PDF Maintenance Manual Raymond 101T Walkie Pallet Truck - 3 MB
Keep your Raymond 101T Walkie Pallet Truck running smoothly with this detailed maintenance instruction manual.
Specifically for models with serial numbers 99-07500 and up, this guide is crucial for your service technicians.
It outlines all the required maintenance procedures, from simple lubrication to more complex adjustments.
Following the factory-recommended service schedule will extend the life of your equipment and prevent unexpected breakdowns.
This manual is a must-have for any facility that relies on Raymond pallet trucks.
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--- Page 1 ---
Maintenance Instructions
Model 101T Walkie Pallet Truck
Serial No.: 99-07500 and up
PDMM-0072 Issued: 1/4/99
--- Page 4 ---
Battery Safety
WARNING
As a battery is being charged, an
explosive gas mixture forms within
and around each cell. If the area is
not properly 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. Should any electrolyte
come in contact with your clothing or
skin, flush the area immediately with
cold water. Should the solution get
on your face or in your eyes, flush
the area with cold water and get
medical help immediately.
Wear personal protective equipment to protect
eyes, face and skin when checking, handling or
filling batteries. This equipment includes
goggles or face shield, rubber gloves (with or
without arm shields) and a rubber apron.
Make sure a shower and eyewash station are
nearby in case there is an accident.
--- Page 5 ---
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 in the vicinity 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 should be carried
out only in well ventilated areas
using local exhaust if necessary.
Before working on this truck, make sure that:
• Fire protection equipment is nearby.
• You know where the nearest eyewash
station is.
• Disconnect the battery before you attempt
to inspect, service or repair the lift truck.
Discharge residual charge in the motor
controller by connecting a load across the
controllers B+ and B- (such as a contactor
coil or by pressing the horn button).
• Check for shorts to frame as described on
page 5-5. If any shorts are detected, remove
them before you proceed with the welding
operation.
• Clean the area to be welded.
• Protect all truck components from heat,
weld spatter and debris.
• Attach the ground cable as close to the weld
area as possible.
--- Page 7 ---
Electrical
Troubleshooting
Guidelines
Many problems are caused by a faulty or dirty
battery. Make sure the battery is clean. Check
the electrolyte level and state of charge. See
“Battery” on page 6-8. Be sure to block the
truck whenever a troubleshooting procedure
requires turning the key switch ON. This will
avoid accidents caused by unexpected truck
travel.
CAUTION
Unless otherwise directed, disconnect
the battery connector when you
check electrical circuits or
components with an ohmmeter.
Electrical current can damage the
ohmmeter.
Save time and trouble by looking for simple
causes first.
Visually inspect all wiring and electrical
components for:
• Loose connections or connectors
• Loose or broken terminals
• Damaged terminals, blocks, or strips.
• Broken wiring and shorted conditions
(especially those that are close to metal
edges or surfaces)
Use an ohmmeter to check for wiring
continuity.
For information on pin, connector, and harness
connections, see “Wiring Harness” on page 6-17
and see “Electrical Connector Locator Chart” on
page 5-12.
--- Page 8 ---
Fault Codes
An internal microcontroller automatically
checks the function of the motor controller.
When this microcontroller detects a fault, it
signals the appropriate fault code through the
LED on the bottom of the motor controller.
Under normal operation, the LED flashes a
single flash at approximately one flash every
five seconds. A two-digit flash code signals a
fault has been detected by the microcontroller.
Correct faults by following the Troubleshooting
Charts beginning on page 5-21.
Fault Code Explanation / Possible Cause
LED off No power or defective controller
Solid on Defective motor controller
Single flash ¤ Controller operational, normal operation, no faults
1, 1 ¤ ¤ Current sensor error: Motor controller defective
1, 2 ¤ ¤¤ Hardware fail-safe error: defective motor controller
1, 3 ¤ ¤¤¤ Internal M- short to B-: Motor controller defective
1, 4 ¤ ¤¤¤¤ Static return to off (SRO) fault: Improper sequence of key switch,
interlock, or direction inputs. Wrong SRO type selected. Interlock
or direction switch circuit open. Sequence delay too short.
2, 1 ¤¤ ¤ Pot wiper circuit fault: Pot wiper wire open. Pot wiper wire shorted
to B- or B+. Throttle pot defective.
2, 2 ¤¤ ¤¤ Emergency reverse wiring fault: Belly button wire open. Belly
button check wire open.
