Raymond® Walkie Pallet Truck Maintenance Manual

Installation

NOTE: All motor controllers are preset to factory default specifications.

1.Secure the motor controller to the electrical panel with the three previously removed hex head cap screws.

2.Reconnect the three power cables (terminals B+, B- and M-) on the motor controller. Torque screws to 12 ft. lbs. (16.3 Nm) maximum. Avoid stressing the cable connections and putting strain on internal components.

3.Connect the PMC connector (control wires) and wiring harness connectors (terminals S1 and S2) to the motor controller.

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

5.Test operation of the truck.

6.Turn the key switch OFF.

7.Install the tractor cover.

Emergency Reverse Check

A wire connected directly between the motor controller and the emergency reverse switch can detect a broken wire.

The emergency reverse check output wire periodically pulses the emergency reverse circuit to check for continuity. If there is no continuity, the motor controller limits the vehicle to 15% speed and indicates Fault Code 2, 2. (See “Fault Codes” on page5-13.)

Component Procedures

Emergency Reverse Check

Component Procedures

Throttle Potentiometer Adjustment

Throttle Potentiometer Adjustment

The throttle is a two wire resistive throttle that connects the pot wiper pin (PMC-6) and the pot low pin (PMC-7). Zero speed corresponds to 0 ohm and full speed corresponds to 6.5K ohm.

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

Warning

Use extreme care whenever the truck is jacked up. Keep hands and feet clear from vehicle while jacking the truck. After the truck is jacked, DO NOT rely on the jack alone to support the truck. For details, see “Jacking Safety” on page2-11.

2.Jack and block the truck.

3.Disconnect the handle harness connector JP6 at the bottom end of the handle prior to adjustment. This will ensure that feedback from other circuitry in the truck will not affect the ohmmeter readings.

4.Remove the four hex head cap screws that secure the control handle bottom cover. Remove the cover to access the throttle potentiometer. See Figure6-26.

5.To electrically center the potentiometer, the throttle must be in the neutral position. Loosen the nut on the potentiometer shaft. See Figure6-27.

6.Connect the ohmmeter to pins VR-2 and VR-4. Measure the potentiometer resistance while rotating the potentiometer body until the ohmmeter reads as close to ‘0’ ohms as possible. Retighten the potentiometer shaft nut.

NOTE: While performing the next step, hold the cam while rotating the Directional/ Speed Control Handle to prevent the assembly from coming out of the control handle assembly.

7.With the ohmmeter still connected to pins VR-2 and VR-4, verify that the forward and reverse throttle positions are equal by