RAYMOND E20i 21i 21iPLUS Operation & Maintenance Instructions Manual

Operation & Maintenance Instructions

Serial No.

Model 20i/21i 21iPLUS

PDMM# 0005

020D-88-29000 and up 021 D-89-04550 and up

Date: Revised 1/10/90

INTRODUCTION TO THE RAYMOND OPERATION AND MAINTENANCE MANUAL

TO THE PURCHASER OF RAYMOND PRODUCTS The Raymond Corporation would like to express its appreciation to you, our customer, for purchasing Raymond equipment. You have made a wise selection. In order to better serve our customers, we supply this manual outlining the care and routine service required to provide a long and productive life for your new equipment.

INTRODUCTION TO THE RAYMOND OPERATION AND MAINTENANCE MANUAL

PREFACE This manual presents factual material on the Raymond Corporation equipment you have purchased. The object is to insure safe operation and/or maintenance practices and procedures for this Raymond product.

MANUAL OVERVIEW This manual consists of both the Operating and Maintenance (O&M) section and the Parts Catalog (P/C) section for the specific equipment listed on the cover.

• The Table of Contents provides easy location of all subject matter within the manual.

• Individual chapter indexes are located at the beginning of each chapter, following the reference tabs.

• Any chapter not applicable to the particular piece of equipment covered in this manual will state "Not Applicable" after the chapter title on the Table of Contents.

• The large section tabs allow a quick location indentification of the O&M section or the P/C section.

The following symbols are used throughout this manual to represent a condition or hazard of which the operator should be aware.

A WARNING

DENOTES A SERIOUS HAZARD THAT COULD CAUSE INJURY OR DEATH TO THE OPERATOR OR OTHER PERSONNEL FROM A PARTICULAR ACTION OR CONDITION.

ACAUTION

DENOTES A LESS SERIOUS HAZARD FROMAN ACTION OR CONDITION THAT COULD CAUSE MINOR INJURY TO THE OPERATOR OR MAINTENANCE PERSONNEL, OR CAUSE DAMAGE TO THE EQUIPMENT ITSELF. Denotes a particular statement pertaining to a particular procedure or explanation.

Revised text and illustrations are indicated by a black vertical line along the left-hand margin of the page, opposite revised, added or deleted material. Revision lines indicate only current revisions with changes and additions to or deletions of existing text and illustrations. Changes in capitalization, spelling, punctuation, indexing, the physical location of the material or complete page additions are not identified by revision lines.

INTRODUCTION TO THE RAYMOND OPERATION AND MAINTENANCE MANUAL

Introduction

The Raymond Corporation manufactures a variety of material handling equipment in both standard and customized configurations. This Operation and Maintenance Instruction manual is organized into major divisions which cover all areas of the equipment. These include the following: • Safety • Description • Installation • Operating Instructions • Theory of Operation • Maintenance • Troubleshooting • Appendix

Using the Manual

This manual contains several elements necessary for effective use, which are: 1. Table of Contents: Indicates what each chapter is about and what page it begins on.

2. General Index: Outlines the topics found throughout the entire manual by page number.

3. Individual Chapter Index: Located at the beginning of each chapter, this index outlines the topics found in that chapter by page number.

4. List of Illustrations: Outlines all illustrations found in the manual by figure num-

ber and page number.

5. Glossary: A complete list of identifications for technical terms and abbreviations used throughout the manual and the material handling industry.

6. Safety First and Last: Gives specific safety guidelines for truck operators, owners and maintenance personnel. This information is given at the beginning of the manual and at various areas throughout the manual.

7. Troubleshooting Charts: For quick logical tracking of troubles and suggested remedies.

8. Schematics: To aid in troubleshooting any part of equipment electrical and/or hydraulic systems.

9. Alphabetical Index: Found at the end of the appendix chapter, it can be used as a quick reference guide to find where in the manual a particular subject can be found.