2, 3 ¤¤ ¤¤¤ High-pedal-disable (HPD) fault: Improper sequencing of key switch,
brake switch and throttle inputs. Wrong HPD type selected,
Misadjusted throttle pot. Sequencing delay too short.
2, 4 ¤¤ ¤¤¤¤ Pot low fault: Pot wiper wire open. Pot wire shorted to B- or B+.
3, 1 ¤¤¤ ¤ Contactor driver output overcurrent or field winding shorted: Main
contactor coil shorted. Field winding shorted.
3, 2 ¤¤¤ ¤¤ Main contactor welded: Main contactor stuck closed. Main
contactor driver shorted.
3, 3 ¤¤¤ ¤¤¤ Motor field winding open: Field winding open. Field connection
open.
3, 4 ¤¤¤ ¤¤¤¤ Missing contactor: Main contactor coil open. Wire to main contactor
coil open or shorted to B-.
--- Page 9 ---
Cloning
With the Programmable Maintenance Tool
(PMT) (P/N 950-180), you are able to copy or
“clone” the parameters and options from one
motor controller to another. Cloning only works
between controllers with the same model
number and software version.
Copy Parameters
1. Turn the key switch OFF. Remove tractor
cover.
2. Turn the key switch ON.
3. Connect the PMT to the motor controller
you want to clone. See Figure 5-6.
4. Press and hold the More Info key, then
press the Program key. Release both keys
after you enter Special Program mode.
5. Scroll through the modes using the Scroll
Display keys until “CONT SETTINGS−PROG”
is the top line in the display.
6. Press the More Info key again. The PMT will
prompt you to acknowledge (save controller
settings in PMT) or cancel.
Enter Parameters
1. Disconnect the PMT from the motor
controller that you used to “clone”
parameters.
2. Turn the key switch OFF. Remove the
tractor cover.
3. Turn the key switch ON.
4. Reconnect the PMT to the motor controller
you want to program.
5. Press and hold the More Info key, and press
the Program key. Release both keys after
you enter Special Program mode.
6. Scroll through the modes using the Scroll
Display keys until “PROG SETTINGS−
CONT” is the top line in the display.
7. Press the More Info key again. The PMT will
prompt you to acknowledge (load
programming settings in controller) or
cancel.
--- Page 10 ---
H-1-5
Is switch OK? No Repair or replace.
Yes Yes
With key switch off,
battery disconnected Go to Chart
and wires removed, END1
measure resistance of
pump contactor coil.
Is
it approximately No Replace contactor.
16 ohms?
Yes
Verify the problem still
exists. Repeat H-1. If Go to Chart
you return here, go to END1
General
Troubleshooting.
Go to Chart
GEN1
--- Page 11 ---
T-2: No Travel in Either Direction, Lift/Lower OK.
Motor Controller Fault Code 3,1.
With key switch off and
battery disconnected,
remove connector PMC
from motor controller.
Measure resistance in Repair or replace
Is wiring OK? No
wiring harness between: wiring.
PMC-16 to PMC-4
With key switch off and
battery disconnected, remove
connector PMC and check for
Yes
continuity and wiring shorts Go to Chart
between: END1
Is resistance
PMC-4 to M1-Y Disconnect and
approximately No
PMC-16 to M1-X measure resistance
30 ohms?
SW1-IGN to M1-X of main contactor
coil.
Programmable Maintenance
Yes Tool can be used here. See
PMT section in
Troubleshooting.
With key switch off
and battery Is resistance
disconnected, approximately No Replace coil
remove wires S1 30 ohms?
and S2 at motor
controller. Measure
resistance in wiring
harness between S1 Yes
and S2. Go to Chart
Remove wires at S1 and
Verify the problem still END1
S2 at motor. Measure
exists. Repeat T-2. If
resistance between S1
you return here, go to
and S2 of motor.
No General
Troubleshooting.
Is resistance less
than 1.0 ohms?
Go to Chart Yes
Is resistance less GEN1
Yes
than 1.0 ohms?
Replace motor
controller. Repair or
replace wiring
With S1 & S2 wires
disconnected from
No
motor controller, check
Go to Chart Is wiring OK?
continuity and for
END1
wiring shorts between: Go to Chart
S1 (motor) to S1 (PMC) END1
S2 (motor) to S2 (PMC)
--- Page 13 ---
T-8: No Emergency Reverse, Travel/Lift/Lower OK.
No Motor Controller Fault Codes.
