Raymond 4460 3-Wheel Sit-Down Counterbalanced Lift Truck Maintenance Manual 1237640A – C30 C35S C35 C40

Description

Raymond Model 4460 3-Wheel Sit-Down Counterbalanced Lift Truck Maintenance Manual

The Raymond Model 4460 3-Wheel Sit-Down Counterbalanced Lift Truck Maintenance Manual, publication 1237640A, is the complete workshop-level service reference for the Raymond 4460 electric counterbalanced trucks. It applies to the C30, C35S, C35 and C40 models, serial number 00001 and up, and to all subsequent releases of this product until otherwise indicated. Across 969 pages the manual documents the AC inverter drive system, the multi-function display, the battery circuit, both drive motors and the pump motor, the drive unit and front axle, rear axle, hydrostatic steering, wet disc brakes, mast assemblies, lift and tilt cylinders, the oil pump, the oil control valve, and the full Performance Stability System (PSS) and Operator Presence Sensor (OPS) safety architecture.

This is the same maintenance manual used by Raymond service centers. It is organised so that a technician can move directly from a symptom to the exact circuit, sensor, solenoid or mechanical assembly responsible, then to the measured values and the correct disassembly, inspection and reassembly procedure.

File Details

• Manual type: Maintenance / Service Manual
• Brand: Raymond
• Model series: 4460 3-Wheel Sit-Down Counterbalanced Lift Truck
• Covered models: C30, C35S, C35, C40
• Serial coverage: S/N 00001 and up
• Publication number: 1237640A
• Copyright: 2017 The Raymond Corporation
• Language: English
• File format: PDF
• Length: 969 pages