Example of Chapter and Page numbering system:

CHAPTER) 2. 10

LPAGE

II

INTRODUCTION TO THE RAYMOND OPERATION AND MAINTENANCE MANUAL

TABLE OF CONTENTS Subject SECTION I: Operation and Maintenance Instructions Introduction Safety Chapter 1: Description .......................................... 1.0 Chapter 2: Operating Instructions ......................... . ........ 2.0 Chapter 3: Installation .......................................... 3.0 Chapter 4: Theory of Operation ........... . ....................... 4.0 Chapter 5: Maintenance ......................................... 5.0 Chapter 6: Troubleshooting ...................................... 6.0 Chapter 7: Appendix ........................................... 7.0

Ill

Model 20i/21 i General Index

Chapter 1 - Description PAGE

SUBJECT TRUCK OVERVIEW

1.1 1.2 1.2

"i• Series Description Model 20i . . . . .

Model·21i . . . . . lYPICAL VEHICLE SPECIFICATIONS (Model 20i)

1.3

lYPICAL VEHICLE SPECIFICATIONS (Model 2li) Description . . . . . . . . . . . . . . . . .

1.4 1.5

MECHANICAL SECTION 1.6 1.6 1.6 1.6 1.6 1.6 1.6 1.6 1.6 1.8 1.9 1.9 1.9 1.9 1.9 1.10 1.10 1.10 1.10 1.10 1.10

Chassis . . . . . . .

Chassis Parts Description Truck Frame Bumper Front . . . .

Door . . . .

Covers . . . .

Operator's Compartment Battery Compartment Drive Unit . . . . . . . .

Drive Unit Parts Description Gear Housing . . . . . .

Drive Motor . . . . . . .

Gear Reduction Assembly Drive Wheel . . . . . . .

Swivel Caster . . . . . . .

Swivel Caster Parts Description Tires . . . . . .

Springs . . . . .

Trac-Qualizer . .

Power Caster (4D)

HYDRAULIC SECTION 1.11 1.11 1.11 1.11 1.11 1.11 1.13 1.13 1.13 1.13 1.13 1.13 1.13 1.13.1 1.13.1 1.13. l

Brake . . . . . . . .

Brake Parts Description Deadman Pedal . . .

Brake Master Cylinder Slave Cylinder . . . .

Brake Adjusting Screw Steering . . . . .

Parts Description Steering Wheel .

Gearbox . . . .

Steering Column Spur Gears Torque Generator 4D Steering Travel Mode Selector Caster Load Wheel

IV

Model 20i/21i General Index

SUBJECT

PAGE

HYDRAULIC SECTION (Cont'd.)

Lift/Lower Parts Description . . . .

Lift Pump . . . . . . .

Lift Motor . . . . . . .

Lift/Lower Control Valve Manifold Assembly . .

Travel Lift Solenoid . .

Travel Lower Solenoid Pressure Relief Valve . .

Low Pressure Adjustable Relief Valve Check Valve . . . . . .

Flow Control Valves . .

Travel Lift/Lower Switch Main Flow Control Lift Cylinder Oil Filter ..

Reservoir . .

P Contactor Pump Motor . . .

Control Valve .

Load Holding Check Valve Lift Cylinder Flow Control Auxiliary Contactor .

Auxiliary Functions Parts Description .

Auxiliary Motor . .

Auxiliary Pump . .

Torque Generator Spool Valves . . .

Equalization Solenoid Carriage Manifold .

1.15 1.15 1.15 1.15 1.15 1.15 1.15 1.15 1.15 1.16 1.16 1.16 1.16 1.16 1.16 1.16 1.16 1.16 1.17 1.17 1.17 1.17 1.17 1.17 1.18 1.18 1.18 1.18 1.18 1.18 1.18 1.18

ELECTRICAL SECTION Travel System . . . . . . . .

Parts Description . . . . . . . .

Keyswitch . . . . . . . . . . . . .

Directional/Speed Control Assembly Travel Contactors Potentiometer VRl Drive Motor . . .

Keyswitch Relay Kl Deadman Switch S2 SCR's . . . . . . . . .

Charging Rectifier (RECl) Plugging Rectifier (REC3) .

