedure, you may

PDMM-0100 Issued: 5/21/01 1-5

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1-6 PDMM-0100 Issued: 5/21/01

How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

PDMM-0100B Revised: Draft 1-7

Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

1-8 PDMM-0100B Revised: Draft

PDMM-0100B Revised: Draft 1-9

This page intentionally left blank.

1-10 PDMM-0100 Issued: 5/21/01

START: Why are you here?

List of Troubleshooting Charts

Go to Chart START Troubleshooting

PDMM-0100 Issued: 5/21/01 1-11

To locate an Go to the Index

1-12 PDMM-0100 Issued: 5/21/01

PDMM-0100 Issued: 5/21/01 2-1

2-2 PDMM-0100 Issued: 5/21/01

Do NOT operate or work on this truck unless

Know the truck’s controls and what they do.

Do NOT operate this truck if it needs repair or if

Operate this truck only from the operator’s

PDMM-0100 Issued: 5/21/01 2-3

Before working on this truck, always turn the

Do NOT wear watches, rings, or jewelry when

Follow the scheduled lubrication, maintenance

Follow exactly the safety and repair instructions

2-4 PDMM-0100 Issued: 5/21/01

Do NOT use an open flame near the truck.

Do NOT use gasoline or other flammable liquids

Clean up any hydraulic fluid, oil or grease that

Always park this truck indoors.

PDMM-0100 Issued: 5/21/01 2-5

Do NOT park this truck in a cold storage area

Do NOT wash this truck with a hose.

Do NOT add to or modify this truck until you

2-6 PDMM-0100 Issued: 5/21/01

Wear personal protective equipment to protect

Make sure a shower and eyewash station are