Raymond 20- Resistor Operation and Maintenance Instructions Manual SN21,000 - PDF DOWNLOAD

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RAYMOND

.MODEL 20 - Resistor Serial No. 21,000 and Up Operation and Maintenance Instructions REPLACES O&M MANUAL FORM MM-35A DATED JULY 1, 1972.

MM-35A REPLACEO FORM MM-35 DATED OCTOBER 15, 1971 AND SUPPL EM ENT 1.

Form: MM-35 8 Dated: 10/15/83 THE RAYMOND C0APORATICN 1 GIREENE, N.V. 1377B

Before Operating, Servicing, or Performing Maintenance on this Vehicle, Read, Understand, and Follow the Safety Instructions Contained in the Owner/Operator Manual Located on the Vehicle.

TH& FIAVM0ND C0RP01=1AT10N MOOEL 20 RESISTOR

MAINTENANCE

TABLE OF CONTENTS

SECTION

DESCRIPTION

INTRODUCTION

1-7 TABLE OF LEADING PARTICULARS

II

DESCRIPTION 2-2 CHASSIS

2-7 DRIVE UNIT 2-12 BRAKE 2-14 STEERING 2-19 SWIVEL CASTER ASSEMBLY 2-21 HYDRAULIC SYSTEM 2-22 LIFT/LOWER 2-33 AUXILIARY FUNCTIONS 2-38 LOW LIFT ·HYDRAULICS 2-45 ELECTRICAL CIRCUITS 2-46 HORN 2-48 HOUR METER 2-50 Low VOLTAGE C JRCUIT BREAKER 2-52 OTHER OPTIONAL FEATURES 2-55 TRAVEL CIRCUIT Ill

OPERA TING INSTRUCTIONS

3-1 CONTROLS 3-3 KEY SWITCH 3-5 BRAKE 3 -7 STEER ING 3-10 TRAVEL DIRECTION ANO SPEED 3-12 LI FT/LOWER .

3-15 AUXILIARY FUNCTIONS 3-17 HORN 3-19 EMERGENCY DISCONNECT 3-21 HOUR METER 3-23 OPTIONAL CONTROLS 3-35 OPERATING TRUCK 3-36 PREPARATION 3-38 To TRAVEL 3-40 To SLOW DOWN OR STOP 3-42 PLUGGING 3-45 RAMP OPERATION

PAGE

1-1 1-3 2-1 2-1 2-1

2-4 2-4 2-6

2-6 2-7 2-9 2-10 2-11 2-11 2-IL 2-11 2-11 2-11

3-1 3-1 3-1 3-1 3-1 3-3 3-3

3-3 3-3

3-3 3-4 3-4 3-4 3-4 3-5 3-5 3-5 3-5

THE RAVM0NCI C0RP0RAT10N MODEL 20 RESISTOR

MAINTENANCE TABLE OF CONTENTS ( CONT 1 D.)

SECTION

Ill

DESCRIPTION

3-48 To TURN INTO AN AISLE

3-50 ENTERING AND LEAVING PALLETS 3-53 ENTERIN.G AND LEAVING SKIDS 3-55 40 TRUCK OPERATION

IV

V

3-6 3-6 3-7 3-7

3-58 SAFETY

3-8

INSTALLATION

4-3 BATTERY AND CHARGER 4-8 TRUCK OPERATIONAL CHECK

4-1 4-1 4-1

THEORY OF OPERATION

S-1

5-2 LIFT/LOWER SYSTEM

5-1 5-1

5-3 LIFT 5-5 LOWER ING

5-7 TRAVEL LIFT/LOWER 5-9 AUXILIARY HYDRAULIC SYSTEM 5-13 POWER STEER ING S-16 REACH-FORK, POWER TILT, SI0ESHIFT CLAMP AND ETC.

VI

PAGE

S-3 5-3 5-4 S-4

5-4

5-19 HYDRAULIC - Low LIFTS

5-6

5-21 TRAVEL SYSTEM

5-7

MAINTENANCE

6-1 6-1 6-7 6-19 6-20 6-26 6-29 6-29 6-30 6-30 6-31 6-31 6-32 6-32 6-34 6-35

6-1 SCHEDULED MAINTENANCE

6-3 DRIVE UNIT 6-11 BRAKE 6-18 STEERING 6-24 SWIVEL CASTER 6-31 HYDRAULIC 6-32 GENERAL 6-41 HYDRAULIC OIL AND FILTER 6-43 BLEEDING AIR FROM Larr CYLINDER 6-45 LIFT AND AUXILIARY PUMP 6-49 LIFT/LOWER CONTROL VALVE 6-51 MANIFOLD ASSEMBLY 6-56 SOLENOID VALVES 6-64 AUXILIARY CONTROL VALVE

6-71 POWER STEER ING TORQUE GENERATOR

II

TH8 l=IAVMCIND C0RPCls:IATICIN MODEL 20 RESISTOR

MAINTENANCE TABLE OF CONTENTS (coNT'o.)