Recirculating Rectifier (REC2) Transformer (Tl ) . . . . . .

1.19 1.19 1.19 1.19 1.19 1.19 1.20 1.20 1.20 1.20 1.20 1.20 1.20 1.20

V

Model 20i/21 i General Index

SUBJECT

PAGE

ELECTRICAL SECTION (Cont'd) 1S Contactor . . . . . . . .

P.O. Module . . . . . . . . .

Resistor R2 . . . . . . . . . .

Capacitors (Cl, C2, C3 and C4) Fuses . . . . . . . . .

Control Unit . . . . • . "intellidrive" Control Unit Safety circuits: . • . . .

Diagnostics . . . . . .

Throttle Card Assembly Transient Suppressors .

Miscellaneous Circuit Parts Description Hom ............ .

Hour Meter . . . . . . . . . .

Curtis Battery Controller . . . .

Optional Circuits Parts Description Lights . . . . . .

Remote lift/Lower Power Disconnect Limit Switches

1.20 1.20 1.20 1.21 1.21 1.21 1.22 1.22 1.23 1.23 1.23 1.24 1.24 1.24 1.24 1.24 1.24 1.24 1.25 1.25

Chapter 2 - Operating Instructions INTRODUCTION

· · · · · , · . . . . . . . . . . . . . . 2.1

CONTROLS Keyswitch Battery Disconnect Reach Lever . . .

Lift/lower - Travel Lift/lower Tilt Lever . . . . . . . . . .

Steering Wheel . . . . . . .

Drive Wheel Direction Indicator (4-D) Travel Mode Selector Handle (4-D) Travel Mode Indicators (4-D) . . .

Directional/ Speed Control Handle Hom Button . . . . . .

Hour Meter . . . . . . . . . . .

Working Lights (optional) . . . . .

Flashing/rotating Lights (optional) Remote Lift/lower (optional)

2.3 2.3

2.3 2.3 2.4 2.4 2.4 2.5 2.5 2.5

2.6 2.6 2.6 2.6 2.7

OPERATOR DAILY CHECKLIST Checks with the keyswitch OFF Checks with keyswitch ON

2.8 2.8

TRUCK TRAVEL Startup Procedure . .

Forward and Reverse 4D Steering Braking . . . . . . .

2.9 2.10 2.10 2.11

VI

Model 20i/21 i General Index

Subiect TRUCK TRAVEL (Cont'd)

2.11 2.11 2.11 2.11 2.12 2.12 2.13 2.13 2.13 2.14 2.15 2.15

Plugging . . . . lift/Lower . . .

Main lift/Lower Travel lift/Lower Auxiliary Functions Process (Reach and Tilt) Ramp Operation . . . . . .

Turning Into an Aisle Entering and Leaving Pallets A. With a Straddle Truck 8. With a Reach Truck Parking Speed Limitation . .

SAFETY

2.16

Safety Guidelines List

Chapter 3 - Installation RECEIVING TRUCK

Reasons For Visual Inspections What To Look For . . . . .

Visual Inspection/Conditions Visual Inspection Checklist Cradled Trucks Visual Inspection . . . .

3.1 3.1 3.1 3.2 3.3 3.3

UNCRADLING

Uprighting a Cradled Vehicle Procedure # 1 Gasket Removal Types of Oils . .

Procedure #2 . .

Gasket Removal Types of Oils . .

3.4 3.4 3.5 3.5 3.6 3.6 3.6

FUNTIONAL INSPECTION

3.7 3.7 3.7 3.7

Vehicle Operation . . . .

Warranty . . . . . . . . .

What To Look For . . . .

Functional Installation Check List COLD STORAGE CONDITIONING

3.8 3.9 3.9

Classes Of Cold Storage . . . . . .

Hydraulic System Oil Change Procedure Drive Unit Procedures . . . . . . . . .

BATTERY

Battery Charger . . . . . . . . . . . . . . ~, Battery Installation . . . . . . . . . . . . .

