Raymond SIDELOADER TRUCK 71B and 76 Maintenance Manual - PDF DOWNLOAD

Maintenance Manual Model 71B/76 Sideloader Truck

Model 71B - Serial No. 1401 and Up Model 76 - Serial No. 001 and Up

PDMM-0102

Issued: 9-30-02

Supercedes MM-75 Issued 12/1/81 (Model 76) Supercedes MM-80 Issued 10/1/83 (Model 71B)

0REACH.EPS

© 2002 The Raymond Corporation

Raymond and Ranger Shelf Height Selector are trademarks of The Raymond Corporation. All other brand and product names are trademarks or registered trademarks of their respective companies.

Raymond ® Sideloader Maintenance Manual

How to Use This Manual

Table of Contents How to Use This Manual

Table of Contents 1:

Page Revision Record . . . . . . . . . . . . . . . . v

Troubleshooting . . . . . . . . . . . . . 6-1

Service Bulletin Index . . . . . . . . . . . . . . . vii

Overview . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Product Improvement Notice Index . . . . .viii

General Instructions . . . . . . . . . . . . . . . 6-4

How to Use This Manual . . . . . . . 1-1

List of Troubleshooting Charts . . . . . . . 6-11

Map of the Manual . . . . . . . . . . . . . . . . 1-2

Troubleshooting Procedure . . . . . . . . . 6-13

Manual Design . . . . . . . . . . . . . . . . . . . 1-3

Component Procedures . . . . . . . . 7-1

START Page . . . . . . . . . . . . . . . . . . . . . 1-5

Component Locator Photos . . . . . . . . . . 7-3

Safety . . . . . . . . . . . . . . . . . . . . . 2-1

General Procedures . . . . . . . . . . . . . . . 7-11

Definitions . . . . . . . . . . . . . . . . . . . . . . 2-2

Tire Replacement . . . . . . . . . . . . . . . . . 7-12

General Safety . . . . . . . . . . . . . . . . . . . 2-3

Motors . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Battery Safety. . . . . . . . . . . . . . . . . . . . 2-7

Drive Axle Assembly. . . . . . . . . . . . . . . 7-23

Jacking Safety . . . . . . . . . . . . . . . . . . 2-11

General . . . . . . . . . . . . . . . . . . . . . . . . 7-24

Welding Safety . . . . . . . . . . . . . . . . . . 2-12

Drive Motor Inspection and Cleaning . . . . . . . . . . 7-25

Systems Overview . . . . . . . . . . . . 3-1

Drive Wheel Replacement. . . . . . . . . . . 7-26

General System Data . . . . . . . . . . . . . . 3-2

Crab Steer Alignment and Adjustment . 7-28

Mechanical Systems . . . . . . . . . . . . . . . 3-3

Drive Axle Removal and Reassembly . . 7-30

Hydraulics . . . . . . . . . . . . . . . . . . . . . . 3-7

Drive Motor Replacement . . . . . . . . . . . 7-32

Electrical . . . . . . . . . . . . . . . . . . . . . . 3-12

Drive Unit Repair and Replacement . . . 7-34

Options . . . . . . . . . . . . . . . . . . . . . . . 3-17

Tie Rod Replacement . . . . . . . . . . . . . . 7-36

Installation . . . . . . . . . . . . . . . . . 4-1

Crab Steer Cylinder Replacement. . . . . 7-36

General . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Chassis Frame . . . . . . . . . . . . . . . . . . . 4-2 Visual Inspection . . . . . . . . . . . . . . . . . 4-3 Mast to Tractor Reassembly . . . . . . . . . 4-4 Batteries and Chargers . . . . . . . . . . . . . 4-7

Steer Axle Assembly. . . . . . . . . . . . . . . 7-37 General . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Steerable Wheel Replacement. . . . . . . . 7-39 Steering Linkage Alignment and Adjustment . . . . . . . . . . . . . . . . . . . . 7-40 Steer Axle Removal and Reassembly . . 7-41

Scheduled Maintenance . . . . . . . 5-1

Steer Linkage Replacement . . . . . . . . . 7-43

Maintenance Guidelines . . . . . . . . . . . . 5-2

Steer Cylinder Replacement . . . . . . . . . 7-44

Monthly Maintenance . . . . . . . . . . . . . . 5-3

Steer Knuckle Replacement . . . . . . . . . 7-45

Semi-Annual Maintenance . . . . . . . . . . 5-6

Steering . . . . . . . . . . . . . . . . . . . . . . . . 7-47

Annual Maintenance. . . . . . . . . . . . . . . 5-7

Steering Chain Adjustment . . . . . . . . . 7-48

Lubrication and Inspection Points. . . . . 5-8

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . 7-49 Service Brake Adjustment . . . . . . . . . . 7-50 Parking Brake Adjustment . . . . . . . . . . 7-51

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Raymond ® Sideloader Maintenance Manual Table of Contents

Brake Shoe Replacement . . . . . . . . . . 7-52

Battery Controller and K5 Relay . . . . 7-129

Wheel Cylinder Repair or Replacement 7-54

Automatic Steer Centering Relay K11 7-130

Attachment and Load Handler . . . . . . 7-55

Deadman Relay K12 and Light Load Relay K13 . . . . . . . . . . . . . . . . . . . . 7-131

General . . . . . . . . . . . . . . . . . . . . . . . 7-56 Mast Tilt Cylinder Repair and Replacement . . . . . . . . . 7-57

Diode Assemblies . . . . . . . . . . . . . . . 7-132

Fork Tilt Cylinder Repair and Replacement . . . . . . . . . 7-59

Suppressor Assemblies . . . . . . . . . . . 7-136

Carriage Reach Cylinder Repair and Replacement (SLR20TT). . . . . . . . . . . . 7-60 Mast Traverse Motor Repair and Replacement . . . . . . . . . 7-61 Lift Chain Repair and Replacement . . . . . . . . . 7-62 Carriage Roller Bearing Replacement . 7-63 Side Cylinder Repacking (TFL and TT) 7-65 Lift Cylinder Repair and Replacement . . . . . . . . . 7-66

Resistor Assemblies . . . . . . . . . . . . . . 7-135

Theory of Operation. . . . . . . . . . . 8-1 Overview . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Steering. . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Lift/Lower . . . . . . . . . . . . . . . . . . . . . . . 8-7 Auxiliary Controls . . . . . . . . . . . . . . . . 8-13 SCR Theory . . . . . . . . . . . . . . . . . . . . . 8-15 Standard Travel. . . . . . . . . . . . . . . . . . 8-17 Plugging . . . . . . . . . . . . . . . . . . . . . . . 8-26

Lift Cylinder Bleeding . . . . . . . . . . . . . 7-68

Miscellaneous Circuits. . . . . . . . . . . . . 8-28

Mast Assembly Removal . . . . . . . . . . . 7-69

Remote Travel . . . . . . . . . . . . . . . . . . . 8-29

Mast Drive Repair and Replacement . . . . . . . . . 7-70

Appendix . . . . . . . . . . . . . . . . . . .A-1

Mast and Telescopic Roller Bearing Replacement . . . . . . . 7-72 Hydraulics . . . . . . . . . . . . . . . . . . . . . 7-73 General . . . . . . . . . . . . . . . . . . . . . . . 7-74 Lift Control and Linkage . . . . . . . . . . . 7-75 Hydraulic Manifolds . . . . . . . . . . . . . . 7-78

Lubrication Specification Chart . . . . . . . A-2 Thread Adhesives, Sealants, and Lubricants A-3 Torque Chart - Standard (Ferrous). . . . . A-4 Torque Chart - Metric (Ferrous) . . . . . . . A-5 Torque Chart - Standard (Brass) . . . . . . A-6

Electrical . . . . . . . . . . . . . . . . . . . . . . 7-81

Decimal Equivalent Chart . . . . . . . . . . . A-7

General . . . . . . . . . . . . . . . . . . . . . . . 7-82

Standard/Metric Conversions . . . . . . . . A-9

Batteries . . . . . . . . . . . . . . . . . . . . . . 7-83 Component Testing . . . . . . . . . . . . . . 7-87

Schematics . . . . . . . . . . . . . . . . . . . . . A-11

Index . . . . . . . . . . . . . . . . . . . . . . I-1

Contactors . . . . . . . . . . . . . . . . . . . . . 7-88 Controls . . . . . . . . . . . . . . . . . . . . . . . 7-95 Directional/Speed Control Assembly . 7-96 Control Unit . . . . . . . . . . . . . . . . . . . .7-102 SCRs . . . . . . . . . . . . . . . . . . . . . . . . .7-122 Rectifiers . . . . . . . . . . . . . . . . . . . . . .7-125 Plugging Relays K1 & K2 . . . . . . . . . . . . . . . . . . . . .7-127

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Raymond ® Sideloader Maintenance Manual

How To Use This Manual Page Revision Record

Page Revision Record 1: How To Use This Manual

This page is a record of the latest revised pages in this manual. When a page is revised, this section is updated and included in the revision.

This manual replaces: • MM-80 Model 71B Maintenance Instructions, dated 10-01-83 • MM-75 Model 76 Maintenance Instructions, dated 12-01-81 This manual has been completely reorganized to current formatting standards. See “Map of the Manual” on page 1-2 and “Manual Design” on page 1-3 for an explanation of the format and layout of this manual.

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How To Use This Manual

Raymond ® Sideloader Maintenance Manual

Page Revision Record

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How to Use This Manual Service Bulletin Index

Service Bulletin Index How to Use This Manual

1:

This page lists the Raymond Sideloader Service Bulletins (RSBs) currently in effect.

Document Number SDL-96-001

Subject Model 76 lift ram seal leakage

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Date 09-10-96

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Raymond ® Sideloader Maintenance Manual

How to Use This Manual Product Improvement Notice Index

Product Improvement Notice Index This page lists the Raymond Sideloader Product Improvement Notices (RPINS) currently in effect.

Document Number

Subject

Date

SDL-97-R001

Obsolete Ranger motherboard

01-07-97

SDL-97-R002

Horn failure

02-25-97

SDL-97-R003

Lift/Lower control panel plate

10-16-97

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How to Use This Manual

How to Use This Manual

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How to Use This Manual

Raymond ® Sideloader Maintenance Manual

Map of the Manual

Map of the Manual 1MAP.WMF

How to Use This Manual

Table of Contents

Page Revision Record

Troubleshooting

Component Procedures

Service Bulletin & RPIN List Map of the Manual

Component Locator Photos

Manual Design Component Procedures by Lift Truck System

Start Page

Safety

Theory of Operation

Systems Overview

Appendix

Installation

Index

Scheduled Maintenance

1-2

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How to Use This Manual Manual Design

Manual Design The Raymond ® Sideloader Maintenance Manual is designed to: • Provide technical coverage for expected levels of user expertise.

• Anticipate your needs and reduce your decisions regarding maintenance.

• Reduce page flipping through a “one-stop shopping” approach.

The two-line page header at the top of each page identifies the: • Name of the manual Raymond ® Sideloader Maintenance Manual) • Current chapter title (for example, this page; How to Use This Manual) • Current topic (for example, this page; Manual Design) We suggest you get in the habit of turning to the START page first when you use this manual.

The START page asks simple questions to guide you to the proper chapter.

• How to Use This Manual explains the manual format and design, and contains the START page.

• Safety explains warning and caution notes, general safety rules, and safety rules for batteries, jacking, and welding.

• Systems Overview includes lift truck specifications and general information.

• Installation gives unpacking, inspection, and assembly procedures for the Sideloader.

• Scheduled Maintenance outlines the recommended schedule of preventative services to keep your lift truck working most efficiently.

• Troubleshooting is a set of troubleshooting guidelines and tables.

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Raymond ® Sideloader Maintenance Manual

Manual Design • Component Procedures gives step-by-step procedures for testing, removal, installation, and adjustment of individual Sideloader components. Components are grouped by lift truck system: • General • Drive Axle • Steer Axle • Steering • Brakes • Attachment & Load Handler • Hydraulics • Electrical • Control To find a component procedure, you can use one of these methods: •

Look up the component name in the list of Component Procedures by system.

See “Component Procedures” on page 7-1.

•

Find the component in the Component Locator Photos. See “Component Locator Photos” on page 7-3.

•

Look up the component name in the Index. See “Index” on page I-1.

• Theory of Operation explains fluid flow within the hydraulic schematics and current flow within the electrical schematics for various conditions of Sideloader operation.

• Appendix contains reference information such as torque values, lubrication specifications, and system schematics.

• Index lists subjects alphabetically.

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How to Use This Manual START Page

START Page How to Use This Manual

START:

Review safety precautions?

1:

What do you want to do?

Yes

Go to Chapter 2 "Safety"

No

Examine specifications?

Yes

Go to Chapter 3 "Systems Overview"

No

Uncrate and assemble Sideloader?

Yes

Go to Chapter 4 "Installation"

No

Perform scheduled maintenance?

Yes

Go to Chapter 5 "Scheduled Maintenance"

No

Go to Chart START-2

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Raymond ® Sideloader Maintenance Manual

How to Use This Manual START Page

START-2

Troubleshoot a problem?

Yes

Go to Chapter 6 "Troubleshooting"

No

Test, inspect, adjust, remove/install a component?

Yes

Go to Chapter 7 "Component Procedures"

Component Locator Photos

No

Find information on theory of operation?

Yes

Go to Chapter 8 "Theory of Operation"

Component Procedures by Lift Truck System

No

Find general reference information?

Yes

Go to the Appendix

No

Locate an object or procedure by name?

1-6

Yes

Go to the Index

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Safety

Safety

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Raymond ® Sideloader Maintenance Manual

Safety Definitions

Definitions Throughout this manual, you will see two kinds of safety reminders:

! WARNING Warning indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.

! CAUTION

Caution indicates a potentially hazardous situation that, if not avoided, could result in minor or moderate injury or in damage to the lift truck or nearby objects. It can also be used to alert against unsafe practices.

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Safety General Safety

General Safety Do NOT operate or work on this lift truck unless you are trained, qualified, and authorized to do so, and have read the Owner/Operator Manual.

28B15004D.EPS

Know the lift truck’s controls and what they do.

22823_001.eps

Do NOT operate this lift truck if it needs repair or if it is in any way unsafe.

22823_002.eps

Operate this lift truck only from the operator’s position.

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Safety

Raymond ® Sideloader Maintenance Manual

General Safety

Before working on this lift truck, always turn the key switch OFF and disconnect the lift truck’s battery connector (unless this manual tells you otherwise).

22823_004.eps

Do NOT wear watches, rings, or jewelry when working on this lift truck.

2jewelry.eps

Follow the scheduled lubrication, maintenance and inspection steps.

2schedmnt.eps

Follow the safety and repair instructions in this manual. Do NOT take “shortcuts.”

28b15008d.eps

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Safety General Safety

Do NOT use an open flame near the lift truck.

22823_005.eps

Do NOT use gasoline or other flammable liquids for cleaning parts.

22823_006.eps

Clean up any hydraulic fluid, oil, or grease that has leaked or spilled on the floor.

2spills.eps

Always operate and park this lift truck indoors.

22823_007.eps

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Safety

Raymond ® Sideloader Maintenance Manual

General Safety

Do NOT wash this lift truck with a hose.

22823_008.eps

Do NOT add to or modify this lift truck until you contact your local authorized Raymond Dealer to receive written manufacturer approval.

22823_009.eps

Do NOT park this lift truck in a cold storage area overnight.

2

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Safety Battery Safety

Battery Safety ! WARNING As a battery is being charged, an explosive gas mixture forms within and around each cell. If the area is not correctly ventilated, this explosive gas can remain in or around the battery for several hours after charging. Be sure there are no open flames or sparks in the charging area. An open flame or spark can ignite this gas, resulting in serious damage or injury.

! WARNING Battery electrolyte is a solution of sulfuric acid and water. Battery acid causes burns. If any electrolyte comes in contact with your clothing or skin, flush the area immediately with cold water. If the solution gets on your face or in your eyes, flush the area with cold water and get medical help immediately.

Read, understand and follow procedures, recommendations, and specifications in the battery and battery charger manufacturer’s manuals.

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Safety

Raymond ® Sideloader Maintenance Manual

Battery Safety

Wear personal protective equipment to protect eyes, face, and skin when testing, handling, or filling batteries. This equipment includes goggles or face shield, rubber gloves (with or without arm shields), and a rubber apron.

225L6S016.eps

Make sure a shower and eyewash station are nearby in case of an accident.

204G6S059.eps

A battery gives off explosive gases. NEVER smoke, use an open flame, or use anything that gives off sparks near a battery.

223L6S012.eps

Keep the charging area well-ventilated to avoid hydrogen gas concentration.

204g6s058.eps

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Safety Battery Safety

Turn the key switch OFF before disconnecting the battery from the lift truck at the battery connector. Do NOT break live circuits at the battery terminals. A spark often occurs at the point where a live circuit is broken.

22823_004.eps

Do NOT lay tools or metal objects on top of the battery. A short circuit or explosion could result.

204g6s057.eps

Keep batteries clean. Corrosion causes shorts to the frame and possibly sparks.

2

Keep plugs, terminals, cables and receptacles in good condition to avoid shorts and sparks.

227Y7S013.tif

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Safety

Raymond ® Sideloader Maintenance Manual

Battery Safety

Vent Hole

Keep filler plugs firmly in position at all times except when the electrolyte level is measured, when water is added to the cells, or when the specific gravity is measured.

Make sure the vent holes in the filler plugs are open to permit the gas to escape from the cells.

209g6s047.tif

Do NOT let cleaning solution, dirt or any foreign matter to enter the cells.

2

Make sure you install the correct size battery. A smaller or lighter weight battery could seriously effect lift truck stability. See the lift truck’s specification plate for more information.

22823_010.eps

NEVER plug a battery charger into the lift truck’s battery connector. Plug the battery charger only into the battery connector from the battery.

22823_011.eps

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Safety Jacking Safety

Jacking Safety You may need to jack the lift truck off the floor to perform maintenance procedures. When doing so, observe the correct safety precautions: 1. Lower the forks completely. Remove any load.

2. Set all controls in neutral.

3. Block the wheels to prevent movement of the vehicle.

4. Turn the key switch OFF and disconnect the battery connector.

5. If possible, stabilize the top of the mast with an overhead chain hoist.

6. Set the jack in the designated jacking area.

See Figure 2-1.

Jack only in these areas

! WARNING Use extreme care when the lift truck is jacked up. Never block the lift truck between the telescopic and the floor. Use a suitable hoist to stabilize the mast. Keep hands and feet clear from vehicle while jacking the lift truck. After the lift truck is jacked, install solid blocks or jack stands beneath it to support it. Do NOT rely on the jack alone to support the lift truck.

2toyrch_t.eps

Figure 2-1:

Correct Jacking Locations

7. Jack the lift truck so that the tires are off the floor no more than 0.5 in. (13 mm).

8. Block the lift truck in position.

NOTE: After working on a vehicle, test all controls and functions to assure correct operation.

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Raymond ® Sideloader Maintenance Manual

Safety Welding Safety

Welding Safety ! WARNING Flame cutting or welding on painted surfaces may produce potentially harmful fumes, smoke and vapors.

Prior to performing flame cutting or welding operations, it is recommended that the coating be removed near where the operation(s) will be performed.

Coating removal may be by mechanical methods, chemical methods or a combination of methods. Flame cutting and/or welding operations must be carried out only in well ventilated areas using local exhaust if necessary.

Before working on this lift truck, make sure that: • Fire protection equipment is nearby.

• You know where the nearest eyewash station is.

! CAUTION

Disconnect the battery before you attempt to inspect, service or repair the lift truck.

204G6S059.eps

• Test for shorts to frame as described on page 6-5. If you detect any shorts, correct them before you proceed with the welding operation.

• Clean the area to be welded.

• Protect all lift truck components from heat, weld spatter and debris.

• Attach the ground cable as close to the weld area as possible.

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Safety Welding Safety

• Disconnect all electrical circuit cards before doing any type of electric resistance welding.

• Do not perform any welding operations near the electrical components.

• If you must do welding near the battery compartment, remove the battery from the lift truck.

• When you are finished welding, re-install circuit cards and perform all ground tests and electrical inspections before operating the lift truck.

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Safety

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Welding Safety

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Raymond ® Sideloader Maintenance Manual

Systems Overview

Systems Overview

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3-1

Raymond ® Sideloader Maintenance Manual

Systems Overview General System Data

General System Data

Telescopic Assembly

Mast Assembly Lift Cylinder Lift Chains Oil Reservoir

Electrical/Hydraulic Compartment

Operator’s Compartment

Auxiliary Fork Carriage (optional) Load Bed

Hydraulic Compartment

Guide Rollers (optional)

Drive Wheels Steer Wheels

3

Figure 3-1:

3-2

Model 71B/76 Sideloader General System Data (shown with optional TF Mast and Auxiliary Fork Carriage)

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Raymond ® Sideloader Maintenance Manual

Systems Overview Mechanical Systems

Mechanical Systems Chassis The chassis includes all those items that provide support, protection or access to vehicle components.

Chassis Frame The chassis frame has a 0.5 in. (13 mm) and 0.75 in. (19.05 mm) formed steel welded into a rigid unit. This unit provides the major support and protection for vehicle components. The operator's compartment and overhead guard are part of the chassis frame and provide protection for the operator. The load beds are an integral part of the chassis frame and contain the rack and roller guides that support the mast assembly.

Battery Compartment The battery compartment, part of the chassis frame, is located behind the mast assembly. Its location adds to the vehicle's stability. The compartment contains rollers to aid in battery changing and a gate to secure the batteries during normal lift truck operation.

Doors and Covers Various doors and covers, are either hinged to or removable from the chassis frame, and provide access to vehicle components. When closed or in place, these doors and covers provide component protection.

Drive Units The two drive units, located on either end of the drive axle, are connected by a tie rod that pivots them together. (See “Crab Steer” on page 3-11.)

Each drive unit includes a drive motor, gear reduction assembly, and drive wheel.

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Systems Overview

Raymond ® Sideloader Maintenance Manual

Drive Motor

Drive Motor The drive motor is a 36-volt, series wound, industrial traction motor. The motor shaft is keyed to a gear in the gear reduction assembly.

Gear Reduction Assembly The gear reduction assembly is an enclosed assembly that provides an overall reduction ratio of 15.75:1. The shafts and gears are continuously splash-lubricated. The final drive shaft is threaded to accept a special mounting nut for the drive wheel.

Drive Wheel The drive wheel has a cast wheel hub and a press-on 15 in. x 8 in. (381 x 203 mm) rubber or poly tire that allows easy, low cost replacement. A special nut and tool are used to mount the drive wheels.

Steering The steering linkage, located on the steer axle, transfers hydraulic force of the steer cylinder to the steerable wheels.

Linkage The steering linkage has two tie rods attached between an intermediate link and the steerable wheels.

Steerable Wheels The steerable wheel has a cast wheel hub and a press-on 15 in. x 8 in. (381 x 203 mm) rubber or poly tire that allows easy, low cost replacement.

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Raymond ® Sideloader Maintenance Manual

Systems Overview Brakes

Brakes Two brake systems, the service brake and the parking brake, are used on the Sideloader.

Although both use the same brake assemblies located on the steerable wheels, the service brake is the primary means of stopping the vehicle. See Figure 3-2.

Parking Brake (Deadman Pedal)

Mast Assembly Components The mast performs the lift, lower, storage and retrieval functions. All Sideloader attachments, Nominal Free Lift (TN), Full Free Lift (TF), or Triple Telescopic (TT), contain the following components:

Mast Assembly

Service Brake Pedal 3

Figure 3-2:

Brakes

The mast assembly is a fixed structural weldment that is mounted between the load beds. The mast varies, depending upon application and customer requirements.

Standard functions of mast traverse and mast tilt are covered in “Hydraulics” on page 3-7.

Telescopic Assemblies The telescopic assemblies are comprised of welded I-beams and cross ties that ride on rollers within the mast assembly. The telescopics are nested within the mast, forming a compact group, providing good visibility.

Carriage Assembly The carriage assembly is a welded unit that engages the load with its forks. The carriage rides on rollers within the inner telescopic. The standard fork tilt and reach functions are covered in “Hydraulics” on page 3-7.

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Mast Assembly Components

Lift Cylinders The lift cylinders correspond with the attachment component types; TN, TF, and TT. • TN - a single cylinder attached between the main frame and telescopic assemblies. It contains a pulley assembly at the top, where the lift chains and hydraulic hoses are routed.

• TF - a welded cluster with one long center cylinder and two short side cylinders. The center cylinder is attached between the main frame and telescopic assemblies. The lift chains are routed over pulleys on top of each side cylinder.

• TT - has two cylinder assemblies; a front cluster, identical to the TF assembly above, and a single back cylinder. The center cylinder of the front cluster is attached between the first and second telescopics, while the back cylinder is attached between the main frame and first telescopic. The lift chains, as with the TF, are routed over pulleys on top of each side cylinder of the front cluster.

Lift Chains The lift chains are anchored between the lift cylinder assembly (front cluster on TT) and the carriage assembly. The chains are routed over the cylinder pulleys, giving the carriage a 2:l lift ratio over the telescopic(s).

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Systems Overview Hydraulics

Hydraulics General The hydraulics fall into three basic categories; lift/lower, auxiliary controls, and steering. All three utilize the same reservoir and return line filter assemblies. The hydraulics contain various manifolds that consolidate the components for ease of service and permit optional manifolds to be added on with little modification.

Reservoir The reservoir is a steel weldment with a 10.25 gallon (38.8 L) capacity. It contains a mesh lift suction strainer, a vented breather/filter cap, a drain, and a removable cover for easy cleaning.

See Figure 3-3.

3

Figure 3-3:

Reservoir

Filter The filter is a screw-on style with a built-in pressure controlled bypass valve. See Figure 3-4.

Check Valve Because the filter is located below the reservoir, a check valve between the filter and reservoir prevents oil from draining out of the reservoir when the filter is removed.

Filter

Check Valve

Lift/Lower The lift/lower system operates at high pressure, up to 3200 psi on the Model 71B and 3300 psi (22753 kpa) on the Model 76 with full capacity loads. The lift/lower system includes the following components:

3

Figure 3-4:

Filter and Check Valve

Lift Pump The lift pump is a manually stroked, variable displacement piston pump. The pump’s output is varied by a slave cylinder that changes the position of the pump's volume control plate when the lift master cylinder is actuated.

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Lift/Lower

Lift Motor The lift motor is a compound-wound, 36-volt motor. It is mounted with the pump on a horizontal bracket that swings out allowing easy inspection, cleaning, and brush replacement. See Figure 3-5.

Lift Control The lift control lever allows the proportional lift of the forks when the handle is pulled back. The farther it is pulled back, the faster the forks will lift.

3

Figure 3-5:

Lift Pump and Motor

Pump Bypass Solenoid The pump bypass solenoid is a normally open solenoid that is closed during lift. Its purpose is to open after lift to allow oil from the lift pump to flow to the reserfoir until the lift pump stops turning.

Lift Check Valve The lift check valve is located between the pump and cylinder. It allows full flow to the cylinder but traps the oil holding the lift position when the pump is shut down.

Lift Cylinders The lift cylinders are single-acting cylinders that are used to lift the forks and telescopics.

Lowering Lock-Out Solenoid The lowering lock-out solenoid is actuated by the deadman switch. With the deadman switch closed, the solenoid is open and allows lowering through the lowering valve. With the deadman switch open, the solenoid is closed and prevents lowering through the lowering valve.

Lowering Valve The lowering valve is a shear-type valve actuated by the lowering lever. The amount of handle actuation determines the flow rate, giving the operator full control of lowering speed. A spring on the control handle returns the handle to the OFF position when released.

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Systems Overview Auxiliary System

Pressure Reliefs A pressure relief is incorporated in the lift/lower system to protect system components from excessive pressure. The relief is set to open when system pressure reaches the valve’s set pressure. The relief diverts lift flow back to the reservoir, eliminating lift.

Auxiliary System The auxiliary system is activated when the deadman pedal is depressed causing the oil to free flow through the control valves and solenoids. The parking brakes and steering operate off auxiliary pressure. The remaining components that make up the auxiliary system are:

Auxiliary Pump The auxiliary pump is a fixed displacement gear pump.

Auxiliary Motor The auxiliary motor is a compound-wound, 36-volt DC motor. It is mounted with the pump on a vertical bracket that swings out allowing for easy inspection, cleaning and brush replacement. See Figure 3-6.

3

Auxiliary Motor

Control Valves The control valves divert the auxiliary flow to the desired function. The amount and direction of handle movement determines the speed and direction of the function. A pressure relief in each valve assembly protects the auxiliary circuits from excessive pressure build-up. An internal spring returns each control handle to neutral when released. See Figure 3-7.

Auxiliary Pump

Figure 3-6:

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Auxiliary Pump and Motor

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Auxiliary System

Flow Limiter

3

The flow limiter is located after the mast tilt valve and reduces flow to and from the mast tilt cylinder to limit tilt speed.

Counterbalance Check Valves The counterbalance check valves are located before the mast traverse motor and the mast tilt cylinder. Pressure from the system allows normal operation but when the valves are in neutral, the oil is trapped in the motor or cylinder. This is provided to prevent the functions from drifting.

Mast Traverse Motor

Figure 3-7:

Control Valves

The mast traverse motor is used to move the mast along the load bed in order to deposit or pick up a load. Oil flow to one side or the other of the motor causes it to turn in a specific direction. This turns the gear attached to its shaft and traverses the mast along the load bed racks.

Double-acting Cylinders Double-acting cylinders are used for steering, mast tilt, fork tilt, and reach. Oil flow in one end or the other causes the cylinders to extend or retract.

Aux (System Pressure) Relief In addition to various component’s pressure relief, there is an auxiliary pressure relief that opens when excessive pressures build up. This diverts the pumps flow directly back to the reservoir.

Heat Sinks Heat sinks for the SCR's and rectifiers are located in the auxiliary return line. These help dissipate heat built-up by these components.

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Systems Overview Steering

Steering The truck incorporates two separate steering systems. Both steering systems operate off the auxiliary hydraulics. The steerable wheels located under the operator compartment are operated through the steering wheel, while crab steering located under the load bed is operated through buttons on the directional/speed control handle. The steering assemblies have the following components:

3

Orbitrol The orbitrol is operated through a chain assembly attached to the steering wheel. When rotated, the orbitrol directs oil flow to one end or the other of the steering cylinder. The direction of rotation determines the steering direction. See Figure 3-8.

Figure 3-8:

Steering Orbitrol

Crab Steer Depressing the left or right crab steer button activates its respective solenoid, directing auxiliary hydraulic flow to the crab steer cylinder. When the center button is depressed, the circuit is completed to the necessary solenoid. Auxiliary flow is directed to the crab steer cylinder until it is centered, then the circuit is disrupted. Indicator lights in the operator's compartment show relative position of crab steering.

Steer Cylinders Both steering cylinders are double-acting types.

Oil flow in one end forces oil flow out the other end causing the cylinder to extend or retract.

Pressure Reliefs Each steering system contains an individual pressure relief to protect the system from excessive pressure build-up.

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Electrical

Electrical General The electrical systems fall into three basic categories; travel, miscellaneous, and options.

The following are general components used by most of the various electrical circuits:

Batteries Two 18-volt batteries connected in series supply power for all electrical circuits. The battery connectors are attached to a emergency disconnect handle that allows the operator to easily remove all vehicle power in an emergency.

Fuses The following fuses are used; • FU1 - This 400 amp fuse protects the travel power circuit.

• FU2 - This 600 amp fuse protects the lift power circuit.

• FU3 - This 150 amp fuse protects the auxiliary power circuit.

• FU5 - This 15 amp fuse protects the B+ end of the entire control circuit.

• FU6 - This 15 amp fuse protects the B- end of the entire control circuit.

Key Switch The key switch is a two-position (ON/OFF) switch that supplies power to all the control circuits. An optional three-position switch is used when the remote control option is ordered.

Deadman Switch The deadman switch, actuated by the deadman pedal, supplies power to the travel, lift, and auxiliary control circuits.

Travel The travel system has the following:

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Systems Overview Travel

Directional/Speed Control Assembly The directional/speed control assembly regulates travel direction and speed. Pulling the handle toward the operator provides reverse travel. Pushing the handle away from the operator provides forward travel.

Potentiometer (VR1) The potentiometer (VR1) on the directional/speed control assembly regulates current to the Control Unit, and therefore, the speed in SCR range. The greater the handle movement in either direction, the faster the vehicle speed.

Speed Limit Module The speed limit module works in conjunction with the limit circuits in the control unit to limit travel speeds under various modes of operation.

Elevated heights and mast traverse position effect the speed limit module. The module contains two speed limits. One is fixed at approximately l/2 full SCR speed. The other is adjustable, but generally set at l/8 speed.

Equalizing Time Delay Because of the need to parallel the motor armatures during initial travel and plugging, an equalizing time delay is added. It senses the activation of either directional control and momentarily keeps the equalizing contactor closed.

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Contactors

Contactors The contactors used in the travel system are: • F and R - The forward and reverse contactors are a dual pole, dual throw design. Activating the directional contactor determines the current path through the drive motors and thus, the direction of travel.

• M - The M speed contactor is a single pole, single throw design with normally open tips. Activating the M contactor bypasses the SCR circuitry, therefore allowing high speed travel.

• 1S - The 1S equalizing contactor is a single pole, single throw design with normally closed tips and a normally open interlock switch. The contactor is closed, paralleling the armatures, as the truck first starts to travel and during plugging. During travel, the contacts open. The interlock prevents plugging if the contactor malfunctions.

Silicon Controlled Rectifiers (SCRs) Disc type SCRs used in the travel system are: • SCR1 - the main SCR directly controls vehicle speed. The more frequently SCR1 is turned on and the longer it stays on, the greater the vehicle speed.

• SCR3 - the charging SCR turns on with SCR1. When on, SCR3 provides a current path through the capacitors, thereby charging the capacitors when SCR1 is on.

• SCR2 - the commutating SCR is turned ON alternately with SCR1 and SCR3. When SCR2 is turned ON a current path is provided through the capacitors, creating a no-flow condition through SCR1, thereby turning SCR1 off.

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Systems Overview Contactors

Rectifiers The disc type rectifiers used are: • REC1 - recirculating rectifier directs drive motor current flow back through the drive motors when SCR1 is turned OFF. Recirculating motor generated current back through the motors smooths out the overall performance and increases vehicle efficiency.

• REC2 and REC3 - allow electrical flow through the plugging relays K1 and K2 during plugging.

Plugging Relays K1 and K2, reduce the frequency output of the control unit to SCR1 during plugging. This limits high current build-up that could cause damage to the motors.

Transformer With SCR1 ON, current flows through the primary windings of the T1 transformer inducing a current flow through its secondary windings in conjunction with SCR3. The secondary current flow charges the capacitors in the necessary polarity for vehicle operation.

Capacitors Charging and discharging of the C1 and C2 capacitors provides the necessary current flow for turning SCR1 OFF.

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Control Unit

Control Unit A self-contained unit that contains the electronic circuitry that controls the travel system. The control unit includes: • Auxiliary Circuit Card - provides F, R, and M contactor time delay and suppression/protection circuitry • Variable Pulse Generator Card (VPG) controls SCR turn on/off, pulse width and frequency oscillation, current limiting, creep speed adjustment, plugging, and speed limits • Power Driver Circuit Card - amplifies the signals received from the oscillator circuits of the VPG Card and sends them to the gate lead of the respective SCRs.

Miscellaneous Horn Activated by the horn button, located on top of the directional/speed control handle, the horn can be sounded when the key switch is ON.

Hour Meter Located on the side compartment cover below the lift and lower levers, the hour meter provides an accurate record of elapsed time that the key switch is ON while the deadman pedal is depressed.

Battery Controller The battery controller monitors battery voltage and provides a visual cue to the operator when voltage is low. When a low battery voltage condition occurs, the battery controller disables the lift function, leaving enough battery voltage to return to the charging area. The batteries must be recharged before further use.

Load Reducing Relays K12 (Deadman) and K13 (Light Load) relays are added to reduce the load through the key switch. K12 will energize after the deadman pedal is depressed, and K13 will engage when the key switch is turned ON.

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Systems Overview Options

Options Auxiliary Fork Carriage The auxiliary fork carriage is used for handling extra long or flexible loads. It provides two additional forks outside the load bed that fold up, out of the way hydraulically, when not in use. The assembly hangs on an extended fork bar and can be easily removed. See Figure 3-9.

Guide Rollers Guide rollers are used in conjunction with guide rails to align and direct the vehicle along an aisle. The guide rollers are mounted at each corner of the chassis frame between 5 in. (127 mm) and 11.5 in. (292 mm) from the floor, depending upon application. If necessary, the guide rollers can be easily removed or replaced.

3

Figure 3-9:

Auxiliary Fork Carriage

Hydraulic Fork Positioning Hydraulic fork positioning permit the operator to adjust the forks from the operator compartment.

Load Weight Indicator The load weight indicator is plumbed into the lift system and converts the system pressure to a scale in pounds. This allows on the spot weight indication. See Figure 3-10.

Ranger ® Shelf Height Selector The Ranger shelf height selector is a microprocessor-controlled device used for precise positioning of the lift forks. The Ranger has a built in memory capable of storing up to 99 different shelf levels and positioning the forks at any one of them on command.

Designed for greater productivity and control in high density storage operations, the Ranger provides an operator with a means of quickly, accurately, and automatically positioning forks at heights where visibility and depth perception require assistance. Refer to Special Supplement Manual SS-10 for further information.

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Figure 3-10: Load Weight Indicator

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Options

Remote Lift/Lower This option provides a modification to the standard carriage for the remote lift/lower controls. An approved add-on platform that mounts on the standard forks is required. The operator must travel to the desired position, turn the key switch to the remote position, then mount the platform to lift and lower the carriage. The only other control at the carriage is the power disconnect.

Miscellaneous Other options that are available include various lights (working, warning, and back-up), and cold storage conditioning.

