PDMM0102 00 093002

Back to START
Maintenance Manual
Model 71B/76 Sideloader Truck
Model 71B - Serial No. 1401 and Up 0REACH.EPS

Model 76 - Serial No. 001 and Up
PDMM-0102 Issued: 9-30-02
Supercedes MM-75 Issued 12/1/81 (Model 76)

Supercedes MM-80 Issued 10/1/83 (Model 71B)
© 2002 The Raymond Corporation
Raymond and Ranger Shelf Height Selector are trademarks of The Raymond Corporation. All other brand and
product names are trademarks or registered trademarks of their respective companies.
Raymond ® Sideloader Maintenance Manual How to Use This Manual
Table of Contents
How to Use This Manual 1:
Table of Contents
Page Revision Record . . . . . . . . . . . . . . . . v Troubleshooting . . . . . . . . . . . . . 6-1
Service Bulletin Index . . . . . . . . . . . . . . . vii Overview . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Product Improvement Notice Index . . . . .viii
General Instructions . . . . . . . . . . . . . . . 6-4
How to Use This Manual . . . . . . . 1-1 List of Troubleshooting Charts . . . . . . . 6-11
Map of the Manual . . . . . . . . . . . . . . . . 1-2 Troubleshooting Procedure . . . . . . . . . 6-13
Manual Design . . . . . . . . . . . . . . . . . . . 1-3 Component Procedures . . . . . . . . 7-1

START Page . . . . . . . . . . . . . . . . . . . . . 1-5 Component Locator Photos . . . . . . . . . . 7-3
Safety . . . . . . . . . . . . . . . . . . . . . 2-1 General Procedures . . . . . . . . . . . . . . . 7-11
Definitions . . . . . . . . . . . . . . . . . . . . . . 2-2 Tire Replacement . . . . . . . . . . . . . . . . . 7-12
General Safety . . . . . . . . . . . . . . . . . . . 2-3 Motors . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Battery Safety. . . . . . . . . . . . . . . . . . . . 2-7 Drive Axle Assembly. . . . . . . . . . . . . . . 7-23
Jacking Safety . . . . . . . . . . . . . . . . . . 2-11 General . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Welding Safety . . . . . . . . . . . . . . . . . . 2-12 Drive Motor

Inspection and Cleaning . . . . . . . . . . 7-25
Systems Overview . . . . . . . . . . . . 3-1 Drive Wheel Replacement. . . . . . . . . . . 7-26
General System Data . . . . . . . . . . . . . . 3-2 Crab Steer Alignment and Adjustment . 7-28
Mechanical Systems . . . . . . . . . . . . . . . 3-3 Drive Axle Removal and Reassembly . . 7-30
Hydraulics . . . . . . . . . . . . . . . . . . . . . . 3-7 Drive Motor Replacement . . . . . . . . . . . 7-32
Electrical . . . . . . . . . . . . . . . . . . . . . . 3-12 Drive Unit Repair and Replacement . . . 7-34
Options . . . . . . . . . . . . . . . . . . . . . . . 3-17 Tie Rod Replacement . . . . . . . . . . . . . . 7-36
Installation . . . . . . . . . . . . . . . . . 4-1 Crab Steer Cylinder Replacement. . . . . 7-36

Steer Axle Assembly. . . . . . . . . . . . . . . 7-37
General . . . . . . . . . . . . . . . . . . . . . . . . 4-2
General . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Chassis Frame . . . . . . . . . . . . . . . . . . . 4-2
Steerable Wheel Replacement. . . . . . . . 7-39
Visual Inspection . . . . . . . . . . . . . . . . . 4-3
Steering Linkage Alignment and
Mast to Tractor Reassembly . . . . . . . . . 4-4
Adjustment . . . . . . . . . . . . . . . . . . . . 7-40
Batteries and Chargers . . . . . . . . . . . . . 4-7
Steer Axle Removal and Reassembly . . 7-41
Scheduled Maintenance . . . . . . . 5-1 Steer Linkage Replacement . . . . . . . . . 7-43
Maintenance Guidelines . . . . . . . . . . . . 5-2 Steer Cylinder Replacement . . . . . . . . . 7-44
Monthly Maintenance . . . . . . . . . . . . . . 5-3 Steer Knuckle Replacement . . . . . . . . . 7-45
Semi-Annual Maintenance . . . . . . . . . . 5-6 Steering . . . . . . . . . . . . . . . . . . . . . . . . 7-47
Annual Maintenance. . . . . . . . . . . . . . . 5-7 Steering Chain Adjustment . . . . . . . . . 7-48
Lubrication and Inspection Points. . . . . 5-8 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . 7-49

Service Brake Adjustment . . . . . . . . . . 7-50
Parking Brake Adjustment . . . . . . . . . . 7-51
PDMM-0102 Issued: 9/30/02 iii

How to Use This Manual Raymond ® Sideloader Maintenance Manual
Table of Contents
Brake Shoe Replacement . . . . . . . . . . 7-52 Battery Controller and K5 Relay . . . . 7-129

Wheel Cylinder Repair or Replacement 7-54 Automatic Steer Centering Relay K11 7-130
Attachment and Load Handler . . . . . . 7-55 Deadman Relay K12 and Light Load
Relay K13 . . . . . . . . . . . . . . . . . . . . 7-131
General . . . . . . . . . . . . . . . . . . . . . . . 7-56
Diode Assemblies . . . . . . . . . . . . . . . 7-132
Mast Tilt Cylinder
Repair and Replacement . . . . . . . . . 7-57 Resistor Assemblies . . . . . . . . . . . . . . 7-135
Fork Tilt Cylinder Suppressor Assemblies . . . . . . . . . . . 7-136
Repair and Replacement . . . . . . . . . 7-59
Theory of Operation. . . . . . . . . . . 8-1
Carriage Reach Cylinder Repair and Re-
placement (SLR20TT). . . . . . . . . . . . 7-60 Overview . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Mast Traverse Motor Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Steering. . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Lift Chain
Lift/Lower . . . . . . . . . . . . . . . . . . . . . . . 8-7
Auxiliary Controls . . . . . . . . . . . . . . . . 8-13
Carriage Roller Bearing Replacement . 7-63
SCR Theory . . . . . . . . . . . . . . . . . . . . . 8-15
Side Cylinder Repacking (TFL and TT) 7-65
Standard Travel. . . . . . . . . . . . . . . . . . 8-17
Lift Cylinder
Repair and Replacement . . . . . . . . . 7-66 Plugging . . . . . . . . . . . . . . . . . . . . . . . 8-26
Lift Cylinder Bleeding . . . . . . . . . . . . . 7-68 Miscellaneous Circuits. . . . . . . . . . . . . 8-28
Mast Assembly Removal . . . . . . . . . . . 7-69 Remote Travel . . . . . . . . . . . . . . . . . . . 8-29
Mast Drive Appendix . . . . . . . . . . . . . . . . . . . A-1
Mast and Telescopic Lubrication Specification Chart . . . . . . . A-2
Roller Bearing Replacement . . . . . . . 7-72 Thread Adhesives, Sealants, and Lubricants
Hydraulics . . . . . . . . . . . . . . . . . . . . . 7-73 A-3
Torque Chart - Standard (Ferrous). . . . . A-4
General . . . . . . . . . . . . . . . . . . . . . . . 7-74
Lift Control and Linkage . . . . . . . . . . . 7-75 Torque Chart - Metric (Ferrous) . . . . . . . A-5
Torque Chart - Standard (Brass) . . . . . . A-6
Hydraulic Manifolds . . . . . . . . . . . . . . 7-78
Electrical . . . . . . . . . . . . . . . . . . . . . . 7-81 Decimal Equivalent Chart . . . . . . . . . . . A-7
General . . . . . . . . . . . . . . . . . . . . . . . 7-82 Standard/Metric Conversions . . . . . . . . A-9

Schematics . . . . . . . . . . . . . . . . . . . . . A-11
Batteries . . . . . . . . . . . . . . . . . . . . . . 7-83
Component Testing . . . . . . . . . . . . . . 7-87 Index . . . . . . . . . . . . . . . . . . . . . . I-1
Contactors . . . . . . . . . . . . . . . . . . . . . 7-88
Controls . . . . . . . . . . . . . . . . . . . . . . . 7-95
Directional/Speed Control Assembly . 7-96
Control Unit . . . . . . . . . . . . . . . . . . . .7-102
SCRs . . . . . . . . . . . . . . . . . . . . . . . . .7-122
Rectifiers . . . . . . . . . . . . . . . . . . . . . .7-125
Plugging Relays
K1 & K2 . . . . . . . . . . . . . . . . . . . . .7-127
iv PDMM-0102 Issued: 9/30/02

Raymond ® Sideloader Maintenance Manual How To Use This Manual
Page Revision Record

1: How To Use This Manual
This page is a record of the latest revised pages

in this manual. When a page is revised, this
section is updated and included in the revision.
This manual replaces:
• MM-80 Model 71B Maintenance
Instructions, dated 10-01-83
• MM-75 Model 76 Maintenance Instructions,
dated 12-01-81
This manual has been completely reorganized
to current formatting standards. See “Map of
the Manual” on page 1-2 and “Manual Design”
on page 1-3 for an explanation of the format
and layout of this manual.
PDMM-0102 Issued: 9/30/02 v

How To Use This Manual Raymond ® Sideloader Maintenance Manual
vi PDMM-0102 Issued: 9/30/02

Service Bulletin Index

Service Bulletin Index

This page lists the Raymond Sideloader Service Bulletins (RSBs) currently in effect.
Document Number Subject Date

SDL-96-001 Model 76 lift ram seal leakage 09-10-96
PDMM-0102 Issued: 9/30/02 vii

Product Improvement Notice Index
Product Improvement Notice Index

This page lists the Raymond Sideloader Product Improvement Notices (RPINS) currently in effect.
Document Number Subject Date

SDL-97-R001 Obsolete Ranger motherboard 01-07-97
SDL-97-R002 Horn failure 02-25-97
SDL-97-R003 Lift/Lower control panel plate 10-16-97
viii PDMM-0102 Issued: 9/30/02

PDMM-0102 Issued: 9/30/02 1-1

Map of the Manual
Map of the Manual

1MAP.WMF
How to Use
This Manual
Trouble-
Table of Contents shooting
Page Revision
Record Component
Procedures
Service Bulletin
& RPIN List
Map of the
Manual
Component
Locator Photos
Manual Design
Component
Procedures by Lift
Start Page Truck System
Theory of
Safety
Operation
Systems
Appendix
Overview
Installation Index
Scheduled
Maintenance
1-2 PDMM-0102 Issued: 9/30/02

Manual Design
Manual Design
The Raymond ® Sideloader Maintenance Manual
is designed to:
• Provide technical coverage for expected
levels of user expertise.
• Anticipate your needs and reduce your
decisions regarding maintenance.
• Reduce page flipping through a “one-stop
shopping” approach.
The two-line page header at the top of each page
identifies the:
• Name of the manual
Raymond ® Sideloader Maintenance
Manual)
• Current chapter title
(for example, this page; How to Use This
Manual)
• Current topic
(for example, this page; Manual Design)
We suggest you get in the habit of turning to the
START page first when you use this manual.
The START page asks simple questions to guide
you to the proper chapter.
• How to Use This Manual explains the
manual format and design, and contains
the START page.
• Safety explains warning and caution notes,
general safety rules, and safety rules for
batteries, jacking, and welding.
• Systems Overview includes lift truck
specifications and general information.
• Installation gives unpacking, inspection,
and assembly procedures for the
Sideloader.
• Scheduled Maintenance outlines the
recommended schedule of preventative
services to keep your lift truck working
most efficiently.
• Troubleshooting is a set of troubleshooting
guidelines and tables.
PDMM-0102 Issued: 9/30/02 1-3

Manual Design
• Component Procedures gives step-by-step

procedures for testing, removal,
installation, and adjustment of individual
Sideloader components. Components are
grouped by lift truck system:
• General
• Drive Axle
• Steer Axle
• Steering
• Brakes
• Attachment & Load Handler
• Hydraulics
• Electrical
• Control
To find a component procedure, you can
use one of these methods:
• Look up the component name in the list
of Component Procedures by system.
See “Component Procedures” on
page 7-1.
• Find the component in the Component
Locator Photos. See “Component Locator
Photos” on page 7-3.
• Look up the component name in the
Index. See “Index” on page I-1.
• Theory of Operation explains fluid flow
within the hydraulic schematics and
current flow within the electrical
schematics for various conditions of
Sideloader operation.
• Appendix contains reference information
such as torque values, lubrication
specifications, and system schematics.
• Index lists subjects alphabetically.
1-4 PDMM-0102 Issued: 9/30/02

START Page
START Page
START: What do you want to do?
Go to Chapter 2
Review safety "Safety"
Yes
precautions?
No
Go to Chapter 3
Examine "Systems Overview"
Yes
specifications?
No
Go to Chapter 4
Uncrate and
"Installation"
assemble Yes
Sideloader?
No
Go to Chapter 5
Perform
"Scheduled Maintenance"
scheduled Yes
maintenance?
No
Go to Chart
START-2
PDMM-0102 Issued: 9/30/02 1-5

START Page
START-2
Go to Chapter 6
Troubleshoot a "Troubleshooting"
Yes
problem?
No
Test,
Go to Chapter 7
inspect, adjust,
"Component Procedures"
remove/install a Yes
component?
Component Locator
No
Photos
Find Go to Chapter 8
Component Procedures by
information on "Theory of Operation"
Yes Lift Truck System
theory of
operation?
No
Go to the
Find
Appendix
general reference Yes
information?
No
Locate
Go to the Index
an object or
Yes
procedure by
name?
1-6 PDMM-0102 Issued: 9/30/02

Raymond ® Sideloader Maintenance Manual Safety
Safety 2:
PDMM-0102 Issued: 9/30/02 2-1

Safety Raymond ® Sideloader Maintenance Manual
Definitions
Definitions
Throughout this manual, you will see two kinds
of safety reminders:
! WARNING
Warning indicates a potentially
hazardous situation that, if not
avoided, could result in death or
serious injury.
! CAUTION
Caution indicates a potentially
hazardous situation that, if not
avoided, could result in minor or
moderate injury or in damage to the
lift truck or nearby objects. It can
also be used to alert against unsafe
practices.
2-2 PDMM-0102 Issued: 9/30/02

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

you are trained, qualified, and authorized to do
so, and have read the Owner/Operator Manual.
28B15004D.EPS
Know the lift truck’s controls and what they do.
22823_001.eps
Do NOT operate this lift truck if it needs repair

or if it is in any way unsafe.
22823_002.eps
Operate this lift truck only from the operator’s

position.
22823_003.eps
PDMM-0102 Issued: 9/30/02 2-3

General Safety
Before working on this lift truck, always turn

the key switch OFF and disconnect the lift
truck’s battery connector (unless this manual
tells you otherwise).
22823_004.eps
Do NOT wear watches, rings, or jewelry when

working on this lift truck.
2jewelry.eps
Follow the scheduled lubrication, maintenance

and inspection steps.
2schedmnt.eps
Follow the safety and repair instructions in this

manual. Do NOT take “shortcuts.”
28b15008d.eps
2-4 PDMM-0102 Issued: 9/30/02

General Safety
Do NOT use an open flame near the lift truck.
22823_005.eps
Do NOT use gasoline or other flammable liquids

for cleaning parts.
22823_006.eps
Clean up any hydraulic fluid, oil, or grease that

has leaked or spilled on the floor.
2spills.eps
Always operate and park this lift truck indoors.
22823_007.eps
PDMM-0102 Issued: 9/30/02 2-5

General Safety
Do NOT wash this lift truck with a hose.
22823_008.eps
Do NOT add to or modify this lift truck until you

contact your local authorized Raymond Dealer
to receive written manufacturer approval.
22823_009.eps
Do NOT park this lift truck in a cold storage

area overnight.
2-6 PDMM-0102 Issued: 9/30/02

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

recommendations, and specifications in the
battery and battery charger manufacturer’s
manuals.
225l6s014.eps
PDMM-0102 Issued: 9/30/02 2-7

Battery Safety
Wear personal protective equipment to protect

eyes, face, and skin when testing, handling, or
filling batteries. This equipment includes
goggles or face shield, rubber gloves (with or
without arm shields), and a rubber apron.
225L6S016.eps
Make sure a shower and eyewash station are

nearby in case of an accident.
204G6S059.eps
A battery gives off explosive gases. NEVER

smoke, use an open flame, or use anything that
gives off sparks near a battery.
223L6S012.eps
Keep the charging area well-ventilated to avoid

hydrogen gas concentration.
204g6s058.eps
2-8 PDMM-0102 Issued: 9/30/02

Battery Safety
Turn the key switch OFF before disconnecting

the battery from the lift truck at the battery
connector. Do NOT break live circuits at the
battery terminals. A spark often occurs at the
point where a live circuit is broken.
22823_004.eps
Do NOT lay tools or metal objects on top of the

battery. A short circuit or explosion could
result.
204g6s057.eps
Keep batteries clean. Corrosion causes shorts

to the frame and possibly sparks.
Keep plugs, terminals, cables and receptacles in

good condition to avoid shorts and sparks.
227Y7S013.tif
PDMM-0102 Issued: 9/30/02 2-9

Battery Safety
Vent
Hole
Keep filler plugs firmly in position at all times

except when the electrolyte level is measured,
when water is added to the cells, or when the
specific gravity is measured.
Make sure the vent holes in the filler plugs are
open to permit the gas to escape from the cells.
209g6s047.tif
Do NOT let cleaning solution, dirt or any foreign

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

smaller or lighter weight battery could seriously
effect lift truck stability. See the lift truck’s
specification plate for more information.
22823_010.eps
NEVER plug a battery charger into the lift

truck’s battery connector. Plug the battery
charger only into the battery connector from the
battery.
22823_011.eps
2-10 PDMM-0102 Issued: 9/30/02

Jacking Safety
Jacking Safety
You may need to jack the lift truck off the floor
to perform maintenance procedures. When
doing so, observe the correct safety
precautions:
1. Lower the forks completely. Remove any
load.
2. Set all controls in neutral.
3. Block the wheels to prevent movement of
the vehicle.
4. Turn the key switch OFF and disconnect
the battery connector.
5. If possible, stabilize the top of the mast with
an overhead chain hoist.
6. Set the jack in the designated jacking area.
See Figure 2-1. Jack only in
these areas
! WARNING
Use extreme care when the lift truck
is jacked up. Never block the lift
truck between the telescopic and the
floor. Use a suitable hoist to stabilize
the mast. Keep hands and feet clear
from vehicle while jacking the lift
truck. After the lift truck is jacked,
install solid blocks or jack stands
beneath it to support it. Do NOT rely
on the jack alone to support the lift 2toyrch_t.eps
truck. Figure 2-1: Correct Jacking Locations
7. Jack the lift truck so that the tires are off

the floor no more than 0.5 in. (13 mm).
8. Block the lift truck in position.
NOTE: After working on a vehicle, test all
controls and functions to assure correct
operation.
PDMM-0102 Issued: 9/30/02 2-11

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

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

that:
• Fire protection equipment is nearby.
• You know where the nearest eyewash
station is.
! CAUTION
Disconnect the battery before you 204G6S059.eps
attempt to inspect, service or repair
the lift truck.
• Test for shorts to frame as described on

page 6-5. If you detect any shorts, correct
them before you proceed with the welding
operation.
• Clean the area to be welded.
• Protect all lift truck components from heat,
weld spatter and debris.
• Attach the ground cable as close to the weld
area as possible.
22823_004.eps
2-12 PDMM-0102 Issued: 9/30/02

Welding Safety
• Disconnect all electrical circuit cards before

doing any type of electric resistance
welding.
• Do not perform any welding operations
near the electrical components.
• If you must do welding near the battery
compartment, remove the battery from the
lift truck.
• When you are finished welding, re-install
circuit cards and perform all ground tests
and electrical inspections before operating
the lift truck.
PDMM-0102 Issued: 9/30/02 2-13

Welding Safety
2-14 PDMM-0102 Issued: 9/30/02

Raymond ® Sideloader Maintenance Manual Systems Overview
Systems Overview 3:
PDMM-0102 Issued: 9/30/02 3-1

Systems Overview Raymond ® Sideloader Maintenance Manual
General System Data
General System Data
Telescopic Assembly
Mast Assembly
Lift Cylinder
Lift Chains
Oil Reservoir
Electrical/Hydraulic
Operator’s Compartment
Compartment
Auxiliary Fork
Carriage (optional)
Hydraulic Load Bed

Compartment
Drive
Wheels
Guide Rollers Steer
(optional) Wheels
Figure 3-1: Model 71B/76 Sideloader General System Data (shown with optional TF Mast and Auxiliary Fork Carriage)
3-2 PDMM-0102 Issued: 9/30/02

Mechanical Systems
Mechanical Systems
Chassis
The chassis includes all those items that
provide support, protection or access to vehicle
components.
Chassis Frame
The chassis frame has a 0.5 in. (13 mm) and
0.75 in. (19.05 mm) formed steel welded into a
rigid unit. This unit provides the major support
and protection for vehicle components. The
operator's compartment and overhead guard
are part of the chassis frame and provide
protection for the operator. The load beds are
an integral part of the chassis frame and
contain the rack and roller guides that support
the mast assembly.
Battery Compartment
The battery compartment, part of the chassis
frame, is located behind the mast assembly. Its
location adds to the vehicle's stability. The
compartment contains rollers to aid in battery
changing and a gate to secure the batteries
during normal lift truck operation.
Doors and Covers

Various doors and covers, are either hinged to
or removable from the chassis frame, and
provide access to vehicle components. When
closed or in place, these doors and covers
provide component protection.
Drive Units
The two drive units, located on either end of the
drive axle, are connected by a tie rod that pivots
them together. (See “Crab Steer” on page 3-11.)
Each drive unit includes a drive motor, gear
reduction assembly, and drive wheel.
PDMM-0102 Issued: 9/30/02 3-3

Drive Motor
Drive Motor
The drive motor is a 36-volt, series wound,
industrial traction motor. The motor shaft is
keyed to a gear in the gear reduction assembly.
Gear Reduction Assembly

The gear reduction assembly is an enclosed
assembly that provides an overall reduction
ratio of 15.75:1. The shafts and gears are
continuously splash-lubricated. The final drive
shaft is threaded to accept a special mounting
nut for the drive wheel.
Drive Wheel
The drive wheel has a cast wheel hub and a
press-on 15 in. x 8 in. (381 x 203 mm) rubber
or poly tire that allows easy, low cost
replacement. A special nut and tool are used to
mount the drive wheels.
Steering
The steering linkage, located on the steer axle,
transfers hydraulic force of the steer cylinder to
the steerable wheels.
Linkage
The steering linkage has two tie rods attached
between an intermediate link and the steerable
wheels.
Steerable Wheels
The steerable wheel has a cast wheel hub and a
press-on 15 in. x 8 in. (381 x 203 mm) rubber
or poly tire that allows easy, low cost
replacement.
3-4 PDMM-0102 Issued: 9/30/02

Brakes
Brakes
Two brake systems, the service brake and the
parking brake, are used on the Sideloader.
Although both use the same brake assemblies Parking Brake
located on the steerable wheels, the service (Deadman Pedal)
brake is the primary means of stopping the
vehicle. See Figure 3-2.
Mast Assembly Components

The mast performs the lift, lower, storage and
retrieval functions. All Sideloader attachments,
Nominal Free Lift (TN), Full Free Lift (TF), or Service Brake
Pedal
Triple Telescopic (TT), contain the following
components: 3
Figure 3-2: Brakes
Mast Assembly
The mast assembly is a fixed structural
weldment that is mounted between the load
beds. The mast varies, depending upon
application and customer requirements.
Standard functions of mast traverse and mast
tilt are covered in “Hydraulics” on page 3-7.
Telescopic Assemblies
The telescopic assemblies are comprised of
welded I-beams and cross ties that ride on
rollers within the mast assembly. The
telescopics are nested within the mast, forming
a compact group, providing good visibility.
Carriage Assembly
The carriage assembly is a welded unit that
engages the load with its forks. The carriage
rides on rollers within the inner telescopic. The
standard fork tilt and reach functions are
covered in “Hydraulics” on page 3-7.
PDMM-0102 Issued: 9/30/02 3-5

Mast Assembly Components
Lift Cylinders
The lift cylinders correspond with the
attachment component types; TN, TF, and TT.
• TN - a single cylinder attached between the
main frame and telescopic assemblies. It
contains a pulley assembly at the top,
where the lift chains and hydraulic hoses
are routed.
• TF - a welded cluster with one long center
cylinder and two short side cylinders. The
center cylinder is attached between the
main frame and telescopic assemblies. The
lift chains are routed over pulleys on top of
each side cylinder.
• TT - has two cylinder assemblies; a front
cluster, identical to the TF assembly above,
and a single back cylinder. The center
cylinder of the front cluster is attached
between the first and second telescopics,
while the back cylinder is attached between
the main frame and first telescopic. The lift
chains, as with the TF, are routed over
pulleys on top of each side cylinder of the
front cluster.
Lift Chains
The lift chains are anchored between the lift
cylinder assembly (front cluster on TT) and the
carriage assembly. The chains are routed over
the cylinder pulleys, giving the carriage a 2:l lift
ratio over the telescopic(s).
3-6 PDMM-0102 Issued: 9/30/02

Hydraulics
Hydraulics
General
The hydraulics fall into three basic categories;
lift/lower, auxiliary controls, and steering. All
three utilize the same reservoir and return line
filter assemblies. The hydraulics contain
various manifolds that consolidate the
components for ease of service and permit
optional manifolds to be added on with little
modification.
Reservoir
The reservoir is a steel weldment with a 10.25
gallon (38.8 L) capacity. It contains a mesh lift 3
suction strainer, a vented breather/filter cap, a Figure 3-3: Reservoir
drain, and a removable cover for easy cleaning.
See Figure 3-3.
Filter
The filter is a screw-on style with a built-in
pressure controlled bypass valve. See
Figure 3-4.
Check Valve
Because the filter is located below the reservoir,
a check valve between the filter and reservoir Filter
prevents oil from draining out of the reservoir Check
Valve
when the filter is removed.
Lift/Lower
The lift/lower system operates at high pressure,
up to 3200 psi on the Model 71B and 3300 psi
(22753 kpa) on the Model 76 with full capacity
3
loads. The lift/lower system includes the
following components: Figure 3-4: Filter and Check Valve
Lift Pump
The lift pump is a manually stroked, variable
displacement piston pump. The pump’s output
is varied by a slave cylinder that changes the
position of the pump's volume control plate
when the lift master cylinder is actuated.
PDMM-0102 Issued: 9/30/02 3-7

Lift/Lower
Lift Motor
The lift motor is a compound-wound, 36-volt
motor. It is mounted with the pump on a
horizontal bracket that swings out allowing
easy inspection, cleaning, and brush
replacement. See Figure 3-5.
Lift Control
The lift control lever allows the proportional lift
of the forks when the handle is pulled back. The
3
farther it is pulled back, the faster the forks will
lift. Figure 3-5: Lift Pump and Motor
Pump Bypass Solenoid

The pump bypass solenoid is a normally open
solenoid that is closed during lift. Its purpose is
to open after lift to allow oil from the lift pump
to flow to the reserfoir until the lift pump stops
turning.
Lift Check Valve

The lift check valve is located between the pump
and cylinder. It allows full flow to the cylinder
but traps the oil holding the lift position when
the pump is shut down.
Lift Cylinders
The lift cylinders are single-acting cylinders
that are used to lift the forks and telescopics.
Lowering Lock-Out Solenoid

The lowering lock-out solenoid is actuated by
the deadman switch. With the deadman switch
closed, the solenoid is open and allows lowering
through the lowering valve. With the deadman
switch open, the solenoid is closed and prevents
lowering through the lowering valve.
Lowering Valve
The lowering valve is a shear-type valve
actuated by the lowering lever. The amount of
handle actuation determines the flow rate,
giving the operator full control of lowering
speed. A spring on the control handle returns
the handle to the OFF position when released.
3-8 PDMM-0102 Issued: 9/30/02

Auxiliary System
Pressure Reliefs
A pressure relief is incorporated in the
lift/lower system to protect system components
from excessive pressure. The relief is set to
open when system pressure reaches the valve’s
set pressure. The relief diverts lift flow back to
the reservoir, eliminating lift.
Auxiliary System
The auxiliary system is activated when the
deadman pedal is depressed causing the oil to
free flow through the control valves and
solenoids. The parking brakes and steering
operate off auxiliary pressure. The remaining
components that make up the auxiliary system
are:
Auxiliary Pump
The auxiliary pump is a fixed displacement gear
pump.
Auxiliary Motor
The auxiliary motor is a compound-wound,
3
36-volt DC motor. It is mounted with the pump
on a vertical bracket that swings out allowing
for easy inspection, cleaning and brush Auxiliary
replacement. See Figure 3-6. Motor
Control Valves
The control valves divert the auxiliary flow to
the desired function. The amount and direction Auxiliary
Pump
of handle movement determines the speed and
direction of the function. A pressure relief in
each valve assembly protects the auxiliary
circuits from excessive pressure build-up. An
internal spring returns each control handle to
neutral when released. See Figure 3-7.
Figure 3-6: Auxiliary Pump and Motor
PDMM-0102 Issued: 9/30/02 3-9

Auxiliary System
Flow Limiter 3
The flow limiter is located after the mast tilt

valve and reduces flow to and from the mast tilt
cylinder to limit tilt speed.
Counterbalance Check Valves

The counterbalance check valves are located
before the mast traverse motor and the mast tilt
cylinder. Pressure from the system allows
normal operation but when the valves are in
neutral, the oil is trapped in the motor or
cylinder. This is provided to prevent the
functions from drifting.
Mast Traverse Motor

Figure 3-7: Control Valves
The mast traverse motor is used to move the
mast along the load bed in order to deposit or
pick up a load. Oil flow to one side or the other
of the motor causes it to turn in a specific
direction. This turns the gear attached to its
shaft and traverses the mast along the load bed
racks.
Double-acting Cylinders
Double-acting cylinders are used for steering,
mast tilt, fork tilt, and reach. Oil flow in one end
or the other causes the cylinders to extend or
retract.
Aux (System Pressure) Relief

In addition to various component’s pressure
relief, there is an auxiliary pressure relief that
opens when excessive pressures build up. This
diverts the pumps flow directly back to the
reservoir.
Heat Sinks
Heat sinks for the SCR's and rectifiers are
located in the auxiliary return line. These help
dissipate heat built-up by these components.
3-10 PDMM-0102 Issued: 9/30/02

Steering
Steering
The truck incorporates two separate steering
3
systems. Both steering systems operate off the
auxiliary hydraulics. The steerable wheels
located under the operator compartment are
operated through the steering wheel, while crab
steering located under the load bed is operated
through buttons on the directional/speed
control handle. The steering assemblies have
the following components:
Orbitrol
The orbitrol is operated through a chain
assembly attached to the steering wheel. When
rotated, the orbitrol directs oil flow to one end
or the other of the steering cylinder. The
direction of rotation determines the steering Figure 3-8: Steering Orbitrol
direction. See Figure 3-8.
Crab Steer
Depressing the left or right crab steer button
activates its respective solenoid, directing
auxiliary hydraulic flow to the crab steer
cylinder. When the center button is depressed,
the circuit is completed to the necessary
solenoid. Auxiliary flow is directed to the crab
steer cylinder until it is centered, then the
circuit is disrupted. Indicator lights in the
operator's compartment show relative position
of crab steering.
Steer Cylinders
Both steering cylinders are double-acting types.
Oil flow in one end forces oil flow out the other
end causing the cylinder to extend or retract.
Pressure Reliefs
Each steering system contains an individual
pressure relief to protect the system from
excessive pressure build-up.
PDMM-0102 Issued: 9/30/02 3-11

Electrical
Electrical
General
The electrical systems fall into three basic
categories; travel, miscellaneous, and options.
The following are general components used by
most of the various electrical circuits:
Batteries
Two 18-volt batteries connected in series supply
power for all electrical circuits. The battery
connectors are attached to a emergency
disconnect handle that allows the operator to
easily remove all vehicle power in an
emergency.
Fuses
The following fuses are used;
• FU1 - This 400 amp fuse protects the travel
power circuit.
• FU2 - This 600 amp fuse protects the lift
power circuit.
• FU3 - This 150 amp fuse protects the
auxiliary power circuit.
• FU5 - This 15 amp fuse protects the B+ end
of the entire control circuit.
• FU6 - This 15 amp fuse protects the B- end
of the entire control circuit.
Key Switch
The key switch is a two-position (ON/OFF)
switch that supplies power to all the control
circuits. An optional three-position switch is
used when the remote control option is ordered.
Deadman Switch
The deadman switch, actuated by the deadman
pedal, supplies power to the travel, lift, and
auxiliary control circuits.
Travel
The travel system has the following:
3-12 PDMM-0102 Issued: 9/30/02

Travel
Directional/Speed Control Assembly

The directional/speed control assembly
regulates travel direction and speed. Pulling the
handle toward the operator provides reverse
travel. Pushing the handle away from the
operator provides forward travel.
Potentiometer (VR1)
The potentiometer (VR1) on the
directional/speed control assembly regulates
current to the Control Unit, and therefore, the
speed in SCR range. The greater the handle
movement in either direction, the faster the
vehicle speed.
Speed Limit Module

The speed limit module works in conjunction
with the limit circuits in the control unit to limit
travel speeds under various modes of operation.
Elevated heights and mast traverse position
effect the speed limit module. The module
contains two speed limits. One is fixed at
approximately l/2 full SCR speed. The other is
adjustable, but generally set at l/8 speed.
Equalizing Time Delay

Because of the need to parallel the motor
armatures during initial travel and plugging, an
equalizing time delay is added. It senses the
activation of either directional control and
momentarily keeps the equalizing contactor
closed.
PDMM-0102 Issued: 9/30/02 3-13

Contactors
Contactors
The contactors used in the travel system are:
• F and R - The forward and reverse
contactors are a dual pole, dual throw
design. Activating the directional contactor
determines the current path through the
drive motors and thus, the direction of
travel.
• M - The M speed contactor is a single pole,
single throw design with normally open
tips. Activating the M contactor bypasses
the SCR circuitry, therefore allowing high
speed travel.
• 1S - The 1S equalizing contactor is a single
pole, single throw design with normally
closed tips and a normally open interlock
switch. The contactor is closed, paralleling
the armatures, as the truck first starts to
travel and during plugging. During travel,
the contacts open. The interlock prevents
plugging if the contactor malfunctions.
Silicon Controlled Rectifiers (SCRs)

Disc type SCRs used in the travel system are:
• SCR1 - the main SCR directly controls
vehicle speed. The more frequently SCR1 is
turned on and the longer it stays on, the
greater the vehicle speed.
• SCR3 - the charging SCR turns on with
SCR1. When on, SCR3 provides a current
path through the capacitors, thereby
charging the capacitors when SCR1 is on.
• SCR2 - the commutating SCR is turned ON
alternately with SCR1 and SCR3. When
SCR2 is turned ON a current path is
provided through the capacitors, creating a
no-flow condition through SCR1, thereby
turning SCR1 off.
3-14 PDMM-0102 Issued: 9/30/02

Contactors
Rectifiers
The disc type rectifiers used are:
• REC1 - recirculating rectifier directs drive
motor current flow back through the drive
motors when SCR1 is turned OFF.
Recirculating motor generated current back
through the motors smooths out the overall
performance and increases vehicle
efficiency.
• REC2 and REC3 - allow electrical flow
through the plugging relays K1 and K2
during plugging.
Plugging Relays
K1 and K2, reduce the frequency output of the
control unit to SCR1 during plugging. This
limits high current build-up that could cause
damage to the motors.
Transformer
With SCR1 ON, current flows through the
primary windings of the T1 transformer
inducing a current flow through its secondary
windings in conjunction with SCR3. The
secondary current flow charges the capacitors
in the necessary polarity for vehicle operation.
Capacitors
Charging and discharging of the C1 and C2
capacitors provides the necessary current flow
for turning SCR1 OFF.
PDMM-0102 Issued: 9/30/02 3-15

