Raymond Forklift SA SB Parts Catalog Manual - PDF DOWNLOAD

PDPM-0189 S/N SA 00623 & Up S/N SB 00215 & Up Issued 6/30/00

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 .....................................................................................................................4-14 Brake Assembly Installation 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: Frame Assembly - DS/DT

2-1

FIGURE 2-2 ITEM NO.

QTY

PART NUMBER

1

5

828-005-691/003

5

828-005-691/001

5

828-005-691/002

A B C

REF 1 1 1 2 2

828-006-283 714-206 828-004-421 861-026 462-032

Frame Weldment Door Weldment Screw Bracket, Latch Pin, Clevis Bearing

8 9 10

1 1 1 1 2 2

710-264P 750-433 828-004-622 828-006-364 750-006 771-049

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

20 21

1 1 1 2 2 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

22 23 24 25 26 27

1 1 1 2 2 1

5-015-003 5-015-004 828-004-672 828-004-671 710-069 411-938/001

Nut, Hex Nut, Hex Bracket Weldment Washer Screw Decal, Keyswitch (Not Shown)

H, L, N, P H, L , N, P

28 29 30

1 1 1 1 1 1

411-938/003 411-938/002 411-938/004 828-004-674 828-004-683 828-004-682

Decal, Keyswitch (Not Shown) Decal, Keyswitch (Not Shown) Decal, Keyswitch (Not Shown) Cable Assembly, SC to SMARTi Bracket, SMARTi Clamp, ODI

G K, L M, N, P H, L, N, P H, L, N, P F, G, K, M

31

1

13 14 15 16 17 18 19

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

USED ON

2 3 4 5 6 7

11 12

4.

DESCRIPTION Roller Assembly (consists of items 36 through 40) Roller Assembly (consists of items 36 through 40) Roller Assembly (consists of items 36 through 40)

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

154-009-117/001 F= Standard G= Remote H= SMARTi K= Standard/Bypass L= SMARTi/Bypass

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

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

F, H

Static Strap, Insulated 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

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 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

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 .................................. 5-3 291-011.................... RingUSED ...................................................

4-3 DESCRIPTION ON 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 400-081/05 .............. Shoe Assembly .................................. 4-15 Door Weldment S 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, Washer H, Operating L, M, P ................................. 2-7 411-681.................... Decal, Replacement Instruction ............. 2-7

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 1 1 1 2 2 1 1 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 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

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

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 Static Strap, Insulated

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.

PC8

PC16

PC7

JC18

JC9

JC23

IL3 IL4 IL5 IL6 IL7

JC24

IL2 IL1

PC21 PC25 PX1

PC19 PC20 PC12

PC15 PH1

PC17 PC10

R1 R2

ELEC. ELEC. ELEC. HYD. HYD .

HYD .

SPS

SPS

838

R1 R2

ELE C. ELEC. ELE C. HY D. HY D. HY D.

A

A

F

F

D

i®

FU70 70 A

FU70

JS28 JS6 S46

S47

PRIOR T O OPERATI NG T HI S T RUCK: Do no t o pe rate th is tru ck un l es s tr a in ed an d auth o ri ze d to do so .

Re ad a l warni ng s and in str u ctio ns c ontai ne d in th e op erato r' s ma nua l an d on the tr u ck.

Ch e ck a l l o pe ra ti n g s ys te ms an d s a fe ty d e vic e s.

WHILE OPERAT ING TH IS TRUCK: Kee p a l l p o rti o ns of th e b od y i n si d e th e op e rato r's en ve l o pe .

Whe n s top pin g , s tay i ns id e co mpa rtme n t until truc k c om es to a com p le te ha lt .

Us e cau ti o n w hen tra v eli ng wi th fo rk s abo ve 24 in c he s .

Trave l wit h for ks i n a n este d p os itio n.

FO R YOUR SA FETY AND THE SAFETY OF O THE RS: 1. Do no t o perat e t hi st ruc ku nle ss yo u have bee n aut ho ri zed and t rai ned t o d os o. Rea d al l warni ngs and i nst ruc ti on sc ont ai ned in op erat or's ma nu al.

2. Do not o per ate t his tr uck unti l you have checked all system s. ( Al l saf tey guar dso r cover sm ust be i npl ace and saft ey int er lock swi tche soper at ive. ) R epor t any unsaf e condi ti oni mm ed iat ely; do not o pera te tr uck unt il cor r ected .

3. O per ate t ruck onl yf r om desi gnat ed oper ati ng posi ti on.

Neve r pla ceany par t of yo ur body bet w eent he m ast upr ight s or ou tsi det he tr uck. D on ot car ry unau tho ri zedp er sonnel.

4. D o not all ow anyon e to st and o r pa ssu nde r l oad or li ft in g mechan is m.

5. Do not o per ate wi th out fa steni ng oper ator r estr ain ing device , placi ng guar dr ai ls in posit io n.

6. D o not o ver load t r uck. C hec kspe cif i cati on pl ate f or capa cit y( l oad w eig ht and l oad cent er inf or mat ion) .

7. St ar t, st op, chan gedi rect ion , tr avel and br ake smoot hl y.

Sl ow down f or tu rns ando nune venor sli pper ysur fa cest hat could cause t ruck to sli deo r ti p. Kee pone f oot f ree f rom deadm an bra keped alat all t im es. I ngui ded appl icat ions, ap-

pr oac ha nd le ave gui de da isl es sl owl y.

8. U seex tr em e care w hen tr avel ing w it hout l oad. Excessi ve speed wi t hab ru pt tu rn sor u neven sur fa cesm ay cause tr ucks ot t ip ove r.

9. E leva te l if ti ng mechan ism onl yt o pic ku po r st ack a loa d. Wat ch out for obst r uct ion s, espe cial l yove rh ead.

10. Lif t ,l ow er and t rave l wi t h fo rk s in pro per l o ad carryin g pos ist i on. R ot at e or si desh if t f orks or at ta chmen t on ly t o pic k up or dis charg e loa ds.

11. A lw aysl ook in di re cti ono f tr ave l. K eep acl ear vie w and when l oad int er fer es wi th vi sibi li t y, tr avel w it h loa dt r ail ing. Tra vel wi t hl oad or l if ti ng me chani sm as low aspo ssibl e.

12. Do no t op era te o n an y in cli ne .

13. D o not l if t pe rson nel ex cept on a secu rel y at tach ed wo rk pl atf or m. U see xtr eme car e, f ull y rot at e and cent er wo rk pl atf or m, pl ace tr uck cont r ols i n neut ral and appl y br akes. Li f ea nd low er s mo othl y. R emai ni n oper at in g pos it io n a sl on g as p erso nn el i s el eva t ed.

14. When usi ng f orks, spre ad asf ar a part asl oad wi l per m it . Bef or el i ft ing, b esu re l oadi s cent er edan df or ks ar ep ushed com ple tel yu nder l oad.

15. Do not handl eunst able or lo ose ly stacked loads. U se specia l car ewh en handl ing long, hi ghor wide l oa ds.

16. O bserve appl icabl et ra f ic regul at ions. Yi eld r ight of way to pedest ri ans. S low down and sound hor nat cr oss aisle sand wher ever vi sion is obstr uct ed.

1 7. Whe n yo ug et o ft ru ck ,p lac e co nt rol si n e utr al an d se t b rak e .If yo u le av et ru ck un at ten d ed ,a lso f ul yl ow er lif tin g m ec ha n ism , sh ut of fp ow e ra nd re m ov ek e y.

1 2 -6 0 4 2