Raymond 101 Walkie Pallet Truck Parts Catalog Manual SN 07500 and Up - PDF DOWNLOAD

Model - 101 Walkie Pallet Truck

Parts Catalog

PDPM-0176 S/N 07500 and Up Issued 2/12/99

©Copyright 1999 The Raymond Corporation All Rights Reserved.

IF THE PART NUMBER IS NOT KNOWN

Major Assemblies

SECTION 7 MAST SECTION 6 HYDRAULIC COMPONENTS

DO THIS

SECTION 3 STEERING AND CONTROLS

1.

SECTION 5 SECTION 4 ELECTRICAL COMPONENTS AND

SECTION 2 FINISH AND ACCESSORIES

Determine in which Section the part is located using the illustration.

Drive and Brake

Drive Unit Assembly SYSTEMS - 271" and Above Elevated Height ..............................................................................4-2 Drive Unit Assembly - 270" and Below Elevated Height...............................................................................4-4 Deadman Brake Assembly ........................................................................................................................4-6 SECTION(used 4 with motor 570-262/500 only) ...............................................................4-8 Brake Assembly/Installation DRIVE Drive Unit Brake AssemblyAND ......................................................................................................................4-12 BRAKE .....................................................................................................................4-14 Brake Assembly Installation Inertial Dampener ..................................................................................................................................4-16

2.

Turn to the TABLE OF CONTENTS in the applicable Section.

Figure 1-1: Major Assemblies

1-3

Frame Assembly - DS/DT

7 29

5

28

30

23

12

26 25 24

20

11

22

4

6 10

19

21

17

18

16 15

14

13 31 2

9 8

40

3.

Refer to the PAGE NUMBER selected from the TABLE OF CONTENTS. Locate the desired part and note the ITEM NO.

37

36

39

3

38 1

FIGURE 2-2 ITEM NO. 1

Figure 2-2: Frame Assembly - DS/DT

2-1

QTY

PART NUMBER

5

828-005-691/003

5

828-005-691/001

5

828-005-691/002

2 3 4 5 6 7

REF 1 1 1 2 2

828-006-283 714-206 828-004-421 861-026 462-032

Roller Assembly (consists of items 36 through 40) Roller Assembly (consists of items 36 through 40) Roller Assembly (consists of items 36 through 40) Frame Weldment Door Weldment Screw Bracket, Latch Pin, Clevis Bearing

8 9 10 11 12

1 1 1 1 2 2

710-264P 750-433 828-004-622 828-006-364 750-006 771-049

Screw Nut, Hex ODI Assembly ODI Assembly Nut, Hex Washer

13 14 15 16 17 18

1 1 1 2 2 1

760-130 810-733 828-004-651 710-067 771-019 114-008-306

Nut, Lock Pin, Roll Bracket, Key Screw Washer Switch Assembly, Key

20 21 22 23 24 25 26 27

1 1 1 1 1 1 1 1 2 2 1

114-009-695 1-150-057 1-150-001 7-590-006/001 114-008-718/005 5-015-003 5-015-004 828-004-672 828-004-671 710-069 411-938/001

Switch Assembly, Key Switch, Push Button Switch, Lock with Keys Switch, Push Button SMARTi Assembly Nut, Hex Nut, Hex Bracket Weldment Washer Screw Decal, Keyswitch (Not Shown)

F, H, K, L, M, P, R M, R, R G, M, N, P K, L, M, P, R H, L , N, P H, L, N, P H, L , N, P

28 29 30

1 1 1 1 1 1

411-938/003 411-938/002 411-938/004 828-004-674 828-004-683 828-004-682

Decal, Keyswitch (Not Shown) Decal, Keyswitch (Not Shown) Decal, Keyswitch (Not Shown) Cable Assembly, SC to SMARTi Bracket, SMARTi Clamp, ODI

G K, L M, N, P H, L, N, P H, L, N, P F, G, K, M

31

1

19

4.

Refer to the corresponding PART LIST. Use the FIGURE & ITEM NO. to find the Part Number, Description, etc.