Control Unit
Control Unit
A self-contained unit that contains the
electronic circuitry that controls the travel
system. The control unit includes:
• Auxiliary Circuit Card - provides F, R, and
M contactor time delay and
suppression/protection circuitry
• Variable Pulse Generator Card (VPG) -
controls SCR turn on/off, pulse width and
frequency oscillation, current limiting,
creep speed adjustment, plugging, and
speed limits
• Power Driver Circuit Card - amplifies the
signals received from the oscillator circuits
of the VPG Card and sends them to the gate
lead of the respective SCRs.
Miscellaneous
Horn
Activated by the horn button, located on top of
the directional/speed control handle, the horn
can be sounded when the key switch is ON.
Hour Meter
Located on the side compartment cover below
the lift and lower levers, the hour meter
provides an accurate record of elapsed time that
the key switch is ON while the deadman pedal
is depressed.
Battery Controller
The battery controller monitors battery voltage
and provides a visual cue to the operator when
voltage is low. When a low battery voltage
condition occurs, the battery controller disables
the lift function, leaving enough battery voltage
to return to the charging area. The batteries
must be recharged before further use.
Load Reducing Relays

K12 (Deadman) and K13 (Light Load) relays are
added to reduce the load through the key
switch. K12 will energize after the deadman
pedal is depressed, and K13 will engage when
the key switch is turned ON.
3-16 PDMM-0102 Issued: 9/30/02

Options
Options
Auxiliary Fork Carriage

The auxiliary fork carriage is used for handling
extra long or flexible loads. It provides two
additional forks outside the load bed that fold
up, out of the way hydraulically, when not in
use. The assembly hangs on an extended fork
bar and can be easily removed. See Figure 3-9.
Guide Rollers
Guide rollers are used in conjunction with
3
guide rails to align and direct the vehicle along
an aisle. The guide rollers are mounted at each Figure 3-9: Auxiliary Fork Carriage
corner of the chassis frame between 5 in. (127
mm) and 11.5 in. (292 mm) from the floor,
depending upon application. If necessary, the
guide rollers can be easily removed or replaced.
Hydraulic Fork Positioning
Hydraulic fork positioning permit the operator
to adjust the forks from the operator
compartment.
Load Weight Indicator

The load weight indicator is plumbed into the
lift system and converts the system pressure to
a scale in pounds. This allows on the spot
weight indication. See Figure 3-10.
Ranger® Shelf Height Selector

The Ranger shelf height selector is a
microprocessor-controlled device used for
precise positioning of the lift forks. The Ranger
has a built in memory capable of storing up to
3
99 different shelf levels and positioning the
forks at any one of them on command. Figure 3-10: Load Weight Indicator
Designed for greater productivity and control in
high density storage operations, the Ranger
provides an operator with a means of quickly,
accurately, and automatically positioning forks
at heights where visibility and depth perception
require assistance. Refer to Special Supplement
Manual SS-10 for further information.
PDMM-0102 Issued: 9/30/02 3-17

Options
Remote Lift/Lower
This option provides a modification to the
standard carriage for the remote lift/lower
controls. An approved add-on platform that
mounts on the standard forks is required. The
operator must travel to the desired position,
turn the key switch to the remote position, then
mount the platform to lift and lower the
carriage. The only other control at the carriage
is the power disconnect.
Miscellaneous
Other options that are available include various
lights (working, warning, and back-up), and
cold storage conditioning.
3-18 PDMM-0102 Issued: 9/30/02

Raymond ® Sideloader Maintenance Manual Installation
Installation 4:
PDMM-0102 Issued: 9/30/02 4-1

Installation Raymond ® Sideloader Maintenance Manual
General
General
Because of its size, the Raymond Sideloader is
shipped in two sections; the tractor and the
mast. Follow “Chassis Frame”, “Visual
Inspection”, and “Mast to Tractor Reassembly”
instructions to assure correct installation of the
truck.
Chassis Frame
Besides the tractor and mast assemblies, other
components are also removed and packed
separately for protection during shipping. These
will be attached to either the tractor or mast.
1. Put the tractor, mast and all tools and
equipment required in an area suitable for
completing the job.
! WARNING
Do NOT cut the band securing the
carriage to the mast until after the
mast is installed. See “Mast to
Tractor Reassembly” on page 4-4.
2. Remove all the individual components and

packing boxes attached to the tractor or
mast.
Examine the items to be sure all required
components are included.
NOTE: Use a sufficient hoist or lifting
mechanism, rated at a minimum of five
ton capacity, to remove the larger items
such as the auxiliary fork carriage,
packing boxes, batteries (if shipped with
vehicle), forks, and so on.
4-2 PDMM-0102 Issued: 9/30/02

Visual Inspection
Visual Inspection
When a vehicle is received, it must be visually
examined for damage that may have occurred
in transit. Use the checklist listed in Table 4-1
and do a visual inspection of the truck.
Table 4-1: Visual Inspection
Item Examine for...
Wheels/Tires Chips or cracks
Wiring Damaged insulation, loose connections
Hoses Physical damage, leaky connections
Chassis Any dents or scrapes that may hinder

operation
Other Any physical damage that may hinder

components operation
PDMM-0102 Issued: 9/30/02 4-3

Mast to Tractor Reassembly

A 4 to 5-ton hoist (or alternate means of lifting)
is required to lift the mast on the tractor.
Mast Traverse Stop
1. Remove the mast traverse stops. See
Figure 4-1.
2. Move the hoist over the mast. Sling the
hoist to the top of the mast.
3. Raise the mast vertically off the floor
approximately 12 to15 in. (300 to 380 mm).
Move the tractor into position.
4. Position the mast between the load beds. 4
Figure 4-1: Mast Traverse Stops

5. Disconnect the two hydraulic hoses from
the mast traverse motor so that the mast
traverse gear shaft can be turned freely. See
Figure 4-2. Mast Traverse Motor
6. Make sure the mast is square to the tractor,
then roll the mast in towards the tractor
until the traverse gears engage a couple
teeth on the gear rack. Use a large pipe
wrench on the mast traverse gear shaft to
aid in engaging the traverse gears into the
gear rack.
Figure 4-2: Mast Traverse Motor

7. Measure between the inner tractor frame
.
and the bottom of the mast ears (see

Figure 4-3 and Figure 4-4). The two sides
must be equal to within 0.125 in. (3.2 mm).
See Figure 4-4
If they are not, roll the mast out away from
the tractor until the mast traverse gears are
disengaged from the gear racks and repeat
step 6.
Inner Tractor
Frame
Figure 4-3: Measure Distance Between Tractor Frame and

Mast
4-4 PDMM-0102 Issued: 9/30/02

8. Reconnect the two mast traverse motor

hydraulic hoses.
Mast Ear
Figure 4-4: Measure Point

9. Adjust the eccentrics. See Figure 4-5.
a. Loosen the two locking nuts.
b. Tighten the eccentric, then back off
1/8 turn.
c. Tighten the two locking nuts.
d. Repeat steps 9a. thru 9c. on the
opposite side.
10. Connect all hydraulic and electrical lines.
Hydraulic and electrical lines are coded for
ease of identification.
Figure 4-5: Adjust Eccentrics

11. Traverse the mast in (toward the tractor) all
the way. Examine the position of the mast
Mast Ear
ears against the tractor frame on the two
sides. See Figure 4-6. If they are even,
proceed to step 12. If they are not, adjust
the gear rack adjacent to the steer axle as
follows:
a. Loosen the gear rack mounting bolts.
Tractor Frame
Figure 4-6: Examine Position of Mast Ears
PDMM-0102 Issued: 9/30/02 4-5

b. Adjust the rack in the necessary

direction, using the gear rack adjuster.
See Figure 4-7. Gear Rack
Adjuster
c. Tighten the adjuster nuts. Apply
thread-locking compound P/N
990-536 to the gear rack mounting
bolts and tighten.
d. Reexamine the position of the mast
ears against the tractor frame.
12. Install the two mast traverse stops. Make
sure they are adjusted evenly.
4
13. Remove the strap securing the mast. Figure 4-7: Gear Rack Adjustment
14. Mount the forks by sliding the fork bar
adequately to one side to insert one fork,
then to the other side to insert the other
fork. Center the fork bar and install the set
screw. On the Model 71B, insert the fork
pins.
15. Mount all additional components that have
been removed and packaged separately.
Refer to specific maintenance instructions
applicable to each component.
16. Refer to the batteries and charger
installation and perform those procedures.
17. Because the mast was removed, each lift
cylinder must be bled as follows:
a. Elevate the carriage until the forks are
approximately 2 ft (610 mm) above the
floor.
b. Loosen (do not remove) the round head
bleed screw in the top of the cylinder to
permit air to escape.
c. When a steady stream of fluid flows from
the screw, retighten the screw.
18. Measure all fluid levels.
19. See “Maintenance Guidelines” on page 5-2.
Perform all the items in the Daily Checklist.
4-6 PDMM-0102 Issued: 9/30/02

Batteries and Chargers
Batteries and Chargers

Install the battery charger in accordance with
the manufacturer’s instructions. Make sure
operation of the charger is thoroughly
understood before attempting to recharge the
batteries. Battery life can be considerably
shortened by incorrect recharging procedures.
NOTE: Because the Sideloader uses two 18-volt
batteries in series to develop the 36-volt
DC operating voltage, the batteries must
be charged in series with a 36-volt
charger.
Battery Installation
1. Remove the battery gate and shipping
batteries. Carefully slide the regular
batteries into the vehicle. Reinstall and
adjust the battery gate.
2. Make sure the battery posts and cable
connectors are clean.
3. Make sure the batteries are adequately
charged before operating the vehicle.
PDMM-0102 Issued: 9/30/02 4-7

Battery Installation
4-8 PDMM-0102 Issued: 9/30/02

Raymond ® Sideloader Maintenance Manual Scheduled Maintenance
Scheduled Maintenance 5:
PDMM-0102 Issued: 9/30/02 5-1

Scheduled Maintenance Raymond ® Sideloader Maintenance Manual
Maintenance Guidelines
Maintenance Guidelines
Following a regularly scheduled maintenance

program:
• Promotes maximum truck performance
• Prolongs maximum truck life
• Reduces costly down time
• Avoids unnecessary repairs
Scheduled maintenance includes:
• Lubrication
• Cleaning
• Inspection
• Service
Perform all of the scheduled checks and
maintenance at the suggested intervals. The
time intervals given in this guide are based on
deadman hours under normal operating
conditions. When operating under severe or
extreme conditions, perform these services
more often as indicated in Table 5-1.
Table 5-1: Working Environments
Type of Service
Working Environment
Service Frequency
30 days or
250 hours,
Moderate An eight hour day of basic material handling
whichever
is less
Severe Extended operating hours or constant use 175 hours
All EE rated lift trucks
Dusty or sandy conditions: for example, cement plant, lumber or
flour mills, coal dust or stone-crushing areas
High temperature areas: for example, steel mills, foundries,
Extreme 100 hours
enclosed (EE) applications
Sudden temperature changes: for example, freezer to room
temperature
Corrosive atmosphere: for example, chlorine, salt-sea air
For lubricant and lubricating fluid information,

see "Lubrication Specification Chart" on page
A-2.
5-2 PDMM-0102 Issued: 9/30/02

Monthly Maintenance
Monthly Maintenance
Perform the checks listed in Table 5-2 monthly

or every 250 operating hours, whichever comes
first.
Table 5-2: Monthly Checklist
Perform all Daily/8-Hour Checks plus the following:
*Item No. Component Monthly/250-Hour Checks
Examine for proper charge, voltage, weight, leakage,

cleanliness, proper installation. See “Batteries” on page 7-83.
Examine for proper gate installation and Emergency Disconnect
1 Batteries
operation.
Examine battery connector for wear, solid electrical
connections.
Control Examine for correct operation of all vehicle control functions.

2
Functions
Cylinders Examine for leaks.

3 Lift, Tilt, Steer
and Reach
Decals/Warning Examine for damaged or illegible decals. Clean or replace as

4
Labels necessary.
5 Hoses/Cables Examine for leaks or wear.
6 Tires Examine for gouges, chunking, flat spots, bond failure
Examine for burned, badly eroded or welded tips. See “Tip

7 Contactors
Inspection” on page 7-88.
Drive Units Measure fluid level. Fluid must be level with bottom of plug
8 hole. If low, add proper fluid. See “Lubrication Specification
Chart” on page A-2. Examine for leaky seals.
Parking Brake Examine brake for proper parking operation.

9 (Deadman) Make sure that brake releases completely when deadman pedal
Actuator is depressed.
Examine for proper brush length and spring tension. See

10 Motors
“Brushes” on page 7-14. Examine for cleanliness.
Measure fluid level. Fluid must be 1 1/2 in. (38.1 mm) from top
Hydraulic
11 with carriage lowered and mast retracted. If low, add proper
Reservoir
fluid. See “Lubrication Specification Chart” on page A-2.
PDMM-0102 Issued: 9/30/02 5-3

Monthly Maintenance
Measure fluid level. Fluid must be 1/2 in. (13 mm) from top. If
Service Brake low, add proper fluid. See “Lubrication Specification Chart” on
12
Master Cylinder page A-2. Examine for leaks. Repair or replace components as
necessary.
Measure fluid level. Fluid must be 1/2 in. (13 mm) from top. If
Lift Master low, add proper fluid. See “Lubrication Specification Chart” on
13
Cylinder page A-2. Examine for leaks. Repair or replace components as
necessary.
Steer Axle Lubricate all grease fittings on king pins, tie rods and steer
14
Assembly cylinder.
Drive Axle Lubricate all grease fittings on king pins, tie rod and steer
15
Assembly cylinder.
Parking Brake Examine for proper operation. Adjust or repair as necessary.

17 (Deadman) See “Parking Brake Adjustment” on page 7-51.
Actuator
Steering Chain Measure tension and adjust as necessary. See “Steering Chain
18
Adjustment” on page 7-48. Lubricate.
Mast Traverse Lubricate grease fittings on top rollers and drive shaft.
19
Drive
Mast Traverse Clean and lubricate with grease. See “Lubrication Specification
20 Rack, Gears and Chart” on page A-2.
Rollers
Mast Channels Clean and lubricate with grease. See “Lubrication Specification
21
and Roller Ways Chart” on page A-2.
21 Chassis/Mast Verify all guards/covers installed.
Examine for loose or broken connections. Repair or tighten as

23 Electrical Wiring
necessary. Clean or replace worn or oil soaked harnesses.
24 Limit Switches Verify that they control the assigned function.
Examine brake for proper stopping action; stops truck within

recommended distance of six feet. Minimum brake pad
25 Service Brake
thickness is 3/32 in. (2.3 mm). Adjust linkage as necessary.
Lubricate grease fitting on pivot shaft.
Control Linkages Examine for smooth operation. Clean and lubricate as

26 (Lift, Lower and necessary.
Auxiliary)
Floor Mats and Replace worn mats or pads.

28
Pads
5-4 PDMM-0102 Issued: 9/30/02

Monthly Maintenance
30 Wheels Examine for wheel and bearing wear.
32 Lights (Optional) Examine operation. Replace bulbs as necessary.
33 Forks Measure heel thickness. Forks must not be bent or modified.
34 Horn Sounds when activated.
Ventilation Slots Ensure that the slots are free of obstructions.
All other Examine for looseness or damage.

components and
hardware
Fire Extinguisher Measure charge. Replace if charge is low.

(Optional)
*See “Lubrication and Inspection Points” on page 5-8.
PDMM-0102 Issued: 9/30/02 5-5

Semi-Annual Maintenance
Semi-Annual Maintenance
Perform the checks listed in Table 5-3

semi-annually or every 1000 operating hours,
whichever comes first.
Table 5-3: Semi-Annual Checklist
Perform all Monthly/250-Hour Checks (including Daily checks) plus the following:
*Item No. Component Semi-Annual/1000-Hour Checks
8 Drive Units Change oil. Drain case and refill with correct lubricant.
Examine for wear and elongation. Repair or replace faulty

22 Lift Chains chains. See “Lift Chain Repair and Replacement” on
page 7-62.
Drive and Repack wheel bearings.

27 Steerable
Wheels
29 Oil Filter Replace oil filter cartridge.
Door Hinges Examine for smooth operation. Clean and lubricate as

31
necessary.
5-6 PDMM-0102 Issued: 9/30/02

Annual Maintenance
Annual Maintenance
Perform the checks listed in Table 5-4 annually

or every 2000 operating hours, whichever
comes first.
Table 5-4: Annual Checklist
Perform all Monthly/250-Hour and Semi-Annual/1000-Hour checks plus the following:
*Item No. Component Annual/2000-Hour Checks
Hydraulic Change oil. Drain and refill with correct lubricant.

11
Reservoir
PDMM-0102 Issued: 9/30/02 5-7

Lubrication and Inspection Points
NOTE: The numbered arrows in the photos on

the following pages refer to item number
in the preceding scheduled maintenance
charts.
21
32
11
4
22
31
33
6
6
53292_034.TIF
Figure 5-1: Lubrication and Inspection Points
5-8 PDMM-0102 Issued: 9/30/02

1 4
28 25
2
53292_027.TIF
Figure 5-2: Lubrication and Inspection Points - Operator’s Compartment
PDMM-0102 Issued: 9/30/02 5-9

26
24
53292_027.TIF
Figure 5-3: Lubrication and Inspection Points - Steer End Hydraulic Compartment
20
19
Figure 5-4: Lubrication and Inspection Points - Elevating Section Extended
5-10 PDMM-0102 Issued: 9/30/02

18
13
23
53292_010.TIF
Figure 5-5: Lubrication and Inspection Points - Operator’s Compartment (cover removed)
29 34
10
10
5P5180009.TIF
Figure 5-6: Lubrication and Inspection Points - Drive End Electrical/Hydraulic Compartment
PDMM-0102 Issued: 9/30/02 5-11

10
6, 30 8
3
15
5P5180009.TIF
Figure 5-7: Lubrication and Inspection Points - Drive Axle
17
27
3 6, 30
14
5
Figure 5-8: Lubrication and Inspection Points - Steer Axle
5-12 PDMM-0102 Issued: 9/30/02

Raymond ® Sideloader Maintenance Manual Troubleshooting
Troubleshooting 6:
PDMM-0102 Issued: 9/30/02 6-1

Troubleshooting Raymond ® Sideloader Maintenance Manual
Overview
Overview
It is important when you troubleshoot truck

problems to:
• Use a logical, common sense approach
• Start with the simplest solution and work
towards the most complex.
The following procedure will aid in developing a
logical and systematic troubleshooting
procedure:
1. Verify the problems:
• Obtain as much information as you can
about the problem
• Determine, if possible, what the truck's
performance was before the problem
began
• Review any records kept about the
truck's performance
• Operate the truck yourself to verify the
problem
2. Find the truck problem area:
• Open the various truck compartment
doors and visually inspect the systems,
then consult the hydraulic, electrical,
and mechanical maintenance sections
for general information that may save
you time.
• Determine if the problem is in the
control circuit or the power circuit if
there is no obvious physical problem.
3. Establish a logical testing sequence:
• Use the schematic diagram. Start at the
battery and establish a sequence of
testing points to find the problem. Use
the schematic in conjunction with the
appropriate Flow Diagram.
• Establish test points that indicate that
all components between any new test
point and the battery are good.
• Avoid haphazard checking that provides
inconclusive results.
6-2 PDMM-0102 Issued: 9/30/02

Overview
4. Use the Troubleshooting Flow Diagrams:

• Consult the “List of Troubleshooting
Charts” on page 6-11.
• Follow the appropriate Flow Diagram
from the start to where the probable
cause is isolated.
5. Identify the cause of the problem:
• Check for incorrect truck usage.
• Bring the problem to the service
manager's attention to avoid repetition
of the cause.
6. Correct the problem:
• Repair or replace bad components
following instructions in the Component
Procedures section of this manual.
• Comply with appropriate safety
procedures.
! WARNING
put solid blocks or jack stands
on the jack alone to support the lift
truck. See “Jacking Safety” on
page 2-11.
! CAUTION
Disconnect the batteries when
measuring electrical circuits with an
ohmmeter. Battery current can cause
damage to the ohmmeter.
NOTE: Use the electrical schematic, hydraulic

schematic, and wiring diagram (found in
the Appendix) when troubleshooting.
PDMM-0102 Issued: 9/30/02 6-3

General Instructions
General Instructions
Save time and trouble; look for simple causes
first.
Wiring Inspection
Visually inspect all wiring in all compartments
for:
• Broken wiring or shorted conditions
(especially close to metal edges or surfaces)
• Loose connections
• Loose or broken terminals
• Damaged terminal blocks
Use an ohmmeter to measure wiring continuity.
Clean, repair or replace the wiring wherever a
problem exists.
! CAUTION
Capacitors C1 and C2 are potentially
dangerous. Avoid contact (either
directly or through uninsulated tools)
with capacitor's terminals or wiring
until the capacitors have been fully
discharged. To discharge the
capacitors, carefully hold the
insulated handle of a screwdriver
and install the metal blade across the
bus bars on the capacitors. Each time
work is to be done on the circuit, the
capacitors must be discharged if the
circuit has been energized since last
discharging.
6-4 PDMM-0102 Issued: 9/30/02

Shorts to Frame
Shorts to Frame
“Shorts to frame” is an industry term for
unintentional current leakage paths between
normally isolated electrical circuits and their
metal enclosures.
Shorts to frame may be metallic connections,
such as a wire conductor contacting metal
through worn insulation. More often, shorts to
frame are resistive “leakage” paths caused by
contamination and/or moisture.
These leakage paths can result in unwanted
electrical noise on the metallic lift truck
structure, and may result in incorrect
operation.
Shorts to frame can be caused by:
• Accumulation of dirt
• Battery electrolyte leakage
• Motor brush dust
• Motor brush leads touching the housing
• Breakdown in insulation
• Bare wires
• Pinched wiring harness
• Incorrect mounting of circuit cards
Shorts to frame can occur at numerous
locations on a lift truck, including:
• Batteries
• Motors
• Cables, wiring, and harnesses
• Heat sinks
• Bus bars
• Solenoids
• Contactors
• Terminal strips
• Switches
• Power panel insulation
• Circuit card mounts
PDMM-0102 Issued: 9/30/02 6-5

Shorts to Frame
To test for shorts to frame:

2. To test the battery for shorts to case,
connect a 12V test light to the battery case
from battery B+, and then to the battery
case from battery B-. If the light lights at
all, even momentarily, there is a serious
problem with the battery, either external
contamination or internal damage. Do NOT
continue until this condition is corrected.
Your meter may be damaged if you proceed
before correcting this condition.
Install another battery in the lift truck and
repeat this procedure from step 1.
If the test light does not light, continue to
the next step.
3. With the battery disconnected from the lift
truck, use a digital volt/ohm/ammeter on
the ampere function to measure the leakage
current from the battery case to battery B+
and from the battery case to battery B-.
Start measuring at the highest ampere
scale and work toward the lowest. A reading
of more than 0.001A (1mA) indicates a
serious short. Do NOT continue until this
condition is corrected. Your meter may be
damaged if you proceed before correcting
this condition.
Install another battery in the lift truck and
repeat this procedure from step 1.
If the current is less than 0.0002A (0.2mA),
go to step 4. If the current is greater than
0.0002A (0.2mA) and less than 0.001A
(1mA), remove the battery from the lift
truck, then continue with step 4. Ensure
the battery case does not touch the lift
truck frame during the remaining tests.
4. With the battery disconnected (or removed
and disconnected) from the lift truck, use a
digital ohmmeter to measure the resistance
from lift truck frame to truck B+, to truck
B- (NOT battery B+ and B-), and to all fuses
and motors. A reading of less than 1000
ohms indicates a serious short. Do NOT
continue until this condition is corrected.
Your meter may be damaged if you proceed
before correcting this condition.
6-6 PDMM-0102 Issued: 9/30/02

Shorts to Frame
a. To identify the cause of the short to

frame, disconnect circuit components
until the low resistance condition
disappears. Do NOT reconnect
components one at a time, but leave
them disconnected until the low
resistance reading disappears. Prevent
disconnected terminals or connectors
from touching lift truck frame or other
conductive surfaces.
b. The most likely areas to examine are:
• Motors
• Heat sinks
• Power cables
• Power circuit components
• Control circuit components
c. Repair or replace the component
causing the low resistance condition,
Then repeat Step 4.
d. Reconnect all other components
previously disconnected, one at a time,
measuring resistance between steps. If a
reading is less than 1000 ohms when
reconnecting a component, that
component or its wiring is bad; repair or
replace as appropriate.
e. When, after all components are
reconnected, you get readings greater
than 1000 ohms, continue with the next
step.
5. Reconnect the battery connector to the lift
truck and turn the key switch ON. If the
battery was previously removed, ensure the
battery case does not touch the lift truck
frame.
6. Use a volt/ohm/ammeter on the current
function to measure leakage current to the
lift truck frame from B+, B-, and all fuses
and motor terminals. Start measuring at
the highest ampere scale and work toward
the lowest. If the current is less than
0.001A (1mA), go to step 7. If the current is
more than 0.001A (1mA), continue to the
steps below.
a. To identify the cause of the short to
frame, disconnect circuit components
until the leakage current reads less than
0.001A (1mA). Do NOT reconnect
PDMM-0102 Issued: 9/30/02 6-7

Shorts to Frame
components one at a time, but leave

them disconnected until the leakage
current reads less than 0.001A (1mA).
Prevent disconnected terminals or
connectors from touching lift truck
frame or other conductive surfaces.
b. The most likely areas to examine are:
• Motors
• Heat sinks
• Power cables
• Power circuit components
• Control circuit components
c. Repair or replace the component(s)
causing the leakage current.
Repeat step 6.
d. Reconnect all other components
previously disconnected, measuring
current between steps. If a reading is
more than 0.001A (1mA) when
reconnecting a component, that
component or its wiring is bad.
Repair/replace as appropriate.
7. When, after all components are
reconnected, you get a reading less than
0.001A (1mA) there is no short to frame
condition with the lift truck or the battery.
If you previously removed the battery from
the lift truck, re-install the battery.
6-8 PDMM-0102 Issued: 9/30/02

Troubleshooting Preparation
If a truck problem can not be found in the
wiring or a shorted-to-frame condition,
troubleshoot in accordance with the Flow
Charts.
! WARNING
install solid blocks or jack stands
on the jack alone to support the lift
truck. See “Jacking Safety” on
page 2-11.
• Determine what operation(s) the truck is

failing to perform. To accomplish this, it is
often advisable to jack up and block the
truck so the drive wheels are off the floor.
• Operate all the truck's functions slowly,
observing during what sequence the truck
malfunctions. See “Troubleshooting
Procedure” on page 6-13.
• Perform the checks in the appropriate
Flowchart.
PDMM-0102 Issued: 9/30/02 6-9

6-10 PDMM-0102 Issued: 9/30/02

List of Troubleshooting Charts

6: Troubleshooting
List of Troubleshooting Charts

Standard Mode
T1: Truck Completely Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
T-2A: Truck Has No Travel - All Other Circuits Function. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
A: F or R and M contactors are NOT activated; 1S is activated . . . . . . . . . . . . . . . . . 6-19
T-2B: Truck Has No Travel - All Other Circuits Function . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
B: F or R contactors are activated then drop out; M and 1S are activated . . . . . . . . 6-20
T-2C: Truck Has No Travel - All Other Circuits Function . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
C: F or R contactors and 1S contactors are activated; M is NOT activated . . . . . . . . 6-21
T-2D: Truck Has No Travel - All Other Circuits Function . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
D: F or R contactors are NOT activated; M and 1S are activated . . . . . . . . . . . . . . . 6-22
T-3: Truck Has No Forward Travel - Reverse Travel Operative . . . . . . . . . . . . . . . . . . . . . . . 6-23
T-4: Truck Has No Reverse Travel - Forward Travel Operative . . . . . . . . . . . . . . . . . . . . . . . 6-24
T-5: Truck Has No M Speed - SCR Range Operative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
T-6: Truck Speed Is Slow In SCR Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
T-7: Truck Runs In Top Speed Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
T-8: Truck Acceleration Is Jerky In SCR Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
T-9: Truck Reacts Violently When Plugged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
T-10: Truck Acceleration Is Jerky Between SCR And M Speed . . . . . . . . . . . . . . . . . . . . . . 6-30
T-11: Truck Travels On One Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
T-12: Truck Overload Kicks Out During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
A: F or R contactors open during routine travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
B: Travel is halted during plugging sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
C: Truck stalls while operating under a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
T-13: Truck Has No Lift - All Other Functions Operative . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
T-14: Remote Lift/Lower Function Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
T-15: Auxiliary And Steering Systems Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
T-16: Crab Steering Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
T-17: Horn Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Remote Mode
T18: Remote Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
T18A: Remote Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
T18B: Remote Travel Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
T18C: Remote Forward Travel Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
T18D: Remote Reverse Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
PDMM-0102 Issued: 9/30/02 6-11

T18E: Remote M Speed Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
T18F: Remote Erratic Travel Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
T18G: Remote Lift Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
G: Lift Function Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
T18H: Remote Lower Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
H: Lower Function Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
T18I: Remote Mode Horn Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
I: Horn Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
Troubleshooting Procedure
Troubleshooting 6:
T1: Truck Completely Inoperative
T-1: TRUCK COMPLETELY INOPERATIVE
Check batteries and

Is Does charger. See
battery charging bring Component
voltage 18V for No battery to proper No Procedures section.
each battery voltage Repair or replace
? level faulty battery or
? charger.
Yes
Yes
Is
B+ present Repair or
at Fuse No replace
FU5-1 wrt wiring.
FU6-1
Yes
Remove
fuses FU5 &
FU6 and check for
No
continuity. Does
continuity exist
in both
? Go to Chart
T-1-1
Yes
Is
circuit open on
keyswitch between Replace
S1-1 & S1-2 when OFF No
switch.
and continuity
when ON
?
Yes
Check wiring for shorts

or grounds and repair
as necessary.
6TS1A.WMF
PDMM-0102 Issued: 9/30/02 6-13

T-1-1
Turn Does Does Activate crab

Activate
keyswitch a fuse blow No a fuse blow No steer center
horn S3.
ON. ? ? switch S30.
Replace blown
fuse(s) and
connect battery.
Yes Yes
No
Turn S1 OFF. Check horn and Does

Does Replace blown fuse SUP3. Replace a fuse blow
and disconnect plug faulty ? Yes
a fuse blow
? to the control unit. components.
Turn S1 ON.
Check relay
Yes K11 and DA6.
No Replace faulty
components.
Does Replace control
Replace fuse and
a fuse blow No unit or a
disconnect lead
? defective card. Activate
BC-1.
crab left
switch S28.
Yes
Does
a fuse blow No Turn S1 OFF.
Replace blown fuse Does
?
and disconnect lead a fuse blow
Yes Yes
from TS1-11 at K13-9. ?
Turn S1 ON.
Check
K5,DA8. If Check solenoid
Yes OK, replace Check warning light, SOL2 and DA2.
No Replace faulty
the battery Does working lights and
controller. No switch S6. Repair or components.
a fuse blow
? replace faulty
components. Activate
crab right
Do Yes switch S29.
contact tips
on K12 and K13
check OK? Consult Factory
Check solenoid
No Does
SOL1 and DA2.
a fuse blow Yes
Replace faulty
?
components.
Replace faulty
relay(s).
No
Go to Chart T-1-3 if
remote lift/lower is
used. If not, go to
Chart T-1-4.
6TS1A.WMF
6-14 PDMM-0102 Issued: 9/30/02

T-1-3
Turn S1 to RMT
and close remote
start switch S31.
Check PC contactor
coil, DA5 and switches
Does
Yes S21 and S27. Repair or
a fuse blow
replace faulty
?
components.
No
Close remote
lower switches
S20A & S20B.
Check SOL6 & DA3.

Does
Yes Replace faulty
a fuse blow
components.
?
No
Close remote lift

switches S19A &
S19B.
Check DA1, DA4, DA8,

SUP1, Relay K5, SOL5
Does
Yes and lift contactor coil P.
a fuse blow
Replace faulty
?
components.
No
Go to Chart
T-1-4
PDMM-0102 Issued: 9/30/02 6-15

T-1-4
Close
deadman Open switch S2.
switch. Replace blown fuse
and disconnect plug
to the control unit.
Close S2.
Yes
Does
a fuse blow
? Does Replace control
a fuse blow No unit or a
? defective card.
Yes
Open switch S2.

