Description
Raymond 7500 7520 Reach-Fork Lift Truck Maintenance Manual – Publication 1112860C
This Raymond 7500 7520 Reach-Fork Lift Truck Maintenance Manual, publication 1112860C, applies to Models 7500 and 7520 Reach-Fork lift trucks from serial number 31,001 and up. It is the full maintenance, diagnostic, and component-procedure reference for the truck, written for technicians who need the actual settings, pressures, fault-code meanings, torque figures, and step-by-step teardown sequences rather than a general overview. The manual runs across eleven major sections plus a schematics set, and it covers three separate drivetrain configurations: standard AC lift, AC lift with regenerative lower, and DC lift.
File Details
- Manual type: Maintenance Manual
- Brand: Raymond
- Models covered: 7500 and 7520 Reach-Fork lift trucks
- Serial number range: 31,001 and up
- Publication number: 1112860C
- Revision: 1112860C issued 09 May 2016 (supersedes 1112860B, 28 Oct 2013, and 1112860A, 15 Feb 2012)
- Language: English
- File format: PDF
- Page count: 497 pages
Chapters Covered
- How to Use This Manual – manual design, Interactive Electronic Technical Manuals, abbreviations and symbols
- Safety – definitions, general safety, battery safety, static precautions, jacking safety, tie-down for transport, welding safety
- Systems Overview – lift truck specifications, model designations, general information, truck installation, FlashWare, operator display, modes of operation
- Scheduled Maintenance – maintenance guidelines, Maintenance Minder tool, initial 90 day/250 deadman hour service, every 180 days or 500 HD, every 360 days or 2000 HD, lubrication points, contactor tip inspection, chain maintenance, fork inspection
- Troubleshooting – electrical troubleshooting, troubleshooting power amplifier error codes, hydraulic troubleshooting guidelines, symptom tables for hydraulic functions, travel functions, and electrical symptoms
- Messages, Codes, and Tests – power amp LED diagnostics, messages and codes, analog tests, input tests, output tests
- Component Procedures – component locator photos, special tools, decals and chassis, steering and controls, drive and brake, electrical components, hydraulic components, hydraulic cylinders, mast, chain, hose and cable
- Theory of Operation – traction system functional operation, cold storage, hydraulic system functional operation for each lift configuration, electric brake operation, pinout matrix
- Appendix – lubrication specification chart, thread adhesives, sealants and lubricants, component specific service/torque chart, torque charts for hydraulic fittings, face seal O-rings, ferrous and brass fasteners, thread-forming screws, decimal equivalent chart, standard/metric conversions
- Index
- Schematics – power distribution diagrams, electrical schematics, hydraulic schematics
Put together, the sections move from what the truck is, to what it should be doing, to what to do when it is not. The Systems Overview establishes the model designation logic, so you can tell a 750A from a 750C from a 750D by tractor series, lift system, and operator stance, and it documents the operator display, the two run modes, and the configure and service menus. The Theory of Operation chapter then explains what the signals and hydraulic flows are actually doing during traction, lift, lower, and every auxiliary function, with a full pinout matrix listing normal voltages, signal sources, and signal users for the major connectors.
Scheduled Maintenance
The scheduled maintenance chapter is built around deadman hours rather than calendar time alone, and it splits the workload across an initial 90 day or 250 HD service, a recurring 180 day or 500 HD service, and a 360 day or 2000 HD service. Tasks include drive unit fluid changes and mounting bolt re-torquing, mast-to-tractor bolt break-free and re-torque, power amplifier terminal nut torque, hydraulic reservoir and filter service, brake stopping-distance checks, air gap measurement, contactor tip inspection, static strap resistance checks, steer caster adjustment, lubrication of all grease points, and lift chain gauging. Fork inspection is documented in full, including blade and shank straightness, fork angle against the caliper indicator lines, fork tip height, hook and pocket wear, and marking legibility, with the wear thresholds and the caliper part numbers given.
Troubleshooting and Diagnostics
The troubleshooting material is organized so you start from a symptom rather than a component. Symptom tables cover auxiliary functions, the lift and lower system, and travel functions, each listing probable causes paired with the specific test or corrective action to run. Intermittent faults, no-lift conditions, slow lift, load drift and settling, slow or sluggish acceleration, and slow travel all have their own entries. Electrical troubleshooting covers shorts to frame in detail, including the test-light and DMM procedures for battery case leakage, truck B+ and B- leakage, and the acceptable current thresholds. The power amplifier error code section decodes the sub-codes behind codes AP, AT, 5G, and 5J, and the messages and codes chapter gives the title, reason, test to run, and corrective action for each code from 1H through X4.