'SECTION

0ESCR IPTION

PAGE

VI

6-77 ELECTRICAL 6-78 BATTERY 6-94 MOTORS 6-106 CONTACTORS 6-121 MASTER SWITCH ASSEMBLY 6-124 SOLID STATE TIMER 6-126 F AND R TIME DELAY 6-129 PLUGGING RELAY 6-131 TRANSIENT SUPPRESSORS 6-138 DIODE ASSEMBLIES 6-140 Low VOLTAGE CIRCUIT BREAKER 6-143 TESTING OTHER ELECTRIC COMPONENTS

6-37 6-37 6-38 6-42 6-48 6-48 6-50 6-50 6-51 6-54 6-56 6-57

VII

TROUBLESHOOTING 7 -1 GENERAL TROUBLESHOOT ING INSTRUCTIONS 7-9 LISTING OF TRUCK PROBLEMS 7-10 GENERAL TRAVEL PROBLEMS 7-22 AUXILIARY CIRCUIT 7-26 LIFT/LOWER CIRCUIT 7-29 HORN INOPERATIVE

7-1 7-1 7-2 7-3 7-15 7-17 7-20

Ill

THE RAVMCINCI CORPORATION MODEL

20 RESISTOR

LIST OF ILLUSTRATIONS

TITLE

FIG. No.

1-1 1-2 2-1 2-2 2-3 2-4 2-5 2-6 3-1 3-2 3-3 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 6-10 6-11 6-12 6-13 6-14 6-15 6-16 6-17 6-18 6-19 6-20 6-21 6-22 6-23 6-24

MO0EL 20 REACH FORK TRUCK TABLE OF LEADING PARTICULARS MO0EL 20 RESISTOR TRUCK WITH DOOR OPEN

1-1 1-3

FIRST SPEED

2-2 2-3 2-5 2-6 2-8 2-14 3-2 3-6 3-7 5-2 5-5 5-8

SECOND SPEED

5-9

THIRD SPEED

5-11

FOURTH SPEED

5-12

PLUGGING

5-15 5-16

CROSS SECTION OF COMPLETE DRIVE UNIT BRAKE INSTALLATION GEARS FOR AUTOMOTIVE AND STANDARD STEER ING IDENTIFYING HYDRAULIC COMPONENTS ELECTRICAL PANEL ASSEMBLY STANDARD MODEL 20 CONTROLS STRADDLE TRUCK ENTERING PALLET REACH-FORK TRUCK ENTERING -PALLET HYDRAULIC SCHEMATIC -

w/AUX.

HYDRAULIC SCHEMATIC - Low LIFTS

ELECTRICAL SCHEMATIC MODEL 20 RESISTOR TRACTOR INSPECTION AND LUBRICATION CHART TRACTOR LUBRICATION AND INSPECTION POINTS STRADDLE ATTACHMENT LUBRICATION REACH-FORK ATTACHMENT L.UBR ICATI0N DRIVE MOTOR INSTALLATION DRIVE UNIT CROSS SECTION OF DRIVE UNIT DRIVE WHEEL FABRICATED RING FOR REMOVING DRIVE UNIT PROPER POSITION OF THRUST AND RADIAL RING EXPLODED VIEW OF BRAKE ASSEMBLY VIEW OF BRAKE SYSTEM VIEW OF BRAKE PEDAL

6-1 6-4 6-S 6-6 6-9 6-10 6-13 6-14 6-16 6-17 6-18 6-21 6-21

STEER ING COLUMN

6-22

EXPLODED VIEW OF CASTER

6-25 6-27 6-33

PRE-LOADING CASTER SPRINGS VIEW OF HYDRAULIC COMPONENTS HYDRAULIC CONTROL VALVES TABLE OF BRUSH LENGTHS AND SPRING PRESSURES DRIVE MOTOR TERMINALS AND CIRCUITS IDENTIFICATION OF C0NTACTORS

6-36 6-39 6-40 6-42

C0NTACTOR

6-44

STANDARD TYPE 8 C0NTACTOR

6-45 6-47

STANDARD TYPE A

VIEW OF P C0NTACT0R ASSEMBLY

V

THE RAYMOND CCIRP0RATICIN MODEL 20 RESISTOR LIST OF ILLUSTRATIONS (CONT'D.)

FIG. NO.