Replace blown fuse
and disconnect K12-
A. Close S2.
No
Check hour meter (HM),

Does
SOL4, SOL7, DA7, SUP1,
a fuse blow Yes
and the X contactor coil.
?
Replace faulty components.
No
Replace relay
K12 or diode
DA12.
Close lift
switch S4.
Yes Check DA4, DA8, SUP1,

relay K5, SOL5 and lift
contactor coil P. Replace
faulty components.
Go to Chart
T-1-5
6-16 PDMM-0102 Issued: 9/30/02

T-1-5
Move control
handle until
forward travel
switch MS1
closes.
Check 1S & F contactor

Does
coils, equalizing time delay
a fuse blow Yes
and control unit. Replace
?
faulty components.
No
Move control
handle until
reverse travel
switch MS2 closes.
Check 1S & R contactor

Does coils, equalizing time
a fuse blow Yes delay and control unit.
? Replace faulty
components.
No
Move control handle

until either high
speed travel switch,
MS5A or MS5B,
closes.
Check M contactor coil,

Does
speed limit module and
a fuse blow Yes
control unit. Replace faulty
?
components.
No
Consult Factory
PDMM-0102 Issued: 9/30/02 6-17

T-2: TRUCK HAS NO TRAVEL - ALL OTHER CIRCUITS FUNCTION
Check fuse
FU1.
Does
Check drive motors for
fuse show
Yes proper operation.
continuity
Replace faulty motors.
?
No
Check drive motors,

rectifiers (REC1, 2 & 3),
heatsink, and wiring for
shorts or grounds. Check
wiring to control unit and THE OVERLOAD CONTROL CAN BE A MAJOR CAUSE FOR A NO
F, R, and M switches. TRAVEL CONDITION AND WILL INDICATE A SPECIFIC
Repair or replace as COMPONENT MALFUNCTION. THE OVERLOAD CONTROL SHOULD
necessary. BE IN THE RESET MODE. REFER TO "OVERLOAD CONTROL
CIRCUIT TEST" IN COMPONENT PROCEDURES. NOW MOVE THE
DIRECTIONAL/SPEED CONTROL HANDLE TO FULL SPEED
FORWARD OR REVERSE, OBSERVING THE F, R, M, AND 1S
CONTACTORS FOR ONE OF THE SITUATIONS GIVEN IN CHARTS
T-2A THRU T-2D.
6-18 PDMM-0102 Issued: 9/30/02

T-2A: Truck Has No Travel - All Other Circuits Function
A: F or R and M contactors are NOT activated; 1S is activated
T-2A: TRUCK HAS NO TRAVEL - ALL OTHER CIRCUITS FUNCTION

F or R and M contactors are NOT activated; 1S is closed
Check
interlock
switch S10.
Does
continuity exist
Replace
between pins 3 & 4 No
switch.
when switch is
activated
?
Yes
Does
equalizing time Replace
No
delay function module.
properly
?
Yes
Do
M, F,
and R contactors Replace
No
function contactors.
properly
?
Yes
Does
control unit Replace card or
No
function properly control unit.
?
Yes
Consult Factory
PDMM-0102 Issued: 9/30/02 6-19

T-2B: Truck Has No Travel - All Other Circuits Function
B: F or R contactors are activated then drop out; M and 1S are activated
T-2B: TRUCK HAS NO TRAVEL - ALL OTHER CIRCUITS FUNCTION

F or R contactors are activated then drop out;
M and 1S are activated
Does
control unit fuse
No Replace fuse.
show continuity
?
Yes
Disconnect Pin B from

the power circuit
Does the truck Replace cards

travel in SCR No or control
Range ? unit.
Does
Replace
transformer test No
Yes OK?
transformer.
Does
Replace faulty Yes
SCR2 & SCR3 No
SCR(s).
Test OK ?
Replace capacitors
C1 & C2 with new
Yes capacitors.
Yes Yes
Does
resistor assy
RA2 test OK ? See
"Resistor Assemblies" in No Replace SCR.
Does Capacitors
Component
truck operate Yes were defective.
Procedures
properly
?
No
Consult Factory
6-20 PDMM-0102 Issued: 9/30/02

T-2C: Truck Has No Travel - All Other Circuits Function
C: F or R contactors and 1S contactors are activated; M is NOT activated
T-2C: TRUCK HAS NO TRAVEL - ALL OTHER CIRCUITS FUNCTION

F or R and 1S contactors are activated; M is NOT activated
Does
No Replace SCR.
SCR1 test OK?
Yes
Is
lead to pin B
at control unit Repair or
No
properly replace lead.
connected
?
Yes
Do Repair or
drive motors test No replace
OK? module.
Yes
Does
speed limit
Replace
module function No
module.
Do properly
plugging ?
No Replace relays.
relays (K1 & K2)
test OK?
Yes
Yes Does
limit switch
Make sure truck
(S11) & S16 (if
is not in speed
equipped) show No
limit mode.
Does Repair or replace continuity between
Replace switch.
deadman switch No switch or relay as pins 3 & 4
(S2) test OK? necessary. ?
Yes
Yes
Yes
Does
Replace faulty
control unit
No card or control
Does function
unit.
control and power properly
Repair or replace
circuit wiring to the M ?
No wiring or switches
contactor show proper
MS5A & MS5B.
continuity
? Yes
Consult Factory
PDMM-0102 Issued: 9/30/02 6-21

T-2D: Truck Has No Travel - All Other Circuits Function
D: F or R contactors are NOT activated; M and 1S are activated
T-2D: TRUCK HAS NO TRAVEL - ALL OTHER CIRCUITS FUNCTION

F or R contactors are NOT activated; M and 1S are activated
Does
SCR1 test OK? No Replace SCR.
Yes
Do
Repair or
M contactor
Yes replace
tips stay
contactor.
closed
?
No
Does
the power Repair or
section wiring show No replace
proper wiring.
continuity
?
Yes
Consult Factory
6-22 PDMM-0102 Issued: 9/30/02

T-3: Truck Has No Forward Travel - Reverse Travel Operative
T-3: TRUCK HAS NO FORWARD TRAVEL - REVERSE TRAVEL OPERATIVE
Does
forward
switch MS1 Replace
No
function switch.
properly
?
Yes
Does control Replace cards

unit function No or control
properly unit.
?
Yes
Does
forward contactor Replace
No
F function contactor.
properly
?
Yes
Does
equalizing time Replace faulty
No
delay function module.
properly
?
Yes
Consult Factory
PDMM-0102 Issued: 9/30/02 6-23

T-4: Truck Has No Reverse Travel - Forward Travel Operative
T-4: TRUCK HAS NO REVERSE TRAVEL - FORWARD TRAVEL OPERATIVE
Does
continuity exist Repair or replace
No
between MS1-1 & wiring.
MS2-1
?
Yes
Does
Replace
reverse switch No
switch.
MS2 test OK?
Yes
Does
Replace faulty
control unit
No cards or
function
control unit.
properly
?
Yes
Does
reverse contactor Replace
No Does
R function contactor.
properly equalizing time Replace
No
? delay function module.
properly
?
Yes
Yes
Consult Factory
6-24 PDMM-0102 Issued: 9/30/02

T-5: Truck Has No M Speed - SCR Range Operative
T-5: TRUCK HAS NO M SPEED - SCR RANGE OPERATIVE
Do
high speed
switches MS5A &
No Replace switch.
MS5B function
properly
?
Yes
Does
speed limit module Replace
No
Does function module.
M contactor Replace properly
No ?
function contactor.
properly
?
Yes
Yes
Does
limit switch Make sure truck is
S11 show conti- not in a speed limit
No
nuity between pins mode. Replace
3&4 switch.
?
Yes
Does
control unit's Replace faulty
M-time delay No card or control
circuit function unit.
properly
?
Yes
Is pin B
properly connected to Repair or
power circuit to sense No replace wiring
condition of at pin B
SCR1?
Yes
Consult Factory
PDMM-0102 Issued: 9/30/02 6-25

T-6: Truck Speed Is Slow In SCR Range
T-6: TRUCK SPEED IS SLOW IN SCR RANGE
Do
limit switches Make sure truck is
S11 & S16 show not in a speed limit
No
continuity between pins mode. Replace
3 & 4 on each switch(es).
switch
?
Yes
Are
Adjust or replace
control
the VPG or
unit's width and
No power driver
frequency pulse
cards as
correct
necessary.
?
Yes
Does Does
speed limit module Replace Adjust or replace
No potentiometer
function module. No the potentiometer
VR1 function
properly as necessary.
properly
? ?
Yes
Yes
Does
Adjust or replace
current limit
No the VPG card as
function
necessary. Yes
properly
?
Consult Factory
6-26 PDMM-0102 Issued: 9/30/02

T-7: Truck Runs In Top Speed Only
T-7: TRUCK RUNS IN TOP SPEED ONLY
Does Adjust or replace the

potentiometer No potentiometer as
VR1 test OK? necessary.
Yes
Is
there a
failure of SCR1 in Replace the SCR
conjunction with a and/or auxiliary
Yes
failure in the circuit card as
overload sensing necessary.
circuit
?
No
Does
M-time delay Replace auxiliary
No
function circuit card.
properly
?
Yes
Consult Factory
PDMM-0102 Issued: 9/30/02 6-27

T-8: Truck Acceleration Is Jerky In SCR Range
T-8: TRUCK ACCELERATION IS JERKY IN SCR RANGE
Does Adjust or replace

potentiometer No potentiometer as
VR1 test OK? necessary.
Yes
Is
Adjust or replace
idle repetition
No VPG card as
rate set correctly
necessary.
?
Yes
Does
No Replace REC1.
REC1 Test OK?
Yes
Does
power driver card Replace power
No
function driver card.
properly
?
Yes
Is
there a Repair or replace
poor connection or Yes wiring as
shorted wire necessary.
?
No
Consult Factory
6-28 PDMM-0102 Issued: 9/30/02

T-9: Truck Reacts Violently When Plugged
T-9: TRUCK REACTS VIOLENTLY WHEN PLUGGED
Do
plugging relays
No Replace relay(s).
K1 & K2 test
OK?
Yes
Is
plugging Adjust or replace
adjustment No VPG card as
properly set necessary.
?
Yes
Do
rectifiers REC2 Replace
No
& REC3 function rectifier(s).
properly
?
Yes
Does
the 1S contactor Replace
No
Does function contactor.
the equalizing properly
time delay function No Replace module. ?
properly
? Yes
Yes
Is
there a loose
Repair or replace
connection or Yes
as necessary.
shorted
wire
?
No
Consult Factory
PDMM-0102 Issued: 9/30/02 6-29

T-10: Truck Acceleration Is Jerky Between SCR And M Speed
T-10: TRUCK ACCELERATION IS JERKY BETWEEN

SCR AND M SPEED
Does
Adjust or replace
potentiometer
No potentiometer as
VR1 function
necessary.
properly
?
Yes
Does
M-time delay Replace auxiliary
No
function circuit card.
properly
?
Yes
Is
idle Adjust or replace
repetition rate set No VPG card as
properly necessary.
?
Yes
Consult Factory
6-30 PDMM-0102 Issued: 9/30/02

T-11: Truck Travels On One Motor
T-11: TRUCK TRAVELS ON ONE MOTOR
Do
drive Repair or replace
No
motors test motor.
OK?
Yes
Do
rectifiers REC2 No Replace rectifier(s).
& REC3 test
OK?
Yes
Do
F&R
contactors function No Replace contactor(s).
properly
?
Yes
Do
F & R contactor Replace auxiliary
suppressors function No circuit card or control
properly unit.
?
Yes
Consult Factory
PDMM-0102 Issued: 9/30/02 6-31

T-12: Truck Overload Kicks Out During Operation
T-12: TRUCK OVERLOAD KICKS OUT DURING OPERATION
IF AN OVERLOAD BECOMES A FREQUENT

OCCURANCE, ISOLATE THE SPECIFIC OPERATION
AND USE ONE OF THE FOLLOWING PROCEDURES TO
LOCATE AND CORRECT THE MALFUNCTION.
6-32 PDMM-0102 Issued: 9/30/02

A: F or R contactors open during routine travel
T-12A: TRUCK OVERLOAD KICKS OUT DURING OPERATION

F or R contactors open during routine travel
Note: In travel conditions where an

overload occurs, it may be beneficial
Are to check the pulse width and
all electrical frequency using an oscilloscope.
Repair or replace
connections in the No
connections.
SCR circuitry
tight
?
Yes
Does
control Replace faulty
unit function No card(s) or control
properly unit.
?
Yes
Do
Replace SCRs one at
SCRs
a time until the
function No
malfunction is
properly
corrected.
?
Yes
Consult Factory
PDMM-0102 Issued: 9/30/02 6-33

B: Travel is halted during plugging sequence
T-12B: TRUCK OVERLOAD KICKS OUT DURING OPERATION

Travel is halted during plugging sequence
Do
plugging relays
Replace
K1 & K2 function No
relay(s).
properly
?
Yes
Do Does
Replace
rectifiers REC2 No control unit
rectifier(s). Replace card(s)
& REC3 test function No
OK? or control unit.
properly
?
Yes
Yes
Does
equalizing
Repair or replace
contactor 1S and Does Battery Repair or replace
No contactor or No
interlock S10 function test OK under load? battery.
switch.
properly
? Yes
Yes
Replace SCRs
Do one at a time
SCRs No until the
test OK? malfunction is
corrected.
Yes
Consult Factory
6-34 PDMM-0102 Issued: 9/30/02

C: Truck stalls while operating under a load
T-12C: TRUCK OVERLOAD KICKS OUT DURING OPERATION

Truck stalls while operating under a load
Does battery Repair or Replace

No battery.
test OK under load? Note: In travel conditions
where an overload occurs, it
may be benificial to check
the pulse width and
Yes
frequency using an
oscilloscope.
Replace SCRs
one at a time
Do
No until the
SCRs test OK?
malfunction is
corrected.
Yes
Do
Replace
rectifiers function No
rectifier(s).
properly
?
Does
Replace the
Yes the transformer No
transformer.
test OK?
Does
control unit Replace
No card(s) or Yes
function
properly control unit.
? Yes
Do the capacitors Replace the

No
charge properly? capacitors.
Yes
Consult Factory
PDMM-0102 Issued: 9/30/02 6-35

T-13: Truck Has No Lift - All Other Functions Operative
T-13: TRUCK HAS NO LIFT - ALL OTHER FUNCTIONS OPERATIVE
Check battery
state-of-charge
gauge.
Is
the meter Recharge, repair, or
needle in the red Yes replace batteries as
zone necessary.
?
No
If Properly position the

truck has actuator plate and/or
remote lift/lower, No replace switch.
is lift actuator plate up and
does lift interlock switch
S33 show continuity
between pins
3&4
?
Yes
Does
lift switch
S4 show continuity Replace
No
between pins 1 & 2 switch. If
when actuated truck has
? Replace
either remote No
module.
option, does DA-1
test OK?
Yes
Yes
Go to Chart
T-13-1
6-36 PDMM-0102 Issued: 9/30/02

T-13-1
Does
battery
controller relay K5 Replace
No
function relay.
properly
?
Yes
Does
Replace
diode DA-8 test No
module.
OK?
Yes
Does
Repair or
lift motor MP
Does No replace
lift contactor P Replace function
No motor.
function contactor. properly
properly ?
?
Yes
Yes
Does
lift circuit
Repair or
wiring indicate
Does Yes replace as
Replace shorts or
suppressor SUP-1 No grounds
necessary.
module.
test OK? ?
Yes No
Yes
Do
Does lift hydraulic Repair
lift fuse FU-2 Replace components No or replace
No
show continuity fuse. function components.
? properly
?
Yes
Consult Factory
PDMM-0102 Issued: 9/30/02 6-37

T-14: Remote Lift/Lower Function Inoperative
T-14: REMOTE LIFT/LOWER FUNCTION INOPERATIVE
With
keyswitch
in RMT position, does
continuity show
between pins S1-1-1 &
S1-1-2
?
Yes
REMOTE REMOTE
LIFT LOWER
Do Do
remote lift remote lower
switches S19A & switches S20A &
No Replace switch(es). No Replace switch(es).
S19B function S20B function
properly properly
? ?
Yes Yes
Does
Does Repair or replace
No Replace module. solenoid SOL6 test No
DA-1test OK? solenoid.
OK?
Yes Yes
Yes
Does
No Replace module.
DA-3 test OK?
Does
Repair or
wiring indicate
Yes replace as
shorts or
necessary.
grounds
?
No
Consult Factory
6-38 PDMM-0102 Issued: 9/30/02

T-15: Auxiliary And Steering Systems Inoperative
T-15: AUXILIARY AND STEERING SYSTEMS INOPERATIVE
Does
auxiliary
Repair or replace
contactor X function No
contactor as required.
properly
?
Yes
Does
Replace
suppressor No
suppressor.
SUP1 test OK?
Yes
Does
auxiliary fuse
FU3 show No Replace fuse.
continuity
?
Yes
Do
Repair or
auxiliary
No replace
hydraulic components
Does components.
test OK?
auxiliary motor
Repair or
MX function No
replace motor.
properly
?
Yes
Yes
No
Does
auxiliary circuit Repair or
wiring indicate Yes replace as
shorts or necessary.
grounds
?
Consult Factory
PDMM-0102 Issued: 9/30/02 6-39

T-16: Crab Steering Inoperative
T-16: CRAB STEERING INOPERATIVE
Do
crab steer
switches S25, Repair or
S26, S28, S29 & No replace
S30 function switch(es).
properly
?
Yes
Does
steer centering
Replace
relay K11 function No
relay.
properly
?
Does
Yes crab steer
Repair or
circuit wiring
Yes replace as
indicate shorts or
necessary.
grounds
Does ?
Replace
diode DA2 No
module.
test OK?
No
Yes Do
Repair or
crab steer
replace
hydraulic No
components as
Yes components test
necessary.
Do OK?
Repair or
crab steer
No replace
solenoids SOL1 &
solenoid(s).
SOL2 test OK? Yes
Consult Factory
6-40 PDMM-0102 Issued: 9/30/02

T-17: Horn Inoperative
T-17: HORN INOPERATIVE
Does
horn switch S3
No Repair switch.
function properly
?
Yes
Does
horn coil H No Replace horn.
test OK?
Yes
Does
Replace
suppressor SUP3 No
suppressor.
test OK?
Yes
Consult Factory
PDMM-0102 Issued: 9/30/02 6-41

T18: Remote Mode Operation
T-18: REMOTE MODE OPERATION
THE FOLLOWING SITUATIONS COVER A VEHICLE WITH

THE REMOTE TRAVEL OPTION WHILE OPERATING IN
THE REMOTE (REM) MODE ONLY. REFER TO PREVIOUS
CHARTS FOR TROUBLESHOOTING THE REMOTE
TRAVEL OPTION IN THE STANDARD (STD) MODE.
6-42 PDMM-0102 Issued: 9/30/02

T18A: Remote Inoperative
T-18A: REMOTE MODE OPERATION

Completely inoperative - Standard Mode operative
With
keyswitch turned
to REM, does continuity
Replace
exist between S1-1-1 & No
switch. With
S1-1-2 and between
S1-3-1 & mast fully re-
S1-3-2 tracted, does continuity Replace
No
? show between pins 3 switch.
& 4 of limit switch
S16
Yes ?
With Yes
platform properly
mounted, does continuity
Replace
exist between pins 3 & 4 No
switch. Does
on Replace
DA9 function No
platform interlock diode.
properly
switch S45
?
?
Yes Yes
Yes
Do Does
operator interlock relay Replace
interlock switches No
K7 function relay.
S42, (S43 & S44 if used) Replace properly
No
show continuity between switch(es). ?
pins 3 & 4 when
activated
? Yes
Consult Factory
PDMM-0102 Issued: 9/30/02 6-43

T18B: Remote Travel Inoperative
T-18B: REMOTE MODE OPERATION

Travel function inoperative
Does
Replace power
power supply test No
supply.
OK?
Yes
Does
interlock relay K7
No Replace relay.
function properly
?
Yes
Does
Does aisle sensor
No
aisle sensor function properly
relay K6 function No Replace relay. ?
properly
?
Replace aisle
Yes sensor.
Yes
does
Does wiring to the No
DA11test No Replace diode. Yes platform test OK?
OK?
Repair or replace
wiring.
Yes
GO TO STANDARD NO TRAVEL - ALL OTHER CIRCUITS FUNCTION

CHART T-2 AND FOLLOW ENTIRE PROCEDURE AS REQUIRED.
6-44 PDMM-0102 Issued: 9/30/02

T18C: Remote Forward Travel Inoperative
T-18C: REMOTE MODE OPERATION

Forward travel inoperative - reverse travel operative
Does
wiring between
forward travel switch
Repair or replace
MS4-1 and reverse travel No
wiring.
switch MS3-1 show
continuity
?
Yes
Does
No Replace switch.
forward travel switch
MS4 test OK?
Yes
Does
relay K10
Replace relay or
function No
diode DA9.
properly
?
Yes
GO TO STANDARD NO FORWARD TRAVEL - REVERSE TRAVEL OPERATIVE

CHART T-3 AND PROCEED FROM F CONTACTOR CHECK.
PDMM-0102 Issued: 9/30/02 6-45

T18D: Remote Reverse Inoperative
T-18D: REMOTE MODE OPERATION

Reverse travel inoperative - forward travel operative
Does
reverse travel
No Replace switch.
switch MS3 test
OK?
Yes
Does
relay K10
function No Replace relay.
properly
?
Yes
GO TO STANDARD NO REVERSE TRAVEL - FORWARD TRAVEL OPERATIVE CHART T-4

AND PROCEED FROM R CONTACTOR CHECK.
6-46 PDMM-0102 Issued: 9/30/02

T18E: Remote M Speed Inoperative
T-18E: REMOTE MODE OPERATION

M speed inoperative - SCR range operative
Do
M speed
Replace
switches MS6A No
switch(es).
& MS6B
test OK?
Yes
Does
relay K9
function No Replace relay.
properly
?
Yes
GO TO STANDARD NO M SPEED - SCR RANGE OPERATIVE CHART T-5

AND PROCEED FROM M CONTACTOR CHECK.
PDMM-0102 Issued: 9/30/02 6-47

T18F: Remote Erratic Travel Conditions
T-18F: REMOTE MODE OPERATION

Erratic travel conditions
REFER TO CHARTS T-6 THRU T-10 PLUS DO A

TEST OF REMOTE TRAVEL POTENTIOMETER
VR2 DIRECTLY AFTER TESTING STANDARD
POTENTIOMETER VR1.
6-48 PDMM-0102 Issued: 9/30/02

T18G: Remote Lift Operation
G: Lift Function Inoperative
T-18G: REMOTE MODE OPERATION

Lift Function Inoperative
Does
relay K7 function
No Replace relay.
properly
?
Yes
Does
lift switch
S19 show continuity
No Replace switch.
between pins 3 & 4
when activated
?
Does
Yes relay K9 function No Replace relay.
properly
?
Does
DA1 test No Replace diode. Yes
OK?
Does
Yes SOL9 No Replace SOL9.
test OK?
Does
Replace
solenoid SOL8 No
solenoid. Yes
test OK?
Yes Yes Does

DA10 No Replace diode.
test OK?
Does
No Replace diode.
DA2 test OK?
Yes
GO TO STANDARD NO LIFT - ALL OTHER

CIRCUITS FUNCTION CHART T-13
AND PROCEED FROM RELAY K5 CHECK.
PDMM-0102 Issued: 9/30/02 6-49

T18H: Remote Lower Operation
H: Lower Function Inoperative
T-18H: REMOTE MODE OPERATION

Lower Function Inoperative
Does
relay K7 function No Replace relay.
properly
?
Yes
Does
lower switch
S20 show continuity
No Replace switch.
between pins 3 & 4
when activated
?
Yes
Does
DA3 function
No Replace diode.
properly
?
Yes
Does
solenoid SOL6
No Replace solenoid.
function
properly
?
Yes
Consult Factory
T18I: Remote Mode Horn Operation

I: Horn Inoperative
6-50 PDMM-0102 Issued: 9/30/02

T-18I: REMOTE MODE OPERATION

Horn Inoperative
Does
horn switch
S3A show continuity
No Replace switch.
between both NO pins
when activated
?
Yes
Does
Replace
suppressor
No suppressor
SUP3 function
SUP3.
properly
?
Yes
Does
horn function
No Replace horn.
properly
?
Yes
Consult Factory
PDMM-0102 Issued: 9/30/02 6-51

6-52 PDMM-0102 Issued: 9/30/02

Raymond ® Sideloader Maintenance Manual Component Procedures
Component Procedures 7:
Component Locator Photos . . . . 7-3 Attachment and Load Handler . 7-55

General Procedures . . . . . . . . . 7-11 General . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
Mast Tilt Cylinder
Tire Replacement . . . . . . . . . . . . . . . . . . 7-12 Repair and Replacement . . . . . . . . . . . . 7-57
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Fork Tilt Cylinder
Brushes . . . . . . . . . . . . . . . . . . . . . . 7-14 Repair and Replacement . . . . . . . . . . . . 7-59
Commutator . . . . . . . . . . . . . . . . . . . 7-16 Carriage Reach Cylinder Repair and Replace-
Terminal Nuts . . . . . . . . . . . . . . . . . 7-18 ment (SLR20TT) . . . . . . . . . . . . . . . . . . 7-60
Electric Motor Tests . . . . . . . . . . . . . 7-18 Mast Traverse Motor
Drive Axle Assembly . . . . . . . . 7-23 Repair and Replacement . . . . . . . . . . . . 7-61
Lift Chain
General . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 Repair and Replacement . . . . . . . . . . . . 7-62
Drive Motor Carriage Roller Bearing Replacement . . . . 7-63
Inspection and Cleaning . . . . . . . . . .. 7-25 NFL and FFL Procedure . . . . . . . . . . . 7-63
Drive Wheel Replacement . . . . . . . . . . .. 7-26 TT Procedure . . . . . . . . . . . . . . . . . . . 7-63
Removal . . . . . . . . . . . . . . . . . . . . .. 7-26 Side Cylinder Repacking (TFL and TT) . . . 7-65
Installation . . . . . . . . . . . . . . . . . . .. 7-27 Lift Cylinder
Crab Steer Alignment and Adjustment .. 7-28 Repair and Replacement . . . . . . . . . . . . 7-66
Drive Axle Removal and Reassembly. . .. 7-30 NFL Procedure . . . . . . . . . . . . . . . . . . 7-66
Drive Motor Replacement . . . . . . . . . . .. 7-32 FFL Procedure . . . . . . . . . . . . . . . . . . 7-67
Removal . . . . . . . . . . . . . . . . . . . . .. 7-32 TT Procedure . . . . . . . . . . . . . . . . . . . 7-67
Installation . . . . . . . . . . . . . . . . . . .. 7-33 Lift Cylinder Bleeding . . . . . . . . . . . . . . . 7-68
Drive Unit Repair and Replacement . . .. 7-34 Mast Assembly Removal . . . . . . . . . . . . . 7-69
Disassembly . . . . . . . . . . . . . . . . . .. 7-34 Mast Drive
Reassembly . . . . . . . . . . . . . . . . . .. 7-35 Repair and Replacement . . . . . . . . . . . . 7-70
Tie Rod Replacement . . . . . . . . . . . . . .. 7-36 Mast and Telescopic
Crab Steer Cylinder Replacement . . . . .. 7-36 Roller Bearing Replacement . . . . . . . . . 7-72
Steer Axle Assembly . . . . . . . . 7-37 Hydraulics . . . . . . . . . . . . . . . . 7-73
General . . . . . . . . . . . . . . . . . . . . . . . . . 7-38 General . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Steerable Wheel Replacement . . . . . . . . . 7-39 Leakage . . . . . . . . . . . . . . . . . . . . . . . 7-74
Steering Linkage Alignment and Adjustment . . Lift Control and Linkage . . . . . . . . . . . . . 7-75
7-40 Linkage and Master Cylinder Maintenance
Steer Axle Removal and Reassembly . . . . 7-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75
Steer Linkage Replacement. . . . . . . . . . . 7-43 Lift Pump and Slave Cylinder Maintenance
Steer Cylinder Replacement . . . . . . . . . . 7-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75
Steer Knuckle Replacement . . . . . . . . . . 7-45 Lift Pump Replacement . . . . . . . . . . . 7-76
Hydraulic Manifolds . . . . . . . . . . . . . . . . 7-78
Steering . . . . . . . . . . . . . . . . . 7-47
Relief Valve Pressure Settings . . . . . . 7-79
Steering Chain Adjustment . . . . . . . . . . 7-48
Electrical. . . . . . . . . . . . . . . . . . 7-81
Brakes . . . . . . . . . . . . . . . . . . 7-49
General . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82
Service Brake Adjustment . . . . . . . . . . . 7-50 Heat Sink Insulation . . . . . . . . . . . . . 7-82
Parking Brake Adjustment . . . . . . . . . . . 7-51 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
Brake Shoe Replacement . . . . . . . . . . . . 7-52 Battery Exterior Cleaning. . . . . . . . . . 7-83
Wheel Cylinder Repair or Replacement . . 7-54 Charging . . . . . . . . . . . . . . . . . . . . . . 7-84
Component Testing . . . . . . . . . . . . . . . . . 7-87
PDMM-0102 Issued: 9/30/02 7-1

Component Procedures Raymond ® Sideloader Maintenance Manual
Contactors . . . . . . . . . . . . . . . . . . . . . . . . 7-88 Transient Suppressors for the M, F, and R

Cleaning. . . . . . . . . . . . . . . . . . . . . . . 7-88 Contactors . . . . . . . . . . . . . . . . . . 7-118
Tip Inspection . . . . . . . . . . . . . . . . . . 7-88 Equalizing Time Delay . . . . . . . . . . . 7-119
Contactor Coil Replacement . . . . . . . . 7-89 Speed Limit Module . . . . . . . . . . . . . 7-120
Replacement of Contactor Tips, Insulation SCRs. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-122
and/or Core and Rod Assembly . . . . 7-90 Test Procedure . . . . . . . . . . . . . . . . 7-122
SCR1 Replacement . . . . . . . . . . . . . 7-122
Controls . . . . . . . . . . . . . . . . . . 7-95 SCR2 & SCR3 Replacement . . . . . . . 7-124
Directional/Speed Control Assembly . . . . 7-96 Rectifiers. . . . . . . . . . . . . . . . . . . . . . . . 7-125
Master Switches . . . . . . . . . . . . . . . . . 7-96 Test Procedure . . . . . . . . . . . . . . . . 7-125
Potentiometer Test . . . . . . . . . . . . . . . 7-97 Replacement . . . . . . . . . . . . . . . . . . 7-125
Potentiometer Removal or Replacement Plugging Relays
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99 K1 & K2 . . . . . . . . . . . . . . . . . . . . . . . 7-127
Potentiometer Gear Binding Adjustment Battery Controller and K5 Relay . . . . . . 7-129
. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-100 Relay Test Procedure . . . . . . . . . . . . 7-129
Directional/Speed Control Reassembly Automatic Steer Centering Relay K11 . . 7-130
Checklist . . . . . . . . . . . . . . . . . . . . 7-101 Deadman Relay K12 and Light Load Relay K13
Control Unit. . . . . . . . . . . . . . . . . . . . . . 7-102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-131
Input Voltage Check . . . . . . . . . . . . . 7-103 Diode Assemblies . . . . . . . . . . . . . . . . . 7-132
Regulated Voltage Check . . . . . . . . . 7-104 DA1. . . . . . . . . . . . . . . . . . . . . . . . . 7-132
Width and Frequency Pulse Checks . 7-105 DA2. . . . . . . . . . . . . . . . . . . . . . . . . 7-132
Idle Repetition (Rep) Rate Adjustment 7-106 DA3, DA4, and DA8. . . . . . . . . . . . . 7-133
Plugging Adjustment . . . . . . . . . . . . 7-106 DA5. . . . . . . . . . . . . . . . . . . . . . . . . 7-133
1/2 Speed Test (VPG Card). . . . . . . . 7-108 DA6. . . . . . . . . . . . . . . . . . . . . . . . . 7-134
1/8 Speed Test. . . . . . . . . . . . . . . . . 7-109 DA7 and DA12 . . . . . . . . . . . . . . . . 7-134
Forward and Reverse Time Delay Circuit Resistor Assemblies . . . . . . . . . . . . . . . 7-135
Test . . . . . . . . . . . . . . . . . . . . . . . . 7-110 RA1 . . . . . . . . . . . . . . . . . . . . . . . . . 7-135
“M” Time Delay Circuit Test . . . . . . . 7-111 RA2 . . . . . . . . . . . . . . . . . . . . . . . . . 7-135
Equalizing Time Delay Circuit Test . . 7-112 Suppressor Assemblies . . . . . . . . . . . . . 7-136
Current Limit . . . . . . . . . . . . . . . . . . 7-113 SUP1 . . . . . . . . . . . . . . . . . . . . . . . . 7-136
“M” Lockout Circuit Test . . . . . . . . . 7-114 SUP3 . . . . . . . . . . . . . . . . . . . . . . . . 7-136
Overload Control Circuit Test . . . . . . 7-115
Schematics . . . . . . . . . . . . . . . . A-11
Weld Detect Circuit . . . . . . . . . . . . . 7-116
Power Driver Circuit Card . . . . . . . . 7-117
7-2 PDMM-0102 Issued: 9/30/02

Component Locator Photos

Mast
Lift
Cylinder
Hose Reel
Lift
Operator’s Chains
Compartment
Hydraulic
Reservoir
Electrical/
Mechanical
Compartment
Hydraulic
Compartment
Auxiliary
Fork
Carriage
Load Bed (optional)
Covers
Steer Wheels Drive Wheels

Guide Roller
Guide Roller (optional)
(optional)
73292_027.TIF
Figure 7-1: Component Locator - Model 71B/76 Sideloader (shown with optional Auxiliary Fork Carriage)
PDMM-0102 Issued: 9/30/02 7-3

Fork Tilt Mast Tilt Mast Traverse Steering

Control Control Control Wheel
Emergency
Disconnect
Crab Steer
Buttons
Lift
Control Horn
Button
Lower
Control
Key
Switch
Battery
Controller
Gauge
Hour
Meter
Emergency Directional/Speed
Manual Control Handle
Lower
73292_029.TIF
Figure 7-2: Component Locator - Operator’s Compartment
7-4 PDMM-0102 Issued: 9/30/02

Lowering
Valve
Lift Control
Lift Master Lever
Cylinder
Steering
Chain
Steering
Orbitrol
73540_009.TIF
Figure 7-3: Operator’s Compartment - Cover Removed
PDMM-0102 Issued: 9/30/02 7-5

Parking Brake
(Deadman Pedal)
Service Brake Pedal
73292_034.TIF
Figure 7-4: Brake Pedals
Mast
Traverse
Motor
Mast Tilt
Cylinder
Wear
Bars
Figure 7-5: Elevating Section - Extended
7-6 PDMM-0102 Issued: 9/30/02

Plugging
Contactors Transformer Heat
Fuses Relays
Sinks
Equalizing
Time
Delay
SCRs
Control
Unit
Speed
Limit
Module
Rectifiers
Horn
Check
Valve
Auxiliary Filter
Motor
Auxiliary
Pump
Lift Pump Lift Motor
7P5180009.TIF
Figure 7-6: Electrical/Hydraulic Compartment - Drive End
PDMM-0102 Issued: 9/30/02 7-7

Control
Valves
Lowering
Lock-Out
Solenoid
Pressure
Reliefs
Brake
Dumping
Solenoid
Speed
Limiting
Switches
7P5180009.TIF
Figure 7-7: Hydraulic Compartment - Steer End
7-8 PDMM-0102 Issued: 9/30/02

Drive
Motor Drive Unit
Crab Steer
Cylinder
Drive
Drive
Wheel
Wheel
Tie Rod
Crab Steer
Switches
7P5180009.TIF
Figure 7-8: Drive Axle
Parking
Brake
Actuators
Steer
Cylinder
Steer
Wheel
Steer
Wheel
Intermediate
Link
Tie Rods
Figure 7-9: Steer Axle
PDMM-0102 Issued: 9/30/02 7-9

7-10 PDMM-0102 Issued: 9/30/02

General Procedures
General Procedures
PDMM-0102 Issued: 9/30/02 7-11

Tire Replacement General Procedures
Tire Replacement
Any misalignment of the tire and hub while the
tire is being pressed on the hub can cause
damage to the hub. For this reason, chamfers
have been provided on the outside edge of the
hub and on the end of the inside diameter of the
tire’s metal insert. The chamfers help to center
the hub and tire during pressing and to reduce
the possibility of misalignment.
! CAUTION
To prevent damage, the hub must be
installed on the circular ram with the
chamfered side up. 7
Figure 7-10: Tire Replacement

1. Examine the inside surface of the metal
insert on the new tire. Remove any scaling
or rust with sandpaper. Clean the inside of
the metal insert.
2. Place a circular ram on the press table. See
Figure 7-10. The length of the ram must be
longer than the width of the old tire to
permit complete removal of the old tire. The
outside diameter of the ram must be small
enough to fit loosely in the insert of the tire
but must be large enough to rest squarely
on the flat surface on the outer edge of the
hub.
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.
7-12 PDMM-0102 Issued: 9/30/02

General Procedures Tire Replacement
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. Start pressing the new tire on the hub and
the old tire off the wheel. Operate 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.
PDMM-0102 Issued: 9/30/02 7-13

Motors General Procedures
Motors
Brushes
Inspection
Conduct a partial inspection of the drive motor
after every 1,000 hours of truck operation. If
you work in an abnormally severe or caustic
environment or if you have a rigorous duty
cycle, inspect the motor more frequently.
Set up and rigidly adhere to a strict inspection
schedule to obtain the maximum efficiency
from the electrical equipment.
Each partial inspection of the motor must
include the following:
1. Inspect the brushes for wear and for correct
contact with the commutator. Record the
level of wear on the brushes and
commutator. This history will give you an 7MTRBRUSH.tif
indication of whether a brush must be Figure 7-11: Drive Motor Brush, Typical Location
changed or if it can wait until the next
inspection. See Table 7-1.
NOTE: Overloading a unit is ultimately reflected
in the motor and brush wear; therefore,
you must take this into account when
considering brush replacement.
2. Measure brush spring tension.
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. Examine brush holders for solid connection
to the mounting support. Tighten the
mounting screws as necessary.
5. Examine 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. Examine 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.
7-14 PDMM-0102 Issued: 9/30/02

General Procedures Brushes
Replacement
If one brush needs replacement, always replace
the entire set of brushes.
Use only genuine Raymond brushes. Using
another type of brush could cause damage to
the commutator or cause excessive brush wear.
If the end of the brush is not already contoured
to fit the commutator, seat the brush to the
commutator:
NOTE: If the motor commutator is not
accessible, form the brush contour
using a brush seating stone.
1. Move the motor brush springs out of your
way.
2. Wrap a piece of 00 sandpaper around the
commutator. Do not use emery cloth to
seat brushes.
3. Move the brushes back down in their
holders. Rotate the armature so that the
face of the brushes are contoured to match
the curve of the commutator.
4. Remove the sandpaper.
5. Blow any dust out of the motor with clean,
compressed air at a maximum of 30 psi
(207 kPa).
PDMM-0102 Issued: 9/30/02 7-15

Commutator General Procedures
Commutator
Inspection
Segments
The commutator must be inspected for surface Mica
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 7-12.
NORMAL
The commutator must be smooth and clean to
UNDERCUT
provide maximum brush wear. When High Mica
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.
HIGH MICA
Good commutation will be indicated by a dark
brown polished commutator and an evenly
polished brush wearing surface. See Table 7-1, 71881 003.tif
“Commutator Surfaces.” Figure 7-12: Mica Inspection
If the commutator appears rough, pitted, or has

signs of burning or heavy arcing between the
commutator bars, the motor must be removed
for servicing.
Table 7-1: 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, etc. This is related to the
winding design of the armature. Difficulty
caused from split windings crossing in the
same slot.
Unsatisfactory Frequently because of under-loaded

Condition-Streaky Film operation, machine grossly over-brushed
With No Commutator or brush grade incorrect for particular
Wear machine application. Atmosphere and
environmental conditions can contribute.
7-16 PDMM-0102 Issued: 9/30/02

