Walkie 102 XM MM

Walkie Pallet Truck
Model 102XM
Serial Number 102-03-00500 - up
Maintenance Manual
Publication No: 1010183A Issued: 24 November 2003

1010183B Revised: 2/17/05
This publication,1010183B, applies to the Walkie Pallet Truck, Model 102XM, S/N 102-03-00500 - up to all
subsequent releases of this product until otherwise indicated in new editions or bulletins. Changes occur
periodically to the information in this publication.
If you need assistance with your lift truck, or to order additional copies of this manual, contact your local
authorized Raymond Dealer.
To find your local authorized Raymond Dealer, go to www.raymondcorp.com.
©2003, 2005 The Raymond Corporation.

The following terms are trademarks of The Raymond Corporation: Raymond. All other brand and product
names are trademarks or registered trademarks of their respective companies.
Model 102XM Maintenance Manual
Table of Contents
How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Map of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Manual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
START Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Definitions . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . . . . . .. . .. . .. . . . . . 2-2
General Safety . . . . . . . . . . . . . . . . . . . .. . .. . .. . . . . . .. . .. . .. . . . . . 2-3
Battery Safety . . . . . . . . . . . . . . . . . . . .. . .. . .. . . . . . .. . .. . .. . . . . . 2-6
Jacking Safety . . . . . . . . . . . . . . . . . . . .. . .. . .. . . . . . .. . .. . .. . . . . . 2-9
Towing . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . . . . . .. . .. . .. . . . . 2-10
Welding Safety . . . . . . . . . . . . . . . . . . . .. . .. . .. . . . . . .. . .. . .. . . . . 2-11
Static Safety . . . . . . . . . . . . . . . . . . . . .. . .. . .. . . . . . .. . .. . .. . . . . 2-12
Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Truck Model Identification . . . . . . . . . . .. . .. . .. .. . .. .. . .. . .. .. . . . 3-2
Vehicle Specifications . . . . . . . . . . . . . .. . .. . .. .. . .. .. . .. . .. .. . . . 3-2
General Information . . . . . . . . . . . . . . .. . .. . .. .. . .. .. . .. . .. .. . . . 3-3
Special Tools . . . . . . . . . . . . . . . . . . . . .. . .. . .. .. . .. .. . .. . .. .. . . . 3-4
Theory of Operation . . . . . . . . . . . . . . . .. . .. . .. .. . .. .. . .. . .. .. . . . 3-5
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
How to Use This Chapter . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. .. . . . 5-2
Electrical Troubleshooting Guidelines . . . . . . . . . . . . .. .. . .. . .. .. . . . 5-3
Hydraulic Troubleshooting Guidelines . . . . . . . . . . . . .. .. . .. . .. .. . . . 5-5
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. .. . . . 5-6
List of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. .. . . . 5-8
Control Handle Display and Programming . . . . . . . . . .. .. . .. . .. .. . . . 5-9
Service Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. .. . . 5-21
Power Amplifier Fault Codes . . . . . . . . . . . . . . . . . . . .. .. . .. . .. .. . . 5-24
Programmable Maintenance Tool (PMT) . . . . . . . . . . . .. .. . .. . .. .. . . 5-26
List of Troubleshooting Charts/Tables . . . . . . . . . . . . .. .. . .. . .. .. . . 5-29
Troubleshooting Flowcharts . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. .. . . 5-31
Symptom Tables: Lift/Lower System . . . . . . . . . . . . . .. .. . .. . .. .. . . 5-35
Symptom Tables: Travel (Forward/Reverse) System . . .. .. . .. . .. .. . . 5-39
Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Component Locator Photo .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . . . 6-3
Battery . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . . . 6-4
Tractor Covers . . . . . . . . . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . . . 6-9
Power Cables . . . . . . . . . . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . . 6-10
Wiring Harness . . . . . . . . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . . 6-11
Fuses . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . . 6-12
Circuit Breaker . . . . . . . . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . . 6-13
Control Handle . . . . . . . . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . . 6-14
Horn . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . . 6-18
Power Amplifier . . . . . . . . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . . 6-19
Publication: 1010183B, Revised: 2/17/05 iii

Model 102XM Maintenance Manual
Contactors . . . . . . . . . . . . . . .. . .. .. . .. .. . ... .. .. . .. ... ... .. . 6-20

Master Control Relay . . . . . . . .. . .. .. . .. .. . ... .. .. . .. ... ... .. . 6-21
Switches (General) . . . . . . . . .. . .. .. . .. .. . ... .. .. . .. ... ... .. . 6-23
Drive Unit . . . . . . . . . . . . . . . .. . .. .. . .. .. . ... .. .. . .. ... ... .. . 6-27
Electromagnetic Brake . . . . . .. . .. .. . .. .. . ... .. .. . .. ... ... .. . 6-33
Motors, General . . . . . . . . . . .. . .. .. . .. .. . ... .. .. . .. ... ... .. . 6-35
Drive Motor . . . . . . . . . . . . . . .. . .. .. . .. .. . ... .. .. . .. ... ... .. . 6-42
Pallet Forks and Load Wheels .. . .. .. . .. .. . ... .. .. . .. ... ... .. . 6-45
Hydraulic Components . . . . . .. . .. .. . .. .. . ... .. .. . .. ... ... .. . 6-47
Cold Storage Conditioning . . . .. . .. .. . .. .. . ... .. .. . .. ... ... .. . 6-55
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
iv Publication: 1010183B, Revised: 2/17/05

Model 102XM Maintenance Manual Section 1. How To Use This Manual
Section 1. How To Use This Manual
Publication: 1010183A, Issued: 24 November 2003 1-1

Section 1. How To Use This Manual Model 102XM Maintenance Manual
Map of the Manual
Map of the Manual
How to Use This

Manual Map of the Manual
Manual Design
Safety
Start Page
Vehicle
Systems
Specifications
Overview
General System
Data
Scheduled
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
Troubleshooting
Index Charts and
Symptom Tables
map.wmf
1-2 Publication: 1010183A, Issued: 24 November 2003

Manual Design
Manual Design • “TS1: START TROUBLESHOOTING” on

page 5-31 will guide you to the
individual troubleshooting symptom
The Model 102XM Maintenance Manual is chart you need.
designed with the following objectives in mind:
• When you are familiar with the
• Provide technical coverage for expected symptoms listed, you may instead find
levels of user expertise the symptom chart from the “List of
• Anticipate your needs and reduce your Troubleshooting Charts/Tables” on
decisions regarding maintenance page 5-29.
• Reduce page flipping through a “one-stop • When you complete a troubleshooting
shopping” approach procedure, make sure to follow the
steps in the “END1: End of
The two-line running page header at the top of Troubleshooting Procedure” on
each page tells you the following: page 5-33.
• Name of the manual • Component Procedures gives
(Model 102XM Maintenance Manual) step-by-step procedures for testing,
removal, installation, and adjustment of
• Current chapter title
individual truck components. Components
(example: this page How to Use This
are listed in an order that considers:
Manual)
• Frequency of attention
• Current topic
(example: this page Manual Design) • Physical attachment (example: brake
must be removed before drive motor)
We suggest you get in the habit of turning to the • Functional relation (for example: drive
START page first when you use this manual. motor and drive unit components are
grouped together)
The START page asks a few simple questions to
To find a component procedure, you may
guide you to the correct chapter.
use one of three methods:
• How to Use This Manual explains the
• Look up the component name. See
manual format and design and contains
“Component Procedures” on page 6-1.
the START page.
• Find the component. See “Component
• Safety explains warning and caution
Locator Photo” on page 6-3.
notes, general safety rules and safety rules
for batteries, static, jacking, and welding. • Look up the component name in the
Index. See “Index” on page I-1.
• Systems Overview includes truck
specifications and theory of operation • Appendix contains reference information
information. such as torque values, lubricants, and
schematics.
• Scheduled Maintenance outlines the
recommended schedule of preventive • Index lists subjects alphabetically.
services to keep your truck working most
efficiently.
• Troubleshooting is a set of “decision-tree”
charts and symptom tables designed to
take you from a symptom to a specific
sequence of tests in order to isolate a bad
component.

Manual Design

START Page
Section 1. How To Use This Manual
START Page
START: Why are you here?
To review Go to Section 2
safety Yes "Safety"
precautions?
No
To examine
Go to Section 3
specifications
Yes "Systems Overview"
or theory of
operations?
No
To do Go to Section 4
scheduled Yes "Scheduled Maintenance"
maintenance?
No
Go to Section 5
To troubleshoot Yes "Troubleshooting"
a problem?
List of Troubleshooting Charts

No
Go to Chart START Troubleshooting

START-2
startpg1.wmf

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

object or Yes
procedure by
name?
startpg2.wmf

Model 102XM Maintenance Manual Section 2. Safety
Section 2. Safety

Section 2. Safety Model 102XM Maintenance Manual
Definitions
Definitions
Throughout this manual, you will see two kinds
of safety reminders:
Warning means a potentially hazardous

situation exists that, if not avoided,
could result in death or serious injury.
Caution means a potentially hazardous

situation exists that, if not avoided,
could result in minor or moderate injury
or cause damage to the truck or nearby
objects.

General Safety
General Safety
1864 002.eps
Do not operate or work on this truck unless you

1808 003.eps
are trained, qualified and authorized to do so
and have read the Owner/Operator Manual. Operate this truck only from the operator’s
position.
Know the truck’s controls and what they do. 1808 004.eps
Before working on this truck, always press the

red OFF key (O) on the keypad and disconnect
the truck’s battery connector (unless this
manual tells you otherwise).
1808 002.eps
Do not operate this truck if it needs repair or if

it is in any way unsafe.
1864 067.eps
Do not wear watches, rings, or jewelry when

working on this truck.

General Safety
schedmnt.eps spills.eps
Follow the scheduled lubrication, maintenance Clean up any hydraulic fluid, oil or grease that
and inspection steps. has leaked or spilled on the floor.
1808 005.eps
Follow exactly the safety and repair instructions Always park this truck indoors.
in this manual. Do not take “shortcuts.”
23L6S012.eps
Do not park this truck in a cold storage area

Do not use an open flame near the truck. overnight.
Do not use gasoline or other flammable liquids Do not wash this truck with a hose.
for cleaning parts.

General Safety
Do not add to or modify this truck until you

contact your local Raymond Dealer to receive
written manufacturer approval.

Battery Safety
Battery Safety
As a battery is being charged, an

explosive gas mixture forms within and
around each cell. If the area is not
correctly ventilated, this explosive gas 04G6S059.eps
can remain in or around the battery for
several hours after charging. Make sure Make sure a shower and eyewash station are
there are no open flames or sparks in nearby in case there is an accident.
the charging area. An open flame or
spark can ignite this gas, resulting in
serious damage or injury.
Battery electrolyte is a solution of

sulfuric acid and water. Battery acid
causes burns. If any electrolyte comes in
23L6S012.eps
contact with your clothing or skin, flush
the area immediately with cold water. If A battery gives off explosive gases. Never
the solution gets on your face or in your smoke, use an open flame, or use anything that
eyes, flush the area with cold water and gives off sparks near a battery.
get medical help immediately.
04G6S058.eps
25L6SO16.eps
Keep the charging area well-ventilated to avoid

Wear personal protective equipment to protect hydrogen gas concentration.
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.

Battery Safety
Press the red OFF key (O) on the keypad before

disconnecting the battery from the truck at the
battery connector. Do not break live circuits at
27Y7S013.tif
the battery terminals. A spark often occurs at
the point where a live circuit is broken. Keep plugs, terminals, cables and receptacles in
good condition to avoid shorts and sparks.
Vent Hole
04G6S057.eps
Do not lay tools or metal objects on top of the

battery. A short circuit or explosion could
result.
09G6S047.tif
Keep filler plugs firmly in position 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 permit the gas to escape from the cells.
Keep batteries clean. Corrosion causes shorts

to the frame and possibly sparks.

Battery Safety
25L6S014.eps
Do not let cleaning solution, dirt or any foreign Follow the charging procedures in the Battery
matter to enter the cells. Instruction Manual and in the Battery Charger
Instruction Manual.
Make sure you install the correct size battery. A

smaller or lighter weight battery could seriously
effect truck stability. See the truck’s
specification plate for more information.
1808 006.eps
Never plug a battery charger into the truck’s

battery connector. Plug the battery charger only
into the battery connector from the battery.

Jacking Safety
Jacking Safety Tractor Section

1. Position the jack in the designated jacking
When it is necessary to jack the truck off the position.
floor to perform maintenance procedures, 2. Jack one side of the truck so that the drive
observe the following safety precautions: tire is off the floor no more than 1 in.
1. Lower the forks completely. Remove any (25.4 mm).
load. 3. Block that side of the truck in place.
2. Position all controls in neutral. 4. Jack the other side of the truck level with
3. Block the wheels to prevent movement of the first side.
the vehicle. 5. Block that side of the truck in place.
4. Press the red OFF key (O) on the keypad
NOTE: After working on a vehicle, test all
and disconnect the battery connector.
controls and functions to assure correct
5. Position the jack under the designated operation.
jacking points.
Use extreme care when the truck is

jacked up. Keep hands and feet clear
from vehicle while jacking the truck.
After the truck is jacked, position 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 on the blocks.
27Y7S068.tif
Figure 2-1. Blocking the Fork Section

Towing
Towing
To safely tow this 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.
NOTE: If a suitable towing vehicle is not
available, the electromagnetic brake
must be disabled to move this truck. See
“Mechanically Releasing the Brake” on
page 6-34.

Welding Safety
Welding Safety
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 1808 004.EPS
coating be removed in the vicinity where

• Disconnect the battery before you attempt
the operation(s) will be performed.
to inspect, service or repair the lift truck.
Discharge residual charge in the power
amplifier by connecting a load across the
power amplifiers B+ and B– (such as a
contactor coil or by pressing the horn
Coating removal may be by mechanical button).
methods, chemical methods or a
combination of methods. Flame cutting • Do a test for shorts to frame. See
and/or welding operations must be “Checking for Shorts from Components to
carried out only in well ventilated areas Truck Frame” on page 5-3. If any shorts
using local exhaust if necessary. 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.
• Do not perform any welding operations
near the electrical components.
• If welding must be done near the battery
04GSO59.eps
compartment, remove the battery from the
truck.
Before working on this truck, make sure that: • When you are finished welding, perform all
• Fire protection equipment is nearby. ground tests and electrical inspections
• You know where the nearest eyewash before the vehicle is operated.
station is located.

Static Safety
Static Safety Wrist straps are available in quantities of 25, as

part number 1-187-058/001.
Electronic circuit boards and devices used on A wrist strap tester is available as part number
this truck can be damaged by the discharge of 1-187-060.
static electricity, called electrostatic discharge.
Contact your authorized Raymond Dealer for
Static charges can accumulate from normal information.
operation of the truck as well as movement or
contact between non-conductive materials
(plastic bags, synthetic clothing, synthetic soles Wrist Strap Static-Dissipative
on shoes, styrofoam coffee cups, etc.). Work Surface
Accumulated static can be discharged through

human skin to a circuit board or component by
touching the parts. Static discharge is also
possible through the air when a charged object
is placed close to another surface at a different
electrical potential. Static discharge can occur
without you seeing or feeling it.
Whenever working on or near static-sensitive

electronics, always use static discharge
precautions.
1. Place a static discharge wrist strap around
your wrist. Connect the ground lead to the Ground Cord
wrist strap connector.
2. Connect the ground strap to an Figure 2-2. Anti-Static Kit (P/N 1-187-059) With Wrist
unpainted, grounded surface on the truck Strap and Mat
frame.
3. If you are removing or installing
static-sensitive components, place them
on a correctly grounded static mat.
4. To transport static-sensitive components,
including failed components being
returned, place the components in an
anti-static bag or box (available from your
Raymond Dealer).
The wrist strap and associated accessories

should be tested monthly to verify they are
working correctly. A defective static discharge
wrist band will not alert you that it is bad.
Figure 2-2 shows the components of the

Raymond anti-static field service kit, part
number 1-187-059. The kit includes a wrist
strap, ground cord and static-dissipative work
surface (mat). Follow the instructions packaged
with this kit.
2-12 Publication: 1010183B, Revised: 2/17/05

Model 102XM Maintenance Manual Section 3. Systems Overview
Section 3. Systems Overview
Publication:1010183A, Issued: 24 November 2003 3-1

Section 3. Systems Overview Model 102XM Maintenance Manual
Truck Model Identification
Truck Model
Identification
1581 001.tif
Figure 3-1. Model 102XM Pallet Truck
Vehicle Specifications
The total weight of the load must include

the pallet and the container or the
device holding the load.
Category Model 102XM

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 28.0 in. (711 mm)
Maximum Lift Height 8.65 in. (219.7 mm)
Regular Speed, Maximum 3.9 mph (6.3 kph)
Stopping Distance 6 ft. (1.83 m)
Battery Compartment Width 7.8 or 9.0 in. (198 or 228 mm)
Battery Voltage 24V
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 x 5 in. Rubber
Wheel: Load 3.25 x 5 in. Polyurethane (2)

General Information
General Information
Control Handle
Page 6-14
Battery Drive Unit

Page 6-4 Page 6-27
Pallet Forks and

Load Wheels
Page 6-45
Figure 3-2. Model 102XM General Information

Special Tools
Special Tools
Programmable Maintenance Service Key
Tool
27y7s021.tif
Figure 3-3. Programmable Maintenance Tool Figure 3-4. Service Key

(P/N 950-185 shown)
Use the optional Service Key (P/N 851-201-500)
The optional Programmable Maintenance Tool directly on the truck to troubleshoot and
(PMT) (P/N 950-180 or 950-185/002) permits program the truck service parameter settings.
you to test and diagnose the power amplifier in See “Programming Service Parameters” on
the truck. See Figure 3-3. page 5-17.
The PMT is powered by the host power amplifier

through the four-pin connector installed at the
bottom of the power amplifier.