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Installation

Installation

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Raymond ® Sideloader Maintenance Manual

Installation General

General Because of its size, the Raymond Sideloader is shipped in two sections; the tractor and the mast. Follow “Chassis Frame”, “Visual Inspection”, and “Mast to Tractor Reassembly” instructions to assure correct installation of the truck.

Chassis Frame Besides the tractor and mast assemblies, other components are also removed and packed separately for protection during shipping. These will be attached to either the tractor or mast.

1. Put the tractor, mast and all tools and equipment required in an area suitable for completing the job.

! WARNING Do NOT cut the band securing the carriage to the mast until after the mast is installed. See “Mast to Tractor Reassembly” on page 4-4.

2. Remove all the individual components and packing boxes attached to the tractor or mast.

Examine the items to be sure all required components are included.

NOTE: Use a sufficient hoist or lifting mechanism, rated at a minimum of five ton capacity, to remove the larger items such as the auxiliary fork carriage, packing boxes, batteries (if shipped with vehicle), forks, and so on.

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Installation Visual Inspection

Visual Inspection When a vehicle is received, it must be visually examined for damage that may have occurred in transit. Use the checklist listed in Table 4-1 and do a visual inspection of the truck.

Table 4-1: Visual Inspection

Item

Examine for...

Wheels/Tires

Chips or cracks

Wiring

Damaged insulation, loose connections

Hoses

Physical damage, leaky connections

Chassis

Any dents or scrapes that may hinder operation

Other components

Any physical damage that may hinder operation

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Installation Mast to Tractor Reassembly

Mast to Tractor Reassembly A 4 to 5-ton hoist (or alternate means of lifting) is required to lift the mast on the tractor.

Mast Traverse Stop

1. Remove the mast traverse stops. See Figure 4-1.

2. Move the hoist over the mast. Sling the hoist to the top of the mast.

3. Raise the mast vertically off the floor approximately 12 to15 in. (300 to 380 mm).

Move the tractor into position.

4. Position the mast between the load beds.

4

Figure 4-1:

5. Disconnect the two hydraulic hoses from the mast traverse motor so that the mast traverse gear shaft can be turned freely. See Figure 4-2.

Mast Traverse Stops

Mast Traverse Motor

6. Make sure the mast is square to the tractor, then roll the mast in towards the tractor until the traverse gears engage a couple teeth on the gear rack. Use a large pipe wrench on the mast traverse gear shaft to aid in engaging the traverse gears into the gear rack.

4

Figure 4-2:

7. Measure between the inner tractor frame and the bottom of the mast ears (see Figure 4-3 and Figure 4-4). The two sides must be equal to within 0.125 in. (3.2 mm).

If they are not, roll the mast out away from the tractor until the mast traverse gears are disengaged from the gear racks and repeat step 6.

Mast Traverse Motor

.

See Figure 4-4

Inner Tractor Frame

4

Figure 4-3:

4-4

Measure Distance Between Tractor Frame and Mast

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Installation Mast to Tractor Reassembly

8. Reconnect the two mast traverse motor hydraulic hoses.

Mast Ear

4

Figure 4-4:

Measure Point

Figure 4-5:

Adjust Eccentrics

9. Adjust the eccentrics. See Figure 4-5. a. Loosen the two locking nuts. b. Tighten the eccentric, then back off 1/8 turn. c. Tighten the two locking nuts. d. Repeat steps 9a. thru 9c. on the opposite side.

10. Connect all hydraulic and electrical lines.

Hydraulic and electrical lines are coded for ease of identification.

4

11. Traverse the mast in (toward the tractor) all the way. Examine the position of the mast ears against the tractor frame on the two sides. See Figure 4-6. If they are even, proceed to step 12. If they are not, adjust the gear rack adjacent to the steer axle as follows:

Mast Ear

a. Loosen the gear rack mounting bolts.

Tractor Frame

4

Figure 4-6:

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Mast to Tractor Reassembly b. Adjust the rack in the necessary direction, using the gear rack adjuster.

See Figure 4-7.

Gear Rack Adjuster

c. Tighten the adjuster nuts. Apply thread-locking compound P/N 990-536 to the gear rack mounting bolts and tighten. d. Reexamine the position of the mast ears against the tractor frame.

12. Install the two mast traverse stops. Make sure they are adjusted evenly.

13. Remove the strap securing the mast.

4

Figure 4-7:

Gear Rack Adjustment

14. Mount the forks by sliding the fork bar adequately to one side to insert one fork, then to the other side to insert the other fork. Center the fork bar and install the set screw. On the Model 71B, insert the fork pins.

15. Mount all additional components that have been removed and packaged separately.

Refer to specific maintenance instructions applicable to each component.

16. Refer to the batteries and charger installation and perform those procedures.

17. Because the mast was removed, each lift cylinder must be bled as follows: a. Elevate the carriage until the forks are approximately 2 ft (610 mm) above the floor. b. Loosen (do not remove) the round head bleed screw in the top of the cylinder to permit air to escape. c. When a steady stream of fluid flows from the screw, retighten the screw.

18. Measure all fluid levels.

19. See “Maintenance Guidelines” on page 5-2.

Perform all the items in the Daily Checklist.

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Installation Batteries and Chargers

Batteries and Chargers Install the battery charger in accordance with the manufacturer’s instructions. Make sure operation of the charger is thoroughly understood before attempting to recharge the batteries. Battery life can be considerably shortened by incorrect recharging procedures.

NOTE: Because the Sideloader uses two 18-volt batteries in series to develop the 36-volt DC operating voltage, the batteries must be charged in series with a 36-volt charger.

Battery Installation 1. Remove the battery gate and shipping batteries. Carefully slide the regular batteries into the vehicle. Reinstall and adjust the battery gate.

2. Make sure the battery posts and cable connectors are clean.

3. Make sure the batteries are adequately charged before operating the vehicle.

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Battery Installation

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Scheduled Maintenance

Scheduled Maintenance

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Scheduled Maintenance Maintenance Guidelines

Maintenance Guidelines Following a regularly scheduled maintenance program: • Promotes maximum truck performance • Prolongs maximum truck life • Reduces costly down time • Avoids unnecessary repairs Scheduled maintenance includes: • Lubrication • Cleaning • Inspection • Service Perform all of the scheduled checks and maintenance at the suggested intervals. The time intervals given in this guide are based on deadman hours under normal operating conditions. When operating under severe or extreme conditions, perform these services more often as indicated in Table 5-1.

Table 5-1: Working Environments

Type of Service

Working Environment

Service Frequency

Moderate

An eight hour day of basic material handling

30 days or 250 hours, whichever is less

Severe

Extended operating hours or constant use

175 hours

Extreme

All EE rated lift trucks Dusty or sandy conditions: for example, cement plant, lumber or flour mills, coal dust or stone-crushing areas High temperature areas: for example, steel mills, foundries, enclosed (EE) applications Sudden temperature changes: for example, freezer to room temperature Corrosive atmosphere: for example, chlorine, salt-sea air

100 hours

For lubricant and lubricating fluid information, see "Lubrication Specification Chart" on page A-2.

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Scheduled Maintenance Monthly Maintenance

Monthly Maintenance Perform the checks listed in Table 5-2 monthly or every 250 operating hours, whichever comes first.

Table 5-2: Monthly Checklist

Perform all Daily/8-Hour Checks plus the following: *Item No.

Component

Monthly/250-Hour Checks Examine for proper charge, voltage, weight, leakage, cleanliness, proper installation. See “Batteries” on page 7-83.

Examine for proper gate installation and Emergency Disconnect operation.

Examine battery connector for wear, solid electrical connections.

1

Batteries

2

Control Functions

Examine for correct operation of all vehicle control functions.

Cylinders Lift, Tilt, Steer and Reach

Examine for leaks.

3

4

Decals/Warning Labels

Examine for damaged or illegible decals. Clean or replace as necessary.

5

Hoses/Cables

Examine for leaks or wear.

6

Tires

Examine for gouges, chunking, flat spots, bond failure

7

Contactors

Examine for burned, badly eroded or welded tips. See “Tip Inspection” on page 7-88.

Drive Units

Measure fluid level. Fluid must be level with bottom of plug hole. If low, add proper fluid. See “Lubrication Specification Chart” on page A-2. Examine for leaky seals.

9

Parking Brake (Deadman) Actuator

Examine brake for proper parking operation.

Make sure that brake releases completely when deadman pedal is depressed.

10

Motors

Examine for proper brush length and spring tension. See “Brushes” on page 7-14. Examine for cleanliness.

11

Hydraulic Reservoir

Measure fluid level. Fluid must be 1 1/2 in. (38.1 mm) from top with carriage lowered and mast retracted. If low, add proper fluid. See “Lubrication Specification Chart” on page A-2.

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Monthly Maintenance Table 5-2: Monthly Checklist

Perform all Daily/8-Hour Checks plus the following: *Item No.

Component

Monthly/250-Hour Checks

12

Service Brake Master Cylinder

Measure fluid level. Fluid must be 1/2 in. (13 mm) from top. If low, add proper fluid. See “Lubrication Specification Chart” on page A-2. Examine for leaks. Repair or replace components as necessary.

13

Lift Master Cylinder

Measure fluid level. Fluid must be 1/2 in. (13 mm) from top. If low, add proper fluid. See “Lubrication Specification Chart” on page A-2. Examine for leaks. Repair or replace components as necessary.

14

Steer Axle Assembly

Lubricate all grease fittings on king pins, tie rods and steer cylinder.

15

Drive Axle Assembly

Lubricate all grease fittings on king pins, tie rod and steer cylinder.

17

Parking Brake (Deadman) Actuator

Examine for proper operation. Adjust or repair as necessary.

See “Parking Brake Adjustment” on page 7-51.

Steering Chain

Measure tension and adjust as necessary. See “Steering Chain Adjustment” on page 7-48. Lubricate.

19

Mast Traverse Drive

Lubricate grease fittings on top rollers and drive shaft.

20

Mast Traverse Rack, Gears and Rollers

Clean and lubricate with grease. See “Lubrication Specification Chart” on page A-2.

21

Mast Channels and Roller Ways

Clean and lubricate with grease. See “Lubrication Specification Chart” on page A-2.

21

Chassis/Mast

Verify all guards/covers installed.

23

Electrical Wiring

Examine for loose or broken connections. Repair or tighten as necessary. Clean or replace worn or oil soaked harnesses.

24

Limit Switches

Verify that they control the assigned function.

25

Service Brake

Examine brake for proper stopping action; stops truck within recommended distance of six feet. Minimum brake pad thickness is 3/32 in. (2.3 mm). Adjust linkage as necessary.

Lubricate grease fitting on pivot shaft.

26

Control Linkages (Lift, Lower and Auxiliary)

Examine for smooth operation. Clean and lubricate as necessary.

28

Floor Mats and Pads

Replace worn mats or pads.

18

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Scheduled Maintenance Monthly Maintenance

Table 5-2: Monthly Checklist

Perform all Daily/8-Hour Checks plus the following: *Item No.

Component

Monthly/250-Hour Checks

30

Wheels

Examine for wheel and bearing wear.

32

Lights (Optional)

Examine operation. Replace bulbs as necessary.

33

Forks

Measure heel thickness. Forks must not be bent or modified.

34

Horn

Sounds when activated.

Ventilation Slots

Ensure that the slots are free of obstructions.

All other components and hardware

Examine for looseness or damage.

Fire Extinguisher (Optional)

Measure charge. Replace if charge is low.

*See “Lubrication and Inspection Points” on page 5-8.

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Scheduled Maintenance Semi-Annual Maintenance

Semi-Annual Maintenance Perform the checks listed in Table 5-3 semi-annually or every 1000 operating hours, whichever comes first.

Table 5-3: Semi-Annual Checklist

Perform all Monthly/250-Hour Checks (including Daily checks) plus the following: *Item No.

Component

Semi-Annual/1000-Hour Checks

8

Drive Units

Change oil. Drain case and refill with correct lubricant.

22

Lift Chains

Examine for wear and elongation. Repair or replace faulty chains. See “Lift Chain Repair and Replacement” on page 7-62.

Drive and Steerable Wheels

Repack wheel bearings.

27 29

Oil Filter

Replace oil filter cartridge.

Door Hinges

Examine for smooth operation. Clean and lubricate as necessary.

31

*See “Lubrication and Inspection Points” on page 5-8.

5-6

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Raymond ® Sideloader Maintenance Manual

Scheduled Maintenance Annual Maintenance

Annual Maintenance Perform the checks listed in Table 5-4 annually or every 2000 operating hours, whichever comes first.

Table 5-4: Annual Checklist

Perform all Monthly/250-Hour and Semi-Annual/1000-Hour checks plus the following: *Item No. 11

Component Hydraulic Reservoir

Annual/2000-Hour Checks Change oil. Drain and refill with correct lubricant.

*See “Lubrication and Inspection Points” on page 5-8.

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5-7

Raymond ® Sideloader Maintenance Manual

Scheduled Maintenance Lubrication and Inspection Points

Lubrication and Inspection Points NOTE: The numbered arrows in the photos on the following pages refer to item number in the preceding scheduled maintenance charts.

21 32

3 5

11

4

22 31

33 6

6

53292_034.TIF

Figure 5-1:

5-8

Lubrication and Inspection Points

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Scheduled Maintenance Lubrication and Inspection Points

1

1

4

2 2 4

9

28 2

25

53292_027.TIF

Figure 5-2:

Lubrication and Inspection Points - Operator’s Compartment

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Raymond ® Sideloader Maintenance Manual

Scheduled Maintenance Lubrication and Inspection Points

26

5

24

53292_027.TIF

Figure 5-3:

Lubrication and Inspection Points - Steer End Hydraulic Compartment

20

19

5

3

5

Figure 5-4:

5-10

Lubrication and Inspection Points - Elevating Section Extended

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Scheduled Maintenance Lubrication and Inspection Points

2

18

13 23

5 53292_010.TIF

Figure 5-5:

Lubrication and Inspection Points - Operator’s Compartment (cover removed)

7

7

34

29 10

10

5P5180009.TIF

Figure 5-6:

Lubrication and Inspection Points - Drive End Electrical/Hydraulic Compartment

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Raymond ® Sideloader Maintenance Manual

Scheduled Maintenance Lubrication and Inspection Points

10

6, 30

8

3 15

5P5180009.TIF

Figure 5-7:

Lubrication and Inspection Points - Drive Axle

17

27

3

6, 30

14

Figure 5-8:

5-12

Lubrication and Inspection Points - Steer Axle

5

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Troubleshooting

Troubleshooting

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6:

6-1

Troubleshooting

Raymond ® Sideloader Maintenance Manual

Overview

Overview It is important when you troubleshoot truck problems to: • Use a logical, common sense approach • Start with the simplest solution and work towards the most complex.

The following procedure will aid in developing a logical and systematic troubleshooting procedure: 1. Verify the problems: •

Obtain as much information as you can about the problem

•

Determine, if possible, what the truck's performance was before the problem began

•

Review any records kept about the truck's performance

•

Operate the truck yourself to verify the problem

2. Find the truck problem area: •

Open the various truck compartment doors and visually inspect the systems, then consult the hydraulic, electrical, and mechanical maintenance sections for general information that may save you time.

•

Determine if the problem is in the control circuit or the power circuit if there is no obvious physical problem.

3. Establish a logical testing sequence:

6-2

•

Use the schematic diagram. Start at the battery and establish a sequence of testing points to find the problem. Use the schematic in conjunction with the appropriate Flow Diagram.

•

Establish test points that indicate that all components between any new test point and the battery are good.

•

Avoid haphazard checking that provides inconclusive results.

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Troubleshooting Overview

4. Use the Troubleshooting Flow Diagrams: •

Consult the “List of Troubleshooting Charts” on page 6-11.

•

Follow the appropriate Flow Diagram from the start to where the probable cause is isolated.

5. Identify the cause of the problem: •

Check for incorrect truck usage.

•

Bring the problem to the service manager's attention to avoid repetition of the cause.

6. Correct the problem: •

Repair or replace bad components following instructions in the Component Procedures section of this manual.

•

Comply with appropriate safety procedures.

! WARNING Use extreme care when the lift truck is jacked up. Never block the lift truck between the telescopic and the floor. Use a suitable hoist to stabilize the mast. Keep hands and feet clear from vehicle while jacking the lift truck. After the lift truck is jacked, put solid blocks or jack stands beneath it to support it. Do NOT rely on the jack alone to support the lift truck. See “Jacking Safety” on page 2-11.

! CAUTION

Disconnect the batteries when measuring electrical circuits with an ohmmeter. Battery current can cause damage to the ohmmeter.

NOTE: Use the electrical schematic, hydraulic schematic, and wiring diagram (found in the Appendix) when troubleshooting.

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Troubleshooting

Raymond ® Sideloader Maintenance Manual

General Instructions

General Instructions Save time and trouble; look for simple causes first.

Wiring Inspection Visually inspect all wiring in all compartments for: • Broken wiring or shorted conditions (especially close to metal edges or surfaces) • Loose connections • Loose or broken terminals • Damaged terminal blocks Use an ohmmeter to measure wiring continuity.

Clean, repair or replace the wiring wherever a problem exists.

! CAUTION

Capacitors C1 and C2 are potentially dangerous. Avoid contact (either directly or through uninsulated tools) with capacitor's terminals or wiring until the capacitors have been fully discharged. To discharge the capacitors, carefully hold the insulated handle of a screwdriver and install the metal blade across the bus bars on the capacitors. Each time work is to be done on the circuit, the capacitors must be discharged if the circuit has been energized since last discharging.

6-4

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Raymond ® Sideloader Maintenance Manual

Troubleshooting Shorts to Frame

Shorts to Frame “Shorts to frame” is an industry term for unintentional current leakage paths between normally isolated electrical circuits and their metal enclosures.

Shorts to frame may be metallic connections, such as a wire conductor contacting metal through worn insulation. More often, shorts to frame are resistive “leakage” paths caused by contamination and/or moisture.

These leakage paths can result in unwanted electrical noise on the metallic lift truck structure, and may result in incorrect operation.

Shorts to frame can be caused by: • Accumulation of dirt • Battery electrolyte leakage • Motor brush dust • Motor brush leads touching the housing • Breakdown in insulation • Bare wires • Pinched wiring harness • Incorrect mounting of circuit cards Shorts to frame can occur at numerous locations on a lift truck, including: • Batteries • Motors • Cables, wiring, and harnesses • Heat sinks • Bus bars • Solenoids • Contactors • Terminal strips • Switches • Power panel insulation • Circuit card mounts

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Troubleshooting

Raymond ® Sideloader Maintenance Manual

Shorts to Frame To test for shorts to frame: 1. Turn the key switch OFF and disconnect the battery connector.

2. To test the battery for shorts to case, connect a 12V test light to the battery case from battery B+, and then to the battery case from battery B-. If the light lights at all, even momentarily, there is a serious problem with the battery, either external contamination or internal damage. Do NOT continue until this condition is corrected.

Your meter may be damaged if you proceed before correcting this condition.

Install another battery in the lift truck and repeat this procedure from step 1.

If the test light does not light, continue to the next step.

3. With the battery disconnected from the lift truck, use a digital volt/ohm/ammeter on the ampere function to measure the leakage current from the battery case to battery B+ and from the battery case to battery B-.

Start measuring at the highest ampere scale and work toward the lowest. A reading of more than 0.001A (1mA) indicates a serious short. Do NOT continue until this condition is corrected. Your meter may be damaged if you proceed before correcting this condition.

Install another battery in the lift truck and repeat this procedure from step 1.

If the current is less than 0.0002A (0.2mA), go to step 4. If the current is greater than 0.0002A (0.2mA) and less than 0.001A (1mA), remove the battery from the lift truck, then continue with step 4. Ensure the battery case does not touch the lift truck frame during the remaining tests.

4. With the battery disconnected (or removed and disconnected) from the lift truck, use a digital ohmmeter to measure the resistance from lift truck frame to truck B+, to truck B- (NOT battery B+ and B-), and to all fuses and motors. A reading of less than 1000 ohms indicates a serious short. Do NOT continue until this condition is corrected.

Your meter may be damaged if you proceed before correcting this condition.

6-6

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Troubleshooting Shorts to Frame

a. To identify the cause of the short to frame, disconnect circuit components until the low resistance condition disappears. Do NOT reconnect components one at a time, but leave them disconnected until the low resistance reading disappears. Prevent disconnected terminals or connectors from touching lift truck frame or other conductive surfaces. b. The most likely areas to examine are: • Motors • Heat sinks • Power cables • Power circuit components • Control circuit components c. Repair or replace the component causing the low resistance condition, Then repeat Step 4. d. Reconnect all other components previously disconnected, one at a time, measuring resistance between steps. If a reading is less than 1000 ohms when reconnecting a component, that component or its wiring is bad; repair or replace as appropriate. e. When, after all components are reconnected, you get readings greater than 1000 ohms, continue with the next step.

5. Reconnect the battery connector to the lift truck and turn the key switch ON. If the battery was previously removed, ensure the battery case does not touch the lift truck frame.

6. Use a volt/ohm/ammeter on the current function to measure leakage current to the lift truck frame from B+, B-, and all fuses and motor terminals. Start measuring at the highest ampere scale and work toward the lowest. If the current is less than 0.001A (1mA), go to step 7. If the current is more than 0.001A (1mA), continue to the steps below. a. To identify the cause of the short to frame, disconnect circuit components until the leakage current reads less than 0.001A (1mA). Do NOT reconnect

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Troubleshooting

Raymond ® Sideloader Maintenance Manual

Shorts to Frame components one at a time, but leave them disconnected until the leakage current reads less than 0.001A (1mA).

Prevent disconnected terminals or connectors from touching lift truck frame or other conductive surfaces. b. The most likely areas to examine are: • Motors • Heat sinks • Power cables • Power circuit components • Control circuit components c. Repair or replace the component(s) causing the leakage current.

Repeat step 6. d. Reconnect all other components previously disconnected, measuring current between steps. If a reading is more than 0.001A (1mA) when reconnecting a component, that component or its wiring is bad.

Repair/replace as appropriate.

7. When, after all components are reconnected, you get a reading less than 0.001A (1mA) there is no short to frame condition with the lift truck or the battery.

If you previously removed the battery from the lift truck, re-install the battery.

6-8

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Raymond ® Sideloader Maintenance Manual

Troubleshooting Troubleshooting Preparation

Troubleshooting Preparation If a truck problem can not be found in the wiring or a shorted-to-frame condition, troubleshoot in accordance with the Flow Charts.

! WARNING Use extreme care when the lift truck is jacked up. Never block the lift truck between the telescopic and the floor. Use a suitable hoist to stabilize the mast. Keep hands and feet clear from vehicle while jacking the lift truck. After the lift truck is jacked, install solid blocks or jack stands beneath it to support it. Do NOT rely on the jack alone to support the lift truck. See “Jacking Safety” on page 2-11.

• Determine what operation(s) the truck is failing to perform. To accomplish this, it is often advisable to jack up and block the truck so the drive wheels are off the floor.

• Operate all the truck's functions slowly, observing during what sequence the truck malfunctions. See “Troubleshooting Procedure” on page 6-13.

• Perform the checks in the appropriate Flowchart.

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6-9

Troubleshooting

Raymond ® Sideloader Maintenance Manual

Troubleshooting Preparation

6-10

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Raymond ® Sideloader Maintenance Manual

Troubleshooting List of Troubleshooting Charts

List of Troubleshooting Charts

6: Troubleshooting

Standard Mode T1: Truck Completely Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 T-2A: Truck Has No Travel - All Other Circuits Function. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 A: F or R and M contactors are NOT activated; 1S is activated . . . . . . . . . . . . . . . . . 6-19 T-2B: Truck Has No Travel - All Other Circuits Function . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 B: F or R contactors are activated then drop out; M and 1S are activated . . . . . . . . 6-20 T-2C: Truck Has No Travel - All Other Circuits Function . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 C: F or R contactors and 1S contactors are activated; M is NOT activated . . . . . . . . 6-21 T-2D: Truck Has No Travel - All Other Circuits Function . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 D: F or R contactors are NOT activated; M and 1S are activated . . . . . . . . . . . . . . . 6-22 T-3: Truck Has No Forward Travel - Reverse Travel Operative . . . . . . . . . . . . . . . . . . . . . . . 6-23 T-4: Truck Has No Reverse Travel - Forward Travel Operative . . . . . . . . . . . . . . . . . . . . . . . 6-24 T-5: Truck Has No M Speed - SCR Range Operative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 T-6: Truck Speed Is Slow In SCR Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26 T-7: Truck Runs In Top Speed Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27 T-8: Truck Acceleration Is Jerky In SCR Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 T-9: Truck Reacts Violently When Plugged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 T-10: Truck Acceleration Is Jerky Between SCR And M Speed . . . . . . . . . . . . . . . . . . . . . . 6-30 T-11: Truck Travels On One Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 T-12: Truck Overload Kicks Out During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32 A: F or R contactors open during routine travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 B: Travel is halted during plugging sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 C: Truck stalls while operating under a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 T-13: Truck Has No Lift - All Other Functions Operative . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 T-14: Remote Lift/Lower Function Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 T-15: Auxiliary And Steering Systems Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 T-16: Crab Steering Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 T-17: Horn Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

Remote Mode T18: Remote Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 T18A: Remote Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43 T18B: Remote Travel Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44 T18C: Remote Forward Travel Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45 T18D: Remote Reverse Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46

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6-11

T18E: Remote M Speed Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47 T18F: Remote Erratic Travel Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48 T18G: Remote Lift Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 G: Lift Function Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 T18H: Remote Lower Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50 H: Lower Function Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50 T18I: Remote Mode Horn Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50 I: Horn Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

Raymond ® Sideloader Maintenance Manual

Troubleshooting Troubleshooting Procedure

Troubleshooting Procedure Troubleshooting

6:

T1: Truck Completely Inoperative

T-1: TRUCK COMPLETELY INOPERATIVE

Is battery voltage 18V for each battery ?

No

No

Check batteries and charger. See Component Procedures section.

Repair or replace faulty battery or charger.

Yes

Yes

Is B+ present at Fuse FU5-1 wrt FU6-1

Does charging bring battery to proper voltage level ?

Repair or replace wiring.

No

Yes

Remove fuses FU5 & FU6 and check for continuity. Does continuity exist in both ?

No

Go to Chart T-1-1

Yes

Is circuit open on keyswitch between S1-1 & S1-2 when OFF and continuity when ON ?

No

Replace switch.

Yes

Check wiring for shorts or grounds and repair as necessary.

6TS1A.WMF

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Raymond ® Sideloader Maintenance Manual

Troubleshooting Troubleshooting Procedure

T-1-1 Turn keyswitch ON.

Replace blown fuse(s) and connect battery.

Does a fuse blow ?

No

Turn S1 OFF. Replace blown fuse and disconnect plug to the control unit.

Turn S1 ON.

Does a fuse blow ?

Does a fuse blow ?

Check horn and SUP3. Replace faulty components.

Does a fuse blow ?

No

Yes

Check relay K11 and DA6.

No Replace faulty components.

Yes

Replace fuse and disconnect lead BC-1.

Activate crab steer center switch S30.

No

Yes

Yes

No

Does a fuse blow ?

Activate horn S3.

Replace control unit or a defective card.

Activate crab left switch S28.

Yes

Does a fuse blow ?

No Yes

Yes

Do contact tips on K12 and K13 check OK?

No

Replace faulty relay(s).

Check K5,DA8. If OK, replace the battery controller.

Turn S1 OFF. Replace blown fuse and disconnect lead from TS1-11 at K13-9.

Turn S1 ON.

Does a fuse blow ?

Does a fuse blow ?

No

Check warning light, working lights and switch S6. Repair or replace faulty components.

Yes

No

Yes

Check solenoid SOL2 and DA2.

Replace faulty components.

Activate crab right switch S29.

Consult Factory Does a fuse blow ?

Yes

Check solenoid SOL1 and DA2.

Replace faulty components.

No

Go to Chart T-1-3 if remote lift/lower is used. If not, go to Chart T-1-4.

6TS1A.WMF

6-14

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Troubleshooting Troubleshooting Procedure

T-1-3

Turn S1 to RMT and close remote start switch S31.

Does a fuse blow ?

Yes

Check PC contactor coil, DA5 and switches S21 and S27. Repair or replace faulty components.

Yes

Check SOL6 & DA3.

Replace faulty components.

Yes

Check DA1, DA4, DA8, SUP1, Relay K5, SOL5 and lift contactor coil P. Replace faulty components.

No

Close remote lower switches S20A & S20B.

Does a fuse blow ?

No

Close remote lift switches S19A & S19B.

Does a fuse blow ?

No

Go to Chart T-1-4

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Raymond ® Sideloader Maintenance Manual

Troubleshooting Troubleshooting Procedure

T-1-4

Close deadman switch.

Yes Does a fuse blow ?

Open switch S2.

Replace blown fuse and disconnect plug to the control unit.

Close S2.

Does a fuse blow ?

No

Replace control unit or a defective card.

Yes

Check hour meter (HM), SOL4, SOL7, DA7, SUP1, and the X contactor coil.

Replace faulty components.

Yes

Open switch S2.

Replace blown fuse and disconnect K12A. Close S2.

No Does a fuse blow ?

No Replace relay K12 or diode DA12.

Close lift switch S4.

Yes

Check DA4, DA8, SUP1, relay K5, SOL5 and lift contactor coil P. Replace faulty components.

Go to Chart T-1-5

6-16

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Troubleshooting Troubleshooting Procedure

T-1-5

Move control handle until forward travel switch MS1 closes.

Does a fuse blow ?

Yes

Check 1S & F contactor coils, equalizing time delay and control unit. Replace faulty components.

Yes

Check 1S & R contactor coils, equalizing time delay and control unit.

Replace faulty components.

Yes

Check M contactor coil, speed limit module and control unit. Replace faulty components.

No Move control handle until reverse travel switch MS2 closes.

Does a fuse blow ?

No Move control handle until either high speed travel switch, MS5A or MS5B, closes.

Does a fuse blow ?

No

Consult Factory

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6-17

Raymond ® Sideloader Maintenance Manual

Troubleshooting Troubleshooting Procedure

T-2: TRUCK HAS NO TRAVEL - ALL OTHER CIRCUITS FUNCTION

Check fuse FU1.

Does fuse show continuity ?

Yes

Check drive motors for proper operation.

Replace faulty motors.

No Check drive motors, rectifiers (REC1, 2 & 3), heatsink, and wiring for shorts or grounds. Check wiring to control unit and F, R, and M switches.

Repair or replace as necessary.

6-18

THE OVERLOAD CONTROL CAN BE A MAJOR CAUSE FOR A NO TRAVEL CONDITION AND WILL INDICATE A SPECIFIC COMPONENT MALFUNCTION. THE OVERLOAD CONTROL SHOULD BE IN THE RESET MODE. REFER TO "OVERLOAD CONTROL CIRCUIT TEST" IN COMPONENT PROCEDURES. NOW MOVE THE DIRECTIONAL/SPEED CONTROL HANDLE TO FULL SPEED FORWARD OR REVERSE, OBSERVING THE F, R, M, AND 1S CONTACTORS FOR ONE OF THE SITUATIONS GIVEN IN CHARTS T-2A THRU T-2D.

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Raymond ® Sideloader Maintenance Manual

Troubleshooting Troubleshooting Procedure

T-2A: Truck Has No Travel - All Other Circuits Function A: F or R and M contactors are NOT acti vated; 1S is activated

T-2A: TRUCK HAS NO TRAVEL - ALL OTHER CIRCUITS FUNCTION F or R and M contactors are NOT activated; 1S is closed

Check interlock switch S10.

Does continuity exist between pins 3 & 4 when switch is activated ?

No

Replace switch.

No

Replace module.

No

Replace contactors.

No

Replace card or control unit.

Yes

Does equalizing time delay function properly ?

Yes

Do M, F, and R contactors function properly ?

Yes

Does control unit function properly ?

Yes

Consult Factory

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6-19

Raymond ® Sideloader Maintenance Manual

Troubleshooting Troubleshooting Procedure T-2B: Truck Has No Travel - All Other Circuits Function B: F or R contacto rs are activated then drop out; M and 1S are activated

T-2B: TRUCK HAS NO TRAVEL - ALL OTHER CIRCUITS FUNCTION F or R contactors are activated then drop out; M and 1S are activated

Does control unit fuse show continuity ?

No

Replace fuse.

No

Replace cards or control unit.

Yes

Disconnect Pin B from the power circuit

Does the truck travel in SCR Range ?

Does transformer test OK?

Yes

Does SCR2 & SCR3 Test OK ?

No

Replace faulty SCR(s).

Replace transformer.

Yes

Capacitors were defective.

Yes

Replace capacitors C1 & C2 with new capacitors.

Yes

Does resistor assy RA2 test OK ? See "Resistor Assemblies" in Component Procedures

No

Yes

No

Replace SCR.

Yes

Does truck operate properly ?

No

Consult Factory

6-20

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Troubleshooting Troubleshooting Procedure

T-2C: Truck Has No Travel - All Other Circuits Function C: F or R contactors and 1S contactors are activated; M is NOT activated

T-2C: TRUCK HAS NO TRAVEL - ALL OTHER CIRCUITS FUNCTION F or R and 1S contactors are activated; M is NOT activated

Does SCR1 test OK?

No

Replace SCR.

Yes

Is lead to pin B at control unit properly connected ?

No

Repair or replace lead.

No

Repair or replace module.

Yes

Do drive motors test OK?

Yes

Do plugging relays (K1 & K2) test OK?

No

Does speed limit module function properly ?

Replace relays.

No

Replace module.

No

Make sure truck is not in speed limit mode.

Replace switch.

No

Replace faulty card or control unit.

Yes Yes

Does deadman switch (S2) test OK?

No

Does limit switch (S11) & S16 (if equipped) show continuity between pins 3 & 4 ?

Repair or replace switch or relay as necessary.

Yes

Yes

Yes

Does control and power circuit wiring to the M contactor show proper continuity ?

No

Repair or replace wiring or switches MS5A & MS5B.

Does control unit function properly ?

Yes

Consult Factory

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Raymond ® Sideloader Maintenance Manual

Troubleshooting Troubleshooting Procedure T-2D: Truck Has No Travel - All Other Circuits Function D: F or R contactors are NOT activated; M and 1S are acti vated

T-2D: TRUCK HAS NO TRAVEL - ALL OTHER CIRCUITS FUNCTION F or R contactors are NOT activated; M and 1S are activated

Does SCR1 test OK?

No

Replace SCR.

Yes

Repair or replace contactor.

No

Repair or replace wiring.

Yes

Do M contactor tips stay closed ?

No

Does the power section wiring show proper continuity ?

Yes

Consult Factory

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Troubleshooting Troubleshooting Procedure

T-3: Truck Has No Forward Travel - Reverse Travel Operative

T-3: TRUCK HAS NO FORWARD TRAVEL - REVERSE TRAVEL OPERATIVE

Does forward switch MS1 function properly ?

No

Replace switch.

No

Replace cards or control unit.

No

Replace contactor.

No

Replace faulty module.

Yes

Does control unit function properly ?

Yes

Does forward contactor F function properly ?

Yes

Does equalizing time delay function properly ?

Yes

Consult Factory

PDMM-0102 Issued: 9/30/02

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Troubleshooting Troubleshooting Procedure T-4: Truck Has No Reverse Travel - For ward Travel Operative

T-4: TRUCK HAS NO REVERSE TRAVEL - FORWARD TRAVEL OPERATIVE

Does continuity exist between MS1-1 & MS2-1 ?

No

Repair or replace wiring.

Yes

Does reverse switch MS2 test OK?

No

Replace switch.

No

Replace faulty cards or control unit.

No

Replace contactor.

Yes

Does control unit function properly ?

Yes

Does reverse contactor R function properly ?

Does equalizing time delay function properly ?

No

Replace module.

Yes Yes

Consult Factory

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Troubleshooting Troubleshooting Procedure

T-5: Truck Has No M Speed - SCR Range Operative

T-5: TRUCK HAS NO M SPEED - SCR RANGE OPERATIVE

Do high speed switches MS5A & MS5B function properly ?

No

Replace switch.

Yes

Does M contactor function properly ?

No

Does speed limit module function properly ?

Replace contactor.

No

Replace module.

Yes Yes

Does limit switch S11 show continuity between pins 3&4 ?

No

Make sure truck is not in a speed limit mode. Replace switch.

No

Replace faulty card or control unit.

No

Repair or replace wiring at pin B

Yes

Does control unit's M-time delay circuit function properly ?

Yes

Is pin B properly connected to power circuit to sense condition of SCR1?

Yes

Consult Factory

PDMM-0102 Issued: 9/30/02

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Raymond ® Sideloader Maintenance Manual

Troubleshooting Troubleshooting Procedure T-6: Truck Speed Is Slo w In SCR Range

T-6: TRUCK SPEED IS SLOW IN SCR RANGE

Do limit switches S11 & S16 show continuity between pins 3 & 4 on each switch ?

No

Make sure truck is not in a speed limit mode. Replace switch(es).

Yes

Are control unit's width and frequency pulse correct ?

No

Adjust or replace the VPG or power driver cards as necessary.

No

Adjust or replace the potentiometer as necessary.

Yes

Does speed limit module function properly ?

No

Yes

Does current limit function properly ?

Does potentiometer VR1 function properly ?

Replace module.

Yes

No

Adjust or replace the VPG card as necessary.

Yes

Consult Factory

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Troubleshooting Troubleshooting Procedure

T-7: Truck Runs In Top Speed Only

T-7: TRUCK RUNS IN TOP SPEED ONLY

Does potentiometer VR1 test OK?

Adjust or replace the potentiometer as necessary.

No

Yes

Is there a failure of SCR1 in conjunction with a failure in the overload sensing circuit ?

Replace the SCR and/or auxiliary circuit card as necessary.

Yes

No

Does M-time delay function properly ?

No

Replace auxiliary circuit card.

Yes

Consult Factory

PDMM-0102 Issued: 9/30/02

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Raymond ® Sideloader Maintenance Manual

Troubleshooting Troubleshooting Procedure T-8: Truck Acceleration Is Jerky In SCR Range

T-8: TRUCK ACCELERATION IS JERKY IN SCR RANGE

Does potentiometer VR1 test OK?