General Procedures Commutator

Table 7-1: Commutator Surfaces
Condition Probable Cause Commutator Surface
Unsatisfactory Patchy colors of changing densities and

Condition-Uneven Film shape. Because of 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.
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 because of armature
Pitch fault, 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. Because of sparking
Spots under brush that gives rise to spots being
of a random distribution. If not corrected,
will result in scored commutator.
PDMM-0102 Issued: 9/30/02 7-17

Terminal Nuts General Procedures
Servicing
Terminal
Servicing a motor for an abnormal commutator Stud
surface condition and high mica or mica
undercutting requires special equipment at a Motor
motor rebuilding facility. Do not attempt to Cable
service the motor yourself. Securing Flat
Nut Washer
Terminal Nuts Fiber

Stud Washer
When you disconnect and reconnect any power Terminal Motor
leads to a motor, always tighten the motor cable Securing Housing
Nut
securing nuts with a torque wrench to prevent
over-tightening them and damaging the motor.
Use a second wrench on the stud terminal 7CABLENUT.eps
securing nut to avoid twisting the stud. Figure 7-13: Motor Terminal Nuts
Measure Table 7-2 torques each time you
examine motor brushes.
Table 7-2: Torque Measurements Compound Motor

Motor Cable Stud Terminal
Stud Size A
Securing Nut Securing Nut
3/8 in. 100-120 in. lbs 140-160 in. lbs
(M10) (11.2-13.6 Nm) (15.8-18.1 Nm)
MX
5/16 in. 90-110 in. lbs 110-140 in. lbs
(M8) (10.2-12.4 Nm) (12.4-15.8 Nm)
1/4 in. 40-50 in. lbs 50-60 in. lbs
(M6) (4.5-5.6 Nm) (5.6-6.8 Nm)
S/D
Electric Motor Tests
Shunt-Wound Motor
Motor Type A2 S2/E2/D2
• Compound-wound motors, such as the lift
and auxiliary motors, have only two MD
external connections because the armature
and field windings are connected internally. A1 S1/E1/D1
See Figure 7-14.
• Shunt-wound motors, such as the drive 7Dschem.eps
motor, has four external connections: two Figure 7-14: Motor Circuits
armature (A) and two field (S, E, or D).
Open Circuit Motor Test

An open circuit is one where the electrical
circuit within the motor has been broken. This
can be caused by:
• Bad brushes or brush springs
7-18 PDMM-0102 Issued: 9/30/02

General Procedures Electric Motor Tests
• A broken wire in the field or armature

winding
• A loose or bad connection
1. Isolate the motor from the truck circuit by
removing the power cables. Use two
wrenches to avoid twisting the terminal
stud. See Figure 7-14.
2. With the motor at room temperature,
connect the leads of a digital ohmmeter
between the individual circuits in the
motor. See Table 7-3.
Table 7-3: Motor Resistance Measurements
Motor Probe Points Acceptable Resistance
Traction S1 to S2 0.9 to 1.5 ohms

(Drive)
A1 to A2 Less than 1 ohm
A1 to S1; A1 to S2 Greater than 100,000 ohms
A2 to S1; A2 to S2 Greater than 100,000 ohms
A1 or A2 to Frame Greater than 100,000 ohms
Lift A to S 0.020–0.030 ohms
A to Frame Greater than 100,000 ohms
Auxiliary A1 to A2 0.01–0.10 ohms
A1 or A2 to Frame Greater than 100,000 ohms
Measure all readings at room temperature.
3. If the meter indicates high resistance in the

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

In a grounded motor, an electrical circuit exists
between the current-carrying conductors and
the motor housing. This can be caused either by
direct contact or through conductive foreign
material.
PDMM-0102 Issued: 9/30/02 7-19

Electric Motor Tests General Procedures
The ground may be caused by:

• Insulation breakdown
• Brush leads touching the motor housing
• Build-up of carbon dust or other materials
To test a motor for grounds:
1. Isolate the motor from the truck circuit by
removing the power cables. Use two
wrenches to avoid twisting the terminal
studs.
2. Attach one lead of a digital ohmmeter to a
motor terminal and the other lead to an
unpainted surface of the motor housing.
Set the ohmmeter to the highest scale.
3. If the ohmmeter reads resistance of less
than 100,000 ohms, the motor is grounded.
Clean, repair or replace the motor as
necessary.
Short-Circuited Winding
A short-circuited winding is one where the
insulation on the field or armature has broken
down at two or more points. The breakdown
creates a low resistance path, permitting
current to flow from one turn of the coil to
another adjacent coil turn, without actually
flowing through the coil wire. The result is a
decrease in total resistance of the motor
winding and an increase in the current flow.
The severity of the short circuit depends on its
location.
A shorted motor may be indicated by:
• Slow or sluggish operation
• Running faster than normal
• Overheating
• Blowing a power fuse
• Severe burning or discoloring on one or two
commutator segments every 90° of rotation
These symptoms can be caused by problems
other than the motor itself:
• Brake too tight or dragging
• Wheel bearings too tight
• Faulty transmission
• Binding in an attached pump
7-20 PDMM-0102 Issued: 9/30/02

General Procedures Electric Motor Tests
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 probably
cause heating and could 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.
PDMM-0102 Issued: 9/30/02 7-21

Electric Motor Tests General Procedures
7-22 PDMM-0102 Issued: 9/30/02

Drive Axle Assembly

Drive Axle Assembly
PDMM-0102 Issued: 9/30/02 7-23

General Drive Axle Assembly
General
The drive axle assembly and its components
require routine lubrication and maintenance.
See “Lubrication and Inspection Points” on
page 5-8.
The lubrication procedures, as well as some
maintenance procedures, can be performed by
removing the load bed covers.
More complex maintenance procedures require
the removal of the drive axle assembly from the
truck.
7-24 PDMM-0102 Issued: 9/30/02

Drive Axle Assembly Drive Motor Inspection and Cleaning
Drive Motor
Inspection and Cleaning
With the crab steering centered and load bed
covers removed, perform the following;
2. Remove the ring cover from the end of the
motor permitting access to the brushes and
springs.
3. Clean dust particles from the motors using
low air pressure [5 psi (35 kPa) max].
Inspect the motors. See “Motors” on
page 7-14.
4. If brushes and springs need to be replaced,
remove the end cover to make removal
easier.
NOTE: Be careful not to disturb the brush
holder assembly when removing the end
cover. If it is displaced, the motor
characteristics can change.
5. Replace worn brushes and springs.
6. Install covers.
PDMM-0102 Issued: 9/30/02 7-25

Drive Wheel Replacement Drive Axle Assembly
Drive Wheel
Replacement
Removal
! WARNING
• Use extreme care when the lift
truck is jacked up.
• Never block the lift truck between
the telescopic and the floor.
• Use a suitable hoist to stabilize the
mast.
• Keep hands and feet clear from
vehicle while jacking the lift truck.
• After the lift truck is jacked, install
solid blocks or jack stands
beneath it to support it.
• Do NOT rely on the jack alone to
support the lift truck. See
“Jacking Safety” on page 2-11.
2. Jack and block the drive end of the truck so

the wheels are approximately 1/4 in.
(6.35 mm) off the floor.
3. Attach special wrench (P/N 111-001-981)
to the wheel nut with a 3/8-16 X 1½ in.
screw (P/N 710-140) and to the chassis
with a 3/4-16 X 2¾ in. screw (P/N
710-428). See Figure 7-15.
4. Reconnect the battery connector and turn
the key switch ON.
5. With the deadman pedal depressed,
activate the directional speed control 7
handle in the direction that will loosen the Figure 7-15: Drive Wheel Removal
nut.
the battery connector. Remove the nut.
7. Attach a wheel puller to the 1/2-20 holes in
the wheel hub and pull the wheel assembly.
8. If the tire needs to be replaced, see “Tire
Replacement” on page 7-12.
7-26 PDMM-0102 Issued: 9/30/02

Drive Axle Assembly Installation
9. Examine and replace any bearings showing

signs of wear. Repack the bearings with
grease. See "Lubrication Specification
Chart" on page A-2.
Installation
1. Mount the wheel on the drive shaft and
hand tighten the wheel nut.
2. Attach the special wrench, as in Step 3 of
the removal instructions.
the key switch ON.
4. Depress the deadman pedal and activate
the control handle in the direction that will
tighten the nut. Apply full stall torque of the
drive motor for 0.5 to 1.0 second.
6. Remove the special wrench.
7. Mark an indication point on the wheel and
perform the torquing procedure after 8
hours, 1 week, 1 month, and 6 months of
operation.
PDMM-0102 Issued: 9/30/02 7-27

Crab Steer Alignment and Adjustment Drive Axle Assembly
Crab Steer Alignment

and Adjustment
Steering alignment or adjustment may be
necessary after replacing components on the
drive axle.
1. Place a straight edge below the vehicle skirt
and flush with or parallel to the drive wheel
hubs, then measure the distances at A and
B. See Figure 7-16. Make sure the straight
edge is on the wheel hubs and not the tire
rims.
Figure 7-16: Crab Steer Alignment and Adjustment
2. If A and B change by more than 1/4 in.

(6.35 mm), adjust the tie rod until they are
within 1/4 in. (6.35 mm).
3. After aligning the wheels, examine the crab
steer switch adjustments.
• Actuators must measure 3/16 to 1/4 in.
(4.83 to 6.35 mm) from the tie rod.
• Actuators must measure 3/16 to 1/4 in.
(4.83 to 6.35 mm) from the cams.
• Actuator arms must measure 90° ±5° from
the tie rod.
4. Activate crab left, then return to center.
7-28 PDMM-0102 Issued: 9/30/02

Drive Axle Assembly Crab Steer Alignment and Adjustment
5. The wheel hub must be parallel within a

3/32 in. (2.3 mm) difference between points
C and D and a straight edge laid along the
skirt.
6. If the wheel did not make it back to parallel,
move Cam E to the right. If the wheel went
beyond parallel, move Cam E to the left.
7. Activate crab right, then return to center.
8. The wheel hub must be parallel within a
3/32 in. (2.3 mm) difference between points
C and D and a straight edge laid along the
skirt.
9. If the wheel did not make it back to parallel,
move Cam F to the left. If the wheel went
beyond parallel, move Cam F to the right.
NOTE: If the crab steer mechanism searches
continuously, move Cams E and F away
from center an equal distance and
repeat steps 3 thru 9.
PDMM-0102 Issued: 9/30/02 7-29

Drive Axle Removal and Reassembly Drive Axle Assembly
Drive Axle Removal and

Reassembly
2. Disconnect drive motor cables underneath
the contactor panel at TP-15 thru TP-22.
3. Remove the three clamps to the rear of the
hydraulic compartment and feed the cables
through the bottom of the compartment.
4. Remove the hoses from the crab steer
cylinder and cap all fittings.
5. Remove the retaining screw and pivot lift
pump and motor assembly out for access to
two of the drive axle mounting bolts.
NOTE: Traverse the mast for access to the axle
mounting bolts on the mast side of the
load bed.
6. Disconnect the wires to the crab steer
switches by separating JP6.
! WARNING
truck is jacked up.
mast.
7. Jack and block the truck to relieve pressure

on the drive axle.
8. Block the drive axle to prevent it from
swinging down when the mounting bolts
are removed.
9. Remove the six mounting bolts.
7-30 PDMM-0102 Issued: 9/30/02

Drive Axle Assembly Drive Axle Removal and Reassembly
10. Raise the truck high enough to remove the

axle, then roll the axle assembly out from
under the truck.
11. Block up the axle assembly and perform
the desired maintenance.
12. To reinstall the axle assembly, reverse the
removal procedure. Apply 300 ft. lb.
(406.75 Nm) of torque to the six axle
mounting bolts.
13. Examine and adjust, if necessary, the crab
steer alignment. See “Crab Steer Alignment
and Adjustment” on page 7-28.
PDMM-0102 Issued: 9/30/02 7-31

Drive Motor Replacement Drive Axle Assembly
Drive Motor Replacement
! WARNING
truck is jacked up.
mast.
With the mast traversed out, jack and block the
truck high enough to access the drive motors
from underneath the truck.
Removal
1. Disconnect the four cables from the motor
terminals.
2. Remove the drain plug and drain the oil
into a clean container.
3. Remove the nine screws and washers
securing the motor to the drive unit.
4. Insert two of the screws removed in step 3
into the motor separator holes and separate
the motor from the drive unit.
5. Pull off the motor and pinion assembly.
6. If the pinion or keys need to be replaced,
remove them by taking off the snap ring.
7. Refer to “When you disconnect and
reconnect any power leads to a motor,
always tighten the motor cable securing
nuts with a torque wrench to prevent
over-tightening them and damaging the
motor. Use a second wrench on the stud
terminal securing nut to avoid twisting the
stud. Measure Table 7-2 torques each time
you examine motor brushes.” on page 7-18.
7-32 PDMM-0102 Issued: 9/30/02

Drive Axle Assembly Installation
Installation
To reinstall the drive motor, reverse the removal
procedure. Apply Permatex 300 (P/N 990-556)
between the mating surfaces of the motor and
drive unit.
PDMM-0102 Issued: 9/30/02 7-33

Drive Unit Repair and Replacement Drive Axle Assembly
Drive Unit Repair and

Replacement
Remove the drive axle assembly from the truck
to access the drive units.
NOTE: For ease of maintenance on the drive
units, remove the drive wheels prior to
removing the drive axle assembly. See
“Drive Wheel Replacement” on page 7-26
and “Drive Axle Removal and
Reassembly” on page 7-30.
Disassembly
1. Remove the drain plug and drain the oil
into a clean container.
2. See Figure 7-17. Remove the three set
screws [5] from the nut [6]. Use Tool P/N
401-000-002. Remove the nut from the
drive shaft.
3. Remove the gland seal [7], oil seal [8],
O-ring [9], and bearing cup and cone [10].
4. Remove the 23 screws [11] and lock
washers [12] that attach the drive axle
support [13] to the gear case [19].
5. Remove the drive axle support [13].
6. Remove the bearing cup and cone [14],
drive axle [15], and outer pinion shaft
bearing (not shown).
7. While holding the drive gear [17] in place,
slide out the pinion shaft [16]. The drive
gear [17] can now be tilted out and the
inner pinion shaft bearing [18] removed.
8. If the gear case [19] has to be removed, first
remove the drive motor. See “Drive Motor
Replacement” on page 7-32. Then
7
disconnect the tie rod and crab steer
Figure 7-17: Drive Unit Assembly
cylinder. See “Tie Rod Replacement” on
page 7-36 and “Crab Steer Cylinder
7-34 PDMM-0102 Issued: 9/30/02

Drive Axle Assembly Reassembly
9. See Figure 7-18. Remove the king pin set

screw [20], bolt [8], and bearing cap [9].
Support the gear case and remove the king
pin [5] out the bottom. Remove the gear
case
NOTE: The king pin has a larger diameter on
the lower end and must be installed
correctly. The bottom of the king pin has
a indicator groove to ensure correct
reassembly.
10. Inspect all components. Replace any
component showing signs of wear.
Reassembly
1. If gear case was removed, install king pin.
NOTE: Make sure bearings [6, 13], spacer [7],
and felt seal [12] are in position and the
indicator groove is on the bottom.
a. Install the set screw [20].
b. Torque the king pin bolt [8] to 80 ft. lb.
(108.5 Nm).
c. Reconnect the tie rod and crab steer
cylinder.
2. Install the drive motor. See “Drive Motor
3. See Figure 7-17. Install the inner pinion 7
shaft bearing [18], drive gear [17], and Figure 7-18: Drive Axle Assembly
pinion shaft [16].
4. Install the bearing cup and cone [14], drive
axle [15], and outer pinion shaft bearing
(not shown).
5. Apply sealant (P/N 990-556) to mating
surfaces of the gear case [19] and drive axle
support [13]. Install the drive axle support
and attach it to the gear case with 23
screws [11] and lock washers [12].
6. Install the bearing cup and cone [10],
O-ring [9], oil seal [8], and gland seal [7].
7. Using Tool P/N 401-000-002, install the
nut [6] on the drive shaft and torque to
100 to 120 ft. lb. (135.6 to 162.7 Nm).
8. Seat the three set screws [5] in nut [6].
Tighten them an additional 1¼ turns.
9. Install drain plug and fill drive unit with oil
until oil is level with plug hole. See
"Lubrication Specification Chart" on page
A-2.
PDMM-0102 Issued: 9/30/02 7-35

Tie Rod Replacement Drive Axle Assembly
Tie Rod Replacement

1. See Figure 7-18. Remove screws [14] and
washers [15]. Slide out retaining pins [16].
2. Slide out one end of the tie rod [10], then
the other. Be careful not to cause damage to
the crab steer switches [19].
3. When installing the tie rod, torque screws
to 12 ft. lb. (16.3 Nm).
4. For alignment and adjustment procedures,
see “Crab Steer Alignment and Adjustment”
on page 7-28.
Crab Steer Cylinder

Replacement
1. See Figure 7-18. Remove screws [21] and
washers [22]. Slide out retaining pins [23].
2. Remove the cylinder [2].
3. Repair or replace cylinder as necessary.
4. Install the cylinder. Torque the retaining
pin screws [21] to 12 ft. lb. (16.3 Nm).
7-36 PDMM-0102 Issued: 9/30/02

Steer Axle Assembly

Steer Axle Assembly
PDMM-0102 Issued: 9/30/02 7-37

General Steer Axle Assembly
General
The steer axle assembly and its components
require routine lubrication and maintenance.
maintenance procedures, are performed by
removing the load bed covers. See “Lubrication
and Inspection Points” on page 5-8.
the removal of the steer axle assembly from the
truck.
7-38 PDMM-0102 Issued: 9/30/02

Steer Axle Assembly Steerable Wheel Replacement
Steerable Wheel
Replacement
With the load bed covers removed, perform the
following; ! WARNING
truck is jacked up.
mast.
1. With the truck jacked up and blocked, bend
the ears on the locking washer [4]. Use
special tool P/N 401-000-015 and remove
the nut [3] and washer [4]. See Figure 7-19.
2. Attach a wheel puller, if necessary, at the
two 1/2-20 holes in the hub and pull off the
wheel assembly.
3. If the tire needs to be replaced, see “Tire
4. Examine the bearings and replace any that
show signs of wear. 7
Figure 7-19: Steerable Wheel Assembly
5. Refer to “Brakes” on page 7-49 for brake
adjustment and repair.
6. To reinstall the wheel, reverse the removal
procedure. Repack the bearings. See
“Lubrication Specification Chart” on page
A-2.
PDMM-0102 Issued: 9/30/02 7-39

Steering Linkage Alignment and Adjustment Steer Axle Assembly
Steering Linkage
Alignment and
Adjustment
Perform the following procedure if the steering
linkage needs alignment or adjustment and
after replacing components on the steer axle.
See Figure 7-20.
1. Place a straight edge below the vehicle skirt
and flush with or parallel to the drive wheel
hubs. Measure the distances at A and B.
Make sure the straight edge is on the wheel
hub and not the tire rim.
Figure 7-20: Steering Linkage Alignment and Adjustment
2. If A and B change by more than 1/4 in. (6.3

mm), equally adjust each tie rod until A and
B are within 1/4 in. (6.3 mm).
3. The wheel hubs must also be parallel
within a 3/32 in. (2.3 mm) difference
between points C and D and a straight edge
laid along the skirt.
4. Fully extend the steer cylinder and adjust
stop F to clear the steer knuckle arm by
1/8 in. (3.3 mm).
5. Retract the steer cylinder until the opposite
wheel is turned 60° beyond center. Adjust
stop E to touch the steer knuckle arm.
7-40 PDMM-0102 Issued: 9/30/02

Steer Axle Assembly Steer Axle Removal and Reassembly
Steer Axle Removal and

Reassembly
1. Disconnect the brake lines from the master
cylinder at each manifold block on the axle
and cap all fittings.
2. Disconnect the hoses from the steer
cylinder and cap all fittings.
3. Remove the floor plate and sub-plate for
access to two of the steer axle mounting
bolts. Removal of the deadman pedal will
permit the removal of one mounting bolt.
NOTE: Traverse the mast for access to the axle
mounting bolts on the mast side of the
load bed.
! WARNING
truck is jacked up.
mast.
4. Jack and block the vehicle to relieve
pressure on the steer axle.
5. Block the steer axle to prevent it from
swinging down when the mounting bolts
are removed.
6. Remove the six mounting bolts and two
screws that attach the axle assembly to the
vehicle frame.
7. Raise the vehicle high enough to roll the
axle out from under the vehicle.
8. Block up the axle and perform the desired
maintenance.
PDMM-0102 Issued: 9/30/02 7-41

Steer Axle Removal and Reassembly Steer Axle Assembly
9. To reinstall the axle assembly, reverse the

removal procedure. Apply 300 ft. lb.
(406.7 Nm) of torque to the six mounting
bolts and 90 ft. lb. (122 Nm) of torque to the
two screws.
10. Examine the steering linkage alignment
and adjust if necessary. See “Steering
Linkage Alignment and Adjustment” on
page 7-40.
7-42 PDMM-0102 Issued: 9/30/02

Steer Axle Assembly Steer Linkage Replacement
Steer Linkage
Replacement
1. See Figure 7-21. Remove the lock nut [10],
screw [8], and washer [11] securing the tie
rods [12] to the knuckle arm.
7
Figure 7-21: Steer Axle Assembly
2. Remove the screw [23] and washer [24] and

slide out the retaining pin [22] on the
intermediate link [30].
3. Remove the linkage assembly.
4. Remove the lock nuts [15], screws [14], and
washers [13] securing the tie rods [12] to
the intermediate link [30].
5. When reinstalling the linkage, torque the
four screws [8 and 14] securing the tie rods
to 100 ft. lb. (135.6 Nm).
6. Torque the screw [23] securing the
retaining pin [6] to 12 ft. lb. (16.3 Nm).
PDMM-0102 Issued: 9/30/02 7-43

Steer Cylinder Replacement Steer Axle Assembly
Steer Cylinder
Replacement
1. See Figure 7-21. Remove the screw [28] and
washer [29]. Slide out the retaining pin [6].
2. Remove the screw [32] and nut [33]. Lift out
the steer cylinder [31].
3. Disassemble the cylinder, as necessary, to
replace worn bearings and/or packings.
4. When reinstalling the steer cylinder, torque
the screw [28] securing the retaining pin [6]
to 12 ft. lb. (16.3 Nm).
7-44 PDMM-0102 Issued: 9/30/02

Steer Axle Assembly Steer Knuckle Replacement
Steer Knuckle
Replacement
1. Disconnect all fittings on the parking brake
actuator and seal with a cap.
Figure 7-22: Steer Axle Piping
2. See Figure 7-22. Remove the screws [2] and

washers [3] securing the actuator assembly
[1 or 13] and lift it off the steer axle.
3. Disconnect the tie rod and steer cylinder
from the knuckle assembly. See “Steer
Linkage Replacement” on page 7-43 and
”Steer Cylinder Replacement” on page 7-44.
4. See Figure 7-21. Remove the screw [18] and
bearing cap [17] from the bottom of the king
pin [3 or 9]. Lift out the king pin and slide
out the knuckle assembly [20 or 25].
PDMM-0102 Issued: 9/30/02 7-45

Steer Knuckle Replacement Steer Axle Assembly
5. To reinstall the knuckle assembly, reverse

the removal procedure. Apply 80 ft. lb.
(108.5 Nm) of torque to the screw [18]
securing the king pin.
6. See “Steer Linkage Replacement” on page
7-43 and “Steer Cylinder Replacement” on
page 7-44 for tie rod and steer cylinder
torque requirements.
7-46 PDMM-0102 Issued: 9/30/02

Steering
Steering
PDMM-0102 Issued: 9/30/02 7-47

Steering Chain Adjustment Steering
Steering Chain
Adjustment
The steering chain, when correctly adjusted,
must permit 1/2 in. (13 mm) deflection at a
point midway between the sprocket [5] on the
orbitrol and the sprocket [1] on the steering
wheel.
1. See Figure 7-23. Loosen locking nut [4] and
rotate the adjustment screw [3] to move the
tightener block until the correct tension is
achieved.
1/2 in.
2. Tighten the locking nut [4].
Figure 7-23: Steering Chain Adjustment
7-48 PDMM-0102 Issued: 9/30/02

Brakes
Brakes
PDMM-0102 Issued: 9/30/02 7-49

Service Brake Adjustment Brakes
Service Brake
Adjustment
The service brake is the primary braking source
for the truck and must stop the truck within six
feet. If the truck fails to stop within this
distance when the service brake is fully
activated, examine the linkage adjustment.
1. See Figure 7-24. With the service brake
released and the master cylinder piston in
the full off position, the distance between
the yoke and mounting plate must measure
2 3/4 in. (69.9 mm).
Figure 7-24: Brake Components and Adjustments
2. Adjust the return spring if the pedal does

not raise fully when released.
3. If the adjustment is correct but the brakes
do NOT adequately stop the truck, bleed
the brakes.
7-50 PDMM-0102 Issued: 9/30/02

Brakes Parking Brake Adjustment
Parking Brake
Adjustment
The parking brake (deadman pedal) must
restrain movement of the truck after the service
brake is used to stop the truck. If the truck
continues to move when the parking brake is
activated, examine the actuator adjustment.
1. See Figure 7-24. With the deadman pedal
up, adjust the actuator to 5 in. (127 mm)
between the jam nut and the block on the
actuator.
2. If the adjustment is correct but the brakes
do NOT adequately restrain the movement
of the truck, bleed the brakes.
PDMM-0102 Issued: 9/30/02 7-51

Brake Shoe Replacement Brakes
Brake Shoe Replacement

If adjustment and bleeding procedures fail to
correct a brake problem, the brake shoes may
need to be replaced. See Figure 7-25.
1. Remove the wheel assembly. See “Steerable
Wheel Replacement” on page 7-39.
2. Inspect the brake assembly for leaks, rust
and dust build-up. Clean as necessary.
Repair or replace a leaky wheel cylinder.
3. If the brake shoes have less than 1/8 in.
(3.3 mm) of lining, replace the shoes.
NOTE: Keep left and right side brake assembly
components separate.
Figure 7-25: Brake Assembly
7-52 PDMM-0102 Issued: 9/30/02

Brakes Brake Shoe Replacement
4. Pull the adjuster lever [33] out toward the

secondary shoe [26] and unhook it from the
shoe web.
5. Pull the adjuster spring [34] toward the
toggle lever [27] and unhook lower adjuster
link [32] from the toggle lever.
6. Remove the adjuster lever and spring.
7. Separate the brake shoes and remove the
adjuster screw assembly [23].
8. Unhook the shoe return springs [24] and
the upper link [1] from the wheel cylinder
bolt [2] and remove them.
NOTE: The shoe return springs are color coded
and must be replaced correctly.
9. Remove cotter pin [25] and washer [28]
from toggle lever [27]. Remove toggle lever.
10. Depress the outer cup [31] on the hold
down pin [12] and rotate the cup 90°. Lift
off the outer cup, spring [30], inner cup
[29], and hold down pin. Lift off the brake
shoe.
11. Reinstall brake shoes in the reverse order of
removal. Make sure:
• Springs and levers are attached so that
their hooks are pointed toward the
wheel cylinder
• Shoes are adjusted to a diameter
approximately 1/32 in. (0.76 mm) less
than the brake drum diameter
12. Apply light oil (one or two drops) at the
following locations:
• Between the shoe rim and the support
plate
• Between the shoe web and the piston
insert
• Between the shoe web and the socket
end of the adjusting screw
• On the adjusting screw threads
• Between the shoe web and the hold
down cup
• Between the toggle lever and the toggle
pin
PDMM-0102 Issued: 9/30/02 7-53

Wheel Cylinder Repair or Replacement Brakes
Wheel Cylinder Repair

or Replacement
1. Remove the brake shoes. See “Brake Shoe
2. See Figure 7-25. Remove the dust boot [22]
from the wheel cylinder and withdraw the
boot and piston assembly. Remove the boot
from the assembly.
3. Remove the rubber cup and spring from the
wheel cylinder.
4. Clean and inspect the cylinder. If
necessary, replace the cylinder as follows.
a. Remove the mounting bolts [18] and
the wheel cylinder bolt [2].
b. Remove the two wheel cylinder
mounting bolts [17] and lift off the
cylinder [21].
c. Reinstall the wheel cylinder in the
reverse order of disassembly:
• Coat the wheel cylinder bore,
rubber cups and dust boot with
clean brake fluid
• Torque the five mounting bolts
and the wheel cylinder bolt to
100 ft. lbs. (135.6 Nm)
7-54 PDMM-0102 Issued: 9/30/02

Attachment and Load Handler

Attachment and Load Handler
PDMM-0102 Issued: 9/30/02 7-55

General Attachment and Load Handler
General
The Attachment and Load Handler require
routine lubrication and maintenance. See
“Lubrication and Inspection Points” on
page 5-8.
maintenance procedures, are performed
without having to remove the mast assembly
from the vehicle.
the removal of the mast assembly from the
truck.
7-56 PDMM-0102 Issued: 9/30/02

Attachment and Load Handler Mast Tilt Cylinder Repair and Replacement
Mast Tilt Cylinder

Repair and Replacement
Remove the mast tilt cylinder only if the
bearings fail or the cylinder is leaking. See
Figure 7-26.
1. Extend the mast assembly to the outer edge
of the load bed.
2. Raise the fork carriage 12 to 15 in. (305 to
380 mm) and block in position.
! WARNING
Use extreme care when blocking the
mast for any reason. Never remove
the block when it is supporting the
mast.
3. Disconnect the tilt lines and cap all fittings.

4. Remove the two screws and washers that
attach the mast tilt cylinder to the frame.
5. Remove the spiral pin and retaining pin
from the other end of the mast tilt cylinder.
6. Remove the mast tilt cylinder assembly and
disassemble, as required, to replace worn
bearings or damaged packings.
7. Reinstall the mast tilt cylinder in the
reverse order of disassembly.
PDMM-0102 Issued: 9/30/02 7-57

Mast Tilt Cylinder Repair and Replacement Attachment and Load Handler
Figure 7-26: Mast Assembly - NFL
7-58 PDMM-0102 Issued: 9/30/02

Attachment and Load Handler Fork Tilt Cylinder Repair and Replacement
Fork Tilt Cylinder

Remove the fork tilt cylinders only if the
bearings fail or the cylinders are leaking. See
Figure 7-27.
Figure 7-27: Carriage Assembly
1. Remove the auxiliary carriage or apron

assembly, if used.
2. Remove the four screws that attach the
cover in front of the cylinders.
3. Disconnect the tilt lines and cap all fittings.
4. Remove the set screw securing the
retaining pin on the lower pivot linkage and
remove the retaining pin.
5. Remove the set screw securing the fork bar,
then drive out the fork bar far enough to
remove the cylinder assembly. Remove the
fork bar slowly, lifting off the forks, spacers,
and cylinder assembly.
6. Disassemble the cylinder assembly, as
required, to replace worn bearings or
damaged packings.
7. Reinstall the fork tilt cylinder in the reverse
order of disassembly.
PDMM-0102 Issued: 9/30/02 7-59

Carriage Reach Cylinder Repair and Replacement (SLR20TT) Attachment and Load Handler
Carriage Reach Cylinder

(SLR20TT)
Remove the carriage reach cylinders only if the
bearings fail or the cylinders are leaking.
1. Extend the carriage reach mechanism and
lock it in the extended position. Block the
carriage to keep it from moving.
2. Rotate the hose reel to loosen hoses and
lock the reel to prevent it from turning.
Remove and plug the hoses on the carriage
manifold.
3. Disconnect and plug the reach piping on
the cylinder(s).
4. Remove the screws and cotter pins that
attach the dowel pins at each end of the
cylinder(s). Drive out the dowel pins and
remove the cylinder(s).
5. Repair or replace any bad component.
6. Reinstall the carriage reach cylinder(s) in
the reverse order of disassembly.
7-60 PDMM-0102 Issued: 9/30/02

Attachment and Load Handler Mast Traverse Motor Repair and Replacement
Mast Traverse Motor

Remove the mast traverse motor only if it leaks
or malfunctions.
1. Extend the mast assembly to the outer edge
of the load bed.
2. Disconnect the hoses on the motor and cap
all fittings.
3. Remove the four screws [34 and 35]
securing the motor assembly to the carriage
drive bracket.
NOTE: The screws are different lengths. When
reinstalling the motor assembly, make
sure the correct length screw is used.
4. Lift off the motor assembly and cover plate.
Remove the bearing [25] if necessary.
5. Remove the gear [22], key [17], screws [20],
mounting plate [19], spacer [18], and
fittings [16] from the motor [15].
6. Replace worn components and reassemble
in the reverse order of disassembly.
Figure 7-28: Mast Traverse Motor
PDMM-0102 Issued: 9/30/02 7-61

Lift Chain Repair and Replacement Attachment and Load Handler
Lift Chain
Remove the lift chains for routine maintenance
per “Scheduled Maintenance” on page 5-1 or
when they show signs of wear. See Figures 7-26
and 7-27.
1. Extend the mast to the outer edge of the
load bed. Raise the carriage and install
blocks beneath it. Lower the carriage on the
blocks so that the chains become slack.
2. Remove the cotter pins from the chain
anchor pins on the carriage. Remove the
chains.
3. Remove the chain anchor nuts on the lift
cylinder and remove the chains.
4. Thoroughly clean the chain in solvent and
inspect it for wear, cracked plates, rust,
tight joints and elongation.
! CAUTION
Do NOT steam clean or degrease the
lift chains.
5. Replace a chain that is excessively worn,

has cracked plates, or will not loosen up
because of excessive rust or tight joints.
6. To examine for elongation:
a. Lay the chain area that runs over the
pulleys on a flat surface and push it
together.
b. Mark a 12 in. (305 mm) length, then
stretch the chain and measure the
same area.
c. If more than 0.33 in. (8.4 mm)
variation is detected, replace the chain.
7. Lubricate the chains. See “Lubrication
Specification Chart” on page A-2. Install the
chains in the reverse order of removal.
8. Make sure the chains are adjusted to
equally share the load and roll flat and
centered on the pulleys.
7-62 PDMM-0102 Issued: 9/30/02

Attachment and Load Handler Carriage Roller Bearing Replacement
Carriage Roller Bearing

Replacement
Remove the carriage assembly only if the roller
bearings have to be replaced and reshimmed.
See Figures 7-26 and 7-27.
NFL and FFL Procedure

1. Disconnect the hydraulic hoses from the
carriage and cap all fittings.
2. Remove the bumper stops on the carriage
and telescopic.
3. Disconnect the lift chains. See “Lift Chain
Repair and Replacement” on page 7-62.
4. Connect a hoist to the carriage and lift it
out the top of the telescopic.
5. Repair or replace any bad component(s).
6. Generally, the same number of roller shims
are needed when replacing roller bearings.
If the carriage is excessively loose, add
additional shims. Make sure to reinstall the
retaining screw and washer when replacing
roller bearings.
7. Reverse the procedure to reinstall the
carriage, making sure all necessary
lubrication, bleeding, and adjustments are
performed.
TT Procedure
1. Raise the carriage and attach a block to the
bottom plate. On reach carriages, extend
and lock the reach extended and block the
two carriages.
2. Lower the carriage(s) on the block(s) to
loosen the lift chains.
3. Rotate the hose reel(s) to loosen the hoses.
Lock the reel(s) to prevent them from
turning. Remove and plug the hoses on the
carriage manifold(s).
4. Disconnect and remove the lift chains from
the pulleys. Pass the chains through the
pulley sheaves beneath the pulleys and
attach them on the carriage side below the
pulley sheaves with locking pliers.
PDMM-0102 Issued: 9/30/02 7-63

TT Procedure Attachment and Load Handler
5. Secure a hoist to the carriage and raise the

telescopic above the carriage. Remove the
carriage and repair or replace any bad
component(s).
6. Reverse the procedure to reinstall the
carriage.
7-64 PDMM-0102 Issued: 9/30/02

Attachment and Load Handler Side Cylinder Repacking (TFL and TT)
Side Cylinder Repacking

