Drive Unit

Removal

1.Lower the forks, 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, place solid blocks beneath it to support it. DO NOT rely on the jack alone to support the truck. For details, see “Jacking Safety” on page 2-11.

2.Jack the truck and block the frame.

3.Remove the tractor cover.

4.Disconnect the control wiring harness and power cables from the electrical panel.

5.Remove the control handle. See “Control Handle” on page6-34.

6.Remove the pivot bearing retaining nut. See Figure6-42.

Warning

Transmission assembly may fall free from mounting after nut is removed.

7.Remove the transmission assembly by lowering through the pivot-frame mount.

8.Feed the control wiring harness and power cables through the transmission pivot mount.

9.Remove the drive unit drain screw (lower cover screw). See Figure6-43. Allow the gear oil to drain.

Component Procedures

Disassembly

1.After draining the gear case lubricant, thoroughly clean the outside with solvent or other non-corrosive cleaning fluid. Air dry all parts, and proceed with disassembly of transmission.

2.Remove the drive wheel. See “Drive Wheel” on page6-64.

3.Remove the drive motor. See “Drive Motor” on page6-53.

4.Remove the 14 hex head cap screws securing the gear case cover. Remove the gear case cover.

5.Block the transmission with the gear case side down. Allow room for the gears to drop between the blocks.

6.Press the drive axle through the collar and bearing. The gear/axle and the cluster gear will come out together.

7.Remove the old bearings and races from the gears and case. Clean the transmission case, making sure that the vent hole located in the upper corner is free of obstructions.

14Screw

Component Procedures

Assembly

1.Install the new bearings [18] on the cluster gear [5].

2.Install the new bearing [13] on the drive axle [7].

3.Place the case in a fabricated assembly base and press the new bearing cups [13] in the transmission case.

4.Position the transmission on the work bench with the gear case side up. Place the drive axle [7] and cluster gear [5] in the case as a unit with the gears meshed. Because of the gear size and bearing tolerances, the gear set and bearing cannot be installed separately.

5.Use P/N 990-411 on the mating surface and install the drive unit gear case cover [3]. Be sure that the two dowel pins [11] are in the case to position the cover. Torque the cover bolts to 30 ft lbs (42 Nm).

6.Reposition the transmission case so that it rests on the gear case cover.

7.Temporarily install the drive motor in the transmission case using only two bolts to hold the motor in place.

8.Install the outer drive axle bearing cone [13] and retaining collar [13]: a.Place the bearing cone over the shaft. Use a standard 1-14 nut and bearing installation tool to push the bearing on the drive axle. At this time the bearing will not seat on the shoulder of drive axle. Remove the nut and pusher. b.Install the drive axle seal [16] in the transmission case. c.Install the bearing collar in the drive axle. Use a bearing installation tool and nut to press the collar on the shaft. This should also press the bearing down, seating it on the shoulder. Turn axle shaft while torquing nut to 250 ft lbs (339 Nm). Control the drive axle turning by holding the brake lever on the drive motor.

Installation

Caution

Be sure the key switch is OFF and the battery connector is disconnected before you begin.

1.Install the drive motor. See “Drive Motor” on page6-53.

2.Install the bearing cups in the frame. Install a Nilos ring over the pivot tube on the top of the transmission assembly and install the bearing cone.

3.Feed the wire harness and power cables through the pivot tube.

4.Reinstall the drive unit assembly through the pivot frame while feeding the harness and cables through the pivot frame mount. Install the bearing cone and Nilos ring.

5.Liberally grease the top and bottom bearing cones on the pivot bearing.

6.Unblock and lower the truck.

7.While tightening the drive unit locking nut, rotate the drive unit to simulate the steering action. Continue to tighten the nut until the nut is snug and the drive unit will not rotate. Back the nut off 1/4 turn and move steering. If the steering feels free, lock the nut with thread-locking compound P/N 990-536. If the steering still feels snug, back the nut off another 1/4 turn before applying thread-locking compound.

8.Install the control handle. See “Control Handle” on page6-34.

9.Reconnect the wiring harness.

10.Ensure the drive unit is filled to the proper level with gear oil. Install the fill/level plug.

11.Install the tractor cover.

12.Install the battery, reconnect the battery connector and the turn key switch ON.

13.Check the controls for proper operation.

Component Procedures

Drive Housing Lubrication

Gear Oil Level

1.Remove the fill/level plug. See Figure6-45.

2.Check the oil level. Wh en the truck is level, the oil should be up to the bottom of the plug opening.