A= 14" Battery Compartment B= 16" Battery Compartment C= 21" Battery Compartment D= Without Rear Posts E= With Rear Posts

154-009-117/001 F= Standard G= Remote H= SMARTi K= Standard/Bypass L= SMARTi/Bypass

DESCRIPTION

USED ON A B C A, Q S

R

O T H, L, M , P

F, H, K, L, M, R

F, H

Static Strap, Insulated M= Remote/Bypass N= Remote/SMARTi O= DT 001 to 3842/DS 001 to 3802 P= Remote/SMARTi/Bypass Q= DT 001 to 3566/DS 001 to 3640

List 2-2: Frame Assembly - DS/DT

2-7

S= DT 3567 and Up/DS 3641 and Up T= DT 3843 and Up/DS 3803 and Up R= Recommended Spare

IF THE PART NUMBER IS KNOWN

APPENDIX B

DO THIS

Numerical Parts List

024-296-290/260 ..... Cable Assembly ................................. 5-15 024-296-420/261 ..... Cable Assembly ................................. 5-15 024-297-280/000 ..... Cable Assembly ................................. 5-15 024-297-310/000 ..... Cable Assembly ................................. 5-15 024-297-430/000 ..... Cable Assembly ................................. 5-15 029-002-380/001 ..... Cable Assembly (MDE2 to S1) .............. 5-3 029-002-380/002 ..... Cable Assembly (MDE2 to S2) .............. 5-3 030-504-008/003 ..... Hose Assembly .................................... 6-5 1-000-013 ................ Battery, 6 Volt .................................... 5-15 1-011-011 ................ Terminal Boot, Right Hand ................. 5-15 1-011-012 ................ Terminal Boot, Left Hand .................... 5-15 1-012-502/003 ......... Bushing, Reducer ................................. 5-6 1-074-104/001 ......... Standoff .............................................. 5-3 1-085-186 ................ Cover, Internal ..................................... 2-7 1-105-216/01 ........... Contact Tip Kit..................................... 5-5 1-105-216/04 ........... Switch/Actuator Assembly ..................... 5-5 1-105-216/05 ........... Cover, Top ........................................... 5-5 1-105-216/07 ........... Spring, Return ...................................... 5-5 1-105-216/09 ........... Coil Assembly...................................... 5-5 1-105-225 ................ Contactor Assembly ............................. 5-5 1-105-225 ................ Contactor, Forward/Reverse.................. 5-3 1-110-920/092 ......... Heater................................................. 3-5 1-120-098 ................ Potentiometer, Gear ............................. 3-5 1-120-098 ................ Potentiometer, Gear ............................. 3-5 1-150-366 ................ Switch, Brake/Lift Cutout....................... 5-3 1-150-368 ................ Switch, Key .......................................... 5-3 1-150-378 ................ Switch, Key .......................................... 5-3 1-150-384 ................ Switch, Emergency, Reverse .................. 3-5 1-150-384 ................ Switch, Emergency, Reverse .................. 3-5 1-150-386 ................ Seal .................................................... 3-5 1-150-386 ................ Seal .................................................... 3-5 1-150-418 ................ Switch, Function ................................... 3-5 1-150-418 ................ Switch, Function ................................... 3-5 1-150-425 ................ Switch, Travel ....................................... 3-5 1-150-425 ................ Switch, Travel ....................................... 3-5 1-187-082 ................ Motor Controller .................................. 5-3 291-011.................... RingUSED ...................................................

4-3 DESCRIPTION ON 291-012.................... Ring ................................................... 4-3 360-049.................... Pad, Bumper Roller Assembly A ....................................... 3-3 360-062/003 ............ Guard, Cable .................................... 5-11 (consists of items 36 through 40) 360-065/001 ............ Cover, Front ........................................ 2-7 Roller Assembly B 360-068.................... Cover, Gearbox Motor ......................... 4-9 (consists of items 36 through 40) 370-637/005 ............ Tape, Double Sided.............................. 3-6 400-081/0 ................ Plate, Backing ................................... 4-15 Roller Assembly C 400-081/02 .............. Cam ................................................ 4-15 (consists of items 36 through 40) 400-081/03 .............. Lever, Brake ...................................... 4-15 Frame Weldment A, Q....................................... 4-15 400-081/04 .............. Ring, Safety 400-081/05 .............. Shoe Assembly .................................. 4-15 Door Weldment S 400-081/06 .............. Spring, Return .................................... 4-15 Screw 400-081.................... Brake Assembly ................................ 4-15 Bracket, Latch 400-081.................... Brake Assembly ................................. 4-11 400-160....................

Pinion, Drive .....................................