With truck jacked and blocked, With key switch off, battery
battery connected, key switch on disconnected and PMC
and handle in travel position; disconnected; check for
measure voltage at PMC-13 (with continuity of emergency reverse
reference to B-) while pushing switch (SW7) between:
emergency reverse switch. C (Common) and NO (Normally
1
PMT can be used here. See PMT Open) while holding switch
section in Troubleshooting. closed.
Is B+ present? No Is switch OK? No Replace switch.
Yes
With key switch off and battery
Yes disconnected, check for continuity
and wiring shorts between:
SW2 (Brake)-NO to JPS-1 Go to Chart
JPS-1 to JP6-6 END1
JP6-6 to SW7 (Emergency Reverse)-C
Replace motor SW7-NO to JP6-7
controller. JP6-7 to PMC-13
Is wiring
No Repair or replace.
OK?
Go to Chart
END1
Yes
1 Programmable
Verify the problem still
Maintenance Tool Go to Chart
exists. Repeat T-8. If you
END1
return here, go to General
Troubleshooting.
Go to Chart
GEN1
--- Page 14 ---
T-15: No Travel,
Motor Controller Fault Code 2,3 - High Pedal Disable.
Condition: Throttle circuit
was active prior to the
handle being lowered (brake
The handle must be switch closing).
moved to the
operating position
before the throttle
is rotated.
Was proper
Lower handle, then
sequence No
apply throttle.
followed?
Yes
Test and adjust throttle
potentiometer.
See Component Go to Chart
Procedures. END1
Programmable
Maintenance Tool can be
used here. See PMT
section in
Troubleshooting.
Adjust or replace
Is throttle throttle
potentiometer No potentiometer.
OK? See Component
Procedures.
Yes
Go to Chart Go to Chart
T-15-2 END1
--- Page 15 ---
Relief Valve
Page 6-72
Lift Motor
Page 6-81
Fill/Vent Plug
Page 6-70
Lift Limit Switch
Page 6-23
Hydraulic
Reservoir
Page 6-78
--- Page 16 ---
Power Cables
Power cables should be checked for damage,
including:
• Evidence of overheating
• Burned spots in the cable
• Nicks in the insulation
• Damaged or overheated terminal lugs
• Damaged mounting hardware or brackets
Repair or replace damaged cables or mounting
hardware as necessary.
Power cables are marked on the terminal lug
with the location where they belong. If the
marking is missing or is not readable, remark
the cable with the correct information.
The terminal lugs should be crimped tightly and
securely on the wire. Replace the lug if
overheating is evident and repair or replace
faulty connectors as necessary.
--- Page 17 ---
Removal
1. Lower the forks completely.
2. Turn the key switch OFF and disconnect
the battery connector.
3. Remove the drive unit cover.
4. Disconnect the wires on the brake
(deadman) switch.
5. Remove the screws holding the brake
(deadman) switch on the mounting bracket.
See Figure 6-13.
6. Remove the brake (deadman) switch.
Installation
1. Mount the brake (deadman) switch to the
mounting bracket.
2. Connect the wires to the brake (deadman)
switch.
3. Reconnect the battery connector and turn
the key switch ON.
4. Test drive the truck.
5. Adjust the switch if necessary. See “Brake
(Deadman) Switch” on page 6-21.
6. Turn the key switch OFF and disconnect
the battery connector.
7. Install the drive unit cover.
8. Reconnect the battery connector.
--- Page 18 ---
Horn
NOTE: The horn can be sounded with the key
switch in the OFF position.
Removal
1. Turn the key switch OFF and disconnect
the battery connector.
2. Remove the tractor cover.
3. Disconnect the two wires from the horn.
Horn
4. Remove the horn mounting bolt. See
Figure 6-21.
Installation
1. Attach the horn to the tractor frame and
tighten the mounting bolt. See Figure 6-21.
2. Attach the two wires.
3. Reconnect the battery connector and test
operation.
4. Turn the key switch OFF and disconnect
the battery connector.
5. Install the tractor cover.
6. Reconnect the battery connector.
Mounting
Bolt
--- Page 19 ---
Motors, General
Drive Motor 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 should
include the following:
1. Inspect the brushes for wear and for proper
contact with the commutator. Record the
level of wear on the brushes. This history
will give you an indication of whether a
brush should be changed or if it can wait
until the next inspection. Refer to page
6- for acceptable brush length and
general motor information.
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. Check brush spring tension. See “Drive
Motor Brush Spring Tension” on page
6-
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. Check brush holders for solid connection to
the mounting support. Tighten the
mounting screws as necessary.