Theory of Operation
Theory of Operation
Truck Starting • lift-limit switch (S36) transmits a lift-limit
signal to the power amplifier which
To start the truck, the battery is plugged in, the removes power to the lift motor when the
main ON/OFF switch is in the ON position, the forks reach a preset lift limit
PIN-key code is entered in the keypad and the
green ON (|) key pressed (or optional key switch When the lift button is released:
is ON). See “Service Display” on page 5-21. • the pump contactor coil (K30) is
de-energized. This stops the lift motor and
Lift/Lower pump. The forks are held in position by
hydraulic fluid trapped in the cylinder by
the check valve, the static position of the
The lift/lower system consists of an electrically
relief valve, and the closed lowering
operated hydraulic pump assembly and related
solenoid valve (Y10)
components.
• the relief valve opens if the hydraulic
The hydraulic pump assembly consists of a pressure exceeds the preset limit.
positive displacement rotary gear pump with
reservoir mounted to an adapter. A DC electric Lower
motor is mounted to the opposite side of the
pump adapter. An adjustable relief valve, check When the battery is connected, the truck is ON
valve, and a solenoid operated lowering valve and the lower button is pressed:
are installed within the adapter.
• lower signal is detected via hall effect
sensors, converted into the lower
With the forks elevated, the normally closed
instruction and transmitted via the CAN to
solenoid valve and the check valve prevent
the power amplifier
hydraulic fluid from returning to the reservoir.
• lowering solenoid valve (Y10) opens
Lift • hydraulic fluid in the lift cylinder returns
to the hydraulic reservoir through the
When the battery is connected, the truck is ON lowering valve and the flow control valve.
and the lift button pressed: The lowering speed is regulated by the flow
• a lift signal is detected via hall effect control valve.
sensors, converted into the lift instruction • the forks lower.
and transmitted via the Controller Area
network (CAN) to the power amplifier Direction/Speed Control
• the lift pump contactor (K30) closes,
applying B+ to the lift pump motor (M3) The following descriptions assume the battery is
causing the lift pump to operate charged and connected, the truck is ON, and
• hydraulic fluid is drawn into the lift pump main contactor (K10) is energized.
• as the pump rotates, oil is forced out the
pressure port through the lift hose to the Control Handle Positioning
lift cylinder. Oil cannot return to the
reservoir because of the closed pressure When the control handle is in the full upright
relief valve and closed lowering solenoid position, the parking brake engages. When the
valve. control handle is positioned from 6° to 46° of
the full upright position, the brake disengages
• hydraulic pressure in the lift cylinder
(when travel is requested), Arm Angle B switch
raises the forks
(S25) closes and enables slow speed travel.
Publication:1010183B, Revised: 2/17/05 3-5

Theory of Operation
When the control handle is placed beyond 46° • the ETAC verifies that both switch S24
from the full upright position, Arm Angle A (Arm Angle A) and switch S25 (Arm Angle
switch (S24) also closes, enabling fast speed B) are engaged for fast speed mode
travel. When the control handle is placed in the • the voltage at M– of the drive motor will
bottom 8° of its operating range, Arm Angle B vary from 24V to 1V. The voltage is
switch opens, activating the parking brake. proportional to the position of the thumb
controls.
Travel Request, Forks Trailing • the drive wheel starts to rotate in reverse
direction at a speed proportional to the
When the thumb controls are rotated in the voltage at M–.
forward direction (tractor first) from neutral:
• a forward travel signal is detected via hall Emergency Reverse
effect sensors, converted into a travel
instruction in the ETAC and transmitted If the emergency reverse button (belly button) is
via the CAN to the power amplifier closed with the control handle lowered in travel
• the ETAC verifies that the emergency mode, the control system provides an
reverse button is not activated before immediate, rapid acceleration in the reverse
supplying the travel command to the (forks-first) direction. The following occurs:
power amplifier • the emergency reverse signal is converted
• the ETAC verifies that switch S25 (Arm into a reverse travel instruction and
Angle B) is engaged for slow speed mode transmitted via CAN-bus to the power
• the ETAC verifies that both switch S24 amplifier
(Arm Angle A) and switch S25 (Arm Angle • travel and speed inputs are ignored
B) are engaged for fast speed mode • the power amplifier provides maximum
• the voltage at M– of the drive motor will torque immediately after the emergency
vary from 24V to 1V. The voltage is reverse button is activated
proportional to the position of the thumb • maximum reverse travel continues until
controls. the emergency reverse button is released.
• the drive wheel starts to rotate in forward
direction at a speed proportional to the
voltage at M–.
Travel Request, Forks First
When the thumb controls are rotated in the

reverse direction (forks first) from neutral:
• reverse travel signal is detected via hall
effect sensors, converted into a travel
instruction in the ETAC and transmitted
via the CAN to the power amplifier
• the ETAC verifies that the emergency
reverse button is not activated before
supplying the travel command to the
power amplifier
• the ETAC verifies that switch S25 (Arm
Angle B) is engaged for slow speed mode

Theory of Operation
Power Amplifier
The basic functions of the power amplifier
includes:
• the direction control section which
controls the drive motor direction by
manipulating the drive motor field polarity
according to the directional signal inputs
from the ETAC
• the speed control section which controls
the drive motor speed and torque by
monitoring the position change of the Arm
Angle A and Arm Angle B switches.
Variable motor speed is accomplished by
separate control of field and armature
currents.
• the emergency reverse circuitry in the
ETAC which provides the directional travel
control commands to the power amplifier
• the control circuit section which controls
all truck inputs and outputs (excluding
handle head inputs)
Electronic Tiller Arm Card (ETAC)

The programmable motor control functions are
performed by the electronic circuitry housed
within the control handle [Electronic Tiller Arm
Card (ETAC)]. The basic functions of the ETAC
include:
• monitoring relative positioning of the
thumb controls to eighteen hall effect
sensors for speed and direction control
• monitoring the position of the emergency
reverse button for emergency reversing of
the truck direction
• monitoring truck performance and
providing input data and commands to the
service display
• providing lift/lower input commands to
the power amplifier
• monitor horn switches S18-1 and S18-2
for horn operation
• monitoring and defining truck
performance parameters

Theory of Operation

Model 102XM Maintenance Manual Section 4. Scheduled Maintenance
Section 4. Scheduled Maintenance

Section 4. Scheduled Maintenance Model 102XM Maintenance Manual
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 necessary 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.

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

page 6-5.
Check the charge.
Check the weight.
Check the “free play” of the battery. Make sure the battery does not
move more than 0.5 in. (13 mm) in any direction.
Battery Connector Check the connector. Make sure all powered functions shut down when
disconnected.
Make sure the battery is correctly installed.
General Operation 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 thumb controls.
Check the steering operation.
Check the lifting and lowering functions.
Check the operation of the emergency reverse button.
Check the operation of the Master ON/OFF Switch.
Note any unusual noise during operation, and report it to your
supervisor or maintenance personnel.
Brake/Control Verify the drive motor does not run while the brake is applied.
Handle Check that the control handle returns to the vertical position when
released.
Decals Warning/Safety/Operational decals must be in position and legible.

Contact your local authorized Raymond Dealer if any decal is
damaged or missing.
Hydraulic System Check for oil leaks.
Wheels/Tires Check the condition of the drive wheel and load wheels. Remove any
steel chips and foreign material to prevent damage to the wheels.
Check for gouging and chunking of the surface. If damaged, report to
your supervisor or maintenance personnel.

Every Two Months or 250 Operating Hours

Perform daily checks plus the following:
Item Every Two Months or Every 250 Operating Hours
Grease Fittings Lubricate all grease fittings.
Forks Check the lift-limit switch for lift motor cut-out. Adjust if
necessary.
Lubrication Points Lubricate all levers, shafts and linkage points.
Lift Cylinder Check the lift cylinder for leaks. Repair or replace cylinder if
necessary. See “Hydraulic Cylinder” on page 6-47.
Hydraulic System Check for correct 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.
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 6-49.
General Check for loose hardware. Tighten if necessary.

Check the tightness of the drive unit mounting bolts. Tighten if
necessary.
Electrical System Visually inspect all cables for damage. Replace if necessary. See
“Power Cables” on page 6-10.
Check for electrical shorts to frame. See “Checking for Shorts from
Battery to Truck Frame” on page 5-3.
Master Control Relay Check contacts for welded condition. See “Inspection/Test” on
page 6-21.
Drive Wheel Check the tightness of the mounting bolts on the drive wheel.
Torque to 55 ft. lb. (75 Nm).
Drive Unit Check for oil leaks. If leaks are found, check the oil level. If the oil
level is low, determine the cause. See “Drive Unit” on page 6-27.
Check the transmission pivot bearing.
Motor Brushes Check the condition of brushes, springs and holders.

Check that the brush length exceeds the minimum length.
• Drive motor - 0.59 in. (15 mm)
• Hydraulic pump motor - 0.35 in. (9 mm)
Arm Angle Switches Check adjustment.
Load Wheel Check the load wheel bearings and linkage.
Brake Check the brake disc for wear. Adjust or replace if necessary. See
“Electromagnetic Brake” on page 6-33.
Battery System Clean the battery and the truck. See “Battery Maintenance” on
page 6-5.

Annually or Every 1500 Operating Hours

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

See “Drive Housing Lubrication” on page 6-30.
Grease Fittings
Figure 4-1: Load Wheel Axle (Cold Storage and

Corrosion Protection Options only)


Model 102XM Maintenance Manual Section 5. Troubleshooting
Section 5. Troubleshooting

Section 5. Troubleshooting Model 102XM Maintenance Manual
How to Use This Chapter
How to Use This Chapter

This chapter uses “decision-tree” charts and
symptom tables 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 5-31 to
guide you to the individual symptom chart
you need.
• When you’re familiar with the symptoms
listed, you may instead simply look up the
symptom chart from the “List of
Troubleshooting Charts/Tables” on
page 5-29.
As you work with a troubleshooting symptom

table, you may be instructed to test various
electrical connector pins.
Every time you complete a troubleshooting

procedure, make sure you follow the steps in
the “END1: End of Troubleshooting
Procedure” on page 5-33.
If the troubleshooting symptom tables do not

isolate the problem, or if the symptoms are not
consistent or repeatable, go to “GEN1: General
Troubleshooting” on page 5-32. This chart
will help you approach the problem in a
systematic and logical manner.

Electrical Troubleshooting Guidelines

Many problems are caused by a faulty or dirty • positive (+) lead to the positive battery
battery. Make sure the battery is clean. Check terminal.
the electrolyte level and state-of-charge. See The voltmeter must show no more than
“Battery” on page 6-4. Block the truck 3V.
whenever a troubleshooting procedure requires
turning the key switch ON. This avoids 3. Now attach the leads as follows:
accidents caused by unexpected truck travel. • negative (–) lead to the negative battery
terminal
• positive (+) lead to an unpainted,
Unless otherwise directed, disconnect grounded surface on the truck frame
the battery connector when you check The voltmeter must show no more than
electrical circuits or components with an 3V.
ohmmeter. Electrical current can cause 4. If you get more than a 3V reading in Steps
damage to the ohmmeter. 2 or 3:
Save time and trouble by looking for simple a. remove the battery from the truck. See
causes first. “Battery” on page 6-4.
b. thoroughly clean the battery. See
Visually inspect all wiring and electrical “Battery Maintenance” on page 6-5.
components for:
c. reinstall the battery
• loose connections or connectors
d. repeat steps 2 and 3 to see if this has
• loose or broken terminals eliminated the problem
• damaged terminals, blocks, or strips e. if excessive voltage is still found, have
• broken wiring and shorted conditions the battery checked for internal
(especially those that are close to metal leakage.
edges or surfaces)
Use an ohmmeter to check for wiring continuity

Checking for Shorts from
and shorts. Components to Truck Frame
1. Press the red OFF (O) key on the keypad
For information on pin, connector, and harness and disconnect the battery connector.
connections, see “Wiring Harness” on page 6-11
and “List of Electrical Symbols” on page 5-8. 2. Use an ohmmeter and measure the
resistance to an unpainted, grounded
surface on the frame at B+, B–, and all
Checking for Shorts from fuses.
Battery to Truck Frame A resistance reading of less than
1. Press the red OFF (O) key on the keypad 1000 ohms indicates a serious short to
and disconnect the battery connector. frame. If this condition exists, find the
source of low resistance or short to frame
2. Using a voltmeter set on a 50Vdc scale. using step 6. Do not continue until this
attach the leads as follows: condition is corrected.
• negative (–) lead to an unpainted, 3. Remove the battery from the truck. See
grounded surface on the truck frame “Battery” on page 6-4.
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 subassembly one at a time,
to determine if that item is causing the low
resistance.

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.
Unless otherwise directed, disconnect

the battery connector when you check
electrical circuits or components with an
ohmmeter. Electrical current can cause
damage to the ohmmeter.
Visually inspect all hydraulic lines and

components for:
• Leaking connections or connectors
• Loose or broken fittings
• Damaged tubing, hoses, vents, or seals

Definitions
Definitions Continuity
A continuous and uninterrupted path between
Acceleration two or more locations in an electrical circuit,
typically having a resistance of less than 1 ohm.
The process where the truck’s acceleration
characteristic is determined when the truck Creep Speed
starts from a stop. This is a driver parameter
(Acceleration). The range is from 30% to 90% in Creep speed defines speed at low throttle
increments of 5%. Default is 80%. A lower positions. Creep speed range is adjustable from
number gives less aggressive acceleration. –10 to 10. The factory default value is –5. A
negative number enhances low speed
Arm Angle Switches maneuverability. A positive number makes the
truck more responsive.
The Arm Angle Switches (S24 and S25)
determine brake activation and truck travel Current Limiting
speed. Each switch is activated by the control
handle. The control handle must be positioned A protective function of the power amplifier that
between 6° of vertical and 8° of horizontal for prevents excessive current levels from
the switches to be closed. See Figure 5-1. damaging drive components.
6° Deceleration
The process where the truck’s braking
(regenerative) characteristic is determined by
8° any reduction in throttle, including neutral.
This is a driver parameter (Deceleration). The
range is from 40% to 90% in increments of 5%.
1820 001.EPS Default is 65%. A lower number gives less
Figure 5-1. Arm Angle Switches and Brake Actuation aggressive deceleration.
When the control handle is in the full upright

position, the parking brake engages. When the
Emergency Reverse
control handle is positioned from 6° to 46° of
the full upright position, the brake disengages Emergency Reverse is activated when the
(when travel is requested), Arm Angle B switch emergency reverse button is pressed while the
(S25) closes and enables slow speed travel. See control arm is in a drive position. After the
Table 5-2. When the control handle is placed button is released, normal operation is
beyond 46° from the full upright position, Arm resumed.
Angle A switch (S24) also closes, enabling fast
speed travel. When the control handle is placed ETAC (Electronic Tiller Arm Card)
within 8° of horizontal, Arm Angle switch B
opens, activating the parking brake. Programmable motor control functions are
Table 5-2. Control Handle/Switch Positions performed by the electronic circuitry (ETAC)
housed within the control handle. See
Position A Switch B Switch Function
“Electronic Tiller Arm Card (ETAC)” on
Top 6° Open Open Top Brake
page 3-7.
6° to 46° Open Closed Slow Speed
46° plus Closed Closed Fast Speed
Bottom 8° Closed Open Bottom Brake

Definitions
Fault Codes Speed Limiting

The ETAC provides fault information by The ETAC limits maximum speed:
displaying fault codes via the LED display built • “Max speed, Slow Mode” parameter
into the handle head. See “Power Amplifier determines the maximum speed value sent
Fault Codes” on page 5-24. by the ETAC to the power amplifier (max.
PWM) for both directions of travel while in
Open Circuit Slow. This is a programmable parameter.
• “Max speed, Fast Mode” parameter
A lack of a continuous path between two or determines the maximum speed value sent
more electrical connections; usually greater by the ETAC to the power amplifier (max.
than one megohm resistance. PWM) for both directions of travel while in
Fast. This is a programmable parameter.
Overvoltage Cutoff
Thermal Cutback (Power
Occurs when there is very high voltage (greater Amplifier)
than 34V) at the power amplifier B+ connection.
Code C42 or E142 may be displayed and the Thermal cutback of the power amplifier is below
truck must be restarted. –13°F (–25°C) or above 185°F (85°C). At 185°F
to 203°F (85°C to 95°C), the PWM drive current
PIN-Key Code limit is linearly decreased from full set current
down to zero. At –13°F to –40°F (–25°C to
Trucks produced with a standard handle –40°C), the current limit is reduced to approx.
mounted keypad are protected from half the set current, resulting in reduced travel
unauthorized operation by Personal speed. Below –40°F (–40°C) or above 203°F
Identification Number (PIN) keypad entry codes. (95°C), the allowed PWM is 0%.
Up to 10 operators can be assigned their own
individual PIN-key code (of one to four digits) for Tractor
access to the truck. Each operator can also set
individual driver parameters. The default The body section of the truck that contains the
operator PIN-key code is number 1. motors, drive unit, controls and handle.
Short Circuit or “Short” Truck Off Delay (Keypad only)

A short circuit is an unspecified path in a
Sets the truck OFF delay time (energy saving
circuit that provides unwanted full or partial
feature). If this time delay passes while the
continuity between two or more locations in an
truck is in a brake position and the truck is idle
electrical circuit.
(no inputs requested), the ETAC powers the
truck OFF. Driver parameter settings are 0 to
Example 1: Two insulated wires are physically
20 minutes. When the parameter is set to 0, or
next to each other and the insulation has worn
the truck has the key switch option, the truck
off each of the wires. The conductors are now
never powers OFF.
touching each other, causing a short circuit.
Example 2: The insulation has worn away on a Undervoltage Cutoff

power cable from the battery to a junction post
in the truck. The wire conductors are touching Occurs when there is very low voltage (less than
the tractor frame, causing a short circuit of the 13V) at power amplifier B+ connection. Code
battery cable. C41 is displayed and the truck must be
restarted.

List of Electrical Symbols
List of Electrical Symbols

Refer also to electrical schematics found in the Appendix and wiring harness component
procedures.
Table 5-3. List of Symbols
Symbol Description Function Remark
A1 Power Amplifier Drive motor controller
A2 Electronic tiller arm card Vehicle controller
A6 Operator display Displays various functions
A17 Keypad PIN inputs and access Trucks with keypad

maintenance modes
B+ Battery Positive 24V
B– Battery Negative 24V
CB1 Circuit Breaker Drive/Pump motor circuit 110 amp
F50 Fuse Keypad and tiller arm card 10 amp
F51 Fuse Main control 10 amp
H1 Horn
J11 Wire Connection Handle stem base
J41 Wire Connection Service key (CAN)
K4 Relay Main
K10 Contactor Main
K30 Contactor Pump motor
M1 Motor Drive
M3 Motor Pump
R1 Resistor Pre-charge PTC
S17 Switch Key Trucks with key switch
S18 Switch Horn
S21 Switch Main ON/OFF
S24 Switch Arm Angle A
S25 Switch Arm Angle B
S36 Switch Lift limit
Y1 Coil Brake
Y10 Coil Lower valve

Control Handle Display and Programming

The display located on the top of the control 3. Choose the desired time to be displayed by
handle displays the operator and pressing the thumb controls:
machine-specific register. • A. = key time
5
• b. = activity time (drive, lift, lower)
A Explanation of • c. = drive motor time
Symbols:
• d. = pump motor time
A A = Numerical Field • s. = time to service
Press the thumb control to step between
B = Hour Meter
Indicator the different functions. The display shows
C = Parameter the number of hours for each function. See
Control “Parameter 20” on page 5-20.
D = Battery 4. Press the red OFF (O) key on the keypad to
E D C B Indicator end the hour meter display.
E = Error Indicator
E D C B Error Codes (E)
Figure 5-4. Control Handle Display When an error occurs, a code is displayed. See
“Caution and Error Codes” on page 5-10.
Special Truck Mode Error Code History

To enter a special truck mode:
To access Error Code History:
1. Press and hold the horn button (S18). At
1. Enter the special truck mode.
the same time turn the key switch ON, or
enter the operator-specific PIN-key code 2. Press and hold the horn button until “E” is
on the keypad, then press the green ON displayed. The error indicator (wrench
button on the keypad. icon) is illuminated. See Figure 5-4.
2. Continue to hold the horn button while • Use the thumb control to scroll through
the display (see Figure 5-4) cycles through the last 50 error codes. The latest fault
the following functions: is shown first. The display first shows
the error code and then the hour the
• H = Hour Meter
fault occurred.
• E = Error Codes
• P = Parameters • The error codes are divided into two
• Pn = Hardware and Software Part groups C = caution and E = error.
Numbers • The C error codes are not stored. It is
3. Release the horn button at the selected only a caution and is highlighted on the
display. display as long as the fault exists.
• For example, if you only have one fault
Hour Meter (H) registered in the memory, the second
empty place is shown like this: Fault: E
To change Hour Meter settings: - - - and time: - - - -.
1. Enter the special truck mode. 3. End displaying the error code history by
pressing the red OFF (O) key on the
2. Continue to hold the horn button until “H” keypad.
is displayed. The hour meter indicator
(hourglass icon) is illuminated. See
Figure 5-4.

Caution and Error Codes
Code C14 - Arm Angle Reference Warning

Reason Control handle was not in up position at power ON or after the truck has not
been used for a time.
Performance Limits Travel is not allowed until code is cleared.
How to Clear Code Code is cleared when tiller arm is moved to upright (Top Brake) position.
Possible Causes Control handle stuck in down position
and Corrective a. Check up-stop
Actions Arm angle input stuck ON
a. Check arm angle switch “A” and “B” for correct operation. Repair or
replace as necessary.
b. Check input to power amplifier.
Code C19 - Default parameter warning

Reason Parameter(s) out-of-range, or incompatible with software version.
Performance Limits Truck functions are not allowed until after this code is cleared.
How to Clear Code Parameter area is automatically corrected and then code is cleared.
Possible Causes ETAC parameter area is bad.
and Corrective If the code does not clear after 10 seconds, try restarting the truck.
Actions Cycle the truck OFF then ON. If the code does not automatically clear,
replace the ETAC.
Code C20 - Thumb Control Warning

Reason Thumb control was not in neutral position at power ON, or a throttle
position sensor failure was detected. See “Code E160 - Error In Reversing
Circuit” on page 5-15.
Performance Limits Truck functions are not allowed until code is cleared.
How to Clear Code Code is cleared after problem is corrected.
Possible Causes Thumb control is stuck in drive position.
and Corrective ETAC is bad.
Actions Check the mechanical portions of the throttle controller. Give special
attention to the magnet arm alignment with the ETAC sensors and to the
non-metallic parts of the emergency reverser.
Code C28 - Master Control ON/OFF Switch Warning

Reason Power amplifier could not be reset via the CAN-bus at power ON, or power
amplifier reports Master Control ON/OFF switch is open.
Performance Limits Truck functions are not allowed after this code has been set.
How to Clear Code This code can only be cleared after the problem is resolved and truck is
cycled OFF/ON.