Suggested Connector Voltage Color Coding

3.10 3.10 3.10

VII

Model 20i/21 i General Index PAGE

SUBJECT STORAGE

Storage Warranty Motors . . . . . . .

Hydraulic System . . • Hydraulic Cylinders Lift/Steering Chains Electronics . . .

Battery . . . . .

Vehicle - General

3.11 3.11 3.11 3.11 3.11 3.11 3.11 3.12

Chapter 4 Theory Of Operation OVERVIEW

Presentation Outline . .

4.1 4.1

LIFT

Lift Process

4.3

LOWER

Lower Process

4.5

· TRAVEL LIFT/LOWER

Travel Lift Process .

Travel Lower Process

4.7 4.9

AUXILIARY SYSTEM

Auxiliary System Process Power Steering .

4.11 4.11

SCR THEORY

SCR Description . . . . . . . . .

SCR Switching . . . . . . . . . .

4.13 4.14

TRAVEL CIRCUIT COMPONENTS

Throttle Card . . . . . . . . . .

Microprocessor Control Card (I.C.C.) Travel Circuit Components/Function I.C.C. Circuits . . . . . . . . . .

4.15 4.16 4.17 4.18

OPERATION OF TRAVEL SYSTEM

Battery Plugged In . . . . . . . .

Keyswitch (Sl) Turned 'ON' . . .

Closing Deodmon Switch (S2) . .

Moving Directional/Speed Control 'M' Speed (By-poss) Operation Plugging . . . .

1S Contoctor Resistor R2 . .

P.D. Module .

4.20 4.23 4.26 4.29 4.35 4.37 4.37 4.37 4.37

D.C. MOTOR BRUSHES

Carbon Brushes . . . .

Film Foundation . . . .

Commutator Film Action Brush Spring Pressure .

4.40 4.41 4.41 4.42

VIII

Model 20i/2 l i General Index

Chapter 5 - Maintenance Page

Subiect

SCHEDULED MAINTENANCE Daily or every 8 Operating hours, whichever occurs first Weekly or every 40 operating hours, whichever occurs first. .

Monthly or every 175 operating hours, whichever occurs first Annually or every 1,000 operating hours, whichever occurs first Straddle/Reach Attachment Straddle/Reach Lubrication Points

5.1 5.2

5.3 5.5 5.8 5.9

TORQUE DATA

5.10

TRUCK JACKING

5.10.1

MECHANICAL Drive Unit . . . . . . . . . . . . . . .

Drive Motor Cleaning and Inspection Drive Motor Replacement Drive Wheel Replacement Drive Unit Removal Drive Unit Disassembly Drive Unit Reassembly and Installation Brake Adjustment Plug Adjustment . . . .

Brake Shoe Adjustment Brake Bleeding Deadman Pedal Adjustment Steering . . . . . . . . . . .

Steering Checklist . . . . . .

Steering Assembly Removal Steering Disassembly/Assembly Swivel Caster and/ or Trac-Qualizer Swivel Caster and/or Trac-Qualizer Checklist . .

Swivel Caster and/or Trac-Qualizer Disassembly/Assembly Checklist ..................... .

Swivel Caster and/or Trac-Qualizer Spring Adjustment Swivel Caster Height Adjustment Trac-Qualizer Height Adjustment Lift Chain . . . . . . . . . . . .

Removal .......... .

Defect-Cause Maintenance Chart Lift Chain Lubrication . . . . . .

Equalization Chain Lubrication Equalization Chain Adjustment (TT) Equalization ChainRemoval/lnstallation (TT) Reach Carriage Chain Anchors Replacing Mast Bumpers . . . . . . . .

Mechanical Stop Adjustment . . . . . .

Equalization Chain Sheave Replacement Over The Mast Hose/Cable Adjustment Over The Mast Hose Replacement Control Replacement (TT Mast) . . . . .

IX

5.11 5.11 5.14 5.17 5.18 5.19 5.20 5.21 5.21 5.23 5.23 5.24 5.25 5.25 5.25 5.27 5.27 5.27 5.29 5.29 5.29 5.31 5.31 5.32 5.32 5.33 5.33 5.33 5.34 5.35 5.37 5.38 5.38 5.39 5.40 5.42 5.44

Model 20i/21 i General Index

Subject

HYDRAULIC MAINTENANCE Leakage . . . . . . . . . . . . . . . . . .