(TFL and TT)
If the side cylinder(s) are leaking, they can be
inspected and repacked without removing the
lift cylinder cluster.
1. Extend the mast and raise the carriage.
Install blocks under the carriage and lower
the carriage on the blocks.
2. Open the lowering valve to relieve the
pressure. Manually push the side cylinders
down to slacken the chains. Lift the chains
off.
3. Loosen the set screw in the pulley sheave.
Unscrew the pulley shaft and remove the
pulley and spacers.
4. Remove the screw and washer securing the
pulley sheave. Lift off the sheave.
5. Remove the outer snap ring, oil seal and
inner snap ring. The piston may now be
pulled up for packing replacement.
NOTE: When repacking a cylinder, replace all
packings. Packings are available in “kit”
form.
6. Reverse the disassembly procedure to
reinstall the side cylinder(s). Bleed the
cylnder(s). See “Lift Cylinder Bleeding” on
page 7-68.
PDMM-0102 Issued: 9/30/02 7-65

Lift Cylinder Repair and Replacement Attachment and Load Handler
Lift Cylinder
Remove the lift cylinders only if they leak, bind,
or the packings have failed. Use the applicable
procedure that follows for cylinder repair and
replacement. See Figure 7-26.
NFL Procedure
1. Activate the lift lever until the telescopic
raises approximately 12 in. (305 mm).
Insert and attach a block under the
telescopic. Lower the telescopic on the
block.
2. Remove the carriage. See “Carriage Roller
Bearing Replacement” on page 7-63.
3. Attach a hoist to the cylinder. Remove and
cap the lift piping at the base of the
cylinder.
4. With a punch through the hole in the guide
rod to keep it from turning, remove the top
mounting nut.
5. With a punch through the guide rod,
collapse the guide rod and piston.
6. Remove the mounting bolts in the support
bracket on the mast cross tie and the nut
on the lower mast bracket. Remove the
cylinder assembly.
7. Remove the snap ring securing the end cap
to the piston.
8. Remove the snap ring in the housing and
lift out the oil seal.
9. Remove the second snap ring in the
housing. Pull out the piston and replace the
packings.
form.
reinstall the lift cylinder. Bleed the cylinder.
See “Lift Cylinder Bleeding” on page 7-68.
7-66 PDMM-0102 Issued: 9/30/02

Attachment and Load Handler FFL Procedure
FFL Procedure
1. Remove the carriage. See “Carriage Roller
Bearing Replacement” on page 7-63.
2. With the lift chains still attached to the lift
cylinders, remove the chains from over the
pulleys and put them under the pulleys.
Attach locking pliers to the chains on the
carriage side just below the pulley sheave.
3. Activate the lift lever until the telescopic
raises approximately 12 in. (305 mm).
Insert and attach a block under the
telescopic. Lower the telescopic on the
block.
4. Attach a hoist to the cylinder. Remove and
cap the lift piping at the base of the
cylinder.
5. Remove the lower mounting nut. Raise the
piston and secure it in the collapsed
position. Remove the upper mounting nut
and remove the cylinder assembly.
6. Remove the snap ring in the housing and
lift out the oil seal.
7. Remove the second snap ring in the
housing. Pull out the piston and replace the
packings.
form.
reinstall the lift cylinder. Bleed the cylinder.
See “Lift Cylinder Bleeding” on page 7-68.
TT Procedure
1. Follow the “FFL Procedure” for removing
the front lift cylinder cluster.
2. Follow the “NFL Procedure” on page 7-66
for removing the back lift cylinder.
reinstall the TT lift cylinders. Bleed the
cylinder. See “Lift Cylinder Bleeding” on
page 7-68.
PDMM-0102 Issued: 9/30/02 7-67

Lift Cylinder Bleeding Attachment and Load Handler
Lift Cylinder Bleeding

Bleed the lift cylinders after maintenance is
performed on the lift system or when lift truck
operation indicates that air has entered the
system.
1. Raise the carriage approximately 6 in.
(152.4 mm). Loosen the bleed screw on top
of the cylinder.
NOTE: Loosen the bleed screw only enough to
permit air to escape.
2. When only oil flows from the cylinder,
tighten the bleed screw.
7-68 PDMM-0102 Issued: 9/30/02

Attachment and Load Handler Mast Assembly Removal
Mast Assembly Removal

1. Position the truck under a hoist and attach
the rigging to the top of the mast.
2. Remove the screws that attach the stop
mounting brackets to the truck.
3. With the hoist rigging tight (no slack),
slowly traverse the mast to the outer edge of
the load bed.
4. Disconnect, label, and cap all hoses and
fittings. Swing the mast assembly off the
truck. Lower the mast assembly to the floor
and refer to the respective maintenance
procedure for component repair and
replacement.
5. Examine the wear strips and rack
assemblies. Replace each as necessary by
removing mounting screws and adjustment
nuts on the rack on the steering end of the
load bed.
NOTE: When reinstalling the racks and wear
strips, use thread-locking compound on
mounting screws and let cure for 12
hours. Make sure racks are square
before applying thread-locking
compound.
6. Reassemble the mast on the tractor in the
reverse order of disassembly. Make sure:
• Eccentric rollers on the carriage drive
are adjusted so the gears are firmly
meshed in racks, but work smoothly at
1500 psi (10342 kPa).
• Stop screws are adjusted correctly. See
Figure 7-29.
Figure 7-29: Mast Traverse Stop Screw Adjustment
PDMM-0102 Issued: 9/30/02 7-69

Mast Drive Repair and Replacement Attachment and Load Handler
Mast Drive
With the mast assembly removed from the truck
and blocked in an upright position, disassemble
the mast drive mechanism as follows.
1. Disconnect hoses from the mast reach
motor and cap all fittings. Disconnect the
yoke end of the mast tilt cylinder.
Figure 7-30: Mast Drive Assembly
2. See Figure 7-30. Remove the screws [28]

that attach the bearing caps [8 and 30] to
the aprons [6 and 43]. Lift the bearing caps
and bearings [31] off, permitting the apron
assembly to swing down.
7-70 PDMM-0102 Issued: 9/30/02

Attachment and Load Handler Mast Drive Repair and Replacement
3. Remove the snap rings [50], rollers and

bearings [47], shims [48], and spacers [49]
from each end of the shaft [54]. Slide the
shaft in either direction, then lift out the
free end and pull the shaft from the mast
frame. Remove the bearing [51], eccentric
[52], and key [53] from the mast frame.
4. Remove the nuts [46] from the roller shafts
[45]. This permits the removal of the rollers
[44] and mast drive assembly.
5. Remove the snap ring [42] from the shaft [3]
and slide off the gear [40], key [1] and
washer [41]. Loosen the set screw [38] and
slide off the spacer [39], apron [43] and
bearings [26 and 37]. Repeat the above
steps for the opposite end. See “Mast
Traverse Motor Repair and Replacement”
on page 7-61 for removal of the mast
traverse motor assembly. Loosen the set
screw [24] and slide off the gear [23] and
key [2].
6. Remove three screws [56] to remove the
bearing cap [57], bearing [58], roller [59],
and washer [60].
7. Remove the snap rings [63 and 64] to
remove the bearing [62] and roller [61].
8. Reassemble the mast drive in the reverse
order of disassembly.
PDMM-0102 Issued: 9/30/02 7-71

Mast and Telescopic Roller Bearing Replacement Attachment and Load Handler
Mast and Telescopic

Roller Bearing
Replacement
Remove the telescopic(s) only when the roller
bearings need to be replaced.
1. Remove the carriage, lift cylinders, and
mast. Refer to “Carriage Roller Bearing
Replacement” on page 7-63, “Lift Cylinder
Repair and Replacement” on page 7-66,
and “Mast Assembly Removal” on page 7-69
respectively.
2. Lay the mast assembly on a table or bench.
3. Remove the remaining bumper stops. With
a hoist attached to the telescopic(s), roll the
telescopic(s) out of the mast.
4. Replace all worn roller bearings.
NOTE: Make sure the same number and size
shims that were removed from the worn
bearings are installed on the new
bearings.
5. Reinstall the telescopic(s).
NOTE: If the telescopic is correctly shimmed, it
will be snug yet move freely within the
mast. Reshim if the telescopic is too
tight or too loose.
7-72 PDMM-0102 Issued: 9/30/02

Hydraulics
Hydraulics
PDMM-0102 Issued: 9/30/02 7-73

General Hydraulics
General
To ease hydraulic component installation and
help prevent problems that may develop:
• Lubricate all seals, packings and O-rings
with hydraulic oil prior to installation.
• Hand tighten all fittings against O-rings,
then snug down with a wrench.
• Immerse components with spring chambers
in hydraulic oil. Activate the spring to
remove any air.
• Inspect oil filter and oil in reservoir
regularly to determine types of
contamination.
Leakage
Situations that indicate leakage are excessive
load drop, load drift, bouncing forks, and noisy
pumps. Wipe the area of the leak clean to
determine the exact location of the leak.
Table 7-4 lists the causes and prevention of
hydraulic leaks.
Table 7-4: Leakage Causes and Prevention
Cause Prevention
Worn packings Poor cylinder alignment and tight packings will cause
excessive wear. Examine piston surface for pitting or
scoring that cause packing wear.
Air leaks Leaky connections on component suction lines may not

be easy to find but can cause considerable trouble. If
air leaks can’t be heard, they may be detected by
bubbles in the hydraulic oil.
NOTE: After locating and repairing leaks, fill the

reservoir and bleed the system.
7-74 PDMM-0102 Issued: 9/30/02

Hydraulics Lift Control and Linkage
Lift Control and Linkage

Erratic operation of the lift system may be
caused by incorrect adjustment of the control
linkage, a low or leaking master cylinder, faulty
slave cylinder operation, or malfunction of the
pump.
Linkage and Master Cylinder

Maintenance
1. If the master cylinder feels spongy, it may
require bleeding. Have another person
loosen the bleed screw on the slave
cylinder. Fully actuate the lift lever and
hold. Tighten the bleed screw, release the
lift lever and repeat the procedure until a
solid stream of fluid flows from the bleed
screw.
2. Adjust the lift linkage so that;
• The master cylinder is at a “zero”
position when the lift lever is released.
• Lift switch S4 is deactivated when the
lift lever is released.
• The master cylinder is fully stroked but
not hard against its stop when the lift
lever is fully actuated against its stop.
• Lift switch S4 is activated as soon as the
lift lever is moved.
Lift Pump and Slave Cylinder

Maintenance
1. If the slave cylinder is leaking or not
functioning correctly, remove the two
mounting screws and lift the slave cylinder
off.
2. Examine the snap ring and O-ring between
the slave cylinder and the adapter plate.
Replace faulty components.
3. Measure the dimension from the plunger to
the stem cover as shown in Figure 7-31.
Replace or reseat the plunger to 9/16 to
19/32 in. (14.2 to 15 mm) using
thread-locking compound to attach it.
7
Figure 7-31: Slave Cylinder Mounting Adjustment
PDMM-0102 Issued: 9/30/02 7-75

Lift Pump Replacement Hydraulics
4. When reinstalling the slave cylinder,

reverse the disassembly procedure. Torque
the mounting screws to 7 to 9 ft. lb.
(9.5 to 12.2 Nm).
NOTE: Examine the load compensator on
Models SL40TT and SLR20TT if the lift
system is not functioning correctly.
Examine the load compensator for leaks,
free movement of internal plunger, and
weak springs.
• If leaks are present or actuation is
sticking, the seals probably need to be
replaced. Replace the seals and bleed
the slave cylinder per Step 4 on
page 7-75.
Lift Pump Replacement

1. Disconnect the battery and drain the
reservoir.
2. Disconnect the inlet and outlet lines from
the pump and drain the pump.
3. Remove the slave cylinder. See “Lift Pump
and Slave Cylinder Maintenance” on
page 7-75.
4. While supporting the pump, remove the two
mounting screws and washers. Lift off the
pump and coupling.
5. Install a new or rebuilt pump and do the
following:
• Coat the coupling with molybdenum
anti-seize compound. See “Thread
Adhesives, Sealants, and Lubricants” on
page A-3.
• Fill the pump with new hydraulic oil.
See "Lubrication Specification Chart" on
page A-2.
• Adjust lift relief valve setting as
required, see “Relief Valve Pressure
Settings” on page 7-79.
! CAUTION
Do NOT operate the pump until the
housing has been filled with oil.
7-76 PDMM-0102 Issued: 9/30/02

Hydraulics Lift Pump Replacement
• Operate the pump at approximately 40%

of maximum lift speed to assure good
initial priming.
• Loosen the upper bleed screw and
operate the pump until oil flows out.
Tighten the bleed screw. Bleed the slave
cylinder. See “Linkage and Master
Cylinder Maintenance” on page 7-75.
PDMM-0102 Issued: 9/30/02 7-77

Hydraulic Manifolds Hydraulics
Hydraulic Manifolds
The manifolds used on the Sideloader are:
• M1 - Hydraulic Compartment Manifold
• M2 - Pump Compartment Manifold
See Figure 7-32.
• MR1 and MR2 - Ranger® Manifolds
(Refer to SS-10)
Figure 7-32: Manifold Assemblies
7-78 PDMM-0102 Issued: 9/30/02

Hydraulics Relief Valve Pressure Settings
Relief Valve Pressure Settings

Incorrect pressure relief settings can cause
various system malfunctions. Use the
procedure and Table 7-5 to measure and adjust
the relief valves.
Procedure
Find the valve. See Figure 7-32. Install a 0 to
5000 psi (0 to 34474 kPa) pressure gauge at the
indicated port. Adjust, as necessary, each valve
to the indicated PSI under the specific
condition.
Table 7-5: Relief Valve Settings
Valve Location Test Port PSI (kPa) Condition
Auxiliary Manifold M2 Manifold 2100 Bottom out the fork tilt

Relief M2-8 (14479 kPa) cylinder.
Crab Steer Top of SOL-1 Manifold 1500 Hold crab steer against
Relief and SOL-2 M2-8 (10342 kPa) cylinder stops.
Steering Manifold M1 Manifold 1500 Hold steering against

Relief M2-8 (10342 kPa) cylinder stops.
Pressure Manifold M1 Manifold 300 Step on deadman pedal,

Reducing M1-6 (2068 kPa) aux pump running.
Lift Relief Manifold M2 Manifold Test PSI with maximum load...then set relief
M2-9 100 psi (689 kPa) higher.
Hang Up Manifold M1 None Lift the unloaded carriage and block.

Relief Actuate lower. Set relief just high enough
to keep lift cylinders from lowering.
PDMM-0102 Issued: 9/30/02 7-79

Relief Valve Pressure Settings Hydraulics
7-80 PDMM-0102 Issued: 9/30/02

Electrical
Electrical
PDMM-0102 Issued: 9/30/02 7-81

General Electrical
General
Maintain accurate records of all electrical
inspections and work performed on the truck.
By doing this, it is easy to keep track of
recurring problems.
! CAUTION
Capacitors C1 and C2 are potentially
dangerous. Avoid contact (either
directly or through uninsulated tools)
with capacitor's terminals or wiring
until the capacitors have been fully
discharged. To discharge the
capacitors, carefully hold the
insulated handle of a screwdriver
and install the metal blade across the
bus bars on the capacitors. Each time
work is to be done on the circuit, the
capacitors must be discharged if the
circuit has been energized since last
discharging.
Heat Sink Insulation

Heat sink insulation may become faulty for
several reasons:
• Poorly insulated screws that attach the
component to the heat sink
• Carbon build-up that permits current to
bypass heat sink insulation
Use the following procedure to examine the heat
sink insulation for shorts to the frame:
1. Remove all electrical connections from the
heat sink.
2. Set the ohmmeter on the R x 100,000 scale.
Attach the positive lead of the ohmmeter to
the heat sink and negative lead to the SCR
panel base. The resistance must register at
least one megohm.
3. If the resistance is lower than one megohm,
clean around the heat sink.
4. If the resistance is still low, replace the
insulation between the heat sink and the
truck frame.
7-82 PDMM-0102 Issued: 9/30/02

Electrical Batteries
Batteries
Lead-acid batteries furnish all power
requirements of the truck. Most industrial
batteries can be expected to function correctly
for more than five years. This section contains
battery maintenance information. Following
this information will extend battery life and
increase truck efficiency.
Battery Exterior Cleaning

1. Inspect the battery.
a. Make sure the cables are not frayed or Cable
loose.
Vent Hole
b. Make sure there is no foreign material
inside the connector.
c. Make sure the filler plugs are tight and
the vent holes in the filler plugs are
open. See Figure 7-33.
2. Keep the top of the battery clean and dry.
Corrosion, dust, and moisture provide a
conducting path to short-circuit cells or
create grounds. Filler Plug
709g6s047.tif
! CAUTION Figure 7-33: Battery Filler Plugs and Vent Holes
Do NOT use soda solution to clean

the top of the battery while it is
installed in the truck. Water will seep
into the electrical compartments and
cause serious damage.
a. Disconnect the battery connector, and

remove the battery from the truck before
you clean it.
b. Tighten the battery filler plugs.
c. Wash dirty batteries (or any that have
had electrolyte spilled on them) with a
solution of 1 lb (0.45 kg) of baking soda
added to 1/2 gal (1.9 liters) of hot water.
d. Use a brush with flexible bristles to
clean the entire top of the battery with
the soda solution. Wait until all foaming
PDMM-0102 Issued: 9/30/02 7-83

Charging Electrical
stops, indicating that the battery

exterior is neutralized.
e. Rinse the battery with clean water.
f. Dry the battery completely before
re-installing it.
g. Apply a thin coat of petroleum jelly to
the battery posts and cable terminals.
Charging
To charge a battery, direct current is passed
through the battery cells in the direction
opposite to that of discharge.
The most important element in battery service
and prolonging battery life is correct charging.
Make sure you follow the correct method for
each application, following the battery and
battery charger manufacturers’ instructions.
! CAUTION
The vent holes in the filler plugs must
be open to permit hydrogen gas to
escape from the cells. When you
charge the battery, make sure the
polarity connections are correct. The
positive lead of the charger must be
connected to the positive terminal,
and the negative lead must be
connected to the negative terminal.
1. Familiarize yourself with the following:

• Charging rate, starting rate, and finish
rate
• Time available for charge
• Overheating, excessive gassing, or
overcharging
• Variations between cell voltage
2. Battery performance varies depending on
the type of application. If you use more
than one truck, one battery, and one
charger, keep the same batteries and
charger assigned to each truck. This makes
it easier to diagnose any battery or charging
problem.
7-84 PDMM-0102 Issued: 9/30/02

Electrical Charging
3. Consult your battery and battery charger

manufacturer’s manual for specific
charging procedures.
4. Wear personal protective equipment. See
“Battery Safety” on page 2-7.
5. Turn the key switch OFF, disconnect the
battery, and remove the battery from the
truck.
6. Inspect the battery.
7. Measure the electrolyte level in each cell.
Electrolyte must cover the top of the battery
plates. If electrolyte level is below the
plates, add just enough water to cover the
plates. Do NOT fill to level yet. Electrolyte
level will rise during charging.
8. Using a hydrometer, measure and record
the specific gravity of each cell.
9. Measure and record the voltage reading for
each cell on the battery maintenance chart.
There must be a difference of no more than
0.2 volt between cells.
10. To get the maximum use out of each
battery, recharge only when effectively
discharged. Routinely recharging batteries
when only partially discharged will
decrease battery life. At maximum
recommended discharge, the specific
gravity must read 1.140 to1.160 or less.
11. Ensure that the filler plugs are clean and
the vent holes are open. Tighten all filler
plugs.
! CAUTION
NEVER plug the battery charger into
the truck. This will severely damage
the electrical system on the truck.
Plug the charger ONLY into the
connector from the battery.
12. Charge the battery, following specific

instructions in your battery and battery
charger manufacturer’s manual.
PDMM-0102 Issued: 9/30/02 7-85

Charging Electrical
13. Using a hydrometer, measure the specific

gravity of each cell. No amount of charging
will increase battery capacity or raise
specific gravity above its fully charged level
(specific gravity 1.280 to 1.300).
14. Measure and record the voltage reading for
each cell on the battery maintenance chart.
There must be a difference of no more than
0.2 volt between cells.
15. If, after charging, the electrolyte level is
below the fill port, add water to put it to the
fill level. Do NOT overfill the cells or permit
electrolyte to spill on the battery case.
7-86 PDMM-0102 Issued: 9/30/02

Electrical Component Testing
Component Testing
Table 7-6 gives the recommended test
procedures for electrical components not
specifically covered. The measurements are all
made by the use of an ohmmeter (Simpson
model 260 or equivalent). The readings do not
absolutely mean components examined will
function correctly in the system under different
current and voltage conditions. The ohmmeter,
however, will indicate most shorted or open
circuit conditions. For specific component
testing, refer to the applicable procedure in
“Controls” on page 7-95.
Table 7-6: Electrical Component Tests
Ohmmeter
Ohmmeter Lead Recommended Ohmmeter
Component Selector
Connections Readings
Setting
Coils, Horn, Rx1 Between coil Ohmmeter must read

Contactors and terminals approximately 1/2 scale reading.
Solenoids If the needle moves to the 0 end
of the scale, the coil is shorted. If
the needle does not move, the
coil is open.
R x 10,000 Between each coil Ohmmeter shall not read less

terminal and truck than 10,000 ohms. Replace coils
frame failing examination.
Transformer T-1 Rx1 Primary winding Ohmmeter must read 0 ohms for
(test for open between TP-4 and the two measurements. If the
circuit primary or TP-28. Secondary ohmmeter needle remains on the
secondary winding between left side of the scale, the
winding) TP-9 and C1-2 transformer has an open circuit
and must be replaced.
Transformer T-1 R x 10,000 Connect one lead to There must be no needle

(test for short one of the primary movement (needle to remain on
between primary wires. Connect the the left side of the scale).
and secondary other lead to a
winding) secondary wire.
PDMM-0102 Issued: 9/30/02 7-87

Contactors Electrical
Contactors
Clean and inspect contactors regularly to help
make sure that they operate correctly. See
“Scheduled Maintenance” on page 5-1.
Cleaning
When cleaning contactors:
• Remove dust, dirt, and other foreign
materials from contactors with dry, filtered,
compressed air [30 psi (207 kPa) max].
• Use a cleaning solution on a clean cloth to
remove stubborn dirt, if necessary.
Visually inspect all parts for:
• Nicks
• Cracked or deteriorated bushings,
insulation or contact guards
• Broken or damaged leads
• Stripped threads
• Broken terminals or springs
• Burned contact tips
• Other obvious damage
Replace bad parts as necessary.
Tip Inspection
When inspecting contactor tips, keep in mind
that:
• Darkening of points does not indicate
burning
• Burning means loss of contact point
material
• The contact may be used until the material
is almost completely gone
• The silver alloy part of the point is usable
contact material; the copper backing is not.
Replace the contact points if there is not
enough contact point material to last until the
next regular inspection.
Do not file contact points or remove
discoloration or minor irregularities. This is
wasteful and produces a surface more
susceptible to sticking.
If a cone and crater appear, remove and repair
the tips.
7-88 PDMM-0102 Issued: 9/30/02

Electrical Contactor Coil Replacement
Contactor Coil Replacement

If you suspect a bad contactor coil, test the coil
with an ohmmeter per Table 7-6. Coil replace-
ment is the same for all contactors. See Figures
7-34 thru 7-37.
! CAUTION
Do not loosen the top frame screws
[9] from the front end plate [6]. They
determine the total stroke. Be careful
when reassembling the movable
core [8] and back end plate [1]. Do
not deform the teflon lining.
1. To remove the coil [5], first remove screws

[9] that attach the back end plate [1] to the
side plates [2 and 3].
2. Carefully remove the frame and core
assembly [1], including the teflon washer
[4] and coil [5].
NOTE: Make sure the brass tube is wedged
tightly into the frame and core
assembly [1]. If it is loose, replace it.
3. Make sure the Teflon washer [4] is not
loose, torn or folded. Replace it if it is
damaged.
4. Slide the frame and core assembly [1] with
the washer [4] and new coil [5] into the
contactor frame assembly [2, 3, 6]. Make
sure the movable core and rod assembly [8]
enters the frame and core assembly [1]
freely in order to avoid causing damage to
to the teflon lining.
5. Using a C-clamp, or hand arbor, press and
attach two 3/4 in. inside diameter nuts,
that encircle the core bottom for protection,
press the end frame and core assembly [1]
into position and tighten the screws that
attach the frame and core assembly [1] to
the side plates [2 and 3].
NOTE: Remove the base bus bar assembly from
multideck units so that clamping
pressure is applied directly to the plate
and tie rod assembly. Apply pressure
until the core bottoms out and there is
no further movement.
PDMM-0102 Issued: 9/30/02 7-89

Replacement of Contactor Tips, Insulation and/or Core and Rod Assembly Electrical
Replacement of Contactor Tips,

Insulation and/or Core and Rod
Assembly
Replacement of these components is very
similar for all contactors.
NOTE: Leave all shims in position when
replacing contact tips. They are
necessary for correct contact gap and
overtravel.
F and R Contactors
See Figure 7-34.
1. Remove nuts [38 and 39] and associated
hardware. Insulation plates [36 and 37],
bushings [34], movable contacts [26],
springs [25], bushings [24], washers [23],
bridge guides [27], tubings [28], bushings
[22], and washers [18] can now be removed.
2. Remove screws [21 and 29] to remove bus
bars [15, 16, 19, 20, 30, 31, 32 and 33].
NOTE: Bus bars [15, 16, 19, 20, 30, 31, 32, and
33] are not identical and must be
replaced in their correct position for
correct function of the contactor,
3. Remove insulator [17] and screws [14], then
remove insulators [12 and 13] and detent
[11].
4. Reassemble in the reverse order of
disassembly.
Figure 7-34: F and R Contactors
7-90 PDMM-0102 Issued: 9/30/02

Electrical X, P, and M Contactors
X, P, and M Contactors
See Figure 7-35.
1. Remove nut [27] and associated hardware.
7
The movable contact bar [23], spring [24],
and bushing [25] can now be lifted off.
2. Remove screws [18 and 22] and associated
hardware. The stationary bus bar [16] can
now be removed.
3. By removing insulator [15] and screws [14],
the insulators [12 and 13] and detent [11]
may be removed.
disassembly.
Figure 7-35: X, P, and M Contactors
PDMM-0102 Issued: 9/30/02 7-91

1S Contactor Electrical
1S Contactor
See Figure 7-36.
1. Remove nuts [31 and 32] and associated
hardware. Insulation plate [29], bushing
[30], bus bars [26 and 27], movable contact
[25], spring [24], bushings [21 and 23],
washer [22], bridge guide [19], and tubings
[20] can now be removed.
2. Removing screws [18] permits removal of
insulators [16 and 17] and detent [15].
3. Remove screws [12] to remove interlock
switch [11]. If the switch needs adjustment,
loosen nuts [14] and move the switch so it
just closes as the contact tips close.
disassembly.
Figure 7-36: 1S Contactor
7-92 PDMM-0102 Issued: 9/30/02

Electrical PC Contactor
PC Contactor
See Figure 7-37.
1. Remove nut [31] and associated hardware.
The movable contact bar [27], spring [28],
and bushing [29] can now be lifted off.
2. Remove screws [22 and 23] and associated
hardware. The stationary bus bars [20] can
now be removed.
3. By removing insulator [19] and screws [18],
the insulators [16 and 17] and detent [15]
may be removed.
4. Remove screws [12] to remove interlock
switch [11]. If the switch needs adjustment,
loosen nuts [14] and move the switch so it
just closes as the contact tips close.
disassembly.
Figure 7-37: PC Contactor
PDMM-0102 Issued: 9/30/02 7-93

PC Contactor Electrical
7-94 PDMM-0102 Issued: 9/30/02

Controls
Controls
PDMM-0102 Issued: 9/30/02 7-95

Directional/Speed Control Assembly Controls
Directional/Speed
Control Assembly
Clean the directional/speed control assembly
occasionally by blowing out dust and dirt with
low air pressure [30 psi (207 kPa) max]. If the
directional/speed control assembly fails to
operate correctly, inspect for broken springs or
other parts.
NOTE: Do NOT apply oil or grease to the cams,
gears, or switches of the directional/
speed control assembly.
Master Switches
The master switches of the directional/speed
control assembly are closed as the directional/
speed control handle is moved through its
various positions. Table 7-7 shows the switches
that must be closed at each position of the
directional/speed control handle.
Table 7-7: Master Switch Position/Readings
Ohmmeter
Handle Position Switch Terminals
Reading
Connect an ohmmeter to the terminal indicated for each position.
Neutral All 1&2 Continuity
SCR speed range forward MS1 1&3 Continuity
High speed forward MS1, MS5A 1&3 Continuity
SCR speed range reverse MS2 1&3 Continuity
High speed reverse MS2, MS5B 1&3 Continuity
Replace any faulty switch.
7-96 PDMM-0102 Issued: 9/30/02

Controls Potentiometer Test
Potentiometer Test
Use a voltmeter to test the existing
potentiometer.
NOTE: Do NOT use an ohmmeter to measure
the potentiometer. The ohmmeter can
cause damage to the potentiometer.
! WARNING
truck is jacked up.
mast.
1. Jack and block up the truck until the drive
wheels are off the floor.
2. Remove the cover on the master switch
assembly.
Figure 7-38: Potentiometer Terminals
3. Connect the positive lead of the voltmeter,

set on 10 VDC, to pin 3 and the negative
lead to pin 2. See Figure 7-38.
the key switch ON. Observe the voltmeter
reading.
PDMM-0102 Issued: 9/30/02 7-97

Potentiometer Test Controls
5. With the directional/speed control handle

in the neutral position, approximately 2 to
2.5 volts must be read.
6. Slowly advance the directional/speed
control handle from the neutral position to
the top SCR speed range forward or reverse.
7. Observe the voltmeter needle for
irregularities that indicate a bad
potentiometer.
8. As the handle is moved to top SCR range,
the voltage must steadily decrease to
approximately 0 volts.
9. Disconnect the positive voltmeter lead from
pin 3 and connect the lead to pin 1.
10. With the handle in neutral, the voltmeter
must indicate approximately 0 volts.
11. Slowly advance the directional/speed
control handle from neutral to top SCR
speed range forward or reverse. Observe the
voltmeter reading.
12. As the handle is moved to top SCR range,
the voltage must steadily increase to
approximately 5 volts.
7-98 PDMM-0102 Issued: 9/30/02

Controls Potentiometer Removal or Replacement
Potentiometer Removal or
Replacement
Maintain correct care when removing or
replacing the potentiometer and/or its gears.
Damage can occur to the potentiometer and
gears if they are not assembled correctly.
Examine the new potentiometer and
potentiometer key assemblies before removing
the old potentiometer. See Figure 7-39.
1. Support
2. Gear Shaft
3. Dual Segment Gear
4. Potentiometer Gear
5. Set Screw
6. Idler Gear
7. Snap Ring
8. Switch Bracket
9. Set Screw
10. Potentiometer Key
11. Binding Head Screw
12. Torsion Spring
13. Lock Nut
14. Potentiometer
15. Nut
16. Nut
17. Return Gear
7
Figure 7-39: Directional/Speed Control Assembly
1. Unsolder the wires from the terminals on

the potentiometer.
2. Rotate potentiometer gear [4] enough to let
an Allen wrench to be inserted into the set
screw [9].
NOTE: Before loosening the set screw, hold the
potentiometer gear [4] with the thumb
and forefinger to prevent the traction
spring [23] from unwinding.
3. Loosen the set screw and remove the
potentiometer while holding the pot gear in
position.
4. Insert the new potentiometer [14] and key
[10] through the bracket [8] and through
the potentiometer gear [4]. The
potentiometer must be seated on the
bracket [8] as far as possible.
5. Rotate the potentiometer shaft
counterclockwise until resistance is felt.
6. Hold the hub on the potentiometer gear
against the set screw [5],
PDMM-0102 Issued: 9/30/02 7-99

Potentiometer Gear Binding Adjustment Controls
7. Tighten the set screw.
If Then
Gear binding occurs... See below.
Torsion spring (with an initial preload of Readjust it.

one turn) fails to return the
potentiometer without binding...
Set screw [5] does not contact the nub on Readjust it. See
the potentiometer gear [4] at the same below.
time or slightly before the potentiometer
contacts the internal stops...
8. Solder the wires to the potentiometer

terminals.
Potentiometer Gear Binding

Adjustment
Incorrect adjustment of the gears can cause
damage to the gears and potentiometer. See
“Directional/Speed Control Assembly” on
page 7-99.
1. Refer to page 7-99 to examine for correct
installation and adjustment of the
potentiometer.
2. Rotate the directional/speed control handle
in a counterclockwise direction to a point
where the first tooth of the dual gear [3]
catches a tooth on the potentiometer gear.
Smooth and unrestricted movement shows
correct meshing of the potentiometer gear
[4] and dual gear [3]. At no time must the
gear tips meet.
NOTE: The potentiometer gear [4] must rest
against the set screw [5] at all times
when making adjustments.
3. If the gears do not mesh correctly
(additional resistance), loosen set screw [9]
while holding potentiometer gear [4] and
adjust set screw [5] by loosening nut [15].
If Then
the set screw is the potentiometer gear [4]

turned IN... moves further ahead.
the set screw is the potentiometer gear [4]

turned OUT... moves further back.
7-100 PDMM-0102 Issued: 9/30/02

Controls Directional/Speed Control Reassembly Checklist
4. Rotate the directional/speed control handle

in a clockwise direction to a point where the
first tooth of dual gear [3] catches a tooth
on idler gear [6]:
• A smooth, unrestricted movement
shows correct meshing of idler gear [6]
and dual gear [3]
• At no time must gear tips meet
• If the potentiometer gear [4] and dual
gear [3] mesh correctly, the idler gear [6]
and dual gear [3] must also mesh
correctly
5. Readjust the potentiometer per page 7-100
and rotate the handle back and forth
several times. Re-examine meshing of the
gears. Readjust as necessary.
Directional/Speed Control
Reassembly Checklist
When reassembling the directional/speed
control assembly, do the following checks. See
“Directional/Speed Control Assembly” on
page 7-96.
Check... If NO...
Is the binding head screw Loosen it.