3.If necessary, add the specified oil through the plug opening, but do not overfill.

4.Install the fill/level plug securely.

Changing Gear Oil

1.Remove the drain screw (lower cover screw) from the bottom of the gear housing cover and allow the oil to drain. See Figure6-45.

2.After the oil has drained completely, flush the housing with a suitable solvent and allow it to drain.

3.Install the drain screw.

4.Fill the drive housing with the specified gear oil through the fill/level plug opening in the cover of the transmission. The drive housing will hold 0.8 qts (0.75 liter) of gear oil. Do not overfill.

Raymond® Walkie Pallet Truck Maintenance Manual

Drive Axle Seal

Replace the drive axle seal without removing the gear case cover by doing the following:

Removal

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, place solid blocks beneath it to support it. DO NOT rely on the jack alone to support the truck. For details, see “Jacking Safety” on page 2-11.

2.Jack the truck and block the frame.

3.Remove the drive unit fill plug and drain screw and allow gear oil to drain.

4.Remove the drive motor cover.

5.Remove the nut holding the drive tire to the drive axle.

6.Remove the drive tire by hand or if wheel is stubborn, use three bolts from the drive motor cover and thread in hub to push drive tire off drive axle.

7.Remove the axle seal with a seal puller. Do not damage the sealing surface or mounting bore.

Installation

1.Install the new oil seal.

2.Reinstall the drive tire. Torque the drive tire retaining nut to 250 ft lbs (339 Nm).

3.Install the drive motor cover. Torque screws to 35 ft lbs (49 Nm).

4.Replace the drain screw. Replace the gear oil and replace the fill plug.

Component Procedures

Drive Housing Lubrication

Component Procedures

Drive Housing Lubrication

Drive Wheel Removal

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, place solid blocks beneath it to support it. DO NOT rely on the jack alone to support the truck. For details, see “Jacking Safety” on page 2-11.

2.Jack and block the truck under the tractor frame.

3.Remove the locking nut holding the drive wheel to the drive axle. See Figure6-46.

4.Remove the drive wheel by hand or if necessary use three bolts from the side cover over the drive wheel and thread in the hub to push the drive wheel off the drive axle.

5.Press the drive tire from the wheel hub.

Cushion Tire Replacement

Any misalignment of the tire and hub while the tire is being pressed onto the hub can cause damage to the hub. For this reason, chamfers have been provided on the outside edge of the hub and on the end of the inside diameter of the tire’s metal insert. The ch amfers help to center the hub and tire during pressing and to reduce the possibility of misalignment.

Caution

To prevent damage, the hub must be installed on the circular ram with the chamfered side up.

1.Check the inside surface of the metal insert on the new tire. Remove any scaling or rust with sandpaper. Clean the inside of the metal insert.

2.Place a circular ram on the press table. See Figure6-47. The length of the ram must be longer than the width of the old tire to allow complete removal of the old tire. The outside diameter of the ram must be small enough to fit loosely in the insert of the tire but must be large enough to rest squarely on the flat surface on the outer edge of the hub.

3.If the outside edge of the hub is not flush with the edge of the metal insert in the old tire, measure how far the hub is recessed inside the tire. The new tire must be placed in the same position the old tire was installed on the hub. You can use a spacer (slightly smaller in diam eter that the inside diameter of the tire insert and the same thickness as the depth of the recess) to obtain the proper amount of recession.

4.Position the hub assembly with the old tire on top of the circular ram so the outside of the wheel is positioned upward. The outside edge of the hub has a chamfer to help guide the new tire onto the wheel. The chamfered edge must always be the leading edge when a tire is pressed onto the hub.

Component Procedures

Drive Housing Lubrication

5.Center the hub assembly on top of the ram and make sure they mate squarely.

6.Position the new tire with its chamfered insert facing the hub. Align the new tire and the hub so they are concentric.

7.Begin pressing the new tire onto the hub and the old tire off the wheel. Run the press slowly for the first few inches of travel because this is the critical stage of the operation. If the tire begins to cock, stop the press immediately and realign the tire. Use a soft-headed mallet to realign the tire on the hub.

NOTE: If the new tire does not press on with a minimum pressure of 5 tons (68,947kPa), replace the hub.

8.Release the press. Remove the wheel, tire assembly and the old tire from the press table. Inspect the wheel and tire assembly.

9.Install the wheel and tire assembly on the drive axle of the truck. Torque the drive retaining nut to 250 ft lbs (339 Nm).