No

Adjust or replace potentiometer as necessary.

Yes

Is idle repetition rate set correctly ?

No

Adjust or replace VPG card as necessary.

No

Replace REC1.

No

Replace power driver card.

Yes

Repair or replace wiring as necessary.

Yes

Does REC1 Test OK?

Yes

Does power driver card function properly ?

Yes

Is there a poor connection or shorted wire ?

No

Consult Factory

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Troubleshooting Troubleshooting Procedure

T-9: Truck Reacts Violently When Plugged

T-9: TRUCK REACTS VIOLENTLY WHEN PLUGGED

Do plugging relays K1 & K2 test OK?

No

Replace relay(s).

No

Adjust or replace VPG card as necessary.

No

Replace rectifier(s).

Yes

Is plugging adjustment properly set ?

Yes

Do rectifiers REC2 & REC3 function properly ?

Yes

Does the equalizing time delay function properly ?

No

Does the 1S contactor function properly ?

Replace module.

No

Replace contactor.

Yes

Repair or replace as necessary.

Yes Yes

Is there a loose connection or shorted wire ?

No

Consult Factory

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Raymond ® Sideloader Maintenance Manual

Troubleshooting Troubleshooting Procedure T-10: Truck Acceleration Is Jerky B etween SCR And M Speed

T-10: TRUCK ACCELERATION IS JERKY BETWEEN SCR AND M SPEED

Does potentiometer VR1 function properly ?

No

Adjust or replace potentiometer as necessary.

No

Replace auxiliary circuit card.

No

Adjust or replace VPG card as necessary.

Yes

Does M-time delay function properly ?

Yes

Is idle repetition rate set properly ?

Yes

Consult Factory

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Troubleshooting Troubleshooting Procedure

T-11: Truck Travels On One Mo tor

T-11: TRUCK TRAVELS ON ONE MOTOR

Do drive motors test OK?

No

Repair or replace motor.

No

Replace rectifier(s).

No

Replace contactor(s).

No

Replace auxiliary circuit card or control unit.

Yes

Do rectifiers REC2 & REC3 test OK?

Yes

Do F&R contactors function properly ?

Yes

Do F & R contactor suppressors function properly ?

Yes

Consult Factory

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Raymond ® Sideloader Maintenance Manual

Troubleshooting Troubleshooting Procedure T-12: Truck Overload Kicks Out D uring Operation

T-12: TRUCK OVERLOAD KICKS OUT DURING OPERATION

IF AN OVERLOAD BECOMES A FREQUENT OCCURANCE, ISOLATE THE SPECIFIC OPERATION AND USE ONE OF THE FOLLOWING PROCEDURES TO LOCATE AND CORRECT THE MALFUNCTION.

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Troubleshooting Troubleshooting Procedure

A: F or R contactors open during routine travel

T-12A: TRUCK OVERLOAD KICKS OUT DURING OPERATION F or R contactors open during routine travel

Are all electrical connections in the SCR circuitry tight ?

No

Repair or replace connections.

No

Replace faulty card(s) or control unit.

No

Replace SCRs one at a time until the malfunction is corrected.

Note: In travel conditions where an overload occurs, it may be beneficial to check the pulse width and frequency using an oscilloscope.

Yes

Does control unit function properly ?

Yes

Do SCRs function properly ?

Yes

Consult Factory

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Raymond ® Sideloader Maintenance Manual

Troubleshooting Troubleshooting Procedure B: Travel is halted during plugging sequence

T-12B: TRUCK OVERLOAD KICKS OUT DURING OPERATION Travel is halted during plugging sequence

Do plugging relays K1 & K2 function properly ?

No

Replace relay(s).

No

Replace rectifier(s).

Yes

Do rectifiers REC2 & REC3 test OK?

Does control unit function properly ?

No

Replace card(s) or control unit.

No

Repair or replace battery.

No

Replace SCRs one at a time until the malfunction is corrected.

Yes Yes

Does equalizing contactor 1S and interlock S10 function properly ?

No

Repair or replace contactor or switch.

Does Battery test OK under load?

Yes Yes

Do SCRs test OK?

Yes

Consult Factory

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Troubleshooting Troubleshooting Procedure

C: Truck stalls while operating under a load

T-12C: TRUCK OVERLOAD KICKS OUT DURING OPERATION Truck stalls while operating under a load

Does battery test OK under load?

No

Repair or Replace battery.

No

Replace SCRs one at a time until the malfunction is corrected.

No

Replace rectifier(s).

Yes

Do SCRs test OK?

Note: In travel conditions where an overload occurs, it may be benificial to check the pulse width and frequency using an oscilloscope.

Yes

Do rectifiers function properly ?

Does the transformer test OK?

Yes

Does control unit function properly ?

No

Replace card(s) or control unit.

No

Replace the transformer.

No

Replace the capacitors.

Yes Yes

Do the capacitors charge properly?

Yes

Consult Factory

PDMM-0102 Issued: 9/30/02

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Raymond ® Sideloader Maintenance Manual

Troubleshooting Troubleshooting Procedure T-13: Truck Has No Lift - All Other Functions Operative

T-13: TRUCK HAS NO LIFT - ALL OTHER FUNCTIONS OPERATIVE

Check battery state-of-charge gauge.

Is the meter needle in the red zone ?

Recharge, repair, or replace batteries as necessary.

Yes

No If truck has remote lift/lower, is lift actuator plate up and does lift interlock switch S33 show continuity between pins 3&4 ?

No

Properly position the actuator plate and/or replace switch.

Yes

Does lift switch S4 show continuity between pins 1 & 2 when actuated ?

No

Replace switch.

If truck has either remote option, does DA-1 test OK?

No

Replace module.

Yes Yes

Go to Chart T-13-1

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Troubleshooting Troubleshooting Procedure

T-13-1

Does battery controller relay K5 function properly ?

No

Replace relay.

No

Replace module.

Yes

Does diode DA-8 test OK?

Yes

Does lift contactor P function properly ?

No

Does lift motor MP function properly ?

Replace contactor.

No

Repair or replace motor.

Yes

Repair or replace as necessary.

No

Repair or replace components.

Yes Yes

Does suppressor SUP-1 test OK?

No

Replace module.

Yes

Yes

Does lift fuse FU-2 show continuity ?

Does lift circuit wiring indicate shorts or grounds ?

No

Replace fuse.

No

Do lift hydraulic components function properly ?

Yes

Consult Factory

PDMM-0102 Issued: 9/30/02

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Troubleshooting Troubleshooting Procedure T-14: Remote Lift/Lower Function Inoperative

T-14: REMOTE LIFT/LOWER FUNCTION INOPERATIVE

With keyswitch in RMT position, does continuity show between pins S1-1-1 & S1-1-2 ?

Yes REMOTE LOWER

REMOTE LIFT Do remote lift switches S19A & S19B function properly ?

No

Replace switch(es).

Yes

Does DA-1test OK?

Do remote lower switches S20A & S20B function properly ?

No

Replace switch(es).

No

Repair or replace solenoid.

No

Replace module.

Yes

No

Replace module.

Yes

Does solenoid SOL6 test OK?

Yes

Yes Does DA-3 test OK? Does wiring indicate shorts or grounds ?

Yes

Repair or replace as necessary.

No

Consult Factory

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Troubleshooting Troubleshooting Procedure

T-15: Auxiliary And Steering Systems Inoperative

T-15: AUXILIARY AND STEERING SYSTEMS INOPERATIVE

Does auxiliary contactor X function properly ?

No

Repair or replace contactor as required.

No

Replace suppressor.

No

Replace fuse.

Yes

Does suppressor SUP1 test OK?

Yes

Does auxiliary fuse FU3 show continuity ?

Yes

Does auxiliary motor MX function properly ?

Do auxiliary hydraulic components test OK? No

No

Repair or replace components.

Repair or replace motor.

Yes

Does auxiliary circuit wiring indicate shorts or grounds ?

No Yes

Yes

Repair or replace as necessary.

Consult Factory

PDMM-0102 Issued: 9/30/02

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Raymond ® Sideloader Maintenance Manual

Troubleshooting Troubleshooting Procedure T-16: Crab Steering Inoperative

T-16: CRAB STEERING INOPERATIVE

Do crab steer switches S25, S26, S28, S29 & S30 function properly ?

No

Repair or replace switch(es).

No

Replace relay.

Yes

Does steer centering relay K11 function properly ?

Does crab steer circuit wiring indicate shorts or grounds ?

Yes

Does diode DA2 test OK?

No

Replace module.

Repair or replace as necessary.

No

Repair or replace components as necessary.

No

Yes

Do crab steer solenoids SOL1 & SOL2 test OK?

Yes

Yes No

Repair or replace solenoid(s).

Do crab steer hydraulic components test OK?

Yes

Consult Factory

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Troubleshooting Troubleshooting Procedure

T-17: Horn Inoperative

T-17: HORN INOPERATIVE

Does horn switch S3 function properly ?

No

Repair switch.

No

Replace horn.

No

Replace suppressor.

Yes

Does horn coil H test OK?

Yes

Does suppressor SUP3 test OK?

Yes

Consult Factory

PDMM-0102 Issued: 9/30/02

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Raymond ® Sideloader Maintenance Manual

Troubleshooting Troubleshooting Procedure T18: Remote Mode Operation

T-18: REMOTE MODE OPERATION THE FOLLOWING SITUATIONS COVER A VEHICLE WITH THE REMOTE TRAVEL OPTION WHILE OPERATING IN THE REMOTE (REM) MODE ONLY. REFER TO PREVIOUS CHARTS FOR TROUBLESHOOTING THE REMOTE TRAVEL OPTION IN THE STANDARD (STD) MODE.

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Troubleshooting Troubleshooting Procedure

T18A: Remote Inoperative

T-18A: REMOTE MODE OPERATION Completely inoperative - Standard Mode operative

With keyswitch turned to REM, does continuity exist between S1-1-1 & S1-1-2 and between S1-3-1 & S1-3-2 ?

No

Replace switch.

With mast fully retracted, does continuity show between pins 3 & 4 of limit switch S16 ?

Yes

With platform properly mounted, does continuity exist between pins 3 & 4 on platform interlock switch S45 ?

Replace switch.

Yes

No

Replace switch.

Yes

Do operator interlock switches S42, (S43 & S44 if used) show continuity between pins 3 & 4 when activated ?

No

Does DA9 function properly ?

Yes

No

Replace switch(es).

No

Replace diode.

No

Replace relay.

Yes

Does interlock relay K7 function properly ?

Yes

Consult Factory

PDMM-0102 Issued: 9/30/02

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Troubleshooting Troubleshooting Procedure T18B: Remote Travel Inoperative

T-18B: REMOTE MODE OPERATION Travel function inoperative

Does power supply test OK?

No

Replace power supply.

No

Replace relay.

Yes

Does interlock relay K7 function properly ?

Yes

Does aisle sensor relay K6 function properly ?

No

Does aisle sensor function properly ?

Replace relay.

No

Replace aisle sensor.

Yes Yes

Does DA11test OK?

No

Replace diode.

Yes

does wiring to the platform test OK?

No Repair or replace wiring.

Yes

GO TO STANDARD NO TRAVEL - ALL OTHER CIRCUITS FUNCTION CHART T-2 AND FOLLOW ENTIRE PROCEDURE AS REQUIRED.

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Troubleshooting Troubleshooting Procedure

T18C: Remote Forward Travel Inoperative

T-18C: REMOTE MODE OPERATION Forward travel inoperative - reverse travel operative

Does wiring between forward travel switch MS4-1 and reverse travel switch MS3-1 show continuity ?

No

Repair or replace wiring.

Yes

Does forward travel switch MS4 test OK?

No

Replace switch.

No

Replace relay or diode DA9.

Yes Does relay K10 function properly ?

Yes GO TO STANDARD NO FORWARD TRAVEL - REVERSE TRAVEL OPERATIVE CHART T-3 AND PROCEED FROM F CONTACTOR CHECK.

PDMM-0102 Issued: 9/30/02

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Raymond ® Sideloader Maintenance Manual

Troubleshooting Troubleshooting Procedure T18D: Remote Reverse Inoperative

T-18D: REMOTE MODE OPERATION Reverse travel inoperative - forward travel operative

Does reverse travel switch MS3 test OK?

No

Replace switch.

No

Replace relay.

Yes

Does relay K10 function properly ?

Yes

GO TO STANDARD NO REVERSE TRAVEL - FORWARD TRAVEL OPERATIVE CHART T-4 AND PROCEED FROM R CONTACTOR CHECK.

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Troubleshooting Troubleshooting Procedure

T18E: Remote M Speed Inoperative

T-18E: REMOTE MODE OPERATION M speed inoperative - SCR range operative

Do M speed switches MS6A & MS6B test OK?

No

Replace switch(es).

No

Replace relay.

Yes

Does relay K9 function properly ?

Yes

GO TO STANDARD NO M SPEED - SCR RANGE OPERATIVE CHART T-5 AND PROCEED FROM M CONTACTOR CHECK.

PDMM-0102 Issued: 9/30/02

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Raymond ® Sideloader Maintenance Manual

Troubleshooting Troubleshooting Procedure T18F: Remote Erratic Travel Conditions

T-18F: REMOTE MODE OPERATION Erratic travel conditions

REFER TO CHARTS T-6 THRU T-10 PLUS DO A TEST OF REMOTE TRAVEL POTENTIOMETER VR2 DIRECTLY AFTER TESTING STANDARD POTENTIOMETER VR1.

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Troubleshooting Troubleshooting Procedure

T18G: Remote Lift O peration G: Lift Function Inoperative

T-18G: REMOTE MODE OPERATION Lift Function Inoperative

Does relay K7 function properly ?

No

Replace relay.

No

Replace switch.

Yes

Does lift switch S19 show continuity between pins 3 & 4 when activated ?

Does relay K9 function properly ?

Yes

Does DA1 test OK?

No

Replace diode.

Does SOL9 test OK?

No

Replace solenoid.

Does DA2 test OK?

No

No

Replace SOL9.

No

Replace diode.

Yes

Yes

Yes

Replace relay.

Yes

Yes

Does solenoid SOL8 test OK?

No

Does DA10 test OK?

Replace diode.

Yes

GO TO STANDARD NO LIFT - ALL OTHER CIRCUITS FUNCTION CHART T-13 AND PROCEED FROM RELAY K5 CHECK.

PDMM-0102 Issued: 9/30/02

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Troubleshooting Troubleshooting Procedure T18H: Remote Lower Operation H: Lower Function Inoperative

T-18H: REMOTE MODE OPERATION Lower Function Inoperative

Does relay K7 function properly ?

No

Replace relay.

No

Replace switch.

Yes

Does lower switch S20 show continuity between pins 3 & 4 when activated ?

Yes

Does DA3 function properly ?

No

Replace diode.

No

Replace solenoid.

Yes

Does solenoid SOL6 function properly ?

Yes

Consult Factory

T18I: Remote Mode Horn Operation I: Horn Inoperative

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Troubleshooting Troubleshooting Procedure

T-18I: REMOTE MODE OPERATION Horn Inoperative

Does horn switch S3A show continuity between both NO pins when activated ?

No

Replace switch.

Yes

Does suppressor SUP3 function properly ?

No

Replace suppressor SUP3.

No

Replace horn.

Yes

Does horn function properly ?

Yes

Consult Factory

PDMM-0102 Issued: 9/30/02

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Raymond ® Sideloader Maintenance Manual

Troubleshooting Procedure

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Component Procedures

Component Procedures

7:

Component Locator Photos . . . . 7-3

Attachment and Load Handler . 7-55

General Procedures . . . . . . . . . 7-11

7-25 7-26 7-26 7-27 7-28 7-30 7-32 7-32 7-33 7-34 7-34 7-35 7-36 7-36

General . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56 Mast Tilt Cylinder Repair and Replacement . . . . . . . . . . . . 7-57 Fork Tilt Cylinder Repair and Replacement . . . . . . . . . . . . 7-59 Carriage Reach Cylinder Repair and Replacement (SLR20TT) . . . . . . . . . . . . . . . . . . 7-60 Mast Traverse Motor Repair and Replacement . . . . . . . . . . . . 7-61 Lift Chain Repair and Replacement . . . . . . . . . . . . 7-62 Carriage Roller Bearing Replacement . . . . 7-63 NFL and FFL Procedure . . . . . . . . . . . 7-63 TT Procedure . . . . . . . . . . . . . . . . . . . 7-63 Side Cylinder Repacking (TFL and TT) . . . 7-65 Lift Cylinder Repair and Replacement . . . . . . . . . . . . 7-66 NFL Procedure . . . . . . . . . . . . . . . . . . 7-66 FFL Procedure . . . . . . . . . . . . . . . . . . 7-67 TT Procedure . . . . . . . . . . . . . . . . . . . 7-67 Lift Cylinder Bleeding . . . . . . . . . . . . . . . 7-68 Mast Assembly Removal . . . . . . . . . . . . . 7-69 Mast Drive Repair and Replacement . . . . . . . . . . . . 7-70 Mast and Telescopic Roller Bearing Replacement . . . . . . . . . 7-72

Steer Axle Assembly . . . . . . . . 7-37

Hydraulics . . . . . . . . . . . . . . . . 7-73

General . . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Steerable Wheel Replacement . . . . . . . . . 7-39 Steering Linkage Alignment and Adjustment . .

7-40 Steer Axle Removal and Reassembly . . . . 7-41 Steer Linkage Replacement. . . . . . . . . . . 7-43 Steer Cylinder Replacement . . . . . . . . . . 7-44 Steer Knuckle Replacement . . . . . . . . . . 7-45

General . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74 Leakage . . . . . . . . . . . . . . . . . . . . . . . 7-74 Lift Control and Linkage . . . . . . . . . . . . . 7-75 Linkage and Master Cylinder Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75 Lift Pump and Slave Cylinder Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75 Lift Pump Replacement . . . . . . . . . . . 7-76 Hydraulic Manifolds . . . . . . . . . . . . . . . . 7-78 Relief Valve Pressure Settings . . . . . . 7-79

Tire Replacement . . . . . . . . . . . . . . . . . .

Motors . . . . . . . . . . . . . . . . . . . . . . . . . .

Brushes . . . . . . . . . . . . . . . . . . . . . .

Commutator . . . . . . . . . . . . . . . . . . .

Terminal Nuts . . . . . . . . . . . . . . . . .

Electric Motor Tests . . . . . . . . . . . . .

7-12 7-14 7-14 7-16 7-18 7-18

Drive Axle Assembly . . . . . . . . 7-23 General . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Motor Inspection and Cleaning . . . . . . . . . . .

Drive Wheel Replacement . . . . . . . . . . . .

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

Installation . . . . . . . . . . . . . . . . . . . .

Crab Steer Alignment and Adjustment . .

Drive Axle Removal and Reassembly. . . .

Drive Motor Replacement . . . . . . . . . . . .

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

Installation . . . . . . . . . . . . . . . . . . . .

Drive Unit Repair and Replacement . . . .

Disassembly . . . . . . . . . . . . . . . . . . .

Reassembly . . . . . . . . . . . . . . . . . . .

Tie Rod Replacement . . . . . . . . . . . . . . .

Crab Steer Cylinder Replacement . . . . . .

7-24

Steering . . . . . . . . . . . . . . . . . 7-47 Steering Chain Adjustment . . . . . . . . . . 7-48

Brakes . . . . . . . . . . . . . . . . . . 7-49 Service Brake Adjustment . . . . . . . . . . .

Parking Brake Adjustment . . . . . . . . . . .

Brake Shoe Replacement . . . . . . . . . . . .

Wheel Cylinder Repair or Replacement . .

PDMM-0102 Issued: 9/30/02

7-50 7-51 7-52 7-54

Electrical. . . . . . . . . . . . . . . . . . 7-81 General . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82 Heat Sink Insulation . . . . . . . . . . . . . 7-82 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . 7-83 Battery Exterior Cleaning. . . . . . . . . . 7-83 Charging . . . . . . . . . . . . . . . . . . . . . . 7-84 Component Testing . . . . . . . . . . . . . . . . . 7-87

7-1

Component Procedures

Contactors . . . . . . . . . . . . . . . . . . . . . . . . 7-88 Cleaning. . . . . . . . . . . . . . . . . . . . . . . 7-88 Tip Inspection . . . . . . . . . . . . . . . . . . 7-88 Contactor Coil Replacement . . . . . . . . 7-89 Replacement of Contactor Tips, Insulation and/or Core and Rod Assembly . . . . 7-90

Controls . . . . . . . . . . . . . . . . . . 7-95 Directional/Speed Control Assembly . . . . 7-96 Master Switches . . . . . . . . . . . . . . . . . 7-96 Potentiometer Test . . . . . . . . . . . . . . . 7-97 Potentiometer Removal or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99 Potentiometer Gear Binding Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-100 Directional/Speed Control Reassembly Checklist . . . . . . . . . . . . . . . . . . . . 7-101 Control Unit. . . . . . . . . . . . . . . . . . . . . . 7-102 Input Voltage Check. . . . . . . . . . . . . 7-103 Regulated Voltage Check . . . . . . . . . 7-104 Width and Frequency Pulse Checks . 7-105 Idle Repetition (Rep) Rate Adjustment 7-106 Plugging Adjustment . . . . . . . . . . . . 7-106 1/2 Speed Test (VPG Card). . . . . . . . 7-108 1/8 Speed Test. . . . . . . . . . . . . . . . . 7-109 Forward and Reverse Time Delay Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . 7-110 “M” Time Delay Circuit Test . . . . . . . 7-111 Equalizing Time Delay Circuit Test . . 7-112 Current Limit . . . . . . . . . . . . . . . . . . 7-113 “M” Lockout Circuit Test . . . . . . . . . 7-114 Overload Control Circuit Test . . . . . . 7-115 Weld Detect Circuit . . . . . . . . . . . . . 7-116 Power Driver Circuit Card . . . . . . . . 7-117

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Raymond ® Sideloader Maintenance Manual

Transient Suppressors for the M, F, and R Contactors . . . . . . . . . . . . . . . . . . 7-118 Equalizing Time Delay . . . . . . . . . . . 7-119 Speed Limit Module . . . . . . . . . . . . . 7-120 SCRs. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-122 Test Procedure . . . . . . . . . . . . . . . . 7-122 SCR1 Replacement . . . . . . . . . . . . . 7-122 SCR2 & SCR3 Replacement . . . . . . . 7-124 Rectifiers. . . . . . . . . . . . . . . . . . . . . . . . 7-125 Test Procedure . . . . . . . . . . . . . . . . 7-125 Replacement . . . . . . . . . . . . . . . . . . 7-125 Plugging Relays K1 & K2 . . . . . . . . . . . . . . . . . . . . . . . 7-127 Battery Controller and K5 Relay . . . . . . 7-129 Relay Test Procedure . . . . . . . . . . . . 7-129 Automatic Steer Centering Relay K11 . . 7-130 Deadman Relay K12 and Light Load Relay K13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-131 Diode Assemblies . . . . . . . . . . . . . . . . . 7-132 DA1. . . . . . . . . . . . . . . . . . . . . . . . . 7-132 DA2. . . . . . . . . . . . . . . . . . . . . . . . . 7-132 DA3, DA4, and DA8. . . . . . . . . . . . . 7-133 DA5. . . . . . . . . . . . . . . . . . . . . . . . . 7-133 DA6. . . . . . . . . . . . . . . . . . . . . . . . . 7-134 DA7 and DA12 . . . . . . . . . . . . . . . . 7-134 Resistor Assemblies . . . . . . . . . . . . . . . 7-135 RA1 . . . . . . . . . . . . . . . . . . . . . . . . . 7-135 RA2 . . . . . . . . . . . . . . . . . . . . . . . . . 7-135 Suppressor Assemblies . . . . . . . . . . . . . 7-136 SUP1. . . . . . . . . . . . . . . . . . . . . . . . 7-136 SUP3. . . . . . . . . . . . . . . . . . . . . . . . 7-136

Schematics . . . . . . . . . . . . . . . . A-11

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Raymond ® Sideloader Maintenance Manual

Component Procedures

Component Locator Photos

Component Locator Photos

Component Procedures

7:

Mast Lift Cylinder

Hose Reel

Lift Chains

Operator’s Compartment

Hydraulic Reservoir

Hydraulic Compartment

Electrical/ Mechanical Compartment

Auxiliary Fork Carriage (optional)

Load Bed Covers

Steer Wheels Guide Roller (optional)

Drive Wheels Guide Roller (optional) 73292_027.TIF

Figure 7-1:

Component Locator - Model 71B/76 Sideloader (shown with optional Auxiliary Fork Carriage)

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Raymond ® Sideloader Maintenance Manual

Component Procedures

Component Locator Photos

Fork Tilt Control

Mast Tilt Control

Mast Traverse Control

Steering Wheel

Emergency Disconnect Crab Steer Buttons

Lift Control

Horn Button

Lower Control

Key Switch Battery Controller Gauge Hour Meter

Emergency Manual Lower

Directional/Speed Control Handle 73292_029.TIF

Figure 7-2:

7-4

Component Locator - Operator’s Compartment

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Component Procedures

Component Locator Photos

Lowering Valve

Lift Master Cylinder

Lift Control Lever

Steering Chain Steering Orbitrol

73540_009.TIF

Figure 7-3:

Operator’s Compartment - Cover Removed

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Raymond ® Sideloader Maintenance Manual

Component Procedures

Component Locator Photos

Parking Brake (Deadman Pedal)

Service Brake Pedal

73292_034.TIF

Figure 7-4:

Brake Pedals

Mast Traverse Motor

Mast Tilt Cylinder Wear Bars

Figure 7-5:

7-6

Elevating Section - Extended

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Component Procedures

Component Locator Photos

Fuses

Contactors

Transformer

Plugging Relays

Equalizing Time Delay

Heat Sinks

SCRs

Control Unit

Speed Limit Module

Rectifiers

Horn Check Valve Filter

Auxiliary Motor

Auxiliary Pump

Lift Pump

Lift Motor

7P5180009.TIF

Figure 7-6:

Electrical/Hydraulic Compartment - Drive End

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7-7

Component Procedures

Raymond ® Sideloader Maintenance Manual Component Locator Photos

Control Valves

Lowering Lock-Out Solenoid

Pressure Reliefs Brake Dumping Solenoid

Speed Limiting Switches

7P5180009.TIF

Figure 7-7:

7-8

Hydraulic Compartment - Steer End

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Component Procedures

Component Locator Photos

Drive Motor

Drive Unit

Crab Steer Cylinder

Drive Wheel

Drive Wheel

Tie Rod Crab Steer Switches 7P5180009.TIF

Figure 7-8:

Drive Axle

Parking Brake Actuators Steer Cylinder

Steer Wheel

Steer Wheel

Intermediate Link Tie Rods

Figure 7-9:

Steer Axle

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7-9

Component Procedures

Raymond ® Sideloader Maintenance Manual Component Locator Photos

7-10

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Component Procedures

General Procedures Component Procedures

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General Procedures 7:

7-11

Component Procedures

Raymond ® Sideloader Maintenance Manual

Tire Replacement

General Procedures

Tire Replacement Any misalignment of the tire and hub while the tire is being pressed on the hub can cause damage to the hub. For this reason, chamfers have been provided on the outside edge of the hub and on the end of the inside diameter of the tire’s metal insert. The chamfers help to center the hub and tire during pressing and to reduce the possibility of misalignment.

! CAUTION

To prevent damage, the hub must be installed on the circular ram with the chamfered side up.

7

Figure 7-10: Tire Replacement

1. Examine the inside surface of the metal insert on the new tire. Remove any scaling or rust with sandpaper. Clean the inside of the metal insert.

2. Place a circular ram on the press table. See Figure 7-10. The length of the ram must be longer than the width of the old tire to permit complete removal of the old tire. The outside diameter of the ram must be small enough to fit loosely in the insert of the tire but must be large enough to rest squarely on the flat surface on the outer edge of the hub.

3. If the outside edge of the hub is not flush with the edge of the metal insert in the old tire, measure how far the hub is recessed inside the tire. The new tire must be placed in the same position the old tire was installed on the hub. You can use a spacer (slightly smaller in diameter that the inside diameter of the tire insert and the same thickness as the depth of the recess) to obtain the correct amount of recession.

4. Position the hub assembly with the old tire on top of the circular ram so the outside of the wheel is positioned upward. The outside edge of the hub has a chamfer to help guide the new tire on the wheel. The chamfered edge must always be the leading edge when a tire is pressed on the hub.

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Raymond ® Sideloader Maintenance Manual General Procedures

Component Procedures Tire Replacement

5. Center the hub assembly on top of the ram and make sure they mate squarely.

6. Position the new tire with its chamfered insert facing the hub. Align the new tire and the hub so they are concentric.

7. Start pressing the new tire on the hub and the old tire off the wheel. Operate the press slowly for the first few inches of travel because this is the critical step of the operation. If the tire starts to cock, stop the press immediately and realign the tire. Use a soft-headed mallet to realign the tire on the hub.

NOTE: If the new tire does not press on with a minimum pressure of 5 tons (68,947 kPa), replace the hub.

8. Release the press. Remove the wheel, tire assembly and the old tire from the press table. Inspect the wheel and tire assembly.

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7-13

Component Procedures Motors

Raymond ® Sideloader Maintenance Manual General Procedures

Motors Brushes Inspection Conduct a partial inspection of the drive motor after every 1,000 hours of truck operation. If you work in an abnormally severe or caustic environment or if you have a rigorous duty cycle, inspect the motor more frequently.

Set up and rigidly adhere to a strict inspection schedule to obtain the maximum efficiency from the electrical equipment.

Each partial inspection of the motor must include the following: 1. Inspect the brushes for wear and for correct contact with the commutator. Record the level of wear on the brushes and commutator. This history will give you an indication of whether a brush must be changed or if it can wait until the next inspection. See Table 7-1.

7MTRBRUSH.tif

Figure 7-11: Drive Motor Brush, Typical Location

NOTE: Overloading a unit is ultimately reflected in the motor and brush wear; therefore, you must take this into account when considering brush replacement.

2. Measure brush spring tension.

3. Clean brushes and holders. Wipe the commutator with a dry, lint-free cloth. Do not use lubricants of any kind on or around the commutator.

4. Examine brush holders for solid connection to the mounting support. Tighten the mounting screws as necessary.

5. Examine the cap screws holding the brush cross connectors to the brush holder body.

6. Make sure the motor terminals are secured tightly to the motor frame. Be careful not to strip the threads or crush the insulating parts.

7. Examine all the cap screws around the frame for tightness.

8. Keep the outside frame of the motor clean and free from dirt. Maintain a free air passage around the motor to permit heat radiation.

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Raymond ® Sideloader Maintenance Manual General Procedures

Component Procedures Brushes

Replacement If one brush needs replacement, always replace the entire set of brushes.

Use only genuine Raymond brushes. Using another type of brush could cause damage to the commutator or cause excessive brush wear.

If the end of the brush is not already contoured to fit the commutator, seat the brush to the commutator: NOTE: If the motor commutator is not accessible, form the brush contour using a brush seating stone.

1. Move the motor brush springs out of your way.

2. Wrap a piece of 00 sandpaper around the commutator. Do not use emery cloth to seat brushes.

3. Move the brushes back down in their holders. Rotate the armature so that the face of the brushes are contoured to match the curve of the commutator.

4. Remove the sandpaper.

5. Blow any dust out of the motor with clean, compressed air at a maximum of 30 psi (207 kPa).

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Raymond ® Sideloader Maintenance Manual

Component Procedures Commutator

General Procedures

Commutator Inspection The commutator must be inspected for surface condition and high mica. Most armatures have the mica undercut. If the armature on your motor does not, do not attempt to cut it. See Figure 7-12.

The commutator must be smooth and clean to provide maximum brush wear. When commutators are not correctly maintained, carbon dust can collect in the grooves between the segments. This can lead to a short circuit in the armature.

Good commutation will be indicated by a dark brown polished commutator and an evenly polished brush wearing surface. See Table 7-1, “Commutator Surfaces.”

Segments

Mica

NORMAL UNDERCUT

High Mica

HIGH MICA 71881 003.tif

Figure 7-12: Mica Inspection

If the commutator appears rough, pitted, or has signs of burning or heavy arcing between the commutator bars, the motor must be removed for servicing.

Table 7-1: Commutator Surfaces

Condition

Probable Cause

Good Condition-Light Film

Uniform coloring indicates satisfactory operation of machine and brushes. Film color is largely an effect of thickness, therefore provided the film is uniform it is perfectly acceptable.

Satisfactory Condition-Light and Dark Pattern

This is not a good condition but in our experience it is known that machines having this commutator pattern have operated with satisfactory results for long periods of time. This condition can appear in alternating bars as shown or every 3rd or 4th bar, etc. This is related to the winding design of the armature. Difficulty caused from split windings crossing in the same slot.

Unsatisfactory Condition-Streaky Film With No Commutator Wear

Frequently because of under-loaded operation, machine grossly over-brushed or brush grade incorrect for particular machine application. Atmosphere and environmental conditions can contribute.

7-16

Commutator Surface

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Raymond ® Sideloader Maintenance Manual General Procedures

Component Procedures Commutator

Table 7-1: Commutator Surfaces

Condition

Probable Cause

Unsatisfactory Condition-Uneven Film

Patchy colors of changing densities and shape. Because of unclean operating conditions or incorrect physical condition of commutator.

Unsatisfactory Condition- Film With Dark Areas

These areas can be isolated or regular.

Commutator out of round. This can be caused by vibration or mechanical deficiencies in equipment operation, bearings, couplings, etc.

Unsatisfactory Condition-Example of Poor Commutator Machining

Bars are low on entry and leaving edges giving rise to the brushes riding on the middle of the bars.

Unsatisfactory Condition-Example of Poor Commutator machining

Bars are low in the middle giving rise to the brushes riding on entry and leaving bar edges. This and the previous illustration indicate the need for better maintenance.

Unsatisfactory Condition-Streaky Film With commutator Wear

This is a further development of the third example. Brush grade, machine applications and working environment are all suspect. Earlier corrective action should have been taken.

Unsatisfactory Condition-Double Pole Pitch

Darkening of commutator in sequences two pole pitches apart is because of armature fault, bad coil, riser bars or equalizer connections.

Unsatisfactory Condition-Brush Contact Mark

Storage of machines, for lengthy periods, with brushes in position. This can also result from operation of machine in prolonged stall conditions.

Unsatisfactory Condition-Bar Edge Burning-Cause High Mica

Illustration shows high mica in every slot.

Same effect can occur on one bar only.

Similar conditions can be caused by a high or low bar.

Unsatisfactory Condition-Small Bright Spots

Related to over-loaded machines and low brush pressure. Because of sparking under brush that gives rise to spots being of a random distribution. If not corrected, will result in scored commutator.

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Commutator Surface

7-17

Raymond ® Sideloader Maintenance Manual

Component Procedures Terminal Nuts

General Procedures

Servicing Servicing a motor for an abnormal commutator surface condition and high mica or mica undercutting requires special equipment at a motor rebuilding facility. Do not attempt to service the motor yourself.

Terminal Nuts When you disconnect and reconnect any power leads to a motor, always tighten the motor cable securing nuts with a torque wrench to prevent over-tightening them and damaging the motor.

Use a second wrench on the stud terminal securing nut to avoid twisting the stud.

Measure Table 7-2 torques each time you examine motor brushes.

Terminal Stud Motor Cable Securing Nut

Flat Washer Fiber Washer

Stud Terminal Securing Nut

Motor Housing

7CABLENUT.eps

Figure 7-13: Motor Terminal Nuts

Table 7-2: Torque Measurements Stud Size 3/8 in.

(M10) 5/16 in.

(M8) 1/4 in.

(M6)

Motor Cable Securing Nut 100-120 in. lbs (11.2-13.6 Nm) 90-110 in. lbs (10.2-12.4 Nm) 40-50 in. lbs (4.5-5.6 Nm)

Compound Motor Stud Terminal Securing Nut 140-160 in. lbs (15.8-18.1 Nm) 110-140 in. lbs (12.4-15.8 Nm) 50-60 in. lbs (5.6-6.8 Nm)

A MX

S/D

Electric Motor Tests Motor Type • Compound-wound motors, such as the lift and auxiliary motors, have only two external connections because the armature and field windings are connected internally.

See Figure 7-14.

• Shunt-wound motors, such as the drive motor, has four external connections: two armature (A) and two field (S, E, or D).

Shunt-Wound Motor A2

S2/E2/D2 MD

A1

S1/E1/D1 7Dschem.eps

Figure 7-14: Motor Circuits

Open Circuit Motor Test An open circuit is one where the electrical circuit within the motor has been broken. This can be caused by: • Bad brushes or brush springs

7-18

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Raymond ® Sideloader Maintenance Manual

Component Procedures

General Procedures

Electric Motor Tests

• A broken wire in the field or armature winding • A loose or bad connection 1. Isolate the motor from the truck circuit by removing the power cables. Use two wrenches to avoid twisting the terminal stud. See Figure 7-14.

2. With the motor at room temperature, connect the leads of a digital ohmmeter between the individual circuits in the motor. See Table 7-3.

Table 7-3: Motor Resistance Measurements

Motor Traction (Drive)

Lift

Auxiliary

Probe Points

Acceptable Resistance

S1 to S2

0.9 to 1.5 ohms

A1 to A2

Less than 1 ohm

A1 to S1; A1 to S2

Greater than 100,000 ohms

A2 to S1; A2 to S2

Greater than 100,000 ohms

A1 or A2 to Frame

Greater than 100,000 ohms

A to S

0.020–0.030 ohms

A to Frame

Greater than 100,000 ohms

A1 to A2

0.01–0.10 ohms

A1 or A2 to Frame

Greater than 100,000 ohms

Measure all readings at room temperature.

3. If the meter indicates high resistance in the armature, examine the condition of the brushes before replacing the motor.