Diagnostic Tests
The Messages, Codes, and Tests chapter contains the analog, input, and output test procedures in full. Analog tests cover the primary and secondary throttle potentiometers, lift and lower potentiometer, traction and lift motor temperatures, TPA and LPA temperatures, motor currents, pressure sensor voltage, the 12 VDC and 5 VDC supplies, battery voltage, brake armature, ambient air temperature, steer power amp current, handle heater reference voltage, EPO switch, and the learned travel and lift potentiometer values. Input tests cover the deadman switch, nested switch, first speed limiting switch, reach and retract switches, tilt up and down, sideshift left and right, steering fuse, horn switch, traction and lift motor speed sensors, lift cutout switch, CAN bus, steer feedback proximity sensor, steer motor encoder, height indicator encoder, and the optional security start switch. Output tests cover the TPC or MPC contactor, STR contactor, LPC contactor, AUX contactor, each directional solenoid, the reach, tilt, and sideshift solenoids, the aux dump and main relief dump, load hold, proportional lower ramp, horn, audible alarm, travel alarm, cooling fans, second pump solenoid, lift motor ramp, traction motor ramp, brake coil, relays K1 through K4, and the customer output.
Component Procedures
For actual repair work, the component procedures section walks through removal, disassembly, reassembly, and installation of the major assemblies. Drive unit coverage includes the complete exploded view, radial ring inspection, drive unit removal and installation, disassembly and assembly, shim calculation formulas, backlash measurement, helical gear and spiral pinion setup, pivot ring and radial ring service, and drive tire pressing. Brake coverage includes air gap inspection, removal, pad replacement, coil replacement, and installation with the specified torque values. Steering and control coverage includes the steer tiller encoder, steer limit switch vertical and lateral adjustment, steerable caster initial and height adjustment, steering linkage, and full disassembly and reassembly of both the primary and secondary control handles, including the travel pot, lift pot, flex circuit, tilt/sideshift card, and ThermaKit heater wiring. Hydraulic coverage includes system bleeding, filter service, lift pump replacement and priming on regenerative lower trucks, lift pressure adjustment, proportional valve adjustment, auxiliary pressure adjustment, and the port-by-port torque specification tables for every manifold variant. Cylinder coverage includes free lift and main lift removal and installation, seal repacking, lowering cushion service, reach cylinder adjustment, tilt cylinder, sideshift cylinder, and both main and free lift flow limiters.
Mast, Chain, Hose, and Cable
Mast work is documented at the assembly level. Carriage bearings, mast shimming, mast and bearing inspection with wear pattern illustrations, bow pad inspection for R35TT, R45TT, and DR32TT masts, carriage removal and installation, main and free lift chain anchors, lift chains, the height encoder belt for both models, and over-the-mast hose and cable routing with the stretch value tables are all included. Complete mast disassembly and assembly procedures are provided separately for the Model 7500 and the Model 7520, covering tractor and mast separation, telescopic separation, bearing shimming in sequence from the outer telescopic through to the carriage, main lift chain installation, and mating the mast back to the tractor with the correct bolt tightening sequence.
Reference Data
The appendix and schematics set gives you the numbers the job depends on. The lubrication specification chart lists the approved fluids and greases by application and operating temperature, including the cold storage variants. The component specific service and torque chart lists torque values by component and sub-component, and it distinguishes between lubricated and dry values so pre-applied thread-locking compounds are handled correctly. Separate torque charts cover hydraulic fittings by SAE dash size, straight thread face seal O-rings, standard and metric ferrous fasteners by grade, standard and metric brass fasteners, and thread-forming screws. The pinout matrix, electrical schematics for standard AC lift, DC lift, and AC lift with regenerative lower, and the hydraulic schematics for each configuration complete the reference set.