Chapters Covered

• 1 General — lift truck exterior view, lift truck models, frame number and punching position, how to use the manual, operating tips, jack-up and hoisting points, standard bolt and nut tightening torque, bolt strength identification, precoat bolts, high pressure hose fitting tightening torque, recommended lubricant quantity and types, lubrication chart, periodic maintenance table, periodic replacement table.
• 2 Battery — battery compartment size and necessary battery weights, service standards, battery list by supplier and model, battery charge indicator and low-battery warnings, battery troubleshooting, battery assembly removal and installation, specific gravity inspection, hydrometer use, insulation resistance, battery control table, replacing battery plug terminals.
• 3 Controller — controller system configuration, electrical components layout, controller cable layout, specifications, insulation resistance and power condenser discharge before inspection, connector inspection using SST, disassembly procedure, main controller removal and installation, drive and pump motor driver, contactor panel components and reassembly, contactor panel insulating resistance test, fan, multi-function display, combination switch, accelerator sensor (potentiometer), brake sensor (potentiometer), brake switch adjustment, over current limit (OCL) measurement.
• 4 Display — general functions and initial screens, administrator functions and password entry, power mode, travel and material handling power control, low speed, maximum speed limiter and overspeed alarm settings, maintenance hour meter, auto power off, administrator second password, menu lock, PIN code entry functions; service functions including Analyzer menu (DIAG MEMORY, DIAG MEMORY QR, I/O TEMP/VOLT, I/O TRAVELING, I/O M.HANDLING, I/O STEERING, I/O OTHERS, ACTIVE TEST, VERSION), Tuning menus, Option Set, Matching, and Others menu (Meter Start, Demo Mode, To Default Set, Mask Password, Manager Pass CLR, Contrast).
• 5 Troubleshooting — connector handling, wire harness and connector inspection procedure, SST list, complete diagnosis code list, symptom-by-symptom procedures for when an error code is displayed (A001, A002, A101–A104, A201–A203, A301, A501, A603, A801, A802, A902, AA01–AA04, AB01, AC01, AD01–AD06, AF01–AF08, C002, C004, C101–C104, C201–C203, C301, C302, C401–C406, C501–C506, C801–C804, CB01–CB05, CC01–CC06, CD01–CD06, E002, E101, E102, E201, E202, E301, E801, E802, EC01–EC06, EE01, EE02, F101, F102, F401–F408, FB01, FB02, FF01, FF02, 3201–3203, 3301–3303, 6101, 6102, 6201, 6202, 6301–6303, 6401–6404, 6501–6504, 6601, 6701, 6901–6904, 7101–7103, 7201–7204, 7301–7304, 7401, H101–H105, H201–H205, H301–H305, H401–H405, H501–H506, H601–H606, H701–H706, H801–H806, HB01–HB03, HC01–HC04, and cold-temperature driver codes), and the full table of symptoms when no error code is displayed.
• 6 Motor — drive motor general, specifications, removal and installation, disassembly, inspection and reassembly; pump motor general, sectional plan, specifications, removal and installation, disassembly, inspection and reassembly.
• 7 Drive Unit and Front Axle — general arrangement, specifications and total reduction ratio, front axle hub and drive unit removal and installation, gear oil type and quantity, front axle hub breakaway torque, disassembly, inspection and reassembly.
• 8 Rear Axle — rear axle assembly general and specifications, removal and installation, rear axle starting force, disassembly, inspection and reassembly, rear axle hub, rear axle cylinder assembly, tire angle sensor removal and installation.
• 9 Steering — specifications, steering wheel diameter and play, hydrostatic steering valve identification, steering wheel and mast jacket, hydrostatic steering valve ASSY troubleshooting, removal and installation, disassembly, inspection and reassembly, relief pressure inspection and adjustment.
• 10 Brake — general layout, specifications, wet disc brake removal and installation, disassembly, inspection and reassembly, disc and plate inspection, brake air bleeding, braking force inspection and adjustment, brake master cylinder, parking brake, parking brake inspection and adjustment, release lever cable adjustment, brake pedal adjustment.
• 11 Body & Frame — battery hood assembly, counterweight removal and installation, operator’s seat, fuse replacement with the complete fuse assignment table (F1 through F82, F5A–F5C).
• 12 Material Handling System — hydraulic circuit diagram, return filter and suction filter removal and installation, natural drop test, natural forward test, oil leak test for lift cylinder and tilt cylinder.
• 13 Mast — chain inspection and elongation limits, chain reassembly, chain adjustment, main lift chain adjustment and service (TT), free lift chain adjustment and service (TT), fork removal, installation and inspection, QM mast assembly and mast adjustment, TT mast assembly removal and installation, roller bearing wear pad adjustment, mast skewing, 3-stage (TT) mast service, cylinder removal and installation, internal reeving installation, lift cylinder rod shim adjustment.
• 14 Cylinder — rear lift cylinder (TT and QM) general, specifications, removal and installation, disassembly, inspection and reassembly; valve removal and installation for QM; front lift cylinder (TT and QM) general, specifications, removal and installation, disassembly, inspection and reassembly; tilt cylinder general, specifications, removal and installation, disassembly, inspection and reassembly, mast forward/backward tilt angle adjustment.
• 15 Oil Pump — general and specifications, removal and installation, disassembly, inspection and reassembly, test method with lifting speed reference tables for 36V and 48V C30/C35S/C35/C40.
• 16 Oil Control Valve — mechanical controlled valve and solenoid controlled valve, inlet section, lift section, tilt section, attachment section, solenoid connector diagram, hydraulic circuit diagram, specifications including relief pressure and attachment flow rate list, lowering speed specification, removal and installation, disassembly, inspection and reassembly, control valve lever assembly, relief pressure adjustment, manual down valve, and the full oil control valve troubleshooting matrix.
• 17 PSS Functions — general system configuration, name and feature of each component, repair work precautions, tilt angle sensor, load sensor, speed sensor, mast lifting height switch, tire angle sensor, matching (Drive, PSS, Lever, Tire Data) with standard vehicle state, general Operator Presence Sensor description, control specification for travel and material handling Operator Presence Sensor, return-to-neutral warning and parking brake OFF warning, renewal of PSS caution label.
• 18 Appendix — SST list, service standards for battery, drive motor, pump motor, drive unit and front axle, rear axle, steering, brake, frame, material handling system, mast, cylinder, oil pump, oil control valve and PSS, connector location diagrams for FR stay and mast, cables, instrument panel, toe board No.1 and No.2, RR body No.1 and No.2, and the complete connector drawing set with pin, colour and junction references.

Read as a whole, the Raymond 4460 Maintenance Manual gives a technician a single continuous workflow: identify the truck by model and serial, isolate the fault using the diagnostic code list or the no-code symptom tables, verify the circuit at the correct connector pins with the listed voltages and resistances, then perform the repair with the printed tightening torque, service limit, shim thickness, backlash, starting force or relief pressure the manual specifies. Nothing in the diagnostic path is left to inference.