4. If an open circuit is found in a series-wound motor, the motor must be disassembled by a motor rebuilding facility to isolate the problem to the field or armature circuit.

Grounded Motor Test In a grounded motor, an electrical circuit exists between the current-carrying conductors and the motor housing. This can be caused either by direct contact or through conductive foreign material.

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7-19

Component Procedures Electric Motor Tests

Raymond ® Sideloader Maintenance Manual General Procedures

The ground may be caused by: • Insulation breakdown • Brush leads touching the motor housing • Build-up of carbon dust or other materials To test a motor for grounds: 1. Isolate the motor from the truck circuit by removing the power cables. Use two wrenches to avoid twisting the terminal studs.

2. Attach one lead of a digital ohmmeter to a motor terminal and the other lead to an unpainted surface of the motor housing.

Set the ohmmeter to the highest scale.

3. If the ohmmeter reads resistance of less than 100,000 ohms, the motor is grounded.

Clean, repair or replace the motor as necessary.

Short-Circuited Winding A short-circuited winding is one where the insulation on the field or armature has broken down at two or more points. The breakdown creates a low resistance path, permitting current to flow from one turn of the coil to another adjacent coil turn, without actually flowing through the coil wire. The result is a decrease in total resistance of the motor winding and an increase in the current flow.

The severity of the short circuit depends on its location.

A shorted motor may be indicated by: • Slow or sluggish operation • Running faster than normal • Overheating • Blowing a power fuse • Severe burning or discoloring on one or two commutator segments every 90° of rotation These symptoms can be caused by problems other than the motor itself: • Brake too tight or dragging • Wheel bearings too tight • Faulty transmission • Binding in an attached pump

7-20

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Raymond ® Sideloader Maintenance Manual General Procedures

Component Procedures Electric Motor Tests

Testing a motor for short-circuited windings requires special equipment at a motor rebuilding facility.

Short-circuited Armature A short circuit in the armature will probably cause heating and could result in burning of: • The armature coil • Brush wires • Commutator segments Visual inspection may reveal these conditions.

Positive determination of a short-circuited armature requires special equipment at a motor rebuilding facility.

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7-21

Component Procedures Electric Motor Tests

7-22

Raymond ® Sideloader Maintenance Manual General Procedures

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Raymond ® Sideloader Maintenance Manual

Component Procedures

Drive Axle Assembly Component Procedures

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Drive Axle Assembly 7:

7-23

Component Procedures General

Raymond ® Sideloader Maintenance Manual Drive Axle Assembly

General The drive axle assembly and its components require routine lubrication and maintenance.

See “Lubrication and Inspection Points” on page 5-8.

The lubrication procedures, as well as some maintenance procedures, can be performed by removing the load bed covers.

More complex maintenance procedures require the removal of the drive axle assembly from the truck.

7-24

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Raymond ® Sideloader Maintenance Manual Drive Axle Assembly

Component Procedures Drive Motor Inspection and Cleaning

Drive Motor Inspection and Cleaning With the crab steering centered and load bed covers removed, perform the following; 1. Turn the key switch OFF and disconnect the battery connector.

2. Remove the ring cover from the end of the motor permitting access to the brushes and springs.

3. Clean dust particles from the motors using low air pressure [5 psi (35 kPa) max].

Inspect the motors. See “Motors” on page 7-14.

4. If brushes and springs need to be replaced, remove the end cover to make removal easier.

NOTE: Be careful not to disturb the brush holder assembly when removing the end cover. If it is displaced, the motor characteristics can change.

5. Replace worn brushes and springs.

6. Install covers.

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7-25

Component Procedures Drive Wheel Replacement

Raymond ® Sideloader Maintenance Manual Drive Axle Assembly

Drive Wheel Replacement Removal 1. Turn the key switch OFF and disconnect the battery connector.

! WARNING • Use extreme care when the lift truck is jacked up.

• Never block the lift truck between the telescopic and the floor.

• Use a suitable hoist to stabilize the mast.

• Keep hands and feet clear from vehicle while jacking the lift truck.

• After the lift truck is jacked, install solid blocks or jack stands beneath it to support it.

• Do NOT rely on the jack alone to support the lift truck. See “Jacking Safety” on page 2-11.

2. Jack and block the drive end of the truck so the wheels are approximately 1/4 in.

(6.35 mm) off the floor.

3. Attach special wrench (P/N 111-001-981) to the wheel nut with a 3/8-16 X 1½ in. screw (P/N 710-140) and to the chassis with a 3/4-16 X 2¾ in. screw (P/N 710-428). See Figure 7-15.

4. Reconnect the battery connector and turn the key switch ON. 5. With the deadman pedal depressed, activate the directional speed control handle in the direction that will loosen the nut.

7

Figure 7-15: Drive Wheel Removal

6. Turn the key switch OFF and disconnect the battery connector. Remove the nut.

7. Attach a wheel puller to the 1/2-20 holes in the wheel hub and pull the wheel assembly.

8. If the tire needs to be replaced, see “Tire Replacement” on page 7-12.

7-26

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Raymond ® Sideloader Maintenance Manual Drive Axle Assembly

Component Procedures Installation

9. Examine and replace any bearings showing signs of wear. Repack the bearings with grease. See "Lubrication Specification Chart" on page A-2.

Installation 1. Mount the wheel on the drive shaft and hand tighten the wheel nut.

2. Attach the special wrench, as in Step 3 of the removal instructions.

3. Reconnect the battery connector and turn the key switch ON. 4. Depress the deadman pedal and activate the control handle in the direction that will tighten the nut. Apply full stall torque of the drive motor for 0.5 to 1.0 second.

5. Turn the key switch OFF and disconnect the battery connector.

6. Remove the special wrench.

7. Mark an indication point on the wheel and perform the torquing procedure after 8 hours, 1 week, 1 month, and 6 months of operation.

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7-27

Raymond ® Sideloader Maintenance Manual

Component Procedures Crab Steer Alignment and Adjustment

Drive Axle Assembly

Crab Steer Alignment and Adjustment Steering alignment or adjustment may be necessary after replacing components on the drive axle.

1. Place a straight edge below the vehicle skirt and flush with or parallel to the drive wheel hubs, then measure the distances at A and B. See Figure 7-16. Make sure the straight edge is on the wheel hubs and not the tire rims.

7

Figure 7-16: Crab Steer Alignment and Adjustment

2. If A and B change by more than 1/4 in.

(6.35 mm), adjust the tie rod until they are within 1/4 in. (6.35 mm).

3. After aligning the wheels, examine the crab steer switch adjustments.

• Actuators must measure 3/16 to 1/4 in.

(4.83 to 6.35 mm) from the tie rod.

• Actuators must measure 3/16 to 1/4 in.

(4.83 to 6.35 mm) from the cams.

• Actuator arms must measure 90° ±5° from the tie rod.

4. Activate crab left, then return to center.

7-28

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Raymond ® Sideloader Maintenance Manual Drive Axle Assembly

Component Procedures Crab Steer Alignment and Adjustment

5. The wheel hub must be parallel within a 3/32 in. (2.3 mm) difference between points C and D and a straight edge laid along the skirt.

6. If the wheel did not make it back to parallel, move Cam E to the right. If the wheel went beyond parallel, move Cam E to the left.

7. Activate crab right, then return to center.

8. The wheel hub must be parallel within a 3/32 in. (2.3 mm) difference between points C and D and a straight edge laid along the skirt.

9. If the wheel did not make it back to parallel, move Cam F to the left. If the wheel went beyond parallel, move Cam F to the right.

NOTE: If the crab steer mechanism searches continuously, move Cams E and F away from center an equal distance and repeat steps 3 thru 9.

PDMM-0102 Issued: 9/30/02

7-29

Component Procedures Drive Axle Removal and Reassembly

Raymond ® Sideloader Maintenance Manual Drive Axle Assembly

Drive Axle Removal and Reassembly 1. Turn the key switch OFF and disconnect the battery connector.

2. Disconnect drive motor cables underneath the contactor panel at TP-15 thru TP-22.

3. Remove the three clamps to the rear of the hydraulic compartment and feed the cables through the bottom of the compartment.

4. Remove the hoses from the crab steer cylinder and cap all fittings.

5. Remove the retaining screw and pivot lift pump and motor assembly out for access to two of the drive axle mounting bolts.

NOTE: Traverse the mast for access to the axle mounting bolts on the mast side of the load bed.

6. Disconnect the wires to the crab steer switches by separating JP6.

! WARNING • Use extreme care when the lift truck is jacked up.

• Never block the lift truck between the telescopic and the floor.

• Use a suitable hoist to stabilize the mast.

• Keep hands and feet clear from vehicle while jacking the lift truck.

• After the lift truck is jacked, install solid blocks or jack stands beneath it to support it.

• Do NOT rely on the jack alone to support the lift truck. See “Jacking Safety” on page 2-11.

7. Jack and block the truck to relieve pressure on the drive axle.

8. Block the drive axle to prevent it from swinging down when the mounting bolts are removed.

9. Remove the six mounting bolts.

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Raymond ® Sideloader Maintenance Manual Drive Axle Assembly

Component Procedures Drive Axle Removal and Reassembly

10. Raise the truck high enough to remove the axle, then roll the axle assembly out from under the truck.

11. Block up the axle assembly and perform the desired maintenance.

12. To reinstall the axle assembly, reverse the removal procedure. Apply 300 ft. lb.

(406.75 Nm) of torque to the six axle mounting bolts.

13. Examine and adjust, if necessary, the crab steer alignment. See “Crab Steer Alignment and Adjustment” on page 7-28.

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7-31

Component Procedures Drive Motor Replacement

Raymond ® Sideloader Maintenance Manual Drive Axle Assembly

Drive Motor Replacement ! WARNING • Use extreme care when the lift truck is jacked up.

• Never block the lift truck between the telescopic and the floor.

• Use a suitable hoist to stabilize the mast.

• Keep hands and feet clear from vehicle while jacking the lift truck.

• After the lift truck is jacked, install solid blocks or jack stands beneath it to support it.

• Do NOT rely on the jack alone to support the lift truck. See “Jacking Safety” on page 2-11.

With the mast traversed out, jack and block the truck high enough to access the drive motors from underneath the truck.

Removal 1. Disconnect the four cables from the motor terminals.

2. Remove the drain plug and drain the oil into a clean container.

3. Remove the nine screws and washers securing the motor to the drive unit.

4. Insert two of the screws removed in step 3 into the motor separator holes and separate the motor from the drive unit.

5. Pull off the motor and pinion assembly.

6. If the pinion or keys need to be replaced, remove them by taking off the snap ring.

7. Refer to “When you disconnect and reconnect any power leads to a motor, always tighten the motor cable securing nuts with a torque wrench to prevent over-tightening them and damaging the motor. Use a second wrench on the stud terminal securing nut to avoid twisting the stud. Measure Table 7-2 torques each time you examine motor brushes.” on page 7-18.

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Raymond ® Sideloader Maintenance Manual Drive Axle Assembly

Component Procedures Installation

Installation To reinstall the drive motor, reverse the removal procedure. Apply Permatex 300 (P/N 990-556) between the mating surfaces of the motor and drive unit.

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Component Procedures

Raymond ® Sideloader Maintenance Manual

Drive Unit Repair and Replacement

Drive Axle Assembly

Drive Unit Repair and Replacement Remove the drive axle assembly from the truck to access the drive units.

NOTE: For ease of maintenance on the drive units, remove the drive wheels prior to removing the drive axle assembly. See “Drive Wheel Replacement” on page 7-26 and “Drive Axle Removal and Reassembly” on page 7-30.

Disassembly 1. Remove the drain plug and drain the oil into a clean container.

2. See Figure 7-17. Remove the three set screws [5] from the nut [6]. Use Tool P/N 401-000-002. Remove the nut from the drive shaft.

3. Remove the gland seal [7], oil seal [8], O-ring [9], and bearing cup and cone [10].

4. Remove the 23 screws [11] and lock washers [12] that attach the drive axle support [13] to the gear case [19].

5. Remove the drive axle support [13].

6. Remove the bearing cup and cone [14], drive axle [15], and outer pinion shaft bearing (not shown).

7. While holding the drive gear [17] in place, slide out the pinion shaft [16]. The drive gear [17] can now be tilted out and the inner pinion shaft bearing [18] removed.

8. If the gear case [19] has to be removed, first remove the drive motor. See “Drive Motor Replacement” on page 7-32. Then disconnect the tie rod and crab steer cylinder. See “Tie Rod Replacement” on page 7-36 and “Crab Steer Cylinder Replacement” on page 7-36.

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7

Figure 7-17: Drive Unit Assembly

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Raymond ® Sideloader Maintenance Manual

Component Procedures

Drive Axle Assembly

Reassembly

9. See Figure 7-18. Remove the king pin set screw [20], bolt [8], and bearing cap [9].

Support the gear case and remove the king pin [5] out the bottom. Remove the gear case NOTE: The king pin has a larger diameter on the lower end and must be installed correctly. The bottom of the king pin has a indicator groove to ensure correct reassembly.

10. Inspect all components. Replace any component showing signs of wear.

Reassembly 1. If gear case was removed, install king pin.

NOTE: Make sure bearings [6, 13], spacer [7], and felt seal [12] are in position and the indicator groove is on the bottom. a. Install the set screw [20]. b. Torque the king pin bolt [8] to 80 ft. lb.

(108.5 Nm). c. Reconnect the tie rod and crab steer cylinder.

2. Install the drive motor. See “Drive Motor Replacement” on page 7-32.

3. See Figure 7-17. Install the inner pinion shaft bearing [18], drive gear [17], and pinion shaft [16].

7

Figure 7-18: Drive Axle Assembly

4. Install the bearing cup and cone [14], drive axle [15], and outer pinion shaft bearing (not shown).

5. Apply sealant (P/N 990-556) to mating surfaces of the gear case [19] and drive axle support [13]. Install the drive axle support and attach it to the gear case with 23 screws [11] and lock washers [12].

6. Install the bearing cup and cone [10], O-ring [9], oil seal [8], and gland seal [7].

7. Using Tool P/N 401-000-002, install the nut [6] on the drive shaft and torque to 100 to 120 ft. lb. (135.6 to 162.7 Nm).

8. Seat the three set screws [5] in nut [6].

Tighten them an additional 1¼ turns.

9. Install drain plug and fill drive unit with oil until oil is level with plug hole. See "Lubrication Specification Chart" on page A-2.

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Component Procedures Tie Rod Replacement

Raymond ® Sideloader Maintenance Manual Drive Axle Assembly

Tie Rod Replacement 1. See Figure 7-18. Remove screws [14] and washers [15]. Slide out retaining pins [16].

2. Slide out one end of the tie rod [10], then the other. Be careful not to cause damage to the crab steer switches [19].

3. When installing the tie rod, torque screws to 12 ft. lb. (16.3 Nm).

4. For alignment and adjustment procedures, see “Crab Steer Alignment and Adjustment” on page 7-28.

Crab Steer Cylinder Replacement 1. See Figure 7-18. Remove screws [21] and washers [22]. Slide out retaining pins [23].

2. Remove the cylinder [2].

3. Repair or replace cylinder as necessary.

4. Install the cylinder. Torque the retaining pin screws [21] to 12 ft. lb. (16.3 Nm).

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Component Procedures

Steer Axle Assembly Component Procedures

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Steer Axle Assembly 7:

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Component Procedures General

Raymond ® Sideloader Maintenance Manual Steer Axle Assembly

General The steer axle assembly and its components require routine lubrication and maintenance.

The lubrication procedures, as well as some maintenance procedures, are performed by removing the load bed covers. See “Lubrication and Inspection Points” on page 5-8.

More complex maintenance procedures require the removal of the steer axle assembly from the truck.

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Raymond ® Sideloader Maintenance Manual Steer Axle Assembly

Component Procedures Steerable Wheel Replacement

Steerable Wheel Replacement With the load bed covers removed, perform the ! following;

WARNING

• Use extreme care when the lift truck is jacked up.

• Never block the lift truck between the telescopic and the floor.

• Use a suitable hoist to stabilize the mast.

• Keep hands and feet clear from vehicle while jacking the lift truck.

• After the lift truck is jacked, install solid blocks or jack stands beneath it to support it.

• Do NOT rely on the jack alone to support the lift truck. See “Jacking Safety” on page 2-11.

1. With the truck jacked up and blocked, bend the ears on the locking washer [4]. Use special tool P/N 401-000-015 and remove the nut [3] and washer [4]. See Figure 7-19.

2. Attach a wheel puller, if necessary, at the two 1/2-20 holes in the hub and pull off the wheel assembly.

3. If the tire needs to be replaced, see “Tire Replacement” on page 7-12.

4. Examine the bearings and replace any that show signs of wear.

5. Refer to “Brakes” on page 7-49 for brake adjustment and repair.

7

Figure 7-19: Steerable Wheel Assembly

6. To reinstall the wheel, reverse the removal procedure. Repack the bearings. See “Lubrication Specification Chart” on page A-2.

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Raymond ® Sideloader Maintenance Manual

Component Procedures Steering Linkage Alignment and Adjustment

Steer Axle Assembly

Steering Linkage Alignment and Adjustment Perform the following procedure if the steering linkage needs alignment or adjustment and after replacing components on the steer axle.

See Figure 7-20.

1. Place a straight edge below the vehicle skirt and flush with or parallel to the drive wheel hubs. Measure the distances at A and B. Make sure the straight edge is on the wheel hub and not the tire rim.

7

Figure 7-20: Steering Linkage Alignment and Adjustment

2. If A and B change by more than 1/4 in. (6.3 mm), equally adjust each tie rod until A and B are within 1/4 in. (6.3 mm).

3. The wheel hubs must also be parallel within a 3/32 in. (2.3 mm) difference between points C and D and a straight edge laid along the skirt.

4. Fully extend the steer cylinder and adjust stop F to clear the steer knuckle arm by 1/8 in. (3.3 mm).

5. Retract the steer cylinder until the opposite wheel is turned 60° beyond center. Adjust stop E to touch the steer knuckle arm.

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Raymond ® Sideloader Maintenance Manual Steer Axle Assembly

Component Procedures Steer Axle Removal and Reassembly

Steer Axle Removal and Reassembly 1. Disconnect the brake lines from the master cylinder at each manifold block on the axle and cap all fittings.

2. Disconnect the hoses from the steer cylinder and cap all fittings.

3. Remove the floor plate and sub-plate for access to two of the steer axle mounting bolts. Removal of the deadman pedal will permit the removal of one mounting bolt.

NOTE: Traverse the mast for access to the axle mounting bolts on the mast side of the load bed.

! WARNING • Use extreme care when the lift truck is jacked up.

• Never block the lift truck between the telescopic and the floor.

• Use a suitable hoist to stabilize the mast.

• Keep hands and feet clear from vehicle while jacking the lift truck.

• After the lift truck is jacked, install solid blocks or jack stands beneath it to support it.

• Do NOT rely on the jack alone to support the lift truck. See “Jacking Safety” on page 2-11.

4. Jack and block the vehicle to relieve pressure on the steer axle.

5. Block the steer axle to prevent it from swinging down when the mounting bolts are removed.

6. Remove the six mounting bolts and two screws that attach the axle assembly to the vehicle frame.

7. Raise the vehicle high enough to roll the axle out from under the vehicle.

8. Block up the axle and perform the desired maintenance.

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7-41

Component Procedures Steer Axle Removal and Reassembly

Raymond ® Sideloader Maintenance Manual Steer Axle Assembly

9. To reinstall the axle assembly, reverse the removal procedure. Apply 300 ft. lb.

(406.7 Nm) of torque to the six mounting bolts and 90 ft. lb. (122 Nm) of torque to the two screws.

10. Examine the steering linkage alignment and adjust if necessary. See “Steering Linkage Alignment and Adjustment” on page 7-40.

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Raymond ® Sideloader Maintenance Manual Steer Axle Assembly

Component Procedures Steer Linkage Replacement

Steer Linkage Replacement 1. See Figure 7-21. Remove the lock nut [10], screw [8], and washer [11] securing the tie rods [12] to the knuckle arm.

7

Figure 7-21: Steer Axle Assembly

2. Remove the screw [23] and washer [24] and slide out the retaining pin [22] on the intermediate link [30].

3. Remove the linkage assembly.

4. Remove the lock nuts [15], screws [14], and washers [13] securing the tie rods [12] to the intermediate link [30].

5. When reinstalling the linkage, torque the four screws [8 and 14] securing the tie rods to 100 ft. lb. (135.6 Nm).

6. Torque the screw [23] securing the retaining pin [6] to 12 ft. lb. (16.3 Nm).

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7-43

Component Procedures Steer Cylinder Replacement

Raymond ® Sideloader Maintenance Manual Steer Axle Assembly

Steer Cylinder Replacement 1. See Figure 7-21. Remove the screw [28] and washer [29]. Slide out the retaining pin [6].

2. Remove the screw [32] and nut [33]. Lift out the steer cylinder [31].

3. Disassemble the cylinder, as necessary, to replace worn bearings and/or packings.

4. When reinstalling the steer cylinder, torque the screw [28] securing the retaining pin [6] to 12 ft. lb. (16.3 Nm).

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Component Procedures Steer Knuckle Replacement

Steer Knuckle Replacement 1. Disconnect all fittings on the parking brake actuator and seal with a cap.

7

Figure 7-22: Steer Axle Piping

2. See Figure 7-22. Remove the screws [2] and washers [3] securing the actuator assembly [1 or 13] and lift it off the steer axle.

3. Disconnect the tie rod and steer cylinder from the knuckle assembly. See “Steer Linkage Replacement” on page 7-43 and ”Steer Cylinder Replacement” on page 7-44.

4. See Figure 7-21. Remove the screw [18] and bearing cap [17] from the bottom of the king pin [3 or 9]. Lift out the king pin and slide out the knuckle assembly [20 or 25].

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7-45

Component Procedures Steer Knuckle Replacement

Raymond ® Sideloader Maintenance Manual Steer Axle Assembly

5. To reinstall the knuckle assembly, reverse the removal procedure. Apply 80 ft. lb.

(108.5 Nm) of torque to the screw [18] securing the king pin.

6. See “Steer Linkage Replacement” on page 7-43 and “Steer Cylinder Replacement” on page 7-44 for tie rod and steer cylinder torque requirements.

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Component Procedures

Steering Component Procedures

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Steering 7:

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Component Procedures

Raymond ® Sideloader Maintenance Manual

Steering Chain Adjustment

Steering

Steering Chain Adjustment The steering chain, when correctly adjusted, must permit 1/2 in. (13 mm) deflection at a point midway between the sprocket [5] on the orbitrol and the sprocket [1] on the steering wheel.

1. See Figure 7-23. Loosen locking nut [4] and rotate the adjustment screw [3] to move the tightener block until the correct tension is achieved.

2. Tighten the locking nut [4].

1/2 in.

7

Figure 7-23: Steering Chain Adjustment

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Component Procedures

Brakes Component Procedures

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Brakes 7:

7-49

Component Procedures

Raymond ® Sideloader Maintenance Manual

Service Brake Adjustment

Brakes

Service Brake Adjustment The service brake is the primary braking source for the truck and must stop the truck within six feet. If the truck fails to stop within this distance when the service brake is fully activated, examine the linkage adjustment.

1. See Figure 7-24. With the service brake released and the master cylinder piston in the full off position, the distance between the yoke and mounting plate must measure 2 3/4 in. (69.9 mm).

7

Figure 7-24: Brake Components and Adjustments

2. Adjust the return spring if the pedal does not raise fully when released.

3. If the adjustment is correct but the brakes do NOT adequately stop the truck, bleed the brakes.

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Raymond ® Sideloader Maintenance Manual Brakes

Component Procedures Parking Brake Adjustment

Parking Brake Adjustment The parking brake (deadman pedal) must restrain movement of the truck after the service brake is used to stop the truck. If the truck continues to move when the parking brake is activated, examine the actuator adjustment.

1. See Figure 7-24. With the deadman pedal up, adjust the actuator to 5 in. (127 mm) between the jam nut and the block on the actuator.

2. If the adjustment is correct but the brakes do NOT adequately restrain the movement of the truck, bleed the brakes.

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Component Procedures

Raymond ® Sideloader Maintenance Manual

Brake Shoe Replacement

Brakes

Brake Shoe Replacement If adjustment and bleeding procedures fail to correct a brake problem, the brake shoes may need to be replaced. See Figure 7-25.

1. Remove the wheel assembly. See “Steerable Wheel Replacement” on page 7-39.

2. Inspect the brake assembly for leaks, rust and dust build-up. Clean as necessary.

Repair or replace a leaky wheel cylinder.

3. If the brake shoes have less than 1/8 in.

(3.3 mm) of lining, replace the shoes.

NOTE: Keep left and right side brake assembly components separate.

7

Figure 7-25: Brake Assembly

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Raymond ® Sideloader Maintenance Manual Brakes

Component Procedures Brake Shoe Replacement

4. Pull the adjuster lever [33] out toward the secondary shoe [26] and unhook it from the shoe web.

5. Pull the adjuster spring [34] toward the toggle lever [27] and unhook lower adjuster link [32] from the toggle lever.

6. Remove the adjuster lever and spring.

7. Separate the brake shoes and remove the adjuster screw assembly [23].

8. Unhook the shoe return springs [24] and the upper link [1] from the wheel cylinder bolt [2] and remove them.

NOTE: The shoe return springs are color coded and must be replaced correctly.

9. Remove cotter pin [25] and washer [28] from toggle lever [27]. Remove toggle lever.

10. Depress the outer cup [31] on the hold down pin [12] and rotate the cup 90°. Lift off the outer cup, spring [30], inner cup [29], and hold down pin. Lift off the brake shoe.

11. Reinstall brake shoes in the reverse order of removal. Make sure: •

Springs and levers are attached so that their hooks are pointed toward the wheel cylinder

•

Shoes are adjusted to a diameter approximately 1/32 in. (0.76 mm) less than the brake drum diameter

12. Apply light oil (one or two drops) at the following locations: •

Between the shoe rim and the support plate

•

Between the shoe web and the piston insert

•

Between the shoe web and the socket end of the adjusting screw

•

On the adjusting screw threads

•

Between the shoe web and the hold down cup

•

Between the toggle lever and the toggle pin

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7-53

Component Procedures Wheel Cylinder Repair or Replacement

Raymond ® Sideloader Maintenance Manual Brakes

Wheel Cylinder Repair or Replacement 1. Remove the brake shoes. See “Brake Shoe Replacement” on page 7-52.

2. See Figure 7-25. Remove the dust boot [22] from the wheel cylinder and withdraw the boot and piston assembly. Remove the boot from the assembly.

3. Remove the rubber cup and spring from the wheel cylinder.

4. Clean and inspect the cylinder. If necessary, replace the cylinder as follows. a. Remove the mounting bolts [18] and the wheel cylinder bolt [2]. b. Remove the two wheel cylinder mounting bolts [17] and lift off the cylinder [21]. c. Reinstall the wheel cylinder in the reverse order of disassembly: • Coat the wheel cylinder bore, rubber cups and dust boot with clean brake fluid • Torque the five mounting bolts and the wheel cylinder bolt to 100 ft. lbs. (135.6 Nm)

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Component Procedures

Attachment and Load Handler Component Procedures

Attachment and Load Handler

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7:

7-55

Component Procedures General

Raymond ® Sideloader Maintenance Manual Attachment and Load Handler

General The Attachment and Load Handler require routine lubrication and maintenance. See “Lubrication and Inspection Points” on page 5-8.

The lubrication procedures, as well as some maintenance procedures, are performed without having to remove the mast assembly from the vehicle.

More complex maintenance procedures require the removal of the mast assembly from the truck.

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Raymond ® Sideloader Maintenance Manual Attachment and Load Handler

Component Procedures Mast Tilt Cylinder Repair and Replacement

Mast Tilt Cylinder Repair and Replacement Remove the mast tilt cylinder only if the bearings fail or the cylinder is leaking. See Figure 7-26.

1. Extend the mast assembly to the outer edge of the load bed.

2. Raise the fork carriage 12 to 15 in. (305 to 380 mm) and block in position.

! WARNING Use extreme care when blocking the mast for any reason. Never remove the block when it is supporting the mast.

3. Disconnect the tilt lines and cap all fittings.

4. Remove the two screws and washers that attach the mast tilt cylinder to the frame.

5. Remove the spiral pin and retaining pin from the other end of the mast tilt cylinder.

6. Remove the mast tilt cylinder assembly and disassemble, as required, to replace worn bearings or damaged packings.

7. Reinstall the mast tilt cylinder in the reverse order of disassembly.

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Component Procedures Mast Tilt Cylinder Repair and Replacement

Raymond ® Sideloader Maintenance Manual Attachment and Load Handler

7

Figure 7-26: Mast Assembly - NFL

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Component Procedures Fork Tilt Cylinder Repair and Replacement

Fork Tilt Cylinder Repair and Replacement Remove the fork tilt cylinders only if the bearings fail or the cylinders are leaking. See Figure 7-27.

7

Figure 7-27: Carriage Assembly

1. Remove the auxiliary carriage or apron assembly, if used.

2. Remove the four screws that attach the cover in front of the cylinders.

3. Disconnect the tilt lines and cap all fittings.

4. Remove the set screw securing the retaining pin on the lower pivot linkage and remove the retaining pin.

5. Remove the set screw securing the fork bar, then drive out the fork bar far enough to remove the cylinder assembly. Remove the fork bar slowly, lifting off the forks, spacers, and cylinder assembly.

6. Disassemble the cylinder assembly, as required, to replace worn bearings or damaged packings.

7. Reinstall the fork tilt cylinder in the reverse order of disassembly.

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Component Procedures

Raymond ® Sideloader Maintenance Manual

Carriage Reach Cylinder Repair and Replacement (SLR20TT)

Attachment and Load Handler

Carriage Reach Cylinder Repair and Replacement (SLR20TT) Remove the carriage reach cylinders only if the bearings fail or the cylinders are leaking.

1. Extend the carriage reach mechanism and lock it in the extended position. Block the carriage to keep it from moving.

2. Rotate the hose reel to loosen hoses and lock the reel to prevent it from turning.

Remove and plug the hoses on the carriage manifold.

3. Disconnect and plug the reach piping on the cylinder(s).

4. Remove the screws and cotter pins that attach the dowel pins at each end of the cylinder(s). Drive out the dowel pins and remove the cylinder(s).

5. Repair or replace any bad component.

6. Reinstall the carriage reach cylinder(s) in the reverse order of disassembly.

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Raymond ® Sideloader Maintenance Manual Attachment and Load Handler

Component Procedures Mast Traverse Motor Repair and Replacement

Mast Traverse Motor Repair and Replacement Remove the mast traverse motor only if it leaks or malfunctions.

1. Extend the mast assembly to the outer edge of the load bed.

2. Disconnect the hoses on the motor and cap all fittings.

3. Remove the four screws [34 and 35] securing the motor assembly to the carriage drive bracket.

NOTE: The screws are different lengths. When reinstalling the motor assembly, make sure the correct length screw is used.

4. Lift off the motor assembly and cover plate.

Remove the bearing [25] if necessary.

5. Remove the gear [22], key [17], screws [20], mounting plate [19], spacer [18], and fittings [16] from the motor [15].

6. Replace worn components and reassemble in the reverse order of disassembly.

7

Figure 7-28: Mast Traverse Motor

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7-61

Component Procedures Lift Chain Repair and Replacement

Raymond ® Sideloader Maintenance Manual Attachment and Load Handler

Lift Chain Repair and Replacement Remove the lift chains for routine maintenance per “Scheduled Maintenance” on page 5-1 or when they show signs of wear. See Figures 7-26 and 7-27.

1. Extend the mast to the outer edge of the load bed. Raise the carriage and install blocks beneath it. Lower the carriage on the blocks so that the chains become slack.

2. Remove the cotter pins from the chain anchor pins on the carriage. Remove the chains.

3. Remove the chain anchor nuts on the lift cylinder and remove the chains.

4. Thoroughly clean the chain in solvent and inspect it for wear, cracked plates, rust, tight joints and elongation.

! CAUTION

Do NOT steam clean or degrease the lift chains.

5. Replace a chain that is excessively worn, has cracked plates, or will not loosen up because of excessive rust or tight joints.

6. To examine for elongation: a. Lay the chain area that runs over the pulleys on a flat surface and push it together. b. Mark a 12 in. (305 mm) length, then stretch the chain and measure the same area. c. If more than 0.33 in. (8.4 mm) variation is detected, replace the chain.

7. Lubricate the chains. See “Lubrication Specification Chart” on page A-2. Install the chains in the reverse order of removal.

8. Make sure the chains are adjusted to equally share the load and roll flat and centered on the pulleys.

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Component Procedures Carriage Roller Bearing Replacement

Carriage Roller Bearing Replacement Remove the carriage assembly only if the roller bearings have to be replaced and reshimmed.

See Figures 7-26 and 7-27.

NFL and FFL Procedure 1. Disconnect the hydraulic hoses from the carriage and cap all fittings.

2. Remove the bumper stops on the carriage and telescopic.

3. Disconnect the lift chains. See “Lift Chain Repair and Replacement” on page 7-62.

4. Connect a hoist to the carriage and lift it out the top of the telescopic.

5. Repair or replace any bad component(s).

6. Generally, the same number of roller shims are needed when replacing roller bearings.

If the carriage is excessively loose, add additional shims. Make sure to reinstall the retaining screw and washer when replacing roller bearings.

7. Reverse the procedure to reinstall the carriage, making sure all necessary lubrication, bleeding, and adjustments are performed.

TT Procedure 1. Raise the carriage and attach a block to the bottom plate. On reach carriages, extend and lock the reach extended and block the two carriages.

2. Lower the carriage(s) on the block(s) to loosen the lift chains.

3. Rotate the hose reel(s) to loosen the hoses.

Lock the reel(s) to prevent them from turning. Remove and plug the hoses on the carriage manifold(s).

4. Disconnect and remove the lift chains from the pulleys. Pass the chains through the pulley sheaves beneath the pulleys and attach them on the carriage side below the pulley sheaves with locking pliers.

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Component Procedures TT Procedure

Raymond ® Sideloader Maintenance Manual Attachment and Load Handler

5. Secure a hoist to the carriage and raise the telescopic above the carriage. Remove the carriage and repair or replace any bad component(s).

6. Reverse the procedure to reinstall the carriage.

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Component Procedures Side Cylinder Repacking (TFL and TT)

Side Cylinder Repacking (TFL and TT) If the side cylinder(s) are leaking, they can be inspected and repacked without removing the lift cylinder cluster.

1. Extend the mast and raise the carriage.

Install blocks under the carriage and lower the carriage on the blocks.

2. Open the lowering valve to relieve the pressure. Manually push the side cylinders down to slacken the chains. Lift the chains off.

3. Loosen the set screw in the pulley sheave.

Unscrew the pulley shaft and remove the pulley and spacers.

4. Remove the screw and washer securing the pulley sheave. Lift off the sheave.

5. Remove the outer snap ring, oil seal and inner snap ring. The piston may now be pulled up for packing replacement.

NOTE: When repacking a cylinder, replace all packings. Packings are available in “kit” form.

6. Reverse the disassembly procedure to reinstall the side cylinder(s). Bleed the cylnder(s). See “Lift Cylinder Bleeding” on page 7-68.

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7-65

Component Procedures Lift Cylinder Repair and Replacement

Raymond ® Sideloader Maintenance Manual Attachment and Load Handler

Lift Cylinder Repair and Replacement Remove the lift cylinders only if they leak, bind, or the packings have failed. Use the applicable procedure that follows for cylinder repair and replacement. See Figure 7-26.

NFL Procedure 1. Activate the lift lever until the telescopic raises approximately 12 in. (305 mm).

Insert and attach a block under the telescopic. Lower the telescopic on the block.

2. Remove the carriage. See “Carriage Roller Bearing Replacement” on page 7-63.

3. Attach a hoist to the cylinder. Remove and cap the lift piping at the base of the cylinder.

4. With a punch through the hole in the guide rod to keep it from turning, remove the top mounting nut.

5. With a punch through the guide rod, collapse the guide rod and piston.

6. Remove the mounting bolts in the support bracket on the mast cross tie and the nut on the lower mast bracket. Remove the cylinder assembly.

7. Remove the snap ring securing the end cap to the piston.

8. Remove the snap ring in the housing and lift out the oil seal.

9. Remove the second snap ring in the housing. Pull out the piston and replace the packings.

NOTE: When repacking a cylinder, replace all packings. Packings are available in “kit” form.

10. Reverse the disassembly procedure to reinstall the lift cylinder. Bleed the cylinder.

See “Lift Cylinder Bleeding” on page 7-68.

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Component Procedures FFL Procedure

FFL Procedure 1. Remove the carriage. See “Carriage Roller Bearing Replacement” on page 7-63.

2. With the lift chains still attached to the lift cylinders, remove the chains from over the pulleys and put them under the pulleys.

Attach locking pliers to the chains on the carriage side just below the pulley sheave.

3. Activate the lift lever until the telescopic raises approximately 12 in. (305 mm).

Insert and attach a block under the telescopic. Lower the telescopic on the block.

4. Attach a hoist to the cylinder. Remove and cap the lift piping at the base of the cylinder.

5. Remove the lower mounting nut. Raise the piston and secure it in the collapsed position. Remove the upper mounting nut and remove the cylinder assembly.

6. Remove the snap ring in the housing and lift out the oil seal.

7. Remove the second snap ring in the housing. Pull out the piston and replace the packings.

NOTE: When repacking a cylinder, replace all packings. Packings are available in “kit” form.

8. Reverse the disassembly procedure to reinstall the lift cylinder. Bleed the cylinder.

See “Lift Cylinder Bleeding” on page 7-68.

TT Procedure 1. Follow the “FFL Procedure” for removing the front lift cylinder cluster.

2. Follow the “NFL Procedure” on page 7-66 for removing the back lift cylinder.

3. Reverse the disassembly procedure to reinstall the TT lift cylinders. Bleed the cylinder. See “Lift Cylinder Bleeding” on page 7-68.