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “Raymond 7500 7520 Reach-Fork Lift Truck Maintenance Manual – Publication 1112860C” are as follows:
Front Coverp. 1
Table of Contentsp. 3
+Document Revision Historyp. 5
Service Information Listp. 5
+Section 1. How to Use This Manualp. 7
Manual Designp. 8
Interactive Electronic Technical Manualsp. 9
Abbreviations and Symbolsp. 10
+Section 2. Safetyp. 13
Definitionsp. 14
General Safetyp. 15
Battery Safetyp. 17
Static Precautionsp. 20
+Jacking Safetyp. 21
To elevate the rear of the lift truck:p. 21
To elevate either side of the lift truck:p. 22
Tie-Down for Transportp. 23
Welding Safetyp. 24
+Section 3. Systems Overviewp. 25
Introductionp. 26
+Lift Truck Specificationsp. 27
+Model Designationsp. 28
Mast Seriesp. 28
Serial Numberp. 28
+General Informationp. 29
Battery Specificationsp. 29
Fluid Capacitiesp. 29
Truck Installationp. 30
+FlashWarep. 31
Overviewp. 31
Installing FlashWare on a Windows Compatible Devicep. 31
Connecting FlashWare to Truckp. 31
Starting FlashWarep. 31
+Operator Displayp. 33
Selecting Display Formatp. 33
+Modes of Operationp. 34
Overview of Modesp. 34
Run Modep. 34
Program Modep. 34
Passwordsp. 35
Entering Program Modep. 35
Entering an Electronic Key, Password, or Superwordp. 36
To change Password or Superwordp. 36
Using Configure Modep. 36
Program Mode Menup. 39
Configure Mode Menup. 40
Service Mode Menup. 45
Using Service Modep. 46
Static Service Modep. 46
Active Service Modep. 47
+Section 4. Scheduled Maintenancep. 49
Maintenance Guidelinesp. 50
+Maintenance Minder ™ Toolp. 51
Factory Configurationp. 51
Enablingp. 51
Setting or Changing Time Interval and Action Optionp. 51
Resetting Maintenance Minderp. 52
Disablingp. 52
Exiting Program Modep. 52
Initial 90 Day/250 Deadman Hours (HD) Maintenancep. 53
Every 180 Days or 500 HDp. 54
Every 360 Days or 2000 HDp. 57
Lubrication Pointsp. 58
Contactor Tip Inspectionp. 59
+Chain Maintenancep. 60
Lift Chain Inspectionp. 60
Condition-Cause Chartp. 60
+Fork Inspectionp. 61
Surface Inspectionp. 61
Straightness of Blade and Shankp. 61
Fork Anglep. 61
Fork Tip Heightp. 62
Positioning Locks (if applicable)p. 62
Wearp. 62
+Section 5. Troubleshootingp. 65
+Electrical Troubleshootingp. 66
Generalp. 66
Shorts to Framep. 66
Battery State-of-Chargep. 69
Fusesp. 70
Electrical Connectionsp. 71
Fuse/Relay Card Troubleshootingp. 76
DC Motorsp. 78
AC Motorsp. 82
Troubleshooting Power Amplifier Error Codesp. 83
Hydraulic Troubleshooting Guidelinesp. 84
+Symptom Tables: Hydraulic Functionsp. 85
Auxiliary Functionsp. 85
Lift/Lower Systemp. 90
+Symptom Tables: Travel Functionsp. 94
Slow or Sluggish Accelerationp. 94
Slow Travelp. 94
+Symptom Tables: Electrical Symptomsp. 95
Motor Overheatingp. 95
Scrambled or Intermittent Displayp. 95
Display is Dark; Lift Truck is Not Operationalp. 96
+Section 6. Messages, Codes, and Testsp. 97
+Power Amp LED Diagnosticsp. 98
+Messages and Codesp. 101
Messagesp. 101
Codesp. 102
Analog Testsp. 125
Input Testsp. 125
Output Testsp. 126
+Analog Testsp. 127
+Test A04 – Primary Throttle Pot (VR1) Voltagep. 128
Run Testp. 128
Diagnosis and Repairp. 128
+Test A05 – Lift/Lower Pot Voltagep. 129
Run Testp. 129
Diagnosis and Repairp. 129
+Test A08 – Traction Motor Temperaturep. 130
Limitsp. 130
Run Testp. 130
Diagnosis and Repairp. 130
+Test A09 – Lift Motor Temperaturep. 131
Limitsp. 131
Run Testp. 131
Diagnosis and Repairp. 132