Hydraulic Leakage Fault-Prevention Chart System Contamination . . . . . . . . . . .

System Contamination Fault Prevention Chart Incorrect Valve Pressure Settings . . .

General Hydraulic Maintenance "Tips" Hydraulic Oil and Filter . . . . . .

Hydraulic Oil and Filter Checklist .

Lift and Auxiliary Pump Lift Pump Replacement Auxiliary Pump Replacement Auxiliary Pump Repair Lift Pump Service Lift Pump Disassembly Lift Pump Inspection .

Lift Pump Assembly .

Hydraulic Manifolds . .

Lift/LowerControl Valve Hydraulic System Pressure Tester .

Lift Pressure Relief Valve Adjustment Carriage Drift . . . . . . . . . . .

Low Pressure Relief Valve Adjustment Solenoid Valves . . . . . . . .

Solenoid Valve Test . . . . .

Power Steering Relief Valve Test Auxiliary Control Valve Spool Valve Disassembly . . .

Spool Valve Parts Inspection Relief Valve Service . . . .

Spool Valve Reassembly . .

Air In The Hydraulic System Bleeding Air From Lift Cylinder Auxiliary Control Switches (S6, S7, SB) Power Caster - 4D Steering . . . . .

Miscellaneous Hydraulic Maintenance Repacking Lift Cylinders . . . . . . .

Repacking Procedure (except side cylinders) Side Cylinder Repacking . . . . . . . . . .

5.47 5.47 5.48 5.48 5.49 5.49 5.49 5.49 5.50 5.50 5.51 5.51 5.53 5.53 5.54 5.54 5.55 5.55 5.55 5.57 5.57 5.58 5.58 5.58 5.59 5.59 5.60 5.62 5.62 5.62 5.63 5.63 5.64 5.64 5.65 5.65 5.65 5.67

X

Model 20i/21 i General Index

Subject ELECTRICAL Wiring Harness Shorts To Frame Shorts to Frame Test Motor Carbon Buildup Heat Sink insulation Other resistances Battery . . . . . . .

5.68 5.68 5.69 5.69 5.69 5.70 5.70 5.70 5.71 5.71 5.71 5.71 5.74 5.74 5.75 5.75 5.75 5.75 5.76 5.76 5.76 5.78 5.78 5.78 5.79 5.79 5.79 5.80 5.80 5.80 5.81 5.82 5.83 5.84 5.84 5.84 5.84 5.85 5.86 5.87 5.87 5.88 5.88 5.89 5.89 5.89 5.90 5.90 5.90

Record Keeping

Cleaning Electrolyte Process Battery Cleaning Battery Electrical Leakage to Frame Test Hydrometer Check Voltage Check Watering . . . . .

Guidelines . . .

Battery controller (Curtis) General . . . . . . .

Battery controllerTest Units Slow Test Using 1142. . .

Fast Test Using 1141. . . .

Battery Controller Adjustments Reset Potentiometer Reset Potentiometer Adjustments Discharge Potentiometer . . . . .

Discharge Potentiometer Adjustment Reset and Discharge Setting Values Motors .....

Motor Cleaning Brush Care Maintenance Schedule Inspection . . . .

Brush Replacement . .

Commutator Care . .

Inspection . . . . . .

Commutator Servicing High Mica . . . . .

Commutator Resurfacing Stoning of MotorCommutators Commutator Segment Trueness Chamfering Commutator Bar Edges Motor Overheating Cause-Prevention Table Motor Test For Open Circuit .

Drive Motor Open Circuit Test Short Circuit Test - Motor Short Circuit test . .

Armature Shorts . .

Motor Grounds Test

XI

Model 20i/21 i General Index Subject ELECTRICAL (cont'd) Contactors . . . . .

General information Cleaning .....

Inspection . . . . .