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7-67

Component Procedures Lift Cylinder Bleeding

Raymond ® Sideloader Maintenance Manual Attachment and Load Handler

Lift Cylinder Bleeding Bleed the lift cylinders after maintenance is performed on the lift system or when lift truck operation indicates that air has entered the system.

1. Raise the carriage approximately 6 in.

(152.4 mm). Loosen the bleed screw on top of the cylinder.

NOTE: Loosen the bleed screw only enough to permit air to escape.

2. When only oil flows from the cylinder, tighten the bleed screw.

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Component Procedures

Attachment and Load Handler

Mast Assembly Removal

Mast Assembly Removal 1. Position the truck under a hoist and attach the rigging to the top of the mast.

2. Remove the screws that attach the stop mounting brackets to the truck.

3. With the hoist rigging tight (no slack), slowly traverse the mast to the outer edge of the load bed.

4. Disconnect, label, and cap all hoses and fittings. Swing the mast assembly off the truck. Lower the mast assembly to the floor and refer to the respective maintenance procedure for component repair and replacement.

5. Examine the wear strips and rack assemblies. Replace each as necessary by removing mounting screws and adjustment nuts on the rack on the steering end of the load bed.

NOTE: When reinstalling the racks and wear strips, use thread-locking compound on mounting screws and let cure for 12 hours. Make sure racks are square before applying thread-locking compound.

6. Reassemble the mast on the tractor in the reverse order of disassembly. Make sure: •

Eccentric rollers on the carriage drive are adjusted so the gears are firmly meshed in racks, but work smoothly at 1500 psi (10342 kPa).

•

Stop screws are adjusted correctly. See Figure 7-29.

7

Figure 7-29: Mast Traverse Stop Screw Adjustment

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Component Procedures Mast Drive Repair and Replacement

Attachment and Load Handler

Mast Drive Repair and Replacement With the mast assembly removed from the truck and blocked in an upright position, disassemble the mast drive mechanism as follows.

1. Disconnect hoses from the mast reach motor and cap all fittings. Disconnect the yoke end of the mast tilt cylinder.

7

Figure 7-30: Mast Drive Assembly

2. See Figure 7-30. Remove the screws [28] that attach the bearing caps [8 and 30] to the aprons [6 and 43]. Lift the bearing caps and bearings [31] off, permitting the apron assembly to swing down.

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Component Procedures Mast Drive Repair and Replacement

3. Remove the snap rings [50], rollers and bearings [47], shims [48], and spacers [49] from each end of the shaft [54]. Slide the shaft in either direction, then lift out the free end and pull the shaft from the mast frame. Remove the bearing [51], eccentric [52], and key [53] from the mast frame.

4. Remove the nuts [46] from the roller shafts [45]. This permits the removal of the rollers [44] and mast drive assembly.

5. Remove the snap ring [42] from the shaft [3] and slide off the gear [40], key [1] and washer [41]. Loosen the set screw [38] and slide off the spacer [39], apron [43] and bearings [26 and 37]. Repeat the above steps for the opposite end. See “Mast Traverse Motor Repair and Replacement” on page 7-61 for removal of the mast traverse motor assembly. Loosen the set screw [24] and slide off the gear [23] and key [2].

6. Remove three screws [56] to remove the bearing cap [57], bearing [58], roller [59], and washer [60].

7. Remove the snap rings [63 and 64] to remove the bearing [62] and roller [61].

8. Reassemble the mast drive in the reverse order of disassembly.

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7-71

Component Procedures Mast and Telescopic Roller Bearing Replacement

Raymond ® Sideloader Maintenance Manual Attachment and Load Handler

Mast and Telescopic Roller Bearing Replacement Remove the telescopic(s) only when the roller bearings need to be replaced.

1. Remove the carriage, lift cylinders, and mast. Refer to “Carriage Roller Bearing Replacement” on page 7-63, “Lift Cylinder Repair and Replacement” on page 7-66, and “Mast Assembly Removal” on page 7-69 respectively.

2. Lay the mast assembly on a table or bench.

3. Remove the remaining bumper stops. With a hoist attached to the telescopic(s), roll the telescopic(s) out of the mast.

4. Replace all worn roller bearings.

NOTE: Make sure the same number and size shims that were removed from the worn bearings are installed on the new bearings.

5. Reinstall the telescopic(s).

NOTE: If the telescopic is correctly shimmed, it will be snug yet move freely within the mast. Reshim if the telescopic is too tight or too loose.

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Component Procedures

Hydraulics Component Procedures Component Procedures

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Hydraulics 7:

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Component Procedures General

Hydraulics

General To ease hydraulic component installation and help prevent problems that may develop: • Lubricate all seals, packings and O-rings with hydraulic oil prior to installation.

• Hand tighten all fittings against O-rings, then snug down with a wrench.

• Immerse components with spring chambers in hydraulic oil. Activate the spring to remove any air.

• Inspect oil filter and oil in reservoir regularly to determine types of contamination.

Leakage Situations that indicate leakage are excessive load drop, load drift, bouncing forks, and noisy pumps. Wipe the area of the leak clean to determine the exact location of the leak.

Table 7-4 lists the causes and prevention of hydraulic leaks.

Table 7-4: Leakage Causes and Prevention

Cause

Prevention

Worn packings

Poor cylinder alignment and tight packings will cause excessive wear. Examine piston surface for pitting or scoring that cause packing wear.

Air leaks

Leaky connections on component suction lines may not be easy to find but can cause considerable trouble. If air leaks can’t be heard, they may be detected by bubbles in the hydraulic oil.

NOTE: After locating and repairing leaks, fill the reservoir and bleed the system.

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Component Procedures

Hydraulics

Lift Control and Linkage

Lift Control and Linkage Erratic operation of the lift system may be caused by incorrect adjustment of the control linkage, a low or leaking master cylinder, faulty slave cylinder operation, or malfunction of the pump.

Linkage and Master Cylinder Maintenance 1. If the master cylinder feels spongy, it may require bleeding. Have another person loosen the bleed screw on the slave cylinder. Fully actuate the lift lever and hold. Tighten the bleed screw, release the lift lever and repeat the procedure until a solid stream of fluid flows from the bleed screw.

2. Adjust the lift linkage so that; •

The master cylinder is at a “zero” position when the lift lever is released.

•

Lift switch S4 is deactivated when the lift lever is released.

•

The master cylinder is fully stroked but not hard against its stop when the lift lever is fully actuated against its stop.

•

Lift switch S4 is activated as soon as the lift lever is moved.

Lift Pump and Slave Cylinder Maintenance 1. If the slave cylinder is leaking or not functioning correctly, remove the two mounting screws and lift the slave cylinder off.

2. Examine the snap ring and O-ring between the slave cylinder and the adapter plate.

Replace faulty components.

3. Measure the dimension from the plunger to the stem cover as shown in Figure 7-31.

Replace or reseat the plunger to 9/16 to 19/32 in. (14.2 to 15 mm) using thread-locking compound to attach it.

7

Figure 7-31: Slave Cylinder Mounting Adjustment

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Component Procedures

Raymond ® Sideloader Maintenance Manual

Lift Pump Replacement

Hydraulics

4. When reinstalling the slave cylinder, reverse the disassembly procedure. Torque the mounting screws to 7 to 9 ft. lb.

(9.5 to 12.2 Nm).

NOTE: Examine the load compensator on Models SL40TT and SLR20TT if the lift system is not functioning correctly.

Examine the load compensator for leaks, free movement of internal plunger, and weak springs.

•

If leaks are present or actuation is sticking, the seals probably need to be replaced. Replace the seals and bleed the slave cylinder per Step 4 on page 7-75.

Lift Pump Replacement 1. Disconnect the battery and drain the reservoir.

2. Disconnect the inlet and outlet lines from the pump and drain the pump.

3. Remove the slave cylinder. See “Lift Pump and Slave Cylinder Maintenance” on page 7-75.

4. While supporting the pump, remove the two mounting screws and washers. Lift off the pump and coupling.

5. Install a new or rebuilt pump and do the following: •

Coat the coupling with molybdenum anti-seize compound. See “Thread Adhesives, Sealants, and Lubricants” on page A-3.

•

Fill the pump with new hydraulic oil.

See "Lubrication Specification Chart" on page A-2.

•

Adjust lift relief valve setting as required, see “Relief Valve Pressure Settings” on page 7-79.

! CAUTION

Do NOT operate the pump until the housing has been filled with oil.

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Component Procedures

Hydraulics

Lift Pump Replacement

•

Operate the pump at approximately 40% of maximum lift speed to assure good initial priming.

•

Loosen the upper bleed screw and operate the pump until oil flows out.

Tighten the bleed screw. Bleed the slave cylinder. See “Linkage and Master Cylinder Maintenance” on page 7-75.

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7-77

Component Procedures Hydraulic Manifolds

Raymond ® Sideloader Maintenance Manual Hydraulics

Hydraulic Manifolds The manifolds used on the Sideloader are: • M1 - Hydraulic Compartment Manifold • M2 - Pump Compartment Manifold See Figure 7-32.

• MR1 and MR2 - Ranger® Manifolds (Refer to SS-10)

7

Figure 7-32: Manifold Assemblies

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Component Procedures

Hydraulics

Relief Valve Pressure Settings

Relief Valve Pressure Settings Incorrect pressure relief settings can cause various system malfunctions. Use the procedure and Table 7-5 to measure and adjust the relief valves.

Procedure Find the valve. See Figure 7-32. Install a 0 to 5000 psi (0 to 34474 kPa) pressure gauge at the indicated port. Adjust, as necessary, each valve to the indicated PSI under the specific condition.

Table 7-5: Relief Valve Settings

Valve

Location

Auxiliary Relief

Manifold M2

Manifold M2-8

2100 (14479 kPa)

Bottom out the fork tilt cylinder.

Crab Steer Relief

Top of SOL-1 and SOL-2

Manifold M2-8

1500 (10342 kPa)

Hold crab steer against cylinder stops.

Steering Relief

Manifold M1

Manifold M2-8

1500 (10342 kPa)

Hold steering against cylinder stops.

Pressure Reducing

Manifold M1

Manifold M1-6

300 (2068 kPa)

Step on deadman pedal, aux pump running.

Lift Relief

Manifold M2

Manifold M2-9

Test PSI with maximum load...then set relief 100 psi (689 kPa) higher.

Hang Up Relief

Manifold M1

None

Lift the unloaded carriage and block.

Actuate lower. Set relief just high enough to keep lift cylinders from lowering.

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Test Port

PSI (kPa)

Condition

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Component Procedures Relief Valve Pressure Settings

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Component Procedures

Electrical Component Procedures

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Component Procedures General

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General Maintain accurate records of all electrical inspections and work performed on the truck.

By doing this, it is easy to keep track of recurring problems.

! CAUTION

Capacitors C1 and C2 are potentially dangerous. Avoid contact (either directly or through uninsulated tools) with capacitor's terminals or wiring until the capacitors have been fully discharged. To discharge the capacitors, carefully hold the insulated handle of a screwdriver and install the metal blade across the bus bars on the capacitors. Each time work is to be done on the circuit, the capacitors must be discharged if the circuit has been energized since last discharging.

Heat Sink Insulation Heat sink insulation may become faulty for several reasons: • Poorly insulated screws that attach the component to the heat sink • Carbon build-up that permits current to bypass heat sink insulation Use the following procedure to examine the heat sink insulation for shorts to the frame: 1. Remove all electrical connections from the heat sink.

2. Set the ohmmeter on the R x 100,000 scale.

Attach the positive lead of the ohmmeter to the heat sink and negative lead to the SCR panel base. The resistance must register at least one megohm.

3. If the resistance is lower than one megohm, clean around the heat sink.

4. If the resistance is still low, replace the insulation between the heat sink and the truck frame.

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Component Procedures

Electrical

Batteries

Batteries Lead-acid batteries furnish all power requirements of the truck. Most industrial batteries can be expected to function correctly for more than five years. This section contains battery maintenance information. Following this information will extend battery life and increase truck efficiency.

Battery Exterior Cleaning 1. Inspect the battery. a. Make sure the cables are not frayed or loose. b. Make sure there is no foreign material inside the connector.

Cable Vent Hole

c. Make sure the filler plugs are tight and the vent holes in the filler plugs are open. See Figure 7-33.

2. Keep the top of the battery clean and dry.

Corrosion, dust, and moisture provide a conducting path to short-circuit cells or create grounds.

! CAUTION

Filler Plug 709g6s047.tif

Figure 7-33: Battery Filler Plugs and Vent Holes

Do NOT use soda solution to clean the top of the battery while it is installed in the truck. Water will seep into the electrical compartments and cause serious damage. a. Disconnect the battery connector, and remove the battery from the truck before you clean it. b. Tighten the battery filler plugs. c. Wash dirty batteries (or any that have had electrolyte spilled on them) with a solution of 1 lb (0.45 kg) of baking soda added to 1/2 gal (1.9 liters) of hot water. d. Use a brush with flexible bristles to clean the entire top of the battery with the soda solution. Wait until all foaming

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Component Procedures Charging

Raymond ® Sideloader Maintenance Manual Electrical

stops, indicating that the battery exterior is neutralized. e. Rinse the battery with clean water. f. Dry the battery completely before re-installing it. g. Apply a thin coat of petroleum jelly to the battery posts and cable terminals.

Charging To charge a battery, direct current is passed through the battery cells in the direction opposite to that of discharge.

The most important element in battery service and prolonging battery life is correct charging.

Make sure you follow the correct method for each application, following the battery and battery charger manufacturers’ instructions.

! CAUTION

The vent holes in the filler plugs must be open to permit hydrogen gas to escape from the cells. When you charge the battery, make sure the polarity connections are correct. The positive lead of the charger must be connected to the positive terminal, and the negative lead must be connected to the negative terminal.

1. Familiarize yourself with the following: •

Charging rate, starting rate, and finish rate

•

Time available for charge

•

Overheating, excessive gassing, or overcharging

•

Variations between cell voltage

2. Battery performance varies depending on the type of application. If you use more than one truck, one battery, and one charger, keep the same batteries and charger assigned to each truck. This makes it easier to diagnose any battery or charging problem.

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Component Procedures Charging

3. Consult your battery and battery charger manufacturer’s manual for specific charging procedures.

4. Wear personal protective equipment. See “Battery Safety” on page 2-7.

5. Turn the key switch OFF, disconnect the battery, and remove the battery from the truck.

6. Inspect the battery.

7. Measure the electrolyte level in each cell.

Electrolyte must cover the top of the battery plates. If electrolyte level is below the plates, add just enough water to cover the plates. Do NOT fill to level yet. Electrolyte level will rise during charging.

8. Using a hydrometer, measure and record the specific gravity of each cell.

9. Measure and record the voltage reading for each cell on the battery maintenance chart.

There must be a difference of no more than 0.2 volt between cells.

10. To get the maximum use out of each battery, recharge only when effectively discharged. Routinely recharging batteries when only partially discharged will decrease battery life. At maximum recommended discharge, the specific gravity must read 1.140 to1.160 or less.

11. Ensure that the filler plugs are clean and the vent holes are open. Tighten all filler plugs.

! CAUTION

NEVER plug the battery charger into the truck. This will severely damage the electrical system on the truck.

Plug the charger ONLY into the connector from the battery.

12. Charge the battery, following specific instructions in your battery and battery charger manufacturer’s manual.

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Component Procedures Charging

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13. Using a hydrometer, measure the specific gravity of each cell. No amount of charging will increase battery capacity or raise specific gravity above its fully charged level (specific gravity 1.280 to 1.300).

14. Measure and record the voltage reading for each cell on the battery maintenance chart.

There must be a difference of no more than 0.2 volt between cells.

15. If, after charging, the electrolyte level is below the fill port, add water to put it to the fill level. Do NOT overfill the cells or permit electrolyte to spill on the battery case.

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Component Procedures Component Testing

Component Testing Table 7-6 gives the recommended test procedures for electrical components not specifically covered. The measurements are all made by the use of an ohmmeter (Simpson model 260 or equivalent). The readings do not absolutely mean components examined will function correctly in the system under different current and voltage conditions. The ohmmeter, however, will indicate most shorted or open circuit conditions. For specific component testing, refer to the applicable procedure in “Controls” on page 7-95.

Table 7-6: Electrical Component Tests

Component Coils, Horn, Contactors and Solenoids

Ohmmeter Selector Setting Rx1

Ohmmeter Lead Connections

Recommended Ohmmeter Readings

Between coil terminals

Ohmmeter must read approximately 1/2 scale reading.

If the needle moves to the 0 end of the scale, the coil is shorted. If the needle does not move, the coil is open.

R x 10,000

Between each coil terminal and truck frame

Ohmmeter shall not read less than 10,000 ohms. Replace coils failing examination.

Transformer T-1 (test for open circuit primary or secondary winding)

Rx1

Primary winding between TP-4 and TP-28. Secondary winding between TP-9 and C1-2

Ohmmeter must read 0 ohms for the two measurements. If the ohmmeter needle remains on the left side of the scale, the transformer has an open circuit and must be replaced.

Transformer T-1 (test for short between primary and secondary winding)

R x 10,000

Connect one lead to one of the primary wires. Connect the other lead to a secondary wire.

There must be no needle movement (needle to remain on the left side of the scale).

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Component Procedures Contactors

Raymond ® Sideloader Maintenance Manual Electrical

Contactors Clean and inspect contactors regularly to help make sure that they operate correctly. See “Scheduled Maintenance” on page 5-1.

Cleaning When cleaning contactors: • Remove dust, dirt, and other foreign materials from contactors with dry, filtered, compressed air [30 psi (207 kPa) max].

• Use a cleaning solution on a clean cloth to remove stubborn dirt, if necessary.

Visually inspect all parts for: • Nicks • Cracked or deteriorated bushings, insulation or contact guards • Broken or damaged leads • Stripped threads • Broken terminals or springs • Burned contact tips • Other obvious damage Replace bad parts as necessary.

Tip Inspection When inspecting contactor tips, keep in mind that: • Darkening of points does not indicate burning • Burning means loss of contact point material • The contact may be used until the material is almost completely gone • The silver alloy part of the point is usable contact material; the copper backing is not.

Replace the contact points if there is not enough contact point material to last until the next regular inspection.

Do not file contact points or remove discoloration or minor irregularities. This is wasteful and produces a surface more susceptible to sticking.

If a cone and crater appear, remove and repair the tips.

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Component Procedures Contactor Coil Replacement

Contactor Coil Replacement If you suspect a bad contactor coil, test the coil with an ohmmeter per Table 7-6. Coil replacement is the same for all contactors. See Figures 7-34 thru 7-37.

! CAUTION

Do not loosen the top frame screws [9] from the front end plate [6]. They determine the total stroke. Be careful when reassembling the movable core [8] and back end plate [1]. Do not deform the teflon lining.

1. To remove the coil [5], first remove screws [9] that attach the back end plate [1] to the side plates [2 and 3].

2. Carefully remove the frame and core assembly [1], including the teflon washer [4] and coil [5].

NOTE: Make sure the brass tube is wedged tightly into the frame and core assembly [1]. If it is loose, replace it.

3. Make sure the Teflon washer [4] is not loose, torn or folded. Replace it if it is damaged.

4. Slide the frame and core assembly [1] with the washer [4] and new coil [5] into the contactor frame assembly [2, 3, 6]. Make sure the movable core and rod assembly [8] enters the frame and core assembly [1] freely in order to avoid causing damage to to the teflon lining.

5. Using a C-clamp, or hand arbor, press and attach two 3/4 in. inside diameter nuts, that encircle the core bottom for protection, press the end frame and core assembly [1] into position and tighten the screws that attach the frame and core assembly [1] to the side plates [2 and 3].

NOTE: Remove the base bus bar assembly from multideck units so that clamping pressure is applied directly to the plate and tie rod assembly. Apply pressure until the core bottoms out and there is no further movement.

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Component Procedures

Raymond ® Sideloader Maintenance Manual

Replacement of Contactor Tips, Insulation and/or Core and Rod Assembly

Electrical

Replacement of Contactor Tips, Insulation and/or Core and Rod Assembly Replacement of these components is very similar for all contactors.

NOTE: Leave all shims in position when replacing contact tips. They are necessary for correct contact gap and overtravel.

F and R Contactors See Figure 7-34.

1. Remove nuts [38 and 39] and associated hardware. Insulation plates [36 and 37], bushings [34], movable contacts [26], springs [25], bushings [24], washers [23], bridge guides [27], tubings [28], bushings [22], and washers [18] can now be removed.

2. Remove screws [21 and 29] to remove bus bars [15, 16, 19, 20, 30, 31, 32 and 33].

NOTE: Bus bars [15, 16, 19, 20, 30, 31, 32, and 33] are not identical and must be replaced in their correct position for correct function of the contactor, 3. Remove insulator [17] and screws [14], then remove insulators [12 and 13] and detent [11].

4. Reassemble in the reverse order of disassembly.

7

Figure 7-34:

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F and R Contactors

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Component Procedures

Electrical

X, P, and M Contactors

X, P, and M Contactors See Figure 7-35.

1. Remove nut [27] and associated hardware.

The movable contact bar [23], spring [24], and bushing [25] can now be lifted off.

7

2. Remove screws [18 and 22] and associated hardware. The stationary bus bar [16] can now be removed.

3. By removing insulator [15] and screws [14], the insulators [12 and 13] and detent [11] may be removed.

4. Reassemble in the reverse order of disassembly.

Figure 7-35: X, P, and M Contactors

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Component Procedures

Raymond ® Sideloader Maintenance Manual

1S Contactor

Electrical

1S Contactor See Figure 7-36.

1. Remove nuts [31 and 32] and associated hardware. Insulation plate [29], bushing [30], bus bars [26 and 27], movable contact [25], spring [24], bushings [21 and 23], washer [22], bridge guide [19], and tubings [20] can now be removed.

2. Removing screws [18] permits removal of insulators [16 and 17] and detent [15].

3. Remove screws [12] to remove interlock switch [11]. If the switch needs adjustment, loosen nuts [14] and move the switch so it just closes as the contact tips close.

4. Reassemble in the reverse order of disassembly.

7

Figure 7-36:

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1S Contactor

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Component Procedures

Electrical

PC Contactor

PC Contactor See Figure 7-37.

1. Remove nut [31] and associated hardware.

The movable contact bar [27], spring [28], and bushing [29] can now be lifted off.

2. Remove screws [22 and 23] and associated hardware. The stationary bus bars [20] can now be removed.

3. By removing insulator [19] and screws [18], the insulators [16 and 17] and detent [15] may be removed.

4. Remove screws [12] to remove interlock switch [11]. If the switch needs adjustment, loosen nuts [14] and move the switch so it just closes as the contact tips close.

5. Reassemble in the reverse order of disassembly.

7

Figure 7-37: PC Contactor

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Component Procedures PC Contactor

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Component Procedures

Controls Component Procedures Component Procedures

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Controls 7:

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Component Procedures Directional/Speed Control Assembly

Controls

Directional/Speed Control Assembly Clean the directional/speed control assembly occasionally by blowing out dust and dirt with low air pressure [30 psi (207 kPa) max]. If the directional/speed control assembly fails to operate correctly, inspect for broken springs or other parts.

NOTE: Do NOT apply oil or grease to the cams, gears, or switches of the directional/ speed control assembly.

Master Switches The master switches of the directional/speed control assembly are closed as the directional/ speed control handle is moved through its various positions. Table 7-7 shows the switches that must be closed at each position of the directional/speed control handle.

Table 7-7: Master Switch Position/Readings

Handle Position

Switch

Terminals

Ohmmeter Reading

Connect an ohmmeter to the terminal indicated for each position.

Neutral

All

1&2

Continuity

SCR speed range forward

MS1

1&3

Continuity

High speed forward

MS1, MS5A

1&3

Continuity

SCR speed range reverse

MS2

1&3

Continuity

High speed reverse

MS2, MS5B

1&3

Continuity

Replace any faulty switch.

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Component Procedures

Controls

Potentiometer Test

Potentiometer Test Use a voltmeter to test the existing potentiometer.

NOTE: Do NOT use an ohmmeter to measure the potentiometer. The ohmmeter can cause damage to the potentiometer.

! WARNING • Use extreme care when the lift truck is jacked up.

• Never block the lift truck between the telescopic and the floor.

• Use a suitable hoist to stabilize the mast.

• Keep hands and feet clear from vehicle while jacking the lift truck.

• After the lift truck is jacked, install solid blocks or jack stands beneath it to support it.

• Do NOT rely on the jack alone to support the lift truck. See “Jacking Safety” on page 2-11.

1. Jack and block up the truck until the drive wheels are off the floor.

2. Remove the cover on the master switch assembly.

7

Figure 7-38: Potentiometer Terminals

3. Connect the positive lead of the voltmeter, set on 10 VDC, to pin 3 and the negative lead to pin 2. See Figure 7-38.

4. Reconnect the battery connector and turn the key switch ON. Observe the voltmeter reading.

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Component Procedures Potentiometer Test

Raymond ® Sideloader Maintenance Manual Controls

5. With the directional/speed control handle in the neutral position, approximately 2 to 2.5 volts must be read.

6. Slowly advance the directional/speed control handle from the neutral position to the top SCR speed range forward or reverse.

7. Observe the voltmeter needle for irregularities that indicate a bad potentiometer.

8. As the handle is moved to top SCR range, the voltage must steadily decrease to approximately 0 volts.

9. Disconnect the positive voltmeter lead from pin 3 and connect the lead to pin 1.

10. With the handle in neutral, the voltmeter must indicate approximately 0 volts.

11. Slowly advance the directional/speed control handle from neutral to top SCR speed range forward or reverse. Observe the voltmeter reading.

12. As the handle is moved to top SCR range, the voltage must steadily increase to approximately 5 volts.

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Component Procedures

Controls

Potentiometer Removal or Replacement

Potentiometer Removal or Replacement Maintain correct care when removing or replacing the potentiometer and/or its gears.

Damage can occur to the potentiometer and gears if they are not assembled correctly.

Examine the new potentiometer and potentiometer key assemblies before removing the old potentiometer. See Figure 7-39.

1. Support 2. Gear Shaft 3. Dual Segment Gear 4. Potentiometer Gear 5. Set Screw 6. Idler Gear 7. Snap Ring 8. Switch Bracket 9. Set Screw 10. Potentiometer Key 11. Binding Head Screw 12. Torsion Spring 13. Lock Nut 14. Potentiometer 15. Nut 16. Nut 17. Return Gear 7

Figure 7-39: Directional/Speed Control Assembly

1. Unsolder the wires from the terminals on the potentiometer.

2. Rotate potentiometer gear [4] enough to let an Allen wrench to be inserted into the set screw [9].

NOTE: Before loosening the set screw, hold the potentiometer gear [4] with the thumb and forefinger to prevent the traction spring [23] from unwinding.

3. Loosen the set screw and remove the potentiometer while holding the pot gear in position.

4. Insert the new potentiometer [14] and key [10] through the bracket [8] and through the potentiometer gear [4]. The potentiometer must be seated on the bracket [8] as far as possible.

5. Rotate the potentiometer shaft counterclockwise until resistance is felt.

6. Hold the hub on the potentiometer gear against the set screw [5],

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Component Procedures Potentiometer Gear Binding Adjustment

Controls

7. Tighten the set screw.

If

Then

Gear binding occurs...

See below.

Torsion spring (with an initial preload of one turn) fails to return the potentiometer without binding...

Readjust it.

Set screw [5] does not contact the nub on the potentiometer gear [4] at the same time or slightly before the potentiometer contacts the internal stops...

Readjust it. See below.

8. Solder the wires to the potentiometer terminals.

Potentiometer Gear Binding Adjustment Incorrect adjustment of the gears can cause damage to the gears and potentiometer. See “Directional/Speed Control Assembly” on page 7-99.

1. Refer to page 7-99 to examine for correct installation and adjustment of the potentiometer.

2. Rotate the directional/speed control handle in a counterclockwise direction to a point where the first tooth of the dual gear [3] catches a tooth on the potentiometer gear.

Smooth and unrestricted movement shows correct meshing of the potentiometer gear [4] and dual gear [3]. At no time must the gear tips meet.

NOTE: The potentiometer gear [4] must rest against the set screw [5] at all times when making adjustments.

3. If the gears do not mesh correctly (additional resistance), loosen set screw [9] while holding potentiometer gear [4] and adjust set screw [5] by loosening nut [15].

If

Then

the set screw is turned IN...

the potentiometer gear [4] moves further ahead.

the set screw is turned OUT...

the potentiometer gear [4] moves further back.

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Component Procedures Directional/Speed Control Reassembly Checklist

4. Rotate the directional/speed control handle in a clockwise direction to a point where the first tooth of dual gear [3] catches a tooth on idler gear [6]: •

A smooth, unrestricted movement shows correct meshing of idler gear [6] and dual gear [3]

•

At no time must gear tips meet

•

If the potentiometer gear [4] and dual gear [3] mesh correctly, the idler gear [6] and dual gear [3] must also mesh correctly

5. Readjust the potentiometer per page 7-100 and rotate the handle back and forth several times. Re-examine meshing of the gears. Readjust as necessary.

Directional/Speed Control Reassembly Checklist When reassembling the directional/speed control assembly, do the following checks. See “Directional/Speed Control Assembly” on page 7-96.

Check...

If NO...

Is the binding head screw [11] that secures key [10] to switch bracket [8] loose?

Loosen it.

Is there a slight gap between the head of the screw and key [10]?

Create the gap.

Does the key ride freely on the binding head screw?

Adjust it correctly.

Can the two gear shafts [2] that hold the support [1] and the gears in position move?

Tighten the tapered segment of the shaft snugly to the tapered hole in switch bracket [8].

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Component Procedures Control Unit

Raymond ® Sideloader Maintenance Manual Controls

Control Unit ! CAUTION

Avoid operating the motor at high speed for more than a few seconds at a time when the truck is jacked up and blocked. Excessive RPM can cause damage to the motor.

! CAUTION

Do not attempt to change the pulse width or frequency by changing the ADJ-1 and ADJ-3 settings on the Control Unit without an oscilloscope.

These are preset at the factory for optimum performance.

! CAUTION

The AUTO/MAN switch (see Figure 7-40) must remain in the MAN (manual) position after tests, repairs, or replacements are complete.

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Component Procedures

Controls

Input Voltage Check

7

Figure 7-40: Control Unit Adjustments and Test Pins

NOTE: Before performing tests on the Control Unit, remove the five-amp fuse and measure it for continuity.

Input Voltage Check 1. With the voltmeter in the 50 volts DC range, connect the positive lead to TP-1 and the negative lead to TP-2. See Figure 7-40.

2. With the battery plugged in and key switch turned ON, approximately 36 volts must be read.

3. Examine the wiring to the Control Unit if there is no voltage reading,

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Component Procedures Regulated Voltage Check

Controls

Regulated Voltage Check Regulated voltage is maintained in the pulse generating circuit.

1. With the voltmeter in the 50 VDC range, connect the positive lead to TP-3 and the negative lead to TP-2. See Figure 7-40.

2. With the key switch turned ON, approximately 9 volts must be read.

NOTE: The Auxiliary (AUX) circuit card can be identified as one of the two larger circuit cards having only one adjustment screw (ADJ-7). See Figure 7-41. The Variable Pulse Generator (VPG) circuit card can be identified as the other large circuit card, having six adjustment screws (ADJ-1 thru 6). The Power Driver circuit card is the smaller of the three cards, installed perpendicular to the AUX and VPG cards and having no adjustment screws. When replacing a circuit card, it is necessary to make the correct adjustments to the card to attain the correct performance characteristics.

7

Figure 7-41: Control Unit-Exploded View

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Component Procedures Width and Frequency Pulse Checks

Width and Frequency Pulse Checks 1. Turn the key switch ON. 2. Make sure the truck is not in a speed limiting condition. See “Speed Limit” on page 8-28.

3. Connect the oscilloscope test lead to TP-4 and the ground lead to TP-2. See Figure 7-40. Set the horizontal time base to l msec/div. Set the vertical sensitivity to 0.2 volts/div.

! WARNING • Use extreme care when the lift truck is jacked up.

• Never block the lift truck between the telescopic and the floor.

• Use a suitable hoist to stabilize the mast.

• Keep hands and feet clear from vehicle while jacking the lift truck.

• After the lift truck is jacked, install solid blocks or jack stands beneath it to support it.

• Do NOT rely on the jack alone to support the lift truck. See “Jacking Safety” on page 2-11.

4. Jack up and block the truck.

5. Activate the deadman switch.

6. Move the directional/speed control handle full forward or reverse. The trace must start at 5.5 to 7.3 volts. See Figure 7-42. The on time must be 5ms. The OFF time must be 1ms, for a total period of 6ms.

7. Turn the key switch OFF.

7

Figure 7-42: Width and Frequency Pulse Trace

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Component Procedures

Raymond ® Sideloader Maintenance Manual

Idle Repetition (Rep) Rate Adjustment

Controls

Idle Repetition (Rep) Rate Adjustment ! CAUTION

Make sure that the switch in the upper left corner of the VPG card is set at 36 volts. The AUTO/ MANUAL switch (see Figure 7-40) must also be in the manual (MAN) position.

1. Connect the oscilloscope test lead to TP-4 and the ground to TP-2. See Figure 7-40.

2. Set the time/div. to 5ms.

3. Turn the key switch ON. 4. With the control handle in the neutral position and the deadman switch activated, observe the waveform on the oscilloscope. It must duplicate Figure 7-43. If the Idle Rep Rate needs adjustment: •

Turn ADJ-4 clockwise to increase the Idle Rep Rate by increasing the frequency of the pulses

•

Turn ADJ-4 counterclockwise to decrease the Idle Rep Rate by decreasing the frequency of the pulses.

7

Figure 7-43: Idle Rep Trace

Plugging Adjustment Plugging is a method to slow speed and change direction while traveling. The driver may also plug to stop the truck. Plugging does not stop the truck as quickly as braking, but is an alternative method for bringing the truck to a controlled stop.

Plugging occurs when the operator moves the control handle from its current position through neutral in the opposite direction. The farther the handle is moved in the opposite direction, the greater the plugging force.

A normal setting for plugging will permit an empty truck traveling at full speed to continue traveling in the original direction approximately one truck length maximum before the truck comes to a stop and starts moving in the opposite direction. With a load, the stopping distance will increase.

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Component Procedures

Controls

Plugging Adjustment

1. Connect the oscilloscope test lead to TP-4 and the ground to TP-2. See Figure 7-40.

2. Set the horizontal time base of the oscilloscope to 10ms/div and the vertical sensitivity to 2 volts/div.

3. Turn the key switch ON. 4. Without activating the deadman switch, move the control handle to full forward or reverse and observe the waveform on the oscilloscope. The trace must duplicate Figure 7-44.

5. Adjusting ADJ-5 to increase the pulse period makes plugging softer. Decreasing the pulse period will stiffen the plugging.

75 ms (Pulse Period)

7

Figure 7-44: Plugging Trace

! WARNING After making a plugging adjustment, operate the truck in an open area.

Incorrect adjustment can result in plugging that could cause damage to the truck drive system.

6. Operate the truck to see how it reacts in a plug.

7. Adjust ADJ-5 in small increments as required.

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Component Procedures

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1/2 Speed Test (VPG Card)

Controls

1/2 Speed Test (VPG Card) ! WARNING • Use extreme care when the lift truck is jacked up.

• Never block the lift truck between the telescopic and the floor.

• Use a suitable hoist to stabilize the mast.

• Keep hands and feet clear from vehicle while jacking the lift truck.

• After the lift truck is jacked, install solid blocks or jack stands beneath it to support it.

• Do NOT rely on the jack alone to support the lift truck. See “Jacking Safety” on page 2-11.

1. Jack up and block the truck.

2. Connect the oscilloscope probe to TP-4 and ground to TP-2. See Figure 7-40. Set the horizontal time base to 2ms/div. Set the vertical sensitivity to 0.2 volts/div.

3. Turn the key switch ON and activate the deadman switch.

4. Put the truck in a half-speed situation. See “Speed Limit” on page 8-28.

5. Move the directional/speed control handle to full forward or reverse. The trace must duplicate Figure 7-45. If it does not approximate it, examine the Speed Limit Module. See “Speed Limit Module” on page 7-120. If the Speed Limit Module is functioning, replace the VPG card.

7

Figure 7-45: 1/2 Speed Trace

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Component Procedures

Controls

1/8 Speed Test

1/8 Speed Test ! WARNING • Use extreme care when the lift truck is jacked up.

• Never block the lift truck between the telescopic and the floor.

• Use a suitable hoist to stabilize the mast.

• Keep hands and feet clear from vehicle while jacking the lift truck.

• After the lift truck is jacked, install solid blocks or jack stands beneath it to support it.

• Do NOT rely on the jack alone to support the lift truck. See “Jacking Safety” on page 2-11.

1. Jack up and block the truck.

2. Connect the oscilloscope probe to TP-4 and ground to TP-2. See Figure 7-40.

3. Turn the key switch ON and activate the deadman switch.

4. Move the directional/speed control handle to full forward or reverse. The trace must duplicate Figure 7-46. If it does not approximate it, examine the Speed Limit Module. See “Speed Limit Module” on page 7-120. If the Speed Limit Module is functioning, replace the VPG card.

5. Adjust the potentiometer setting on the Speed Limit Module.

7

Figure 7-46: 1/8 Speed Trace

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Component Procedures

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Forward and Reverse Time Delay Circuit Test

Controls

Forward and Reverse Time Delay Circuit Test ! WARNING • Use extreme care when the lift truck is jacked up.

• Never block the lift truck between the telescopic and the floor.

• Use a suitable hoist to stabilize the mast.

• Keep hands and feet clear from vehicle while jacking the lift truck.

• After the lift truck is jacked, install solid blocks or jack stands beneath it to support it.

• Do NOT rely on the jack alone to support the lift truck. See “Jacking Safety” on page 2-11.

1. Jack up and block the truck.

2. Connect the oscilloscope probe to TP-14 and ground to TP-2. See Figure 7-40. Set the horizontal time base to 20msec/div. Set the vertical sensitivity to 10 volts/div.

