Professional Documents
Culture Documents
Model 102XM
Serial Number 102-03-00500 - up
Maintenance Manual
If you need assistance with your lift truck, or to order additional copies of this manual, contact your local
authorized Raymond Dealer.
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
Manual Design
Safety
Start Page
Vehicle
Systems
Specifications
Overview
General System
Data
Scheduled
Maintenance
Theory of
Operations
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
Manual Design
Manual Design
START Page
Section 1. How To Use This Manual
START Page
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?
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
startpg2.wmf
Section 2. Safety
Definitions
Definitions
Throughout this manual, you will see two kinds
of safety reminders:
General Safety
General Safety
1864 002.eps
Know the truck’s controls and what they do. 1808 004.eps
1808 002.eps
1864 067.eps
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 use gasoline or other flammable liquids Do not wash this truck with a hose.
for cleaning parts.
General Safety
Battery Safety
Battery Safety
04G6S058.eps
25L6SO16.eps
Battery Safety
Vent Hole
04G6S057.eps
09G6S047.tif
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.
1808 006.eps
Jacking Safety
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.
4. Press the red OFF key (O) on the keypad
and disconnect the battery connector.
27Y7S068.tif
Towing
Towing
To safely tow this truck:
1. Lower the forks and remove any load.
2. Press the red OFF key (O) on the keypad
and disconnect the battery connector.
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
Static Safety
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
Truck Model
Identification
1581 001.tif
Figure 3-1. Model 102XM Pallet Truck
Vehicle Specifications
General Information
General Information
Control Handle
Page 6-14
Special Tools
Special Tools
Programmable Maintenance Service Key
Tool
27y7s021.tif
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.
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–.
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)
Theory of Operation
Maintenance Guidelines
Maintenance Guidelines
Following a regularly scheduled maintenance
program:
• Promotes maximum truck performance
• Prolongs truck life
• Reduces costly down time
• Avoids unnecessary repairs
Maintenance Guidelines
Daily
Perform the daily checks and report any faults
or abnormal conditions to your supervisor.
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.
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.
Maintenance Guidelines
Forks Check the lift-limit switch for lift motor cut-out. Adjust if
necessary.
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.
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.
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.
Maintenance Guidelines
Grease Fittings
Maintenance Guidelines
Section 5. Troubleshooting
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.
Definitions
H1 Horn
K4 Relay Main
M1 Motor Drive
M3 Motor Pump
Y1 Coil Brake
Figure 5-4. Control Handle Display When an error occurs, a code is displayed. See
“Caution and Error Codes” on page 5-10.
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.
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
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.
Service Display
A
E D C B
A
E D C B
F B Figure
G Segments
Service Display
The second most significant figure active The third most significant figure active (marked
(marked with arrow). with arrow).
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
Service Display
Status Comments
16 Passive restraint
10 Regen
Connector
Menu
Navigation
Key
1665 037.tif
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
Section 5. Troubleshooting
Section 5. Troubleshooting
Troubleshooting Flowcharts
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
Gather as much
information as you Eliminate unlikely
What is the problem?
can about the causes.
problem.
Gen1.wmf
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
Section 5. Troubleshooting
Slow Lower
Load Drifting/Settling
Horn Does Not Sound When Horn Button Pushed. No Fault Codes.
C L
P
F
Power Amplifier .................................. 6-19
Fuses ................................................. 6-12
Power Cables ...................................... 6-10
Pump, Hydraulic ................................ 6-51
G
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
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
Battery
Battery
The pallet truck may be equipped with a
multiple (swingout) battery pack or a
maintenance-free battery and charger.
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)
1. Press the red OFF (O) key on the keypad.
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
Battery
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
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.
Battery
Storage
Tractor Covers
Tractor Covers
NOTE: For replacement parts information refer
to Parts Catalog.
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
Installation
Power Cables
Power Cables
NOTE: For replacement parts information refer
to Parts Catalog.
