Raymond® Walkie Pallet Truck Maintenance Manual

3.Connect the wiring harness connectors and install new cable ties where previously located.

NOTE: If the truck is a Cold Storage Unit, apply an ample amount of sealing compound (P/N 990-564) where wires enter plugs or receptacles. The amount applied should be enough to prevent moisture from entering the connector. Disconnect connectors to apply compound both internally and externally. Avoid sealing compound on pin contact area.

4.Install the lower control handle cover with the four hex head cap screws removed previously.

5.Install the control handle bottom cover with the four hex head cap screws removed previously.

6.Connect the battery connector and turn the key switch ON.

7.Test the operation of the truck.

Control Handle Stem Removal

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

2.Remove the four hex head cap screws securing the lower control handle cover.

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

Caution

Before removing the chain master link in the next step, make sure you are holding the handle. When the master link is re moved, the handle will fall.

4.Pull the handle down to operating range. Insert a wire or punch through a chain link close to the handle (or use a pair of locking pliers to grasp the chain close to the handle).

Component Procedures

Control Handle

Component Procedures

Control Handle

5.Release the handle to relieve tension on the chain and the anchor.

6.Disconnect the handle return chain at the master link located near the transmission case. See Figure6-21.

7.Remove any remaining cable ties and pull the wiring harness out the bottom of the handle.

8.Remove the motor side cover. Remove the cotter pin retaining bolt and cotter pin and slide the pivot pin out. See Figure6-22.

9.Carefully remove the handle.

Control Handle Stem Reassembly

1.During reassembly, be certain that the brake release cam on the handle pivot pin is in the correct position before installing the cotter pin.

2.Slide in the handle pivot pin through the lower control handle assembly and reinstall the cotter pin and retaining bolt.

3.Raise the handle and reconnect the handle return spring at the chain master link located near the transmission case.

4.Pull handle down to operating range and remove the wire, punch or pliers installed earlier.

5.Thread the handle harnesses through the handle base.

6.Reattach the control handle head unit if removed.

7.Reconnect the handle harness connectors. Install the cable ties in their original locations on the handle harness and drive motor cables.

8.Install the control handle cover.

9.Install the motor side cover.

10.Connect the battery connector and turn the key switch ON.

11.Test the operation of the truck.

Horn

The horn can be sounded regardless of key switch position, provided the Main ON/OFF switch is in the ON position.

Removal

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

2.Remove the tractor cover.

3.Disconnect the two wires from the horn. See Figure6-23.

4.Remove the horn mounting bolt.

Installation

1.Attach the horn to the electrical panel and tighten the mounting bolt.

2.Attach the two wires.

3.Reconnect the battery connector and test operation.

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

5.Install the tractor cover.

6.Reconnect the battery connector.

Motor Controller

Caution

Do not open the controller. Opening the controller could damage it and will void the warranty.

Cleaning

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

2.Remove the tractor cover.

3.Discharge the capacitors in the controller by connecting a load (such as a contactor coil or a horn) across the controller’s B+ and B- terminals.

4.Clean the controller with a moist rag. Allow it to dry before connecting the battery.

5.Make sure the power cable connections are tight. Avoid stressing the cable connections and putting strain on internal components.

Removal

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

2.Remove the tractor cover.

3.Discharge the capacitors in the controller by connecting a load (such as a contactor coil or a horn) across the controller’s B+ and B- terminals.

4.Push the locking tab and disconnect the PMC connector (control wires) from the motor controller. See Figure6-25.

5.Disconnect the three power cables (terminals B+, B- and M-) on the motor controller. Avoid stressing the power cable connections. Disconnect wiring harness connectors (terminals S1 and S2).

6.Remove the three hex head cap screws securing the motor controller to the electrical panel. Remove the controller.