+Test A10 – TPA Temperaturep. 133
Limitsp. 133
Run Testp. 133
Diagnosis and Repairp. 133
+Test A11 – Traction Motor Currentp. 134
Limitsp. 134
Run Testp. 134
Diagnosis and Repairp. 134
+Test A13 – Pressure Sensor Voltagep. 135
Run Testp. 135
Diagnosis and Repairp. 135
+Test A14 – +12VDC Power Supplyp. 136
Run Testp. 136
Diagnosis and Repairp. 136
+Test A15 – Battery Voltagep. 137
Run Testp. 137
Diagnosis and Repairp. 137
+Test A19 – LPA Temp (AC Lift)p. 138
Limitsp. 138
Run Testp. 138
Diagnosis and Repairp. 138
+Test A20 – Lift Motor Current (AC Lift)p. 139
Limitsp. 139
Run Testp. 139
Diagnosis and Repairp. 139
+Test A22 – Traction Throttle (VR1) Requestp. 140
Run Testp. 140
Diagnosis and Repairp. 140
+Test A23 – Lift Throttle (VR2) Requestp. 141
Run Testp. 141
Diagnosis and Repairp. 141
+Test A26 – +5VDC Power Supplyp. 142
Run Testp. 142
Diagnosis and Repairp. 142
+Test A29 – Secondary Traction Throttle Pot (VR3) Voltage (optional)p. 143
Run Testp. 143
Diagnosis and Repairp. 143
+Test A30 – Secondary Traction Throttle (VR3) Request (optional)p. 144
Run Testp. 144
Diagnosis and Repairp. 144
+Test A31 – Solenoid 5T (AUX1) Currentp. 145
Run Testp. 145
Diagnosis and Repairp. 145
+Test A32 – Solenoid 5B (AUX2) Currentp. 146
Run Testp. 146
Diagnosis and Repairp. 146
+Test A33 – Aux Dump (SOL6 or SOL8)/Main Relief Dump (SOL3) Currentp. 147
Run Testp. 147
Diagnosis and Repairp. 147
+Test A34 – Lift/Lower Current (SOL2)p. 148
Run Testp. 148
Diagnosis and Repairp. 148
+Test A35 – Brake Armaturep. 149
Run Testp. 149
Diagnosis and Repairp. 149
+Test A36 – Ambient Air Temp Sensorp. 150
Run Testp. 150
Diagnosis and Repairp. 150
+Test A37 – Steer Power Amp Currentp. 151
Run Testp. 151
Diagnosis and Repairp. 151
+Test A39 – Analog Reference Voltage (AC Lift)p. 152
Run Testp. 152
Diagnosis and Repairp. 152
+Test A40 – Handle Heater Reference Voltage (optional)p. 153
Run Testp. 153
Diagnosis and Repairp. 153
+Test A41 – Emergency Power Off (EPO) Switchp. 154
Run Testp. 154
Diagnosis and Repairp. 154
Test A42 – Primary Travel Pot LEARN Valuep. 155
Test A43 – Lift Pot LEARN Valuep. 156
Test A96 – BSM Currp. 157
Test A97 – BSM Voltp. 158
Test A98 – BSM Tempp. 159
Test A99 – H2O Snsep. 160
Test A100 – BSM Commp. 161
+Input Testsp. 163
+Test I00 – Deadman Switch (DS1)p. 164
Run Testp. 164
Diagnosis and Repairp. 164
+Test I01 – Nested Switch (S14)p. 165
Run Testp. 165
Diagnosis and Repairp. 165
+Test I02 – 1st Speed Limiting Switch (S12)p. 166
Run Testp. 166
Diagnosis and Repairp. 166
+Test I06 – Reach Switch (S4)p. 167
Run Testp. 167
Diagnosis and Repairp. 167
+Test I07 – Retract Switch (S5)p. 168
Run Testp. 168
Diagnosis and Repairp. 168
+Test I08 – Tilt Up Switch (S6)p. 169
Run Testp. 169
Diagnosis and Repairp. 169
+Test I09 – Tilt Down Switch (S7)p. 170
Run Testp. 170
Diagnosis and Repairp. 170
+Test I10 – Sideshift Right Switch (S9)p. 171
Run Testp. 171
Diagnosis and Repairp. 171
+Test I11 – Sideshift Left Switch (S8)p. 172
Run Testp. 172
Diagnosis and Repairp. 172
+Test I14 – Steering Fuse (FU1)p. 173
Run Testp. 173
Diagnosis and Repairp. 173
+Test I15 – Horn Switch (S3)p. 174
Run Testp. 174
Diagnosis and Repairp. 174
+Test I19 – Traction Motor Speed Sensorp. 175
Run Testp. 175
Diagnosis and Repairp. 175
+Test I20 – Lift Motor Speed Sensor (AC Lift)p. 176
Run Testp. 176
Diagnosis and Repairp. 176
+Test I22 – Lift Cutout Switch (S27)p. 177
Run Testp. 177
Diagnosis and Repairp. 177
