Raymond® Walkie Pallet Truck Maintenance Manual

Lift-Limit Switch

When the forks are fully raised, the lift-limit switch (SW10) turns the hydraulic pump motor off. This keeps the pump from trying to extend the lift cylinder beyond its maximum travel. See Figure6-17.

Adjustment

1.Raise the forks until they reach their fully raised position. If the lift-limit switch does not shut the pump down when the lift cylinder reaches its upper limit, the relief valve on the hydraulic pump will make a high-pitched squeal, indicating that the relief valve is opening.

2.Turn the key switch OFF and disconnect the battery.

3.Loosen the bolt and slide the switch bracket up or down to activate (cut power off) when the lift is 1/2 to 1 in. (12.7 to 25.4 mm) before its fully raised position.

4.Tighten the bolt.

5.Reconnect the battery and turn the key switch ON. Lower the forks and then raise them until they reach their fully raised position. The lift-limit switch should cut power off to the pump when the lift cylinder reaches 1/2 to 1 in. (12.7 to 25.4 mm) before its fully raised position.

Component Procedures

Component Procedures

Hydraulic Solenoid

Removal

1.Make sure that the forks are fully lowered.

2.Turn the key switch to OFF. Disconnect the battery connector.

3.Remove the two wires from the terminals on the solenoid.

4.Remove the nut holding the solenoid coil to the solenoid valve.

5.Lift the solenoid coil off the solenoid valve.

6.Remove the solenoid valve from the manifold.

Installation

1.Inspect the seat where the solenoid seals against the manifold. The sealing surface should be completely clean and free from any nicks or damage.

2.Inspect the O-ring for any damage. If the O-ring is damaged or deformed in any way, replace it.

3.Thread the solenoid valve into the manifold. Torque the solenoid valve to 144-180 in. lbs (16-20 Nm).

4.Install the solenoid coil onto the solenoid valve and tighten the nut. Torque the nut to 48-60 in. lbs (5-7 Nm).

5.Connect the wires to the terminals.

6.Reconnect the battery connector and turn the key switch ON. Test the functions of the truck.

7.Turn the key switch OFF. Disconnect the battery.

8.Install the tractor cover.

Gauges

The Model 101 comes standard with an hour meter. A combination hour meter/battery discharge meter is optional.

Hour Meter

When the battery is co nnected, this meter shows the number of hours. The digital quartz “hour glass” icon flashes and the counter increases when the brake (deadman) switch is closed.

Inspection

If the numbers do not illuminate when the battery is plugged in, use a voltmeter to check for B+ at pin 1 on the back of the gauge (with respect to pin 2, B-). If voltage is not present, use the schematic in the Appendix and trace B+ and B- to the source (battery).

If the meter does not log hours, verify that B+ is present on pin 3 when the brake (deadman) switch is closed (the handle is in drive position). If voltage is not present, use the schematic in the Appendix and trace B+ to the source (brake (deadman) switch).

If the required voltages are present (as outlined above) and no other problems are found, replace the hour meter.

Removal

1.Turn the key switch OFF and disconnect the battery connector.

2.Remove the tractor cover.

3.Remove the gauge console from the electrical panel.

4.Remove wires from the back of the gauge and make careful note of their orientation.

5.Remove the mounting nuts (2) and slide off the gauge mounting bracket.

6.Remove the gauge by lifting through the top of the gauge console.

Component

Gauges

Installation

1.Place the new gauge in the mounting hole.

2.Replace the gauge bracket, install the nuts, and tighten them securely.

3.Connect the wires to the proper terminals.

4.Re-install the gauge console on the electrical panel.

5.Reconnect the battery connector and test operation.

6.Install the tractor cover.

Combination Hour/Battery Discharge Meter

Hour Meter

When power is applied, the meter’s digital quartz “hour glass” icon flashes and counter increases. The meter logs hours when the brake (deadman) switch is closed.

Battery Discharge Meter

The battery discharge meter measures the battery state-of-charge when the key switch is ON.

When the battery is fully and properly charged, the green bar closest to 1 is lit. As the battery loses its charge, a green or yellow bar moves closer to 0. Two red bars begin flashing when the battery is almost fully discharged.

Inspection

If the displays do not illuminate when the key switch is ON, use the voltmeter to check for B+ at pin 6 on the back of the gauge (with respect to pin 2, B-). If the voltage is not present, use the schematic in the Appendix and trace B+ and B- to the source (battery via key switch).

If the point does not move when the key switch is ON, use the voltmeter to check for B+ at pin 5 on the back of gauge (with respect to pin 2, B-). If the voltage is not present, use the schematic in the Appendix and trace B+ and B- to the source (battery via FU1).

If the meter does not log hours, verify that B+ is present on pin 3 when the brake (deadman) switch is closed (handle is in drive position). If the voltage is not present, use the schematic in the Appendix and trace B+ to the source (brake (deadman) switch.

If the required voltages are present (as outlined above) and no other problems are found, replace the gauge.

Caution

If the battery is replaced with another battery that is not fully charged (i.e., the gauge does not reset its indication to a full charge state) the disp lay may provide wrong information for the battery state-of-charge.

Removal

1.Turn the key switch OFF and disconnect the battery connector.

2.Remove the tractor cover.

3.Remove the gauge console from the electrical panel.

4.Remove the wires from the back of the gauge and make careful note of their orientation.

5.Remove the mounting nuts and slide off the mounting bracket.

6.Remove the gauge by lifting through the top of the gauge console.

Installation

1.Place the new gauge in the mounting hole.

2.Replace the bracket, install the nuts, and tighten them securely.

3.Connect wires to the proper terminals.

4.Re-install the gauge console on the electrical panel.

5.Reconnect the battery connector and test operation.

6.Install the tractor cover.

Component Procedures

Control Handle

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

Head Unit Removal

1.Turn the key switch OFF and disconnect the battery connector.

2.Remove the four hex head cap screws that secure the control handle bottom cover. See Figure6-19.

3.Remove the four hex head cap screws securing the lower control handle cover. See Figure6-20.

4.Disconnect the wiring harness connectors. See Figure6-20. Note the position of cable ties holding the harness. When reassembling, attach new cable ties in the same locations.

5.Remove the four hex head cap screws securing the tie plate.

6.Remove the four hex head cap screws, washers, and nuts (two in front and one on each side of the handle) that secure the head unit to the handle. The head is now loose and may be removed from the handle.

Head Unit Reassembly

1.Install the head unit to the handle with the four hex head cap screws, washers, and nuts removed previously.

2.Install the tie plate with the four hex head cap screws removed previously.