Wiring Harness
Inspection
Fuses
Fuses
NOTE: For replacement parts information refer
to Parts Catalog.
Test/Inspection
1665 031.tif
Circuit Breaker
Circuit Breaker
NOTE: For replacement parts information refer
to Parts Catalog.
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
Control Handle
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
Control Handle
3. Press out the switch from its mounting in Control Handle Stem
the top cover assembly.
NOTE: For replacement parts information refer
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
Arm Angle
Switch
Connections
Control Handle
Allen Head
Cap Screws
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
NOTE: For replacement parts information refer
to Parts Catalog.
Removal
1. Press the red OFF (O) key on the keypad.
Disconnect the battery connector.
2. Remove the tractor cover.
3. Disconnect the two wires from the horn.
See Figure 6-15.
Horn
1665 031.tif
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.
4. Press the red OFF (O) key on the keypad.
Disconnect the battery connector.
5. Install the tractor cover.
6. Reconnect the battery connector.
Power Amplifier
Contactors
X and Y
Terminals
Bus Bar
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.
Inspection/Test
1. Remove the tractor cover.
2. With the battery connected, press the
green ON (I) key on the keypad.
3. Use a voltmeter to check the voltage
between wire #26 (terminal 4) and wire
#24 (terminal 2).
1665 031.tif
Switches (General)
Inspection
Switches (General)
Section 6. Component Procedures
Main ON/OFF
Switch
1581 004.tif
Switches (General)
Adjustment
1. Press the red OFF (O) key on the keypad. Figure 6-22. Arm Angle Switch Screws
Disconnect the battery connector.
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
jacked up. Keep hands and feet clear
contact with the switch lever.
from vehicle while jacking the truck.
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
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.
11. Test the operation of the truck.
Switches (General)
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
green ON (I) key on the keypad.
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.
2. Press the red OFF (O) key on the keypad.
Disconnect the battery connector.
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)
Inspection
1. Remove the tractor cover.
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
Transmission Assembly
Removal
1. Lower the forks, press the red OFF (O) key
on the keypad. Disconnect the battery
connector.
1665 045.tif
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
Drive Unit
1581 007.tif
tire.pcx
Drive Unit
Electromagnetic Brake
1581 009.tif
1665 053.tif
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).
Motors, General
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
Motors, General
leather
loop Mica Segments
coil spring
NORMAL
Paper UNDERCUT
High Mica
TENSION.tif
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
Motors, General
Table 6-1: Commutator Surfaces
Servicing
Motors, General
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
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
Motors, General
Short-Circuited Armature
Drive Motor
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.
Disconnect the battery connector.
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
Drive Motor
Pallet Forks and Load position with a plastic mallet. Make sure
Section 6. Component Procedures
27y7s173.tif
Hydraulic Components
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
pressure on the hydraulic cylinder. Figure 6-44. Removing Hydraulic Line from Cylinder
Hydraulic Components
Hydraulic Components
Hydraulic Unit
Draining and cleaning the hydraulic reservoir is
important to control the accumulation of
condensation and contamination that can
damage the hydraulic system.
Hydraulic Components
Lift Motor
Solenoid
Adapter Body
(Pump)
Hydraulic
Solenoid
Fill/Vent
Plug
Hydraulic
Reservoir
1665 040.tif
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 Components
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.
Hydraulic Components
Hydraulic Components
Changing Fluid 8. Press the red OFF (O) key on the keypad.
Disconnect the battery connector.
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
Equivalency Chart” on page A-2.
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.
Pressure Settings
Truck Capacity
PSI kPa
Hydraulic Components
Hydmtrpm.tif
Adjust Setting
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.
Appendix
Lubrication Equivalency
Chart
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.
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
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
Schematics
1881 002.eps
1881 002.eps
1881 002.eps
Lift
Cylinder
Solenoid
Valve
Pressure
Relief
Valve
Motor
Pump
Filter
Reservoir
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
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
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