3. Turn the key switch ON and activate the deadman switch.

4. Move the directional/speed control handle in and out of forward or reverse and observe the scope. The trace must start at 36 volts and sweep across 80 to 125ms, then drop to approximately 0 volts. See Figure 7-47. Repeat this test for the two directions.

7

Figure 7-47: F/R Time Delay Trace

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Component Procedures “M” Time Delay Circuit Test

“M” Time Delay Circuit Test ! WARNING • Use extreme care when the lift truck is jacked up.

• Never block the lift truck between the telescopic and the floor.

• Use a suitable hoist to stabilize the mast.

• Keep hands and feet clear from vehicle while jacking the lift truck.

• After the lift truck is jacked, install solid blocks or jack stands beneath it to support it.

• Do NOT rely on the jack alone to support the lift truck. See “Jacking Safety” on page 2-11.

1. Jack up and block the truck.

2. Connect the oscilloscope probe to TP-12 and ground to TP-2. See Figure 7-40. Set the time/div. to 0.5 seconds and the volts/div. to 1.0.

3. Turn the key switch ON and activate the deadman switch.

4. Move the directional/speed control handle full forward or reverse and observe the scope. The trace must start at 36 volts and sweep across 2.5 to 3 seconds, then drop to ground. See Figure 7-48. Repeat this test for the two directions.

7

Figure 7-48: M Time Delay Trace

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Component Procedures

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Equalizing Time Delay Circuit Test

Controls

Equalizing Time Delay Circuit Test ! WARNING • Use extreme care when the lift truck is jacked up.

• Never block the lift truck between the telescopic and the floor.

• Use a suitable hoist to stabilize the mast.

• Keep hands and feet clear from vehicle while jacking the lift truck.

• After the lift truck is jacked, install solid blocks or jack stands beneath it to support it.

• Do NOT rely on the jack alone to support the lift truck. See “Jacking Safety” on page 2-11.

1. Jack up and block the truck.

2. Connect the oscilloscope probe to terminal Y on the 1S contactor and ground to TP-2.

Set the time/div. to 0.1 seconds and the volts/div. to 1.0.

3. Turn the key switch ON and activate the deadman switch.

4. Move the directional/speed control handle forward or reverse and observe the scope.

The trace must start at 36 volts and sweep across 0.5 to 0.7 seconds, then drop to ground. See Figure 7-49. Repeat this test for the two directions.

7

Figure 7-49: Equalizing Time Delay Trace

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Component Procedures Current Limit

Current Limit To correctly adjust the current limit circuit, the battery specific gravity must be at least 1.240 or greater. The drive motor must be relatively cool (at room temperature).

! CAUTION

Do NOT jack up and block the truck.

1. Disconnect the battery and connect a 750 amp shunt (with matching meter) between the battery and the truck connector. See Figure 7-50.

2. Block open the M contactor tips to disable it.

3. Turn the key switch ON. 4. Securely restrain the truck so that it can not move. In order to obtain an accurate reading, the wheels must not spin.

! CAUTION

Do NOT hold power on longer than 15 seconds. For every 15 seconds that the motor is on, wait 30 seconds for the motor to cool off.

7

Figure 7-50: Current Shunt and Meter Arrangement

5. Turn the speed control handle fully in the two directions and observe the current reading on the ammeter. It must read 550 amps. If it does not, turn ADJ-2 until it does. See Figure 7-40.

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Component Procedures

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“M” Lockout Circuit Test

Controls

“M” Lockout Circuit Test ! WARNING • Use extreme care when the lift truck is jacked up.

• Never block the lift truck between the telescopic and the floor.

• Use a suitable hoist to stabilize the mast.

• Keep hands and feet clear from vehicle while jacking the lift truck.

• After the lift truck is jacked, install solid blocks or jack stands beneath it to support it.

• Do NOT rely on the jack alone to support the lift truck. See “Jacking Safety” on page 2-11.

1. Jack up and block the truck.

2. Disconnect the main SCR1 gate lead from terminal strip TS3-1.

3. Turn the key switch ON and activate the deadman switch.

4. Move the directional/speed control handle to the full forward or reverse position.

5. If the M contactor does not energize in 5 seconds, it is functioning correctly. If the M contactor functions incorrectly, replace the Control Unit or AUX circuit card.

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Component Procedures Overload Control Circuit Test

Overload Control Circuit Test ! WARNING • Use extreme care when the lift truck is jacked up.

• Never block the lift truck between the telescopic and the floor.

• Use a suitable hoist to stabilize the mast.

• Keep hands and feet clear from vehicle while jacking the lift truck.

• After the lift truck is jacked, install solid blocks or jack stands beneath it to support it.

• Do NOT rely on the jack alone to support the lift truck. See “Jacking Safety” on page 2-11.

1. Jack up and block the truck.

2. Disconnect the commutating gate lead from terminal strip TS3-3.

3. Place the Control Unit reset switch on MAN. See Figure 7-40.

4. Turn the key switch ON and activate the deadman switch.

5. Move the directional/speed control handle in the forward or reverse position without going into M speed.

6. The appropriate contactors must energize and then de-energize.

7. If the contactor remains de-energized until reset by the key switch, the overload circuit is functioning correctly.

8. Reconnect the SCR2 gate lead if the unit tests OK.

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Component Procedures Weld Detect Circuit

Raymond ® Sideloader Maintenance Manual Controls

Weld Detect Circuit ! WARNING • Use extreme care when the lift truck is jacked up.

• Never block the lift truck between the telescopic and the floor.

• Use a suitable hoist to stabilize the mast.

• Keep hands and feet clear from vehicle while jacking the lift truck.

• After the lift truck is jacked, install solid blocks or jack stands beneath it to support it.

• Do NOT rely on the jack alone to support the lift truck. See “Jacking Safety” on page 2-11.

1. Jack up and block the truck.

2. Hold or push the M contactor tips together with a block of wood or insulated bar.

3. Operate the truck in either forward or reverse. The F or R contactor must not energize.

4. If this does not happen, examine the wiring from terminal B to the anode of the main SCR and any connections in between.

5. If the wiring in step 4 tests OK, the weld detect circuit is bad. Replace the AUX card.

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Component Procedures Power Driver Circuit Card

Power Driver Circuit Card Examine the Power Driver card for correct operation by measuring pulses to the main, charging and commutating SCRs. To determine whether the main SCR1, charging SCR2, and commutating SCR3 are functioning correctly, perform the following tests:

Main SCR Pulse Test 1. With the ground clip on pin c of the motherboard and the probe on TP-6, set the scope time/div. to 10ms and volts/div. to 0.5 volts (10x probe). See Figure 7-40.

2. With the key switch ON and the deadman switch activated, a pulse amplitude of 12 to 18 volts with a pulse width of 10 to 30ms must be read.

3. Turn the time/div. to 5ms. The pulse amplitude must remain the same with a repetition rate of 35ms.

Commutating SCR Pulse Test 1. With the ground clip on TP-2 and the probe on TP-10, set the scope time/div. to 10ms and volts/div. to 0.5 volts (10x probe). See Figure 7-40.

2. With the key switch ON and the deadman switch activated, the scope must read a pulse amplitude of 12 to 18 volts with a pulse width of 10 to 30ms.

3. Turn time/div. to 5ms the pulse amplitude must remain the same with the repetition rate of 35ms.

Charging SCR Pulse Test 1. With the ground clip on TP-8 and the probe on TP-7, set scope time/div. to 10ms and volts/div, to 0.5 volts (10x probe). See Figure 7-40.

2. With the key switch ON and deadman switch activated, the scope must read a pulse amplitude of 10 to 15 volts with a pulse width of 10 to 25ms.

3. Turn the time/div. to 5ms. The pulse amplitude must remain the same with a repetition rate of 35ms.

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Component Procedures

Raymond ® Sideloader Maintenance Manual

Transient Suppressors for the M, F, and R Contactors

Controls

Transient Suppressors for the M, F, and R Contactors The transient suppressors reduce to an acceptable level the transient voltages produced when the M, F and R contactor coils are de-energized. They are installed on the AUX circuit card in the Control Unit. Use a voltmeter and the circuit shown in Figure 7-51 to test these suppressors or refer to SS-2C. 1. Set the voltmeter on the 2that50 volt scale.

For the M coil suppressor, connect test circuit lead T1 to pin JP2-J in the Control Unit and lead T2 to test pin TP-12, also in the Control Unit.

2. Energize and de-energize the M contactor. If the meter reads more than 50 volts, the suppressor is bad. Replace the AUX circuit card. If the meter reads less than 50 volts, discharge the test capacitor C1, set the meter on the 50-volt scale and proceed with step 3.

7

Figure 7-51: Test Circuit for the M, F, and R Coil Suppressors

3. Energize and de-energize the M contactor observing the meter reading, The meter must swing slightly past 30 volts, appear to stabilize at approximately 24 volts, then move slowly to zero. Replace the AUX circuit card if the reading is not attained.

4. When examining the F coil suppressor, connect lead T1 to pin JP2-C and T2 to TP-14 in the Control Unit.

5. When examining the R coil suppressor, connect lead T1 to pin JP2-E and T2 to TP-14 in the Control Unit.

6. Test results for Steps 4 and 5 must be the same as those for the M suppressor in steps 2 and 3 above.

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Component Procedures

Controls

Equalizing Time Delay

Equalizing Time Delay Prior to examining the equalizing time delay: • Examine the 1S contactor per page 7-88 and page 7-89. Replace a faulty contactor.

• Examine the plugging relays. Reference “Plugging Relays K1 & K2” on page 7-127.

Replace faulty relays.

• Examine the 1S contactor suppressor as follows: •

Use test circuit in Figure 7-51.

•

Connect T1 to pins 1S-X and T2 to pin 1S-Y.

•

Follow the procedure on page 7-118, steps 2 and 3.

•

Replace the module failing the test.

! WARNING • Use extreme care when the lift truck is jacked up.

• Never block the lift truck between the telescopic and the floor.

• Use a suitable hoist to stabilize the mast.

• Keep hands and feet clear from vehicle while jacking the lift truck.

• After the lift truck is jacked, install solid blocks or jack stands beneath it to support it.

• Do NOT rely on the jack alone to support the lift truck. See “Jacking Safety” on page 2-11.

1. Jack up and block the truck.

2. Using a Simpson 260 Volt/Ohmmeter or equivalent, set the meter on the 50 volt scale.

3. Attach the positive lead to the 1S-Y terminal and the negative lead to FU6-2.

4. Turn the key switch ON and activate the deadman switch.

5. Move the directional/speed control handle to either the forward or reverse position.

The meter must read approximately 36

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Component Procedures Speed Limit Module

Controls

volts for 0.6 seconds, then fall to 0 for either position.

6. If the meter remains at 36 volts, replace the delay.

7. Set the Simpson Meter on the R x 1 DC+ scale. Remove the module from the truck.

7

Figure 7-52: Equalizing Time Delay

8. Attach the positive lead to pin 1 and the negative lead to pin 5. See Figure 7-52. The meter must read between 10 and 15 ohms.

9. Leave the negative lead on pin 5. Attach the positive lead to pin 2, then pin 3, then pin 4. A 10 to 15 ohm reading must be measured for each position.

10. Reverse the polarity for each position (the positive lead to pin 5 and the negative lead to pins 1, then pin 2, then pin 3, then pin 4.

The meter must read open for each position.

11. Replace any module that fails the above tests.

Speed Limit Module The circuitry necessary for speed limit control, with the exception of travel cutout, is contained in a replaceable module. As shown in Figure 7-53, the Speed Limit Module contains three relays and associated diodes and resistors necessary to limit speed dependent on load elevation and position. Although the module is not field repairable, it is necessary to examine the unit in order to determine whether or not it is operable.

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Component Procedures

Controls

Speed Limit Module

7

Figure 7-53: Speed Limit Schematic

NOTE: If the truck enters M range during any mode of operation that calls for speed limiting, replace the Speed Limit Module immediately.

Do NOT attempt to repair the Speed Limit Module. Replace any faulty speed limit module.

Remove the Speed Limit Module from the truck.

Connect 36-volt DC negative to pin 13 for all tests to be performed. Connect 36-volt DC positive to the pins as shown in Table 7-8: Table 7-8: Speed Limit Module

Voltage Pin Connection +

Ohmmeter Scale

Ohmmeter Pin Connections

Ohmmeter Reading (No Voltage)

Ohmmeter Reading (Voltage)

13

7

Rx1

3

2

open

continuity

13

11

R x 10,000

1

5

pot. setting

open

13

11

R x 10,000

1

4

pot. setting

open

NOTE: Pins 6, 10, 14 thru 18 are not used.

Input on pin 7 will result in no “M” speed and half SCR speed - 2-1/2 mph (S11).

Input on pin 11 will result in 1/8 speed SCR - 1/2 mph (S16).

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7-121

Component Procedures SCRs

Raymond ® Sideloader Maintenance Manual Controls

SCRs Examine the SCRs with a Simpson 260 volt/ohmmeter or equivalent. The readings do not guarantee that the components being examined will function correctly in the system under different current and voltage conditions, however, they will indicate most shorted or open circuit conditions. A Pipps gauge (1-074-025) is required for replacing a faulty SCR.

Test Procedure 1. Disconnect all leads to the SCR being examined and use the heat sinks and bus bars as anode and cathode connections for the meter leads.

NOTE: It is not recommended to remove the SCR and clamp assembly for test procedures, however, if the assembly is removed it must remain clamped for correct testing.

2. With the meter set on the R x 100 scale, connect the meter leads to the anode and cathode and note the reading. Reverse the leads and note the reading again. Replace the SCR if the reading is less than 1000 ohms in either direction.

3. With the meter set on the R x 1 scale, connect the meter leads to the cathode and gate and note the reading. Reverse the leads and note the reading again. Replace the SCR if the reading does not fall within the 5 ohm to 50 ohm range in either direction.

SCR1 Replacement SCR1 may be replaced without having to remove the entire assembly from the truck. See Figure 7-54.

1. Discharge the capacitors per page 7-82 and disconnect the SCR leads from TS3-1 and TS3-2.

2. Loosen the mounting screws that attach the bus bars to the heatsinks.

3. Loosen mounting clamp screws enough to permit the SCR to be removed.

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Component Procedures

Controls

SCR1 Replacement

4. Insert a new SCR in the clamp, making sure the anode and cathode are in the correct position and the SCR is installed and centered on the spiral pins.

5. Finger tighten the clamp screws to attach the SCR in position. Tighten each screw 2-1/2 turns.

6. Examine the clamp with a Pipps gauge as shown in Figure 7-56. If the tips of the gauge coincide, the clamp is correctly adjusted.

7. If the tips of the gauge overlap, turn each screw 1/4 turn until the tips of the gauge coincide.

8. If the tips of the gauge are spread apart, excessive adjustment is present.

NOTE: If the clamp is over-adjusted, Do not back the screws off to attain a correct gauge reading. Loosen the screws completely and repeat steps to correctly adjust the clamp.

Clamp Bus Bar

Heat Sinks Clamp Bus Bar Clamp

SCR1

7

Figure 7-54: SCR1 Clamp and Heat Sink Assembly

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Component Procedures

Raymond ® Sideloader Maintenance Manual

SCR2 & SCR3 Replacement

Controls

SCR2 & SCR3 Replacement To assure correct installation of SCR2 and SCR3, it is necessary to remove the entire SCR panel assembly.

1. Discharge the capacitors per page 7-82, then disconnect all bus bars and cables on the SCR panel assembly.

Bus Bar

2. Remove the two screws that mount the SCR panel to the frame. Slide the panel out far enough to permit access to the SCRs. NOTE: It will not be necessary to disconnect the heat sink hoses when replacing SCR2 and SCR3.

3. Loosen the screws that attach the clamp assembly to the heat sink. See Figure 7-55.

4. Disconnect the SCR2 leads from TS3-2 and TS3-3 and SCR3 leads from TS3-4 and TS3-5. Remove the SCRs. 5. Insert the new SCR(s) in the clamp, making sure the anode and cathode are in the correct position and the SCR(s) is (are) installed and centered on the spiral pins.

6. Finger tighten the clamp screws to attach the SCRs in position, then tighten each screw 1/2 turn.

7

Figure 7-55: SCR2 and SCR3 Clamp and Heat Sink Assembly

7. Examine the clamp with a Pipps gauge (P/N 1-074-025) as shown in Figure 7-56, View B. If the holes in the gauge coincide, the clamp is correctly adjusted. If the holes in the gauge have not come together as shown in Figure 7-56, View A, turn each screw 1/4 turn and re-examine. Continue tightening each screw 1/4 turn until the holes in the gauge coincide. If the holes in the gauge have crossed over, excessive adjustment is present.

NOTE: If the clamp is over adjusted, Do not back the screws off to attain the correct gauge reading. Loosen the screws completely and repeat steps 6 & 7 to correctly adjust the clamp.

7-124

View A

View B 7

Figure 7-56: Pipps Gauge Showing Correct Torque Positions

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Raymond ® Sideloader Maintenance Manual Controls

Component Procedures Rectifiers

Rectifiers Examine the rectifiers with a Simpson 260 volt/ohmmeter or equivalent. The readings do not guarantee that the components being examined will function correctly in the system under different current and voltage conditions, however, they will indicate most shorted or open circuit conditions. A Pipps gauge is required for replacing faulty rectifiers.

Test Procedure 1. Disconnect all leads to the rectifier being examined and use the heat sinks and bus bars as anode and cathode connections for the meter leads.

NOTE: It is not recommended to remove the rectifier and clamp assembly for test procedures. However, if the assembly is removed, it must remain clamped for correct testing.

2. With the meter set on the R x 100 scale, connect the meter leads to the anode and cathode and note the reading. Reverse the leads and note the reading again. Replace the rectifier if the meter does not indicate less than 500 ohms in one polarity and greater than 10,000 ohms in the other polarity.

Replacement To ensure correct installation of the rectifiers, it is necessary to remove the entire SCR panel.

1. Discharge the capacitors per page 7-82, then disconnect all bus bars and cables on the SCR panel assembly.

2. Remove the two screws that mount the SCR panel to the frame. Slide the panel out far enough to permit access to the rectifiers.

NOTE: It will not be necessary to disconnect the heat sink hoses when replacing the rectifiers.

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Component Procedures

Raymond ® Sideloader Maintenance Manual

Replacement

Controls

3. Loosen the screws that attach the rectifier to the heat sink. See Figure 7-57. Remove the rectifier.

4. Insert the new rectifier(s) in the clamp, making sure the anode and cathode are in the correct position and the rectifier(s) is (are) installed and centered on the spiral pins.

Bus Bar

Bus Bar

5. Install rectifier REC1 using steps of SCR1 Replacement on page 7-122.

6. Install rectifiers REC2 and REC3 using steps of SCR2 & SCR3 Replacement on page 7-124.

7

Figure 7-57: Rectifier Clamp and Heat Sink Assembly

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Component Procedures Plugging Relays K1 & K2

Plugging Relays K1 & K2 ! WARNING • Use extreme care when the lift truck is jacked up.

• Never block the lift truck between the telescopic and the floor.

• Use a suitable hoist to stabilize the mast.

• Keep hands and feet clear from vehicle while jacking the lift truck.

• After the lift truck is jacked, install solid blocks or jack stands beneath it to support it.

• Do NOT rely on the jack alone to support the lift truck. See “Jacking Safety” on page 2-11.

1. Jack up and block the truck.

2. Disconnect wires from terminals K1-3, K1-4, K2-3, and K2-4 on the plugging relays.

3. Connect an ohmmeter set on the R x 1 scale between K1-3 and K1-4 then between K2-3 and K2-4. The ohmmeter must indicate an open circuit for both. Replace the relay(s) if continuity exists. Reconnect all leads.

4. Using a Simpson 260 voltmeter or equivalent, disconnect leads K1-3 and K1-4. Connect the positive meter lead to K2-4 and negative lead to K2-3. With the key switch ON and the deadman depressed, operate travel control to approximately half speed, then 'plug'. The meter must read approximately 9 volts, momentarily drop to near 0 volts, then return to approximately 9 volts.

5. With K2-3 and K2-4 disconnected and K1-3 and K1-4 connected, attach the positive meter lead to K1-4 and the negative meter lead to K l-3. Performing the same operation as in Step 4 must produce the same results.

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Component Procedures Plugging Relays K1 & K2

Raymond ® Sideloader Maintenance Manual Controls

NOTE: Occasionally a relay will close and stay closed causing the meter reading to drop to 0 volts and stay there until the travel control is returned to neutral. If the two relays remain closed, it can be detected by the meter or the fact that the vehicle coasts to a long stop and will not travel in the opposite direction when plugged.

6. Replace the plugging relay(s) that fail the tests or operate incorrectly.

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Component Procedures Battery Controller and K5 Relay

Battery Controller and K5 Relay The battery controller is preset for the most efficient operation and will not require additional adjustments. The following checklist and relay test procedure will indicate if the unit is functioning correctly.

• When a new, fully charged battery is installed in the truck, the discharge meter must indicate full charge.

• As battery power is used, the needle must move toward empty.

• When the needle is completely in the yellow, but before it gets to the red, the warning light must come on.

• When the needle gets to the red, lift will be inoperative.

• Examine the gauge and bulbs for burnouts or malfunctions.

• Replace any unit that is not functioning correctly.

Relay Test Procedure 1. Using a Simpson 260 volt/ohmmeter or equivalent, do the following tests: Test Points

Meter Setting

K5-A to K5-B

R x 100

425 ±10%

K5-7 to K5-1

Rx1

Continuity

K5-7 to K5-4

Rx1

Open Circuit

Reading

2. Make sure the batteries are well charged.

Disconnect leads K5-7 and K5-4.

3. Attach the positive lead of a voltmeter on the 50 volt scale to K5-7 and the negative lead to TS1-16.

4. With the key switch ON and the deadman depressed, activate the lift.

5. The meter must read 36 volts.

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Component Procedures Automatic Steer Centering Relay K11

Controls

Automatic Steer Centering Relay K11 1. Using a Simpson 260 volt/ohmmeter or equivalent, do the following tests: Test Points

Meter Setting

Reading

K11-A to K11-B

R x 100

1000-1100 ohms

K11-8 to K11-5

Rx1

open circuit

2. Disconnect leads K11-8 and K11-5.

3. Attach the positive lead of a voltmeter on the 50 VDC scale to K11-5 and the negative lead to TS1-16.

4. Turn the key switch ON and momentarily activate the crab steer centering switch.

5. The meter must indicate 36 volts and maintain 36 volts until a left or right crab steer button is depressed or the key switch is turned OFF.

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Raymond ® Sideloader Maintenance Manual Controls

Component Procedures Deadman Relay K12 and Light Load Relay K13

Deadman Relay K12 and Light Load Relay K13 1. Using a Simpson 260 volt/ohmmeter or equivalent, do the following tests: Test Points

Meter Setting

Reading

K12-A to K12-B

R x 100

1000-1100 ohms

K12-9 to K12-3

Rx1

Continuity

K12-9 to K12-6

Rx1

Open Circuit

K12-8 to K12-2

Rx1

Continuity

K12-8 to K12-5

Rx1

Open Circuit

K13-A to K13-B

R x 100

1000-1100 ohms

13-9 to K13-3

Rx1

Continuity

13-9 to K13-6

Rx1

Open Circuit

2. Disconnect the lead at TS1-11 (goes to the relays).

3. Turn the key switch (S1) ON. Continuity must be read between K13-9 and K13-6.

4. With the key switch ON, depress the deadman (S2). Continuity must be read between K12-9 and K12-6 as well as K12-8 and K12-5.

5. Replace the relay failing any test.

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Component Procedures Diode Assemblies

Controls

Diode Assemblies Diode assemblies block current in one direction and let it flow in the other direction. This prevents possible signals that appear at the cathode (-) from feeding back into the anode (+) (control) circuits.

Use a Simpson 260 volt/ohmmeter or equivalent, to do the following tests:

DA1 Location

Appearance

Schematic

DA1, optional with remote control, is installed in the hydraulic compartment behind the auxiliary motor.

DA1 Checks Ohmmeter Lead Connections (+) (-) 5&2 4 4 5&2

Ohmmeter Setting (R x _) 1 1

Ohmmeter Reading Ohms 10 - 15 open

Replace the module if it fails any test.

DA2 Location

Appearance

Schematic

DA2 is installed below the directional/ speed control.

DA2 Checks Ohmmeter Lead Connections (+) (-) 4 2, 3, 5 & 6 2, 3, 5 & 6 4 4 1 1 4

Ohmmeter Setting (R x _) 1 1 1 1

Ohmmeter Reading Ohms 10 - 15 open 180 180

Replace the module if it fails any test.

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Component Procedures

Controls

DA3, DA4, and DA8

DA3, DA4, and DA8 Location DA3, optional with remote control, is installed below the directional/speed control. DA4 is installed behind the auxiliary motor. DA8 is installed near the lowering valve.

Appearance

Schematic

DA3, DA4, and DA8 Checks Ohmmeter Lead Connections (+) (-) 4 2 2 4

Ohmmeter Setting (R x _) 1 1

Ohmmeter Reading Ohms 10 - 15 open

Replace the module if it fails any test.

DA5 Location DA5, optional with remote control, is installed below the Control Unit.

Appearance

Schematic

DA5 Checks Ohmmeter Lead Connections (+) (-) 1, 5 & 6 4 4 1, 5 & 6

Ohmmeter Setting (R x _) 1 1

Ohmmeter Reading Ohms 10 - 15 open

Replace the module if it fails any test.

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Component Procedures DA6

Controls

DA6 Location DA6 is installed below the directional/ speed control.

Appearance

Schematic

DA6 Checks Ohmmeter Lead Connections (+) (-) 1 6 6 1 2 3 3 2 4 5 5 4

Ohmmeter Setting (R x _) 1 1 1 1 1 1

Ohmmeter Reading Ohms 10 - 15 open 10 - 15 open 10 - 15 open

Replace the module if it fails any test.

DA7 and DA12 Location DA7 and DA12 are installed near the lowering valve.

Appearance

Schematic

DA7 and DA12 Checks Ohmmeter Lead Connections (+) (-) 4 5&2 5&2 4

Ohmmeter Setting (R x _) 1 1

Ohmmeter Reading Ohms 10 - 15 open

Replace the module if it fails any test.

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Component Procedures

Controls

Resistor Assemblies

Resistor Assemblies Resistor assemblies remove temporary extreme voltage fluctuations (spikes).

Using a Simpson 260 volt/ohmmeter or equivalent, perform the following tests. Do NOT omit any test.

RA1 Location RA1 is installed below the Control Unit.

Appearance

Schematic

RA1 Tests Ohmmeter Lead Connections (+) (-) 4 1&6 1&6 4

Ohmmeter Setting (R x _) 100 100

Ohmmeter Reading Ohms 4.7K 4.7K

Replace the module if it fails any test.

RA2 Location RA2 is installed on the rectifier heat sink.

Appearance

Schematic

RA2 Tests Ohmmeter Lead Connections (+) (-) 4 2&5 2&5 4 1 6 6 1

Ohmmeter Setting (R x _) 1 1 1 1

Ohmmeter Reading Ohms 22 22 22 22

Replace the module if it fails any test.

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Component Procedures

Raymond ® Sideloader Maintenance Manual

Suppressor Assemblies

Controls

Suppressor Assemblies Transient suppressors are used to reduce the high transient voltages produced to an acceptable level when a coil is de-energized .

Use a voltmeter and the circuit shown in Figure 7-51 to test suppressors SUP1 and SUP3 or refer to SS-2C. 1. Set the voltmeter on the 250 VDC scale. For the P coil, connect test circuit lead T1 to pin P-X on the P contactor and lead T2 to FU6-2.

2. Energize and de-energize the P contactor. If the meter reads more than 50 volts, replace the suppressor. If the meter reads less than 50 volts: discharge the test capacitor C1, set the meter on the 50 VDC scale, and proceed with step 3.

3. Energize and de-energize the P contactor observing the meter reading. The meter must swing slightly past 30 volts, appear to stabilize at approximately 24 volts, then move slowly to zero. Replace SUP1 if these readings are not attained.

4. When testing SUP1 for the X coil, connect lead T1 to pin X-X and T2 to FU6-2.

5. When testing the horn coil, connect lead T1 to H-1 and T2 to FU6-2.

Test results for steps 4 and 5 must be the same as those for steps 2 and 3 above.

SUP1 Location SUP1 is installed below the Control Unit.

Appearance

Schematic

Appearance

Schematic

SUP3 Location SUP3 is installed on the horn assembly.

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Theory of Operation

Theory of Operation

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8:

8-1

Theory of Operation

Raymond ® Sideloader Maintenance Manual

Overview

Overview This section will provide a better understanding of the operation of the Raymond Sideloader.

Because of the interrelation of the electrical and hydraulic systems, the diagram for each specific function will have the most relevant schematic: • Hydraulic • Brakes • Steering • Lift/Lower (Except Remote Lift) • Auxiliary • Electrical • Travel NOTE: Do NOT use these schematics to troubleshoot or repair the lift truck.

Always use the schematics in the Appendix for troubleshooting and repair.

Outline The following system functions will be covered in this section:

• SCR Theory • Travel •

Key Switch ON

•

Deadman Pedal Depressed

•

Directional Switch Closed

•

High Speed

•

Plugging

•

Miscellaneous Circuits

• Remote Travel •

Key Switch ON

•

Interlocks Closed

•

Remote Start Closed

•

Lift

•

Lower

•

Directional Switch Closed

•

High Speed

•

Plugging

NOTE: Power circuit functions for remote travel are the same as for standard travel.

• Brakes •

Service Brakes

•

Parking Brakes

• Steering •

Power Steering

•

Crab Steering

• Lift/Lower •

Lift

•

Lower

•

Remote Lift

•

Remote Lower

•

Emergency Lower

• Auxiliary Controls

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Theory of Operation Brakes

Brakes Service Brakes The service brakes function like an automobile's brakes and may be operated at any time. See Figure 8-1.

5. When the deadman pedal is released, SOL4 opens, releasing pressure to the brake actuators and permits the actuator springs to apply the brakes.

8

Figure 8-1:

Service Brake Applied

1. Depressing the brake pedal strokes the master cylinder applying pressure to the system.

2. The pressure actuates the brake cylinders that press the brake shoes against the wheel.

3. Releasing the pedal relieves the pressure letting the internal springs withdraw the brakes shoes.

Parking Brake The parking brake utilize auxiliary system pressure to release the brakes. See Figure 8-2.

1. With the key switch ON and the deadman pedal depressed, the auxiliary pump/motor and brake dump solenoid, SOL4, are activated. See Figure 8-13.

8

Figure 8-2:

Parking Brake Released

2. Auxiliary system flow passes through the normally open center of the auxiliary controls, as well as through the pressure reducing relief, check valve and is diverted by the closed SOL4 to the parking brake actuators.

3. The pressure reducing relief permits 330 psi (2275 kPa) to build up the brakes, then opens, limiting excessive pressure build-up.

4. The pressure is held by the check valve and the closed SOL4, maintaining brake release.

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8-3

Theory of Operation

Raymond ® Sideloader Maintenance Manual

Steering

Steering Power Steering Power steering utilizes auxiliary system pressure for its operation. See Figure 8-3.

1. With the key switch ON and the deadman pedal depressed, the auxiliary pump/motor and brake dump solenoid, SOL4, are activated. See Figure 8-13.

2. Auxiliary system flow passes through the normally open center of the auxiliary and steering controls.

3. When the steering wheel is turned, the power steering orbitrol is turned, and its internal ports are aligned.

4. The auxiliary flow is diverted through these ports to the steering cylinder that turns the steerable wheels.

5. The speed and direction of the steering is determined by the speed and direction that the steering wheel is turned.

3. When the crab steer center button is depressed, the opposite solenoid, SOL2 wheels turned right or SOL1 wheels turned left, is activated. Auto re-centering Relay K11 is also activated. The circuit is opened by switches S25 or S26 on the axle when the wheels are centered.

4. K11 Relay, when activated, is held active by its own points. This provides automatic re-centering of the wheels if they drift off center while traveling.

5. When the crab steer cylinder hits its stops or oil flow is otherwise restricted, the crab steer relief, set at 1450 psi (9997 kPa), opens to prevent any pressure build-up.

NOTE: Because of the open center auxiliary hydraulic flow, the steering functions will operate simultaneously.

6. When the steering wheel stops, internal springs in the orbitrol return its ports to a neutral position trapping oil in the cylinder, thereby holding the steering position.

7. When the steering cylinder hits its stops or oil flow is otherwise restricted, the steering relief, set at 1450 psi (9997 kPa), opens to limit any pressure build-up.

Crab Steering Crab steering utilizes auxiliary system pressure for its operation. See Figure 8-4.

1. With the key switch ON and the deadman pedal depressed, the auxiliary pump/motor and brake dump solenoid, SOL4, are activated. See Figure 8-13.

2. When a directional crab steering button is depressed, the respective solenoid, SOL1 for right turns or SOL2 for left turns, is activated, diverting auxiliary flow to the crab steer cylinder, and turns the drive wheels.

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Theory of Operation

Figure 8-3:

Power Steering Activated

Crab Steering

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8-5

Theory of Operation

Raymond ® Sideloader Maintenance Manual

Figure 8-4:

Crab Steer - Right Activated

Crab Steering

8

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Theory of Operation Lift/Lower

Lift/Lower Lift Operation of the standard lift function is controlled entirely through the lift lever. See Figure 8-5.

1. With the key switch ON and the deadman pedal depressed, the lift circuit is ready for activation. See Figure 8-13.

2. Pulling back on the lift lever closes lift switch S4 and strokes the lift master cylinder.

3. Closing S4 completes a circuit to pump bypass solenoid SOL5, closing it, and to the battery controller relay K5.

4. If the battery is adequately charged, the battery controller completes a circuit through Relay K5, closing its points and completing a circuit to the lift pump contactor P. 5. Closing the P contactor completes a circuit to the lift pump/motor providing the lift hydraulic flow.

6. The output of the pump is hydraulically controlled by the lift master cylinder. The master cylinder actuates a slave cylinder on the lift pump that controls the volume control plate within the pump. The volume control plate determines the pump's output that flows through the check valve and flow control to the lift cylinder.

NOTE: On the SL40TT and SLR20TT, an automatic pressure compensating control is added. This control senses lift pressure and overrides the master cylinder, de-stroking the lift pump as lift pressures become greater. Therefore, the high volume lift of these trucks is limited to its maximum efficient level of performance.

8. When the pump/motor is de-energized, SOL5 opens to route additional pump output to the reservoir.

9. When full lift is attained, or when an overload is being lifted, the lift pressure relief opens to limit any pressure build-up.

The relief is set to open at approximately 100 psi (689 kPa) greater than the pressure required to lift the maximum recommended load.

Lower Operation of the standard lower function is controlled entirely through the lower lever. See Figure 8-6.

1. With the key switch ON and the deadman pedal depressed, the lower lockout solenoid, SOL7, is opened and the lower system is ready for actuation. See Figure 8-13.

2. Pushing on the lower lever opens the sheartype lowering valve. The further the lever is moved, the greater the valve is opened, thereby increasing lowering speed.

3. The oil flows from the lift cylinder, through the lower lockout solenoid, and the lowering valve. Lowering pressure opens the hang-up pressure relief lets oil flow to the reservoir.

4. If the forks hang-up during lowering, the system pressure drops and the hang-up pressure relief closes, eliminating lowering.

5. If the deadman pedal is de-activated, the lower lockout solenoid closes and eliminates the lowering.

7. The check valve stops the return flow to the pump when the pump/motor is de-energized. The flow control permits full flow for lifting, but limits the lowering flow.

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8-7

Theory of Operation

Raymond ® Sideloader Maintenance Manual

Figure 8-5:

Lift Activated

Lower

8

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Theory of Operation

Figure 8-6:

Lower Activated

Lower

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8-9

Theory of Operation

Raymond ® Sideloader Maintenance Manual

Remote Lift

Remote Lift

Remote Lower

Operation of the remote lift requires the turning of the three-position key switch to the REMOTE position, the lowering of the valve lock plate so that it engages the stroked lift lever and depresses the remote start switch. See Figure 8-7.

Because it is necessary to lift prior to lowering, remote lift steps 1, 2 and 3 will have been completed when remote lower is required. See Figure 8-8.

1. Turning the key switch to the REMOTE position energizes the remote circuitry while de-energizing all other control circuits.

2. Lowering the valve lock plate holds the stroked lift lever. This adjusts the pump's volume control plate, enabling lift flow.

Lowering the plate also opens the lift interlock switch, S33, eliminating lift activation from the operator's compartment during remote function.

3. Depressing the remote start switch, S31, completes a circuit to the PC contactor.

When the PC contactor closes, interlock switch, S27, closes, maintaining a circuit to the contactor. The contacts close, providing a circuit for the lift motor.

4. Simultaneously depressing the two remote lift switches, S19A and S19B, completes a circuit to the lift control circuit. See “Lift” on page 8-7, steps 3, 4 and 5. Releasing either remote lift switch stops lift.

1. Simultaneously depressing the two remote lower switches, S20A and S20B, completes a circuit to remote lower solenoid, SOL6.

2. When SOL6 is activated it opens, permitting flow from the lift cylinder through the two flow controls. The lowering pressure opens the hang-up pressure relief, letting oil flow to the reservoir.

3. Releasing either remote lower switch de-activates SOL6 and stops lowering.

Emergency Lower Operation of the emergency manual lower function is controlled entirely through the Emergency Lower control valve installed above the deadman brake on the left side of the operator compartment.

The emergency manual lower control valve permits lowering the carriage during an emergency. To activate, turn the knob counterclockwise. The valve opens letting oil flow from the lift cylinder directly to the reservoir.

5. Hydraulic flow for remote lift is the same as standard lift (See “Lift” on page 8-7, steps 6, 7, 8, and 9 and Figure 8-5) except that the volume control plate position is fixed. This is determined by the position that the lift lever is held by the valve lock plate.

