Description
The Raymond 7700 7720 Reach-Fork Trucks Maintenance Manual is the complete service publication for the Models 7700 and 7720 Reach-Fork lift trucks, covering serial numbers 31,001 and up. Published under document number 1137893E and issued 22 May 2017, this PDF manual contains the maintenance procedures, troubleshooting charts, diagnostic test steps, hydraulic and electrical theory, and component-level repair instructions used by technicians to service these AC-powered reach trucks. Whether you are performing scheduled maintenance, diagnosing a fault code, or overhauling a drive unit, this Raymond 7700 7720 maintenance manual provides the procedures and specifications needed to complete the work correctly.
File Details
- Manual Type: Maintenance Manual
- Brand: The Raymond Corporation
- Models Covered: 7700, 7720 (Reach-Fork Trucks)
- Serial Numbers: 31,001 and Up
- Publication Number: 1137893E
- Date Issued: 22 May 2017
- Language: English
- Page Count: 494
- File Format: PDF
Chapters Covered in This Raymond 7700 7720 Reach-Fork Service Manual
- How to Use This Manual – IETM access, abbreviations and symbols
- Safety – General safety, battery safety, static precautions, jacking safety, transport tie-down, welding safety
- Systems Overview – Lift truck specifications, model designations, battery specifications, truck installation, FlashWare, operator display, modes of operation
- Scheduled Maintenance – Maintenance guidelines, Maintenance Minder tool, initial 90 day/250 HD service, 180 day/500 HD service, 360 day/2000 HD service, lubrication points, contactor tip inspection, chain maintenance, fork inspection
- Troubleshooting – Electrical troubleshooting, shorts to frame test, battery state-of-charge, fuses, electrical connector locator, circuit card connectors, fuse/relay card troubleshooting, DC motors, AC motors, power amplifier error codes, hydraulic troubleshooting guidelines, symptom tables for hydraulic and travel functions, electrical symptoms
- Messages, Codes, and Tests – Power amp LED diagnostics, messages and codes summary, full code definitions with corrective action, analog tests, input tests, output tests
- Component Procedures – Component locator photos, special tools and decals, baselegs, steering and controls, control handle, drive unit, brake, deadman pedals, inertial dampener, battery procedures, wiring and harness connectors, power cables, motors, steer amplifier, cold storage conditioning, hydraulic components, hydraulic system bleeding, hydraulic filter, lift pump replacement and priming, pressure adjustments, proportional valve adjustment, auxiliary pump service, manifolds, cylinders (free lift, main lift, reach, tilt, sideshift), flow limiters, carriage bearings, mast shimming, bow pads, carriage, chain anchors, lift chains, height encoder belt, over-the-mast hose and cable, complete mast disassembly and assembly for both 7700 and 7720, back tilt and lateral lean inspection
- Theory of Operation – Traction system functional operation, cold storage, hydraulic system theory (standard lift/lower, regen lower, regen lower with AC aux), electric brake operation, pinout matrix
- Appendix – Lubrication specification chart, thread adhesives and sealants, component specific service/torque chart, torque charts (hydraulic fittings, straight thread face seal O-rings, standard ferrous, metric ferrous, standard brass, metric brass, thread forming screws), decimal equivalent chart, standard/metric conversions
- Index
- Schematics – Power distribution diagrams, electrical schematics (standard AC lift, AC regen with DC aux, AC regen with AC aux), hydraulic schematics (standard AC lift, AC regen with AC aux, AC regen with DC aux, AC regen narrow mast)
This Raymond 7700 7720 maintenance manual covers every major system on the reach truck. The component procedures chapter alone spans over 250 pages of step-by-step removal, installation, disassembly, reassembly, adjustment, and inspection instructions. The troubleshooting section gives technicians structured symptom tables that map a customer complaint to a likely cause and a recommended action, while the messages and codes chapter lists every fault code the Vehicle Manager and power amplifiers can display along with the specific test or repair each code points to. The theory of operation section explains how the traction, hydraulic, and electric brake systems function, which is essential for diagnosing intermittent problems and understanding why a test result indicates a particular failure.
