Raymond Forklift EASi Swing-Reach® 537 Parts Catalog Manual SN 800 and Up

Model - 537 EASi Swing-Reach®

Parts Catalog

PDPM-0007 S/N 800 and Up Issued 3/1/97

©Copyright 1996 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 Brake Assembly Installation.....................................................................................................................4-14 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

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

28 29 30

1 1 1 2 2 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1

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

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

31

1

154 -009-117/001

Static Strap, Insulated

19 20 21 22 23 24 25 26 27

5

828 -005-691/003

5

828-005 -691/001

5

828 -005-691/002

DESCRIPTION

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

2 3 4 5 6 7 8 9 10

13 14 15 16 17 18

4.

PART NUMBER

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

11 12

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

QTY

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

F= Standard G= Remote H= SMARTi K= Standard/Bypass L= SMARTi/Bypass

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

USED ON A B C A, Q S

R

O T H, L, M, P

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

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 DESCRIPTION ON 291-011 .................... RingUSED ...................................................

4-3 291-012 .................... 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 Door Weldment S 400-081/05 .............. Shoe Assembly .................................. 4-15 400-081/06 .............. 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, 2-7 Washer H, Operating.................................

L, M, P 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

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

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

1 1 1 2 2 1 1 1 1 1 1 1 1

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

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

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

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.

Y

B

X

X

302 294

P17

FU14 FU13

2 TP1 TP4

X

1

2

1

1

IS

PC

2

TP2

1

TP7

P

2

2

L1 Q1

E 1

FU1 FU2 FU3 FU4 FU5 FU6

FU16 FU15

TP5

TP3

E

JPT

TP6

FW-B+

FW-B-

1

2

1

2

JPH

Z

A = Standard (S/N 800 to ____) B = Cold Storage (S/N 800 to ____) C = Standard (S/N ____ and up) D = Cold Storage (S/N ____ and up)

A = Standard B = Cold Storage

NSS = Not Sold Separately

A = Standard B = Cold Storage

A = Standard B = Cold Storage

A = Standard B = Cold Storage

A = Standard B = Cold Storage

A = Standard B = Cold Storage

A = Standard B = Cold Storage

B

B

P17 PS20

A = Standard B = Cold Storage

A = Connector Label (JF5) B = Connector Label (PM2) C = Connector Label (JF12) D = Connector Label (JZ) E = Connector Label (JY2) F = Connector Label (No Label) G = Connector Label (J4)

DISPLAY

A = S/N 800 to 882 B = S/N 883 to 1128 C = S/N 1129 to 1261 D = S/N 1262 to 2060 E = S/N 2061 and Up

A = Standard and Cold Storage B = EE

A = Standard and Cold Storage B = EE

1S

P

PC

X

A = Standard and Cold Storage B = EE

A = Standard and Cold Storage B = EE

A = 001 B = 002 C = 003 D = 004

A = 001 - Assembly as Shown -15A B = 002 - Assembly Opposite Hand -15A C = 003 - Assembly as Shown -15A D = 004 - Assembly Opposite Hand -15A E = 005 - Assembly as Shown (C.S.) -15A F = 006 - Assembly Opposite Hand (C.S.) -15A G = 007 - Assembly as Shown - 1A H = 008 - Assembly Opposite Hand - 1A

A = Standard B = Cold Storage C = No Options D = Lift By-Pass E = Wire Guidance F = Lift By-Pass and Wire Guidance

A = Standard with Lift By-Pass B = Cold Storage with Lift By-Pass

A = Standard B = Cold Storage C = No Options D = Lift By-Pass

A = Standard B = Cold Storage

PL1 (REF.)

PL1 (REF.)

A = Standard B = Cold Storage

A = Standard B = Cold Storage

A = Standard B = Cold Storage C = No Option D = Lift By-Pass

A = Standard B = Cold Storage

A = Standard B = Cold Storage C = No Options D = Lift By-Pass

A = Standard B = Cold Storage C = No Options D = Lift By-Pass

1 3

VIEW F-F

A = Red B = Amber

A = With 2 fans, 1 fluorescent light, and 2 work lights B = With 1 fluorescent light and 2 work lights C = With 2 fans and 2 work lights D = With 2 fans E = With 2 work lights F = No lights or fan G = With 2 fans and 1 fluorescent light H = With 1 fluorescent light

A = Red B = Amber C = Blue D = Green E = Clear

A = Right B = Left

A = 5.2 KHz B = 6.25 KHz C = 48”/1219mm Base Leg Width D = 56”/1422mm Base Leg Width E = 62”/1574mm Base Leg Width F = 68“/1727mm Base Leg Width

A = 6.25 KHz B = 5.2 KHz C = 1.4 KHz

A = Standard B = Cold Storage

** By-pass height is defined as the maximum load elevation at which the override button, located on the control handle, must be activated to continue lift.

A = Standard B = Cold Storage C = 118”/2997mm OACH D = 130”/3302mm OACH E = 142”/3606mm OACH F = 154”/3911mm OACH G = 166”/4216mm OACH H = 178”/4521mm OACH J = 190”/4826mm OACH K = 203”/5156mm OACH

A = Lift/Limit height equal to or less than aux. + 186 B = Lift/Limit height greater than aux. + 186

A = Standard B = Cold Storage

NOTE: There is no seal kit available for the Manual Lowering Valve. The Valve must be replaced.

A = Standard B = Cold Storage C = EE

A = Standard B = Cold Storage C = EE

A = Standard B = Cold Storage C = 32” M Turret

A = Standard B = Cold Storage C = 32” M Turret

A = Standard B = Cold Storage C = 32” M Turret

A = Standard B = Cold Storage C = 32” M Turret

* Serial Numbers 001 to 459 only + Serial Numbers 460 and Up

A = Standard B = Cold Storage C = 32” M Turret

A = Standard B = Cold Storage C = 32” M Turret

A = Standard B = Cold Storage C = 32” M Turret

A = Standard B = Cold Storage C = 32” M Turret

A = Standard B = Cold Storage C = 32” M Turret

* Serial Numbers 001 to 459 only + Serial Numbers 460 and Up

A = Standard B = Cold Storage C = 32” M Turret

A = Standard B = Cold Storage C = 32” M Turret

A = Standard B = Cold Storage C = 32” M Turret

A = Standard B = Cold Storage C = 32” M Turret

* Serial Numbers 001 to 459 only + Serial Numbers 460 and Up

A = Rope Tether B = Retractable Tether

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