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Raymond ® Sideloader Maintenance Manual

Theory of Operation

Figure 8-7:

Remote Lift Activated

Emergency Lower

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Raymond ® Sideloader Maintenance Manual

Figure 8-8:

Remote Lower

Emergency Lower

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Theory of Operation Auxiliary Controls

Auxiliary Controls The auxiliary controls; mast traverse, mast tilt, fork tilt, and reach, direct the auxiliary hydraulic flow to their respective functions when actuated. The direction of actuation determines the direction of flow to each control function. See Figure 8-9.

1. With the key switch ON and the deadman pedal depressed, the auxiliary pump/motor and brake dump solenoid, SOL4, are activated. See Figure 8-13.

2. When an auxiliary control is actuated, oil flow is directed in one side of the function and out the other.

3. The mast traverse and mast tilt functions have load holding valves in their system.

These pressure sensing valves maintain an even flow to and from the functions, and prevent oil seepage back through the valves when the valves are returned to neutral, thereby minimizing the drifting of the function.

4. The mast tilt also incorporates a flow limiter that regulates the amount of flow to and from the function.

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Raymond ® Sideloader Maintenance Manual

Figure 8-9:

Auxiliary Controls - Mast Tilt Shown

Auxiliary Controls

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Theory of Operation SCR Theory

SCR Theory The Raymond Sideloader has two travel speed ranges (SCR and M Speed) in the two forward and reverse directions. In SCR range, the vehicle employs the use of Silicon Controlled Rectifiers (SCRs) to control travel speed. The SCRs permit an infinite selection of speeds from 0 up to approximately 80% of full speed. They also permit drive motor plugging for slowing or reversing directions without causing damage to vehicle components. In M speed range, SCR control is bypassed. The vehicle's drive motors are reconnected directly across the battery giving a top speed of up to 6 mph. SCR topics covered in this manual include: • SCR description • SCR switching

SCR Description An SCR is a solid state semiconductor device.

SCR operation is like that of a static switch with no moving parts or contact points. The turning ON and OFF of the SCR is electrically controlled, and can be done at a much faster rate than mechanical switches. In addition, the SCR has a much longer service life since it contains no moving or mechanical parts.

Figure 8-10 View A shows the physical characteristics of a SCR while Figure 8-10 View B shows the electrical symbol. The switching characteristic of an SCR lies between the anode and cathode connections. The gate lead controls the turning ON (closing of the SCR switch). By applying a very low current signal to the gate, the SCR is turned ON permitting a much larger current to flow from anode to cathode. When turned ON, however, the gate has no further control of the SCR. To turn an SCR OFF, the current flow between anode and cathode must be reduced to zero by external means.

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A

B 8

Figure 8-10: SCRs Physical Appearance and Electrical Symbol

SCR Switching To demonstrate SCR switching action, an SCR is connected to the circuit shown in Figure 8-11.When switch S1 is closed, a voltage is applied between anode and cathode. The SCR acts as an open switch permitting no current to flow.

S1

24 Volt 6 Volt

RESISTOR 8

Figure 8-11: SCR Operation Diagram

1. To close the switch or turn the SCR ON, a gate signal is applied. By closing switch S2, a path is completed and a small current flows to the SCR gate.

2. This current flow immediately turns the SCR ON, letting a larger current flow from anode to cathode.

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Raymond ® Sideloader Maintenance Manual

SCR Switching 3. When the SCR is turned ON, the gate signal may be removed by opening switch S2 without any effect on anode to cathode current.

4. To turn the SCR OFF, the current flow between anode and cathode is reduced to zero, either by opening switch S1 or by some external means.

5. The SCR is polarity sensitive. The anode of an SCR must be connected to the positive (+) side of the circuit and the cathode to the negative (-) side of the circuit. When connected in opposite polarity, the SCR will not conduct.

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Theory of Operation Standard Travel

Standard Travel Key Switch ON

Deadman Pedal Depressed

1. Connect the battery connector and turn the key switch ON.

Depressing the deadman pedal closes deadman switch S2 and also:

2. An electrical circuit is completed to terminal A of the Control Unit preparing the unit's internal circuitry for operation. See Figure 8-12. However, until deadman switch S2 is depressed, the Control Unit is held at a minimum pulse frequency and no current flow to the directional contactors prevents their activation. Circuits in the Control Unit are readied for operation:

1. Closing S2 simultaneously removes the reset circuit on the Control Unit and activates deadman relay K12. See Figure 8-13.

•

•

•

The current Limit circuit that monitors the current in the drive motor, is ready for operation, but is inoperative until a directional contactor is closed.

The fail safe protective circuits that monitor the power circuits, are operational and readied to prevent operation of the vehicle if a malfunction exists.

The oscillator and power driver circuits are also ready for operation but are in an idle position until deadman switch S2 closes, releasing the reset circuit of the Control Unit.

3. The crab steer indicator lights are activated notifying the operator of the crab steer position.

2. Closing one set of the relay’s points causes: •

A current through the normally closed side of the high speed switches, MS5A and MS5B, to the Control Unit pin H activates the M blank overload circuit.

This circuit maintains the fail safe circuits while M speed is not activated.

•

The overload circuits in the Control Unit are activated, monitoring the system. If a malfunction occurs, these circuits are ready to prevent vehicle travel.

•

A circuit is provided to the directional switches readying them for activation.

3. Closing the other set of the relay’s points completes circuits to the following, causing the activation of: •

Hour Meter (HM)

•

Brake Dump Solenoid (SOL4)

•

Lowering Lockout Solenoid (SOL7)

•

Auxiliary Contactor (X)

4. The light load relay, K13, is activated and completes a circuit to the warning and working light circuits. This relay reduces the load on the key switch when it is turned ON. 5. On vehicles with Remote Control, the PC contactor is activated, closing its contacts and providing a power circuit for lift and travel.

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Raymond ® Sideloader Maintenance Manual

Figure 8-12: key switch ON - Standard Travel

Deadman Pedal Depressed

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Theory of Operation

Figure 8-13: deadman pedal Depressed

Deadman Pedal Depressed

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Raymond ® Sideloader Maintenance Manual

Directional Switch Closed

Directional Switch Closed See Figures 8-14, 8-15, and 8-16.

1. When the directional/speed control handle is rotated to the forward or reverse travel position, the first few degrees of the control handle movement closes directional master switch MS1 (forward) or MS2 (reverse). A small current now flows from the battery through MS1 or MS2 to the directional coils (F or R), to the Control Unit, and back to the negative side of the battery. This flow is not large enough to energize the directional contactors, but does activate the contactor delay in the Control Unit.

2. After a very short (100 millisecond) delay, the contactor delay circuit completes a low resistance circuit between terminals D and L of the Control Unit. A larger energizing current now flows through contactor coils F or R. The applicable directional contact tips are closed, directing a current flow to the drive motors.

3. Because of the need to parallel the armatures during startup and plugging but not throughout travel, an equalizing contactor 1S and time delay are added to the travel circuit. The equalizing time delay receives a small current flow from the directional switches at the same time as the forward and reverse time delay. This current flows through the 1S coil but is not large enough to energize the coil. The equalizing delay takes approximately 600 milliseconds before it completes a low resistance circuit to the 1S coil. The energized 1S coil opens the 1S contact tips and interlock switch S10 closes. The closing of S10 assures that the time delay circuit will remain inactive if the 1S contact tips remain open. The contactor will remain open until a directional switch, MS1 or MS2, is opened.

4. The closing of directional contactors F or R also completes the monitoring circuit for current limit from the motor field windings to terminals X of the Control Unit.

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5. Movement of the control handle also turns the shaft of the potentiometer VR1 (installed within the directional/speed controller). VR1 controls the voltage input to the frequency and width circuits of the Control Unit, which controls the truck speed. The potentiometer, in neutral position, supplies a high voltage to the width circuit and a low voltage to the frequency circuit. As the control handle is moved to high speed, the voltage input to the frequency circuit is increased and the voltage to the width circuit is decreased.

6. After the directional switch (MS1 or MS2) has closed, further movement of the control handle changes the voltage output of the potentiometer. The increase in voltage to the frequency circuit turns the main SCR ON at a faster rate. The decrease in voltage to the width circuit permits the main SCR to remain ON for longer periods of time. The average current flow through the motor is increased.

7. When main SCR1 and charging SCR3 are turned ON, (see Figure 8-15) current flows from the batteries through fuse FU1, directional contactor tips, motor field windings, motor armatures, primary windings of transformer T1, main SCR1, and back to the battery. The flow of current through the primary windings of T1 induces a voltage across its secondary windings. The resultant secondary current, flows from T1 through capacitors C1 and C2, the main SCR1, the charging SCR3, and back to T1. Capacitors C1 and C2 are charged, as shown, by this current.

8. Charging SCR3 is turned ON at the same time the main SCR1 is turned ON. As soon as capacitors C1 and C2 are fully charged, current flow through SCR3 stops. Stopping current flow through SCR3 turns SCR3 OFF. SCR3 will maintain the charge on the capacitors as an SCR permits current to flow in one direction only. SCR1 will continue to conduct current until it is turned OFF.

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Theory of Operation

Figure 8-14: Directional Switch Closed - Standard Travel

Directional Switch Closed

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Figure 8-15: Turning On SCR1 and SCR3

Directional Switch Closed

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Theory of Operation

Figure 8-16: Turning SCR2 On, SCR1 Off

Directional Switch Closed

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High Speed 9. When it is time to turn the main SCR1 OFF, the Control Unit sends a pulse to the gate lead of commutating SCR2. See Figure 8-16. SCR2 is turned ON, completing a circuit from capacitors C1 and C2, through SCR2, and back to the battery.

The capacitors discharging through SCR2 causes a high current flow into the capacitors from the opposite direction. This high current flow charges the capacitors and diverts the current from flowing through main SCR1. This no-current-flow condition exists until the capacitors are fully charged. The main SCR1, experiencing a no-current-flow condition, is turned OFF. 10. The turning ON and OFF of the main SCR1 normally occurs within 5 milliseconds. If the main SCR1 has not turned OFF after 100 milliseconds, main SCR1 has shorted or the commutating circuit has failed. The overload protective circuit monitors the main SCR1 through terminal B of the Control Unit. If the main SCR1 remains on for 100 milliseconds, the overload circuit deactivates the F and R contactor delay circuit, de-energizing the forward or reverse contactor coils. The overload circuit is equipped with either a manual or automatic reset. With the manual reset, the key switch must be turned OFF and then back to ON to reset the circuit. With the automatic reset, the directional contactors will cycle in and out as the delay circuit is activated and deactivated. If there is not a false firing of the overload circuit, the truck will be inoperative until the malfunction is corrected.

11. The Control Unit alternately turns the main SCR ON and OFF. The further the control handle is moved, the faster the Control Unit's frequency pulses, and increases the truck's speed.

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12. REC1 is a recirculating rectifier. During the intervals when main SCR1 is turned OFF, the magnetic fields built up around the motors' field winding collapse, producing a current flow in the same direction as the battery circuit. REC1 routes this current through the motors' circuitry, utilizing the current to turn the drive motors. As a result, the motor current is a higher average value than current supplied by the battery. In addition, operation of the drive motor is smoother.

High Speed See Figure 8-17.

1. When the directional/speed control handle is moved to the high speed position (forward or reverse), master switch MS5A (forward) or MS5B (reverse) is closed. The closing of either MS5 switch completes a small current flow from the switch, through the M contactor coil, to terminal R of the Control Unit, and through the speed limit module to pin B on the Control Unit, through the M time delay circuit of the Control Unit, to terminal L of the Control Unit and back to the battery. Approximately 2.5 seconds after MS5 closes, the M time delay circuit completes a low resistance path between terminals B and L of the Control Unit. The M contactor is now energized, closing its contacts and placing the drive motors directly across the batteries. The speed limit module regulates truck speed under various modes of operation. The speed limiting varies with fork elevation and mast traverse function.

2. To the overload control circuit, the closing of the M contact tips appears the same as a shorted main SCR. This will normally cause the overload circuit to be activated and interrupt power to the travel circuit.

However, the closing of either M speed switch activates the M blank overload circuit. This circuit, when activated, in turn deactivates the overload monitoring circuit from the power circuit. This stops the overload circuit from deactivating the F and R time delay circuit.

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Theory of Operation

Figure 8-17: High Speed

High Speed

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Plugging

Plugging See Figure 8-18.

1. When the directional/speed control handle is plugged (moved through neutral to the opposite travel direction), the farther the handle is moved in the opposite direction, the greater the plugging force, and thus, the quicker the truck reacts to the plug.

8. The proportional aspect of plugging is accomplished through inputs to the width and frequency circuits. The width and frequency circuits are held to a limited rate change. The rate increases as the handle is moved. Therefore, the greater the handle movement, the greater the plugging force.

2. If the truck is traveling in high speed, master switch MS5 opens and the M contactor is de-energized. The overload circuit is reactivated, ready to monitor the SCRs when MS5A or MS5B is opened.

3. Directional switches MS1 and MS2 are reversely actuated.

4. The directional contactor (F or R), originally closed, now opens, and the originally open contactor now closes.

5. When the control handle passes through neutral, the equalizing contactor 1S is deactivated. The equalizing time delay is held inactive through lead F of the Control Unit, keeping the 1S contactor tips closed throughout plugging.

6. The current flow through the motors' field windings is reversed, attempting to turn the armatures in the opposite direction. While this spinning continues, the motors act as generators producing a voltage.

7. Also connected in series with REC2 and REC3 are plugging relays K1 and K2. The flow of the plugging current through the rectifiers and relay coils close the relays' contacts. The contacts complete a circuit between terminals R and d of the Control Unit. This circuit resets the Control Unit's pulse width and frequency. The K1 and K2 contacts remain closed until the motors come to a stop. The relay's contacts then open letting the Control Unit to smoothly accelerate the motors in the new direction.

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Theory of Operation

Figure 8-18: Plugging

Plugging

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Miscellaneous Circuits

Miscellaneous Circuits Miscellaneous circuits provide system protection and function only when specific malfunctions occur.

Weld Detection Circuit The weld detection circuit is designed to prevent the truck from traveling if the M contact tips weld or the main SCR has shorted. If the M contact tips weld during a plugging operation, the weld detection circuit does not permit the F and R time delay circuit to be reactivated after the directional/speed control handle passes through neutral.

Speed Limit Speed limits incorporated in the Raymond Sideloader: • 1/2 speed - when elevated heights are above 19 in. (483 mm) • 1/8 speed - mast extended, elevated height above 15 ft. (457.2 cm) with remote travel.

NOTE: Contactor coils F, R and M have a transient suppressor in parallel with their coil. The transient suppressors for the F, R and M coils are installed within the Control Unit. The transient suppressors reduce, to an acceptable level, the build-up of voltages produced when a coil is de-energized.

Current Limit Circuit The current limit circuit, installed within the Control Unit, is activated when too high a current is built up in the drive motors, such as when the truck is stalled. The current limit circuit measures the amount of current in the drive circuit.

1. When the current reaches a given level, the current limit circuit is activated through pin X and provides a high input to the width circuit.

2. The current limit controls the ON time of the main SCR1. The average motor current is held at a level determined by the current limit circuit.

M Lockout Circuit The M lockout circuit is one of the fail safe circuits. It is designed to prevent the M contactor from being energized if the main SCR1 fails to turn ON.

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Raymond ® Sideloader Maintenance Manual

Theory of Operation Remote Travel

Remote Travel Because of the various components; relays, sensors, etc. required to transfer operation for remove travel, standard operation on vehicles incorporating remote travel operate through many of these components. However, the basic function of standard operations will remain the same and therefore will not be covered here.

NOTE: Because all standard operational controls; travel, lift, lower, auxiliary, steering and parking brake cannot be reactivated when the key switch is turned to REMOTE, the vehicle must be properly positioned in the working isle before switching to remote.

NOTE: Prior to remote operation, the auxiliary carriage and remote platform must be properly mounted on the vehicle, with the mast fully retracted, so the platform interlock S45 and the mast traverse switch S16 are activated.

Key Switch ON See Figure 8-19 With the batteries plugged in and the key switch turned to the REMOTE position, the following occurs: 1. An electrical circuit is completed to terminal A of the Control Unit, preparing the units internal circuitry for operation.

However, until aisle sensor relay K6 is activated, the Control Unit is held at a minimum pulse frequency and no current flow to the directional contactors eliminates their activation. The follow circuits in the Control Unit are readied for operation: •

Current limit circuit, which monitors the current in the drive motors’ field windings, is ready for operation, but is inoperative until a directional contactor has closed.

•

The fail safe protective circuits, which monitor the power circuits, are operational.

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•

The oscillator and power driver circuits are also ready for operation but are in an idle position until K6 aisle sensor relay points open releasing the reset circuit of the Control Unit.

2. The crab steer indicator lights are activated notifying the operator of the crab steer position.

3. Activates light load relay K13 completing a circuit to the warning and working lights.

This relay reduces the load on the key switch when it is turned ON. 4. The remote mode relays K8, R9 and R10 are activated. Activating these relays causes the following to occur: a. Activating K8: • closes two sets of points which diverts the circuit from pins 2 and 3 on potentiometer VR1 to pins 2 and 3 on potentiometer VR2 • opens one set of points which disrupts the standard lift circuit b. Activating K9: • closes one set of points which completes a circuit to auxiliary bypass solenoid SOL0 diverting auxiliary hydraulic flow for activation of remote lift. Closing this set of points also disrupts the circuit to crab steering control switches and the deadman switch • closes one set of points which diverts the circuit from pin 1 potentiometer VR1 to pin 1 on potentiometer VR2 • closes one set of points which diverts the circuit from MS5 high speed switches in the standard controller to MS6 high speed switches in the remote controller.

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Key Switch ON 8

Figure 8-19: Key Switch ON - Remote Travel

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Theory of Operation Interlocks Closed

c. Activating K10: • closes two sets of points which divert the circuits from MS1 forward and MS2 reverse directional switches in the standard controller to MS4 forward and MS3 reverse in the remote controller • opens one set of points which disrupts the circuit to the lower lockout solenoid SOL7 eliminating standard lowering.

5. Circuits for remote lower, remote start and remote horn are readied for activation.

6. A circuit is completed through the power supply, through the mast sensor (normally closed below 15 ft. (457.2 cm) elevated height) and back to the batteries. This circuit activates a relay within he power supply, closing its points. Closing the power supply relay points completes a circuit through the speed limit module to the Control Unit and back to the batteries. This circuit provides various speed limits for varying operational conditions.

7. Turning the key switch to Remote disrupts the circuit to the PC contactor, removing the travel and lift power circuits until the PC is reactivated.

NOTE: After activating the key switch to Remote, the operator must move to the remote platform for additional remote operation.

Interlocks Closed See Figure 8-20 With the platform properly mounted so interlock S45 is closed, the mast retracted so switch S11 is closed, closing the operator interlock switch S42 and if used, helper interlocks S43 and S44, causes the following to occur:

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1. With all interlocks closed, a circuit is completed through interlock relay K7 closing its points.

•

Closing one set of points readies a circuit for remote lift.

•

Closing one set of points readies a circuit for remote lower.

•

Closing one set of points provides a circuit for the aisle sensor relay K6.

2. With the vehicle in a rail-guided aisle, the aisle sensor is closed, completing a circuit through the aisle sensor relay K6 activating points.

•

One set of points opens, removing the reset circuit on the Control Unit.

•

Closing one set of points diverts the circuit from going through MS5A and MS5B of the standard controller to going through MS6A and MS6B of the remote controller.

•

Closing one set of points readies the remote travel circuit for operation and provides current to pin H of the Control Unit, activating the M blank overload circuit. This circuit maintains the fail safe circuits while M speed is not activated.

3. The overload circuits in the Control Unit are activated, monitoring the system.

Should a malfunction occur, these circuits will eliminate vehicle travel.

4. Circuits are also completed to the following causing their activation: •

Hour Meter (HM)

•

Brake Dump Solenoid (SOL4)

•

Auxiliary Contactor (X)

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Raymond ® Sideloader Maintenance Manual

Interlocks Closed 8

Figure 8-20: Interlocks Closed - Remote Travel

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Theory of Operation Remote Start

Remote Start See Figure 8-21 The remote start switch enables the operator to activate the remote travel controls only from a proper operating position on the platform.

Activating remote start causes the following to occur: 1. Closing the momentary contact remote start switch S31 competes a circuit to the PC contactor.

2. Activating the PC contactor closes its contacts readying the travel and lift power circuits for operation.

3. Activating the PC contactor also closes its interlock switch S27 which completes a circuit through the power disconnect switch S21 and switch S27 maintaining a circuit through the PC contactor when the remote start switch is released.

4. In emergency situations, the power disconnect switch S21 deactivates the PC contactor, eliminating lift and travel. The PC contactor may be reactivated by depressing the remote start switch.

Lift See Figure 8-22 The fixed speed remote lift, approximately 15 fpm, is controlled entirely through the remote lift button. Activating the remote lift causes the following to occur: 1. Closing remote lift switch S19 completes a circuit through lift pump advance solenoid SOL8, pump bypass solenoid SOL5, closing it, and to the battery controller relay K5.

2. Activating SOL8 diverts auxiliary flow to a hydraulic cylinder which strokes the lift lever, providing a fixed lift volume flow from the lift pump.

3. If the battery is adequately charged, the battery controller completes a circuit through relay K5, closing its points and completing a circuit to the lift pump contactor P.

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4. Closing the P contactor completes a circuit to the lift pump/motor providing the lift hydraulic flow.

5. See “Lift” on page 8-7, steps 6 through 9 for remote lift hydraulic flow.

6. A backup pressure relief relieves auxiliary hydraulic pressure when the hydraulic cylinder, which strokes the lift lever, is fully extended.

7. Releasing S19 deactivates remote lift.

Lower See Figure 8-23 The fixed speed remote lower is controlled entirely through the remote lower button.

Activating the remote lower button causes the following to occur: 1. Closing remote lower switch S20 completes a circuit through remote lower solenoid SOL6.

2. Activating SOL6 allows flow from the lift cylinder through the two flow controls. The lowering pressure opens the hang-up pressure relief allowing oil to flow to the reservoir.

3. Releasing S20 deactivates remote lower.

Directional Switch Closed See Figure 8-24 When the remote directional/speed control handle is rotated to the forward or reverse travel position, the following occurs: 1. The first few degrees of the control handle movement closes remote directional master switch MS4 (forward) or MS3 (reverse). A small current now flows from the battery through MS4 or MS3,through the closed K10 relay points, to the directional coils (F or R), to the Control Unit and back to the negative side of the battery. This flow is not large enough to energize the directional contactors but does activate the contactor delay in the Control Unit.

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Directional Switch Closed 8

Figure 8-21: Remote Start - Remote Travel

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Theory of Operation Directional Switch Closed 8

Figure 8-22: Lift - Remote Travel

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Directional Switch Closed 8

Figure 8-23: Lower - Remote Travel

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Theory of Operation Directional Switch Closed 8

Figure 8-24: Directional Switch Closed - Remote Travel

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High Speed 2. After a very short (100 millisecond) delay, the contactor delay circuit completes a low resistance circuit between terminals D and L of the Control Unit. A larger energizing current now flows through contactor coils F or R. The applicable directional contact tips ore closed, directing a current flow to the drive motors.

3. Because of the need to parallel the armatures during start up and plugging but not throughout travel, an equalizing contactor 1S and time delay are added to the travel circuit. The equalizing time delay receives a small current flow from the directional switches at the same time as the forward and reverse time delay. This current flows through the 1S coil but is not large enough to energize the coil. The equalizing delay takes approximately 600 milliseconds before it completes a low resistance circuit to the 1S coil. The energized 1S coil opens the 1S contact tips and interlock switch S10 closes. The closing of S10 assures that the time delay circuit will remain inactive if the 1S contact tips remain open. The contactor will remain open until a directional switch, MS4 or MS3 is opened.

4. The closing of directional contactors F or R also completes the monitoring circuit for current limit from the motor field windings to terminals X of the Control Unit.

5. Movement of the control handle also turns the shaft of the potentiometer VR2 (located within the remote directional/speed controller). VR2 directs current through K8 and K9 relay points to the Control Unit where it controls the voltage input to the frequency and width circuits which in turn control the vehicle speed. The potentiometer in neutral position supplies a high voltage to the width circuit and a low voltage to the frequency circuit. As the control handle is moved toward high speed the voltage input to the frequency circuit is increased and the voltage to the width circuit is decreased.

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6. After the directional switch (MS4 or MS3) has closed, further movement of the control handle changes the voltage output of the potentiometer, The increase in voltage to the frequency circuit turns the Main SCR ON at a faster rate, The decrease in voltage to the width circuit allows the Main SCR to remain on for longer periods of time. The average current flow through the motor is increased.

7. See “Directional Switch Closed” on page 8-20, steps 7 through 12 for SCR operation which remains the same for remote travel.

High Speed See Figure 8-25.

When the remote directional/speed control handle is moved to the sigh speed position (forward or reverse), the following occurs: 1. A remote high speed master switch MS6A (forward) or MS6B (reverse) is closed. The closing of either remote high speed master switch completes a small current flow from the switch, through the closed K9 relay points, through the M contactor coil. to terminal K of the Control Unit, and through the speed limit module to pin b on the Control Unit, through the M time delay circuit of the Control Unit, to terminal L of the Control Unit and back to the battery.

Approximately 2.5 seconds after an MS6 closes, the M time delay circuit completes a low resistance path between terminals b and L of the control Unit. The M contactor is now energized, closing its contacts, and placing the drive motors directly across the batteries. The speed limit module regulates truck speed under various modes of operation. The speed limiting varies with fork elevation.

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Theory of Operation High Speed 8

Figure 8-25: High Speed - Remote Travel

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Plugging 2. To the overload control circuit, the closing of the M contact tips appears the same as a shorted main SCR. This would normally cause the overload circuit to be activated and interrupt power to the travel circuit.

However, the closing of either M speed switch activates the M blank overload circuit. This circuit, when activated, in turn deactivates the overload monitoring circuit from the power circuit. This stops the overload circuit from deactivating the F and R time delay circuit.

Plugging See Figure 8-26.

When the remote directional/speed control handle is plugged, moved through neutral to the opposite travel direction, the following occurs: 1. The remote directional/speed control handle is moved from original position back through neutral to a speed in the opposite direction. The farther the handle is moved in the opposite direction, the greater the plugging force, and thus, the quicker the truck reacts to the plug.

2. If the truck was traveling in high speed, a master switch MS6 opens and the M contactor is de-energized. The overload circuit is reactivated and is ready to monitor the SCR’s when MS6A or MS6B is opened.

6. The current flow through the motors’ field windings is reversed and is attempting to turn the armatures in the opposite direction. While this spinning continues, the motors act as generators, producing a voltage. Rectifiers REC2 and REC3 limit this voltage to approximately 1 volt, limiting high currents which could damage motors or SCR circuits.

7. Also connected in series with REC2 and REC3 are plugging relays K1 and K2. The flow of the plugging current through the rectifiers and relay coils close the relays’ contacts. The contacts complete a circuit between terminals R and D of the Control Unit. This circuit resets the Control Unit’s pulse frequency to a reduced rate determined by the position of the directional/speed control handle. The K1 and K2 contacts remain closed until the motors come to a stop. The relay’s contacts then open allowing the control unit to smoothly accelerate the motors in the new direction.

8. The proportional aspect of plugging is accomplished through leads ti the width and frequency circuits. The width circuit is held to a limited rate change while the frequency rate increases the further the handle is moved. Therefore, the greater the handle movement, the greater the plugging force.

3. Directional switches MS4 and MS3 are reverse actuated.

4. The directional contactor (F or R) which was originally closed now opens and the contactor that was originally open now closes.

5. When the control handle passes through neutral, the equalizing contactor 1S is deactivated. The equalizing time delay is held inactive through lead F of the Control Unit, keeping the 1S contactor tips closed throughout plugging.

8-40

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Raymond ® Sideloader Maintenance Manual

Theory of Operation Plugging 8

Figure 8-26: Plugging - Remote Travel

PDMM-0102 Issued: 9/30/02

8-41

Theory of Operation

Raymond ® Sideloader Maintenance Manual

Plugging

8-42

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Appendix

Appendix

PDMM-0102 Issued: 9/30/02

A:

A-1

Raymond ® Sideloader Maintenance Manual

Appendix Lubrication Specification Chart

Lubrication Specification Chart Approved Raymond Lubricants Where Used

Type

Specification

Raymond Part Number

Drive Unit Gear Case

Gear Lubricant

75W-90 Synthetic Gear Oil API Service GL-5

990-655/001(1 qt./0.9 liter) 990-655/003 (1 gal./3.8 liters)

Lift Chains

Oil

10W-30 Motor Oil API Service CE,CD,CC,SG,SF

990-603/04 (1 qt./0.9 liter) 990-603/03 (5 gal./18.9 liters)

Hydraulic Reservoir (Non-Cold Storage Trucks) (+50°F to +120°F) (+10°C to +49°C))

Hydraulic Fluid

ISO 46

990-616/04 (1 qt./0.9 liter) 990-616/01 (1 gal./3.8 liters) 990-616/02 (2 gal./7.6 liters) 990-616/03 (5 gal./18.9 liters)

Hydraulic Reservoir (Cold Storage Trucks) (-20°F to 0°F) (-29°C to -18°C) (confined to freezer)

Hydraulic Fluid

MIL-H-5606E

990-618/TX1 (1 gal./3.785 liters) 990-618/01 (1 gal./3.785 liters)

Hydraulic Reservoir (Cold Storage Trucks) (-20°F to +70°F) (-29°C to +21°C) (in and out of freezer)

Hydraulic Fluid

ISO 32

990-617/01 (1 gal./3.785 liters) 990-617/03 (5 gal./18.9 liters)

Mast Uprights, Bearings, (etc.)

Grease

NLGI Grade2

990-620/01 (10 cartridges per case) 990-620/02 (5 gal./18.9 liters)

Mast Uprights, Bearings, (etc.)

Grease with Teflon

NLGI 2

990-652/001 (spray)

Brake Fluid

SAE Standard J1705F Federal Motor Vehicle Standard No. 116, DOT-5

(cold storage) Hydraulic Brake

990-652/002 (cartridge) 990-625/01 (1 gal./3.785 liters) 990-625/02 (1 qt./0.9 liter) 990-625/03 (1 pint/0.47 liter)

Table A-1: Lubrication Specification Chart

A-2

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Appendix Thread Adhesives, Sealants, and Lubricants

Thread Adhesives, Sealants, and Lubricants Application Thread-locking 0.25 in. (6.35 mm) and below Thread-locking 0.25 in. (6.35 mm) to 0.75 in.

(19.05 mm) contamination tolerant Thread-locking 1.0 in. (25.4 mm) and under Thread-locking 1.0 in. (25.4 mm) and under, contamination tolerant Thread-locking 1.0 in. (25.4 mm) and over Thread-locking Cleaner Thread-locking Primer Hydraulic Sealant Molybdenum Anti-Seize Compound (Molykote) Gasket Cement Corrosion Inhibitor Coating Silicone Sealant (cold storage)

Raymond P/N 990-403 990-536

Loctite* Number/Color 222/Purple 243/Blue

990-544 990-463

271/Red 603/Green

990-571 990-538 990-533 990-552 990-638 990-556 990-456/001 990-445

277/Red 7075 T7471 569 Silver Permatex 300 Dow Corning III

Table A-2: Thread Adhesives, Sealants, Lubricants

NOTE: * Loctite is a registered trademark of the Loctite Corporation. Brand endorsement is not implied here, but listed only as a commonly identified product.

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A-3

Raymond ® Sideloader Maintenance Manual

Appendix Torque Chart - Standard (Ferrous)

Torque Chart - Standard (Ferrous) Grade Identification Marking

None SAE Grade 2 Bolts Tightening Torque

SAE Grade 5 Bolts Tightening Torque

SAE Grade 8 Bolts Tightening Torque

Dry

Oiled*

Dry

Oiled*

Dry

Oiled*

4-40 4-48 6-32 8-32 8-36 10-24 10-32 1/4-20 1/4-28

in. lbs.

5 6 10 19 20 27 31 66 78

in. lbs.

4 5 8 14 15 21 23 49 56

in. lbs.

8 9 16 30 31 43 49 96 120

in. lbs.

6 7 12 22 23 32 36 75 86

in. lbs.

12 13 23 41 43 60 68 144 168

in. lbs.

9 10 17 31 32 45 51 108 120

5/16-18 5/16-24 3/8-16 3/8-24 7/16-14 7/16-20 1/2-13 1/2-20 9/16-12 9/16-18 5/8-11 5/8-18 3/4-10 3/4-16 7/8-9 7/8-14 1-8 1-12 1 1/8-7 1 1/8-12 1 1/4-7 1 1/4-12 1 3/8-6 1 3/8-12 1 1/2-6 1 1/2-12

ft. lbs.

11 12 20 23 30 35 50 55 65 75 90 110 160 180 140 155 220 240 300 340 420 460 560 640 740 840

ft. lbs.

8 9 15 17 24 25 35 40 50 55 70 85 120 140 110 120 160 170 220 260 320 360 420 460 560 620

ft. lbs.

17 19 30 35 50 55 75 90 110 120 150 180 260 300 400 440 580 640 800 880 1120 1240 1460 1680 1940 2200

ft. lbs.

13 14 23 25 35 40 55 65 80 90 110 130 200 220 300 320 440 480 600 660 840 920 1100 1260 1460 1640

ft. lbs.

25 25 45 50 70 80 110 120 150 170 220 240 380 420 600 660 900 1000 1280 1440 1820 2000 2380 2720 3160 3560

ft. lbs.

18 20 35 35 55 60 80 90 110 130 170 180 280 320 460 500 680 740 960 1080 1360 1500 1780 2040 2360 2660

Size

Table A-3: Torque Chart - Standard * NOTE: Use”oiled” values for bolts with thread-locking compound

A-4

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Appendix Torque Chart - Metric (Ferrous)

Torque Chart - Metric (Ferrous) Ferrous Metric Bolts, Coarse Thread (The grade rating is stamped on the head of the bolt.)

Diameter (in millimeters)

Grade 8.8

Grade 10.9

Torque (with bolts oiled*)

Torque (with bolts oiled*)

Newton-meters

Foot-pounds

Newton-meters

Foot-pounds

6

8.6

6

12

9

8

21

15

29

21

10

42

30

68

43

12

72

55

101

75

16

174

130

245

181

20

340

255

475

350

24

580

435

820

605

Table A-4: Torque Chart - Ferrous Metric * NOTE: Use "oiled” values for bolts with thread-locking compound

Brass MS63 Metric Bolts, Coarse Thread Torque (with bolts oiled*)

Diameter (in millimeters)

Newton-meters

Inch-pounds

3

0.5

4.4

3.5

0.79

7.0

4

1.2

10

5

2.2

19

6

3.9

34

8

9

79

10

17

150

Table A-5: Torque Chart - Brass Metric * NOTE: Use "oiled” values for bolts with thread-locking compound

PDMM-0102 Issued: 9/30/02

A-5

Raymond ® Sideloader Maintenance Manual

Appendix Torque Chart - Standard (Brass)

Torque Chart - Standard (Brass) Brass MS63 Standard Bolts, Coarse Thread Size

Torque (with bolts oiled*) Newton-meters

Inch-pounds

4-40

0.37

3.3

4-48

0.40

3.6

6-32

0.69

6.1

6-40

0.77

6.8

8-32

1.24

11

8-36

1.24

11

10-24

1.58

14

10-32

1.92

17

1/4-20

3.96

35

1/4-28

4.52

40

5/16-18

8.25

73

5/16-24

9.15

81

3/8-16

14.69

130

3/8-24

16.61

147

Table A-6: Torque Chart - Standard Brass * NOTE: Use "oiled” values for bolts with thread-locking compound

A-6

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Appendix Decimal Equivalent Chart

Decimal Equivalent Chart

4ths

8ths

16ths

32nds

64ths

To 3 Places

To 2 Places

MM Equivalent

1/64

.016

.02

.397

.031

.03

.794

.047

.05

1.191

.062

.06

1.587

.078

.08

1.984

.094

.09

2.381

.109

.11

2.778

.125

.12

3.175

.141

.14

3.572

.156

.16

3.969

.172

.17

4.366

.188

.19

4.762

.203

.20

5.159

.219

.22

5.556

.234

.23

5.593

.250

.25

6.350

.266

.27

6.747

.281

.28

7.144

.297

.30

7.540

.312

.31

7.937

.328

.33

8.334

.344

.34

8.731

.359

.36

9.128

.375

.38

9.525

.391

.39

9.922

.406

.41

10.319

.422

.42

10.716

.438

.44

11.112

.453

.45

11.509

.469

.47

11.906

.484

.48

12.303

.500

.50

12.700

1/32 3/64 1/16 5/64 3/32 7/64 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 Table A-7: Decimal Equivalent Chart

PDMM-0102 Issued: 9/30/02

A-7

Raymond ® Sideloader Maintenance Manual

Appendix Decimal Equivalent Chart 4ths

8ths

16ths

32nds

64ths

To 3 Places

To 2 Places

MM Equivalent

33/64

.516

.52

13.097

.531

.53

13.494

17/32 35/64 9/16 37/64 19/32 39/64 5/8 41/64 21/32 43/64 11/16 45/64 23/32 47/64 3/4 49/64 25/32 51/64 13/16 53/64 27/32 55/64 7/8 57/64 29/32 59/64 15/16 61/64 31/32 63/64

.547

.55

13.891

.562

.56

14.288

.578

.58

14.684

.594

.59

15.081

.609

.61

15.478

.625

.62

15.875

.641

.64

16.272

.665

.66

16.669

.672

.67

17.065

.688

.69

17.462

.703

.70

17.859

.719

.72

18.256

.734

.73

18.653

.750

.75

19.050

.766

.77

19.447

.781

.78

19.844

.797

.80

20.241

.812

.81

20.637

.828

.83

21.034

.844

.84

21.431

.859

.86

21.828

.875

.88

22.225

.891

.89

22.622

.906

.91

23.019

.922

.92

23.416

.938

.94

23.812

.953

.95

24.209

.969

.97

24.606

.984

.98

25.003

1.000

1.00

25.400

Table A-7: Decimal Equivalent Chart

A-8

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Raymond ® Sideloader Maintenance Manual

Appendix Standard/Metric Conversions

Standard/Metric Conversions To Convert...