[11] that secures key [10]
to switch bracket [8] loose?
Is there a slight gap Create the gap.

between the head of the
screw and key [10]?
Does the key ride freely on Adjust it correctly.

the binding head screw?
Can the two gear shafts [2] Tighten the tapered

that hold the support [1] segment of the shaft
and the gears in position snugly to the tapered hole
move? in switch bracket [8].
PDMM-0102 Issued: 9/30/02 7-101

Control Unit Controls
Control Unit
! CAUTION
Avoid operating the motor at high
speed for more than a few seconds
at a time when the truck is jacked up
and blocked. Excessive RPM can
cause damage to the motor.
! CAUTION
Do not attempt to change the pulse
width or frequency by changing the
ADJ-1 and ADJ-3 settings on the
Control Unit without an oscilloscope.
These are preset at the factory for
optimum performance.
! CAUTION
The AUTO/MAN switch (see
Figure 7-40) must remain in the MAN
(manual) position after tests, repairs,
or replacements are complete.
7-102 PDMM-0102 Issued: 9/30/02

Controls Input Voltage Check
Figure 7-40: Control Unit Adjustments and Test Pins
NOTE: Before performing tests on the Control

Unit, remove the five-amp fuse and
measure it for continuity.
Input Voltage Check

1. With the voltmeter in the 50 volts DC range,
connect the positive lead to TP-1 and the
negative lead to TP-2. See Figure 7-40.
2. With the battery plugged in and key switch
turned ON, approximately 36 volts must be
read.
3. Examine the wiring to the Control Unit if
there is no voltage reading,
PDMM-0102 Issued: 9/30/02 7-103

Regulated Voltage Check Controls
Regulated Voltage Check

Regulated voltage is maintained in the pulse
generating circuit.
1. With the voltmeter in the 50 VDC range,
connect the positive lead to TP-3 and the
negative lead to TP-2. See Figure 7-40.
2. With the key switch turned ON,
approximately 9 volts must be read.
NOTE: The Auxiliary (AUX) circuit card can be
identified as one of the two larger circuit
cards having only one adjustment screw
(ADJ-7). See Figure 7-41. The Variable
Pulse Generator (VPG) circuit card can
be identified as the other large circuit
card, having six adjustment screws
(ADJ-1 thru 6). The Power Driver circuit
card is the smaller of the three cards,
installed perpendicular to the AUX and
VPG cards and having no adjustment
screws. When replacing a circuit card, it
is necessary to make the correct
adjustments to the card to attain the
correct performance characteristics.
7
Figure 7-41: Control Unit-Exploded View
7-104 PDMM-0102 Issued: 9/30/02

Controls Width and Frequency Pulse Checks
Width and Frequency Pulse

Checks
1. Turn the key switch ON.
2. Make sure the truck is not in a speed
limiting condition. See “Speed Limit” on
page 8-28.
3. Connect the oscilloscope test lead to TP-4
and the ground lead to TP-2. See
Figure 7-40. Set the horizontal time base to
l msec/div. Set the vertical sensitivity to
0.2 volts/div.
! WARNING
truck is jacked up.
mast.
4. Jack up and block the truck.
5. Activate the deadman switch.
6. Move the directional/speed control handle
full forward or reverse. The trace must start
at 5.5 to 7.3 volts. See Figure 7-42. The on
time must be 5ms. The OFF time must be
1ms, for a total period of 6ms.
7. Turn the key switch OFF.
Figure 7-42: Width and Frequency Pulse Trace
PDMM-0102 Issued: 9/30/02 7-105

Idle Repetition (Rep) Rate Adjustment Controls
Idle Repetition (Rep) Rate

Adjustment
! CAUTION
Make sure that the switch in the
upper left corner of the VPG card is
set at 36 volts. The AUTO/ MANUAL
switch (see Figure 7-40) must also be
in the manual (MAN) position.

and the ground to TP-2. See Figure 7-40.
2. Set the time/div. to 5ms.
4. With the control handle in the neutral
position and the deadman switch activated,
observe the waveform on the oscilloscope. It
must duplicate Figure 7-43. If the Idle Rep
Rate needs adjustment:
• Turn ADJ-4 clockwise to increase the
Idle Rep Rate by increasing the
frequency of the pulses
• Turn ADJ-4 counterclockwise to 7
decrease the Idle Rep Rate by decreasing Figure 7-43: Idle Rep Trace
the frequency of the pulses.
Plugging Adjustment
Plugging is a method to slow speed and change
direction while traveling. The driver may also
plug to stop the truck. Plugging does not stop
the truck as quickly as braking, but is an
alternative method for bringing the truck to a
controlled stop.
Plugging occurs when the operator moves the
control handle from its current position
through neutral in the opposite direction. The
farther the handle is moved in the opposite
direction, the greater the plugging force.
A normal setting for plugging will permit an
empty truck traveling at full speed to continue
traveling in the original direction approximately
one truck length maximum before the truck
comes to a stop and starts moving in the
opposite direction. With a load, the stopping
distance will increase.
7-106 PDMM-0102 Issued: 9/30/02

Controls Plugging Adjustment

and the ground to TP-2. See Figure 7-40.
2. Set the horizontal time base of the
oscilloscope to 10ms/div and the vertical
sensitivity to 2 volts/div.
4. Without activating the deadman switch,
move the control handle to full forward or 75 ms
reverse and observe the waveform on the (Pulse Period)
oscilloscope. The trace must duplicate
Figure 7-44.
5. Adjusting ADJ-5 to increase the pulse
period makes plugging softer. Decreasing
7
the pulse period will stiffen the plugging.
Figure 7-44: Plugging Trace
! WARNING
After making a plugging adjustment,
operate the truck in an open area.
Incorrect adjustment can result in
plugging that could cause damage to
the truck drive system.
6. Operate the truck to see how it reacts in a

plug.
7. Adjust ADJ-5 in small increments as
required.
PDMM-0102 Issued: 9/30/02 7-107

1/2 Speed Test (VPG Card) Controls
1/2 Speed Test (VPG Card)
! WARNING
truck is jacked up.
mast.
2. Connect the oscilloscope probe to TP-4 and
ground to TP-2. See Figure 7-40. Set the
horizontal time base to 2ms/div. Set the
vertical sensitivity to 0.2 volts/div.
3. Turn the key switch ON and activate the
deadman switch.
4. Put the truck in a half-speed situation. See
“Speed Limit” on page 8-28.
to full forward or reverse. The trace must
duplicate Figure 7-45. If it does not
approximate it, examine the Speed Limit
Module. See “Speed Limit Module” on
page 7-120. If the Speed Limit Module is
functioning, replace the VPG card.
Figure 7-45: 1/2 Speed Trace
7-108 PDMM-0102 Issued: 9/30/02

Controls 1/8 Speed Test
1/8 Speed Test
! WARNING
truck is jacked up.
mast.
2. Connect the oscilloscope probe to TP-4 and
ground to TP-2. See Figure 7-40.
deadman switch.
to full forward or reverse. The trace must
duplicate Figure 7-46. If it does not
approximate it, examine the Speed Limit
Module. See “Speed Limit Module” on
page 7-120. If the Speed Limit Module is
functioning, replace the VPG card.
5. Adjust the potentiometer setting on the
Speed Limit Module. 7
Figure 7-46: 1/8 Speed Trace
PDMM-0102 Issued: 9/30/02 7-109

Forward and Reverse Time Delay Circuit Test Controls
Forward and Reverse Time

Delay Circuit Test
! WARNING
truck is jacked up.
mast.
2. Connect the oscilloscope probe to TP-14
and ground to TP-2. See Figure 7-40. Set
the horizontal time base to 20msec/div. Set
the vertical sensitivity to 10 volts/div.
deadman switch.
in and out of forward or reverse and
observe the scope. The trace must start at
36 volts and sweep across 80 to 125ms,
then drop to approximately 0 volts. See
Figure 7-47. Repeat this test for the two
directions.
7
Figure 7-47: F/R Time Delay Trace
7-110 PDMM-0102 Issued: 9/30/02

Controls “M” Time Delay Circuit Test
“M” Time Delay Circuit Test
! WARNING
truck is jacked up.
mast.
2. Connect the oscilloscope probe to TP-12
and ground to TP-2. See Figure 7-40. Set
the time/div. to 0.5 seconds and the
volts/div. to 1.0.
deadman switch.
full forward or reverse and observe the
scope. The trace must start at 36 volts and
sweep across 2.5 to 3 seconds, then drop to
ground. See Figure 7-48. Repeat this test
for the two directions.
Figure 7-48: M Time Delay Trace
PDMM-0102 Issued: 9/30/02 7-111

Equalizing Time Delay Circuit Test Controls
Equalizing Time Delay Circuit

Test
! WARNING
truck is jacked up.
mast.
2. Connect the oscilloscope probe to terminal
Y on the 1S contactor and ground to TP-2.
Set the time/div. to 0.1 seconds and the
volts/div. to 1.0.
deadman switch.
forward or reverse and observe the scope.
The trace must start at 36 volts and sweep
across 0.5 to 0.7 seconds, then drop to
ground. See Figure 7-49. Repeat this test
for the two directions.
7
Figure 7-49: Equalizing Time Delay Trace
7-112 PDMM-0102 Issued: 9/30/02

Controls Current Limit
Current Limit
To correctly adjust the current limit circuit, the
battery specific gravity must be at least 1.240 or
greater. The drive motor must be relatively cool
(at room temperature).
! CAUTION
Do NOT jack up and block the truck.
1. Disconnect the battery and connect a 750

amp shunt (with matching meter) between
the battery and the truck connector. See
Figure 7-50.
2. Block open the M contactor tips to disable
it.
4. Securely restrain the truck so that it can
not move. In order to obtain an accurate
reading, the wheels must not spin.
! CAUTION
Do NOT hold power on longer than
15 seconds. For every 15 seconds
that the motor is on, wait 30 seconds
for the motor to cool off. 7
Figure 7-50: Current Shunt and Meter Arrangement
5. Turn the speed control handle fully in the

two directions and observe the current
reading on the ammeter. It must read 550
amps. If it does not, turn ADJ-2 until it
does. See Figure 7-40.
PDMM-0102 Issued: 9/30/02 7-113

“M” Lockout Circuit Test Controls
“M” Lockout Circuit Test
! WARNING
truck is jacked up.
mast.
2. Disconnect the main SCR1 gate lead from
terminal strip TS3-1.
deadman switch.
to the full forward or reverse position.
5. If the M contactor does not energize in 5
seconds, it is functioning correctly. If the M
contactor functions incorrectly, replace the
Control Unit or AUX circuit card.
7-114 PDMM-0102 Issued: 9/30/02

Controls Overload Control Circuit Test
Overload Control Circuit Test
! WARNING
truck is jacked up.
mast.
2. Disconnect the commutating gate lead from
terminal strip TS3-3.
3. Place the Control Unit reset switch on MAN.
See Figure 7-40.
deadman switch.
in the forward or reverse position without
going into M speed.
6. The appropriate contactors must energize
and then de-energize.
7. If the contactor remains de-energized until
reset by the key switch, the overload circuit
is functioning correctly.
8. Reconnect the SCR2 gate lead if the unit
tests OK.
PDMM-0102 Issued: 9/30/02 7-115

Weld Detect Circuit Controls
Weld Detect Circuit
! WARNING
truck is jacked up.
mast.
2. Hold or push the M contactor tips together
with a block of wood or insulated bar.
3. Operate the truck in either forward or
reverse. The F or R contactor must not
energize.
4. If this does not happen, examine the wiring
from terminal B to the anode of the main
SCR and any connections in between.
5. If the wiring in step 4 tests OK, the weld
detect circuit is bad. Replace the AUX card.
7-116 PDMM-0102 Issued: 9/30/02

Controls Power Driver Circuit Card
Power Driver Circuit Card

Examine the Power Driver card for correct
operation by measuring pulses to the main,
charging and commutating SCRs.
To determine whether the main SCR1, charging
SCR2, and commutating SCR3 are functioning
correctly, perform the following tests:
Main SCR Pulse Test

1. With the ground clip on pin c of the
motherboard and the probe on TP-6, set the
scope time/div. to 10ms and volts/div. to
0.5 volts (10x probe). See Figure 7-40.
2. With the key switch ON and the deadman
switch activated, a pulse amplitude of 12 to
18 volts with a pulse width of 10 to 30ms
must be read.
3. Turn the time/div. to 5ms. The pulse
amplitude must remain the same with a
repetition rate of 35ms.
Commutating SCR Pulse Test

1. With the ground clip on TP-2 and the probe
on TP-10, set the scope time/div. to 10ms
and volts/div. to 0.5 volts (10x probe). See
Figure 7-40.
switch activated, the scope must read a
pulse amplitude of 12 to 18 volts with a
pulse width of 10 to 30ms.
3. Turn time/div. to 5ms the pulse amplitude
must remain the same with the repetition
rate of 35ms.
Charging SCR Pulse Test

1. With the ground clip on TP-8 and the probe
on TP-7, set scope time/div. to 10ms and
volts/div, to 0.5 volts (10x probe). See
Figure 7-40.
2. With the key switch ON and deadman
switch activated, the scope must read a
pulse amplitude of 10 to 15 volts with a
pulse width of 10 to 25ms.
3. Turn the time/div. to 5ms. The pulse
amplitude must remain the same with a
repetition rate of 35ms.
PDMM-0102 Issued: 9/30/02 7-117

Transient Suppressors for the M, F, and R Contactors Controls
Transient Suppressors for the

M, F, and R Contactors
The transient suppressors reduce to an
acceptable level the transient voltages produced
when the M, F and R contactor coils are
de-energized. They are installed on the AUX
circuit card in the Control Unit. Use a voltmeter
and the circuit shown in Figure 7-51 to test
these suppressors or refer to SS-2C.
1. Set the voltmeter on the 2that50 volt scale.
For the M coil suppressor, connect test
circuit lead T1 to pin JP2-J in the Control
Unit and lead T2 to test pin TP-12, also in
the Control Unit.
2. Energize and de-energize the M contactor. If
the meter reads more than 50 volts, the
suppressor is bad. Replace the AUX circuit
card. If the meter reads less than 50 volts,
7
discharge the test capacitor C1, set the
Figure 7-51: Test Circuit for the M, F, and R Coil
meter on the 50-volt scale and proceed with
Suppressors
step 3.
3. Energize and de-energize the M contactor
observing the meter reading, The meter
must swing slightly past 30 volts, appear to
stabilize at approximately 24 volts, then
move slowly to zero. Replace the AUX
circuit card if the reading is not attained.
4. When examining the F coil suppressor,
connect lead T1 to pin JP2-C and T2 to
TP-14 in the Control Unit.
5. When examining the R coil suppressor,
connect lead T1 to pin JP2-E and T2 to
TP-14 in the Control Unit.
6. Test results for Steps 4 and 5 must be the
same as those for the M suppressor in steps
2 and 3 above.
7-118 PDMM-0102 Issued: 9/30/02

Controls Equalizing Time Delay
Equalizing Time Delay

Prior to examining the equalizing time delay:
• Examine the 1S contactor per page 7-88
and page 7-89. Replace a faulty contactor.
• Examine the plugging relays. Reference
“Plugging Relays K1 & K2” on page 7-127.
Replace faulty relays.
• Examine the 1S contactor suppressor as
follows:
• Use test circuit in Figure 7-51.
• Connect T1 to pins 1S-X and T2 to pin
1S-Y.
• Follow the procedure on page 7-118,
steps 2 and 3.
• Replace the module failing the test.
! WARNING
truck is jacked up.
mast.
2. Using a Simpson 260 Volt/Ohmmeter or
equivalent, set the meter on the 50 volt
scale.
3. Attach the positive lead to the 1S-Y
terminal and the negative lead to FU6-2.
deadman switch.
to either the forward or reverse position.
The meter must read approximately 36
PDMM-0102 Issued: 9/30/02 7-119

Speed Limit Module Controls
volts for 0.6 seconds, then fall to 0 for

either position.
6. If the meter remains at 36 volts, replace the
delay.
7. Set the Simpson Meter on the R x 1 DC+
scale. Remove the module from the truck.
Figure 7-52: Equalizing Time Delay
8. Attach the positive lead to pin 1 and the

negative lead to pin 5. See Figure 7-52. The
meter must read between 10 and 15 ohms.
9. Leave the negative lead on pin 5. Attach the
positive lead to pin 2, then pin 3, then pin
4. A 10 to 15 ohm reading must be
measured for each position.
10. Reverse the polarity for each position (the
positive lead to pin 5 and the negative lead
to pins 1, then pin 2, then pin 3, then pin 4.
The meter must read open for each
position.
11. Replace any module that fails the above
tests.
Speed Limit Module

The circuitry necessary for speed limit control,
with the exception of travel cutout, is contained
in a replaceable module. As shown in
Figure 7-53, the Speed Limit Module contains
three relays and associated diodes and resistors
necessary to limit speed dependent on load
elevation and position. Although the module is
not field repairable, it is necessary to examine
the unit in order to determine whether or not it
is operable.
7-120 PDMM-0102 Issued: 9/30/02

Controls Speed Limit Module
7
Figure 7-53: Speed Limit Schematic
NOTE: If the truck enters M range during any

mode of operation that calls for speed
limiting, replace the Speed Limit Module
immediately.
Do NOT attempt to repair the Speed
Limit Module. Replace any faulty speed
limit module.
Remove the Speed Limit Module from the truck.
Connect 36-volt DC negative to pin 13 for all
tests to be performed. Connect 36-volt DC
positive to the pins as shown in Table 7-8:
Table 7-8: Speed Limit Module
Voltage Pin Ohmmeter Ohmmeter

Ohmmeter Ohmmeter Pin
Connection Reading Reading
Scale Connections
- + (No Voltage) (Voltage)
13 7 Rx1 3 2 open continuity
13 11 R x 10,000 1 5 pot. setting open
13 11 R x 10,000 1 4 pot. setting open
NOTE: Pins 6, 10, 14 thru 18 are not used.

Input on pin 7 will result in no “M” speed and half SCR speed - 2-1/2 mph (S11).
Input on pin 11 will result in 1/8 speed SCR - 1/2 mph (S16).
PDMM-0102 Issued: 9/30/02 7-121

SCRs Controls
SCRs
Examine the SCRs with a Simpson 260
volt/ohmmeter or equivalent. The readings do
not guarantee that the components being
examined will function correctly in the system
under different current and voltage conditions,
however, they will indicate most shorted or open
circuit conditions. A Pipps gauge (1-074-025) is
required for replacing a faulty SCR.
Test Procedure
1. Disconnect all leads to the SCR being
examined and use the heat sinks and bus
bars as anode and cathode connections for
the meter leads.
NOTE: It is not recommended to remove the
SCR and clamp assembly for test
procedures, however, if the assembly is
removed it must remain clamped for
correct testing.
2. With the meter set on the R x 100 scale,
connect the meter leads to the anode and
cathode and note the reading. Reverse the
leads and note the reading again. Replace
the SCR if the reading is less than 1000
ohms in either direction.
connect the meter leads to the cathode and
gate and note the reading. Reverse the
the SCR if the reading does not fall within
the 5 ohm to 50 ohm range in either
direction.
SCR1 Replacement
SCR1 may be replaced without having to
remove the entire assembly from the truck. See
Figure 7-54.
1. Discharge the capacitors per page 7-82 and
disconnect the SCR leads from TS3-1 and
TS3-2.
2. Loosen the mounting screws that attach the
bus bars to the heatsinks.
3. Loosen mounting clamp screws enough to
permit the SCR to be removed.
7-122 PDMM-0102 Issued: 9/30/02

Controls SCR1 Replacement
4. Insert a new SCR in the clamp, making

sure the anode and cathode are in the
correct position and the SCR is installed
and centered on the spiral pins.
5. Finger tighten the clamp screws to attach
the SCR in position. Tighten each screw
2-1/2 turns.
6. Examine the clamp with a Pipps gauge as
shown in Figure 7-56. If the tips of the
gauge coincide, the clamp is correctly
adjusted.
7. If the tips of the gauge overlap, turn each
screw 1/4 turn until the tips of the gauge
coincide.
8. If the tips of the gauge are spread apart,
excessive adjustment is present.
NOTE: If the clamp is over-adjusted, Do not
back the screws off to attain a correct
gauge reading. Loosen the screws
completely and repeat steps to correctly
adjust the clamp.
Clamp
Bus Bar
Heat
Sinks
Clamp
Bus Bar
Clamp
SCR1
Figure 7-54: SCR1 Clamp and Heat Sink Assembly
PDMM-0102 Issued: 9/30/02 7-123

SCR2 & SCR3 Replacement Controls
SCR2 & SCR3 Replacement

To assure correct installation of SCR2 and
SCR3, it is necessary to remove the entire SCR
panel assembly.
1. Discharge the capacitors per page 7-82,
then disconnect all bus bars and cables on Bus Bar
the SCR panel assembly.
2. Remove the two screws that mount the SCR
panel to the frame. Slide the panel out far
enough to permit access to the SCRs.
NOTE: It will not be necessary to disconnect the
heat sink hoses when replacing SCR2
and SCR3.
3. Loosen the screws that attach the clamp
assembly to the heat sink. See Figure 7-55.
4. Disconnect the SCR2 leads from TS3-2 and
TS3-3 and SCR3 leads from TS3-4 and
TS3-5. Remove the SCRs.
5. Insert the new SCR(s) in the clamp, making
sure the anode and cathode are in the
correct position and the SCR(s) is (are)
installed and centered on the spiral pins.
7
6. Finger tighten the clamp screws to attach
the SCRs in position, then tighten each Figure 7-55: SCR2 and SCR3 Clamp and Heat Sink
Assembly
screw 1/2 turn.
7. Examine the clamp with a Pipps gauge
(P/N 1-074-025) as shown in Figure 7-56,
View B. If the holes in the gauge coincide,
the clamp is correctly adjusted. If the holes
in the gauge have not come together as
shown in Figure 7-56, View A, turn each
screw 1/4 turn and re-examine. Continue
tightening each screw 1/4 turn until the
holes in the gauge coincide. If the holes in
the gauge have crossed over, excessive
adjustment is present.
NOTE: If the clamp is over adjusted, Do not
back the screws off to attain the correct
gauge reading. Loosen the screws View A View B
completely and repeat steps 6 & 7 to 7
correctly adjust the clamp. Figure 7-56: Pipps Gauge Showing Correct Torque
Positions
7-124 PDMM-0102 Issued: 9/30/02

Controls Rectifiers
Rectifiers
Examine the rectifiers with a Simpson 260
volt/ohmmeter or equivalent. The readings do
not guarantee that the components being
examined will function correctly in the system
under different current and voltage conditions,
however, they will indicate most shorted or open
circuit conditions. A Pipps gauge is required for
replacing faulty rectifiers.
Test Procedure
1. Disconnect all leads to the rectifier being
examined and use the heat sinks and bus
bars as anode and cathode connections for
the meter leads.
NOTE: It is not recommended to remove the
rectifier and clamp assembly for test
procedures. However, if the assembly is
removed, it must remain clamped for
correct testing.
connect the meter leads to the anode and
cathode and note the reading. Reverse the
the rectifier if the meter does not indicate
less than 500 ohms in one polarity and
greater than 10,000 ohms in the other
polarity.
Replacement
To ensure correct installation of the rectifiers, it
is necessary to remove the entire SCR panel.
1. Discharge the capacitors per page 7-82,
then disconnect all bus bars and cables on
the SCR panel assembly.
2. Remove the two screws that mount the SCR
panel to the frame. Slide the panel out far
enough to permit access to the rectifiers.
NOTE: It will not be necessary to disconnect the
heat sink hoses when replacing the
rectifiers.
PDMM-0102 Issued: 9/30/02 7-125

Replacement Controls
3. Loosen the screws that attach the rectifier

to the heat sink. See Figure 7-57. Remove
the rectifier.
4. Insert the new rectifier(s) in the clamp, Bus Bar
making sure the anode and cathode are in
the correct position and the rectifier(s) is
Bus Bar
(are) installed and centered on the spiral
pins.
5. Install rectifier REC1 using steps of SCR1
Replacement on page 7-122.
6. Install rectifiers REC2 and REC3 using
steps of SCR2 & SCR3 Replacement on
page 7-124.
7
Figure 7-57: Rectifier Clamp and Heat Sink Assembly
7-126 PDMM-0102 Issued: 9/30/02

Controls Plugging Relays K1 & K2
Plugging Relays
K1 & K2
! WARNING
truck is jacked up.
mast.
2. Disconnect wires from terminals K1-3,
K1-4, K2-3, and K2-4 on the plugging
relays.
3. Connect an ohmmeter set on the R x 1 scale
between K1-3 and K1-4 then between K2-3
and K2-4. The ohmmeter must indicate an
open circuit for both. Replace the relay(s) if
continuity exists. Reconnect all leads.
4. Using a Simpson 260 voltmeter or
equivalent, disconnect leads K1-3 and
K1-4. Connect the positive meter lead to
K2-4 and negative lead to K2-3. With the
key switch ON and the deadman depressed,
operate travel control to approximately half
speed, then 'plug'. The meter must read
approximately 9 volts, momentarily drop to
near 0 volts, then return to approximately 9
volts.
5. With K2-3 and K2-4 disconnected and K1-3
and K1-4 connected, attach the positive
meter lead to K1-4 and the negative meter
lead to K l-3. Performing the same
operation as in Step 4 must produce the
same results.
PDMM-0102 Issued: 9/30/02 7-127

Plugging Relays K1 & K2 Controls
NOTE: Occasionally a relay will close and stay

closed causing the meter reading to drop
to 0 volts and stay there until the travel
control is returned to neutral. If the two
relays remain closed, it can be detected
by the meter or the fact that the vehicle
coasts to a long stop and will not travel
in the opposite direction when plugged.
6. Replace the plugging relay(s) that fail the
tests or operate incorrectly.
7-128 PDMM-0102 Issued: 9/30/02

Controls Battery Controller and K5 Relay
Battery Controller and

K5 Relay
The battery controller is preset for the most
efficient operation and will not require
additional adjustments. The following checklist
and relay test procedure will indicate if the unit
is functioning correctly.
• When a new, fully charged battery is
installed in the truck, the discharge meter
must indicate full charge.
• As battery power is used, the needle must
move toward empty.
• When the needle is completely in the yellow,
but before it gets to the red, the warning
light must come on.
• When the needle gets to the red, lift will be
inoperative.
• Examine the gauge and bulbs for burnouts
or malfunctions.
• Replace any unit that is not functioning
correctly.
Relay Test Procedure

1. Using a Simpson 260 volt/ohmmeter or
equivalent, do the following tests:
Meter
Test Points Reading
Setting
K5-A to K5-B R x 100 425 ±10%
K5-7 to K5-1 Rx1 Continuity
K5-7 to K5-4 Rx1 Open Circuit
2. Make sure the batteries are well charged.

Disconnect leads K5-7 and K5-4.
3. Attach the positive lead of a voltmeter on
the 50 volt scale to K5-7 and the negative
lead to TS1-16.
depressed, activate the lift.
5. The meter must read 36 volts.
PDMM-0102 Issued: 9/30/02 7-129

Automatic Steer Centering Relay K11 Controls
Automatic Steer
Centering Relay K11
Meter
Test Points Reading
Setting
K11-A to K11-B R x 100 1000-1100 ohms
K11-8 to K11-5 Rx1 open circuit
2. Disconnect leads K11-8 and K11-5.

3. Attach the positive lead of a voltmeter on
the 50 VDC scale to K11-5 and the negative
lead to TS1-16.
4. Turn the key switch ON and momentarily
activate the crab steer centering switch.
5. The meter must indicate 36 volts and
maintain 36 volts until a left or right crab
steer button is depressed or the key switch
is turned OFF.
7-130 PDMM-0102 Issued: 9/30/02

Controls Deadman Relay K12 and Light Load Relay K13
Deadman Relay K12

and Light Load Relay
K13
Meter
Test Points Reading
Setting
K12-A to K12-B R x 100 1000-1100 ohms
K13-A to K13-B R x 100 1000-1100 ohms
13-9 to K13-3 Rx1 Continuity
13-9 to K13-6 Rx1 Open Circuit
2. Disconnect the lead at TS1-11 (goes to the

relays).
3. Turn the key switch (S1) ON. Continuity
must be read between K13-9 and K13-6.
4. With the key switch ON, depress the
deadman (S2). Continuity must be read
between K12-9 and K12-6 as well as K12-8
and K12-5.
5. Replace the relay failing any test.
PDMM-0102 Issued: 9/30/02 7-131

Diode Assemblies Controls
Diode Assemblies
Diode assemblies block current in one direction
and let it flow in the other direction. This
prevents possible signals that appear at the
cathode (-) from feeding back into the anode (+)
(control) circuits.
Use a Simpson 260 volt/ohmmeter or
equivalent, to do the following tests:
DA1
Location Appearance Schematic
DA1, optional with remote control, is

installed in the hydraulic compartment
behind the auxiliary motor.
DA1 Checks
Ohmmeter Lead Ohmmeter Ohmmeter
Connections Setting Reading
(+) (-) (R x _) Ohms
5&2 4 1 10 - 15
4 5&2 1 open
Replace the module if it fails any test.
DA2
DA2 is installed below the directional/
speed control.
DA2 Checks
(+) (-) (R x _) Ohms
4 2, 3, 5 & 6 1 10 - 15
2, 3, 5 & 6 4 1 open
4 1 1 180
1 4 1 180
7-132 PDMM-0102 Issued: 9/30/02

Controls DA3, DA4, and DA8
DA3, DA4, and DA8

installed below the directional/speed
control. DA4 is installed behind the
auxiliary motor. DA8 is installed near the
lowering valve.
DA3, DA4, and DA8 Checks

(+) (-) (R x _) Ohms
4 2 1 10 - 15
2 4 1 open
DA5
installed below the Control Unit.
DA5 Checks
(+) (-) (R x _) Ohms
1, 5 & 6 4 1 10 - 15
4 1, 5 & 6 1 open
PDMM-0102 Issued: 9/30/02 7-133

DA6 Controls
DA6
DA6 is installed below the directional/
speed control.
DA6 Checks
(+) (-) (R x _) Ohms
1 6 1 10 - 15
6 1 1 open
2 3 1 10 - 15
3 2 1 open
4 5 1 10 - 15
5 4 1 open
DA7 and DA12

DA7 and DA12 are installed near the
lowering valve.
DA7 and DA12 Checks

(+) (-) (R x _) Ohms
4 5&2 1 10 - 15
5&2 4 1 open
7-134 PDMM-0102 Issued: 9/30/02

Controls Resistor Assemblies
Resistor Assemblies
Resistor assemblies remove temporary extreme
voltage fluctuations (spikes).
Using a Simpson 260 volt/ohmmeter or
equivalent, perform the following tests. Do NOT
omit any test.
RA1
RA1 is installed below the Control Unit.
RA1 Tests
(+) (-) (R x _) Ohms
4 1&6 100 4.7K
1&6 4 100 4.7K
RA2
RA2 is installed on the rectifier heat sink.
RA2 Tests
(+) (-) (R x _) Ohms
4 2&5 1 22
2&5 4 1 22
1 6 1 22
6 1 1 22
PDMM-0102 Issued: 9/30/02 7-135

Suppressor Assemblies Controls
Suppressor Assemblies
Transient suppressors are used to reduce the
high transient voltages produced to an
acceptable level when a coil is de-energized .
Use a voltmeter and the circuit shown in
Figure 7-51 to test suppressors SUP1 and SUP3
or refer to SS-2C.
1. Set the voltmeter on the 250 VDC scale. For
the P coil, connect test circuit lead T1 to pin
P-X on the P contactor and lead T2 to
FU6-2.
2. Energize and de-energize the P contactor. If
the meter reads more than 50 volts, replace
the suppressor. If the meter reads less than
50 volts: discharge the test capacitor C1,
set the meter on the 50 VDC scale, and
proceed with step 3.
3. Energize and de-energize the P contactor
observing the meter reading. The meter
must swing slightly past 30 volts, appear to
stabilize at approximately 24 volts, then
move slowly to zero. Replace SUP1 if these
readings are not attained.
4. When testing SUP1 for the X coil, connect
lead T1 to pin X-X and T2 to FU6-2.
5. When testing the horn coil, connect lead T1
to H-1 and T2 to FU6-2.
Test results for steps 4 and 5 must be the
same as those for steps 2 and 3 above.
SUP1
SUP1 is installed below the Control Unit.
SUP3
SUP3 is installed on the horn assembly.
7-136 PDMM-0102 Issued: 9/30/02

Raymond ® Sideloader Maintenance Manual Theory of Operation
Theory of Operation 8:
PDMM-0102 Issued: 9/30/02 8-1

Theory of Operation Raymond ® Sideloader Maintenance Manual
Overview
Overview
This section will provide a better understanding • SCR Theory

of the operation of the Raymond Sideloader. • Travel
Because of the interrelation of the electrical and • Key Switch ON
hydraulic systems, the diagram for each specific
• Deadman Pedal Depressed
function will have the most relevant schematic:
• Directional Switch Closed
• Hydraulic
• High Speed
• Brakes
• Plugging
• Steering
• Miscellaneous Circuits
• Lift/Lower (Except Remote Lift)
• Remote Travel
• Auxiliary
• Key Switch ON
• Electrical
• Interlocks Closed
• Travel
• Remote Start Closed
NOTE: Do NOT use these schematics to
• Lift
troubleshoot or repair the lift truck.
Always use the schematics in the • Lower
Appendix for troubleshooting and repair. • Directional Switch Closed
• High Speed
Outline • Plugging
The following system functions will be covered NOTE: Power circuit functions for remote travel
in this section: are the same as for standard travel.
• Brakes
• Service Brakes
• Parking Brakes
• Steering
• Power Steering
• Crab Steering
• Lift/Lower
• Lift
• Lower
• Remote Lift
• Remote Lower
• Emergency Lower
• Auxiliary Controls
8-2 PDMM-0102 Issued: 9/30/02

Brakes
Brakes
Service Brakes 5. When the deadman pedal is released, SOL4

opens, releasing pressure to the brake
The service brakes function like an automobile's actuators and permits the actuator springs
brakes and may be operated at any time. See to apply the brakes.
Figure 8-1.
Figure 8-1: Service Brake Applied
1. Depressing the brake pedal strokes the

master cylinder applying pressure to the
system.
2. The pressure actuates the brake cylinders
that press the brake shoes against the
wheel.
3. Releasing the pedal relieves the pressure
letting the internal springs withdraw the
brakes shoes.
Parking Brake
The parking brake utilize auxiliary system
pressure to release the brakes. See Figure 8-2.
pedal depressed, the auxiliary pump/motor
and brake dump solenoid, SOL4, are 8
activated. See Figure 8-13. Figure 8-2: Parking Brake Released
2. Auxiliary system flow passes through the
normally open center of the auxiliary
controls, as well as through the pressure
reducing relief, check valve and is diverted
by the closed SOL4 to the parking brake
actuators.
3. The pressure reducing relief permits 330
psi (2275 kPa) to build up the brakes, then
opens, limiting excessive pressure build-up.
4. The pressure is held by the check valve and
the closed SOL4, maintaining brake
release.
PDMM-0102 Issued: 9/30/02 8-3

Steering
Steering
Power Steering 3. When the crab steer center button is

depressed, the opposite solenoid, SOL2
Power steering utilizes auxiliary system wheels turned right or SOL1 wheels turned
pressure for its operation. See Figure 8-3. left, is activated. Auto re-centering Relay
1. With the key switch ON and the deadman K11 is also activated. The circuit is opened
pedal depressed, the auxiliary pump/motor by switches S25 or S26 on the axle when
and brake dump solenoid, SOL4, are the wheels are centered.
activated. See Figure 8-13. 4. K11 Relay, when activated, is held active by
2. Auxiliary system flow passes through the its own points. This provides automatic
normally open center of the auxiliary and re-centering of the wheels if they drift off
steering controls. center while traveling.
3. When the steering wheel is turned, the 5. When the crab steer cylinder hits its stops
power steering orbitrol is turned, and its or oil flow is otherwise restricted, the crab
internal ports are aligned. steer relief, set at 1450 psi (9997 kPa),
opens to prevent any pressure build-up.
4. The auxiliary flow is diverted through these
ports to the steering cylinder that turns the NOTE: Because of the open center auxiliary
steerable wheels. hydraulic flow, the steering functions
will operate simultaneously.
5. The speed and direction of the steering is
determined by the speed and direction that
the steering wheel is turned.
6. When the steering wheel stops, internal
springs in the orbitrol return its ports to a
neutral position trapping oil in the cylinder,
thereby holding the steering position.
7. When the steering cylinder hits its stops or
oil flow is otherwise restricted, the steering
relief, set at 1450 psi (9997 kPa), opens to
limit any pressure build-up.
Crab Steering
Crab steering utilizes auxiliary system pressure
for its operation. See Figure 8-4.
and brake dump solenoid, SOL4, are
activated. See Figure 8-13.
2. When a directional crab steering button is
depressed, the respective solenoid, SOL1
for right turns or SOL2 for left turns, is
activated, diverting auxiliary flow to the
crab steer cylinder, and turns the drive
wheels.
8-4 PDMM-0102 Issued: 9/30/02