4-11 Pin, Clevis 400-160.................... Pinion, Drive ........................................ 4-9 Bearing R 411-511/015 ............ Decal, Raymond .................................. 2-7 411-534.................... Decal, Emergency Disconnect ............... 2-7 Screw 411-552.................... Decal, Warning.................................... 2-7 Nut, Hex 411-582.................... Decal, Made In Canada ....................... 2-7 411-587/001 ............ Decal, No ODI Assembly ORiding, Black 9" ................... 2-7 411-633.................... Decal, Caution, Bilingual ..................... 2-7 ODI Assembly T 411-637/001 ............ Decal, Emergency Disconnect, Bilingual 2-7 Nut, Hex 411-639.................... Decal, Clear ........................................ 2-7 411-680.................... Decal, Washer H, Operating L, M, P ................................. 2-7 411-681.................... Decal, Replacement Instruction ............. 2-7

411-773.................... Decal, No Riding, Bilingual ..................2-7 411-789.................... Decal, Warning....................................2-7 411-790.................... Decal, Warning, Bilingual ....................2-7 411-848.................... Decal, 24 Volt Cable System .............. 5-11 411-849.................... Decal, 24 Volt Cable System .............. 5-11 411-850.................... Decal, Charging Warning ..................5-11 411-851.................... Decal, Charging Warning ..................5-11 411-852.................... Decal, Battery Swivel Warning ............ 5-11 411-853.................... Decal, Battery Swivel Warning ............ 5-11 412-454.................... Decal, ISO 9001..................................2-7 412-586.................... Plate, Lowlift Specification (U.S.) ...........2-7 412-588.................... Plate, Lowlift Specification (Canadian) ..2-7 441-013.................... Bearing, Sealed....................................4-9 441-127.................... Bearing, Shield ...................................7-5 447-098.................... Bearing, Cone ....................................4-3 447-108.................... Bearing, Cone ....................................4-3 447-562.................... Bearing, Cup ......................................4-3 447-579.................... Bearing, Cup ......................................4-3 462-029.................... Bushing, Flanged ................................4-5 464-034.................... Bushing ..............................................2-3 464-035.................... Bushing ..............................................2-3 464-035.................... Bushing ..............................................7-3 464-036.................... Bearing, Oilite Super ...........................7-5 520-078/03 .............. Plug, Shipping ..................................... 6-9 530-449.................... O-Ring ...............................................4-5 530-490/038 ............ O-Ring, Motor ....................................4-9 540-062 /100 ........... Cylinder, Hydraulic (Eaton) ...................6-9 540-062/01 .............. Rod, Piston .........................................6-9 540-062/02 .............. Barrel Assembly ..................................6-9 540-062/03 .............. Seal Kit ...............................................6-9 540-062/200 ............ Cylinder, Hydraulic (Ultra).....................6-9 540-062.................... Cylinder, Hydraulic............................... 6-5 560-206/123 ............ Valve, Flow Control (2 GPM) ................6-7 560-206/130 ............ Reservoir Kit (With Tubes) .....................6-7 560-206/132 ............ Adapter Block (With Check Valve) .........6-7 560-206/135 ............ Plug, Vent (With 40 Micron Filter) ......... 6-7 560-209/04 .............. Valve/Coil, Solenoid Release.................6-7 560-209/06 .............. Valve, Adjustable Relief ........................6-7 560-209/07 .............. Pump (With Coupling, Bolts & Gasket) ..6-7 560-209/08 .............. Elbow, 90 Degree ...............................6-7 560-209/09 .............. Switch, Solenoid Start ...........................6-7 560-213/01 .............. Motor, 24 Volt DC 2 Terminal ...............6-7 560-213/01 .............. Pump Motor....................................... 5-23 560-213/02 .............. Brush Set ........................................... 5-23 560-213.................... Pump and Motor Assembly ...................6-5 560-213.................... Pump/Motor Assembly ........................6-7 570-271/515 ............ Brush Lead Assembly Kit .................... 5-23 570-271/516 ............ Commutator End Bearing .................. 5-23 570-271/516 ............ Drive End Bearing ............................. 5-23 570-271/517 ............ Washer ............................................. 5-23 570-316/511 ............ Seal .................................................. 5-23 570-316/513 ............ Retaining Ring ...................................5-23 570-360/511 ............ Brush Set ........................................... 5-23 570-360/512 ............ Brush Spring Set................................. 5-23 570-864.................... Drive Motor - S/N 5478 & Up ............ 5-23 570-864.................... Drive Motor, 24 Volt ........................... 4-11 590-514.................... Fuse, 15 Amp ......................................5-3 590-638/001 ............ Horn Assembly.....................................5-3 590-701.................... Battery Connector ..............................5-15 590-701.................... Battery Connector ..............................5-17 590-701.................... Battery Connector ................................ 5-6 600-213.................... Grommet .......................................... 5-15 610-307.................... Shaft, Flexible ......................................3-7

123-456-789.......................2-5

1.