Contactor Tip Inspection Contactor Table . . . .

Contactors Maintenance Contactor Coil replacement . . . . . .

Replacement Of Contactor Tips, Insulation And/or Core And Rod Assembly Disassembly/Reassembly Diagnostic Test Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Voltage into the "intellidrive" Control Unit Check (using the test cable) Regulated Voltage . . . . . . . . . . .

Throttle Card Null Adjustment . . . . .

Throttle Card Speed Limit Adjustment "lntellidrive" Control Installation Voltage Regulator . . . . . . . . . . .

Cold Storage Application . . . . . . . "lntellidrive" System Adjustment w/Throttle Card 114-007-329/003 Current Limit Adjustment - Potentiometer "M" Plugging Adjustment - Potentiometer "B" . . .

Procedure . . . . . . . . . . . . . . . . .

Ramp Acceleration Adjustment Potentiometer Directional/ Speed controller . . . . .

Removal From Vehicle . . . . . . .

Potentiometer Removal/ Disassembly Electrical Assembly . . . . . . .

Directional/ Speed Control Assembly Diode Assemblies DA2 checks DA3 and DA5 checks DA7 checks DAS checks DAl 1 checks DA 10 and DA 12 checks DA13 Checks DA14 Checks Transient Suppressors Suppressor List . . .

Test Specifications . .

Relays . . . . . . .

Test Procedure For Kl Relay Testing Other Electrical components

XII

5.91 5.91 5.91 5.91 5.91 5.92 5.93 5.93 5.94 5.94 5.96 5.98 5.99 5.99 5.100 5.101 5.102 5.102 5.102 5.103 5.106 5.107 5.107 5.107 5.108 5.108 5.108 5.109 5.110 5.112 5.112 5.113 5.114 5.114 5.115 5.115 5.116 5.116 5.117 5.117 5.117 5.118 5.118 5.119

Model 20i/21 i General Index

Chapter 6 - Troubleshooting Subiect

Page

OVERVIEW . . . . . . .

6.1

WIRING - GENERAL • • • Discharge Capacitor • •

6.3 6.3

TRUCK COMPLETELY INOPERATIVE

6.4

TRAVEL CIRCUIT/1.C.C. PROBLEMS I.C.C. Control Display Codes System Status Codes • • • • • • • • Fault Codes • • • . • • • • • . • . . • . • . • • • • • Motor Overheats/Poor Brush Life (Model 21 i PLUS Only) R2 Overheats (Model 21 i PLUS Only)

6.10 6.24 6.24 6.24 6.24.1 6.24.2

LIFT/LOWER PROBLEMS

6.25

HYDRAULIC PROBLEMS

6.31

AUXILIARY PUMP PROBLEMS

6.34

AUXILIARY SYSTEM PROBLEMS

6.35

CURTIS BATTERY CONTROLLER PROBLEMS Battery Controller Will Not Reset Fuel Gauge Remains ct Full No Lockout . . • • No Lift • . • • . • •

6.38 6.38 6.39 6.39

HORN INOPERATIVE

6.40

6.39

Chapter 7 - Appendix Subject Lubrication Equivalency Chart Electrical Schematic (Sheet 1 of 2) Electrical Schematic (Sheet 2 of 2) Wiring Diagram (Sheet 1 of 4) • .

Wiring Diagram (Sheet 2 of 4) ..

Wiring Diagram (Sheet 3 of 4) ..

Wiring Diagram (Sheet 4 of 4) ..

Legend - Electrical Schematics and Wiring Diagrams Notes for Electrical Schematics .

Notes for Wiring Diagrams Hydraulic Schematic (standard)

XIII

7.1

7.2 7.3 7.4 7.5 7.6 7.7

7.8 7.9 7.9 7.10

Model 20i/21 i: List of Illustrations

Chapter 1 - Description Figure

Title

Page

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.9.1 1.10 1.11

Model 20i/21 i Fork Lift Truck . . . . . . . . . . . . .

Model 20i/21 i With Door Open and Covers Removed Model 20i/21 i Chassis . . . . . . . . . . . . .