Multiply...

Inches to Millimeters

Inches x 25.4

Millimeters to Inches

Millimeters x 0.039

Inches to Centimeters

Inches x 2.54

Centimeters to Inches

Centimeters x 0.394

Feet to Meters

Feet x 0.305

Meters to Feet

Meters x 3.281

Yards to Meters

Yards x 0.914

Meters to Yards

Meters x 1.094

Miles to Kilometers

Miles x 1.609

Kilometers to Miles

Kilometers x 0.621

Square Inches to Square Centimeters

Square Inches x 6.452

Square Centimeters to Square Inches

Square Centimeters x 0.155

Square Feet to Square Meters

Square Feet x 0.093

Square Meters to Square Feet

Square Meters x 10.753

Square Yards to Square Meters

Square Yards x 0.836

Square Meters to Square Yards

Square Meters x 1.196

Pints to Liters

Pints x 0.473

Liters to Pints

Liters x 2.113

Quarts to Liters

Quarts x 0.946

Liters to Quarts

Liters x 1.057

Gallons to Liters

Gallons x 3.785

Liters to Gallons

Liters x 0.26

Ounces to Grams

Ounces x 28.35

Grams to Ounces

Ounces x 0.035

Table A-8: Standard/Metric Conversion Chart

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A-9

Raymond ® Sideloader Maintenance Manual

Appendix Standard/Metric Conversions To Convert...

Multiply...

Ounces to Kilograms

Ounces x 0.028

Kilograms to Ounces

Kilograms x 35.27

Pounds to Kilograms

Pounds x 0.454

Kilograms to Pounds

Kilograms x 2.2

Pounds per Square Inch (PSI) to Kilopascals (kPa)

Pounds per Square Inch x 6.894

Kilopascals to Pounds per Square Inch

Kilopascals x 0.145

Pounds per Square Inch (PSI) to Kilograms per square centimeter (kg/cm2)

Pounds per Square Inch (PSI) x 0.0704

Kilograms per square centimeter (kg/cm 2) to Pounds per Square Inch (PSI)

Kilograms per Square Centimeter (kg/cm2) x 14.2

Inch Pounds (in. lbs.) to Newton Meters (Nm)

Inch Pounds x 0.113

Newton Meters (Nm) to Inch Pounds (in. lbs.)

Newton Meters x 8.85

Foot Pounds (ft. lbs.) to Newton Meters (Nm)

Foot Pounds x 1.3568

Newton Meters (Nm) to Foot Pounds (ft. lbs.)

Newton Meters x 0.737

Miles per Hour to Kilometers per Hour

Miles per Hour x 1.609

Kilometers per Hour to Miles per Hour

Kilometers per Hour x 0.6214

Fahrenheit to Celsius

(°F - 32) x 0.555

Celsius to Fahrenheit

(°C x 1.8) + 32

Table A-8: Standard/Metric Conversion Chart

A-10

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Schematics

PDMM-0102 Issued: 9/30/02

Schematics

Schematics A:

A-11

Raymond ® Sideloader Maintenance Manual

Figure A-1:

Electrical Schematic - Standard Travel

Schematics

0

A-12

PDMM-0102 Issued: 9/30/02

Schematics

Figure A-2:

Wiring Diagram - Standard Travel

Raymond ® Sideloader Maintenance Manual

1R89667_1A.EPS 828-009-667 sheet 1

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A-13

Raymond ® Sideloader Maintenance Manual

Wiring Diagram - Standard Travel Con’t.

Schematics

1

A-14

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Schematics

1

Figure A-3:

Electrical Schematic - Remote Travel

PDMM-0102 Issued: 9/30/02

A-15

Raymond ® Sideloader Maintenance Manual

Schematics

1

Figure A-4:

A-16

Wiring Diagram - Remote Travel

PDMM-0102 Issued: 9/30/02

Raymond ® Sideloader Maintenance Manual

Schematics Legend for Electrical Schematic

Legend for Electrical Schematic Key

Description

MS5A & B

"M" Range Switch Forward & Reverse

MS6A & B

Remote "M" Range Switch Forward & Reverse

P Key

Pump Contactor Description

PC

Power Disconnect Control (R.C. option)

RA REC1 REC2 & 3 S1 S2 S3 S4 S6 S10

Resistor Module Assembly Free Wheeling Rectifier Plugging Rectifiers Key Switch Deadman Switch Horn Switch Variable Lift Switch Working Lights Switch Interlock Switch on 1S Contactor

S11 S15

Limit Switch Thermostat in Control - Elec.

(C.S. option)

S16 S19 & 20 S21

Limit Switch - Mast Extend Remote Switch & Lower Switch Power Disconnect Switch (R.C. option)

1 & 2, B- & B+ BC C1 & C2 DA DI EQ F&R FU1 FU2 FU3 FU5 & FU6 H HM HTR

Battery Connectors Battery Controller Commutating Capacitors Diode Module Assembly Discharge Indicator Equalizing TD Module Directional Contactors Power Fuse (Travel) - 400 amps Power Fuse (Lift) - 600 amps Power Fuse (Aux) - 150 amps B+ & B- Control Fuse 15 amps Horn Hour Meter Heater in Control - Elec. & Cord Reel (C.S. option)

IL1, 2 & 3

Indicator Lights - left, center, right respect.

IS JP1 JP2 JP3 JP4 JP5 & JP6

Equalizing Contactor Connector for Control - Elec.

Connector for Control Unit Connector for Contactor Comp.

Connector for Cab Connector for Direct. Indicator Lights & Switches respect.

JP7

Connector for Brake Dump solenoid

S25 & 26

JP8

Connector at Base of Mast (R.C. option)

Direction Indicator Switch left & right respect.

S27

JP9

Connector at Base of Mast (Remote Platform Option)

Interlock Switch on PC Contactor (R.C. option)

S28, 29, 30

Crab Steer Switch - left, right, center respect.

S31 S32 S33

Remote Start Switch Thermostat in Cord Reel Lift Interlock Switch (R.C. option)

SCR1 SCR2 SCR3 SL SOL1 & 2

Main SCR Commutating SCR Charging SCR Speed Limit Module Crab Steer Solenoids - left, right respect.

SOL4 SOL5 SOL6

Brake Dump Solenoid Pump Bypass Solenoid Remote Lower Solenoid (R.C. option)

SOL7 SPL SUP T1

Lower Lockout Solenoid Splice Transient Suppressor Modules Transformer

JP10 JP11

Connector for Contactor Comp.

Connector for Carriage (R.C. option)

JP12

Connector for Speed Limit Module

JP18 K1 & K2 K5 K11 K12 K13 L1 M MD1 & MD2 MP MX MS1 & 2 MS3 & 4

Connector for FG & HM Plugging Relays Battery Controller Relay Auto Re-centering Relay Deadman Relay Light Load Relay Commutating Coil Shorting Contactor Drive Motors Pump Motor Auxiliary Motor Forward & Reverse Switch Remote Forward & Reverse Control

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A-17

Raymond ® Sideloader Maintenance Manual

Schematics Notes for Electrical Schematic TP1 & 2 TP3 TP4 thru 11

Feed Thru B- & B+ respect.

Feed Thru Aux B+ Feed Thru Between Contactor and SCR Comp.

TP12 thru 22

From Contactor Comp. to Motors

Key

Description

TP23, 24 TP25, 26, 27 TP28 thru 31 TS1

On Main SCR On SCR Manifold On Rectifier Manifold Terminal Strip near Control Elec.

TS2

Terminal Strip near Contactor Comp.

TS3

Terminal Strip on Rectifier Manifold

Key

Description

TS4

Terminal Strip for Remote Control (R.C. option)

TS5 TS6

Terminal Strip on Mast Terminal Strip on Guard Mtg. (option.)

TS20

Terminal Strip on Cord (C.S. option.)

VR1 VR2

Potentiometer in Control Elec.

Potentiometer in Control Elec.

(Remote)

X

Auxiliary Contactor

Notes for Electrical Schematic 1. Schematic shown in the "Power OFF" condition with carriage lowered and mast retracted.

2. Standard Travel - Wiring diagram for this schematic 154-000-051.

Remote Travel - Wiring diagram for this schematic 154-000-051 & 151-000-322.

3. Standard Travel - For Installation drawing, see power section 154-008-050.

Remote Travel - For installation drawing, see power section 115-001-403 4. For Transient Suppressor PN identification, refer to the Parts Manual or Installation drawing.

5. Limit Switch S11 not used on trucks with load beds greater than 42 in.

6. Standard Travel - Used with remote control. When not used, TS2-1 & 2, FU1-2 & P-1 are common.

Remote Travel - With Ranger®, omit jumper between TS2-14 & 15.

7. Standard Travel - With Ranger®, omit jumper between TS2-14 & 15.

Remote Travel - When helper is not required, S43 and S44 are replaced with jumper 115-001-324.

A-18

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Raymond ® Sideloader Maintenance Manual

Schematics

Figure A-5:

Hydraulic Schematic

Notes for Electrical Schematic

1

PDMM-0102 Issued: 9/30/02

A-19

Schematics

Raymond ® Sideloader Maintenance Manual

Notes for Electrical Schematic

A-20

PDMM-0102 Issued: 9/30/02

Raymond ® Sideloader Maintenance Manual

Index

Index A Attachment & Load Handler . . . . . . . . . . 7-55 Fork Tilt Cylinder Repair . . . . . . . . . . . 7-59 General . . . . . . . . . . . . . . . . . . . . . . . . 7-56 Lift Chain Repair . . . . . . . . . . . . . . . . . 7-62 Lift Cylinder Repair . . . . . . . . . . . . . . . 7-66 Mast Assembly Removal . . . . . . . . . . . . 7-69 Mast Drive Repair and Replacement . . . 7-70 Mast Tilt Cylinder Repair . . . . . . . . . . . 7-57 Mast Traverse Motor Repair . . . . . . . . . 7-61 Mast/Telescopic Roller Bearing Replacement 7-72 Reach Cylinder Repair . . . . . . . . . . . . . 7-60 Roller Bearing Replacement . . . . . . . . . 7-63 Side Cylinder Repacking . . . . . . . . . . . . 7-65 Auxiliary Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Auxiliary Fork Carriage . . . . . . . . . . . . . . 3-17 Auxiliary System . . . . . . . . . . . . . . . . . . . . 3-9

B Batteries . . . . . . . . . . . . . . . . . . . . . 3-12, 7-83 Charging . . . . . . . . . . . . . . . . . . . . . . . 7-84 Exterior Cleaning . . . . . . . . . . . . . . . . . 7-83 Record Keeping . . . . . . . . . . . . . . . . . . 7-87 Battery Compartment . . . . . . . . . . . . . . . . 3-3 Battery Controller . . . . . . . . . . . . . 3-16, 7-129 Battery Safety . . . . . . . . . . . . . . . . . . . . . . 2-7 Brakes . . . . . . . . . . . . . . . . . . . . . . . 3-5, 7-49 Parking Brake Adjustment . . . . . . . . . . 7-51 Service Brake Adjustment . . . . . . . . . . 7-50 Shoe Replacement . . . . . . . . . . . . . . . . 7-52 Wheel Cylinder Repair or Replacement . 7-54

C C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Capacitors . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Carriage Roller Bearing . . . . . . . . . . . . . . 7-63 Commutator . . . . . . . . . . . . . . . . . . . . . . 7-16

Issued: 9/30/02

Component Locator Photos . . . . . . . . . . . . . 7-3 Component Procedures Attachment & Load Handler . . . . . . . . . 7-55 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49 Controls . . . . . . . . . . . . . . . . . . . . . . . . 7-95 Drive Axle Assembly . . . . . . . . . . . . . . . 7-23 Electrical . . . . . . . . . . . . . . . . . . . . . . . . 7-81 General . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . 7-74 Steering . . . . . . . . . . . . . . . . . . . . . . . . . 7-47 Contactors . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Control Unit . . . . . . . . . . . . . . . . . 3-16, 7-102 Controls Auto Steer Centering Relay K11 . . . . . . 7-130 Battery Controller and K5 Relay . . . . . . 7-129 Test Procedure . . . . . . . . . . . . . . . . . 7-129 Battery Controller and Relay K5 . . . . . . 7-129 Control Unit . . . . . . . . . . . . . . . . . . . . 7-102 “M” Lockout Circuit Test . . . . . . . . . . 7-114 “M” Time Delay Test . . . . . . . . . . . . . 7-111 1/2 Speed Test (VPG Card) . . . . . . . . 7-108 1/8 Speed Test . . . . . . . . . . . . . . . . . 7-109 Current Limit . . . . . . . . . . . . . . . . . . 7-113 Equalizing Time Delay . . . . . . . . . . . . 7-119 Equalizing Time Delay Test . . . . . . . . 7-112 Fwd/Rev Time Delay Test . . . . . . . . . 7-110 Idle Rep Rate Adjust . . . . . . . . . . . . . 7-106 Input Voltage Check . . . . . . . . . . . . . 7-103 Overload Control Circuit Test . . . . . . 7-115 Plugging Adjustment . . . . . . . . . . . . . 7-106 Power Driver Card . . . . . . . . . . . . . . . 7-117 Regulated Voltage Check . . . . . . . . . . 7-104 Speed Limit Module . . . . . . . . . . . . . 7-120 Transient Suppressors . . . . . . . . . . . 7-118 Weld Detect Circuit . . . . . . . . . . . . . . 7-116 Width and Freq Pulse Checks . . . . . . 7-105 Deadman Relay K12 . . . . . . . . . . . . . . 7-131 Diode Assemblies . . . . . . . . . . . . . . . . . 7-132 Directional/Speed Control Assy . . . . . . . 7-96 Light Load Relay K13 . . . . . . . . . . . . . . 7-131 Plugging Relays K1 & K2 . . . . . . . . . . . 7-127 Rectifier’s Replacement . . . . . . . . . . . . . . . . . . . 7-125 Test Procedure . . . . . . . . . . . . . . . . . 7-125 Rectifiers . . . . . . . . . . . . . . . . . . . . . . . 7-125 Resistor Assemblies . . . . . . . . . . . . . . . 7-135 SCR’s SCR1 Replacement . . . . . . . . . . . . . . 7-122

I-1

Raymond ® Sideloader Maintenance Manual

Index

SCR2 & SCR3 Replacement . . . . . . . .7-124 Test Procedure . . . . . . . . . . . . . . . . .7-122 Suppressor Assemblies . . . . . . . . . . . .7-136 Conversions, Standard/Metric . . . . . . . . . A-9 Crab Steer . . . . . . . . . . . . . . . . . . . . . . . 3-11 Crab Steer Alignment and Adjustment . . 7-28 Crab Steer Cylinder Replacement . . . . . . 7-36 Current Limit . . . . . . . . . . . . . . . . . . . . .7-113 Current Limit Circuit . . . . . . . . . . . . . . . 8-28 Cylinders Fork Tilt . . . . . . . . . . . . . . . . . . . . . . . . 7-59 Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66 Mast Tilt . . . . . . . . . . . . . . . . . . . . . . . 7-57 Master . . . . . . . . . . . . . . . . . . . . . . . . . 7-75 Reach . . . . . . . . . . . . . . . . . . . . . . . . . 7-60 Slave . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75 Steer . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Cylinders, Hydraulic . . . . . . . . . . 7-57 to 7-68

D Deadman Switch . . . . . . . . . . . . . . . . . . . 3-12 Decimal to Fraction Conversion . . . . . . . . A-7 Design, Manual . . . . . . . . . . . . . . . . . . . . . 1-3 Diode Assemblies DA1 . . . . . . . . . . . . . . . . . . . . . . . . . . .7-132 DA2 and DA9 . . . . . . . . . . . . . . . . . . . .7-132 DA3, DA4, DA8 and DA10 . . . . . . . . . .7-133 DA5 and DA11 . . . . . . . . . . . . . . . . . . .7-133 DA6 . . . . . . . . . . . . . . . . . . . . . . . . . . .7-134 DA7 and DA12 . . . . . . . . . . . . . . . . . . .7-134 Directional/Speed Control Assy . . . 3-13, 7-96 Master Switches . . . . . . . . . . . . . . . . . . 7-96 Potentiometer Check . . . . . . . . . . . . . . . . . . . . . . . . 7-97 Gear Binding Adjustment . . . . . . . . .7-100 Removal/Replacement . . . . . . . . . . . . 7-99 Reassembly . . . . . . . . . . . . . . . . . . . . .7-101 Double Acting Cylinders . . . . . . . . . . . . . 3-10 Drive Axle Assembly . . . . . . . . . . . . . . . . 7-23 Axle Removal and Reassembly . . . . . . . 7-30 General . . . . . . . . . . . . . . . . . . . . . . . . 7-24 Tie Rod Replacement . . . . . . . . . . . . . . 7-36 Wheel Replacement . . . . . . . . . . . . . . . 7-26 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Inspection and Cleaning . . . . . . . . . . . . 7-25 Replacement . . . . . . . . . . . . . . . . . . . . 7-32 Drive Unit Repair and Replacement . . . . . 7-34 Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . 3-4

I-2

E Electrical . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Component Testing . . . . . . . . . . . . . . . . 7-87 Contactors Cleaning . . . . . . . . . . . . . . . . . . . . . . . 7-88 Coil Replacement . . . . . . . . . . . . . . . . 7-89 Core/Rod Assy Replacement . . . . . . . . 7-90 Insulation Replacement . . . . . . . . . . . 7-90 Tip Inspection . . . . . . . . . . . . . . . . . . . 7-88 Tip Replacement . . . . . . . . . . . . . . . . . 7-90 General . . . . . . . . . . . . . . . . . . . . . . . . . 7-82 Heat Sink Insulation . . . . . . . . . . . . . . . 7-82 Emergency Manual Lower Valve . . . . . . . . 8-10 Equalizing Time Delay . . . . . . . . . . . . . . . 3-13

F Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Flow Limiter . . . . . . . . . . . . . . . . . . . . . . . 3-10 Fork Tilt Cylinder . . . . . . . . . . . . . . . . . . . 7-59 Fraction to Decimal Conversion . . . . . . . . . A-7 Frequency Pulse . . . . . . . . . . . . . . . . . . . 7-105 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

G Gear Reduction . . . . . . . . . . . . . . . . . . . . . 3-4 Guide Rollers . . . . . . . . . . . . . . . . . . . . . . 3-17

H Heat Sinks . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . 3-16 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Hydraulic Adjustable Forks . . . . . . . . . . . 3-17 Hydraulics . . . . . . . . . . . . . . . . . . . . 3-7, 7-73 Auxiliary Controls and Linkage . . . . . . . 7-78 General . . . . . . . . . . . . . . . . . . . . . . . . . 7-74 Leakage . . . . . . . . . . . . . . . . . . . . . . . . . 7-74 Lift Control and Linkage . . . . . . . . . . . . 7-75 Lift Pump Maintenance . . . . . . . . . . . . . . . . . . . . 7-75 Replacement . . . . . . . . . . . . . . . . . . . . 7-76 Manifolds . . . . . . . . . . . . . . . . . . . . . . . 7-78

Issued: 9/30/02

Raymond ® Sideloader Maintenance Manual

Relief Valve Pressure Settings . . . . . . 7-79 Slave Cylinder . . . . . . . . . . . . . . . . . . . 7-75

I Idle Rep Rate . . . . . . . . . . . . . . . . . . . . . 7-106 Inspection Points . . . . . . . . . . . . . . . . . . . . 5-8 Installation . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Inspection . . . . . . . . . . . . . . . . . . . . . . . 4-3 Reassembly, Mast to Tractor . . . . . . . . . . 4-4

J Jacking Safety . . . . . . . . . . . . . . . . . . . . . 2-11

K K1 . . . . . . . . . . . . . . . . . . . . . . . . . 3-15, 7-127 K11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-130 K12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-131 K13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-131 K2 . . . . . . . . . . . . . . . . . . . . . . . . . 3-15, 7-127 K5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-129 Key Switch . . . . . . . . . . . . . . . . . . . . . . . 3-12

L Lift Chain . . . . . . . . . . . . . . . . . . . . . . . 3-6, 7-62 Check Valve . . . . . . . . . . . . . . . . . . . . . . 3-8 Control . . . . . . . . . . . . . . . . . . . . . . 3-8, 7-75 Cylinder Bleeding . . . . . . . . . . . . . . . . . 7-68 Cylinders . . . . . . . . . . . . . . . . 3-6, 3-8, 7-66 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Lift Linkage . . . . . . . . . . . . . . . . . . . . . . . 7-75 Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . 7-75 Replacement . . . . . . . . . . . . . . . . . . . . . 7-76 Load Reducing Relays . . . . . . . . . . . . . . . 3-16 Load Weight Indicator . . . . . . . . . . . . . . . 3-17 Locator Photos Components . . . . . . . . . . . . . . . . . . . . . . 7-3 Lowering Lock-Out Solenoid . . . . . . . . . . . . . . . . . 3-8 Lowering Valve . . . . . . . . . . . . . . . . . . . . . 3-8 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Lubrication Specification Chart . . . . . . . . . A-2

Issued: 9/30/02

Index

M M Lockout Circuit . . . . . . . . . . . . . . . . . . . 8-28 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . 7-78 Manual Design . . . . . . . . . . . . . . . . . . . . . . 1-3 Map, Navigating the Manual . . . . . . . . . . . . 1-2 Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 Mast Assembly . . . . . . . . . . . . . . . . . . . . . 7-69 Mast Drive . . . . . . . . . . . . . . . . . . . . . . . . 7-70 Mast Tilt Cylinder . . . . . . . . . . . . . . . . . . . 7-57 Mast Traverse Motor . . . . . . . . . . . . 3-10, 7-61 Master Cylinder . . . . . . . . . . . . . . . . . . . . 7-75 Metric to Standard Conversion . . . . . . . . . .A-9 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Brushes . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Inspection . . . . . . . . . . . . . . . . . . . . . . 7-14 Replacement . . . . . . . . . . . . . . . . . . . . 7-15 Commutator . . . . . . . . . . . . . . . . . . . . . 7-16 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32 Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Mast Traverse . . . . . . . . . . . . . . . . . . . . 7-61 Terminal Nuts . . . . . . . . . . . . . . . . . . . . 7-18

O Operation Lift/Lower . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Options Auxiliary Fork Carriage . . . . . . . . . . . . . 3-17 Guide Rollers . . . . . . . . . . . . . . . . . . . . . 3-17 Hydraulic Adjustable Forks . . . . . . . . . . 3-17 Load Weight Indicator . . . . . . . . . . . . . . 3-17 Miscellaneous . . . . . . . . . . . . . . . . . . . . 3-18 Ranger® Shelf Height Selector . . . . . . . . 3-17 Remote Lift/Lower . . . . . . . . . . . . . . . . . 3-18 Orbitrol . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

P Plugging Relays . . . . . . . . . . . . . . . . . . . . 3-15 Power Driver Card . . . . . . . . . . . . . . . . . 7-117 Charging SCR Pulse Test . . . . . . . . . . . 7-117 Commutating SCR Pulse Test . . . . . . . 7-117 Pressure Relief System . . . . . . . . . . . . . . . 3-10 Pressure Reliefs . . . . . . . . . . . . . . . . . . . . . 3-9 Pressure Settings Relief Valve . . . . . . . . . . . . . . . . . . . . . . 7-79 Pulse Width . . . . . . . . . . . . . . . . . . . . . . 7-105

I-3

Raymond ® Sideloader Maintenance Manual

Index

R R1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 R2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Ranger® Shelf Height Selector . . . . . . . . . 3-17 Reach Cylinder . . . . . . . . . . . . . . . . . . . . 7-60 Rectifiers . . . . . . . . . . . . . . . . . . . 3-15, 7-125 Relays Load Reducing . . . . . . . . . . . . . . . . . . . 3-16 Plugging . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Relief Valve Pressure Settings . . . . . . . . . 7-79 Remote Lift/Lower . . . . . . . . . . . . . . . . . 3-18 Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Resistor Assemblies RA1 . . . . . . . . . . . . . . . . . . . . . . . . . . .7-135 RA2 . . . . . . . . . . . . . . . . . . . . . . . . . . .7-135

S Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Definitions . . . . . . . . . . . . . . . . . . . . . . . 2-2 General . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Jacking . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Welding . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Scheduled Maintenance . . . . . . . . . 5-2 to 5-7 Annual . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Guidelines . . . . . . . . . . . . . . . . . . . . . . . 5-2 Monthly . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Photos . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Semi-Annual . . . . . . . . . . . . . . . . . . . . . 5-6 SCR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 SCR1 Replacement . . . . . . . . . . . . . . . . .7-122 SCR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 SCR2 & SCR3 Replacement . . . . . . . . . .7-124 SCR3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Shorts to Frame . . . . . . . . . . . . . . . . . . . . 6-5 Side Cylinder . . . . . . . . . . . . . . . . . . . . . 7-65 Silicon Controlled Rectifiers . . . . . . . . . . 3-14 Speed Limit . . . . . . . . . . . . . . . . . . . . . . . 8-28 Speed Limit Module . . . . . . . . . . . 3-13, 7-120 Standard to Metric Conversion . . . . . . . . . A-9 Steer Axle Assembly Cylinder Replacement . . . . . . . . . . . . . 7-44 General . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Knuckle Replacement . . . . . . . . . . . . . . 7-45 Linkage Replacement . . . . . . . . . . . . . . 7-43 Removal and Reassembly . . . . . . . . . . . 7-41 Steer Centering Relay . . . . . . . . . . . . . . .7-130

I-4

Steer Cylinder Replacement . . . . . . . . . . . 7-44 Steer Cylinders . . . . . . . . . . . . . . . . . . . . 3-11 Steer Knuckle Replacement . . . . . . . . . . . 7-45 Steer Linkage Replacement . . . . . . . . . . . 7-43 Steerable Wheel Replacement . . . . . . . . . . 7-39 Steering . . . . . . . . . . . . . . . . . . 3-4, 3-11, 7-47 Alignment . . . . . . . . . . . . . . . . . . . . . . . 7-40 Chain Adjustment . . . . . . . . . . . . . . . . . 7-48 Linkage Adjustment . . . . . . . . . . . . . . . 7-40 Orbitrol . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Suppressor Assemblies SUP1 . . . . . . . . . . . . . . . . . . . . . . . . . . 7-136 SUP3 . . . . . . . . . . . . . . . . . . . . . . . . . . 7-136 Switch Deadman . . . . . . . . . . . . . . . . . . . . . . . 3-12 Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 System Pressure Relief . . . . . . . . . . . . . . . 3-10

T T1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Telescopic . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Theory of Operation . . . . . . . . . . . . . . . . . . 8-1 Auxiliary Controls . . . . . . . . . . . . . . . . . 8-13 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Lift/Lower . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Miscellaneous Circuits . . . . . . . . . . . . . 8-28 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Plugging . . . . . . . . . . . . . . . . . . . . . . . . 8-26 Remote Travel . . . . . . . . . . . . . . . . . . . . 8-29 SCR Theory . . . . . . . . . . . . . . . . . . . . . . 8-15 Standard Travel . . . . . . . . . . . . . . . . . . . 8-17 Steering . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Tie Rod Replacement . . . . . . . . . . . . . . . . 7-36 Tire Replacement . . . . . . . . . . . . . . . . . . . 7-12 Torque Chart . . . . . . . . . . . . . . . . . . . . . . . A-4 Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 Standard . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Transformer T1 . . . . . . . . . . . . . . . . . . . . 3-15 Transient Suppressors . . . . . . . . . . . . . . 7-118 Travel System . . . . . . . . . . . . . . . . . . . . . 3-12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . 6-1 General Instructions . . . . . . . . . . . . . . . . 6-4 Overview . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Start Procedure . . . . . . . . . . . . . . . . . . . 6-13 Wiring Inspection . . . . . . . . . . . . . . . . . . 6-4 Troubleshooting Charts . . . . . . . . . . . . . . 6-11

Issued: 9/30/02

Raymond ® Sideloader Maintenance Manual

Index

V VR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

W Weld Detection Circuit . . . . . . . . . . . . . . 8-28 Welding Safety . . . . . . . . . . . . . . . . . . . . 2-12 Wheel Replacement Steerable . . . . . . . . . . . . . . . . . . . . . . . 7-39 Wiring Inspection . . . . . . . . . . . . . . . . . . . 6-4

Issued: 9/30/02

I-5

Index

I-6

Raymond ® Sideloader Maintenance Manual

Issued: 9/30/02

PDMM-0102

!PDMM-0102 PDMM-0102

Printed in the USA

RAYMOND SERVICE INFORMATION

The Raymond Corporation Corporate Headquarters P O Box 130 Greene, New York 13778-0130

RSI MUL-15-006

Model

June 29, 2015

Multi Product

SUBJECT:

Updated Torque Check Procedures

GENERAL INFORMATION:

Updates are being made to the procedures for checking bolt torque during scheduled maintenance.

SERVICE INFORMATION:

When a fastener requires a torque check after the initial 90 day/250 HD Maintenance, there are now two procedures that can be used.

•

If the fastener was previously marked with a paint pen when torqued, look at the markings to verify the fastener has not moved. If the fastener has moved or is in question, remove the fastener, clean the threads, and apply the appropriate thread locker. Install the fastener and torque to the proper value, turning it in the tightening direction. Use a paint pen and mark the fastener for future inspections.

•

If the fastener was not previously marked with a paint pen, determine the proper torque value. Set the torque wrench to 85% of the required torque value and check the torque of the fastener, turning it in the tightening direction. If the fastener does not move, use a paint pen and mark the fastener for future inspections. If the fastener moves, remove the fastener, clean the threads, and apply the appropriate thread locker. Install the fastener and torque to the proper value. Use a paint pen and mark the fastener for future inspections.

PARTS AVAILABILITY:

N/A

FILING INSTRUCTIONS:

File this notice in all Maintenance Manuals next to the 180 day or 500 HD Scheduled Maintenance chart.

®

Raymond is a registered trademark of The Raymond Corporation 2015 The Raymond Corporation.

FOTP-0060/1-7-15/F

RSI MUL-15-006 Page 1 of 1

RAYMOND SERVICE INFORMATION

The Raymond Corporation Corporate Headquarters P O Box 130 Greene, New York 13778-0130

RSI MUL-15-001

Models

March 17, 2015

Multi-Product

SUBJECT:

Recommended Lift Chain Lubrication

GENERAL INFORMATION:

The chain lubricant specified in maintenance manuals may not adequately penetrate and lubricate the joints of the chain.

SERVICE INFORMATION:

Use P/N 1151877/001 (Rexoil) or 1151877/002 (Rocol) when lubricating lift chains on all trucks.

PARTS AVAILABILITY:

Now available through the Parts Distribution Center.

FILING INSTRUCTIONS:

Remove and discard RPIN GEN-10-R004. File this notice in the Appendix of all maintenance manuals for trucks that have lift chains (that do not already reflect this information) next to the Lubrication Specification Chart. Cross out the information presently in the chart.

®

Raymond is a registered trademark of The Raymond Corporation 2015 The Raymond Corporation.

FOTP-0060/1-7-15/F

RSI MUL-15-001 Page 1 of 1

RAYMOND SERVICE INFORMATION

The Raymond Corporation Corporate Headquarters P O Box 130 Greene, New York 13778-0130

RSI SDL-13-002

Models

October 1, 2013

71/76/9300/9400

SUBJECT:

Parking Brake Seal Leaks

GENERAL INFORMATION:

There have been reports of parking brake actuator seals leaking hydraulic oil.

SERVICE INFORMATION:

A new wiper seal (P/N 1170449) replaces the previous seal used (P/N 530-528).

When installing the actuator, check the piston rod to verify it is centered on the piston to avoid side load. If necessary, adjust the assembly as follows: Piston rod centered on piston Loosen the 4 mounting bolts and adjust the assembly so the piston rod is centered on the piston.

NOTE: The assembly does not have to be parallel with the wheel.

PARTS AVAILABILITY:

Now available through the Parts Distribution Center.

FILING INSTRUCTIONS:

File this notice in Maintenance Manuals PDMM-0102 next to page 7-51 and 1089026 next to page 7-38. Make a note in Parts Manuals 1089004 on page 4-71 and 1014470 on pages 4-11 and 8-59.

Raymond is a registered trademark of The Raymond Corporation 2013 The Raymond Corporation.

FOTP-0060/1-23-12/C ®

RSI SDL-13-002 Page 1 of 1

RAYMOND SERVICE INFORMATION

The Raymond Corporation Corporate Headquarters P O Box 130 Greene, New York 13778-0130

RSI SDL-13-003

Models

October 1, 2013

71/76/9300/9400

SUBJECT:

Master Cylinder Replacement

GENERAL INFORMATION:

The design of Master Cylinder P/N 870-688 has changed.

SERVICE INFORMATION:

For older versions of Master Cylinder P/N 870-688 (prior to 2013), an insert seat was removed to facilitate the correct fit of the P/N 812-001-347 fitting. Starting in 2013, there is a possibility that the insert is cast-in and not removable.

Replacement of the P/N 870-688 Master Cylinder requires a new fitting (P/N 1172845).

NOTE: If the Master Cylinder is supplied with a removable seat, do not remove the seat.

Use the new fitting.

PARTS AVAILABILITY:

Now available through the Parts Distribution Center.

FILING INSTRUCTIONS:

File this notice in Maintenance Manuals PDMM-0102 next to page 7-50 and 1089026 next to page 7-38. Make a note in Parts Manuals 1089004 on page 4-5 and 1014470 on pages 4-3.

Raymond is a registered trademark of The Raymond Corporation 2013 The Raymond Corporation.

FOTP-0060/6-28-13/D ®

RSI SDL-13-003 Page 1 of 1

RAYMOND PRODUCT IMPROVEMENT NOTICE

The Raymond Corporation Corporate Headquarters P O Box 130 Greene, New York 13778-0130

Models

RPIN GEN-06-R003A

General: All Trucks with Electric Brake

June 6, 2007

SUBJECT:

Updated Scheduled Maintenance Suggested Intervals

DESCRIPTION:

Based on an analysis of field data available from different environments of use, the suggested intervals between scheduled maintenance are extended in some applications to maximize operational efficiencies.

REMEDY:

See page 2 for suggested intervals.

PROCEDURES:

Make a copy of page 2 and insert it in each maintenance manual next to the existing chart.

PARTS AVAILABILITY:

NA

FILING INSTRUCTIONS:

In all current Maintenance Manuals next to the existing interval chart.

Raymond is a registered trademark of The Raymond Corporation 2007 The Raymond Corporation.

FOTP-0005/jwr/03-16-07/D

RPIN GEN-06-R003A Page 1 of 2

Suggested Scheduled Maintenance Intervals Operating Conditions Light to Moderate Severe

Extreme

Working Environment An eight hour shift of basic material handling.

Extended heavy duty operations.

Freezer operations.

Sudden temperature changes.

All EE rated lift trucks.

Dusty or sandy conditions, eg…

High temperature areas, eg…

Corrosive atmosphere, eg…

Raymond is a registered trademark of The Raymond Corporation 2007 The Raymond Corporation.

FOTP-0005/jwr/03-16-07/D

Service Frequency 180 days or 500 hrs., whichever comes first 250 hrs.

100 hrs.

RPIN GEN-06-R003A Page 2 of 2

RAYMOND PRODUCT IMPROVEMENT NOTICE

The Raymond Corporation Corporate Headquarters P O Box 130 Greene, New York 13778-0130

RSB SDL-06-R001

Models

February 8, 2006

071 /076

SUBJECT:

Improved Auxiliary Motor

DESCRIPTION:

The auxiliary motor used in Sideloader trucks has been improved to run cooler in aggressive applications. This will result in longer auxiliary motor life.

REMEDY:

Should the auxiliary motor (P/N 570-435) fail, replace it with larger auxiliary motor (P/N 1032510/010).

NOTE:

When using the larger auxiliary motor, the auxiliary pump (P/N 500-024) must be replaced with auxiliary pump (P/N 1042696) which has a higher volume to compensate for the lower RPM motor. Failure to do so may cause the brakes to not release.

Refer to RPIN SDL-04-R001 for proper shimming instructions for the auxiliary pump.

PROCEDURES:

Refer to the Maintenance Manual, PDMM-0102, dated 9/30/02

PARTS AVAILABILITY:

Now available through the Parts Distribution Center.

FILING INSTRUCTIONS:

File this bulletin in Maintenance Manual PDMM-0102 in front of page 7-1.

®

Raymond is a registered trademark of The Raymond Corporation © 2006 The Raymond Corporation.

FOTP-0005/mlc/01-01--03/C

RPIN SDL-06-R001 Page 1 of 1

RAYMOND PRODUCT IMPROVEMENT NOTICE

The Raymond Corporation Corporate Headquarters PO Box 130 Greene, New York 13778-0130

RPIN SDL-04-R001

Models

January 19, 2004

071, 076

SUBJECT:

Auxiliary motor failure

DESCRIPTION:

The coupling between the auxiliary motor (P/N 570-435) and the pump (P/N 500-024) may bind causing the auxiliary motor to overheat.

REMEDY:

Adding a shim between the pump and the motor relieves the binding between the coupler halves.

PROCEDURES:

Should this condition exist, or when replacing either the auxiliary pump or auxiliary motor, install a gasket (P/N 531-002) between the pump and motor to space the coupler halves apart.

PARTS AVAILABILITY:

Parts are now available through the Parts Distribution Center.

FILING INSTRUCTIONS:

File this notice in front of page 7-1 in Maintenance Manual PDMM-0102.

®

Raymond is a registered trademark of The Raymond Corporation 2004 The Raymond Corporation.

FOTP-0005/mlc/02-13-02/C

RPIN No. SDL-04-R001 Page 1 of 1