Raymond® Walkie Pallet Truck Maintenance Manual

rotating the Directional/Speed Control Handle fully in both directions. Record the maximum resistance value in both directions. In either direction the resistance value should be 6.5K ± 500 ohms. In addition, the difference between the two readings must be 300 ohms or less.

Component Procedures

Throttle Potentiometer Adjustment

8.To determine the ideal potentiometer position, add the previously recorded readings in Step 7 and divide that result in half. (See example below.) Loosen the potentiometer nut (1/2 turn) so that the potentiometer will move in the bracket when you apply force with your finger.

Example:

6,500 ohms CW + 6,200 ohms CCW = 12,700 ohms

12,700 ÷ 2 = 6,350 ohms (ideal maximum resistance value setting)

9.Rotate the throttle control fully in one direction. Move the potentiometer body until the ideal maximum resistance value is obtained. Once the potentiometer is electrically centered, tighten the potentiometer shaft nut securely to prevent the pot from moving in the bracket.

10.Reattach the switch cover to the control handle with the four screws previously removed.

11.Reconnect the battery connector.

12.Test the truck’s operation.

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

14.Jack and remove the blocks from underneath the truck. See “Jacking Safety” on page2-11.

15.Reconnect the battery connector.

Contactors

Contactors Removal

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

2.Remove the tractor cover.

3.Disconnect the wires from the X and Y terminals on the contactor coils. See Figure6-28.

4.Remove the nuts securing the bus bar and cables to the contactor. Note the location for assembly later. See Figure6-28.

5.Remove the two screws holding the contactor assembly to the electrical panel.

Installation

1.Secure the contactor to the electrical panel with the two screws removed earlier.

2.Secure the bus bar and cable to the contactor with the nuts.

3.Connect the wires to the X and Y terminals.

4.Install the tractor cover.

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

6.Test the operation of the truck.

Brake

Caution

Allow the brake to cool completely before servicing.

Brake Shoe Adjustment

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. See “Jacking Safety” on page 2-11.

2.Jack the truck and block the frame.

3.Remove the drive motor cover.

4.Fully raise the control handle and remove the brake application spring. This will allow the brake to release. See Figure6-33.

5.Lower the control handle into the operating range so that the brake linkage bearing is on top of the brake release cam.

6.Adjust the brake rod linkage to the clevis so that the clevis pin just goes in the brake lever. See Figure6-34

7.Reinstall the spring and test braking ability.

NOTE: Use a maximum rated load when you measure the stopping distance. The truck should stop within approximately 6 feet (1.83 meters).

8.If the brake is inadequate, then shorten the brake rod linkage to the clevis to get adequate braking. Th is establishes the braking force on the brake shoes.

Component Procedures

Brake Shoe Adjustment

NOTE: The brake drum may be removed and the brake lever moved one “spline” to compensate for brake wear.

Removal

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

2.Remove the drive motor cover.

3.Fully raise the control handle and remove the brake application spring. Disconnect the clevis from the brake lever.

4.Loosen the nut and remove the brake drum.

5.Remove the springs and remove the brake shoes.

6.Remove the screws holding the brake assembly to the drive motor assembly.

7.Remove the brake assembly.

NOTE: By lifting one brake shoe of the brake assembly at a time, the mounting screws can be removed without disassembling the brake assembly.

Installation

NOTE: During reassembly, the brake lever should be checked to see that it is set at 60° and that the brake drum nut is torqued to 75 ft lbs (105 Nm).

1.Install the brake assembly to the drive motor. Apply thread-locking compound P/N 990-536 to mounting screws and torque to 11 ft lbs (15 Nm).

2.Install the brake drum and secure with the locking nut.

3.Install the brake adjusting rod assembly.

4.Install the clevis pin holding the lever.

5.Reinstall the brake application spring.

6.Adjust the brake. See “Brake Shoe Adjustment” on page6-43.

7.Install the drive motor cover.

8.Reconnect the battery connector. Turn the key switch ON and test-operate the truck.