Code C28 - Master Control ON/OFF Switch Warning

Possible Causes • Master Control ON/OFF switch activated
and Corrective • Low voltage to power amplifier (especially while lifting or driving) due to
Actions over-current or short-circuit.
• Try a known-good battery
• PTC R1 missing, faulty, or tripped (very high resistance, due to excessive
current while main contactor is open; should automatically recover).
• Carefully check to see if R1 is hot (tripped). If so, unplug battery and
allow it to cool. Locate low impedance path that tripped R1 and correct.
• Wire #24 at 0V due to J5 not connected, blown fuse, or bad wiring.
• Check for 24 V at J5-16
• Short or open circuit in CAN wiring, or electrical noise in CAN wiring due
to bad connection or outside interference, both at power ON.
• Check CAN wiring
• Try operating truck in different environment
• Bad power amplifier
Code C29 - Time To Service Warning

Reason See Service Parameter 25 on page 5-19.
Performance Limits None
How to Clear Code See Service Parameter 25 on page 5-19.
Possible Causes Time to perform service or service counter not reset after last service.
and Corrective
Actions
Code C41 - Battery Undervoltage Warning

Reason Voltage at power amplifier B+ connection less than 17V. Note: Low voltage
can also cause problems such as electrical components not powering
up/staying activated and CAN errors.
Performance Limits Truck functions are allowed unless the voltage was below 13V. If voltage was
below 13V, the truck must be restarted. (Code C28 may be displayed)
How to Clear Code Code is cleared when voltage recovers.
Possible Causes Battery voltage less than 17V
and Corrective • Time to charge battery
Actions • Check for correct voltage
Battery parameter not adjusted correctly.
Circuit breaker open due to overloading, or short circuit (a misadjusted
brake may have caused overloading leading to an open circuit breaker).
Open circuit to power amplifier B+ connection.
• Check cabling
Bad power amplifier
Code C42 - Battery Overvoltage Warning

Reason High voltage (greater than 30V) at power amplifier B+ connection.
Performance Limits When 34V is exceeded, overvoltage cutoff occurs and no truck functions are
allowed. Truck may need to be restarted (Code E142 may be displayed)
How to Clear Code Code is cleared when voltage recovers.

Code C42 - Battery Overvoltage Warning

Possible Causes High battery voltage.
and Corrective • Check for correct voltage
Actions • Battery may be overcharged
Extreme regenerative braking.
Battery charger attached to truck.
Code C43 - Power Amplifier Thermal Cutback

Reason High or low temperature (above 185°F [85°C] or below –13°F [–25°C]) at
power amplifier heat sink.
Performance Limits Truck functions may be allowed.
How to Clear Code Code is cleared when power amplifier heat sink temperature recovers.
Possible Causes Operating in extreme environment.
and Corrective Excessive load on vehicle.
Actions • Check brake adjustment
• Reduce the value of parameters 2, 3, and/or 4 to help decrease motor
temperature.
Imcorrect power amplifier mounting.
Bad power amplifier.
Code C44 (“hot” is displayed) - Traction Motor Thermal Cutback

Reason High traction motor temperature detected.
Performance Limits Truck functions are allowed, but maximum speed value sent to power
amplifier is reduced.
How to Clear Code Code is cleared when temperature recovers.
Possible Causes Operating in extreme environment,
temperature.
Airflow to motor restricted.
Bad motor wiring, or bad motor.
Code C46 - Severe Traction Motor Thermal Cutback

Reason Very high traction motor temperature or extreme operation detected.
Performance Limits Truck functions are allowed, but maximum speed value sent to power
amplifier is reduced.
How to Clear Code Code is cleared when temperature recovers.
Possible Causes Operating in extreme environment,
temperature.
Airflow to motor restricted.
Bad motor wiring, or bad motor.
NOTE: For 100 series error codes, throttle is dropped. Code is cleared when problem
not allowed, outputs are off (brake is is resolved and truck is cycled OFF/ON
engaged), and main contactor is (unless otherwise noted).

Code E101 - Power Amplifier Does Not Correspond with the Type of Truck
Reason Power amplifier is not compatible with ETAC software.
Possible Cause/ Replace power amplifier with correct power amplifier.
Corrective Action
Code E104 - Brake Output Error

Reason Power amplifier could not detect presence of brake coil.
Possible Cause/ Open circuit due to brake or wiring; check brake and wiring.
Corrective Action Brake may not be releasing or stuck on motor end bell.
Master control relay missing or stuck open.
Main contactor open circuit (especially after it has closed).
Communication error due to PMT. Unplug PMT and allow to completely
reboot before turning truck ON.
Code E106 - Digital Output or Field Overcurrent

Reason Power amplifier attempted to deliver more current than allowed to main
contactor coil, traction motor field winding, or digital output.
Possible Cause/ Check main contactor coil, traction motor field winding, digital outputs, and
Corrective Action associated wiring.
Replace power amplifier.
Code E107 - Contactor Off

Reason Contactor probably present but controller could not close it successfully.
Possible Cause/ Problem with main contactor tips.
Corrective Action • If contactor clicks prior to displaying this code, polish contactor tips. If
this is unsuccessful, replace contactor.
Low voltage.
• Try closing contactor with a known-good battery.
Short in contactor coil wiring.
• Replace contactor.
Code E108 - Contactor Welded or Missing

Reason Main contactor tips probably welded or missing.
Possible Cause/ Main contactor tips welded.
Corrective Action Open or short circuit in contactor circuit.
• Check contactor, wiring (coil), and cabling.
Code E110 - Braking System Fault

Reason Power amplifier detected problem with braking functions.
Possible Cause/ Short-circuit in brake circuit.
Corrective Action • Check brake and wiring.

Code E112 - Arm Angle Sequence Fault

Reason Imcorrect sequence of arm angle inputs.
Possible Cause/ Arm angle input stuck on or off.
Corrective Action Problem with arm angle input wiring.
Problem with tiller arm. Check for correct sequence of arm angle switches.
Communication error due to power amplifier PMT; allow PMT to reboot
before turning truck ON.
Code E114 - Traction Motor Speed Fault

Reason Controller detected stalled traction motor.
Possible Cause/ Traction motor stalled.
Corrective Action Excessive traction motor load at low speed. Brake may not be releasing or
stuck on motor endbell. Check brake adjustment.
Power amplifier may be bad.
Code E140 - Checksum Error

Reason ETAC software detected that checksum was invalid.
Possible Cause/ Internal ETAC fault (Control handle head).
Corrective Action Bad software. Try downloading new software.
Code E141 - Software Problem

Reason ETAC found problem with software.
Possible Cause/ Internal ETAC fault (Control handle head).
Corrective Action Bad software. Try downloading new software.
Code E142 - Power Amplifier Disable Error

Reason Power amplifier detected a major fault.
Possible Cause/ Severe overvoltage (especially at main contactor close); check for correct
Corrective Action voltage.
High current through a digital output. Check power amplifier outputs and
wiring.
Open circuit in traction motor field circuit wiring or windings.
Replace power amplifier.
Code E150 - Drive Communication Error

Reason ETAC did not receive CAN data from the power amplifier.
Possible Cause/ Short or open circuit in CAN wiring.
Corrective Action Electrical noise in CAN wiring caused by bad connection, outside
interference, or low voltage. Check CAN wiring. Try driving with a
known-good battery or in a different environment.
Bad power amplifier; ETAC internal error.
Code E151 - Drive Communication Tx Error

Reason ETAC could not send CAN data to the power amplifier.

Code E151 - Drive Communication Tx Error

interference, or low voltage (especially while lifting or driving) possibly
caused by over-current or short-circuit. Check CAN wiring. Try driving with
a known-good battery or in a different environment.
Code E157 - CAN-bus Off Error

Reason ETAC detected problem with the CAN-bus.
Code E159 - Over Run Error

Reason ETAC detected problem with the CAN-bus.
Code E160 - Error In Reversing Circuit

Reason ETAC detected problem with throttle position sensors, including the sensor
used to initiate emergency reversing. See “Code C20 - Thumb Control
Warning”.
Possible Cause/ Check the mechanical portions of the throttle controller. Give special
Corrective Action attention to the magnet arm alignment with the ETAC sensors and to the
non-metallic parts of the emergency reverser.
Bad ETAC.
Code E161 - Lower Valve Error

Reason Power amplifier could not detect presence of lower valve coil.
Possible Cause/ Lower valve missing.
Corrective Action Open or short circuit in lower valve or wiring; master control relay missing
or stuck open; main contactor open circuit (especially after it has closed);
communication error due to PMT. Allow PMT to reboot before turning truck
ON. Bad power amplifier.
Code E200 - Field Open

Reason Power amplifier detected open field.
Possible Cause/ Open circuit in traction motor field circuit. Check traction motor field wiring
Corrective Action and field windings in motor.
Harness broken. Bad power amplifier.
Code E201 - M– Error

Reason Power amplifier detected a drive circuit fault.
Possible Cause/ Traction motor cabling bad; bad power amplifier.
Corrective Action

Code E202 - Power Amplifier Sensor Error

Reason Power amplifier reported an armature current sensor fault.
Possible Cause/ Abnormal vehicle operation.
Corrective Action Low battery voltage or undersized battery.
Code E214 - Power Amplifier CAN Time-out

Reason Power amplifier did not receive CAN data from the ETAC, or power amplifier
selftest failed.
Bad power amplifier; Bad ETAC.

Changing Truck Parameters (P) change or view. See Table 5-5. Release the
thumb control to neutral when the desired
parameter number is shown.
4. Press the horn button once to access the
parameter. The parameter symbol on the
Modifying specific truck parameters will display starts flashing.
change the driving characteristics of the
truck. 5. Change the parameter value by pressing
the thumb control up or down. Release the
thumb control to neutral when the desired
Programming Truck Parameters parameter number is shown.
To program the trucks operating parameters 6. Press the horn button again to confirm the
follow directions below (also see “Setting change. The parameter symbol on the
Individual PIN-key codes” on page 5-18): display stops flashing and remains
illuminated.
1. Enter special truck mode. See “Special
Truck Mode” on page 5-9. 7. End programming by pressing the red OFF
(O) key on the keypad.
2. Release the horn button when the “P” is
displayed. The parameter control indicator The parameter change is complete. The next
(wheel icon) is illuminated. time the truck is started, the new parameter is
3. Use the thumb control to scroll to the in effect.
desired truck parameter you want to
Table 5-5. Truck Parameters
Parameter Name Unit Range Step Default Description
01 Max speed, % 10 to 40 2 20 Speed, slow mode
slow mode 10: low speed
40: full speed
02 Max speed, % 70 to 98 2 94 Max speed, fast mode
fast mode 70: low speed
98: full speed
03 Acceleration % 30 to 90 5 80 30: low acceleration
90: full acceleration
04 Deceleration % 40 to 90 5 65 Defines motor speed reduction
force when thumb control goes
to neutral position.
40: low reduction force
90: full reduction force
05 Truck off delay min. 0 to 20 1 0 The time until the truck is
(keypad only) powered OFF (truck with
key-pad only). Time is counted
while the truck is idle and brake
is applied.
Programming Service Parameters 3. Press and hold the horn button until “P” is
displayed. The parameter control indicator
1. Connect the service key at J41. See (wheel icon) is illuminated. See Figure 5-4.
“Special Tools” on page 3-4.
4. Use thumb control to scroll to the desired
2. Enter Special Truck Mode. See “Special service parameter to be changed. See
Truck Mode” on page 5-9. Table 5-6.

NOTE: All parameters can be viewed; however, operator; the default value of “1” will be
not all parameters can be changed. displayed.
Driver parameters may or may not be 5. Press the horn button once to access this
accessed, depending on the value of parameter. The parameter symbol on the
parameter 39. display flashes. Now you can make
changes to the value of the 1st operator’s
Service Parameter Display PIN-key code.
When parameters 1 thru 5, and 10 are viewed

with the service key, both the parameter
number (left side of display) and the 1st Changing the 1st operator’s PIN-key
operator number (right side of display) are code will alter default operation. You
shown. will not be able to press “1” and green
ON (I) to power the truck unless a
As the service parameter number display operator’s PIN-key code is set to a value
progresses through parameters 1, 2 ..., 10 the of “1.”
display will roll over to the next operator (the
operator number increases). If a parameter is 6. Rotate the thumb control in fork direction
changed, it is valid only for the operator shown. to increase the PIN-key code value, or in
After all operators and operator parameters are operator direction to decrease the value.
scrolled through, service parameters 11 thru 40 Holding the thumb control in a direction
are displayed. for a time will help quickly advance to
larger numbers (for example, codes greater
To quickly display/access a service parameter than 100). The PIN-key code can be from
rotate the thumb control away from the forks one to four digits long. Release the thumb
(sequence backwards through the control when the desired value is reached.
parameters/operators). 7. Press the horn button again to confirm the
new PIN-key code value. The parameter
Setting Individual PIN-key codes symbol on the display stops flashing.
8. To enable additional operators; rotate the
1. Connect the service key at J41. See
thumb control in the fork direction to roll
“Special Tools” on page 3-4. Make sure
over to the 2nd operator, and stop at
that the Master Control ON/OFF switch is
parameter 10. The default value of “0” will
ON.
be displayed. Follow the previous steps for
2. Enter Special Truck Mode. See “Special the desired number of different PIN-key
Truck Mode” on page 5-9. codes you want to set up. There are a total
3. Press and hold the horn button until “P” is of ten operators.
displayed. The parameter control indicator NOTE: Disabling all operators (all PIN-key code
(wheel icon) is illuminated. If the horn values = 0) prohibits truck operation
button is released at the wrong time, turn without the service key.
the truck OFF and start over.
NOTE: Use unique PIN-key codes to avoid
4. Use the thumb control to scroll through
confusion. If two operators have the
the service parameters. While the thumb
same PIN-key code, the higher number
control is held and briefly after it is
operator’s parameters will be used. For
released, both the parameter number (on
example if both the 1st and 2nd
the left side of the display) and the
operator PIN-key code is 1111, and the
operator number (on the right-this only
1st operator’s max speed is 80% and the
occurs if the service key is connected) are
2nd operator’s max speed is 90%, when
displayed. Stop (release the thumb control)
someone logs in with 1111 the max
at parameter 10 (PIN-key code) (See
speed used will be 90%.
“Parameter 10” on page 5-20.) for the 1st

Table 5-6. Service Parameters

Parameter Name Unit Range Step Default Description
10 PIN-key 0 to 9999 1 1 Capability to assign up to 10 PIN-key codes
code (for 10 different operators)
14 Creep –10 to 10 1 –5 Defines how much output the power
speed amplifier gives when you reach the first
speed sensor.
–10 = low speed when reaching first speed
sensor
10 = high speed when reaching first speed
sensor
20 Hour 1 to 5 1 2 1 (A.) = key time
meter 2 (b.) = activity time
selection 3 (c.) = drive
4 (d.) = lift
5 (s.) = time to service
21 Battery 1 to 20 1 8 Battery size selection
size
25 Service hours 0 to 2000 50 0 Sets/resets service timer. C29 displays
interval when time is up. To reset timer, access this
parameter without changing the value.
39 Access 1 to 4 1 3 Defines what access level service personnel
code have to parameters.
1 = key switch/driver parameters open,
2 = key switch/driver parameters closed,
3 = keypad/driver parameters open,
4 = keypad/driver parameters closed (when
closed, Service Key is required to access
driver parameters).
Parameter Description Parameter 4
Parameter 1 Auto-Plug Braking in Neutral - Defines the

truck’s automatic plug-braking characteristic
Maximum speed value sent to the power when throttle is reduced (including to neutral).
amplifier while in Slow mode except during A lower number gives less aggressive
Turtle Torque (gives torque boost if high load is deceleration.
encountered).
Parameter 5
Parameter 2
Automatic Time Off Interval (touch pad only) -
Top Speed - Reduces speed value sent from the The time until the truck is switched OFF
ETAC to the power amplifier while in Fast mode (energy saving feature) when the truck is idle
(all throttle positions). and the brake is applied. Time is counted from
when the latest power output is requested. If
Parameter 3 truck has key switch option, the truck never
powers OFF. Range is from 1 minute to 20
Acceleration - Defines the truck’s acceleration minutes (a setting of “0” disables automatic
characteristic when the truck starts from a time off).
stop. A high number gives maximum
acceleration, a lower number gives less
aggressive acceleration.

Parameter 10 NOTE: Acid concentration varies with different

battery brands.
All trucks with a touch pad have a temporary
key code set at the factory. By default the 1st
operator’s PIN-key code is the single digit
number “1” and all other operator’s PIN-key
codes are “0” which disables that operator. The Make sure that you have the correct
key code logic has ten (10) registers for parameter setting. Otherwise the
individual operator key codes. To add additional battery can be destroyed.
operators, change these PIN-key codes to
numbers other than “0.” See “Setting Individual Parameter 25
PIN-key codes” on page 5-18. A Service Key is
required to assign up to 10 operators their own With this parameter you can set a time limit to
PIN-key code (one to four digits) for access to next service from 0 to 2000 hours in steps of 50
the truck. hours. When it is time for service, you will get
caution 29 (C29) on the display. To disable the
Parameter 14 service timer, set this parameter to 0. To reset
the service timer, simply access this parameter
Defines the speed at low throttle positions. A without changing the value.
negative number enhances low speed
maneuverability. A positive number makes the Parameter 39
truck more responsive.
This parameter determines whether the truck
Parameter 20 has a key switch or keypad and what access
level service personnel will have to the driver
You choose the hour meter you want to display. parameters. This parameter is adjustable:
• 1 = A. (key time) • 1 = key switch connected, driver
parameters open
• 2 = b. (activity time)
• 2 = key switch connected, driver
• 3 = c. (drive motor time) parameters opened with service key
• 4 = d. (pump motor time) • 3 = keypad connected, driver parameters
• 5 = S. (time to service) open
• 4 = keypad connected, driver parameters
Parameter 21 must be opened with service key
Data must be provided about the battery
installed in the truck. Display Part Numbers (Pn)
1. Enter the special truck mode.
The battery state-of-charge reset voltage is
25.2V and the lift cutout occurs when the 2. Press and hold the horn button until “Pn”
display shows 0% state-of-charge. is displayed.
3. Use the thumb control to scroll and
To adjust the disconnection point of the battery display the following information:
discharge indicator, measure:
• HPn = Hardware part number
• the acid concentration of a fully-charged
• HSn = Hardware serial number
battery (must be between 1.27 and
1.29 SG) • SPn = Software part number
• at lift cutout, acid concentration should be 4. End displaying the part number by
about 1.14 SG. pressing the red OFF (O) key on the
keypad.

Service Display
Service Display Digital Inputs/Outputs from Power

Amplifier
• Connect the service key (see “Special
Tools” on page 3-4) in connection point The first most significant figure active (marked
J41 and press the green ON key (I) to start with arrow).
the lift truck.
• The battery status is displayed and the Power amplifier inputs.
symbol “D” is lit continually.
• Press horn button (S18) to toggle between
display modes. See table below: A
A
E D C B
A
E D C B
F B Figure
G Segments
Flashing Symbol Displayed Data

E C
DP
B Speed reference value sent to D
power amplifier.
C Digital inputs/outputs from

power amplifier and ETAC. Figure
See “Digital Inputs/Outputs Function
Segment
from Power Amplifier”.
* See explanation following A
BC Battery voltage (V) at ETAC B Input (J5-14): Arm Angle B
D Armature current (A) C Input (J5-15): Lift limit
BD Field current (A) D Input (J5-12): Arm Angle A
CD Armature PWM in % E Input (J5-2): Lower valve (lit if

valve is present and not powered)
BCD Status of power amplifier.
See “Typical Statuses of F
Power Amplifier” on
page 5-23. G Input (J5-5): Brake (lit if brake is
present and not released)
E Field resistance (Ohms),
used for thermal cutback. DP
* They are displayed by highlighting the

segments of three of the figures (A).

Service Display
The second most significant figure active The third most significant figure active (marked
(marked with arrow). with arrow).
Power amplifier outputs. Digital input from ETAC control

sensors.
A
A
E D C B
E D C B
A
A
F B
G Figure
Segments F B Figure
G Segments
E C
DP E C
D
DP
D
Figure
Function Figure
Segment Function
Segment
A
A
B
B
C Output (J5-2): Lower valve
C
D
D ETAC input: lift forks
E Output (J5-4): Main contactor
interlock E ETAC input: lower forks
F Output (J5-7): Horn F (not used)
G Output (J5-5): Brake G (not used)
DP Output (J5-6): Pump contactor DP ETAC input: horn

Service Display
Typical Statuses of Power Amplifier
Status Comments
13 No Activity: Main contactor open

because no output requested for
30 seconds or an error occurred.
24 Passive restraint (transitional)
16 Passive restraint
1 Motor drive, plug, or active

neutral braking
17 Active restraint while driving

(overspeed)
10 Regen
11 Regen taper (transitional)
4 Field reversal (transitional)
74 Emergency reverse (regen)
65 Emergency reverse (drive)
6 Disable (major fault, such as

severe overvoltage)
129 Emergency shutdown while in

drive
144 Emergency shutdown while in

passive restraint

Power Amplifier Fault Codes
Power Amplifier Fault

Codes
An internal microcontroller automatically
checks the function of the power amplifier.
When this microcontroller detects a fault, the
LED on the bottom of the power amplifier
flashes the appropriate code. See Table 5-7.
Under normal operation, the LED flashes a
single flash (heartbeat) at approx. one flash
every five seconds. A double flash indicates a
fault has been detected by the microcontroller.
Correct faults by following the “Troubleshooting
Flowcharts” on page 5-31.
Table 5-7. Fault Codes
Fault Code Display Possible Cause Explanation

Open circuit at power Power amplifier does not
LED amplifier +24Vdc logic input have voltage at +24Vdc
N/A
OFF due to wire, fuse, or bad logic power supply input.
power amplifier.
Solid Power amplifier is not
N/A Bad power amplifier.
ON functioning correctly.
Single Normal “heartbeat”,
¤ NO KNOWN FAULTS N/A
flash everything is okay.
1, 1 ¤¤ CURRENT SHUNT FAULT See “Code E202 - Power Amplifier Sensor Error” on
page 5-16.
See “Code E214 - Power Power amplifier is
Amplifier CAN Time-out” on reporting that it is not
page 5-16 if ETAC is keyed receiving CAN messages
ON. from the ETAC, or that
1, 2 ¤ ¤¤ HW FAILSAFE selftest failed.
Otherwise, the controller is
reporting it is not receiving
CAN messages from the
ETAC, which is normal when
the truck is not turned ON.
1, 3 ¤ ¤¤¤ M– SHORTED See “Code E201 - M– Error” on page 5-15.
1, 4 ¤ ¤¤¤¤ SRO Bad power amplifier or ETAC.
2, 1 ¤¤ ¤ THROTTLE FAULT 1
Bad power amplifier. Power amplifier is not
2, 2 ¤¤ ¤¤ EMR REV WIRING setup or functioning
correctly.
2, 3 ¤¤ ¤¤¤ HPD Bad power amplifier or ETAC.
2, 4 ¤¤ ¤¤¤¤ THROTTLE FAULT 2 Bad power amplifier.
3, 1 ¤¤¤ ¤ CONT COIL/FLD SHORT See “Code E106 - Digital Output or Field Overcurrent” on
page 5-13.