+Test I23 – CAN Bus Testp. 178
Run Testp. 178
Diagnosis and Repairp. 178
+Test I24 – Steer Feedback Prox Sensor (AC Lift)p. 181
Run Testp. 181
Diagnosis and Repairp. 181
+Test I25 – Steer Motor Encoder (AC Lift)p. 182
Run Testp. 182
Diagnosis and Repairp. 182
+Test I26 – Height Indicator Encoderp. 183
Run Testp. 183
Diagnosis and Repairp. 183
+Test I27 – Secondary Horn Switch (S10)p. 184
Run Testp. 184
Diagnosis and Repairp. 184
+Test I33 – Steer Tiller Encoder 1 Connect Detect (AC Lift)p. 185
Run Testp. 185
Diagnosis and Repairp. 185
+Test I34 – Steer Tiller Encoder 2 Connect Detect (AC Lift)p. 186
Run Testp. 186
Diagnosis and Repairp. 186
+Test I35 – Steer Tiller Encoder 1 – Channels A & B (AC Lift)p. 187
Run Testp. 187
Diagnosis and Repairp. 187
+Test I36 – Steer Tiller Encoder 2 – Channels A & B (AC Lift)p. 188
Run Testp. 188
Diagnosis and Repairp. 188
+Test I39 – Neutral Pulses (AC Lift)p. 189
Run Testp. 189
Diagnosis and Repairp. 189
+Test I60 – Security Start Switch (S23) (optional)p. 190
Run Testp. 190
Diagnosis and Repairp. 190
+Test I63 – High Speed Travel Switch (S25)p. 191
Run Testp. 191
Diagnosis and Repairp. 191
+Test I80 – OCSS Upper Beamp. 192
Run Testp. 192
Diagnosis and Repairp. 192
+Test I81 – OCSS Lower Beamp. 194
Run Testp. 194
Diagnosis and Repairp. 194
Test I82 – OCSS Cntp. 196
+Test I83 – BatGateLp. 197
Run Testp. 197
Diagnosis and Repairp. 197
+Test I84 – BatGateRp. 198
Run Testp. 198
Diagnosis and Repairp. 198
+Test I86 – Lift Heightp. 199
Run Testp. 199
Diagnosis and Repairp. 199
+Test I90 – Degrees Turned Past Steer Flagp. 200
Run Testp. 200
Diagnosis and Repairp. 200
+Test I91 – iPORT Communication Testp. 201
Run Testp. 201
Diagnosis and Repairp. 201
Test I92 – iPORT Error Bitmapp. 203
+Output Testsp. 205
+Test O00 – Toggle TPC or MPC Contactorp. 206
Run Testp. 206
Diagnosis and Repairp. 206
+Test O01 – Toggle STR Contactorp. 207
Run Testp. 207
Diagnosis and Repairp. 207
+Test O02 – Toggle LPC Contactorp. 208
Run Testp. 208
Diagnosis and Repairp. 208
+Test O03 – Toggle AUX Contactorp. 209
Run Testp. 209
Diagnosis and Repairp. 209
Test O04 – Toggle Aux1 Directional (SOL5T) Solenoidp. 210
Test O05 – Toggle Aux2 Directional (SOL5B) Solenoidp. 211
+Test O06 – Toggle Reach Solenoidp. 212
Run Testp. 212
Diagnosis and Repairp. 212
+Test O07 – Toggle Tilt Solenoidp. 213
Run Testp. 213
Diagnosis and Repairp. 213
+Test O08 – Toggle the Sideshift Solenoidp. 214
Run Testp. 214
Diagnosis and Repairp. 214
Test O09 – Aux Dump (SOL6 or SOL8)/Main Relief Dump (SOL3)p. 215
+Test O11 – Toggle the Load Hold (SOL1) Solenoidp. 216
Run Testp. 216
Diagnosis and Repairp. 216
Test O12 – Ramp the Proportional Lower (SOL2) Solenoidp. 217
+Test O18 – Toggle Hornp. 218
Run Testp. 218
Diagnosis and Repairp. 218
+Test O19 – Audible Alarmp. 219
Run Testp. 219
Diagnosis and Repairp. 219
+Test O20 – Travel Alarmp. 220
Run Testp. 220
Diagnosis and Repairp. 220
+Test O23 – Toggle Fansp. 221
Run Testp. 221
Diagnosis and Repairp. 221
+Test O25 – Toggle the 2d Pump (SOL4) Solenoidp. 222
Run Testp. 222
Diagnosis and Repairp. 222
+Test O28 – Ramp Lift Motor (AC Lift)p. 223
Run Testp. 223
Diagnosis and Repairp. 223
+Test O29 – Ramp Traction Motorp. 224
Run Testp. 224
Diagnosis and Repairp. 224
Test O30 – Toggle Brake Coilp. 225
+Test O32 – Toggle Relays K1, K2, K3, and K4p. 226
Run Testp. 226
Diagnosis and Repairp. 226
+Test O61 – Customer Outputp. 227
Run Testp. 227