Diagnostic and Troubleshooting Coverage

Chapter 5 is the largest part of the document, and it is where the manual earns its keep. Every stored diagnostic code is listed with its indicator behaviour, the ECU that detects it, the failure mode description and a step-by-step procedure. Each procedure names the connectors and pins to probe, states the expected voltage, resistance or continuity value, and branches on the result so the technician is directed either to a harness defect, a connector contact defect, a solenoid or sensor defect, a driver defect or the main controller. The related-portion diagrams at the top of each procedure show exactly which harness runs and which components are in circuit, so the wiring can be traced without guesswork.

Alongside the code list is the counterpart section for faults that never set a code — heavy steering with a healthy pump, load handling that stops working while the pump still runs, forks that lower but will not lift, mast tilt that behaves unevenly, speed limits that trigger when they should not, and the many PSS and Operator Presence Sensor symptoms that only show up as a change in behaviour. Both halves of the troubleshooting chapter are indexed together so a technician can move between them quickly.

PSS and Operator Presence Sensor Systems

Chapter 17 explains the Performance Stability System and the Operator Presence Sensor as designed systems, not just as a set of sensors. The manual identifies each component in the system — height switch, tilt angle sensor, tilt lever switch, lift lever angle sensor, load sensor, automatic fork leveling control switch, tire angle sensor, accelerator pedal angle sensor, forward and reverse switches, tilt forward and tilt backward lock valves, lift lock valve, unload valve and drive motor — and explains what each one detects and how the main controller acts on it. The matching procedures for tilt level, tilt forward limit, tire position, mast type, all four lever neutral positions and tire data are given with the standard vehicle conditions each one requires, so a sensor replacement or mast change can be commissioned correctly rather than approximately.

Hydraulic, Mast and Material Handling Repairs

Chapters 12 through 16 cover the material handling system end to end: the hydraulic circuit, return and suction filters, natural drop and natural forward test limits, oil leak test volumes, chain elongation gauges and chain types for TT and QM masts, mast roller and mast strip clearances, carriage roller and side roller clearances, wear pad adjustment on the TT mast, QM and TT cylinder specifications with bore, rod diameter and bend limits, oil pump delivery and internal wear limits, and the mechanical and solenoid controlled oil control valves with their relief pressures, attachment flow rates and I-Q starting current setting. Where a repair depends on a shim, a backlash or a starting force, the manual states the value and the acceptable range.

Service Standards, Torque Values and Special Tools

The appendix gathers the numerical core of the manual in one place: service standards for the battery, both motors, the drive unit and front axle, rear axle, steering, brakes, frame, material handling system, mast, cylinders, oil pump, oil control valve and PSS, plus the SST list that names each special tool and the section it is used in. Standard bolt and nut tightening torques, bolt strength identification, precoat bolt reuse rules and high pressure hose fitting torques are covered in Chapter 1, so the correct fastener value is always within reach of the procedure being performed.

Why This Raymond 4460 Manual Matters

A Raymond 4460 is a fully AC, CAN-bus controlled electric counterbalanced truck. Its travel, lift, tilt, steering and stability behaviour are all governed by sensor input and controller logic, so a fault that looks mechanical is often an electrical signal outside its expected window. This manual is what lets a technician tell the difference. It supplies the connector pin-outs, the acceptable voltage and resistance windows, the matching procedures, the solenoid and sensor resistance values, the relief pressures, the cylinder bore and rod limits, the mast clearances and the tightening torques that turn a symptom into a repair. Without it, a technician is left probing a live CAN network and an AC inverter drive with no reference points and no safe way to confirm a component before replacing it.

For an owner-operator or a small fleet, the manual supports the jobs that come up repeatedly: reading and clearing diagnostic codes, adjusting the brake pedal and parking brake cable, bleeding the brakes, checking battery specific gravity and insulation resistance, replacing fuses by assignment, servicing the lift and tilt cylinders, adjusting chain tension and mast roller clearance, resetting the maintenance hour meter, and re-running matching after a sensor or mast change. For a service shop, it covers the full teardown and rebuild of the drive unit, rear axle, steering valve, oil pump and oil control valve, together with the special tool numbers needed to do the work properly.

IMAGES PREVIEW

Delivery is instant. The Raymond 4460 Maintenance Manual 1237640A is supplied as a PDF file that downloads immediately after payment, with no shipping and no waiting. It opens on any computer, tablet or phone, can be printed for the workshop bench, and can be kept on a service laptop so the relevant procedure, wiring diagram or specification table is available on the truck, at the machine, whenever it is needed.