Power Amplifier Fault Codes

Table 5-7. Fault Codes
Fault Code Display Possible Cause Explanation

Power amplifier is not
3, 2 ¤¤¤ ¤¤ MAIN CONT WELDED Bad power amplifier or ETAC. setup or functioning
correctly.
3, 3 ¤¤¤ ¤¤¤ FIELD OPEN See “Code E200 - Field Open” on page 5-15.
3, 4 ¤¤¤ ¤¤¤¤ MISSING CONTACTOR Bad power amplifier or ETAC. setup or functioning
correctly.
4, 1 ¤¤¤¤ ¤ LOW BATTERY VOLTAGE See “Code C41 - Battery Undervoltage Warning” on
page 5-11.
4, 2 ¤¤¤¤ ¤¤ OVERVOLTAGE See “Code C42 - Battery Overvoltage Warning” on
page 5-11.
4, 3 ¤¤¤¤ ¤¤¤ THERMAL CUTBACK See “Code C43 - Power Amplifier Thermal Cutback” on
page 5-12.
4, 4 ¤¤¤¤ ¤¤¤¤ ANTI-TIEDOWN Bad power amplifier or ETAC. setup or functioning
correctly.

Programmable Maintenance Tool (PMT)
Programmable The Main Menu is the starting point for the

PMT. The main menu displays menu titles:
Maintenance Tool (PMT) • Program (not used)
• Monitor
• Faults
Data Inc/Dec • Functions (not used)
Key
• Information
• Programmer Setup
Bookmark
Keys If there are no entries within a Menu, then the
Menu title will not be displayed.
Connector
Menu
Navigation
Key
1665 037.tif
Figure 5-8. Programmable Maintenance Tool

(P/N 950-185/002 shown)
The optional Programmable Maintenance Tool

(P/N 950-180 or 950-185/002) permits you to
test and diagnose the power amplifier in this
pallet truck.
The PMT is powered by the power amplifier

1665 037.tif
through a four-pin connector at the bottom of Figure 5-9. Connecting PMT to Power Amplifier
the power amplifier. See Figure 5-9. (P/N 950-185/002 shown)
The Menu Navigation Key moves the screen

curser up or down through the Menu list (top or Monitor Mode
bottom arrow), and opens or closes Sub-Menus
(right or left arrows). Real-time status information is displayed in the
Monitor mode for various inputs, outputs,
The Data Inc/Key changes the value of the temperature, etc. This information can be
parameter indicated by the curser. helpful in troubleshooting many problems and
is useful for checking out the operation of the
The Bookmark Keys allow you to quickly go controller during initial installation.
back to your favorite selections without having 1. Press the red OFF (O) key on the keypad.
to navigate back through the Menu. 2. Remove the tractor cover.
• To select a position in the menu, hold a 3. Connect the PMT to the power amplifier.
Bookmark Key down for three seconds Wait for the PMT to “boot up” before
until the bookmark set screen is proceeding to the next step.
displayed.
4. Enter the PIN key code and press the
• To jump to a selected Bookmark position, green ON (I) key on the keypad or turn key
press the appropriate Bookmark Key. switch ON.
NOTE: The Bookmarks are not permanently 5. Use the Menu Navigation Key to select
stored in the PMT. They are cleared Monitor.
when the PMT is unplugged.

6. Press the right arrow on the Menu 7. Use the Up and Down Buttons arrows on
Navigation Key to enter the sub-menu. the Menu Navigation Key to scroll through
7. Use the Up and Down Button arrows to list of multiple faults.
scroll through the sub-menu list of
monitor variables. Clear
8. Use the right arrow to select and view a
single variable. After you have diagnosed and corrected the
problem, clear the diagnostic history file. This
9. To change the value of the parameter use permits the power amplifier to accumulate a
the Data Inc/Dec Key. Alternately, you can new file of faults. By checking the new history
press the right arrow Menu Navigation Key file at a later date, you can easily determine
once more and enter the detail screen. A whether the problem was completely fixed.
bar graph appears as well as min and max
data points. Change the parameter value 1. To clear the fault history of the unit, use
by pressing the Data Inc/Dec Key. The the Menu Navigation Key to select
new value is set as soon as the Data Faults -> Clear Fault History.
Inc/Dec Key is released. 2. Press the increment arrow (+) for yes and
the decrement arrow (-) to cancel and not
To close a Monitor Menu, sub-menu, or detail clear the fault history.
screen, press the left arrow on the Navigation
Key. Table 5-10 on page 5-28 lists possible messages
you may see displayed when the PMT is
operating in either System Faults or Fault
Faults Mode History mode.
In System Faults mode, currently active faults
detected by the controller are displayed. Information Mode
In Faults History mode, the controller’s The Information Menu provides access to
diagnostic history file is displayed. This field product information describing the basic
includes a list of all faults observed and revision level of the PMT.
recorded by the controller since the history was
last cleared. To view, use the Menu Navigation Key to select
Information in the Main Menu. Remember to
NOTE: Each fault is listed only once, regardless
press the right arrow to select a Menu. Press
of the number of times it occurred.
the left arrow to exit.
1. Press the red OFF (O) key on the keypad.
2. Remove the tractor cover. Programmer Mode
3. Connect the PMT to the power amplifier.
Wait for the PMT to “boot up” before Programmer mode permits you to perform a
proceeding to the next step. variety of tasks.
4. Enter the PIN key code and press the 1. Press the red OFF (O) key on the keypad.
green ON (I) key on the keypad or turn key 2. Remove the tractor cover.
switch ON.
3. Connect the PMT to the power amplifier.
5. To view the present status of the unit, use Wait for the PMT to “boot up” before
the Menu Navigation Key to select proceeding to the next step.
Faults -> System Faults
4. Enter the PIN key code and press the
6. To access the log, use the Menu Navigation green ON (I) key on the keypad or turn key
Key to select Faults -> Fault History. switch ON.
5. Use the Menu Navigation Key to select
Programmer.

6. Press the right arrow on the Menu Change the parameter value by pressing the
Navigation Key to enter the sub-menu. Data Inc/Dec Key. The new value is set as soon
7. Use the Up and Down arrows on the as the Data Inc/Dec Key is released.
Navigation Key to scroll through the
sub-menu list of Programmer displays.
8. Use the right arrow to select and view a
single variable.
Table 5-10. Test Mode Menu
Test Mode
Display Explanation
THROTTLE% Throttle reading, in % 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 power amplifier B+ (bus bar)
HEAT SINK TEMP Heat sink temperature - °C
FORWARD INPUT Forward switch: on/off
REVERSE INPUT Reverse switch: on/off
MODE Power Amplifier operating mode: 1 to 4
INTRLCK INPUT Interlock (brake/deadman) switch: on/off
PEDAL INPUT (not used)
EMR REV INPUT Emergency reverse button: 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

List of Troubleshooting Charts/Tables

Troubleshooting Charts
TS1: START TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
GEN1: General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
END1: End of Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . 5-33
Hydraulic Symptom Tables

No Lift, Lift Motor Does Not Run, Travel is OK. . . . . . . . . . . . . . . . . . . . 5-35
No Lift or Slow Lift, Lift Motor Does Run . . . . . . . . . . . . . . . . . . . . . . . . 5-36
No Lower, Lift and Travel OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Unable to Pick Up a Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Slow Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Load Drifting/Settling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Travel Symptom Tables

Slow Travel, Lift/Lower OK. No Fault Codes . . . . . . . . . . . . . . . . . . . . . 5-39
Truck Does Not Accelerate Correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Green/Red LED on Keypad Not Illuminated When Key Pressed. . . . . . . 5-40
No Fast Travel Mode. No Fault Codes.. . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
No Travel Mode. No Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Horn Does Not Sound When Horn Button Pushed. No Fault Codes. . . . 5-41
No Lift or Lower. No Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

List of Troubleshooting Charts/Tables
5-30 Publication:1010183B, Revised: 2/17/05

Raymond® Walkie Pallet Truck Maintenance Manual Section 5. Troubleshooting
Troubleshooting Flowcharts
TS1: START TROUBLESHOOTING
TS1: START TROUBLESHOOTING
Is a
Message or
Yes
Fault Code
displayed?
Find
Message or Code
No in Chapter 5
Is
symptom listed in
No
Symptom Tables in
Chapter 5?
Go to
Chart GEN-1
Yes
Follow
Symptom Table
directions in
Chapter 5
TS-1.wmf
Publication: 1010183B Revised: 2/17/05 5-31

Section 5. Troubleshooting Raymond® Walkie Pallet Truck Maintenance Manual
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
5-32 Publication: 1010183B Revised: 2/17/05

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


Symptom Tables: Lift/Lower System

NOTE: If it is determined that a component failed as a result of hydraulic fluid contamination,
replace the failed component and flush, fill, and bleed the hydraulic system. See “Hydraulic
Fluid” on page 6-52.
NOTE: Reference electrical schematics beginning on Page A-9 and hydraulic schematic beginning
on page A-12.
No Lift, Lift Motor Does Not Run, Travel is OK
Possible Cause Action

Bad lift pump contactor With main ON/OFF switch ON, the PIN-key
code entered, the green ON (I) key on the
keypad pressed and lift switch depressed,
does main contactor (K10) and pump
contactor (K30) energize (click)? If not,
measure voltage between pump contactor
coil terminals. If B+ voltage is present,
replace the pump contactor.
Bad control handle card (A2) With main ON/OFF switch ON, the PIN-key
code entered, the green ON (I) key on the
keypad pressed and lift switch depressed,
does pump contactor (K30) energize (click)?
If not, check for lift signal input at CAN (see
Service Display). If no signal is detected,
replace control handle card (A2). Note:
Check for mechanical problems in the
handle head before replacing control handle
card.
Bad wiring continuity or wiring shorts With main ON/OFF switch OFF and battery
disconnected, check for continuity and
wiring shorts in wiring harness or cables.
Bad lift-limit switch With main ON/OFF switch OFF, battery
disconnected and forks lowered, check
continuity through the lift-imit switch.
Replace if necessary.
Bad lift pump motor brushes... With main ON/OFF switch ON, the PIN code
entered, the green ON (I) key on the keypad
pressed and the lift switch depressed, does
pump contactor (K30) energize (click)? If
YES, measure voltage between B– and lift
pump motor terminal. If OK, check lift
motor brushes...
...or bad lift pump motor... ...if brushes are OK, test the pump motor.

No Lift or Slow Lift, Lift Motor Does Run

Battery problems Replace battery with fully-charged battery.
Mechanical binding in lift mechanism Repair lift mechanism.
Low hydraulic pressure or relief valve Check hydraulic pressure setting and adjust
setting if necessary. See “Adjusting Hydraulic
Pump Pressure Relief Valve” on page 6-53.
Relief valve contaminated or bad. (Unable With main ON/OFF switch OFF and battery
to get the correct hydraulic pressure) disconnected, remove the pressure relief
valve. Check for damage or contamination.
Replace valve or flush system and replace
the hydraulic fluid. See “Hydraulic Fluid”
on page 6-52.
Bad lift pump motor or brushes Check the lift pump motor brushes. If OK,
replace the pump.
Contamination found in the pump Flush the system and replace hydraulic fluid.
Bad pump If lift motor is OK, remove motor from pump
and rotate pump by hand. Replace pump if
not OK.
No Lower, Lift and Travel OK

Bad lower solenoid valve... With the main ON/OFF switch ON, cycle the
lower switch. Does the lower solenoid valve
energize (click)? If YES, disconnect the
battery, then slowly loosen, but DO NOT
REMOVE the hydraulic line at the hydraulic
pump assembly. Permit the forks to slowly
lower. Have rags and drain pan ready to
catch fluid.
... if the forks do not lower, check for Replace lift cylinder or repair lift mechanism.
mechanical binding in lift cylinder or
fork mechanism...
...if the forks lower, remove and inspect Inspect for free movement and for signs of
the solenoid valve... contamination. Clean the solenoid valve or
flush the system, clean the filter and
replace hydraulic fluid.
If no contamination is found, repair or
replace the solenoid valve or pump
assembly.


...check for bad control handle (ETAC) With main ON/OFF switch ON, the PIN-key
card code entered, the green ON (I) key on the
keypad pressed, and the lower button
depressed, check for lower signal input at
CAN (see Service Display). If no signal is
detected, replace ETAC. Note: Check for
mechanical problems in handle head before
replacing ETAC.
Unable to Pick Up a Load

Load too large for lift truck capacity Check load weight. Check lift pressure
setting.
Battery problems Replace battery with fully-charged good
battery.
Incorrect lift pressure adjustment Check and adjust lift pressure setting.
Contaminated or bad pressure relief valve Check for contamination in hydraulic fluid.
If contamination is present, flush, fill and
bleed the hydraulic system. Clean the relief
valve.
If no contamination is found, replace relief
valve.
Bad lift pump or motor Replace lift pump or motor.
Slow Lower

Bad lift/lower solenoid valve or wiring Repair or replace the solenoid valve or wiring.
Plugged or malfunctioning flow control Check for contamination in hydraulic fluid.
valve If contamination is present, flush, fill and
bleed the hydraulic system and clean the
relief valve.
If no contamination is found, replace the flow
control valve.
Contamination in lowering solenoid valve Inspect solenoid for contamination or binding.
Mechanical binding in lift mechanism Adjust or replace mechanism.
Bad or misadjusted lift-limit switch Adjust or replace lift-limit switch (pump
should not hit relief if lift-limit switch is
operating correctly).
NOTE: If the pump hits relief and lower is attempted, lowering will be slow. Release the
lower button momentarily, then continue to lower. Normal lower speed should
resume.

Load Drifting/Settling

Incorrect lift pressure adjustment Check and adjust lift pressure setting.
Contaminated or bad check valve Check for contamination in hydraulic fluid.
If contamination is present, flush, fill and
bleed the hydraulic system. Clean the check
valve.
If no contamination is found, replace check
valve.
Leaking or contaminated lowering Check for contamination in hydraulic fluid.
solenoid valve If contamination is present, flush, fill and
bleed the hydraulic system. Clean the
solenoid valve.
If no contamination is found, replace the
solenoid valve.
Load too large for lift truck capacity Check load weight. Check lift pressure
setting.

Symptom Tables: Travel (Forward/Reverse) System

NOTE: Reference electrical schematics beginning on Page A-9 and hydraulic schematic beginning
on Page A-12.
Slow Travel, Lift/Lower OK. No Fault Codes

Truck configured for slow acceleration Check truck configuration.
Battery problems Replace battery with fully-charged good
battery.
Binding drive wheel assembly/drive Jack and block truck. Disable brake. See
motor “Mechanically Releasing the Brake” on page
6-34. Check that drive wheel spins freely. If
not, repair or replace.
Binding brake disc Check ”Air Gap Adjustment” on page 6-33.
Bad drive motor Repair or replace drive motor or brushes.
(may test OK with no load, but fail
under load) or worn brushes
Truck Does Not Accelerate Correctly

Truck configured for slow acceleration Check truck configuration.
Battery problem Verify a correct, fully-charged good battery
(24V) is installed in truck.
Binding or mechanical problem Jack and block truck. Turn main ON/OFF
switch ON. Check brake, wheel bearings
and load wheels to see if there is a
mechanical problem. Repair or replace.
Bad motor brushes or motor With main ON/OFF switch OFF and battery
disconnected, check drive motor brushes
and motor. See “Drive Motor Brush
Inspection” on page 6-35. Repair or replace.
Bad power amplifier If all other possible causes check out, replace
power amplifier.

Green/Red LED on Keypad Not Illuminated When Key Pressed.

No power supplied to the ETAC Check control wires, especially wires #1, 20,
22 (red in control handle arm cable), and 40
(black in control handle arm cable).
Faulty Connectors Repair and replace faulty connectors (check
connector J11 at control handle arm base,
connector into ETAC, and connector J5 to
motor controller).
F50 Open Ensure control fuse has not tripped.
Key switch jumper not connected Connect keyswitch jumper.
Faulty LED(s) Check LED(s) if truck functions normally but
LED(s) not lighting correctly.
No Fast Travel Mode. No Fault Codes.

Open Arm Angle Switch Check for correct operation of arm angle
switch “A” and correct if necessary, check
wiring, power amplifier, and switch
adjustment. Arm Angle switch A is
open-circuited. See “Arm Angle Switches”
on page 5-6.
No Travel Mode. No Fault Codes.

Arm Angle Switch Failure Check arm angle switch adjustment, wiring,
power amplifier. Arm Angle switch A or B is
open-circuited. See “Arm Angle Switches”
on page 5-6.
Throttle magnet-actuator arm (in control Check with service display and repair as
handle) out of adjustment needed.
Bad ETAC. If no other problems are noted
but the ETAC does not detect the presence
of the magnet, replace the ETAC.

Horn Does Not Sound When Horn Button Pushed. No Fault Codes.

Faulty horn switch/wiring in handle head Repair or replace as necessary.
Faulty Horn Replace horn.
Faulty power amplifier Check fuse and replace if necessary.
No Lift or Lower. No Fault Codes.

'

Throttle magnet-actuator arm (in control Check with service display and repair as
handle) out of adjustment needed.
Bad ETAC. If no other problems are noted
but the ETAC does not detect the presence
of the magnet, replace the ETAC.
Lift contactor missing, open or short Perform standard electrical troubleshooting
circuit in lift circuit (contactor, wiring, procedures in the lift circuit.
motor), faulty power amplifier
Incorrect ETAC software installed. Note: this is only possible if ETAC was
recently replaced.
Lowering may not occur if incorrect software
was inadvertently installed (drive function
will also not function correctly). Check for
correct software part number and replace
ETAC if not correct.