Diagnosis and Repairp. 227
+Section 7. Component Proceduresp. 229
List of Component Proceduresp. 230
+Component Locator Photosp. 233
Mast and Carriagep. 233
Tractor, AC Lift, Fore/Aft Stancep. 234
Tractor Deck, Standard AC Lift, Fore/Aft Stancep. 235
Tractor Deck, AC Lift, Fore/Aft Stance, Regen Lowerp. 235
Tractor, AC Lift, Dockstancep. 236
Tractor Deck, AC Lift, Dockstance (Standard Lift shown)p. 237
Tractor, DC Lift (Fore/Aft Stance shown)p. 238
Tractor Deck, DC Lift (Fore/Aft Stance shown)p. 239
Standard Carriage, Operator View (Mast Guard removed for clarity)p. 240
Underside Componentsp. 241
+Special Tools, Decals, and Chassisp. 243
Special Toolsp. 244
Decals and Platesp. 245
+Baselegsp. 250
Removalp. 250
Installationp. 250
+Steering and Controlsp. 251
+Steer Tiller Encoder (AC Lift)p. 252
Removalp. 252
Installationp. 252
+Steer Limit Switch (S11)p. 253
Vertical Gap Adjustmentp. 253
Lateral Adjustmentp. 253
+Steerable Casterp. 254
Initial Adjustmentp. 254
Caster Height Adjustmentp. 255
Steering Linkagep. 257
+Control Handlep. 258
Primary Control Handle – Fore/Aft Stancep. 258
Dockstance Control Handlep. 263
Secondary Control Handle – Fore/Aft Stancep. 267
+Drive and Brakep. 269
+Drive Unitp. 270
Required Toolsp. 271
Troubleshootingp. 273
Radial Ring Inspectionp. 274
Drive Unit Removalp. 274
Drive Unit Disassemblyp. 275
Drive Unit Assemblyp. 279
+Brakep. 288
Inspectionp. 288
Brake Removalp. 288
Pad Replacementp. 288
Coil Replacementp. 289
Brake Installationp. 289
Deadman Pedalp. 290
+Inertial Dampenerp. 291
Removalp. 291
Installation and Adjustmentp. 292
+Electrical Componentsp. 295
+Battery Proceduresp. 296
Battery Connector/Cablesp. 296
Battery Exterior Cleaningp. 297
Testing, Charging, and Maintenancep. 297
Battery State-of-Chargep. 298
+Wiring and Harness Connectorsp. 299
General Repair Proceduresp. 299
Molex Connectorsp. 300
AMP Water-Resistant Connectorsp. 301
AMP Harness/Power Amp Connectorp. 304
+Power Cablesp. 307
+Motorsp. 309
Power Cable Terminalsp. 309
DC Motor Troubleshootingp. 309
AC Motor Troubleshootingp. 309
DC Motor Servicep. 309
Polishing the Commutatorp. 311
AC Motor Servicep. 312
+Steer Amplifier (AC Lift)p. 313
Removalp. 313
Installationp. 313
+Cold Storage Conditioningp. 314
Componentsp. 314
Lubricantsp. 314
Sealing Treatmentp. 314
Corrosion Inhibitor Coatingp. 314
Condensation Drip Guardp. 314
+Hydraulic Componentsp. 315
Hydraulic Steer Motor Shaft Seal Replacement (DC Lift)p. 316
+Hydraulic System Bleedingp. 317
+Hydraulic Filterp. 318
AC Liftp. 318
DC Liftp. 318
Lift Pump Replacement (Regen Lower)p. 320
Lift Pump Priming – Regen Lowerp. 321
+Lift Pressure Adjustmentp. 322
AC Lift with Regen Lowerp. 322
DC Liftp. 322
+Manual Lowering of Fork Carriagep. 324
AC Lift – Standardp. 324
AC Lift – Regen Lowerp. 324
DC Liftp. 324
Proportional Valve Adjustmentp. 325
+Auxiliary Pressure Adjustmentp. 326
AC Liftp. 326
DC Liftp. 326
Auxiliary No-Load Pressure Test (AC Regen only)p. 326
Main Manifold – Standard AC Liftp. 327
Lift/Lower Manifold – AC Lift with Regen Lowerp. 328
Aux Manifold – AC Lift with Regen Lowerp. 329
Main Manifold – DC Liftp. 330
+Aux Manifold (Standard Reach)p. 331
Removalp. 332
Installationp. 332
+Deep-Reach ® Manifoldp. 333
Removalp. 333
Installationp. 333
+Tilt/Sideshift Manifold (Deep-Reach ®)p. 334
Removalp. 334
Installationp. 334
Manifold Port Torque Specificationsp. 335
+Hydraulic Components, Cylinderp. 337
