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Model 4700 Maintenance Manual
Section 4.Scheduled Maintenance
Every 180 Days or 500 Pump Hours
Perform the following tasks every 180 days/500 pump hours, whichever comes first.
Hydraulic HosesInspect all hydraulic hoses for leaks, nicks, cuts, chafing, and bulges. Replace damaged hoses as soon as possible. Inspect fittings for leaks. Repair any leaks immediately. Inspect OTM hoses for correct tension. Make sure OTM pulleys spin freely and show no signs of wear.
Hydraulic ReservoirCheck fluid level.
Lift Chains Check adjustment. Inspect for excessive stretch or wear. Lubricate. Page4-9
Lights Check for correct operation.
Lubrication Apply grease to all fittings. Apply lithium grease to the travel direction lever ball joint on the steering column. Coat all chains with spray lubricant.
Mast Wipe old grease off mast uprights and apply new grease. Examine mast bearings. Inspect rails for abnormal wear, metal flakes, or shavings. Repair any grooves worn in the mast deeper than 1/8 in. (3mm). Check upright and guide shoe (puck) adjustment.
Motors Check cable lugs to make sure they are tight to the terminal studs. Replace any cable that shows signs of excessive heat. Check sensor wires for sound connection and condition. Blow out the inside of the motor with compressed air.
Overhead GuardInspect guard for physical damage. If structurally damaged, replace the guard.
Power Amplifiers and Fan
Check torque on power amplifier connections. Make sure power amplifier heat sink fins are free of debris and that air flows freely through them.
Seat Belt Check for signs of wear, fraying, or damage.
Seat Switch Check for correct activation and deactivation of the seat switch.
Shorts to FrameCheck for electrical shorts to frame. Wipe compartments clean.
Static Strap Make sure static strap is not worn or broken. Clean debris from straps. Check resistance of resistor in standoff; should be 200 to 250k ohm. EE Labeled trucks require a phosphor bronze static strap; do not use steel braided cable on EE labeled lift trucks.
Steering Inspect hoses and cylinder for leaks. Check steer cylinder mounting holes, screws, and dowel pins for damage.
Switches Check all switches for correct operation and adjust as needed.
Travel AlarmIf equipped, check for correct operation.
Ventilation SlotsMake sure ventilation slots in the chassis are clear of obstructions and debris. Clean the fan filter.
Warning DecalsReplace missing, illegible, or damaged decals.
Warning LightIf equipped, check for correct operation.
Publication 1160093, Issued: 20 May 2013
Every 180 Days or 500 Pump Hours
Perform the following tasks every 180 days/500 pump hours, whichever comes first.
Publication 1160093, Issued: 20 May 2013
Section 4.Scheduled Maintenance Model 4700 Maintenance Manual
Every 360 Days or 2000 Pump Hours
Every 360 Days or 2000 Pump Hours
Perform all 180 day/500 pump hour tasks plus the following maintenance tasks every 360 days or 2000 pump hours, whichever comes first.
Component What to do Refer to Drive UnitsChange fluid.
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Page7-27
Hydraulic ReservoirChange fluid and filter.
Lift PumpSeparate lift pump and motor. Apply molybdenum anti-seize compound (P/N 990-638) to the splines.
Steering Inspect wheel bearings for side play. There should be no more than 0.002 in. (0.05 mm) of movement. If excessive, torque the retaining nut to 44 ft. lb. (60 Nm) and spin the wheel in both directions 2 to 3 turns. Back off retaining nut and torque to 14.7 ft. lb. (20 Nm). Check for side play and make sure the bearing is not binding. If binding, replace bearings.
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Publication 1160093, Issued: 20 May 2013
Chain Maintenance
Lift Chain Inspection
Make sure chains are not damaged. Check the chain for wear using a Chain Gauge (P/N950-350/CG). See Figure4-1.
Condition-Cause Chart
Replace chains with g enuine Raymond spare parts. See “Lift Chains” on page 7- .