Model 102XM Maintenance Manual Section 6. Component Procedures
Section 6. Component Procedures

A H
Arm Angle Switches ............................ 6-24 Horn ................................................... 6-18

Hydraulic Components
B Cylinder ........................................ 6-47
Fluid ............................................. 6-52
Hydraulic Unit .............................. 6-49
Battery ................................................. 6-4
Filter Screen ............................ 6-51
Adding Water .................................. 6-7
Pump ...................................... 6-51
Charging ........................................ 6-6
Relief Valve Adjustment ........... 6-53
Exterior Cleaning ............................ 6-5
Reservoir ................................. 6-51
Maintenance Free ........................... 6-8
Solenoid .................................. 6-49
Specific Gravity .............................. 6-7
Suction Tube ........................... 6-51
Storage ........................................... 6-8
Voltage Check ................................. 6-7
Battery Pack K
Swingout ........................................ 6-4
Brake ................................................. 6-33 Key Switch (Optional) ......................... 6-26
C L
Circuit Breaker .................................. 6-13 Lift Motor ........................................... 6-52

Contactors ......................................... 6-20 Lift-Limit Switch ................................. 6-25
Control Handle ................................... 6-14 Load Wheel
Cover, Tractor ...................................... 6-9 Pull Rod Adjustment ..................... 6-45
Load Wheels ....................................... 6-45
D Lubrication
Drive Housing ............................... 6-30
Drive Unit .......................................... 6-27
Brake, Eletromagnetic .................. 6-33 M
Drive Housing Lubrication ............ 6-30
Drive Motor .................................. 6-42 Motors
Drive Wheel .................................. 6-31 Brush Spring Tension ................... 6-36
Transmission Assembly ................ 6-27 Brushes ........................................ 6-35
Drive Wheel ........................................ 6-31 Commutator ................................. 6-36
Drive ............................................. 6-42
E General ......................................... 6-35
Lift ................................................ 6-52
Tests ............................................. 6-39
Electromagnetic Brake ....................... 6-33
P
F
Power Amplifier .................................. 6-19
Fuses ................................................. 6-12
Power Cables ...................................... 6-10
Pump, Hydraulic ................................ 6-51
G
Gear Oil ............................................. 6-30

Section 6. Component Procedures Model 102XM Maintenance Manual
Switches
Arm Angle .....................................6-24
General .........................................6-49
Key Switch (Optional) ....................6-26
Lift-Limit .......................................6-25
Main ON/OFF ...............................6-23
Wheels
Load ..............................................6-45
Wiring Harness ...................................6-11

Component Locator Photo
Component Locator Photo

Battery
Connector
Hydraulic Cylinder
Main page 6-47
Contactor
page 6-20
Power
Amplifier Fill/Vent
page 6-19 Plug
Master
Control Hydraulic
Relay Reservoir
page 6-21 page 6-51
Horn
Drive Unit
page 6-18
page 6-27
Figure 6-1. Tractor Interior

Battery
Battery
The pallet truck may be equipped with a
multiple (swingout) battery pack or a
maintenance-free battery and charger.
Before working on the battery, batteries

can weigh more than 500 pounds. Use
extreme care during replacement. Use a
suitable battery replacement device or
hoist for lifting. See “Battery Safety” on
page 2-6.
Swingout Battery Pack

NOTE: For replacement parts information refer
to Parts Catalog.
1790 001.eps
Removal (single battery) Figure 6-2. Multiple Battery Wiring Hookup
1. After the truck is stopped and the handle Installation (single battery)
is returned to the full up position, press
the red OFF (O) key on the keypad. 1. Position the fully-charged and tested
2. Disconnect the battery connector found at batteries in the battery pack.
the top of the tractor cover. Remove the 2. Reconnect the battery cables to the battery
battery cover. terminals in accordance with the battery
3. Lift up on the top battery frame to get wiring hookup shown on the decal in the
access to the lower two batteries. battery frame.
4. As the frame is lifted, swing the battery 3. Reconnect the battery connector, reinstall
toward the center of the forks. the battery cover, press the green ON (I)
key on the keypad, and test the operation
5. The cables may now be disconnected from of the pallet truck.
the battery terminals and the batteries
may be serviced or replaced if necessary.
See Figure 6-2.
Removal (entire battery pack)
2. Disconnect the battery connector found at
the top of tractor cover.
3. Position the battery replacement device
above the battery and attach it to the
battery manufacturer’s designated lift
points.
4. Remove the battery with the lifting device.
5. Put the discharged battery on the charging
stand.

Battery
Installation
1. With a fully charged and tested battery on Cable
the lifting device, position the lifting device
Vent Hole
in accordance with the manufacturer’s
recommendations.
2. Position the battery in the compartment.
Make sure the battery has no more than
1/2 in. (13 mm) of “free play” movement in
the battery compartment in any direction.
3. Remove the lifting device from the area.
4. Reconnect the battery connector, turn the
key switch ON, and test the operation of Filler Plug
the truck. 09g6s047.tif
Figure 6-3. Battery Filler Plugs and Vent Holes

Maintenance-Free Batteries
2. Keep the top of the battery clean and dry.
NOTE: For replacement parts information refer Corrosion, dust, and moisture provide a
to Parts Catalog. conducting path to short-circuit cells or
create grounds.
The truck may be equipped with a

maintenance-free battery and charger pack.
The specific gravity need not be measured on a Do not clean the top of the battery with
maintenance-free battery. Please follow the soda solution while it is installed in
manufacturer’s recommendations for service of the truck. Water will seep into the
these batteries. electrical compartments and cause
serious damage.
A maintenance-free battery still requires some
care. The battery must be kept clean and dry 3. Disconnect the battery connector, and
and may be washed to remove any accumulated remove the battery from the truck before
foreign matter. See “Exterior Cleaning” on you clean it.
page 6-5. 4. Tighten the battery filler plugs.
5. Wash dirty batteries (or any that have had
Battery Maintenance electrolyte spilled on them) with a solution
of 1 lb. (0.45 kg) of baking soda added to
Exterior Cleaning 1/2 gal (1.9 liters) of hot water.
1. Inspect the battery. 6. Use a brush with flexible bristles to clean

the entire top of the battery with the soda
a. Make sure the cables are not frayed or solution. Wait until all foaming stops,
loose. indicating that the battery exterior is
b. Make sure there is no foreign material neutralized.
inside the connector. 7. Rinse the battery with clean water.
c. Make sure the filler plugs are tight and 8. Dry the battery completely before
the vent holes in the filler plugs are re-installing it.
open. See Figure 6-3.
9. Apply a thin coat of petroleum jelly to the
battery posts and cable terminals.

Battery
Charging battery plates. If electrolyte level is below

the plates, add just enough water to cover
To charge a battery, direct current is passed the plates. Do not fill to level yet.
through the battery cells in the direction Electrolyte level will increase during
opposite to that of discharge. Charging time is charging. See “Adding Water” on page 6-7.
5% to 20% longer than discharge time.
8. Using a hydrometer, measure and record
The most important element in battery service the specific gravity of each cell. See
and prolonging battery life is correct charging. “Specific Gravity” on page 6-7.
Make sure you follow the approved method for 9. Measure and record the voltage of each
each application, following the battery and cell.
battery charger manufacturers’ instructions. 10. To get the maximum use out of each
battery, recharge only when effectively
discharged. Routinely recharging batteries
The vent holes in the filler plugs must be when only partially discharged will
open to permit hydrogen gas to escape decrease battery life. At maximum
from the cells. When you charge the recommended discharge, the specific
battery, make sure the polarity gravity must read 1.140 to 1.160 or less.
connections are correct. The positive 11. Make sure that the filler plugs are clean
lead of the charger must be connected to and the vent holes are open. Tighten all
the positive terminal, and the negative filler plugs.
lead must be connected to the negative
terminal.
1. Familiarize yourself with the following: NEVER plug the battery charger into the
truck. This will severely damage the
• Charging rate, starting rate, and finish
truck’s electrical system. Plug the
rate
charger ONLY into the connector from
• Time available for charge the battery.
• Overheating, excessive gassing, or
overcharging 12. Charge the battery, following specific
instructions in your battery and battery
• Variations between cell voltage
charger manufacturer’s manual.
2. Battery performance varies depending on
13. Using a hydrometer, measure the specific
the type of application. If you use more
gravity of each cell. No amount of charging
than one truck, one battery, and one
will increase battery capacity or increase
charger, keep the same batteries and
specific gravity above its fully charged level
charger assigned to each truck. This
(specific gravity 1.280 to 1.300).
makes it easier to diagnose any battery or
charging problem. 14. If, after charging, the electrolyte level is
below the fill port, add water to move it to
3. Consult your battery and battery charger
the fill level. Do not overfill the cells or
manufacturer’s manual for specific
permit electrolyte to spill on the battery
charging procedures.
case. See “Adding Water”.
4. Wear personal protective equipment, See
“Battery Safety” on page 2-6. In general, a lead-acid battery may be charged
5. Press the red OFF (O) key on the keypad, at any rate in amperes that does not cause
and disconnect the battery. excessive gassing or produce electrolyte
temperatures above 110° F (43° C).
6. Inspect the battery.
Temperatures of 120° F (49° C) are permitted
7. Examine the electrolyte level in each cell. only for short periods of time.
Electrolyte must cover the top of the

Battery
Adding Water Procedure

1. Wear personal protective equipment. See
Water must be added to battery cells “Battery Safety” on page 2-6.
periodically. Frequency and quantity depend on
2. Insert the nozzle of the hydrometer into
the water level above the plates and the amount
the battery cell and draw enough
of gassing during charge.
electrolyte into the tube to permit the float
to ride free.
Guidelines:
3. Leave the hydrometer nozzle in the battery
• Wear personal protective equipment. Use
and read the specific gravity of the cell.
only distilled water or water approved by
the battery manufacturer. See “Battery 4. If there is not enough electrolyte in the
Safety” on page 2-6. battery to get a hydrometer reading then:
• Before charging, make sure battery plates • Add just enough water to cover the
are covered with electrolyte. Add water, if battery plates
necessary, only to cover plates. • Charge the battery, then take readings
• Electrolyte level increases during charging. 5. Record the specific gravity reading on the
To prevent overflow, add water to fill port, battery maintenance chart.
if necessary, after charging, and after
hydrometer and voltmeter readings are
Voltage Check
taken.
• Keep the outside of the battery case clean Perform a voltage check on each cell after
and dry. performing the specific gravity check. Attach a
voltmeter to the positive and negative terminals
Specific Gravity of each cell. Voltage readings will change with
the state-of-charge. See “Specific Gravity” on
Specific gravity readings for lead acid batteries page 6-7.
with electrolyte temperatures at 80° F (27° C)
Charge Voltage Reading
change with the state-of-charge as follows:
100% 2.14
Charge Specific Gravity
75% 2.07
100% 1.280 to 1.300
50% 1.95
75% 1.250 to 1.260
25% 1.80
50% 1.200 to 1.210
25% 1.150 to 1.160 Record the voltage reading for each cell on the
battery maintenance chart. There must be a
0% 1.080
difference of less than 0.2V between cells.
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 measurements.

Battery
Storage
Before storing a battery, make sure electrolyte

is at the correct level in every cell, filler plugs
are tight, and battery is fully charged.
Store the battery in a clean, cool, dry location

away from radiators and other sources of heat.
Measure the electrolyte level and the specific

gravity every 30 days during storage. Whenever
the specific gravity is less than 1.230, charge
the battery.

Tractor Covers
Tractor Covers
to Parts Catalog.
The tractor covers are designed to be easily

removed and re-installed for service and
maintenance.
Removal
1. Grasp upper cover at location shown. Lift
cover upward to disengage captivating
clasps. See Figure 6-4.
2. Remove two captivating screws located at
the top of the cover then remove lower
cover.
Grasp Upper
Cover Here
Lower Cover
Figure 6-4. Upper Cover Removal (decals omitted)
Installation
To install the upper cover, slide it back into the

original position, and secure by engaging the
captivating clasps located on the top of the
cover.

Power Cables
Power Cables
to Parts Catalog.
Power cables are used to connect power from

the battery to the drive motor and lift motor.
Examine the power cables 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.
Figure 6-5. Power Cables
The terminal lugs must be crimped tightly and

securely on the wire. Replace the lug if
overheating is evident. Repair or replace bad
connectors as necessary.

Wiring Harness
Wiring Harness • Replace terminations with exposed wire

visible at the connectors. Damaged
terminations, exposed wires, or damaged
NOTE: For replacement parts information refer connectors can cause operational failure of
to Parts Catalog. the truck.
The wiring harness is designed to connect the During troubleshooting and repairs, it is
electrical components of the pallet truck. 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. (25.4 to 38.1 mm) on
the wire, there is a wire marker at each
Figure 6-6. Wiring Harness termination. If the marker is missing or
unreadable, remark the wire to permit easier
All wires in the harness are marked with a wire identification.
identification number. These numbers
correspond to wire identification given in the NOTE: It is normal to find unused connectors
schematic. All connectors are represented by for uninstalled options that have had
“J” followed by a number. See “Schematics” on heat shrink applied over them and have
page A-9. been strapped to the 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.
• Examine harness wires for abrasions,
scrapes, nicks in the wire, damage from
overheating or burns, or other general
insulation damage.

Fuses
Fuses
to Parts Catalog.
Under extreme operating conditions, fuses

(F50, F51) protect the electrical circuits and
components from excessive current or voltage
overloads.
Test/Inspection
Examine each fuse for signs of overheating,

discoloration, cracking, or other physical
damage. Replace the fuse if you find damage.
See Figure 6-7.
Fuse F50 Fuse F51
1665 031.tif
Figure 6-7. Fuse/Circuit Breaker Location
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
connections from one side of the fuse.
Use an ohmmeter set to Rx1 scale and measure

the resistance across the fuse. The resistance
must be less than 1 ohm.

Circuit Breaker
Circuit Breaker
to Parts Catalog.
Under extreme operating conditions the current

demand on the battery may exceed the rating
for the main circuit breaker (M1) and force it
open. This causes 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. Replace the circuit breaker if you find
damage. See Figure 6-8.
Circuit Breaker
CB1
Figure 6-8. Circuit Breaker Location
To test a circuit breaker, remove the circuit

breaker from the truck or isolate it from the
electrical circuit by removing all the
connections from one side. Let it cool (or reset
itself).
Use an ohmmeter set to Rx1 scale and measure

the resistance across the circuit breaker. The
resistance must be less than 1 ohm.

Control Handle
Control Handle NOTE: For replacement parts information refer

to Parts Catalog.
20
19
21 18
17
22
23
15
24
14
25 11
13
26
10
27
16
28
30
12
32
29
33
35 31
36
31
34
7
35 6
4 5
8 1
9

Control Handle
Pos Description Pos Description Pos Description
1 Screw 13 Electronic circuit board 25 Gasket
2 Keypad 14 Push button (option) 26 Signal button
3 Screw, 2 x M5 x 45 - 15 Top cover 27 Push button (option)

2 x M5 x 60
4 Handle 16 Display card 28 Wire, hold down
5 Cover, keypad (Optional) 17 Push button 29 Screw
6 Top Plate 18 Emergency reverse button 30 Control switch
7 Screw 19 Push button (not used) 31 Sliding bearing
8 Bottom plate 20 Plate 32 Control stop
9 Grommet 21 Holder 33 Arm
10 Screw, M4 x 40 22 Push button, lift/lower 34 Axle
11 Spring 23 Arm 35 Spring holder
12 Lower cover 24 Display glass 36 Spring
Control Handle Disassembly Changing Horn Button/Switch

[26, 27]
1. Remove screw [1], then unplug and
remove the keypad [2]. 1. Remove the horn button. See Figure 6-9.
2. Remove the four screws [3] that secure the
top cover assembly to the handle. Hold the
top cover [15] firmly while removing
Do not use excessive force when prying
screws.
on the button or you can damage the
3. Disconnect the cable connected to the locking tabs.
electronic circuit board [13].
4. For access to the electronic circuit board
(13), remove the screws [10] securing the
lower cover [12].
Static electricity! Risk of static discharge

that can damage the electronics. Make
sure to take the necessary precautions
before working with the electronics.
5. Carefully lift off the lower cover [12].

NOTE: Place your finger between the lower
Figure 6-9. Horn Button Removal
cover [12] and button [18] to hold the
control switch [30] in place.
2. Disconnect the connection for the switch
on the electronic circuit board [13].

Control Handle
3. Press out the switch from its mounting in Control Handle Stem
the top cover assembly.
to Parts Catalog.
Changing Lift/Lower Button [22]
1. Remove the button by placing a Removal
screwdriver in the hole [A]. See
Figure 6-10. 1. Press the red OFF (O) key on the keypad.
Disconnect the battery connector.
2. Remove the hex head cap screw securing
the stem mount cover. See Figure 6-12.
3. Disconnect the wiring harness connector
and arm angle switch connections. See
Figure 6-13.
Cap Screw
A A
Figure 6-10. Lift/Lower Button Removal
2. Unscrew the holder [21] so that the arm

[23] comes loose.
Cover
Changing Push Button [19]
1581 010.tif
1. Press the push button sideways. Figure 6-12. Removing Cover

2. Insert a screwdriver and carefully pry the
button loose. See Figure 6-11.
Wiring Harness
Connector
Arm Angle
Switch
Connections
Figure 6-13. Cover Removed
Figure 6-11. Push Button Removal
3. Unscrew the button’s holder and arm.

Control Handle
Before removing the cap screws in the

next step, make sure you are holding
the handle. When the cap screws are
removed, the handle will fall.
4. Remove the three Allen head cap screws

located at the base of the control handle
stem. See Figure 6-14.
Allen Head
Cap Screws
Figure 6-14. Allen Head Cap Screws
5. Carefully remove the control handle stem

and mount.
Reassembly
1. During reassembly, make sure that the
brake release cam assembly is in the
correct position before installing.
2. Position the control handle mounting base
on the pivot assembly.
3. Reinstall the three Allen head cap screws.
4. Thread the wiring harness through the
handle base.
5. Reattach the control handle head unit if
removed.
6. Reconnect the handle harness connector
and arm angle switch connections. Install
the cable ties in their original locations on
the handle harness.
7. Install the control handle cover.
8. Connect the battery connector. Press the
green ON (I) key on the keypad.
9. Test the operation of the truck.

Horn
Horn
to Parts Catalog.
Removal
2. Remove the tractor cover.
3. Disconnect the two wires from the horn.
See Figure 6-15.
Horn
1665 031.tif
Figure 6-15. Horn Location
4. Remove the horn mounting bolt.
Installation
1. Attach the horn to the electrical panel and
tighten the mounting bolt.
2. Attach the two wires.
3. Reconnect the battery connector, press the
green ON (I) key on the keypad, and test
operation.
5. Install the tractor cover.
6. Reconnect the battery connector.

Power Amplifier
Power Amplifier Removal

NOTE: For replacement parts information refer and disconnect the battery connector.
to Parts Catalog.
The power amplifier is installed in the tractor 3. Discharge the capacitors in the power
compartment. See Figure 6-16. amplifier by connecting a load (such as a
contactor coil or a horn) across the power
amplifier’s B+ and B– terminals.
4. Push the locking tab and disconnect the
J5 connector from the power amplifier. See
Figure 6-16.
5. Disconnect the three power cables
(terminals B+, B– and M–) on the power
amplifier. Do not stress the power cable
Power
connections. Disconnect wiring harness
Amplifier
connectors (terminals F1 and F2).
J5 Connector
6. Remove the three hex head cap screws
securing the power amplifier to the
electrical panel. Remove the power
1665 031.tif
amplifier.
Figure 6-16. Power Amplifier Location
Installation
NOTE: All power amplifiers are preset to factory
default specifications.
Do not open the power amplifier.
Opening the power amplifier could 1. Secure the power amplifier to the electrical
damage it and will void the warranty. panel with the three previously removed
hex head cap screws.
Cleaning 2. Reconnect the three power cables
(terminals B+, B– and M–) on the power
1. Press the red OFF (O) key on the keypad amplifier. Torque screws to 12 ft. lb.
and disconnect the battery connector. (16.3 Nm) maximum. Do not stress the
2. Remove the tractor cover. cable connections and put strain on
3. Discharge the capacitors in the power internal components.
amplifier by connecting a load (such as a 3. Connect the J5 connector and wiring
contactor coil) across the power amplifier’s harness connectors (terminals F1 and F2)
B+ and B– terminals. to the power amplifier.
4. Clean the power amplifier with a moist 4. Connect the battery connector and press
rag. Let it dry before connecting the the green ON (I) key on the keypad.
battery. 5. Test operation of the truck.
5. Make sure the power cable connections 6. Press the red OFF (O) key on the keypad.
are tight. Do not stress the cable
connections or put strain on internal 7. Install the tractor cover.
components.

Contactors
Contactors 4. Install the tractor cover.

5. Connect the battery connector. Press the
NOTE: For replacement parts information refer green ON (I) key on the keypad.
to Parts Catalog. 6. Test the operation of the truck.
Contactors (K10 and K30) control the

transmission of battery power to the drive and
Lift Motor Contactor
lift motors.
Main Contactor Lift Motor

Contactor
Removal
3. Disconnect the wires from the X and Y
terminals on the contactor coils. See
Figure 6-17.
4. Remove the nuts securing the bus bar and Figure 6-18. Lift Motor Contactor K30
cables to the contactor. Note the location
for assembly later. See Figure 6-17. See “Hydraulic Components” on page 6-47.
5. Remove the two screws holding the
contactor assembly to the electrical panel.
X and Y
Terminals
Bus Bar
Figure 6-17. Main Contactor K10
Installation
1. Secure the contactor to the electrical panel
with the two screws removed earlier.
2. Secure the bus bar and cable to the
contactor with the nuts.
3. Connect the wires to the X and Y
terminals.

Master Control Relay

The master control relay (K4) should be
regularly tested for correct operation.
Inspection/Test
2. With the battery connected, press the
3. Use a voltmeter to check the voltage
between wire #26 (terminal 4) and wire
#24 (terminal 2).
Wire #26 Wire #24
1665 031.tif
Figure 6-19. Master Control Relay
The voltmeter should read approximately

24V.
4. Move the control handle down into the
operating position. The voltmeter should
now read 0V. If not, replace the master
control relay.