Crab Steering
Power Steering Activated

Figure 8-3:
PDMM-0102 Issued: 9/30/02 8-5

Crab Steering
Crab Steer - Right Activated

Figure 8-4:
8-6 PDMM-0102 Issued: 9/30/02

Lift/Lower
Lift/Lower
Lift 8. When the pump/motor is de-energized,

SOL5 opens to route additional pump
Operation of the standard lift function is output to the reservoir.
controlled entirely through the lift lever. See
9. When full lift is attained, or when an
Figure 8-5.
overload is being lifted, the lift pressure
1. With the key switch ON and the deadman relief opens to limit any pressure build-up.
pedal depressed, the lift circuit is ready for The relief is set to open at approximately
activation. See Figure 8-13. 100 psi (689 kPa) greater than the pressure
2. Pulling back on the lift lever closes lift required to lift the maximum recommended
switch S4 and strokes the lift master load.
cylinder.
3. Closing S4 completes a circuit to pump Lower
bypass solenoid SOL5, closing it, and to the Operation of the standard lower function is
battery controller relay K5. controlled entirely through the lower lever. See
4. If the battery is adequately charged, the Figure 8-6.
battery controller completes a circuit 1. With the key switch ON and the deadman
through Relay K5, closing its points and pedal depressed, the lower lockout
completing a circuit to the lift pump solenoid, SOL7, is opened and the lower
contactor P. system is ready for actuation. See
5. Closing the P contactor completes a circuit Figure 8-13.
to the lift pump/motor providing the lift 2. Pushing on the lower lever opens the shear-
hydraulic flow. type lowering valve. The further the lever is
6. The output of the pump is hydraulically moved, the greater the valve is opened,
controlled by the lift master cylinder. The thereby increasing lowering speed.
master cylinder actuates a slave cylinder on 3. The oil flows from the lift cylinder, through
the lift pump that controls the volume the lower lockout solenoid, and the lowering
control plate within the pump. The volume valve. Lowering pressure opens the
control plate determines the pump's output hang-up pressure relief lets oil flow to the
that flows through the check valve and flow reservoir.
control to the lift cylinder.
4. If the forks hang-up during lowering, the
NOTE: On the SL40TT and SLR20TT, an system pressure drops and the hang-up
automatic pressure compensating pressure relief closes, eliminating lowering.
control is added. This control senses lift
pressure and overrides the master 5. If the deadman pedal is de-activated, the
cylinder, de-stroking the lift pump as lift lower lockout solenoid closes and
pressures become greater. Therefore, the eliminates the lowering.
high volume lift of these trucks is limited
to its maximum efficient level of
performance.
7. The check valve stops the return flow to the
pump when the pump/motor is
de-energized. The flow control permits full
flow for lifting, but limits the lowering flow.
PDMM-0102 Issued: 9/30/02 8-7

Lower
Lift Activated
Figure 8-5:
8-8 PDMM-0102 Issued: 9/30/02

Lower
Lower Activated
Figure 8-6:
PDMM-0102 Issued: 9/30/02 8-9

Remote Lift
Remote Lift Remote Lower

Operation of the remote lift requires the turning Because it is necessary to lift prior to lowering,
of the three-position key switch to the REMOTE remote lift steps 1, 2 and 3 will have been
position, the lowering of the valve lock plate so completed when remote lower is required. See
that it engages the stroked lift lever and Figure 8-8.
depresses the remote start switch. See
1. Simultaneously depressing the two remote
Figure 8-7.
lower switches, S20A and S20B, completes
1. Turning the key switch to the REMOTE a circuit to remote lower solenoid, SOL6.
position energizes the remote circuitry
2. When SOL6 is activated it opens,
while de-energizing all other control
permitting flow from the lift cylinder
circuits.
through the two flow controls. The lowering
2. Lowering the valve lock plate holds the pressure opens the hang-up pressure relief,
stroked lift lever. This adjusts the pump's letting oil flow to the reservoir.
volume control plate, enabling lift flow.
3. Releasing either remote lower switch
Lowering the plate also opens the lift de-activates SOL6 and stops lowering.
interlock switch, S33, eliminating lift
activation from the operator's compartment
during remote function. Emergency Lower
3. Depressing the remote start switch, S31, Operation of the emergency manual lower
completes a circuit to the PC contactor. function is controlled entirely through the
When the PC contactor closes, interlock Emergency Lower control valve installed above
switch, S27, closes, maintaining a circuit to the deadman brake on the left side of the
the contactor. The contacts close, providing operator compartment.
a circuit for the lift motor.
The emergency manual lower control valve
4. Simultaneously depressing the two remote permits lowering the carriage during an
lift switches, S19A and S19B, completes a emergency. To activate, turn the knob
circuit to the lift control circuit. See “Lift” counterclockwise. The valve opens letting oil
on page 8-7, steps 3, 4 and 5. Releasing flow from the lift cylinder directly to the
either remote lift switch stops lift. reservoir.
5. Hydraulic flow for remote lift is the same as
standard lift (See “Lift” on page 8-7, steps 6,
7, 8, and 9 and Figure 8-5) except that the
volume control plate position is fixed. This
is determined by the position that the lift
lever is held by the valve lock plate.
8-10 PDMM-0102 Issued: 9/30/02

Emergency Lower
Remote Lift Activated

Figure 8-7:
PDMM-0102 Issued: 9/30/02 8-11

Emergency Lower
Remote Lower
Figure 8-8:
8-12 PDMM-0102 Issued: 9/30/02

Auxiliary Controls
Auxiliary Controls
The auxiliary controls; mast traverse, mast tilt,

fork tilt, and reach, direct the auxiliary
hydraulic flow to their respective functions
when actuated. The direction of actuation
determines the direction of flow to each control
function. See Figure 8-9.
and brake dump solenoid, SOL4, are
activated. See Figure 8-13.
2. When an auxiliary control is actuated, oil
flow is directed in one side of the function
and out the other.
3. The mast traverse and mast tilt functions
have load holding valves in their system.
These pressure sensing valves maintain an
even flow to and from the functions, and
prevent oil seepage back through the valves
when the valves are returned to neutral,
thereby minimizing the drifting of the
function.
4. The mast tilt also incorporates a flow limiter
that regulates the amount of flow to and
from the function.
PDMM-0102 Issued: 9/30/02 8-13

Auxiliary Controls
Auxiliary Controls - Mast Tilt Shown

Figure 8-9:
8-14 PDMM-0102 Issued: 9/30/02

SCR Theory
SCR Theory
The Raymond Sideloader has two travel speed

ranges (SCR and M Speed) in the two forward
and reverse directions. In SCR range, the
vehicle employs the use of Silicon Controlled
Rectifiers (SCRs) to control travel speed. The
SCRs permit an infinite selection of speeds from
0 up to approximately 80% of full speed. They
also permit drive motor plugging for slowing or
reversing directions without causing damage to
A B
vehicle components. In M speed range, SCR
8
control is bypassed. The vehicle's drive motors
are reconnected directly across the battery Figure 8-10: SCRs Physical Appearance and Electrical
Symbol
giving a top speed of up to 6 mph. SCR topics
covered in this manual include:
SCR Switching
• SCR description
To demonstrate SCR switching action, an SCR
• SCR switching is connected to the circuit shown in
Figure 8-11.When switch S1 is closed, a voltage
SCR Description is applied between anode and cathode. The SCR
acts as an open switch permitting no current to
An SCR is a solid state semiconductor device. flow.
SCR operation is like that of a static switch with
no moving parts or contact points. The turning
S1
ON and OFF of the SCR is electrically
controlled, and can be done at a much faster
rate than mechanical switches. In addition, the
SCR has a much longer service life since it
contains no moving or mechanical parts.
24 Volt
Figure 8-10 View A shows the physical
6 Volt
characteristics of a SCR while Figure 8-10
View B shows the electrical symbol. The
switching characteristic of an SCR lies between
the anode and cathode connections. The gate RESISTOR
lead controls the turning ON (closing of the SCR 8
switch). By applying a very low current signal to Figure 8-11: SCR Operation Diagram
the gate, the SCR is turned ON permitting a
much larger current to flow from anode to 1. To close the switch or turn the SCR ON, a
cathode. When turned ON, however, the gate gate signal is applied. By closing switch S2,
has no further control of the SCR. To turn an a path is completed and a small current
SCR OFF, the current flow between anode and flows to the SCR gate.
cathode must be reduced to zero by external 2. This current flow immediately turns the
means. SCR ON, letting a larger current flow from
anode to cathode.
PDMM-0102 Issued: 9/30/02 8-15

SCR Switching
3. When the SCR is turned ON, the gate signal

may be removed by opening switch S2
without any effect on anode to cathode
current.
4. To turn the SCR OFF, the current flow
between anode and cathode is reduced to
zero, either by opening switch S1 or by
some external means.
5. The SCR is polarity sensitive. The anode of
an SCR must be connected to the positive
(+) side of the circuit and the cathode to the
negative (-) side of the circuit. When
connected in opposite polarity, the SCR will
not conduct.
8-16 PDMM-0102 Issued: 9/30/02

Standard Travel
Standard Travel
Key Switch ON Deadman Pedal Depressed

1. Connect the battery connector and turn the Depressing the deadman pedal closes deadman
key switch ON. switch S2 and also:
2. An electrical circuit is completed to 1. Closing S2 simultaneously removes the
terminal A of the Control Unit preparing the reset circuit on the Control Unit and
unit's internal circuitry for operation. See activates deadman relay K12. See
Figure 8-12. However, until deadman Figure 8-13.
switch S2 is depressed, the Control Unit is
2. Closing one set of the relay’s points causes:
held at a minimum pulse frequency and no
current flow to the directional contactors • A current through the normally closed
prevents their activation. Circuits in the side of the high speed switches, MS5A
Control Unit are readied for operation: and MS5B, to the Control Unit pin H
activates the M blank overload circuit.
• The current Limit circuit that monitors
This circuit maintains the fail safe
the current in the drive motor, is ready
circuits while M speed is not activated.
for operation, but is inoperative until a
directional contactor is closed. • The overload circuits in the Control Unit
are activated, monitoring the system. If
• The fail safe protective circuits that
a malfunction occurs, these circuits are
monitor the power circuits, are
ready to prevent vehicle travel.
operational and readied to prevent
operation of the vehicle if a malfunction • A circuit is provided to the directional
exists. switches readying them for activation.
• The oscillator and power driver circuits 3. Closing the other set of the relay’s points
are also ready for operation but are in completes circuits to the following, causing
an idle position until deadman switch the activation of:
S2 closes, releasing the reset circuit of • Hour Meter (HM)
the Control Unit.
• Brake Dump Solenoid (SOL4)
3. The crab steer indicator lights are activated
• Lowering Lockout Solenoid (SOL7)
notifying the operator of the crab steer
position. • Auxiliary Contactor (X)
4. The light load relay, K13, is activated and
completes a circuit to the warning and
working light circuits. This relay reduces
the load on the key switch when it is turned
ON.
5. On vehicles with Remote Control, the PC
contactor is activated, closing its contacts
and providing a power circuit for lift and
travel.
PDMM-0102 Issued: 9/30/02 8-17

Deadman Pedal Depressed
Figure 8-12: key switch ON - Standard Travel
8-18 PDMM-0102 Issued: 9/30/02

Deadman Pedal Depressed
Figure 8-13: deadman pedal

Depressed
PDMM-0102 Issued: 9/30/02 8-19

Directional Switch Closed
Directional Switch Closed 5. Movement of the control handle also turns

the shaft of the potentiometer VR1
See Figures 8-14, 8-15, and 8-16. (installed within the directional/speed
1. When the directional/speed control handle controller). VR1 controls the voltage input
is rotated to the forward or reverse travel to the frequency and width circuits of the
position, the first few degrees of the control Control Unit, which controls the truck
handle movement closes directional master speed. The potentiometer, in neutral
switch MS1 (forward) or MS2 (reverse). A position, supplies a high voltage to the
small current now flows from the battery width circuit and a low voltage to the
through MS1 or MS2 to the directional coils frequency circuit. As the control handle is
(F or R), to the Control Unit, and back to moved to high speed, the voltage input to
the negative side of the battery. This flow is the frequency circuit is increased and the
not large enough to energize the directional voltage to the width circuit is decreased.
contactors, but does activate the contactor 6. After the directional switch (MS1 or MS2)
delay in the Control Unit. has closed, further movement of the control
2. After a very short (100 millisecond) delay, handle changes the voltage output of the
the contactor delay circuit completes a low potentiometer. The increase in voltage to
resistance circuit between terminals D and the frequency circuit turns the main SCR
L of the Control Unit. A larger energizing ON at a faster rate. The decrease in voltage
current now flows through contactor coils F to the width circuit permits the main SCR
or R. The applicable directional contact tips to remain ON for longer periods of time. The
are closed, directing a current flow to the average current flow through the motor is
drive motors. increased.
3. Because of the need to parallel the 7. When main SCR1 and charging SCR3 are
armatures during startup and plugging but turned ON, (see Figure 8-15) current flows
not throughout travel, an equalizing from the batteries through fuse FU1,
contactor 1S and time delay are added to directional contactor tips, motor field
the travel circuit. The equalizing time delay windings, motor armatures, primary
receives a small current flow from the windings of transformer T1, main SCR1,
directional switches at the same time as the and back to the battery. The flow of current
forward and reverse time delay. This through the primary windings of T1
current flows through the 1S coil but is not induces a voltage across its secondary
large enough to energize the coil. The windings. The resultant secondary current,
equalizing delay takes approximately 600 flows from T1 through capacitors C1 and
milliseconds before it completes a low C2, the main SCR1, the charging SCR3,
resistance circuit to the 1S coil. The and back to T1. Capacitors C1 and C2 are
energized 1S coil opens the 1S contact tips charged, as shown, by this current.
and interlock switch S10 closes. The 8. Charging SCR3 is turned ON at the same
closing of S10 assures that the time delay time the main SCR1 is turned ON. As soon
circuit will remain inactive if the 1S contact as capacitors C1 and C2 are fully charged,
tips remain open. The contactor will remain current flow through SCR3 stops. Stopping
open until a directional switch, MS1 or current flow through SCR3 turns SCR3
MS2, is opened. OFF. SCR3 will maintain the charge on the
4. The closing of directional contactors F or R capacitors as an SCR permits current to
also completes the monitoring circuit for flow in one direction only. SCR1 will
current limit from the motor field windings continue to conduct current until it is
to terminals X of the Control Unit. turned OFF.
8-20 PDMM-0102 Issued: 9/30/02

Figure 8-14: Directional Switch Closed - Standard Travel
PDMM-0102 Issued: 9/30/02 8-21

Figure 8-15: Turning On SCR1 and SCR3
8-22 PDMM-0102 Issued: 9/30/02

Figure 8-16: Turning SCR2 On, SCR1 Off
PDMM-0102 Issued: 9/30/02 8-23

High Speed
9. When it is time to turn the main SCR1 OFF, 12. REC1 is a recirculating rectifier. During the
the Control Unit sends a pulse to the gate intervals when main SCR1 is turned OFF,
lead of commutating SCR2. See the magnetic fields built up around the
Figure 8-16. SCR2 is turned ON, motors' field winding collapse, producing a
completing a circuit from capacitors C1 and current flow in the same direction as the
C2, through SCR2, and back to the battery. battery circuit. REC1 routes this current
The capacitors discharging through SCR2 through the motors' circuitry, utilizing the
causes a high current flow into the current to turn the drive motors. As a
capacitors from the opposite direction. This result, the motor current is a higher
high current flow charges the capacitors average value than current supplied by the
and diverts the current from flowing battery. In addition, operation of the drive
through main SCR1. This no-current-flow motor is smoother.
condition exists until the capacitors are
fully charged. The main SCR1, experiencing High Speed
a no-current-flow condition, is turned OFF.
10. The turning ON and OFF of the main SCR1 See Figure 8-17.
normally occurs within 5 milliseconds. If 1. When the directional/speed control handle
the main SCR1 has not turned OFF after is moved to the high speed position
100 milliseconds, main SCR1 has shorted (forward or reverse), master switch MS5A
or the commutating circuit has failed. The (forward) or MS5B (reverse) is closed. The
overload protective circuit monitors the closing of either MS5 switch completes a
main SCR1 through terminal B of the small current flow from the switch, through
Control Unit. If the main SCR1 remains on the M contactor coil, to terminal R of the
for 100 milliseconds, the overload circuit Control Unit, and through the speed limit
deactivates the F and R contactor delay module to pin B on the Control Unit,
circuit, de-energizing the forward or reverse through the M time delay circuit of the
contactor coils. The overload circuit is Control Unit, to terminal L of the Control
equipped with either a manual or automatic Unit and back to the battery. Approximately
reset. With the manual reset, the key 2.5 seconds after MS5 closes, the M time
switch must be turned OFF and then back delay circuit completes a low resistance
to ON to reset the circuit. With the path between terminals B and L of the
automatic reset, the directional contactors Control Unit. The M contactor is now
will cycle in and out as the delay circuit is energized, closing its contacts and placing
activated and deactivated. If there is not a the drive motors directly across the
false firing of the overload circuit, the truck batteries. The speed limit module regulates
will be inoperative until the malfunction is truck speed under various modes of
corrected. operation. The speed limiting varies with
11. The Control Unit alternately turns the main fork elevation and mast traverse function.
SCR ON and OFF. The further the control 2. To the overload control circuit, the closing
handle is moved, the faster the Control of the M contact tips appears the same as a
Unit's frequency pulses, and increases the shorted main SCR. This will normally cause
truck's speed. the overload circuit to be activated and
interrupt power to the travel circuit.
However, the closing of either M speed
switch activates the M blank overload
circuit. This circuit, when activated, in turn
deactivates the overload monitoring circuit
from the power circuit. This stops the
overload circuit from deactivating the F and
R time delay circuit.
8-24 PDMM-0102 Issued: 9/30/02

High Speed
Figure 8-17: High Speed
PDMM-0102 Issued: 9/30/02 8-25

Plugging
Plugging
See Figure 8-18. 8. The proportional aspect of plugging is

accomplished through inputs to the width
1. When the directional/speed control handle
and frequency circuits. The width and
is plugged (moved through neutral to the
frequency circuits are held to a limited rate
opposite travel direction), the farther the
change. The rate increases as the handle is
handle is moved in the opposite direction,
moved. Therefore, the greater the handle
the greater the plugging force, and thus,
movement, the greater the plugging force.
the quicker the truck reacts to the plug.
2. If the truck is traveling in high speed,
master switch MS5 opens and the M
contactor is de-energized. The overload
circuit is reactivated, ready to monitor the
SCRs when MS5A or MS5B is opened.
3. Directional switches MS1 and MS2 are
reversely actuated.
4. The directional contactor (F or R), originally
closed, now opens, and the originally open
contactor now closes.
5. When the control handle passes through
neutral, the equalizing contactor 1S is
deactivated. The equalizing time delay is
held inactive through lead F of the Control
Unit, keeping the 1S contactor tips closed
throughout plugging.
6. The current flow through the motors' field
windings is reversed, attempting to turn the
armatures in the opposite direction. While
this spinning continues, the motors act as
generators producing a voltage.
7. Also connected in series with REC2 and
REC3 are plugging relays K1 and K2. The
flow of the plugging current through the
rectifiers and relay coils close the relays'
contacts. The contacts complete a circuit
between terminals R and d of the Control
Unit. This circuit resets the Control Unit's
pulse width and frequency. The K1 and K2
contacts remain closed until the motors
come to a stop. The relay's contacts then
open letting the Control Unit to smoothly
accelerate the motors in the new direction.
8-26 PDMM-0102 Issued: 9/30/02

Plugging
Figure 8-18: Plugging
PDMM-0102 Issued: 9/30/02 8-27

Miscellaneous Circuits
Miscellaneous Circuits
Miscellaneous circuits provide system Speed Limit

protection and function only when specific
malfunctions occur. Speed limits incorporated in the Raymond
Sideloader:
Weld Detection Circuit • 1/2 speed - when elevated heights are
above 19 in. (483 mm)
The weld detection circuit is designed to prevent
the truck from traveling if the M contact tips • 1/8 speed - mast extended, elevated height
weld or the main SCR has shorted. If the M above 15 ft. (457.2 cm) with
contact tips weld during a plugging operation, remote travel.
the weld detection circuit does not permit the F
and R time delay circuit to be reactivated after
the directional/speed control handle passes
through neutral.
NOTE: Contactor coils F, R and M have a
transient suppressor in parallel with
their coil. The transient suppressors for
the F, R and M coils are installed within
the Control Unit. The transient
suppressors reduce, to an acceptable
level, the build-up of voltages produced
when a coil is de-energized.
Current Limit Circuit

The current limit circuit, installed within the
Control Unit, is activated when too high a
current is built up in the drive motors, such as
when the truck is stalled. The current limit
circuit measures the amount of current in the
drive circuit.
1. When the current reaches a given level, the
current limit circuit is activated through
pin X and provides a high input to the
width circuit.
2. The current limit controls the ON time of
the main SCR1. The average motor current
is held at a level determined by the current
limit circuit.
M Lockout Circuit
The M lockout circuit is one of the fail safe
circuits. It is designed to prevent the M
contactor from being energized if the main
SCR1 fails to turn ON.
8-28 PDMM-0102 Issued: 9/30/02

Remote Travel
Remote Travel
Because of the various components; relays, • The oscillator and power driver circuits
sensors, etc. required to transfer operation for are also ready for operation but are in
remove travel, standard operation on vehicles an idle position until K6 aisle sensor
incorporating remote travel operate through relay points open releasing the reset
many of these components. However, the basic circuit of the Control Unit.
function of standard operations will remain the 2. The crab steer indicator lights are activated
same and therefore will not be covered here. notifying the operator of the crab steer
NOTE: Because all standard operational position.
controls; travel, lift, lower, auxiliary, 3. Activates light load relay K13 completing a
steering and parking brake cannot be circuit to the warning and working lights.
reactivated when the key switch is This relay reduces the load on the key
turned to REMOTE, the vehicle must be switch when it is turned ON.
properly positioned in the working isle
before switching to remote. 4. The remote mode relays K8, R9 and R10 are
activated. Activating these relays causes
NOTE: Prior to remote operation, the auxiliary the following to occur:
carriage and remote platform must be
properly mounted on the vehicle, with a. Activating K8:
the mast fully retracted, so the platform • closes two sets of points which
interlock S45 and the mast traverse diverts the circuit from pins 2 and 3
switch S16 are activated. on potentiometer VR1 to pins 2 and 3
on potentiometer VR2
Key Switch ON • opens one set of points which
disrupts the standard lift circuit
See Figure 8-19
b. Activating K9:
With the batteries plugged in and the key
switch turned to the REMOTE position, the • closes one set of points which
following occurs: completes a circuit to auxiliary
bypass solenoid SOL0 diverting
1. An electrical circuit is completed to
auxiliary hydraulic flow for activation
terminal A of the Control Unit, preparing
of remote lift. Closing this set of
the units internal circuitry for operation.
points also disrupts the circuit to
However, until aisle sensor relay K6 is
crab steering control switches and
activated, the Control Unit is held at a
the deadman switch
minimum pulse frequency and no current
flow to the directional contactors eliminates • closes one set of points which diverts
their activation. The follow circuits in the the circuit from pin 1 potentiometer
Control Unit are readied for operation: VR1 to pin 1 on potentiometer VR2
• Current limit circuit, which monitors • closes one set of points which diverts
the current in the drive motors’ field the circuit from MS5 high speed
windings, is ready for operation, but is switches in the standard controller to
inoperative until a directional contactor MS6 high speed switches in the
has closed. remote controller.
• The fail safe protective circuits, which
monitor the power circuits, are
operational.
PDMM-0102 Issued: 9/30/02 8-29

Key Switch ON
Figure 8-19: Key Switch ON - Remote Travel
8-30 PDMM-0102 Issued: 9/30/02

Interlocks Closed
c. Activating K10: 1. With all interlocks closed, a circuit is

completed through interlock relay K7
• closes two sets of points which divert
closing its points.
the circuits from MS1 forward and
MS2 reverse directional switches in • Closing one set of points readies a
the standard controller to MS4 circuit for remote lift.
forward and MS3 reverse in the • Closing one set of points readies a
remote controller circuit for remote lower.
• opens one set of points which • Closing one set of points provides a
disrupts the circuit to the lower circuit for the aisle sensor relay K6.
lockout solenoid SOL7 eliminating
2. With the vehicle in a rail-guided aisle, the
standard lowering.
aisle sensor is closed, completing a circuit
5. Circuits for remote lower, remote start and through the aisle sensor relay K6 activating
remote horn are readied for activation. points.
6. A circuit is completed through the power • One set of points opens, removing the
supply, through the mast sensor (normally reset circuit on the Control Unit.
closed below 15 ft. (457.2 cm) elevated
• Closing one set of points diverts the
height) and back to the batteries. This
circuit from going through MS5A and
circuit activates a relay within he power
MS5B of the standard controller to going
supply, closing its points. Closing the power
through MS6A and MS6B of the remote
supply relay points completes a circuit
controller.
through the speed limit module to the
Control Unit and back to the batteries. This • Closing one set of points readies the
circuit provides various speed limits for remote travel circuit for operation and
varying operational conditions. provides current to pin H of the Control
Unit, activating the M blank overload
7. Turning the key switch to Remote disrupts
circuit. This circuit maintains the fail
the circuit to the PC contactor, removing
safe circuits while M speed is not
the travel and lift power circuits until the
activated.
PC is reactivated.
3. The overload circuits in the Control Unit
NOTE: After activating the key switch to are activated, monitoring the system.
Remote, the operator must move to the Should a malfunction occur, these circuits
remote platform for additional remote will eliminate vehicle travel.
operation.
4. Circuits are also completed to the following
causing their activation:
Interlocks Closed
• Hour Meter (HM)
See Figure 8-20
• Brake Dump Solenoid (SOL4)
With the platform properly mounted so • Auxiliary Contactor (X)
interlock S45 is closed, the mast retracted so
switch S11 is closed, closing the operator
interlock switch S42 and if used, helper
interlocks S43 and S44, causes the following to
occur:
PDMM-0102 Issued: 9/30/02 8-31

Interlocks Closed
Figure 8-20: Interlocks Closed - Remote Travel
8-32 PDMM-0102 Issued: 9/30/02

Remote Start
Remote Start 4. Closing the P contactor completes a circuit

to the lift pump/motor providing the lift
See Figure 8-21 hydraulic flow.
The remote start switch enables the operator to 5. See “Lift” on page 8-7, steps 6 through 9 for
activate the remote travel controls only from a remote lift hydraulic flow.
proper operating position on the platform.
6. A backup pressure relief relieves auxiliary
Activating remote start causes the following to
hydraulic pressure when the hydraulic
occur:
cylinder, which strokes the lift lever, is fully
1. Closing the momentary contact remote extended.
start switch S31 competes a circuit to the
7. Releasing S19 deactivates remote lift.
PC contactor.
2. Activating the PC contactor closes its
contacts readying the travel and lift power
Lower
circuits for operation. See Figure 8-23
3. Activating the PC contactor also closes its The fixed speed remote lower is controlled
interlock switch S27 which completes a entirely through the remote lower button.
circuit through the power disconnect Activating the remote lower button causes the
switch S21 and switch S27 maintaining a following to occur:
circuit through the PC contactor when the
remote start switch is released. 1. Closing remote lower switch S20 completes
a circuit through remote lower solenoid
4. In emergency situations, the power SOL6.
disconnect switch S21 deactivates the PC
contactor, eliminating lift and travel. The 2. Activating SOL6 allows flow from the lift
PC contactor may be reactivated by cylinder through the two flow controls. The
depressing the remote start switch. lowering pressure opens the hang-up
pressure relief allowing oil to flow to the
reservoir.
Lift
3. Releasing S20 deactivates remote lower.
See Figure 8-22
The fixed speed remote lift, approximately 15 Directional Switch Closed
fpm, is controlled entirely through the remote
lift button. Activating the remote lift causes the See Figure 8-24
following to occur: When the remote directional/speed control
1. Closing remote lift switch S19 completes a handle is rotated to the forward or reverse
circuit through lift pump advance solenoid travel position, the following occurs:
SOL8, pump bypass solenoid SOL5, closing 1. The first few degrees of the control handle
it, and to the battery controller relay K5. movement closes remote directional master
2. Activating SOL8 diverts auxiliary flow to a switch MS4 (forward) or MS3 (reverse). A
hydraulic cylinder which strokes the lift small current now flows from the battery
lever, providing a fixed lift volume flow from through MS4 or MS3,through the closed
the lift pump. K10 relay points, to the directional coils (F
or R), to the Control Unit and back to the
3. If the battery is adequately charged, the negative side of the battery. This flow is not
battery controller completes a circuit large enough to energize the directional
through relay K5, closing its points and contactors but does activate the contactor
completing a circuit to the lift pump delay in the Control Unit.
contactor P.
PDMM-0102 Issued: 9/30/02 8-33

Figure 8-21: Remote Start - Remote Travel
8-34 PDMM-0102 Issued: 9/30/02

Figure 8-22: Lift - Remote Travel
PDMM-0102 Issued: 9/30/02 8-35

Figure 8-23: Lower - Remote Travel
8-36 PDMM-0102 Issued: 9/30/02

Figure 8-24: Directional Switch Closed - Remote Travel
PDMM-0102 Issued: 9/30/02 8-37

High Speed
2. After a very short (100 millisecond) delay, 6. After the directional switch (MS4 or MS3)
the contactor delay circuit completes a low has closed, further movement of the control
resistance circuit between terminals D and handle changes the voltage output of the
L of the Control Unit. A larger energizing potentiometer, The increase in voltage to
current now flows through contactor coils F the frequency circuit turns the Main SCR
or R. The applicable directional contact tips ON at a faster rate, The decrease in voltage
ore closed, directing a current flow to the to the width circuit allows the Main SCR to
drive motors. remain on for longer periods of time. The
average current flow through the motor is
3. Because of the need to parallel the
increased.
armatures during start up and plugging
but not throughout travel, an equalizing 7. See “Directional Switch Closed” on page
contactor 1S and time delay are added to 8-20, steps 7 through 12 for SCR operation
the travel circuit. The equalizing time delay which remains the same for remote travel.
receives a small current flow from the
directional switches at the same time as the High Speed
forward and reverse time delay. This
current flows through the 1S coil but is not See Figure 8-25.
large enough to energize the coil. The
When the remote directional/speed control
equalizing delay takes approximately 600
handle is moved to the sigh speed position
milliseconds before it completes a low
(forward or reverse), the following occurs:
resistance circuit to the 1S coil. The
energized 1S coil opens the 1S contact tips 1. A remote high speed master switch MS6A
and interlock switch S10 closes. The (forward) or MS6B (reverse) is closed. The
closing of S10 assures that the time delay closing of either remote high speed master
circuit will remain inactive if the 1S contact switch completes a small current flow from
tips remain open. The contactor will remain the switch, through the closed K9 relay
open until a directional switch, MS4 or MS3 points, through the M contactor coil. to
is opened. terminal K of the Control Unit, and through
the speed limit module to pin b on the
4. The closing of directional contactors F or R
Control Unit, through the M time delay
also completes the monitoring circuit for
circuit of the Control Unit, to terminal L of
current limit from the motor field windings
the Control Unit and back to the battery.
to terminals X of the Control Unit.
Approximately 2.5 seconds after an MS6
5. Movement of the control handle also turns closes, the M time delay circuit completes a
the shaft of the potentiometer VR2 (located low resistance path between terminals b
within the remote directional/speed and L of the control Unit. The M contactor
controller). VR2 directs current through K8 is now energized, closing its contacts, and
and K9 relay points to the Control Unit placing the drive motors directly across the
where it controls the voltage input to the batteries. The speed limit module regulates
frequency and width circuits which in turn truck speed under various modes of
control the vehicle speed. The operation. The speed limiting varies with
potentiometer in neutral position supplies a fork elevation.
high voltage to the width circuit and a low
voltage to the frequency circuit. As the
control handle is moved toward high speed
the voltage input to the frequency circuit is
increased and the voltage to the width
circuit is decreased.
8-38 PDMM-0102 Issued: 9/30/02

High Speed
Figure 8-25: High Speed - Remote Travel
PDMM-0102 Issued: 9/30/02 8-39

Plugging
2. To the overload control circuit, the closing 6. The current flow through the motors’ field
of the M contact tips appears the same as a windings is reversed and is attempting to
shorted main SCR. This would normally turn the armatures in the opposite
cause the overload circuit to be activated direction. While this spinning continues,
and interrupt power to the travel circuit. the motors act as generators, producing a
However, the closing of either M speed voltage. Rectifiers REC2 and REC3 limit
switch activates the M blank overload this voltage to approximately 1 volt, limiting
circuit. This circuit, when activated, in turn high currents which could damage motors
deactivates the overload monitoring circuit or SCR circuits.
from the power circuit. This stops the 7. Also connected in series with REC2 and
overload circuit from deactivating the F and REC3 are plugging relays K1 and K2. The
R time delay circuit. flow of the plugging current through the
rectifiers and relay coils close the relays’
Plugging contacts. The contacts complete a circuit
between terminals R and D of the Control
See Figure 8-26. Unit. This circuit resets the Control Unit’s
When the remote directional/speed control pulse frequency to a reduced rate
handle is plugged, moved through neutral to determined by the position of the
the opposite travel direction, the following directional/speed control handle. The K1
occurs: and K2 contacts remain closed until the
motors come to a stop. The relay’s contacts
1. The remote directional/speed control then open allowing the control unit to
handle is moved from original position back smoothly accelerate the motors in the new
through neutral to a speed in the opposite direction.
direction. The farther the handle is moved
in the opposite direction, the greater the 8. The proportional aspect of plugging is
plugging force, and thus, the quicker the accomplished through leads ti the width
truck reacts to the plug. and frequency circuits. The width circuit is
held to a limited rate change while the
2. If the truck was traveling in high speed, a
frequency rate increases the further the
master switch MS6 opens and the M
handle is moved. Therefore, the greater the
contactor is de-energized. The overload
handle movement, the greater the plugging
circuit is reactivated and is ready to
force.
monitor the SCR’s when MS6A or MS6B is
opened.
3. Directional switches MS4 and MS3 are
reverse actuated.
4. The directional contactor (F or R) which was
originally closed now opens and the
contactor that was originally open now
closes.
5. When the control handle passes through
neutral, the equalizing contactor 1S is
deactivated. The equalizing time delay is
held inactive through lead F of the Control
Unit, keeping the 1S contactor tips closed
throughout plugging.
8-40 PDMM-0102 Issued: 9/30/02

Plugging
8
Figure 8-26: Plugging - Remote Travel
PDMM-0102 Issued: 9/30/02 8-41

Plugging
8-42 PDMM-0102 Issued: 9/30/02

Raymond ® Sideloader Maintenance Manual Appendix
Appendix A:
PDMM-0102 Issued: 9/30/02 A-1

Appendix Raymond ® Sideloader Maintenance Manual
Lubrication Specification Chart
Lubrication Specification Chart
Approved Raymond Lubricants
Where Used Type Specification Raymond Part Number
Drive Unit Gear Case Gear 75W-90 Synthetic Gear Oil 990-655/001(1 qt./0.9 liter)
Lubricant API Service GL-5 990-655/003 (1 gal./3.8
liters)
Lift Chains Oil 10W-30 Motor Oil 990-603/04 (1 qt./0.9 liter)

API Service 990-603/03 (5 gal./18.9
CE,CD,CC,SG,SF liters)
Hydraulic Reservoir Hydraulic ISO 46 990-616/04 (1 qt./0.9 liter)

(Non-Cold Storage Trucks) Fluid 990-616/01 (1 gal./3.8 liters)
(+50°F to +120°F) 990-616/02 (2 gal./7.6 liters)
(+10°C to +49°C)) 990-616/03 (5 gal./18.9
liters)
Hydraulic Reservoir Hydraulic MIL-H-5606E 990-618/TX1 (1 gal./3.785

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

(Cold Storage Trucks) Fluid liters)
(-20°F to +70°F) 990-617/03 (5 gal./18.9
(-29°C to +21°C) liters)
(in and out of freezer)
Mast Uprights, Bearings, (etc.) Grease NLGI Grade2 990-620/01 (10 cartridges
per case)
990-620/02 (5 gal./18.9
liters)
Mast Uprights, Bearings, (etc.) Grease NLGI 2 990-652/001 (spray)

with
(cold storage) Teflon 990-652/002 (cartridge)
Hydraulic Brake Brake SAE Standard J1705F 990-625/01 (1 gal./3.785

Fluid Federal Motor Vehicle liters)
Standard No. 116, DOT-5 990-625/02 (1 qt./0.9 liter)
990-625/03 (1 pint/0.47
liter)
Table A-1: Lubrication Specification Chart
A-2 PDMM-0102 Issued: 9/30/02

Thread Adhesives, Sealants, and Lubricants
Thread Adhesives, Sealants, and Lubricants
Raymond Loctite*
Application
P/N Number/Color
Thread-locking 0.25 in. (6.35 mm) and below 990-403 222/Purple
Thread-locking 0.25 in. (6.35 mm) to 0.75 in. 990-536 243/Blue
(19.05 mm) contamination tolerant
Thread-locking 1.0 in. (25.4 mm) and under 990-544 271/Red
Thread-locking 1.0 in. (25.4 mm) and under, 990-463 603/Green
contamination tolerant
Thread-locking 1.0 in. (25.4 mm) and over 990-571 277/Red
Thread-locking Cleaner 990-538 7075
Thread-locking Primer 990-533 T7471
Hydraulic Sealant 990-552 569
Molybdenum Anti-Seize Compound (Molykote) 990-638 Silver
Gasket Cement 990-556 Permatex 300
Corrosion Inhibitor Coating 990-456/001
Silicone Sealant (cold storage) 990-445 Dow Corning III
Table A-2: Thread Adhesives, Sealants, Lubricants
NOTE: * Loctite is a registered trademark of the