+Lift Cylinder, Free Lift, Remove/Installp. 338
Model 7500p. 338
Model 7520p. 340
+Lift Cylinder, Free Lift, Seal Repackingp. 342
AC Liftp. 342
DC Liftp. 343
+Lift Cylinder, Main, Remove/Installp. 344
Left Side Main Lift Cylinderp. 344
Right Side Main Lift Cylinderp. 345
+Lift Cylinder, Main, Seal Repackingp. 347
Disassemblyp. 347
Reassemblyp. 347
+Lift Cylinder Lowering Cushionp. 348
Main Lift Cylindersp. 348
Free Lift Cylinders – AC Liftp. 348
Free Lift Cylinders – DC Liftp. 349
+Reach Cylinderp. 350
Removalp. 350
Disassemblyp. 350
Reassemblyp. 350
Installationp. 351
Adjustmentp. 351
+Tilt Cylinderp. 353
Removalp. 353
Disassemblyp. 353
Reassemblyp. 354
Installationp. 354
+Sideshift Cylinderp. 355
Removalp. 355
Disassemblyp. 355
Reassemblyp. 355
Installationp. 355
+Flow Limiter, Main Liftp. 356
Removalp. 356
Installationp. 356
+Flow Limiter, Free Liftp. 357
Removalp. 357
Installationp. 357
+Mast, Chain, Hose, Cablep. 359
+Carriage Bearingsp. 360
Removalp. 360
Installationp. 360
Adjustmentp. 360
+Mast Shimmingp. 361
Mast and Bearing Inspectionp. 361
Shimming Procedurep. 362
+Bow Pad Inspectionp. 363
R35TT Mastsp. 363
R45TT and DR32TT Mastsp. 365
+Carriagep. 366
Removalp. 366
Installationp. 366
+Chain Anchorsp. 367
Main Lift Chain Anchorsp. 367
Free Lift Chain Anchorsp. 368
+Lift Chainsp. 370
Chains, Main Liftp. 370
Chains, Free Liftp. 370
+Height Encoder Beltp. 372
Model 7500p. 372
Model 7520p. 372
+Hose and Cable, Over-the-Mastp. 375
Removalp. 376
Installationp. 377
+Cable, Over-the-Mastp. 381
Over-the-Mast Cable Replacementp. 381
+Hose/Tubing, Free Lift Feedp. 384
Removalp. 384
Installationp. 384
+Mast, Model 7500 (Complete Disassembly)p. 385
Separation of Tractor and Mastp. 385
Hose/Cable, Free Lift Cylinder, and Carriage Removalp. 385
Main Lift Chain Removalp. 386
Separation of Telescopicsp. 386
+Mast, Model 7500 (Complete Assembly)p. 389
Assembling and Shimming Outer Telescopic to Main Framep. 389
Assembling and Shimming Inner Telescopic to Outer Telescopicp. 390
Main Lift Chain Installationp. 390
Shimming Carriage to Inner Telescopicp. 391
Carriage, Free Lift Cylinder, and Hose/Cable Installationp. 392
Mating Mast to Tractorp. 394
+Mast, Model 7520 (Complete Disassembly)p. 397
Separation of Tractor and Mastp. 397
Hose/Cable, Free Lift Cylinder, and Carriage Removalp. 397
Main Lift Chain Removalp. 399
Separation of Telescopicsp. 400
+Mast, Model 7520 (Complete Assembly)p. 402
Assembling and Shimming Outer Telescopic to Main Framep. 402
Assembling and Shimming Inner Telescopic to Outer Telescopicp. 403
Main Lift Chain Installationp. 403
Shimming Carriage to Inner Telescopicp. 404
Carriage, Free Lift Cylinder, and Hose/Cable Installationp. 404
Mating Mast to Tractorp. 407
Back Tilt and Lateral Lean Inspectionp. 408
+Section 8. Theory of Operationp. 411
+Traction System Functional Operationp. 412
Battery Connectedp. 412
Key Turned ONp. 412
Deadman Pedal Pressedp. 413
Electric Steeringp. 414
Travel Requestp. 414
Cold Storagep. 416
+Hydraulic System Functional Operation (AC Lift Without Regen Lower)p. 417
System Componentsp. 417
Tilt Solenoid (TILT SOL)p. 418
Theory of Lift/Aux Functionsp. 418
Auxiliary Functionsp. 419
+Hydraulic System Functional Operation (AC Lift With Regen Lower)p. 422
System Componentsp. 422
Reach/Retract Solenoid (REACH SOL)p. 422
Tilt Solenoid (TILT SOL)p. 423
Theory of Lift/Aux Functionsp. 424
Auxiliary Functionsp. 425