Switches (General)
Inspection
Switches (General)
1. With the battery plugged in and the Main

NOTE: For replacement parts information refer ON/OFF switch in the ON position, battery
to Parts Catalog. voltage B+ must be present on the two
terminals of the switch.
Refer to the schematic in the Appendix to 2. Test the Main ON/OFF switch with an
identify the electrical circuit location of the ohmmeter after disconnecting the battery
switch. See “Schematics” on page A-9. and removing the wires from the switch
terminals.
Test/Inspection In the OFF position, the ohmmeter must
read greater than 1 megohm, and in the
Examine the switch for signs of arcing, ON position, the ohmmeter must read less
overheating, discoloration, cracking, or other than 1 ohm. If not, replace the switch.
physical damage. Replace the switch if you see
such damage.
Removal
To test a switch, isolate it from the electrical 1. Disconnect the battery connector.
circuit. Do this by removing all the connections 2. Remove the tractor cover.
from the switch, making sure all wires are
labeled and identified for later reconnection. 3. Disconnect the wires from the switch.
4. Remove the Main ON/OFF switch.
Use an ohmmeter set to a low resistance scale
to measure the resistance across the switch. In Installation
the closed position, the switch must have a
resistance of less than 1 ohm. In an open 1. Install the new Main ON/OFF switch.
position, the switch must show a resistance 2. Connect the wires to the new Main
greater than 10 megohms. ON/OFF switch terminals.
3. Reconnect the battery connector and verify
Main ON/OFF Switch operation.
A Main ON/OFF switch (S21) is provided on the
truck. In the OFF (O) position, battery power to
all control functions is interrupted. In the ON (I)
position, battery potential is provided to all
control functions via the power amplifier. See
Figure 6-20.
Main ON/OFF
Switch
1581 004.tif
Figure 6-20. Main ON/OFF Switch Location

Switches (General)
Arm Angle Switches

S24 and S25 determine brake activation and
truck travel speed. Each switch is activated by
the control handle position. The control handle
must be positioned between 5° of vertical and 5°
of horizontal in order for the switches to be
closed, permitting travel.
Adjustment
The arm angle switches are found at the base of Screws

the control handle stem. See Figure 6-21. 1581 008.tif
1. Press the red OFF (O) key on the keypad. Figure 6-22. Arm Angle Switch Screws
5. Slide the switch back in until the switch
“clicks.” Move the switch out (approx.
1/32 in. [0.7 mm]) until it “clicks” again.
Retighten the screws.
Use extreme care when the truck is
6. Make sure that the cam arm makes solid
contact with the switch lever.
After the truck is jacked, DO NOT rely on 7. Verify that the switch “clicks” near the
the jack alone to support the truck. For middle of the cam movement.
details, See “Jacking Safety” on 8. Switch S25 must operate within 5° of the
page 2-9. full up or down handle position. Make
sure the switch does not bottom out when
2. Jack the truck and block the frame. fully compressed.
9. Install the stem mount cover. See
Figure 6-23.
Arm Angle Switches
1581 007.tif
Figure 6-21. Arm Angle Switches
3. Remove the stem mount cover. Figure 6-23. Control Handle Cover Installed
4. Loosen the two screws holding the bracket 10. Remove the blocks, connect the battery
on the stem mount. Slide the bracket out connector and press the green ON (I) key
as far as possible. See Figure 6-22. on the keypad.

Switches (General)
Removal Lift-Limit Switch

1. Lower the forks completely.
When the forks are fully raised, the lift-limit
2. Press the red OFF (O) key on the keypad. switch (S36) turns the hydraulic pump motor
Disconnect the battery connector. off. This keeps the pump from trying to extend
3. Remove the stem mount cover. the lift cylinder beyond its maximum travel. See
Figure 6-24.
4. Disconnect the wires on the switch.
5. Remove the mounting bracket from the
stem mount.
6. Remove the screws holding the switch on Lift-Limit Switch
the mounting bracket.
7. Remove the switch.
Installation
1. Mount the switch to the mounting bracket.
2. Connect the wires to the switch.
3. Install the mounting bracket. 1581 014.tif
4. Reconnect the battery connector. Press the Figure 6-24. Lift-Limit Switch
5. Test drive the truck. Adjustment
6. Adjust the switch if necessary. 1. Raise the forks until they reach their fully
7. Press the red OFF (O) key on the keypad. raised position. If the lift-limit switch does
Disconnect the battery connector. not shut the pump down when the lift
cylinder reaches its upper limit, the relief
8. Install the stem mount cover. valve on the hydraulic pump will make a
9. Reconnect the battery connector. high-pitched squeal, indicating that the
relief valve is opening.
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 the fully raised position.
4. Tighten the bolt.
5. Reconnect the battery connector. Press the
green ON (I) key on the keypad. Lower the
forks and then lift them until they reach
their fully raised position. The lift-limit
switch must 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.

Switches (General)
Key Switch (Optional)

A two-position (ON/OFF) key switch (S17),
located on the main console, energizes all truck
control functions when in the ON position,
provided the Main ON/OFF switch is in the ON
position.
Inspection
2. With the battery plugged in and the key
switch ON, battery voltage B+ must be
present on the two terminals of the switch.
3. Turn the key switch to OFF, disconnect
the battery and remove the wires from the
switch terminals.
4. Test the key switch for continuity with an
ohmmeter.
In the OFF position, the ohmmeter must
read greater than 1 megohm, and in the
ON position, the ohmmeter must read less
than 1 ohm. If not, replace the switch.

Drive Unit
Drive Unit 5. Remove the three Allen head cap screws

that secure the control handle assembly to

the drive unit assembly. See Figure 6-25.
The drive unit includes the drive motor,
electromagnetic brake assembly, drive wheel,
and transmission assembly.
NOTE: For replacement parts information refer Allen Head
to Parts Catalog. Cap Screws
Transmission Assembly
Removal
1. Lower the forks, press the red OFF (O) key
on the keypad. Disconnect the battery
connector.
1665 045.tif
Figure 6-25. Control Handle Assembly Removal
6. Disconnect the cables/wire from the

Use extreme care whenever the truck is terminal block on the transmission. See
jacked up. Keep hands and feet clear Figure 6-26.
After the truck is jacked, put solid blocks
beneath it to support it. DO NOT rely on
the jack alone to support the truck. For
details, See “Jacking Safety” on
page 2-9.
2. Jack the truck and block the frame.

4. Remove the stem mount cover. Disconnect Terminal Block
the handle harness and arm angle Connections
sensors.
Figure 6-26: Terminal Block
7. Remove the ten Allen head bolts that

secure the transmission and bearing
assembly to the frame.
NOTE: Remove four Allen head bolts to remove
only the transmission but not the steer
bearing.

Drive Unit
Assembly
1. Install the new bearings in the gear case
and cover for the 2nd stage gear set.
Transmission assembly may fall free
from mounting after bolts are removed. 2. Install the new bearings, spacer, and seal
in the gear case for the drive axle.
8. Remove the transmission and steer 3. Place the case in a fabricated assembly
bearing assembly by lowering through the base and carefully press the drive axle in
pivot-frame mount. the gear case.
9. Feed the control wiring harness and power 4. Position the transmission on the work
cables through the transmission pivot bench with the gear case side up. Install
mount. the output gear in the case and secure
with the retaining ring.
Disassembly 5. Install the 2nd stage gear set.
1. After draining the gear case lubricant, 6. Install the drive motor bearing, bearing
thoroughly clean the outside with solvent shim, and seal in the gear case if removed
or other non-corrosive cleaning fluid. Air previously.
dry all parts, and proceed with the
NOTE: The seal must be installed correctly with
disassembly of transmission.
its open side and seal ring positioned
2. Remove the drive wheel. See “Drive Wheel” towards the bearing.
on page 6-31.
7. Carefully slide the drive motor armature
3. Remove the nine hex head cap screws shaft into the gear case if removed
securing the gear case cover. Remove the previously. See “Drive Motor” on
gear case cover. page 6-42.
4. Remove the retaining ring that secures the
top (pinion) gear.
5. Remove the top (pinion) gear and Woodruff
Make sure that the motor end cap is
key attached to the drive motor armature
installed before proceeding to the next
shaft.
step.
6. Remove the drive motor if required. See
“Drive Motor” on page 6-42. 8. Install the pinion gear, woodruff key, and
7. Remove the drive motor bearing, bearing the retaining ring on the armature shaft.
shim, and seal from the gear case if 9. Use gasket eliminator (P/N 990-411) on
required. the mating surface and install the gear
8. Remove the 2nd stage gear set from the case cover. Torque the cover bolts to
gear case. 30 ft. lb. (42 Nm).
9. Remove the retaining ring from the drive
axle then remove the output gear.
10. Press the drive axle through the inner and
outer gear case bearings.
11. Remove the old bearings, spacers, and
seals from the gear case. Thoroughly clean
the case.

Drive Unit
1 9
21
4
5
3 25 20
17
2
16
13
12 19
10 13 11
18
27 7
W08175b.eps
Figure 6-27. Transmission Assembly, Exploded View
Legend:
1 Housing, Gearbox 15 Seal, Motor (not shown)
2 Cover, Gearbox 16 Seal
3 Screw 17 Drive Axle
4 Pinion, Drive 1st Stage 18 Bearing, Sealed
5 Gear Set, 2nd Stage 19 Spacer, Bearing
7 Gear Set, Output 20 Ring, Retaining
9 Bearing, Steering Outer Race 21 Key, Woodruff
10 Plug, Fill/Level 22 Cap Screw, Allen Head
11 Plug, Drain 23 Hub, Wheel (not shown)
12 Bearing, Sealed 25 Axle, 2nd Stage
13 Bearing Set, Cup & Cone 26 Key, Output (not shown)
14 Bearing, Motor (not shown) 27 Ring, Retaining

Drive Unit
Installation Drive Housing Lubrication

Gear Oil Level
Make sure the main ON/OFF switch is 1. Remove the fill/level plug. See
OFF and the battery connector is Figure 6-28.
disconnected before you start.
1. Install the steer bearing assembly if

removed previously.
2. Reinstall the drive unit assembly through Drain Screw
the pivot frame while feeding the harness Fill/Level Plug
and cables through the pivot frame mount.
3. Secure the assembly with the ten Allen
head bolts removed previously.
4. Feed the wire harness and power cables
through the pivot tube.
5. Reconnect the cables/wire to the terminal
block on the transmission.
1665 039.tif
6. Install the drive wheel. See “Drive Wheel”
Figure 6-28. Transmission Assembly Fill/Drain Plugs
on page 6-31.
7. Unblock and lower the truck. 2. Check the oil level. When the truck is level,
8. Install the control handle. the oil must be up to the bottom of the
plug opening.
9. Reconnect the wiring harness.
3. If necessary, add the specified oil through
10. Ensure the drive unit is filled to the the plug opening, but do not overfill.
correct level with gear oil. Install the
fill/level plug. 4. Install the fill/level plug securely.
11. Install the stem mount cover and tractor
cover. Changing Gear Oil
12. Install the battery, reconnect the battery 1. Remove the drain plug from the bottom of
connector and the turn the main ON/OFF the gear housing and permit the oil to
switch ON. Press the green ON (I) key on drain. See Figure 6-28.
the keypad. 2. After the oil has drained completely, flush
13. Check the controls for correct operation. the housing with a suitable solvent and
allow it to drain.
3. Install the drain plug.
4. Fill the drive housing with the specified
gear oil through the fill/level plug opening
in the cover of the transmission.

Drive Unit
Drive Wheel Tire Replacement

NOTE: For replacement parts information refer Any misalignment of the tire and hub while the
to Parts Catalog. tire is being pressed on the hub can cause
damage to the hub. For this reason, chamfers
Removal are 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.
Use extreme care whenever the truck is

To prevent damage, the hub must be
installed on the circular ram with the
chamfered side up.
After the truck is jacked, put solid blocks
beneath it to support it. DO NOT rely on
1. Check the inside surface of the metal
the jack alone to support the truck. For
insert on the new tire. Remove any scaling
details, See “Jacking Safety” on
or rust with sandpaper. Clean the inside of
page 2-9.
the metal insert.
2. Jack and block the truck under the tractor 2. Place a circular ram on the press table.
frame. The length of the ram must be longer than
the width of the old tire to permit complete
3. Remove the five drive wheel mounting
removal of the old tire. The outside
nuts. See Figure 6-29.
diameter of the ram must be small enough
to fit loosely in the insert of the tire but
must be large enough to rest squarely on
Drive
the flat surface on the outer edge of the
Wheel hub. See Figure 6-30.
Nuts (5)
1581 007.tif
Figure 6-29. Drive Wheel Nuts
4. Remove the drive wheel.
tire.pcx
Figure 6-30. Tire Replacement

Drive Unit
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 correct 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 on the wheel. The
chamfered edge must always be the
leading edge when a tire is pressed on the
hub.
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 on 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 step of
the operation. If the tire starts 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. Reinstall the five
drive wheel mounting nuts. Torque to
55 ft. lbs. (75 Nm).

Electromagnetic Brake
Electromagnetic Brake Air Gap Adjustment

The nominal gap between the coil housing and

the pressure plate in the applied position is
to Parts Catalog.
0.008 to 0.010 in. (0.2 to 0.25 mm).
Allow the brake to cool completely
before servicing.
Brake Disc Location Use extreme care whenever the truck is

The electromagnetic brake assembly is from vehicle while jacking the truck.
mounted directly to the drive motor. See After the truck is jacked, Do NOT rely on
Figure 6-31. the jack alone to support the truck. See
“Jacking Safety” on page 2-9.
2. Jack the truck and block the frame.

3. Remove the drive unit cover.
Electromagnetic
Brake 4. Loosen the three 4 mm Allen head brake
assembly mounting bolts. See Figure 6-32.
Air gap Mounting

Adjusting Bolt
Screw 0.008 - 0.010 in.
(0.2 - 0.25 mm)
1581 009.tif
Figure 6-31. Brake Location
Friction Disc Pressure Plate Coil Housing
1665 053.tif
Figure 6-32. Brake Gap Adjustment
5. Turn the adjusting screws while checking

the air gap at several points with a
0.008 in. (0.2 mm) feeler gauge.
6. Tighten the mounting bolts to 50 in. lb.
(5.6 Nm). Recheck the gap with the feeler
gauge.
Publication: 1010183B, Revised: 2/17/05 6-33

Electromagnetic Brake
Friction Disc Replacement 4. Adjust the gap and torque mounting bolts.
See “Air Gap Adjustment” on page 6-33.
Replace the friction disc when its total 5. Install the drive unit cover.
thickness is reduced to 0.20 in. (5.5 mm).
1. Loosen and remove the three 4 mm

mounting bolts and remove the brake coil
assembly. See Figure 6-33.
2. Replace the friction disc on the hub.
Inspect friction plate for wear. Replace the
friction plate if the surface is worn
unevenly.
3. Install the brake coil assembly on the
motor end. Adjust the gap and torque
mounting bolts. See “Air Gap Adjustment”
on page 6-33.
Adjusting Screw (x3) Mounting Bolt (x3)
Friction Disc Brake Coil Assy
Figure 6-33: Friction Disc Replacement
Mechanically Releasing the

Brake
If the brake cannot be electrically released,
perform the following:
1. Remove the drive unit cover.
2. Loosen the three 4 mm Allen head
mounting bolts evenly until the clamping
force on the friction disc is low enough to
allow the truck to roll.
3. Move the truck to the desired location.

Motors, General
Motors, General you must take this into account when

considering brush replacement.
NOTE: For replacement parts information refer 2. Check brush spring tension. See “Drive
to Parts Catalog. Motor Brush Spring Tension” on
page 6-36.
Drive Motor Brush Inspection 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.
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.
MTRBRUSH.tif
Figure 6-34. Drive Motor Brush, Typical Location Replacement

Conduct a partial inspection of the drive motor If one brush needs replacement, always replace
after every 1,000 hours of truck operation. If the entire set of brushes.
you work in an abnormally severe or caustic
environment or if you have a rigorous duty Use only genuine Raymond brushes. Using
cycle, inspect the motor more frequently. another type of brush could damage the
commutator or cause excessive brush wear.
Set up and rigidly adhere to a strict inspection
schedule to obtain the maximum efficiency If the end of the brush is not already contoured
from the electrical equipment. to fit the commutator, use the following
procedure to seat the brush to the commutator:
Each partial inspection of the motor must
NOTE: If the motor commutator is not
include the following:
accessible, form the brush contour
1. Inspect the brushes for wear and for using a brush seating stone.
correct contact with the commutator.
Record the level of wear on the brushes. 1. Move the motor brush springs out of your
This history will give you an indication of way.
whether a brush must be changed or if it 2. Wrap a piece of 00 sandpaper around the
can wait until the next inspection. Refer to commutator. DO NOT use emery cloth to
page 6-36 for acceptable brush length and seat brushes.
general motor information. 3. Move the brushes back down in their
NOTE: Overloading a unit is ultimately reflected holders so that the face of the brushes
in the motor and brush wear; therefore, matches the curve of the commutator.

Motors, General
4. Remove the sandpaper. 7. While gently pulling the scale outward,

5. Blow any dust out of the motor with clean, slowly pull the paper strip in the direction
compressed air at a maximum of 30 psi that the commutator normally rotates.
(207 kPa). 8. When the paper strip starts to move freely,
the spring scale will read the spring brush
tension.
Drive Motor Brush Spring
Tension 9. Refer to the table below for correct spring
tension.
Inspection Minimum Spring

Motor
Brush Length Tension
Disconnect the battery connector. Drive 0.59 in. 20 oz. min.
Motor (15 mm) (568 grams)
2. Remove the drive motor cover.
3. Slide the brush up slightly in its holder.
10. Repeat steps 3 through 9 for the
4. Insert a paper strip between the brush remaining brushes.
face and the commutator. See Figure 6-35.
Motor Commutator
Inspection
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 6-36.
leather
loop Mica Segments
coil spring
NORMAL
Paper UNDERCUT
High Mica
TENSION.tif
Figure 6-35. Motor Brush Spring Tension Inspection

HIGH MICA
5. Place a small leather loop around the coil 1881 003.tif
spring for the brush. If the brush spring Figure 6-36. Mica Inspection
has a loop at the brush, hook the spring
scale directly to the spring. The commutator must be smooth and clean to
6. Attach a 5 lb. (2.27 kg) spring scale to the provide maximum brush wear. When
leather loop. commutators are not correctly maintained,
carbon dust can collect in the grooves between
the segments. This can lead to a short circuit in
the armature.

Motors, General
Good commutation is indicated by a dark If the commutator appears rough, pitted, or has
brown polished commutator and an evenly signs of burning or heavy arcing between the
polished brush wearing surface. See Table 6-1, commutator bars, remove the motor for
“Commutator Surfaces.” servicing.
Table 6-1: Commutator Surfaces
Condition Probable Cause Commutator Surface
Good Condition-Light Uniform coloring indicates satisfactory

Film operation of machine and brushes. Film
color is largely an effect of thickness;
therefore, provided the film is uniform, it is
perfectly acceptable.
Satisfactory This is not a good condition but in our

Condition-Light and experience it is known that machines
Dark Pattern having this commutator pattern have
operated with satisfactory results for long
periods of time. This condition can appear
in alternating bars as shown or every 3rd
or 4th bar and so on. This is related to the
winding design of the armature. Difficulty
caused from split windings crossing in the
same slot.
Unsatisfactory Frequently due to under-loaded operation,

Condition-Streaky Film machine grossly over-brushed or brush
With No Commutator grade incorrect for particular machine
Wear application. Atmosphere and
environmental conditions can contribute.
Unsatisfactory Patchy colors of varying densities and

Condition-Uneven Film shape. Due to unclean operating
conditions or incorrect physical condition
of commutator.
Unsatisfactory These areas can be isolated or regular.

Condition- Film With Commutator out of round. This can be
Dark Areas caused by vibration or mechanical
deficiencies in equipment operation,
bearings, couplings, etc.
Unsatisfactory Bars are low on entry and leaving edges

Condition-Example of giving rise to the brushes riding on the
Poor Commutator middle of the bars.
Machining
Unsatisfactory Bars are low in the middle giving rise to the

Condition-Example of brushes riding on entry and leaving bar
Poor Commutator edges. This and the previous illustration
machining indicate the need for better maintenance.

Motors, General
Table 6-1: Commutator Surfaces
Condition Probable Cause Commutator Surface
Unsatisfactory This is a further development of the third

Condition-Streaky Film example. Brush grade, machine
With commutator Wear applications and working environment are
all suspect. Earlier corrective action
should have been taken.
Unsatisfactory Darkening of commutator in sequences two

Condition-Double Pole pole pitches apart is due to armature fault,
Pitch bad coil, riser bars or equalizer
connections.
Unsatisfactory Storage of machines, for lengthy periods,

Condition-Brush with brushes in position. This can also
Contact Mark result from operation of machine in
prolonged stall conditions.
Unsatisfactory Illustration shows high mica in every slot.

