Raymond® Walkie Pallet Truck Maintenance Manual

Tractor Cover

Removal

To remove the tractor cover, unscrew the two captive screws on top of the cover and lift the cover slightly outward and upward away from the truck.

Installation

To install the cover, slide it back into the original position, and screw the two captive screws in on top of the cover.

Component

Battery CAUTION

Before working on the battery, see “Battery Safety” on page2-7. Batteries may weigh more than 500 pounds. Use extreme care during replacement. Use a suitable battery replacement device or hoist for lifting.

The Model 101 may be equipped with either a multiple battery pack, single battery or a maintenance free battery and charger.

Multiple Battery Pack Removal

1.After the truck is stopped and the handle is returned to the full up position, turn the key switch OFF.

2.Disconnect the battery connector located at the top of the tractor cover. Remove the battery cover.

3.To gain access to the lower two batteries, lift up on one of the top battery frames.

4.As the frame is lifte d, swing the battery toward the center of the forks.

5.The cables may now be disconnected from the battery terminals and the batteries may be serviced or replaced if necessary. See Figure6-3.

Installation

1.Position the fully charged and tested batteries in the battery pack.

2.Reconnect the battery cables to the battery terminals in accordance with the battery wiring hookup shown on the decal in the battery frame.

3.Reconnect the battery connector, reinstall the battery cover, turn the key switch ON, and test the operation of the pallet truck.

1790 001.eps

Single Battery Pack (Optional)

Removal

1.Turn the key switch OFF.

2.Disconnect the battery connector located at the top of tractor cover.

3.Position the battery replacement device above the battery and attach to the battery manufacturer’s designated lift points. See Figure6-4.

4.Remove the battery with the lifting device.

5.Place the discharged battery on the charging stand.

Installation

1.With a fully charged and tested battery on the lifting device, position the lifting device in accordance with the manufacturer’s recommendations.

2.Position the battery in the compartment. Be sure the battery has no more that 0.50 in. (12.7 mm) of “free play” movement in the battery compartment.

3.Move the lifting device from the area.

4.Reconnect the battery connector, turn the key switch ON, and test the operation of the truck.

Battery Exterior Cleaning

1.Inspect the battery.

a.Make sure the cables are not frayed or loose.

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 Figure6-5.

2.Keep the top of the battery clean and dry. Corrosion, dust, and moisture provide a conducting path to short-circuit cells or create grounds.

Caution

Do not clean the top of the battery with the soda solution while it is installed in the truck. Water would seep into the electrical compartments and cause serious damage.

a.Disconnect the battery connector, and remove the battery fr om the truck before you clean it.

b.Tighten the battery filler plugs.

c.Wash dirty batteries (or any that have had electrolyte spilled on them) with a solution of 1 lb (0.45 kg) of baking soda added to 1/2 gal (1.9 liters) of hot water.

d.Use a brush with flexible bristles to clean the entire top of the battery with the soda solution. Wait until all foaming stops, indicating that the battery exterior is neutralized.

e.Rinse the battery with clean water.

f.Dry the battery completely before reinstalling it.

g.Apply a thin coat of petroleum jelly to the battery posts and cable terminals.

Charging

To charge a battery, direct current is passed through the battery cells in the direction opposite to that of discharge. Charging time is 5% to 20% longer than discharge time.

The most important element in battery service and prolonging battery life is proper charging. Make sure you follow the proper method for each application, following the battery and battery charger manufacturers’ instructions.

Caution

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

1. Familiarize yourself with the following:

•Charging rate, starting rate, and finish rate

•Time available for charge

•Overheating, excessive gassing, or overcharging

•Variations between cell voltage

2.Battery performance varies depending on the type of application. If you use more than one truck, one battery, and one charger, keep the same batteries and charger assigned to each truck. This makes it easier to diagnose any battery or charging problem.

3.Consult your battery and battery charger manufacturer’s manual for specific charging procedures.

4.Wear personal protective equipment, see “Battery Safety” on page2-7.

5.Turn the key switch OFF, disconnect the battery, and remove th e battery from the truck.

6.Inspect the battery.

7.Check the electrolyte level in each cell. Electrolyte should cover the top of the battery plates. If electrolyte level is below the plates, add just enough water to cover the plates. See “Adding Water” on page6-13. 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. See “Specific Gravity” on page6-14.

9.Check and record the voltage of each cell.

10.To get the maximum use out of each battery, recharge only when effectively discharged. Routinely recharging batteries when only partially discharged will decrease battery life. At maximum recommended discharge, the specific gravity should read 1.140-1.160 or less.

11.Ensure that the filler plugs are clean and the vent holes are open. Tighten all filler plugs.

Caution

NEVER plug the battery charger into the truck. This will severely damage the truck’s electrical system. Plug the charger ONLY into the connector from the battery.

12.Charge the battery, following specific instructions in your battery and battery charger manufacturer’s manual.

13.Using a hydrometer, check the specific gravity of each cell. No amount of charging will increase battery capacity or raise specific gravity above its fully charged level (specific gravity 1.280 to 1.300).

14.If, after charging, the electrolyte level is below the fill port, add water to bring it to the fill level. See “Adding Water” on page6-13. Do not overfill the cells or allow electrolyte to spill onto the battery case.

In general, a lead-acid battery may be charged at any rate in amperes that does not cause excessive gassing or produce electrolyte temperatures above 110 F (43 C).

Temperatures of 120 F (49 C) are allowed only for short periods of time.