+Hydraulic System Functional Operation (DC Lift)p. 427
Steering Systemp. 427
Lift/Lower Systemp. 427
Auxiliary Systemp. 429
+Electric Brake Operationp. 432
Overviewp. 432
Brake Releasep. 432
Brake Applicationp. 432
Brake Release Screwsp. 432
Pinout Matrixp. 433
+Section A. Appendixp. 449
Lubrication Specification Chartp. 450
Thread Adhesives, Sealants, and Lubricantsp. 451
Component Specific Service/Torque Chartp. 452
Torque Chart – Hydraulic Fittingsp. 456
Torque Chart – Straight Thread Face Seal O-Ringsp. 457
Torque Chart – Standard (Ferrous)p. 458
Torque Chart – Metric (Ferrous)p. 459
Torque Chart – Standard (Brass)p. 460
Torque Chart – Metric (Brass)p. 461
Torque Chart – Thread Forming Screwsp. 462
Decimal Equivalent Chartp. 463
Standard/Metric Conversionsp. 465
Section I. Indexp. 467
+Schematicsp. 481
Figure 1-1. Power Distribution Diagram – Standard AC Liftp. 482
Figure 1-2. Power Distribution Diagram – DC Liftp. 483
Figure 1-3. Power Distribution Diagram – AC Lift with Regen Lowerp. 484
Figure 1-4. Electrical Schematic – Standard AC Lift (Sheet 1 of 6)p. 485
Figure 1-5. Electrical Schematic – DC Lift (Sheet 2 of 6)p. 486
Figure 1-6. Electrical Schematic – AC Lift with Regen Lower (Sheet 3 of 6)p. 487
Figure 1-7. Electrical Schematic – Options (Sheet 4 of 6)p. 488
Figure 1-8. Electrical Schematic – Options (con’t) (Sheet 5 of 6)p. 489
Figure 1-9. Electrical Schematic – Legend (Sheet 6 of 6)p. 490
Figure 1-10. Hydraulic Schematic – Standard AC Lift (Sheet 1 of 2)p. 491
Figure 1-11. Hydraulic Schematic – Standard AC Lift (Sheet 2 of 2)p. 492
Figure 1-12. Hydraulic Schematic – AC Lift with Regen Lower (Sheet 1 of 2)p. 493
Figure 1-13. Hydraulic Schematic – AC Lift with Regen Lower (Sheet 2 of 2)p. 494
Figure 1-14. Hydraulic Schematic – DC Lift – Standard Reach (Sheet 1 of 3)p. 495
Figure 1-15. Hydraulic Schematic – DC Lift – Deep-Reach (Sheet 2 of 2)p. 496
Figure 1-16. Hydraulic Schematic – DC Lift – Aux Functions (Sheet 3 of 3)p. 497
What This Manual Lets You Do
With this Raymond 7500 7520 Reach-Fork maintenance manual on hand, you can run a scheduled maintenance program on the actual intervals the truck calls for, diagnose a fault from the operator display code to the specific connector pin, and carry out the repair without guessing at torque values or seal orientation. You can set lift pressure, adjust the proportional lower valve, prime a regenerative lower lift pump, reshim a mast, repack a cylinder, rebuild a drive unit, or replace a brake coil using the same sequence and the same figures shown here. The pinout matrix alone saves hours on intermittent electrical faults, because it tells you what each wire should read, where the signal comes from, and where it goes.
Getting those values right matters. An incorrectly adjusted proportional valve causes a carriage that will not feather or that creeps when it should hold. A mast shimmed too tight wears the rail; shimmed too loose, it moves under load. Contactor tips that should have been replaced weld shut and stop the truck mid-shift. A brake air gap outside the limit changes stopping distance. This manual gives you the thresholds to catch those problems before they become downtime.
Delivery is instant. This is a PDF download, so there is no shipping and no waiting. The file opens on a laptop, tablet, or phone in the shop, and any page can be printed for the job at hand.
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