Locate the Part Number in the NUMERICAL INDEX (APPENDIX B). Note the Section & page number(s) where the part is decribed.

FIGURE 2-2 ITEM NO. 1

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

Frame Assembly - DS/DT

7 29

5

28

30

23

12

10

11

22

4

6

21

28 29 30 31

26 25

QTY

PART NUMBER

5

828-005-691/003

5

828-005-691/001

5

828-005-691/002

REF 1 1 1 2 2 1 1 1 1 2 2 1 1 1 2 2 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1

828-006-283 714-206 828-004-421 861-026 462-032 710-264P 750-433 828-004-622 828-006-364 750-006 771-049 760-130 810-733 828-004-651 710-067 771-019 114-008-306 114-009-695 1-150-057 1-150-001 7-590-006/001 114-008-718/005 5-015-003 5-015-004 828-004-672 828-004-671 710-069 411-938/001 411-938/003 411-938/002 411-938/004 828-004-674 828-004-683 828-004-682 154-009-117/001

24 Compartment A= 14" Battery 20 B= 16" Battery Compartment C= 21" Battery Compartment 19 D= Without Rear Posts E= With Rear Posts 18

F= Standard G= Remote H= SMARTi

17 K= Standard/Bypass L= SMARTi/Bypass

16

15 14

Nut, Lock Pin, Roll Bracket, Key Screw Washer Switch Assembly, Key Switch Assembly, Key Switch, Push Button Switch, Lock with Keys Switch, Push Button SMARTi Assembly Nut, Hex Nut, Hex Bracket Weldment Washer Screw Decal, Keyswitch (Not Shown) Decal, Keyswitch (Not Shown) Decal, Keyswitch (Not Shown) Decal, Keyswitch (Not Shown) Cable Assembly, SC to SMARTi Bracket, SMARTi Clamp, ODI Static Strap, Insulated

M= Remote/Bypass N= Remote/SMARTi O= DT 001 to 3842/DS 001 to 3802 P= Remote/SMARTi/Bypass Q= DT 001 to 3566/DS 001 to 3640

B-1 F, H, K, L, M, R F, H, K, L, M, P, R M, R, R G, M, N, P K, L, M, P, R H, L, N, P H, L, N, P H, L, N, P

F, H G K, L M, N, P H, L, N, P H, L, N, P F, G, K, M S= DT 3567 and Up/DS 3641 and Up T= DT 3843 and Up/DS 3803 and Up R= Recommended Spare

2.

Find the Section & page number in the PARTS LIST referenced by the Numerical Index. Locate the Part Number. Note the part's FIGURE & ITEM NO.

List 2-2: Frame Assembly - DS/DT

13

2-7 31 2

123-456-789 9 8

40

37

36

39

3.

3

38 1

Figure 2-2: Frame Assembly - DS/DT

2-1

Find the FIGURE & ITEM NO. on the associated illustration for a pictorial view of the part.

SW1

TO METERS (OPTION)

CB 80A

MP-2 TO B-

BAT AUX

FU1 15A

-2

SECURE HARNESS TO LIFT POWER CABLE

-1

M2-X

M2 M2-Y

M1

TO FU1-2

-X -Y

PMC

SOL -X

B+

SOL -Y

TO B+ TO S2 MD-A2

MD-E2

S1 TO

TO M-

TO HANDLE ASSEMBLY

MD-A1

S1S2 M-

MD-E1

B-

TO LIFT LIMIT SWITCH SW 10

TO BRAKE SWITCH SW 2

AC FUSE OR CIRCUIT BREAKER

DC FUSE OR CIRCUIT BREAKER SOLDER CONNECTION amp BELL CRIMP A

1

SCR

TX PRI

AC WHITE

DC POS. RED

BELL CRIMP WHT

HEATSINK

D

2 BELL CRIMP

NOTE: VARISTOR LEADS MUST BE COVERED WITH VARFLEX

WHT

B C

8

WHT

7

GRN

7 9

WHT

13

WHT

12 12

BLK

14

WHT

ORG

WHITE

BLK

YELLOW

SCR

ORG

AC GREEN

GROUND SCREW VARISTOR

YELLOW

AC BLACK

.001 OHM SHUNT

HEATSINK

10

11

15

6

16

17 1 BLUE 5 GRN

8 7 9

13 12 14

CIRCUIT BOARD HARNESS

4

WHT STOP (N.O.)

3 2

GRN WHT

BUTT SPLICE

GREEN

DC NEG. BLACK