Loctite Corporation. Brand endorsement
is not implied here, but listed only as a
commonly identified product.
PDMM-0102 Issued: 9/30/02 A-3

Torque Chart - Standard (Ferrous)
Torque Chart - Standard (Ferrous)

Grade
Identification None
Marking
SAE Grade 2 Bolts SAE Grade 5 Bolts SAE Grade 8 Bolts
Tightening Torque Tightening Torque Tightening Torque
Size
Dry Oiled* Dry Oiled* Dry Oiled*
in. lbs. in. lbs. in. lbs. in. lbs. in. lbs. in. lbs.
4-40 5 4 8 6 12 9
4-48 6 5 9 7 13 10
6-32 10 8 16 12 23 17
8-32 19 14 30 22 41 31
8-36 20 15 31 23 43 32
10-24 27 21 43 32 60 45
10-32 31 23 49 36 68 51
1/4-20 66 49 96 75 144 108
1/4-28 78 56 120 86 168 120
ft. lbs. ft. lbs. ft. lbs. ft. lbs. ft. lbs. ft. lbs.
5/16-18 11 8 17 13 25 18
5/16-24 12 9 19 14 25 20
3/8-16 20 15 30 23 45 35
3/8-24 23 17 35 25 50 35
7/16-14 30 24 50 35 70 55
7/16-20 35 25 55 40 80 60
1/2-13 50 35 75 55 110 80
1/2-20 55 40 90 65 120 90
9/16-12 65 50 110 80 150 110
9/16-18 75 55 120 90 170 130
5/8-11 90 70 150 110 220 170
5/8-18 110 85 180 130 240 180
3/4-10 160 120 260 200 380 280
3/4-16 180 140 300 220 420 320
7/8-9 140 110 400 300 600 460
7/8-14 155 120 440 320 660 500
1-8 220 160 580 440 900 680
1-12 240 170 640 480 1000 740
1 1/8-7 300 220 800 600 1280 960
1 1/8-12 340 260 880 660 1440 1080
1 1/4-7 420 320 1120 840 1820 1360
1 1/4-12 460 360 1240 920 2000 1500
1 3/8-6 560 420 1460 1100 2380 1780
1 3/8-12 640 460 1680 1260 2720 2040
1 1/2-6 740 560 1940 1460 3160 2360
1 1/2-12 840 620 2200 1640 3560 2660
Table A-3: Torque Chart - Standard
* NOTE: Use”oiled” values for bolts with thread-locking compound
A-4 PDMM-0102 Issued: 9/30/02

Torque Chart - Metric (Ferrous)
Torque Chart - Metric (Ferrous)
Ferrous Metric Bolts, Coarse Thread

(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 68 43
12 72 55 101 75
16 174 130 245 181
20 340 255 475 350
24 580 435 820 605
Table A-4: Torque Chart - Ferrous Metric
* NOTE: Use "oiled” values for bolts with thread-locking compound
Brass MS63 Metric Bolts, Coarse Thread
Diameter Torque (with bolts oiled*)

(in millimeters) Newton-meters Inch-pounds
3 0.5 4.4
3.5 0.79 7.0
4 1.2 10
5 2.2 19
6 3.9 34
8 9 79
10 17 150
Table A-5: Torque Chart - Brass Metric
PDMM-0102 Issued: 9/30/02 A-5

Torque Chart - Standard (Brass)
Torque Chart - Standard (Brass)
Brass MS63 Standard Bolts, Coarse Thread

Torque (with bolts oiled*)
Size
Newton-meters Inch-pounds
4-40 0.37 3.3
4-48 0.40 3.6
6-32 0.69 6.1
6-40 0.77 6.8
8-32 1.24 11
8-36 1.24 11
10-24 1.58 14
10-32 1.92 17
1/4-20 3.96 35
1/4-28 4.52 40
5/16-18 8.25 73
5/16-24 9.15 81
3/8-16 14.69 130
3/8-24 16.61 147
Table A-6: Torque Chart - Standard Brass
A-6 PDMM-0102 Issued: 9/30/02

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
Table A-7: Decimal Equivalent Chart
PDMM-0102 Issued: 9/30/02 A-7

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
Table A-7: Decimal Equivalent Chart
A-8 PDMM-0102 Issued: 9/30/02

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

Table A-8: Standard/Metric Conversion Chart
PDMM-0102 Issued: 9/30/02 A-9

To Convert... Multiply...
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 (PSI) to Kilopascals Pounds per Square Inch x 6.894
(kPa)
Kilopascals to Pounds per Square Inch Kilopascals x 0.145
Pounds per Square Inch (PSI) to Kilograms per Pounds per Square Inch (PSI) x 0.0704
square centimeter (kg/cm2)
Kilograms per square centimeter (kg/cm2) to Kilograms per Square Centimeter (kg/cm2) x
Pounds per Square Inch (PSI) 14.2
Inch Pounds (in. lbs.) to Newton Meters (Nm) Inch Pounds x 0.113
Newton Meters (Nm) to Inch Pounds (in. lbs.) Newton Meters x 8.85
Foot Pounds (ft. lbs.) to Newton Meters (Nm) Foot Pounds x 1.3568
Newton Meters (Nm) to Foot Pounds (ft. lbs.) Newton Meters x 0.737
Miles per Hour to Kilometers per Hour Miles per Hour x 1.609
Kilometers per Hour to Miles per Hour Kilometers per Hour x 0.6214
Fahrenheit to Celsius (°F - 32) x 0.555
Celsius to Fahrenheit (°C x 1.8) + 32

Table A-8: Standard/Metric Conversion Chart
A-10 PDMM-0102 Issued: 9/30/02

Raymond ® Sideloader Maintenance Manual Schematics
Schematics A:
Schematics
PDMM-0102 Issued: 9/30/02 A-11

Schematics Raymond ® Sideloader Maintenance Manual
Electrical Schematic - Standard Travel

Figure A-1:
A-12 PDMM-0102 Issued: 9/30/02

Wiring Diagram - Standard Travel

Figure A-2:
1R89667_1A.EPS 828-009-667 sheet 1
PDMM-0102 Issued: 9/30/02 A-13

Wiring Diagram - Standard Travel Con’t.
A-14 PDMM-0102 Issued: 9/30/02

Figure A-3: Electrical Schematic - Remote Travel
PDMM-0102 Issued: 9/30/02 A-15

Figure A-4: Wiring Diagram - Remote Travel
A-16 PDMM-0102 Issued: 9/30/02

Legend for Electrical Schematic
Legend for Electrical Schematic

Key Description MS5A & B "M" Range Switch Forward &
Reverse
1 & 2, B- & B+ Battery Connectors
BC Battery Controller MS6A & B Remote "M" Range Switch
C1 & C2 Commutating Capacitors Forward & Reverse
DA Diode Module Assembly P Pump Contactor
DI Discharge Indicator Key Description
EQ Equalizing TD Module
F&R Directional Contactors PC Power Disconnect Control
(R.C. option)
FU1 Power Fuse (Travel) - 400 amps
FU2 Power Fuse (Lift) - 600 amps RA Resistor Module Assembly
FU3 Power Fuse (Aux) - 150 amps REC1 Free Wheeling Rectifier
FU5 & FU6 B+ & B- Control Fuse 15 amps REC2 & 3 Plugging Rectifiers
H Horn S1 Key Switch
HM Hour Meter S2 Deadman Switch
HTR Heater in Control - Elec. & S3 Horn Switch
Cord Reel (C.S. option) S4 Variable Lift Switch
S6 Working Lights Switch
IL1, 2 & 3 Indicator Lights - left, center,
right respect. S10 Interlock Switch on 1S
Contactor
IS Equalizing Contactor
JP1 Connector for Control - Elec. S11 Limit Switch
JP2 Connector for Control Unit S15 Thermostat in Control - Elec.
JP3 Connector for Contactor Comp. (C.S. option)
JP4 Connector for Cab S16 Limit Switch - Mast Extend
JP5 & JP6 Connector for Direct. Indicator S19 & 20 Remote Switch & Lower Switch
Lights & Switches respect. S21 Power Disconnect Switch
JP7 Connector for Brake Dump (R.C. option)
solenoid S25 & 26 Direction Indicator Switch -
JP8 Connector at Base of Mast left & right respect.
(R.C. option) S27 Interlock Switch on PC
JP9 Connector at Base of Mast Contactor (R.C. option)
(Remote Platform Option) S28, 29, 30 Crab Steer Switch - left, right,
JP10 Connector for Contactor Comp. center respect.
JP11 Connector for Carriage S31 Remote Start Switch
(R.C. option) S32 Thermostat in Cord Reel
JP12 Connector for Speed Limit S33 Lift Interlock Switch (R.C.
Module option)
JP18 Connector for FG & HM SCR1 Main SCR
K1 & K2 Plugging Relays SCR2 Commutating SCR
K5 Battery Controller Relay SCR3 Charging SCR
K11 Auto Re-centering Relay SL Speed Limit Module
K12 Deadman Relay SOL1 & 2 Crab Steer Solenoids - left,
K13 Light Load Relay right respect.
L1 Commutating Coil SOL4 Brake Dump Solenoid
M Shorting Contactor SOL5 Pump Bypass Solenoid
MD1 & MD2 Drive Motors SOL6 Remote Lower Solenoid (R.C.
MP Pump Motor option)
MX Auxiliary Motor
MS1 & 2 Forward & Reverse Switch SOL7 Lower Lockout Solenoid
SPL Splice
MS3 & 4 Remote Forward & Reverse
Control SUP Transient Suppressor Modules
T1 Transformer
PDMM-0102 Issued: 9/30/02 A-17

Notes for Electrical Schematic
TP1 & 2 Feed Thru B- & B+ respect. TS3 Terminal Strip on Rectifier
TP3 Feed Thru Aux B+ Manifold
TP4 thru 11 Feed Thru Between Contactor Key Description
and SCR Comp.
TS4 Terminal Strip for Remote
TP12 thru 22 From Contactor Comp. to Control (R.C. option)
Motors
TS5 Terminal Strip on Mast
Key Description
TS6 Terminal Strip on Guard Mtg.
TP23, 24 On Main SCR (option.)
TP25, 26, 27 On SCR Manifold TS20 Terminal Strip on Cord
TP28 thru 31 On Rectifier Manifold (C.S. option.)
TS1 Terminal Strip near Control -
Elec. VR1 Potentiometer in Control Elec.
VR2 Potentiometer in Control Elec.
TS2 Terminal Strip near Contactor (Remote)
Comp.
X Auxiliary Contactor

1. Schematic shown in the "Power OFF" condition with carriage lowered and mast retracted.
2. Standard Travel - Wiring diagram for this schematic 154-000-051.
Remote Travel - Wiring diagram for this schematic 154-000-051 & 151-000-322.
3. Standard Travel - For Installation drawing, see power section 154-008-050.
Remote Travel - For installation drawing, see power section 115-001-403
4. For Transient Suppressor PN identification, refer to the Parts Manual or Installation drawing.
5. Limit Switch S11 not used on trucks with load beds greater than 42 in.
6. Standard Travel - Used with remote control. When not used, TS2-1 & 2, FU1-2 & P-1 are
common.
Remote Travel - With Ranger®, omit jumper between TS2-14 & 15.
7. Standard Travel - With Ranger®, omit jumper between TS2-14 & 15.
Remote Travel - When helper is not required, S43 and S44 are replaced with jumper
115-001-324.
A-18 PDMM-0102 Issued: 9/30/02

Hydraulic Schematic
Figure A-5:
PDMM-0102 Issued: 9/30/02 A-19

A-20 PDMM-0102 Issued: 9/30/02

Raymond ® Sideloader Maintenance Manual Index
Index
A Component Locator Photos . . . . . . . . . . . . . 7-3

Component Procedures
Attachment & Load Handler . . . . . . . . . 7-55
Attachment & Load Handler . . . . . . . . . . 7-55 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49
Fork Tilt Cylinder Repair . . . . . . . . . . . 7-59 Controls . . . . . . . . . . . . . . . . . . . . . . . . 7-95
General . . . . . . . . . . . . . . . . . . . . . . . . 7-56 Drive Axle Assembly . . . . . . . . . . . . . . . 7-23
Lift Chain Repair . . . . . . . . . . . . . . . . . 7-62 Electrical . . . . . . . . . . . . . . . . . . . . . . . . 7-81
Lift Cylinder Repair . . . . . . . . . . . . . . . 7-66 General . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Mast Assembly Removal . . . . . . . . . . . . 7-69 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . 7-74
Mast Drive Repair and Replacement . . . 7-70 Steering . . . . . . . . . . . . . . . . . . . . . . . . . 7-47
Mast Tilt Cylinder Repair . . . . . . . . . . . 7-57 Contactors . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Mast Traverse Motor Repair . . . . . . . . . 7-61 Control Unit . . . . . . . . . . . . . . . . . 3-16, 7-102
Mast/Telescopic Roller Bearing Replacement Controls
7-72 Auto Steer Centering Relay K11 . . . . . . 7-130
Reach Cylinder Repair . . . . . . . . . . . . . 7-60 Battery Controller and K5 Relay . . . . . . 7-129
Roller Bearing Replacement . . . . . . . . . 7-63 Test Procedure . . . . . . . . . . . . . . . . . 7-129
Side Cylinder Repacking . . . . . . . . . . . . 7-65 Battery Controller and Relay K5 . . . . . . 7-129
Auxiliary Control Unit . . . . . . . . . . . . . . . . . . . . 7-102
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 “M” Lockout Circuit Test . . . . . . . . . . 7-114
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 “M” Time Delay Test . . . . . . . . . . . . . 7-111
Auxiliary Fork Carriage . . . . . . . . . . . . . . 3-17 1/2 Speed Test (VPG Card) . . . . . . . . 7-108
Auxiliary System . . . . . . . . . . . . . . . . . . . . 3-9 1/8 Speed Test . . . . . . . . . . . . . . . . . 7-109
Current Limit . . . . . . . . . . . . . . . . . . 7-113
Equalizing Time Delay . . . . . . . . . . . . 7-119
B Equalizing Time Delay Test . . . . . . . . 7-112
Fwd/Rev Time Delay Test . . . . . . . . . 7-110
Batteries . . . . . . . . . . . . . . . . . . . . . 3-12, 7-83 Idle Rep Rate Adjust . . . . . . . . . . . . . 7-106
Charging . . . . . . . . . . . . . . . . . . . . . . . 7-84 Input Voltage Check . . . . . . . . . . . . . 7-103
Exterior Cleaning . . . . . . . . . . . . . . . . . 7-83 Overload Control Circuit Test . . . . . . 7-115
Record Keeping . . . . . . . . . . . . . . . . . . 7-87 Plugging Adjustment . . . . . . . . . . . . . 7-106
Battery Compartment . . . . . . . . . . . . . . . . 3-3 Power Driver Card . . . . . . . . . . . . . . . 7-117
Battery Controller . . . . . . . . . . . . . 3-16, 7-129 Regulated Voltage Check . . . . . . . . . . 7-104
Battery Safety . . . . . . . . . . . . . . . . . . . . . . 2-7 Speed Limit Module . . . . . . . . . . . . . 7-120
Brakes . . . . . . . . . . . . . . . . . . . . . . . 3-5, 7-49 Transient Suppressors . . . . . . . . . . . 7-118
Parking Brake Adjustment . . . . . . . . . . 7-51 Weld Detect Circuit . . . . . . . . . . . . . . 7-116
Service Brake Adjustment . . . . . . . . . . 7-50 Width and Freq Pulse Checks . . . . . . 7-105
Shoe Replacement . . . . . . . . . . . . . . . . 7-52 Deadman Relay K12 . . . . . . . . . . . . . . 7-131
Wheel Cylinder Repair or Replacement . 7-54 Diode Assemblies . . . . . . . . . . . . . . . . . 7-132
Directional/Speed Control Assy . . . . . . . 7-96
Light Load Relay K13 . . . . . . . . . . . . . . 7-131
C Plugging Relays K1 & K2 . . . . . . . . . . . 7-127
Rectifier’s
C1 . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . 3-15 Replacement . . . . . . . . . . . . . . . . . . . 7-125
C2 . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . 3-15 Test Procedure . . . . . . . . . . . . . . . . . 7-125
Capacitors . . . . . . . . . . . .. . .. . . . . . . . . 3-15 Rectifiers . . . . . . . . . . . . . . . . . . . . . . . 7-125
Carriage Roller Bearing . .. . .. . . . . . . . . 7-63 Resistor Assemblies . . . . . . . . . . . . . . . 7-135
Commutator . . . . . . . . . .. . .. . . . . . . . . 7-16 SCR’s
SCR1 Replacement . . . . . . . . . . . . . . 7-122
Issued: 9/30/02 I-1

Index Raymond ® Sideloader Maintenance Manual
SCR2 & SCR3 Replacement . . . . . . . .7-124 E

Test Procedure . . . . . . . . . . . . . . . . .7-122
Suppressor Assemblies . . . . . . . . . . . .7-136
Conversions, Standard/Metric . . . . . . . . . A-9 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Crab Steer . . . . . . . . . . . . . . . . . . . . . . . 3-11 Component Testing . . . . . . . . . . . . . . . . 7-87
Crab Steer Alignment and Adjustment . . 7-28 Contactors
Crab Steer Cylinder Replacement . . . . . . 7-36 Cleaning . . . . . . . . . . . . . . . . . . . . . . . 7-88
Current Limit . . . . . . . . . . . . . . . . . . . . .7-113 Coil Replacement . . . . . . . . . . . . . . . . 7-89
Current Limit Circuit . . . . . . . . . . . . . . . 8-28 Core/Rod Assy Replacement . . . . . . . . 7-90
Cylinders Insulation Replacement . . . . . . . . . . . 7-90
Fork Tilt . . . . . . . . . . . . . . . . . . . . . . . . 7-59 Tip Inspection . . . . . . . . . . . . . . . . . . . 7-88
Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66 Tip Replacement . . . . . . . . . . . . . . . . . 7-90
Mast Tilt . . . . . . . . . . . . . . . . . . . . . . . 7-57 General . . . . . . . . . . . . . . . . . . . . . . . . . 7-82
Master . . . . . . . . . . . . . . . . . . . . . . . . . 7-75 Heat Sink Insulation . . . . . . . . . . . . . . . 7-82
Reach . . . . . . . . . . . . . . . . . . . . . . . . . 7-60 Emergency Manual Lower Valve . . . . . . . . 8-10
Slave . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75 Equalizing Time Delay . . . . . . . . . . . . . . . 3-13
Steer . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Cylinders, Hydraulic . . . . . . . . . . 7-57 to 7-68
F
D Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Flow Limiter . . . . . . . . . . . . . . . . . . . . . . . 3-10
Deadman Switch . . . . . . . . . . . . . . . . . . . 3-12 Fork Tilt Cylinder . . . . . . . . . . . . . . . . . . . 7-59
Decimal to Fraction Conversion . . . . . . . . A-7 Fraction to Decimal Conversion . . . . . . . . . A-7
Design, Manual . . . . . . . . . . . . . . . . . . . . . 1-3 Frequency Pulse . . . . . . . . . . . . . . . . . . . 7-105
Diode Assemblies Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
DA1 . . . . . . . . . . . . . . . . . . . . . . . . . . .7-132
DA2 and DA9 . . . . . . . . . . . . . . . . . . . .7-132
DA3, DA4, DA8 and DA10 . . . . . . . . . .7-133
G
DA5 and DA11 . . . . . . . . . . . . . . . . . . .7-133
DA6 . . . . . . . . . . . . . . . . . . . . . . . . . . .7-134 Gear Reduction . . . . . . . . . . . . . . . . . . . . . 3-4
DA7 and DA12 . . . . . . . . . . . . . . . . . . .7-134 Guide Rollers . . . . . . . . . . . . . . . . . . . . . . 3-17
Directional/Speed Control Assy . . . 3-13, 7-96
Master Switches . . . . . . . . . . . . . . . . . . 7-96
Potentiometer H
Check . . . . . . . . . . . . . . . . . . . . . . . . 7-97
Gear Binding Adjustment . . . . . . . . .7-100 Heat Sinks . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Removal/Replacement . . . . . . . . . . . . 7-99 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Reassembly . . . . . . . . . . . . . . . . . . . . .7-101 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . 3-16
Double Acting Cylinders . . . . . . . . . . . . . 3-10 Hydraulic
Drive Axle Assembly . . . . . . . . . . . . . . . . 7-23 Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Axle Removal and Reassembly . . . . . . . 7-30 Hydraulic Adjustable Forks . . . . . . . . . . . 3-17
General . . . . . . . . . . . . . . . . . . . . . . . . 7-24 Hydraulics . . . . . . . . . . . . . . . . . . . . 3-7, 7-73
Tie Rod Replacement . . . . . . . . . . . . . . 7-36 Auxiliary Controls and Linkage . . . . . . . 7-78
Wheel Replacement . . . . . . . . . . . . . . . 7-26 General . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Leakage . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Inspection and Cleaning . . . . . . . . . . . . 7-25 Lift Control and Linkage . . . . . . . . . . . . 7-75
Replacement . . . . . . . . . . . . . . . . . . . . 7-32 Lift Pump
Drive Unit Repair and Replacement . . . . . 7-34 Maintenance . . . . . . . . . . . . . . . . . . . . 7-75
Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . 3-4 Replacement . . . . . . . . . . . . . . . . . . . . 7-76
Manifolds . . . . . . . . . . . . . . . . . . . . . . . 7-78
I-2 Issued: 9/30/02

Relief Valve Pressure Settings . . . . . . 7-79 M

Slave Cylinder . . . . . . . . . . . . . . . . . . . 7-75
M Lockout Circuit . . . . . . . . . . .. . . . . . . . 8-28

I Maintenance . . . . . . . . . . . . . . .. . . . . . . . . 5-1
Manifolds . . . . . . . . . . . . . . . . .. . . . . . . . 7-78
Idle Rep Rate . . . . . . . . . . . . . . . . . . . . . 7-106 Manual Design . . . . . . . . . . . . .. . . . . . . . . 1-3
Inspection Points . . . . . . . . . . . . . . . . . . . . 5-8 Map, Navigating the Manual . . .. . . . . . . . . 1-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Mast . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 3-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . 4-3 Mast Assembly . . . . . . . . . . . . .. . . . . . . . 7-69
Reassembly, Mast to Tractor . . . . . . . . . . 4-4 Mast Drive . . . . . . . . . . . . . . . .. . . . . . . . 7-70
Mast Tilt Cylinder . . . . . . . . . . .. . . . . . . . 7-57
Mast Traverse Motor . . . . . . . . .. . . 3-10, 7-61
J Master Cylinder . . . . . . . . . . . .. . . . . . . . 7-75
Metric to Standard Conversion .. . . . . . . . .A-9
Motors . . . . . . . . . . . . . . . . . . .. . . . . . . . 7-14
Jacking Safety . . . . . . . . . . . . . . . . . . . . . 2-11 Brushes . . . . . . . . . . . . . . . . .. . . . . . . . 7-14
Inspection . . . . . . . . . . . . . .. . . . . . . . 7-14
K Replacement . . . . . . . . . . . .. . . . . . . . 7-15
Commutator . . . . . . . . . . . . .. . . . . . . . 7-16
Drive . . . . . . . . . . . . . . . . . . .. . . . . . . . 7-32
K1 . . . . . . . . . . . . . . . . . . . . . . . . . 3-15, 7-127 Lift . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 3-8
K11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-130 Mast Traverse . . . . . . . . . . . .. . . . . . . . 7-61
K12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-131 Terminal Nuts . . . . . . . . . . . .. . . . . . . . 7-18
K13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-131
K2 . . . . . . . . . . . . . . . . . . . . . . . . . 3-15, 7-127
K5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-129 O
Key Switch . . . . . . . . . . . . . . . . . . . . . . . 3-12
Operation
L Lift/Lower . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Options
Auxiliary Fork Carriage . . . . . . . .. . . . . 3-17
Lift Guide Rollers . . . . . . . . . . . . . . . .. . . . . 3-17
Chain . . . . . . . . . . . . . . . . . . . . . . . 3-6, 7-62 Hydraulic Adjustable Forks . . . . .. . . . . 3-17
Check Valve . . . . . . . . . . . . . . . . . . . . . . 3-8 Load Weight Indicator . . . . . . . . .. . . . . 3-17
Control . . . . . . . . . . . . . . . . . . . . . . 3-8, 7-75 Miscellaneous . . . . . . . . . . . . . . .. . . . . 3-18
Cylinder Bleeding . . . . . . . . . . . . . . . . . 7-68 Ranger® Shelf Height Selector . . .. . . . . 3-17
Cylinders . . . . . . . . . . . . . . . . 3-6, 3-8, 7-66 Remote Lift/Lower . . . . . . . . . . . .. . . . . 3-18
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Orbitrol . . . . . . . . . . . . . . . . . . . . .. . . . . 3-11
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Lift Linkage . . . . . . . . . . . . . . . . . . . . . . . 7-75
Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . 7-75 P
Replacement . . . . . . . . . . . . . . . . . . . . . 7-76
Load Reducing Relays . . . . . . . . . . . . . . . 3-16 Plugging Relays . . . . . . . . . . . . . . . . . . . . 3-15
Load Weight Indicator . . . . . . . . . . . . . . . 3-17 Power Driver Card . . . . . . . . . . . . . . . . . 7-117
Locator Photos Charging SCR Pulse Test . . . . . . . . . . . 7-117
Components . . . . . . . . . . . . . . . . . . . . . . 7-3 Commutating SCR Pulse Test . . . . . . . 7-117
Lowering Pressure Relief System . . . . . . . . . . . . . . . 3-10
Lock-Out Solenoid . . . . . . . . . . . . . . . . . 3-8 Pressure Reliefs . . . . . . . . . . . . . . . . . . . . . 3-9
Lowering Valve . . . . . . . . . . . . . . . . . . . . . 3-8 Pressure Settings
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Relief Valve . . . . . . . . . . . . . . . . . . . . . . 7-79
Lubrication Specification Chart . . . . . . . . . A-2 Pulse Width . . . . . . . . . . . . . . . . . . . . . . 7-105
Issued: 9/30/02 I-3

R Steer Cylinder Replacement . . . . . . . . . . . 7-44

Steer Cylinders . . . . . . . . . . . . . . . . . . . . 3-11
Steer Knuckle Replacement . . . . . . . . . . . 7-45
R1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Steer Linkage Replacement . . . . . . . . . . . 7-43
R2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Steerable Wheel Replacement . . . . . . . . . . 7-39
R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Steering . . . . . . . . . . . . . . . . . . 3-4, 3-11, 7-47
Ranger® Shelf Height Selector . . . . . . . . . 3-17 Alignment . . . . . . . . . . . . . . . . . . . . . . . 7-40
Reach Cylinder . . . . . . . . . . . . . . . . . . . . 7-60 Chain Adjustment . . . . . . . . . . . . . . . . . 7-48
Rectifiers . . . . . . . . . . . . . . . . . . . 3-15, 7-125 Linkage Adjustment . . . . . . . . . . . . . . . 7-40
Relays Orbitrol . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Load Reducing . . . . . . . . . . . . . . . . . . . 3-16 Suppressor Assemblies
Plugging . . . . . . . . . . . . . . . . . . . . . . . . 3-15 SUP1 . . . . . . . . . . . . . . . . . . . . . . . . . . 7-136
Relief Valve Pressure Settings . . . . . . . . . 7-79 SUP3 . . . . . . . . . . . . . . . . . . . . . . . . . . 7-136
Remote Lift/Lower . . . . . . . . . . . . . . . . . 3-18 Switch
Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Deadman . . . . . . . . . . . . . . . . . . . . . . . 3-12
Resistor Assemblies Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
RA1 . . . . . . . . . . . . . . . . . . . . . . . . . . .7-135 System Pressure Relief . . . . . . . . . . . . . . . 3-10
RA2 . . . . . . . . . . . . . . . . . . . . . . . . . . .7-135
T
S
T1 . . . . . . . . . . . . . . . . . . . .. .. . . . . . . . 3-15
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Telescopic . . . . . . . . . . . . . .. .. . . . . . . . . 3-5
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Theory of Operation . . . . . . .. .. . . . . . . . . 8-1
Definitions . . . . . . . . . . . . . . . . . . . . . . . 2-2 Auxiliary Controls . . . . . . .. .. . . . . . . . 8-13
General . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Brakes . . . . . . . . . . . . . . .. .. . . . . . . . . 8-3
Jacking . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Lift/Lower . . . . . . . . . . . . .. .. . . . . . . . . 8-7
Welding . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Miscellaneous Circuits . . .. .. . . . . . . . 8-28
Scheduled Maintenance . . . . . . . . . 5-2 to 5-7 Outline . . . . . . . . . . . . . . .. .. . . . . . . . . 8-2
Annual . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Overview . . . . . . . . . . . . . .. .. . . . . . . . . 8-2
Guidelines . . . . . . . . . . . . . . . . . . . . . . . 5-2 Plugging . . . . . . . . . . . . . .. .. . . . . . . . 8-26
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Remote Travel . . . . . . . . . .. .. . . . . . . . 8-29
Photos . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 SCR Theory . . . . . . . . . . . .. .. . . . . . . . 8-15
Semi-Annual . . . . . . . . . . . . . . . . . . . . . 5-6 Standard Travel . . . . . . . . .. .. . . . . . . . 8-17
SCR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Steering . . . . . . . . . . . . . .. .. . . . . . . . . 8-4
SCR1 Replacement . . . . . . . . . . . . . . . . .7-122 Tie Rod Replacement . . . . . .. .. . . . . . . . 7-36
SCR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Tire Replacement . . . . . . . . .. .. . . . . . . . 7-12
SCR2 & SCR3 Replacement . . . . . . . . . .7-124 Torque Chart . . . . . . . . . . . .. .. . . . . . . . . A-4
SCR3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Metric . . . . . . . . . . . . . . . .. .. . . . . . . . . A-5
Shorts to Frame . . . . . . . . . . . . . . . . . . . . 6-5 Standard . . . . . . . . . . . . . .. .. . . . . . . . . A-4
Side Cylinder . . . . . . . . . . . . . . . . . . . . . 7-65 Transformer T1 . . . . . . . . . .. .. . . . . . . . 3-15
Silicon Controlled Rectifiers . . . . . . . . . . 3-14 Transient Suppressors . . . . .. .. . . . . . . 7-118
Speed Limit . . . . . . . . . . . . . . . . . . . . . . . 8-28 Travel System . . . . . . . . . . .. .. . . . . . . . 3-12
Speed Limit Module . . . . . . . . . . . 3-13, 7-120 Troubleshooting . . . . . . . . . .. .. . . . . . . . . 6-1
Standard to Metric Conversion . . . . . . . . . A-9 General Instructions . . . . .. .. . . . . . . . . 6-4
Steer Axle Assembly Overview . . . . . . . . . . . . . .. .. . . . . . . . . 6-2
Cylinder Replacement . . . . . . . . . . . . . 7-44 Start Procedure . . . . . . . . .. .. . . . . . . . 6-13
General . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Wiring Inspection . . . . . . .. .. . . . . . . . . 6-4
Knuckle Replacement . . . . . . . . . . . . . . 7-45 Troubleshooting Charts . . . .. .. . . . . . . . 6-11
Linkage Replacement . . . . . . . . . . . . . . 7-43
Removal and Reassembly . . . . . . . . . . . 7-41
Steer Centering Relay . . . . . . . . . . . . . . .7-130
I-4 Issued: 9/30/02

VR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Weld Detection Circuit . . . . . . . . . . . . . . 8-28

Welding Safety . . . . . . . . . . . . . . . . . . . . 2-12
Wheel Replacement
Steerable . . . . . . . . . . . . . . . . . . . . . . . 7-39
Wiring Inspection . . . . . . . . . . . . . . . . . . . 6-4
Issued: 9/30/02 I-5

I-6 Issued: 9/30/02

PDMM-0102 !PDMM-0102
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Printed in the USA

PDMM0102 00 093002

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Back to START

Model 71B - Serial No. 1401 and Up 0REACH.EPS

PDMM-0102 Issued: 9-30-02

Supercedes MM-75 Issued 12/1/81 (Model 76)

Map of the Manual . . . . . . . . . . . . . . . . 1-2 Troubleshooting Procedure . . . . . . . . . 6-13

Manual Design . . . . . . . . . . . . . . . . . . . 1-3 Component Procedures . . . . . . . . 7-1

Definitions . . . . . . . . . . . . . . . . . . . . . . 2-2 Tire Replacement . . . . . . . . . . . . . . . . . 7-12

General Safety . . . . . . . . . . . . . . . . . . . 2-3 Motors . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Battery Safety. . . . . . . . . . . . . . . . . . . . 2-7 Drive Axle Assembly. . . . . . . . . . . . . . . 7-23

Jacking Safety . . . . . . . . . . . . . . . . . . 2-11 General . . . . . . . . . . . . . . . . . . . . . . . . 7-24

Welding Safety . . . . . . . . . . . . . . . . . . 2-12 Drive Motor

Installation . . . . . . . . . . . . . . . . . 4-1 Crab Steer Cylinder Replacement. . . . . 7-36

Maintenance Guidelines . . . . . . . . . . . . 5-2 Steer Cylinder Replacement . . . . . . . . . 7-44

Monthly Maintenance . . . . . . . . . . . . . . 5-3 Steer Knuckle Replacement . . . . . . . . . 7-45

Semi-Annual Maintenance . . . . . . . . . . 5-6 Steering . . . . . . . . . . . . . . . . . . . . . . . . 7-47

Annual Maintenance. . . . . . . . . . . . . . . 5-7 Steering Chain Adjustment . . . . . . . . . 7-48

Lubrication and Inspection Points. . . . . 5-8 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . 7-49

PDMM-0102 Issued: 9/30/02 iii

Brake Shoe Replacement . . . . . . . . . . 7-52 Battery Controller and K5 Relay . . . . 7-129

General . . . . . . . . . . . . . . . . . . . . . . . 7-82 Standard/Metric Conversions . . . . . . . . A-9

iv PDMM-0102 Issued: 9/30/02

Page Revision Record

Page Revision Record

This page is a record of the latest revised pages

PDMM-0102 Issued: 9/30/02 v

Page Revision Record

vi PDMM-0102 Issued: 9/30/02

Service Bulletin Index

Service Bulletin Index

Document Number Subject Date

PDMM-0102 Issued: 9/30/02 vii

Product Improvement Notice Index

Product Improvement Notice Index

Document Number Subject Date

SDL-97-R002 Horn failure 02-25-97

SDL-97-R003 Lift/Lower control panel plate 10-16-97

viii PDMM-0102 Issued: 9/30/02

How to Use This Manual 1:

PDMM-0102 Issued: 9/30/02 1-1

Map of the Manual

Map of the Manual

1-2 PDMM-0102 Issued: 9/30/02

PDMM-0102 Issued: 9/30/02 1-3

• Component Procedures gives step-by-step

1-4 PDMM-0102 Issued: 9/30/02

START: What do you want to do?

PDMM-0102 Issued: 9/30/02 1-5

1-6 PDMM-0102 Issued: 9/30/02

PDMM-0102 Issued: 9/30/02 2-1

2-2 PDMM-0102 Issued: 9/30/02

Do NOT operate or work on this lift truck unless

Know the lift truck’s controls and what they do.

Do NOT operate this lift truck if it needs repair

Operate this lift truck only from the operator’s

PDMM-0102 Issued: 9/30/02 2-3

Before working on this lift truck, always turn

Do NOT wear watches, rings, or jewelry when

Follow the scheduled lubrication, maintenance

Follow the safety and repair instructions in this

2-4 PDMM-0102 Issued: 9/30/02

Do NOT use an open flame near the lift truck.

Do NOT use gasoline or other flammable liquids

Clean up any hydraulic fluid, oil, or grease that