5. Check 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.
--- Page 20 ---
Drive Unit
6:snCo mponent Procedures
Removal
1. Lower the forks. Turn the key switch OFF.
Disconnect the battery connector.
WARNING
Use extreme care whenever the
truck is jacked up. Keep hands and
feet clear from vehicle while jacking Fill/Level Plug
the truck. After the truck is jacked,
place solid blocks beneath it to
support it. DO NOT rely on the jack
alone to support the truck.
For details, see “Jacking Safety” on Drain Screw
page 2-13.
2. Jack the truck and block the frame.
3. Remove the drive unit fill plug and drain
screw (lower cover screw). See Figure 6-42.
Allow the gear oil to drain.
4. Remove the tractor cover.
5. Disconnect the control wiring harness and
power cables from the electrical panel. Use
two wrenches to avoid twisting the motor
stud.
6. Remove the control handle. See “Control
Handle” on page 6-29.
7. Remove the pivot bearing retaining nut. See
Figure 6-43. Pivot Bearing
Retaining Nut
WARNING
Transmission assembly may fall free
from mounting after nut is removed.
8. Remove the transmission assembly by
lowering through the mounting bracket.
9. Remove the control wiring harness and
power cable through the transmission pivot
mount.
--- Page 21 ---
6:snCo mponent Procedures
Load Wheels
Replacement
1. Lift the forks to maximum height and block
them. See “Jacking Safety” on page 2-13.
2. With a hammer and pin punch, drive out
the tension pin. See Figure 6-48.
3. Drive the axle out of the load arm casting
with a hammer and brass drift pin. See
Figure 6-49.
4. Push the tire out. Note the location of the
washers and pin. See Figure 6-50.
5. If the bearings are to be reused, insert a
brass drift pin into each end of the load
wheel and knock the bearings out.
6. Install the bearings in the load wheel with
the shields facing out.
7. Place the new load wheel upright on a flat
surface. Position the bearing over the load Axle Pin
wheel. Place a flat metal plate over the Axle Wheel
bearing, and hammer the bearing in place
with a plastic mallet. Make sure the bearing
is fully seated in the load wheel.
8. Align the tire and washers with the holes in
the load arm casting.
9. Drive the axle through the load arm
casting, tire and washers. Make sure the
pin hole in the axle aligns with the housing.
10. Install the tension pin. Washers (2)
11. Lubricate the grease fittings.
--- Page 22 ---
Hydraulic Unit
Pump Motor
Draining and cleaning the hydraulic reservoir is
important to control the accumulation of
condensation and contamination which damage
the hydraulic system.
Condensation is caused by the repeated heating
and cooling of hydraulic fluid during normal Pump
operation. Contaminants include dirt, rust, Adapter
scaling and products of fluid deterioration.
Removal
The hydraulic pump and motor assembly must
be removed from the truck in order to separate
the pump from the motor. Vent
1. Lower the forks completely. Plug
2. Disconnect the battery. Remove the access
cover and the key switch mounting bracket.
3. Remove and tag all wires and cables
Hydraulic
connected to the pump motor. Reservoir
See Figure 6-58.
4. Remove and cap the hydraulic line from the
hydraulic unit. Disconnect the solenoid
control.
5. Remove the bolts that secure the hydraulic
unit mounting bracket to the tractor frame.
6. Remove the hydraulic unit from the truck.
Installation
1. Install the hydraulic unit on the tractor
frame and secure with the previously
removed cap screws.
2. Install the hydraulic line on the hydraulic
unit.
3. Fill the reservoir with the specified
hydraulic fluid. See “Lubrication
Equivalency Chart” on page 7-2. Use a
funnel with a flexible neck. Fill the reservoir
only until the fluid is visible at the bottom
of the vent plug elbow. See Figure 6-58. Use
up to 1.5 quarts (1.41 liters).
4. Install the vent plug. See Figure 6-58.
5. Connect all wires and cables to the pump
motor. Connect the battery.
--- Page 23 ---
Approved Raymond Lubricants
Raymond Part
Where Used Type Approved Manufacturer
Number
Bearings, etc. Grease Chevron Avi-Motive Grease 990-620/01 (10
cartridges per case)
Citgo HEP2 (above 30° F only)
990-620/02 (5 gal./
Exxon RONEX MP or UNIREX N2 18.9 liters)
Gulf Gulfcrown Grease No. 2
Mobil Grease 77
Phillips Philube 1B and RB Grease
Shell Alvania Grease EP2
Sohio Bearing Guard “LT”
Texaco Regal AFB 2 Grease MIL-G-
18709A