Cross Section of the Complete Drive Unit . . . .

Cross Section of Swivel Caster with Trac-Qualizer Brake Installation . . . . . . . . . . . . . .

Gears for Automotive and Standard Steering .

Definition of 4D Travel Direction . . . . . . .

Hydraulic System Components . . . . . . . .

1S Contactor/P.D. Module Location Reference Electrical Panel . . . . . .

Remote Lift/Lower Controls . . . . . . . . . .

1.1 1.5 1.7 1.8 1.10 1.12 1.13 1.14 1.15 1.21 1.22 1.26

Chapter 2 - Operating Instructions 2.1 2.2 2.3 2.4 2.5 2.6 2.7

Operator Controls . . . . . . . . . . . . . . .

Drive Wheel Indicator and Caster Indicator Lights Remote Lift/Lower Controls . . .

Side Travel Directional Reference Straddle Truck Entering Pallet Reach Truck Entering Pallet Safety Decal

2.2 2.4 2.7 2.10 2.13 2.14 2.18

Chapter 3 - Installation 3.1

Recommended Oils by Temperature

. . . . . . . . . . . . . . . . . . . . . . . 3.8

Chapter 4 - Theory of Operation 4.1 4.2A 4.2B 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.13 4.14 4.14 4.15

Hydraulic Schematic - Standard . . . . . . . . . .

Lift - Lift Motor/Pump ON - Control Valve Open Lift - Lift/Lower Control Valve Closing Lower . . . . .

Travel Lift . . .

Travel Lower .

Auxiliary System SCR Physical Appearance SCR Electrical Symbol . .

Diagram of How an SCR Operates Throttle Card Schematic Travel Circuit . . . . . . . . . .

Battery Plugged In - Sheet l of 2 Battery Plugged In - Sheet 2 of 2 Keyswitch Turned - ON - Sheet 1 of 2 Keyswitch Turned - ON - Sheet 2 of 2 Deadman Switch Depressed - Sheet l of 2 Deadman Switch Depressed - Sheet 2 of 2 The Directional/Speed Control Handle is Rotated to the Forward Position

XIV

4.2 4.3 4.4 4.6 4.8 4.9 4.10 4.12 4.12 4.14 4.15 4.19 4.21 4.22 4.24 4.25 4.27 4.28 4.30

Model 20i/2li: List of Illustrations

Chapter 4 - Theory of Operation (Cont'd) Figure

Title

4.16 4.17 4.18 4.19 4.20 4.21

Turning ON the Main SCRl and Charging Capacitors Cl, C2, C3, C4.

Turning OFF the Main SCRl Control Handle Movement . . . . . . .

High Speed M Range . . . . . . . . . .

Operation of 1S, R2, and P.O. Module Plugging . . . . . . . . . . . . . . .

4.32 4.33 4.34 4.36 4.38 4.39

Chapter 5 - Maintenance 5.1 5.2 5.3 5.4 5.4.1 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16 5.17 5.18 5.19 5.20 5.21 5.22 5.23 5.24 5.25 5.26 5.27 5.28 5.29 5.30 5.31 5.32 5.33 5.34 5.35 5.36 5.37 5.38 5.39 5.40

Scheduled Maintenance Chart Lubrication Equivalency Chart Straddle/Reach Attachment Lubrication Standard Torque Data for Bolts . . . . .

Correct Jacking Locations for the Model 20i/21 i Drive Unit . . . . . . . . . . .

Cross Section of the Drive Unit . . . . . . .

Drive Motor Installation (Typical) . . . . . .

Drive Wheel . . . . . . . . . . . . . . . . .

Fabricated Ring for Removing the Drive Unit Proper Position of Thrust and Radial Rings Exploded View of Brake Assembly . . . . . .

Brake Bleed Procedure . . . . . . . . . . .

Deadman Pedal Adjustment . . . . . . . . . .

Steering Column Assembly Power Steering, Standard Type Exploded View of the Swivel Caster . . • . . . .