Condition-Bar Edge Same effect can occur on one bar only.
Burning-Cause High Similar conditions can be caused by a high
Mica or low bar.
Unsatisfactory Related to over-loaded machines and low

Condition-Small Bright brush pressure. Due to sparking under
Spots brush that gives rise to spots being of a
random distribution. If not corrected, will
result in scored commutator.
Servicing
If the commutator requires service, you will

need to remove the armature from the motor.
DO NOT use a stone to even out high and low

spots on the commutator. Use only a suitable
abrasive rubber polisher.
Servicing a motor for an abnormal commutator

surface condition and high mica or mica
undercutting requires special equipment at a
motor rebuilding facility.

Motors, General
Terminal Nuts Electric Motor Tests

Motor Types
Whenever you disconnect and reconnect any
power leads to a motor, always tighten the • A shunt-wound motor, such as the drive
motor cable securing nuts with a torque wrench motor, has four external connections: two
to prevent over-tightening them and damaging armature (A) and two field (E). See
the motor. Use a second wrench on the stud Figure 6-38.
terminal securing nut to avoid twisting the • A compound motor, such as the lift motor,
stud. See Figure 6-37. has only two external connections because
the armature and field windings are
Terminal connected internally.
Stud
Motor Shunt-Wound Motor

Cable Flat A2 S2/E2/D2
Securing Washer
Nut
Fiber MD
Washer
Stud
Terminal Motor A1 S1/E1/D1
Securing Housing
Nut
Compound Motor
CABLENUT.eps
A
Figure 6-37. Motor Terminal Nuts
Check these torques each time you check motor

MX
brushes.
Stud
Motor Cable
Stud Size Terminal
Securing Nut
Securing Nut
S/D
3/8 in. 100-120 in. lb. 140-160 in. lb. Dschem.eps
(M10) (11.2-13.6 Nm) (15.8-18.1 Nm) Figure 6-38. Motor Circuits
5/16 in. 90-110 in. lb. 110-140 in. lb.

(M8) (10.2-12.4 Nm) (12.4-15.8 Nm) Open Circuit Motor Test
1/4 in. 40-50 in. lb. 50-60 in. lb. An open circuit is one where the electrical
(M6) (4.5-5.6 Nm) (5.6-6.8 Nm) 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
Test using 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.

Motors, General
2. With the motor at room temperature, 4. If the meter indicates high resistance in
connect the leads of a digital ohmmeter the armature, check the condition of the
between the individual circuits in the brushes before replacing the motor.
motor. 5. If an open circuit is found in a compound
3. Observe the measurements given in motor, the motor must be disassembled by
Table 6-2. a motor rebuilding facility to isolate the
problem to the field or armature circuit.
Acceptable
Unacceptable
Motor Terminals Resistance
Resistance Readings
Readings
Traction Armature A1 to A2 0.01 to 0.10 ohms Greater than

(Drive) 0.10 ohms
Field E1 to E2 0.8 - 1.7 ohms Less than 0.5 ohms

(S1 to S2) or Greater than
2.0 ohms
Lift A to S 0.020 - 0.030 ohms Greater than

0.1 ohms
NOTE: Measure all readings at room temperature.

See Figure 6-38 on page 6-39.
Table 6-2: Motor Resistance Readings
Grounded Motor Test If the ohmmeter reads resistance of less than

100,000 ohms, the motor is grounded. Clean,
In a grounded motor, an electrical circuit exists repair or replace the motor as necessary.
between the current-carrying conductors and
the motor housing. This can be caused either by Short-Circuited Winding
direct contact or through conductive foreign
material. A short-circuited winding is one where the
insulation on the field or armature has broken
The ground may be caused by: down at two or more points. The breakdown
• Insulation breakdown creates a low resistance path, permitting
current to flow from one turn of the coil to
• Brush leads touching the motor housing
another adjacent coil turn, without actually
• Build-up of carbon dust or other materials flowing through the coil wire. The result is a
decrease in total resistance of the motor
To test a motor for grounds: winding and an increase in the current flow.
The severity of the short circuit depends on its
Isolate the motor from the truck circuit by location.
removing the power cables. Use two wrenches
to avoid twisting the terminal studs. A shorted motor may be indicated by:
• Slow or sluggish operation
Attach one lead of a digital ohmmeter to a motor
terminal and the other lead to an unpainted • Running faster than normal
surface of the motor housing. Set the ohmmeter • Overheating
to the highest scale.
• Blowing a power fuse

Motors, General
• Severe burning or discoloring on one or

two commutator segments every 90° of
rotation
These symptoms can also be caused by

problems other than the motor itself, such as:
• 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.
Short-Circuited Armature
A short circuit in the armature will cause

heating, and 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.

Drive Motor
Drive Motor 5. Remove the electromagnetic brake

assembly by removing the three mounting
bolts that secure the assembly to the
NOTE: For replacement parts information refer motor end bell cover.
to Parts Catalog.
6. Remove the brake disc from the brake
hub.
Brush Replacement
7. Remove the retaining ring that secures the
1. Press the red OFF (O) key on the keypad. brake hub. Remove the hub and woodruff
Disconnect the battery connector. key.
2. Remove the tractor covers. 8. Remove the four screws and lock washers
3. Remove any shields around the motor end holding the brush end bell to the housing.
cover to expose the brushes. See 9. Separate the end bell from the motor
Figure 6-39. housing. The armature will come out with
the end bell.
10. To remove the end bell from the armature,
remove the snap ring that holds the
Brush bearing in the end bell. If needed, press off
Shield the bearing and replace.
Installation
1. Thoroughly clean all parts with solvent or
other non-corrosive cleaning fluid. Air dry
all parts.
NOTE: Assemble the drive motor in a dirt-free
area.
Figure 6-39: Drive Motor Brush Shield
2. If previously removed, install the drive
4. Lift the spring off the brush, pull the motor bearing, bearing shim, and seal in
brush out of the holder. the gear case.
5. Follow the brush replacement NOTE: The seal must be replaced any time the
instructions. See “Drive Motor Brush motor is removed from the housing.
Inspection” on page 6-35. The seal must be installed correctly with
6. Replace the shields around the motor end its open side and seal ring positioned
that were removed in step 3. towards the bearing.
Motor Disassembly 3. Reinstall the end bell cover, with the brush
plate attached, on the motor armature
1. Press the red OFF (O) key on the keypad. shaft.
4. Carefully slide the drive motor armature in
2. Remove the tractor covers. the motor housing.
3. Disconnect the power cables from the 5. Attach the end bell cover to the motor
terminal block on the drive motor, noting housing with the four cap screws.
their correct position. 6. Install the pinion gear, woodruff key, and
4. Follow steps 1 through 5 in “Disassembly” the retaining ring on the armature shaft.
on page 6-28 to remove the top (pinion)
7. Use gasket eliminator (P/N 990-411) on
gear attached to the motor armature shaft.
the mating surface and install the gear
case cover.

Drive Motor
8. Make sure the drive unit is filled to the

correct level with gear oil. Install the
fill/level plug. See “Drive Housing
Lubrication” on page 6-30.
9. Install the brake hub and woodruff key
then secure with the retaining ring.
10. Install the brake disc on the hub.
11. Install the brake coil assembly and attach
with three hex head cap screws.
12. Reattach the power cables and
electromagnetic brake wiring connections
to the terminal block.
13. 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.
14. Install the battery, reconnect the battery
connector and the turn the main ON/OFF
switch ON. Enter your PIN-key code then
press the green ON (I) key on the keypad.

Drive Motor

Pallet Forks and Load Wheels
Pallet Forks and Load position with a plastic mallet. Make sure
the bearing is fully seated in the load

Wheels wheel.
8. Align the wheel with the holes in the load
NOTE: For replacement parts information refer arm casting.
to Parts Catalog. 9. Drive the axle through the load arm
casting and wheel. Align the “dimple” in
Load Wheels the axle with the set screw hole.
10. Install and tighten the set screw.
Load wheels are installed on each pallet fork
and are designed to support the rated load at Load Wheel Pull Rod
the forks fully raised height.
Load wheel pull rods are installed on each fork
Removal and Replacement and are designed to transfer the hydraulic
cylinder lifting action at the tractor end to the
1. Lift the forks to maximum height and
load wheel fork.
block them. See “Jacking Safety” on
page 2-9.
Removal and Replacement
2. Remove the axle set screw. See
Figure 6-40. 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. Remove the
set screw and shaft connecting the wheel
fork to the pallet fork. See Figure 6-41.
Axle Set
Screw
27y7s173.tif
Figure 6-40. Removing Set Screw

Wheel fork
3. Drive the axle out of the load arm casting Set Screw
with a hammer and brass drift pin.
4. Push the wheel out.
Figure 6-41. Wheel Fork Set Screw Location (top view)
5. If the bearings are to be reused, insert a
brass drift pin into each end of the load
2. Remove the pivot pin locking bolt and
wheel and knock the bearings out.
drive the pivot pin out with a brass drift
6. Install the bearings in the new load wheel pin.
with the shields facing out.
3. With the lower links out of the lift frame
7. Place the new load wheel upright on a flat channels, the links can be separated and
surface. Position the bearing over the load the pull rod removed from the link pin.
wheel. Put a flat metal plate over the Each link has one set screw at opposite
bearing, and hammer the bearing in

Pallet Forks and Load Wheels
ends. The link can be pulled apart without

removing any other set screws.
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

to Parts Catalog.
The bushings on the lower 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 battery connections before
removing the links.
2. Remove the upper and lower linkages and
lift the lift frame off the carrier frame. See
Figure 6-42.
Figure 6-42: Lower Links

Hydraulic Components Manually press down on the cylinder after

the forks come to rest on the blocking to

disengage the cylinder from the tractor
NOTE: For replacement parts information refer frame. See Figure 6-43.
to Parts Catalog.
General Guidelines
To prolong the life of your Raymond Walkie
Pallet Truck, follow these guidelines:
• Keep all fittings and connections tight to
prevent leaks. Do not 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 Hydraulic
cleaning solvent to prevent foreign matter Cylinder
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 1665 033.tif
outside of the threads before you reinstall Figure 6-43. Hydraulic Cylinder (shown extended)
the fitting. (Do not use Teflon® tape.) Make
sure all parts are clean. 5. Press the red OFF (O) key on the keypad.
• When you install a hose assembly, make Disconnect the battery connector.
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. Hot oil under pressure is present. Make
sure truck is safely blocked and
pressure is released.
Hydraulic Cylinder
6. Thoroughly clean the outside of the
Fluid leakage indicates that the seal is worn. cylinder before removing the hydraulic
Replace the seal, wiper, and retaining ring (Seal hose. Remove the hose from the cylinder.
Kit P/N 939-028) when fluid leakage becomes Cap and plug the fittings. See Figure 6-44.
excessive.
Cylinder Removal
Hydraulic
1. Remove the tractor cover. Line
2. Press the green ON (I) key on the keypad.

Leave the control handle in the neutral
(vertical) position.
3. Press the lift button, raise the forks to
maximum height and block them. See
“Jacking Safety” on page 2-9.
4. Lower the forks on the blocking to release 1665 041.tif
pressure on the hydraulic cylinder. Figure 6-44. Removing Hydraulic Line from Cylinder

NOTE: Catch hydraulic fluid under the Cylinder Assembly

hydraulic cylinder in a suitable
container. 1. Make sure all parts are cleaned and dried
thoroughly. Lightly oil all metal parts
7. Lift the cylinder up and out of the tractor before reassembly.
frame. Some spillage of hydraulic oil may
2. Install new seal in the barrel. Install new
occur.
wiper in the barrel with lips facing inward.
Cylinder Disassembly 3. Install new retaining ring in deep groove of

the piston rod end.
1. Thoroughly clean the outside of the 4. Oil outside of piston rod and carefully
cylinder. insert rod into barrel.
2. Pull the rod out until the end of the rod 5. Push rod into barrel until the retaining
and the retaining ring are visible through ring is seen through the inlet port.
the inlet port. See Figure 6-45.
6. Insert a screwdriver into the inlet port and
3. Insert a screwdriver into the inlet port and slide the retaining ring into the lock
slide the retaining ring into the deep position.
groove in the piston rod assembly.
7. Extend rod to full out position to make
4. Remove the rod assembly from the barrel. sure the retaining ring is locked in place.
5. Remove the retaining ring from the piston
rod. Cylinder Installation
6. Remove the wiper and seal from inside the
1. Place the new cylinder into position in the
barrel assembly.
tractor frame.
NOTE: To prevent air from filling the cylinder,
Inlet Port install the cylinder with the rod
retracted.
2. Connect the hydraulic hose.
3. Reconnect the battery connector and press
the green ON (I) key on the keypad.
Barrel
4. Press the lift button to extend the cylinder.
Wiper
5. Check the hydraulic reservoir fluid level. If
Seal necessary, add fluid. See “Lubrication
Equivalency Chart” on page A-2.
Retaining Ring Rod
6. Remove the blocking. Lift and lower the
Figure 6-45. Hydraulic Cylinder Disassembly forks several times. Look for leakage
around the fittings and cylinder seal.
Cylinder Inspection 7. Recheck the hydraulic reservoir fluid level.
If necessary, add fluid.
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.

Hydraulic Solenoid 4. Connect the wires to the terminals.

5. Reconnect the battery connector and press
The hydraulic solenoid activates the hydraulic the green ON (I) key on the keypad. Test
solenoid release valve that releases pressure on the functions of the truck.
the lift cylinder, lowering the forks. See 6. Press the red OFF (O) key on the keypad.
Figure 6-46. Disconnect the battery connector.
Hydraulic Unit
Draining and cleaning the hydraulic reservoir is
important to control the accumulation of
condensation and contamination that can
damage the hydraulic system.
Condensation is caused by the repeated heating

and cooling of hydraulic fluid during normal
Hydraulic Solenoid operation. Contaminants include dirt, rust,
scaling and products of fluid deterioration.
1665 033.tif
Figure 6-46. Hydraulic Solenoid Removal

Removal Remove the hydraulic unit from the truck in
order to separate the pump from the motor.
1. Make sure that the forks are fully lowered.
1. Lower the forks completely.
Disconnect the battery connector. 2. Press the red OFF (O) key on the keypad.
Disconnect the battery connector. Remove
3. Remove the two wires from the terminals
the tractor cover.
on the solenoid.
3. Remove and tag all wires and cables
4. Remove the nut holding the solenoid coil
connected to the pump motor. See
to the solenoid valve.
Figure 6-47.
5. Lift the solenoid coil off the solenoid valve
4. Remove and cap the hydraulic line from
stem.
the hydraulic unit. Disconnect the
6. Remove the solenoid valve stem from the solenoid control wires.
manifold.
5. Remove the bolts that attach the hydraulic
unit mounting bracket to the tractor
Installation frame.
1. Inspect the seat where the solenoid valve 6. Remove the hydraulic unit from the truck.
stem seals against the manifold. The
sealing surface must be completely clean
and free from any nicks or damage.
2. Thread the solenoid valve body into the
manifold. Torque the valve body to 204 to
240 in. lbs (23 to 27 Nm).
3. Install the solenoid coil and tighten the
nut. Torque the nut to 48 to 60 in. lbs (5 to
7 Nm).

9. Check the hydraulic fluid level in the

reservoir.
Pump Motor
Lift Motor
Solenoid
Adapter Body
(Pump)
Hydraulic
Solenoid
Fill/Vent
Plug
Hydraulic
Reservoir
1665 040.tif
Figure 6-47. Hydraulic Unit
Installation
1. Install the hydraulic unit on the tractor
frame and attach 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. (25.4 mm) below
the filler plug elbow. Use up to 0.8 qt.
(0.75 liters). See Figure 6-47.
4. Install the vent plug. See Figure 6-47.
5. Connect all wires and cables to the pump
motor switch and hydraulic solenoid.
6. Connect the battery connector and press
the green ON (I) key on the keypad.
7. Raise and lower the forks. Check all hoses
and fittings for leaks.
8. Lower the forks.

Hydraulic Reservoir 4. From the pump side, blow dry with clean,
dry compressed air.
Removal
1. Remove the hydraulic unit from the truck. Filter
See “Removal” on page 6-49. Screen
2. Remove the hose clamp that secures the
hydraulic reservoir to the adapter housing.
3. Tap the reservoir lightly to loosen. Wiggle
the reservoir sideways while pulling up on
the pump and motor at the same time to
remove. Inlet
4. Remove the reservoir and correctly dispose Tube
of the old hydraulic fluid.
27y7s158.tif
5. After the fluid has drained, flush the
Figure 6-48. Cleaning Filter Screen
inside of the reservoir with a suitable
cleaning solvent.
Installation
6. Dry the inside of the reservoir with clean,
dry compressed air. 1. Inspect the filter screen and inlet tube for
defects. Replace if necessary.
Installation 2. Install the inlet tube sealing washer and
fitting in the pump housing. Torque to 245
1. Inspect the reservoir O-ring and the inside to 275 in. lbs. (27 to 31 Nm).
leading edge for burrs. Replace if
necessary. 3. Install the hydraulic reservoir. See
“Hydraulic Reservoir”.
2. Lubricate the O-ring (with applicable
hydraulic fluid) and install the O-ring.
3. Carefully install the reservoir on the
Hydraulic Pump
adapter housing and attach with hose NOTE: For replacement parts information refer
clamp. Torque clamp to 48 to 60 in. lb. to Parts Manual.
(5.5 to 7 Nm).
4. Install hydraulic unit in the truck. See Removal
“Installation” on page 6-50.
1. Remove the hydraulic unit from the truck
and put on a clean bench for disassembly.
Filter Screen and Inlet Tube See “Hydraulic Unit” on page 6-49.
1. Remove the reservoir. See “Hydraulic 2. Remove the reservoir to gain access to the
Reservoir”. pump. See “Hydraulic Reservoir” on
2. With the pump assembly inverted, page 6-51.
unthread and remove the inlet tube fitting 3. Remove the inlet tube with the filter screen
and sealing washer from the pump from the pump housing.
housing. 4. Remove the two pump mounting bolts
3. Clean the filter screen at the bottom of the then remove the pump from the adapter
inlet tube with a suitable solvent. See body.
Figure 6-48.

Installation 4. Rotate the pump or the motor shaft to

align the motor shaft correctly with the
1. Stand the motor assembly on end, with coupling.
the adapter body facing up.
5. Install the new motor on the adapter body.
2. Lubricate the O-ring and install on the Rotate the pump or the motor shaft if
adapter body facing up. necessary to allow the motor to contact the
3. Insert the pump drive coupling on the end adapter body.
of the motor armature shaft and fill the 6. Insert the screws into the motor end plate,
cavity with lubricant (P/N 990-638). through the motor and into the adapter
4. Align the splines on the motor drive and body.
pump shaft. Gently push the pump pilot 7. Make sure the motor is mating flush with
on the adapter. the adapter body. Torque screws to 36 to
5. Secure the pump with the two pump 45 in. lb. (4 to 5 Nm) maximum.
mounting bolts and torque to 40 to 8. Install the start solenoid.
45 in. lb. (4.5 to 5 Nm).
9. Install the hydraulic unit. See “Hydraulic
6. Check the inlet screen for clogging. Clean Unit” on page 6-49.
with a suitable solvent. Install the inlet
tube fitting into the pump. Torque fitting
to 245 to 275 in. lb. (27 to 31 Nm).
Brush Replacement
7. Install the reservoir. See “Hydraulic Brush Replace brushes when they have
Reservoir” on page 6-51. Replacement worn to the minimum length of
0.35 in. (9 mm).
Lift Motor Spring Adjust the spring tension of new

Tension brushes to 32 to 40 oz. (908.8 to
1136 gm).
Removal
1. Remove the hydraulic unit from the truck. 1. Remove lift motor from hydraulic assembly
See “Hydraulic Unit” on page 6-49. before inspecting brushes.
2. Remove the two bolts from the end plate 2. Remove the two screws from the motor end
that attach the motor to the adapter body. cover. Remove end cover to access
3. Separate the motor and the adapter body. brushes.
4. Remove the start solenoid from the side of 3. Push each brush back into holder to
the motor housing for later reuse. disengage springs. Remove nuts and
washers from side of drive end head.
Installation Remove brush assembly then replace each
brush and replace with a new one.
1. Stand the pump assembly on end, with
the adapter body facing up.
Hydraulic Fluid
2. Set aside the pump drive coupling for later
reuse.
Correct Level
NOTE: The coupling is the mechanical
connection between the pump shaft and To prevent air from entering the lines, fill the
the electric motor armature shaft. It fluid level (with the forks fully lowered) to within
may have been removed with the motor. 1 in. (25.4 mm) below the fill port elbow. See
Figure 6-43. The usable reservoir capacity is
3. Insert the pump drive coupling on the end
0.8 qt. (0.75 L). Add the specified fluid if
of the pump shaft and fill coupling cavity
necessary. See “Lubrication Equivalency Chart”
with lubricant (P/N 990-638).
on page A-2.

