Raymond 4750 C80 C100 C120 Forklift Maintenance Manual – PDF Download

Description

Raymond 4750 C80 C100 C120 Maintenance Manual

This maintenance manual covers the Raymond 4750 series 4-wheel sit-down counterbalanced lift trucks, specifically models C80, C100, and C120 from serial number 00001 and up. Publication 1393839/001, dated January 2022, provides comprehensive maintenance, diagnosis, and service procedures for the chassis, body, load handling system, controller, and display. Whether you are a professional technician or a forklift owner performing your own repairs, this Raymond 4750 maintenance manual delivers the exact procedures, specifications, and torque values required to keep these electric lift trucks running reliably.

File Details

• Manual Type: Maintenance Manual
• Brand: Raymond
• Models Covered: 4750-C80, 4750-C100, 4750-C120
• Serial Numbers: 00001 and Up
• Publication Number: 1393839/001
• Publication Date: January 2022
• Language: English
• File Format: PDF
• Page Count: Approximately 595 pages

Chapters Covered

• General – Exterior views, lift truck models, frame numbers, jack-up points, hoisting, towing, circuit tester usage, standard bolt and nut tightening torque, high pressure hose fitting torque, wire rope suspension, component weights, recommended lubricants, periodic maintenance
• Battery – Battery compartment and required weight, service standards, display, troubleshooting, battery assembly removal and installation, inspection, battery stopper adjustment
• Controller – General information, added functionalities, specifications, components, traveling controller, material handling controller, contactor panel, PSS controller, board inspection, control panel disassembly and reassembly, continuity checks, display inspection, combination switch, accelerator potentiometer adjustment, brake switch adjustment, material handling lever switch adjustment, forward/reverse travel pedal
• Multi-Display Functions – Multiple display, general functions, display indication list, specifications, normal function screen, mask functions, manager’s function, service function, analyzer, tuning, option set, matching, wheel diameter, diagnosis, diagnosis code list
• Troubleshooting – Before troubleshooting, connector handling, wire harness and connector inspection, troubleshooting method, SST setting methods, CPU board connector, DC/MD board connector, SCPU board connector, DC/PD board connector, CD board connector, ST board connector, traveling controller connector-component, material handling controller connector-component, PSS controller connector-component, contactor panel connector-component, diagnostic code list
• Motor – Drive motor, pump motor, motor brush wear and overheat warning
• Drive Unit – General, specifications, components, drive unit assembly removal and installation, disassembly, inspection, reassembly, differential case assembly
• Front Axle – General, specifications, components, front axle shaft and axle hub removal and installation, differential housing removal and installation
• Rear Axle – General, specifications, components, rear axle assembly removal and installation, steering knuckle removal and installation, rear axle cylinder removal and installation, disassembly, inspection, reassembly
• Steering – General, specifications, components, steering wheel and mast jacket removal and installation, hydrostatic steering valve assembly troubleshooting, removal, installation, disassembly, inspection, reassembly, relief pressure inspection and adjustment
• Brake – General, specifications, components, front brake disassembly, inspection, reassembly, brake air bleeding, braking force inspection and adjustment, brake booster troubleshooting, removal, installation, disassembly, inspection, reassembly, parking brake inspection and adjustment, brake pedal inspection and adjustment
• Body – Components, battery hood assembly removal and installation, counterweight removal and installation, driver’s seat removal and installation, fuse mounting position, fuse names, circuits, and capacities
• Material Handling System – Hydraulic system diagram, components, return filter and suction filter removal and installation, natural drop test, natural forward tilt test, oil leak test, lift cylinder, tilt cylinder
• Mast – TN mast assembly, components, removal and installation, removal and installation with lift bracket, mast disassembly, inspection, reassembly, lift bracket disassembly, inspection, reassembly, mast adjustment, mast roller removal and installation, chain inspection, reassembly, adjustment, fork removal, installation, inspection, TF and TT mast assembly, components, mast adjustment, lift cylinder rod shim adjustment
• Cylinder – Lift cylinder and rear lift cylinder, front lift cylinder, tilt cylinder, removal, installation, disassembly, inspection, reassembly, flow regulator valve, safety down valve, mast forward backward tilting angle adjustment
• Oil Pump – General, specifications, components, oil pump assembly removal and installation, disassembly, inspection, reassembly, test method
• Oil Control Valve – General, specifications, components, oil control valve assembly removal and installation, disassembly, inspection, reassembly, lift and tilt lock valve assembly, tilt lock valve assembly for OPS, relief pressure adjustment, control valve lever assembly
• PSS Functions – General, PSS system configuration, components, before starting repair work, yaw rate sensor, swing lock cylinder, tilt angle sensor, load sensor, speed sensor, mast lifting height switch, matching, standard state of vehicle, cautions on modifying vehicles, renewal of PSS caution label
• Appendix – SST list mechanical tools, SST list electrical tools, service standards mechanical, service standards electrical, connector listing, component/connector diagrams, joint diagram, connecting diagram, wiring diagram

This Raymond 4750 C80 C100 C120 maintenance manual is a comprehensive service resource covering every major system on these electric counterbalanced lift trucks. From the 36V/48V electrical system and controller diagnostics to the hydraulic material handling system, mast assembly, and PSS (Performance Stability System) functions, the manual provides step-by-step procedures with illustrations, torque specifications, and service standards. The troubleshooting section includes a complete diagnostic code list and detailed flowcharts for diagnosing electrical and hydraulic faults, making it an essential tool for any technician working on these machines.

What This Manual Enables You to Do

With this Raymond 4750 series maintenance manual, you can confidently perform:

• Complete preventive maintenance according to the periodic maintenance schedule
• Battery inspection, electrolyte testing, and replacement procedures
• Controller diagnostics, board inspection, and replacement for traveling, material handling, and PSS controllers
• Multi-display analyzer functions, tuning, option setting, and sensor matching
• Troubleshooting using diagnostic codes and flowcharts for all electrical systems
• Drive motor and pump motor removal, disassembly, inspection, and reassembly
• Drive unit, differential, front axle, and rear axle service
• Steering system repair including hydrostatic steering valve service
• Brake system service including front brakes, brake booster, and parking brake adjustment
• Mast assembly removal, disassembly, adjustment, and chain service for TN, TF, and TT masts
• Lift cylinder, tilt cylinder, and rear axle cylinder overhaul
• Oil pump service and testing
• Oil control valve service and relief pressure adjustment
• PSS system component replacement, matching, and calibration
• Wiring diagram interpretation and connector identification

Why This Manual Matters

Working on Raymond 4750 series lift trucks without the correct procedures and specifications can lead to costly mistakes, damaged components, and unsafe operating conditions. This maintenance manual provides the exact torque values, service limits, adjustment procedures, and diagnostic steps that Raymond specifies for these machines. The manual covers C80, C100, and C120 models with 36V and 48V electrical systems, and includes information for UL-EE Option models. Having the correct service information on hand helps you complete repairs correctly the first time, reducing downtime and extending the life of your equipment.

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Instant PDF Delivery

This Raymond 4750 C80 C100 C120 maintenance manual is delivered as an instant PDF download after payment. No shipping, no waiting for a physical book to arrive. The PDF can be viewed on any device — computer, tablet, or smartphone — and printed pages can be taken directly to the shop floor. Whether you need to look up a single torque specification or follow a complete disassembly procedure, the information is immediately accessible. Search, zoom, and print exactly what you need, when you need it.