Chain ElongationWearUse a chain gauge or lay the chain on a flat surface and push it together. Measure and mark a 12 in. (305 mm) length that has operated over the pulley sheave. Stretch the chain; if more than 1/3 in. (8.5 mm) play is detected, replace the chain.
Rust and corrosionSteam cleaning or degreasing new truck chains
Lubricate chain frequently.
Cracked PlatesInfrequent OilingReplace the chain. Rust
Corrosion Chain Fatigue
Tight JointsBent pins or platesReplace the chain.
Rusty joints or peened plate edges Replace the chain.
Chain side wearChain misalignmentReplace the chain.
Section 4.Scheduled Maintenance Model 4700 Maintenance Manual
Fork Inspection
Fork Inspection
The following tools are required to perform fork inspection:
•Fork Wear Caliper (P/N 922-369)
•Tape Measure or ruler
•24 in. Framing Square
•4 ft. Level
Do the following when performing Scheduled Maintenance.
Surface Inspection
Remove the forks from the carriage. Visually inspect all fork surfaces for signs of damage, including, but not limited to:
•cracks
•excessive wear
•excessive heat
•deformation
•unauthorized modifications
Pay special attention to the heel and welds attaching mounting components. If any damage is found, remove the fork from service.
Straightness of Blade and Shank
NOTE : This measurement can be done with the forks on or removed from the carriage.
1.Measure the length of the blade and the height of the shank. See Figure4-2.
2.Multiply these numbers by 0.005 for maximum allowable deviation.
• Length of blade _____ x 0.005 = ______
• Height of shank _____ x 0.005 = ______
3.Place a straight edge on the blade of the fork, 2 in. away from the heel of the fork . Measure any deviation and compare to th e number calculated in step 2 for length of blade.
4.Place a straight edge on the shank of the fork, 2 in. away from the heel of the fork. Measure any deviation and compare to th e number calculated in step 2 for height of shank.
5.If either maximum deviation is exceeded, remove the fork from service.
Fork Angle
NOTE : This measurement can be done with the forks on or removed from the carriage.
1.Place the fork caliper on the blade. Make sure that the two extruded points are touching the blade of the fork. Se e Figure4-3.
2.Now open and move the caliper so the two extruded points are touching the shan k. See Figure4-3.
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Publication 1160093, Issued: 20 May 2013
3.When all four extruded points are in contact with the fork, gently remove the caliper and note the reading on the indicator line, located right above the hinge pin. See Figure4-3.
4.If the deviation is greater than 3° of the original angle, remove the fork from service.
NOTE : Most forks are manufactured with a 90° angle; therefore, a reading greater than 93° or less than 87° is unacceptable. However, there are some forks that are purposely manufactured to angles greater than or less than 90°.
Fork Tip Height
1.With truck parked on a level surface and forks on the carriage, measure the length of the blade. See Figure4-2.
•For forks 42 in. (106.7 cm) or less, max. deviation is 0.25 in. (6.3mm).
•If length of fork is >42 in. (106.7 cm), multiply length of blade by 0.03. Blade length _____in. x 0.03 = _____in. This is the maximum deviation.
2.Elevate forks approx. 4 ft. (1.2 m) off the floor.
3.Place a 4 ft. level across the tips of the forks. See Figure4-4.
4.Raise one end of the level to make it level. See Figure4-4.
5.Measure the distance from the tip of the fork. See Figure4-4.
6.Compare this measurement to the maximum deviation.
7.If the maximum deviation number is exceeded, remove the fork from service.
Positioning Locks (if applicable)
1.With the forks on the carriage, visually inspect the positioning locks for damage.
2.Test the positioning locks to verify they work correctly.
3.If the positioning locks are damaged or do not work correctly, remove the fork from service.
Wear
Fork Blade and Shank
1.Remove the forks from the carriage.
2.Approximately half way up the shank, set the front teeth of the jaws of the caliper on the shank. Make sure the caliper is held square across the shank to get an accurate reading. The caliper is now set to measure fork blade wear. Carefully remove the caliper from the shank. See Figure4-5.