Changing Fluid 8. Press the red OFF (O) key on the keypad.
Store and handle the hydraulic fluid with 9. Reconnect the lift cylinder hose.
extreme care to prevent moisture and foreign
10. Remove the vent plug and fill the reservoir
matter from entering the hydraulic system.
to within 1 in. (25.4 mm) below the filler
port elbow with the recommended
Contaminated hydraulic fluid is the major
hydraulic fluid. See “Lubrication
cause of hydraulic system failures. Keep any
service equipment, such as containers, funnels,
and hand pumps, clean at all times. Cover them 11. Replace the vent plug.
when not in use. 12. Connect the battery connector and press
1. Lower the forks. the green ON (I) key on the keypad.
2. Press the red OFF (O) key on the keypad. 13. Raise and lower the forks several times to
Disconnect the battery connector. purge air from the system.
3. Remove the upper tractor cover. 14. Install the upper tractor cover.
4. Disconnect the lift cylinder hose at the 15. Dispose of the waste fluid correctly.
hydraulic cylinder. See Figure 6-49.
Adjusting Hydraulic Pump
Pressure Relief Valve
Lift Cylinder
Hose The hydraulic system is protected by a relief
valve installed in the adapter body. The relief
valve is set by the manufacturer to open at a
specified pressure.
Relief Valve Settings
Pressure Settings
Truck Capacity
PSI kPa
1665 040.tif 4,500 lb. (2,041 kg) 3,000 20,684

Figure 6-49. Hydraulic Connections
Table 6-3: Truck Pressure Levels
5. Insert the hose in a waste fluid container.
Check Setting
1. Attach a jumper wire across the terminals
of the lift-limit switch so the switch will
Fluid is under pressure and may spray
not shut the pump down when the forks
or splash. Point hose away from your
reach their upper limit.
body and hold firmly in waste fluid
container. 2. Retract the lift cylinder completely. Press
the red OFF (O) key on the keypad.
6. Connect the battery connector and press Remove the 90° elbow. Replace the elbow
the green ON (I) key on the keypad. with a female run tee with a 1/8 in. NPT
0 to 3,500 psi (0 to 24131 kPa) pressure
7. Run the hydraulic pump by pressing the
gauge. See Figure 6-50.
lift button until all the hydraulic fluid is
pumped from the system.

7. Remove the pressure gauge. Replace the

elbow.
Raise the forks. Inspect all hoses and
fittings for leaks.
9. Adjust the lift-limit switch to shut down
the pump when the forks reach their
upper limit. See “Lift-Limit Switch” on
page 6-25.
Hydmtrpm.tif
Figure 6-50. Checking Relief Valve Pressure

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.
Adjust Setting
If the relief valve opens at a lower or higher

pressure than the specified pressure, adjust the
relief valve as follows:
1. Remove the hex cap covering the relief
valve adjustment screw.
2. As you depress the lift button, turn the
adjusting screw inward to increase the
pressure setting or outward to decrease
the pressure setting.
3. Check the indicator on the pressure
gauge. After the relief valve is correctly set,
release the lift button.
4. Reinstall the hex cap. Torque to 144 to
180 in. lb. (16 to 20 Nm).
5. Recheck the relief valve setting.
6. Lower the forks completely. Press the red
OFF (O) key on the keypad.

Cold Storage Conditioning
Cold Storage
Conditioning
New Raymond Walkie Pallet Trucks supplied
with a standard conditioning package are
designed to operate in an environment where
temperatures range from 32° to 104°F (0° to
40°C) in a continuous duty cycle.
Trucks supplied with a cold storage

conditioning package are designed to operate in
temperatures to 5°F (–15°C) in a continuous
duty cycle or to –13°F (–25°C) for in and out
operation.
When a truck is installed in a cold storage

environment, change the fluid in the hydraulic
reservoir according to the recommended fluids
listed in the Appendix. See “Lubrication

Cold Storage Conditioning

Model 102XM Maintenance Manual Appendix
Appendix
Publication: 1010183A, Issued: 24 November 2003 A-1

Appendix Model 102XM Maintenance Manual
Lubrication Equivalency Chart
Lubrication Equivalency
Chart
Approved Raymond Lubricants
Where Used Type Specification Raymond Part Number
Drive Unit Gear Case Synthetic 80W - 90 Gear Oil 990-655/001

–25° to +110°F Gear API Service GL-5 (1 quart/0.9 liter)
(–31.5° to +43.3°C) Lubricant 990-655/004
(5 gal./18.9 liters)
Hydraulic Reservoir Hydraulic ISO 46 990-616/04

(non-cold storage trucks) Fluid (1 quart/0.9 liter)
+35° to +120°F 990-616/01
(+1.6° to +48.8°C) (1 gal./3.8 liters)
990-616/02
(2 gal./7.6 liters)
990-616/03
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 with NLGI 2 990-652/001 (Spray)

(Cold Storage) Teflon 990-652/002 (Cartridge)
A-2 Publication: 1010183A, Issued: 24 November 2003

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. lb. in. lb. in. lb. in. lb. in. lb. in. lb.
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. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb.
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-1. Torque Chart - Standard
*NOTE: Use “oiled” values for bolts with thread-locking compound.

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-2. 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-3. Torque Chart - Non-Ferrous Metric

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-4. Decimal Equivalent Chart

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-4. Decimal Equivalent Chart

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

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. lb.) to Newton Meters (Nm) Inch Pounds x 0.113
Newton Meters (Nm) to Inch Pounds (in. lb.) Newton Meters x 8.85

Standard/Metric Conversions
To Convert... Multiply...
Foot Pounds (ft. lb.) to Newton Meters (Nm) Foot Pounds x 1.3568
Newton Meters (Nm) to Foot Pounds (ft. lb.) 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

Model 102XM Maintenance Manual Schematics
Schematics

Schematics Model 102XM Maintenance Manual
1881 002.eps
Figure A-5. Electrical Schematic - Sheet 1 of 2

Model 102XM Maintenance Manual Schematics
1881 002.eps
Figure A-6. Electrical Schematic - Sheet 2 of 2

Schematics Model 102XM Maintenance Manual
1881 002.eps
Lift
Cylinder
Solenoid
Valve
Check Flow Control

Valve
Pressure
Relief
Valve
Motor
Pump
Filter
Reservoir
Figure A-7. Hydraulic Schematic

Model 102XM Maintenance Manual Index
Index
A Definitions . . . . . . . . . . . . . . . . . . . . . . 5-6
Display and Programming
Acceleration . . . . . . . . . . . . . . . . . . . . 5-6 Error Codes . . . . . . . . . . . . . . . . . . 5-9
Anti-Static Kit . . . . . . . . . . . . . . . . . . 2-12 Hourmeter . . . . . . . . . . . . . . . . . . . 5-9
Arm Angle Switches . . . . . . . . . . . . . . 6-24 Part Numbers . . . . . . . . . . . . . . . . 5-20
Drive Housing Lubrication . . . . . . . . . 6-30
Drive Motor
B Brush Inspection/Replacement . . . 6-35
Brush Spring Tension . . . . . . . . . . 6-36
Battery Commutator . . . . . . . . . . . . . . . . . 6-36
Adding Water . . . . . . . . . . . . . . . . . 6-7 Drive Unit
Charging . . . . . . . . . . . . . . . . . . . . 6-6 Brake, Electromagnetic . . . . . . . . . 6-33
Maintenance . . . . . . . . . . . . . . . . . 6-5 Drive Motor
Maintenance-Free . . . . . . . . . . . . . 6-5 Brush Replacement . . . . . . . . . 6-42
Safety . . . . . . . . . . . . . . . . . . . . . . 2-6 Drive Wheel . . . . . . . . . . . . . . . . . 6-31
Specific Gravity . . . . . . . . . . . . . . . 6-7 Lubrication . . . . . . . . . . . . . . . . . . 6-30
Storage . . . . . . . . . . . . . . . . . . . . . 6-8 Transmission Assembly . . . . . . . . 6-27
Voltage Check . . . . . . . . . . . . . . . . 6-7 Drive Wheel . . . . . . . . . . . . . . . . . . . . 6-31
Brake . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Disc Location . . . . . . . . . . . . . . . . 6-33
E
Friction Disc Replacement . . . . . . 6-34
Gap Adjustment . . . . . . . . . . . . . 6-33
Electrical Schematic . . . . . . . . . . . . . . A-10
Electrical Symbols, List of . . . . . . . . . . . 5-8
C Electrical Troubleshooting . . . . . . . . . . 5-3
Electromagnetic Brake . . . . . . . . . . . . 6-33
Cables, Power . . . . . . . . . . . . . . . . . . 6-10 Electrostatic Discharge . . . . . . . . . . . . 2-12
Carrier Frame Linkage . . . . . . . . . . . 6-46 Emergency Reverse . . . . . . . . . . . . . . . . 5-6
Caution and Error Codes . . . . . . . . . . 5-10 Equivalent Chart, Decimal . . . . . . . . . . A-5
Circuit Breaker . . . . . . . . . . . . . . . . . 6-13 Error and Caution Codes . . . . . . . . . . 5-10
Codes, Caution and Error . . . . . . . . . 5-10 Error Codes . . . . . . . . . . . . . . . . . . . . . 5-9
Cold Storage Conditioning . . . . . . . . . 6-55 History . . . . . . . . . . . . . . . . . . . . . . 5-9
Contactors . . . . . . . . . . . . . . . . . . . . 6-20 ESD, See Electrostatic Discharge
Control Handle
Changing Horn Button/Switch . . 6-15
F
Changing Lift/Lower Button . . . . 6-16
Changing Push Button . . . . . . . . 6-16
Disassembly . . . . . . . . . . . . . . . . 6-15 Fault Codes . . . . . . . . . . . . . . . . 5-7, 5-24
Display and Programming . . . . . . . 5-9 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Stem . . . . . . . . . . . . . . . . . . . . . . 6-16
Control Handle Assembly . . . . . . . . . 6-18 G
Conversions, Standard/Metric . . . . . . . A-7
Cover, Tractor . . . . . . . . . . . . . . . . . . . 6-9 Grease Fittings . . . . . . . . . . . . . . . . . . . 4-5
Creep Speed . . . . . . . . . . . . . . . . . . . . 5-6
Current Limiting . . . . . . . . . . . . . . . . . 5-6
H
D Horn . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Decimal Equivalent Chart . . . . . . . . . . A-5
Publication: 1010183B, Revised: 2/17/05 I-1

Index Model 102XM Maintenance Manual
Hydraulic Components M
Cylinder
Assembly . . . . . . . . . . . . . . . . . 6-48 Maintenance
Disassembly . . . . . . . . . . . . . . 6-48 Annually/Every 1500 Hours . . . . . . 4-5
Inspection . . . . . . . . . . . . . . . . 6-48 Daily . . . . . . . . . . . . . . . . . . . . . . . 4-3
Installation . . . . . . . . . . . . . . . 6-48 Every Two Months/250 Hours . . . . 4-4
Removal . . . . . . . . . . . . . . . . . 6-47 Map, Navigating the Manual . . . . . . . . . 1-2
Fluid Master Control Relay . . . . . . . . . . . . . 6-21
Changing . . . . . . . . . . . . . . . . . 6-53 Metric Conversions . . . . . . . . . . . . . . . A-7
Level . . . . . . . . . . . . . . . . . . . . 6-52 Model Identification . . . . . . . . . . . . . . . 3-2
Hydraulic Pump Motor Controller . . . . . . . . . . . . . . . . . . 3-7
Removal/Installation . . . . . . . . 6-51 Undertemperature . . . . . . . . . . . . . 5-7
Hydraulic Reservoir Motors
Installation . . . . . . . . . . . . . . . 6-51 Drive . . . . . . . . . . . . . . . . . .6-35, 6-42
Removal . . . . . . . . . . . . . . . . . 6-51 General . . . . . . . . . . . . . . . . . . . . 6-35
Hydraulic Unit Lift . . . . . . . . . . . . . . . . . . . . . . . . 6-52
Installation . . . . . . . . . . . . . . . 6-50
Relief Valve Adjustment . . . . . . 6-53
Removal . . . . . . . . . . . . . . . . . 6-49 N
Solenoid
Installation . . . . . . . . . . . . . . . 6-49 Neutral Braking . . . . . . . . . . . . . . . . . . 5-6
Removal . . . . . . . . . . . . . . . . . 6-49
Hydraulic Schematic . . . . . . . . . . . . . .A-12 O
Hydraulic Troubleshooting . . . . . . . . . .5-5
Operation
I Directional/Speed Control . . . . . . . 3-5
Lift/Lower . . . . . . . . . . . . . . . . . . . 3-5
Identification, Model . . . . . . . . . . . . . . .3-2 Motor Controller . . . . . . . . . . . . . . . 3-7
Truck Starting . . . . . . . . . . . . . . . . 3-5
Overvoltage Cutoff . . . . . . . . . . . . . . . . 5-7
J
Jacking Safety . . . . . . . . . . . . . . . . . . .2-9 P
Pallet Forks . . . . . . . . . . . . . . . . . . . . 6-45

K
PIN-key code . . . . . . . 5-7, 5-9, 5-19, 5-20
Plugging . . . . . . . . . . . . . . . . . . . . . . . . 5-7
key code . . . . . . . . . . . 5-7, 5-9, 5-19, 5-20 Power Amplifier
Key Switch (Optional) . . . . . . . . . . . . . 6-26 Thermal Cutback . . . . . . . . . . . . . . 5-7
Programmable Maintenance Tool .3-4, 5-26
L Pump, Hydraulic . . . . . . . . . . . . . . . . 6-51
Lift Motor . . . . . . . . . . . . . . . . . . . . . . 6-52 R

Lift-Limit Switch . . . . . . . . . . . . . . . . . 6-25
Adjustment . . . . . . . . . . . . . . . . . . 6-25 Ramp Shape . . . . . . . . . . . . . . . . . . . . 5-7
List of Electrical Symbols . . . . . . . . . . .5-8 Relay, Master Control . . . . . . . . . . . . . 6-21
Load Wheels . . . . . . . . . . . . . . . . . . . . 6-45
Carrier Frame Linkage . . . . . . . . . 6-46
Pull Rod Removal/Replacement . . . 6-45
Removal/Replacement . . . . . . . . . . 6-45
Lubrication Equivalency Chart . . . . . . .A-2
Lubrication, Drive Housing . . . . . . . . . 6-30
I-2 Publication: 1010183A, Issued: 24 November 2003

Model 102XM Maintenance Manual Index
S Troubleshooting
Electrical . . . . . . . . . . . . . . . . . . . . 5-3
Safety Hydraulic . . . . . . . . . . . . . . . . . . . . 5-5
Battery . . . . . . . . . . . . . . . . . . . . . 2-6 List of Charts/Tables . . . . . . . . . . 5-29
Definitions . . . . . . . . . . . . . . . . . . . 2-2 Symptom Tables . . . . . . . . . 5-35, 5-39
General . . . . . . . . . . . . . . . . . . . . . 2-3 Truck Model Identification . . . . . . . . . . 3-2
Jacking . . . . . . . . . . . . . . . . . . . . . 2-9 Truck Specifications . . . . . . . . . . . . . . . 3-2
Static . . . . . . . . . . . . . . . . . . . . . . 2-12
Towing . . . . . . . . . . . . . . . . . . . . . 2-10 U
Welding . . . . . . . . . . . . . . . . . . . . 2-11
Schematics Undervoltage Cutback . . . . . . . . . . . . . 5-7
Electrical . . . . . . . . . . . . . . . . . . . A-10
Hydraulic . . . . . . . . . . . . . . . . . . A-12
V
Sequencing Delay . . . . . . . . . . . . . . . . 5-7
Service Key . . . 3-4, 5-17, 5-18, 5-20, 5-21
Solenoid, Hydraulic . . . . . . . . . . . . . . 6-49 Vehicle Specifications . . . . . . . . . . . . . . 3-2
Special Tools . . . . . . . . . . . . . . . . . . . . 3-4
Programmable Maintenance Tool . . 3-4 W
Service Key . . . . . . . . . . . . . . . . . . 3-4
Specifications, Vehicle . . . . . . . . . . . . . 3-2 Welding Safety . . . . . . . . . . . . . . . . . . 2-11
Speed Limiting . . . . . . . . . . . . . . . . . . 5-7 Wheels
Static Discharge . . . . . . . . . . . . . . . . 2-12 Load . . . . . . . . . . . . . . . . . . . . . . . 6-45
Static Wrist Strap . . . . . . . . . . . . . . . 2-12 Wiring Harness . . . . . . . . . . . . . . . . . . 6-11
Static-Sensitive Components . . . . . . . 2-12 Inspection . . . . . . . . . . . . . . . . . . . 6-11
Strap, Static . . . . . . . . . . . . . . . . . . . 2-12 Wrist Strap . . . . . . . . . . . . . . . . . . . . . 2-12
Switches
Arm Angle . . . . . . . . . . . . . . . . . . 6-24
General . . . . . . . . . . . . . . . . . . . . 6-23
Key Switch (Optional) . . . . . . . . . 6-26
Lift-Limit . . . . . . . . . . . . . . . . . . . 6-25
Main ON/OFF . . . . . . . . . . . . . . . 6-23
Test/Inspection . . . . . . . . . . . . . . 6-23
Symptom Tables
Lift/Lower System . . . . . . . . . . . . 5-35
Travel (Forward/Reverse) System . 5-39
Tests
Electric Motor . . . . . . . . . . . . . . . 6-39
Theory of Operation . . . . . . . . . . . . . . . 3-5
Torque Chart
Metric . . . . . . . . . . . . . . . . . . . . . . A-4
Standard . . . . . . . . . . . . . . . . . . . . A-3
Towing Safety . . . . . . . . . . . . . . . . . . 2-10
Tractor Cover . . . . . . . . . . . . . . . . . . . 6-9
Installation . . . . . . . . . . . . . . . . . . 6-9
Removal . . . . . . . . . . . . . . . . . . . . 6-9
Publication: 1010183B, Revised: 2/17/05 I-3

Index Model 102XM Maintenance Manual
I-4 Publication: 1010183A, Issued: 24 November 2003

Section I. Back Cove
!1010183!
1010183B

Walkie 102 XM MM

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Walkie 102 XM MM

Uploaded by

Copyright:

Available Formats

Walkie Pallet Truck

Publication No: 1010183A Issued: 24 November 2003

To find your local authorized Raymond Dealer, go to www.raymondcorp.com.

©2003, 2005 The Raymond Corporation.

Publication: 1010183B, Revised: 2/17/05 iii

Contactors . . . . . . . . . . . . . . .. . .. .. . .. .. . ... .. .. . .. ... ... .. . 6-20

iv Publication: 1010183B, Revised: 2/17/05

Section 1. How To Use This Manual

Publication: 1010183A, Issued: 24 November 2003 1-1

Map of the Manual

Map of the Manual

How to Use This

Trouble Electrical &

1-2 Publication: 1010183A, Issued: 24 November 2003

Manual Design • “TS1: START TROUBLESHOOTING” on

Publication: 1010183A, Issued: 24 November 2003 1-3

1-4 Publication: 1010183A, Issued: 24 November 2003

START: Why are you here?

List of Troubleshooting Charts

Go to Chart START Troubleshooting

Publication: 1010183A, Issued: 24 November 2003 1-5

To locate an Go to the Index

1-6 Publication: 1010183A, Issued: 24 November 2003

Publication: 1010183A, Issued: 24 November 2003 2-1

Warning means a potentially hazardous

Caution means a potentially hazardous

2-2 Publication: 1010183A, Issued: 24 November 2003

Do not operate or work on this truck unless you

Before working on this truck, always press the

Do not operate this truck if it needs repair or if

Do not wear watches, rings, or jewelry when

Publication: 1010183A, Issued: 24 November 2003 2-3

Do not park this truck in a cold storage area

2-4 Publication: 1010183A, Issued: 24 November 2003

Do not add to or modify this truck until you

Publication: 1010183A, Issued: 24 November 2003 2-5

As a battery is being charged, an

Battery electrolyte is a solution of

Keep the charging area well-ventilated to avoid

2-6 Publication: 1010183A, Issued: 24 November 2003

Press the red OFF key (O) on the keypad before

Do not lay tools or metal objects on top of the

Keep filler plugs firmly in position at all times

Make sure the vent holes in the filler plugs are

Keep batteries clean. Corrosion causes shorts

Publication: 1010183A, Issued: 24 November 2003 2-7

Make sure you install the correct size battery. A

Never plug a battery charger into the truck’s

2-8 Publication: 1010183A, Issued: 24 November 2003

Jacking Safety Tractor Section

Use extreme care when the truck is

Figure 2-1. Blocking the Fork Section

Publication: 1010183A, Issued: 24 November 2003 2-9

2-10 Publication: 1010183A, Issued: 24 November 2003

Flame cutting or welding on painted

coating be removed in the vicinity where

Publication: 1010183A, Issued: 24 November 2003 2-11

Static Safety Wrist straps are available in quantities of 25, as

Accumulated static can be discharged through

Whenever working on or near static-sensitive

The wrist strap and associated accessories

Figure 2-2 shows the components of the

2-12 Publication: 1010183B, Revised: 2/17/05