HandlingTheLoad

Obey these rules when handling a load:

•Handle only loads that are within the hand pallet lift truck’s permitted lifting capacity.

•Adjust the forks length/width to handle the size and shape of the load.

•Handle only loads that are stable, evenly distributed on the forks, and safely arranged.

•Use caution when handling long and high loads. Load support is recommended for high loads.

Models RJ50, RJ50-SS, RJ50-K, and RJ50-PB

Assembly Instructions WARNING

•Loaded or unloaded, operate the hand pallet lift truck with great care. Overturning can occur, particularly when handling high loads or when operating with a hand pallet lift truck fitted with a load support or an extension frame in the raised position.

Before assembling the hand pallet lift truck, always ensure that you are wearing protective/safety glasses, safety shoes, and heavy-duty protective gloves. See Figure6 on page11 and Table2 on page12 for an exploded view of the hand pallet lift truck, the assembly reference, and location numbers.

•Use extreme care when cornering. If operating at too high a speed, the load could fall from the hand pallet lift truck.

Parking the Hand Pallet Lift Truck When parking the hand pallet lift truck, follow these instructions:•Ensure the fork frame is fully lowered.

• Never park on an incline or with a raised load.

• Never park in areas that could obstruct other traffic or work areas.

• Never park in areas that could cause personal injury or damage to any equipment.

on page11 .)

1.Secure the tow bar (1) in the tow bar bracket (2).

2.Fit the axle (3) in the bracket (2).

3.Using the spiral pin (4), lock the axle.

4.Thread the valve rod (5) over the profile section (6).

5.Fit the spring strip (7) and the nut (8) on the valve rod (5).

6.Fit the spring strip (7) on the lowering pedal (9).

7.Adjust the lifting/lowering function and the neutral position using the nut (8).

Assembling The Tow Bar

CAUTION !

Always fit the tow bar (1) before dismantling the locking strip (11). Failure to do so may cause the spring (10) to jump out of position, causing damage.

To assemble the tow bar, follow these instructions:

( See Figure7 on page13 for a visual of the required assembly tools. Refer to Figure6 on page11 for location of assembly reference numbers, and refer to Table2 for the legend on assembly reference numbers.)

Note

Always clean and inspect dismantled parts before re-assembling. Always replace gaskets before re-assembling. To assemble hydraulics in the body, follow these instructions: ( Refer to Figure6 on page11 and Table2 on page12 .)

1.With the upper section (12) of the hydraulics positioned in the top cap (13), insert the pressure plate (14) between link arms (15).

2.Fit arm bolts (16) and lock, using spiral pins.

3.Fit circlip (18) in the top cap’s groove.

Figure 7. Assembly Tools

Assembling Hydraulics In The Body CAUTION

! When fitting a circlip (18) there is a risk that the circlip will release from the circlip bar and cause damage. Raymond recommends using circlip pliers as shown in Figure7 . Use caution when inserting spiral pins (4, 17) with a hammer. The force can cause the spiral pins to bounce, causing damage.

Models RJ50, RJ50-SS, RJ50-K, and RJ50-PB

The hand pallet lift truck’s hydraulic system is maintenance free. Do not add hydraulic oil unless there is or has been a leak. If additional oil is required, position the forks in the lowered position. Remove the oil level plug. Refill with hydraulic oil to the plug-hole level. Replace the oil level plug.

Maintenance Maintenance and Repair

The hand pallet lift truck should be maintained on a regular basis, as set out in the service checks and lubrication diagram. ( See Figure8 on page20 .) Only authorized and trained personnel are permitted to maintain, adjust, or repair the hand pallet lift truck. To ensure that your hand pallet lift truck is operating efficiently, economically, and safely, it is strongly recommended that a service and maintenance agreement be signed with your Raymond Dealership.

Note

Hydraulic System

Before adding hydraulic oil, check with your supervisor to ensure that the correct type of hydraulic oil is used. ( See Table3 on page15 for “ Types of Oil for the Hydraulic System. ” )

Table 3. Types of

Safe maintenance practices conform with the following general guidelines:

• Always keep the area where you work clean. Oil and/or water make the floor slippery.

• Never wear loose fitting objects or jewelry.

•Properly store or dispose of used oil. Follow manufacturer’s instructions.

Safety Regulations for Maintenance Work

•Properly dispose of used solvents and all other cleaning/washing chemicals. Do not flush down drains. Follow manufacturer’s instructions for proper disposal.

WARNING ! Before welding or grinding on painted surfaces always sandblast (remove) at least 4-6 in. (102-152 mm) of paint. Heated paint gives off harmful gases.

WARNING ! Always secure the hand pallet lift truck when carrying out repairs. A badly supported hand pallet lift truck could cause injury.

Troubleshooting

Pull up on the fingertip control and hold while pumping the handle several times to bleed air from the system. Add oil to the filler plug level.

Add oil to the filler plug level. Adjust the setting of the valve chain with the adjusting nut. Change the ball, scraper, O-ring, and washer.

Pull up on the fingertip control and hold while pumping the handle several times.Change the valve cone and the washer.

Possible Cause

TroubleshootingTable 4. TroubleshootingCondition

Action Pump does not take full load.Air lock in the hydraulic system. Insufficient hydraulic oil.

Insufficient hydraulic oil.

Forks do not rise although valve handle is in lifting position.

Lowering valve does not open. Leak from the non-return valve.

Air lock in the hydraulic system. Leak from the valve cone.

Forks are sinking after every pump stroke.

Lowering valve does not open properly.Adjust the setting of the valve chain with the adjusting nut.

Lowering action does not function or only functions slowly.

Models RJ50, RJ50-SS, RJ50-K, and RJ50-PB

Action

Adjust setting of the valve chain with the adjusting nut. Change the valve cone and the washer. Change the U-ring and the O-ring.

Possible Cause

Lower valve does not close properly. Leak from the valve cone. Leak from the sealing rings.

Troubleshooting (Cont.)Condition

Valve ball is not effective.Adjust setting of the valve chain with the adjusting nut. Oil leaks from the lowering valve.Sealing ring damaged or worn out.Change the scraper, O-ring, and washer. Table 4.

Forks sink when the handle is in the neutral position.

Troubleshooting

Pumping occurs when the valve handle is in the neutral position.

NOTE When overhauling the hydraulic system always do so in a clean environment and properly clean all parts. Carefully clean and inspect all dismantled parts.Always replace O-rings and sealing washers.