Pre-loading Caster and/or Trac-Qualizer Springs Lift Chain Lubrication . . . . . . . .

Adjusting Equalization Chain Anchor Blocking the Mast . . . . . . .

Reinstalling Equalization Chain . . .

Reach Carriage Chain Anchors . . .

Mast Bumper Installation . . . . . .

Mechanical Stop Adjustment - Typical Removing Equalization Chain Sheave Blocking Mast . . . . . . . . . . . .

Hose Clamping On Inner Telescopic Hose/Cable Tension Spring Adjustment Blocking Reach Mast . . . . . . . . .

Hose Routing Detail . . . . . . . . . .

Rear TT Cylinder Piston/End Cap . . .

TT Mast Flow Control - Exploded View View of Hydraulic Components . . . .

Hydraulic Control Valves . . . . . . . . . . . .

Auxiliary Pump -P/N 500-417-200 or 201: Exploded View Lift Pump -P/N 500-417-100: Exploded View Lift Pump P/N 500-41 7-100: Sectional View Shaft Seal . . . . . . . . . . . . . . . . .

Right Hand Rotation view From Cover End Hydraulic Components . . . . . . . .

Maximum Rate of Allowable Load Drop

xv

5.6 5.7 5.8 5.10 5.11 5.12 5.13 5.15 5.17 5.17 5.19 5.22 5.24 5.24 5.26 5.28 5.30 5.32 5.34 5.35 5.36 5.37 5.38 5.38 5.39 5.40 5.41 5.41 5.42 5.43 5.44 5.44 5.45 5.46 5.52 5.52 5.53 5.54 5.54 5.56 5.57

Model 20i/2 l i: List of Illustrations

Chapter 5 - Maintenance (Cont'd) Figure

Title

5.41 5.42 5.43 5.44 5.45 5.46 5.47 5.48 5.49 5.50 5.51 5.52 5.53 5.54 5.55 5.56 5.57 5.58

Spool Valve - Exploded View . . . . . .

Auxiliary Control Switches S6, S7, and S8 40 - Power Caster - Load Wheel Lih Cylinder Packing . . . . . .

Battery Controller Tester (Curtis) Pot Settings and Volts per Cell Cleaning A Motor (Typical) . . .

Maintenance Inspection Chart Measuring Spring Tension .

Table of Brush Lengths and Spring Pressures Mica Undercutting . . . . . . . . . . • . .

Commutator Cutting Tool . . . . . . . . . . . . . .

Proper Technique of Chamfering Commutator Segments Chamfering Segment Bar Edges on the Commutator Drive Motor Terminals and Circuits . . . . . .

Contactor Specfications . . . . . . . . . . . .

Typical Contactor Exploded View . . . . . . . "intellidrive" and Test Unit (P/N 154-008-767) Throttle Card Nulling (VRl) . . . . . . . . . .

Throttle Card Adjustment Points. . . . . . . . "lntellidrive" Adjustment Potentiometers . . . . . . .

Throttle Control Card - II (T.C.C.-11) Adjustment Points Directional/Speed Control Assembly Directional/Speed Control - Exploded View Contactor Suppressors . . . . . . .

Electrical Components Test . . . . .

SCR Torque Ratings and Installation

5.59 5.60 5.61 5.62 5.63 5.64 5.65 5.66 5.67

5.61 5.63 5.64 5.65

5.77 5.79 5.80 5.81 5.82 5.83 5.84 5.85 5.86 5.87 5.89 5.92 5.95 5.99 5.100 5.101 5.103 5.104 5.110 5.111 5.117 5.119 5.120

Chapter 6 - Troubleshooting No illustrations available

Chapter 7 - Appendix 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8

Lubrication Equivalency Chart Electrical Schematic (Sheet l of 2) Electrical Schematic (Sheet 2 of 2) Wiring Diagram (Sheet l of 4 .

Wiring Diagram (Sheet 2 of 4) Wiring Diagram (Sheet 3 of 4) Wiring Diagram (Sheet 4 of 4) Hydraulic Schematic - Standard

7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.10

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