6-25 6-26 6-27 6-28 7- 1

TITLE

PAGE

TRANSIENT SUPPRESSOR AND DIODE ASSEMBLIES

TEST CIRCUIT FOR Low VOLT. CIRC. BREAKER

Low VOLTAGE CIRCUIT BREAKER ELECTRICAL COMPONENTS TEST

WIRING O IAGRAM

MODEL 20 RESISTOR

VI

6-55 6-58 6-58 6-59 7-23

TH ■ IIIAVM0NCI QC11111110111ATl0N MODEL 20 RESISTOR

SECTION 1 INTRODUCTION

1-1

This manual provides the Description, Operating Instructions, Installation, Theory of Operation, Maintenance and Troubleshooting Instructions for Raymond Model 20 Resistor Model B trucks.

Figure 1-1 shows a Model 20 Reach-Fork Truck.

1-2

The Model 20 Resistor power lift truck is primarily built for general indoor warehouse use, or for bulk storage outdoors on paved or other hard surfaces. The truck is a stand-up rider type designed for narrow aisle installations. Right angle stacking of palletized loads can be accomplished in aisles as narrow as 6 feet.

Figure 1-1 Model 20 Reach Fork Truck

1-1 Revised 9/15/82

'TH ■ RAYM0NC, C0RP0111ATl0N MODEL 20 RESISTOR

SECTION I

1-3

INTRODUCTION

POWER FOR THE MODEL 20 RESISTOR TRUCK IS PROVIDED BY A 24 VOLT INDUSTRIAL BATTERY•

T~

MODEL 20 TRUCK HAS THE ABILITY, FOR EXAMPLE, TO CARRY A 2000 LB. LOAD AT SPEEDS UP TO 5 MILES PER HOUR, TO ELEVATE AT SPEEDS UP TO 45 FEET PER MINUTE, AND TO STACK LOADS AT HEIGHTS UP TO 240 INCHES•

THESE FACTORS PLUS ITS EXCEPTIONAL MANEUVERABILITY

MAKE MODEL 20 TRUCKS THE LEADING PERFORMER OF

(-4

24 VOLT NA_RROW AISLE TRUCKS.

MODEL 20 SERIES TRUCKS ARE AVAILABLE I~ 2000, 3.000 AND 4000 POUND CAPACITIES AND CAN BE PROVIDED WITH STRADDLE, REACH-FORK, Low-LIFT-PLATFORM ANO FORK, 4D ( FOUR DIRECTIONAL), HIGH LIFT PALLET, SI0EREACH ATTACHMENTS• EITHER TWO OR THREE STAGE CONSTRUCTION.

A

THE MAST IS OFFERED IN

VARIETY OF COLLAPSED AND ELEVATED

HEIGHTS ARE AVAILABLE TO FIT EVERY APPLICATION.

IN ADDITION, VARIOUS SPECIAL FEA-

TURES SUCH AS POWER TILT, SIDESHIFT, CLAMP, DEEP REACH, EXTENDED REACH, ETC., ADAPT THE TRUCK TO SPECIFIC SITUATIONS• FEATURE,

1-5

MODEL 20 RESISTOR TRUCKS HAVE, AS A STANDARD

U. L. TYPE E APPROVAL.

POWER STEERING IS STANDARD ON E3RT-TT, E4ST-TT, E4RT-TT, 4D AND SIDEREACH MODEL TRUCKS AND IS AVAILABLE ON ALL OTHER MODELS•

OTHER CONVENIENCES WHICH THE

TRUCKS OFFER ARE A LOW STEP INTO COMPARTMENT ( ONLY II" HIGH), AND LOCATION OF CONTROLS•

CONTROLS ARE LOCATED SO OPERATOR CAN DRIVE FACING EITHER TOWARDS OR AWAY

FROM LOAD.

THE OPERATOR CONTROLS STEER ING WITH ONE HAND WHILE TRAVEL DIRECTION

AND SPEED, LIFT, LOWER AND AUXILIARY FUNCTIONS ARE ALL WITHIN EASY REACH OF THE OTHER HAND.

1-6 THE MODEL 20 RESISTOR TRUCK INCORPORATES THE USE OF RESISTORS AND C0NTACT0RS TO CONTROL. TRAVEL.: SPEEDS• DRIVE MOTOR.

THE SPEED VARIATIONS ARE OBTAINED BY CHANGING THE VOLTAGE APPLIED TO

THIS SYSTEM ALLOWS THE OPERATOR FOUR SPEEDS IN FORWARD OR REVERSE

DIRECTIONS, WITH A TOP SPEED OF 5. MILES PER HOUR•

REVISED s/1/n.

1-2