What This Manual Enables You to Do
With this Raymond 7700 7720 Reach-Fork truck service manual in hand, a technician can perform the full range of scheduled maintenance — from the initial 90-day/250 deadman-hour service through the 360-day/2000-hour service — including hydraulic fluid changes, filter replacement, drive unit fluid service, lift chain inspection and lubrication, and brake inspection. The manual provides the torque values for every critical fastener, from mast-to-tractor mounting bolts to power cable terminals on the AC motors and power amplifiers.
Diagnostics are covered in depth. The manual walks through the use of FlashWare for connecting a PC to the truck, entering Service Mode, running analog tests, input tests, and output tests, and interpreting the results. The power amplifier error codes are broken down with sub-codes, corrective actions, and notes on whether a code is intermittent or hard failure. The pinout matrix gives normal voltage levels and signal sources for every connector pin on the Vehicle Manager, which turns circuit tracing into a systematic process rather than guesswork.
Major component work is fully supported. The drive unit chapter covers removal, disassembly, bearing and seal replacement, gear set replacement, shim calculation, backlash measurement, and reassembly. The hydraulic cylinder chapters cover free lift, main lift, reach, tilt, and sideshift cylinders with seal repacking procedures and staging zone mechanism service for the free lift cylinders. The mast chapters cover complete disassembly and reassembly of both the 7700 and 7720 masts, including telescopic separation, bearing shimming, main lift chain installation, and mating the mast to the tractor.
Why the Correct Specifications Matter
Reach trucks operate in tight aisles and lift heavy loads to significant heights. A mast that is shimmed too loose or too tight will wear prematurely or cause load instability. A drive unit that is reassembled with incorrect backlash will fail early and may damage the traction motor. A hydraulic system that is not properly bled will behave erratically and may damage the pump. This manual provides the exact measurements, torque values, clearances, and adjustment procedures required to return the truck to specification.
For example, the lift chain adjustment procedure specifies a gap of 0.25 in. (6.4 mm) at the narrowest point between the inner and outer telescopics when the carriage is fully lowered, with equal tension on both chains. The brake air gap is specified at 0.040 in. (1 mm) maximum. The mast bearing shimming procedure specifies 0.000 ±0.010 in. overall interference. These values are not generic suggestions — they are the factory specifications for this machine, and the manual presents them alongside the procedures needed to achieve them.
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “Raymond 7700 7720 Reach-Fork Trucks Maintenance Manual 2017 – Serial 31,001 & Up PDF” 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
+Battery Specificationsp. 29
Truck Installationp. 30
+FlashWarep. 31
Overviewp. 31
Installing FlashWare on PCp. 31
Connecting PC 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. 46
Using Service Modep. 47
Static Service Modep. 47
Active Service Modep. 48
+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. 77
AC Motorsp. 83
Troubleshooting Power Amplifier Error Codesp. 84
Hydraulic Troubleshooting Guidelinesp. 85
+Symptom Tables: Hydraulic Functionsp. 86
Auxiliary Functionsp. 86
Lift/Lower Systemp. 90
+Symptom Tables: Travel Functionsp. 93
Slow or Sluggish Accelerationp. 93
Slow Travelp. 93
+Symptom Tables: Electrical Symptomsp. 94
Motor Overheatingp. 94
Scrambled or Intermittent Displayp. 94
Display is Dark; Lift Truck is Not Operationalp. 95
+Section 6. Messages, Codes, and Testsp. 97
+Power Amp LED Diagnosticsp. 98
+Messages and Codesp. 103
Messagesp. 103
Codesp. 104
Analog Testsp. 131
Input Testsp. 131
Output Testsp. 132
+Analog Testsp. 133
+Test A04 – Throttle Pot (VR1) Voltagep. 134
Run Testp. 134
Diagnosis and Repairp. 134
+Test A05 – Lift/Lower Pot Voltagep. 135
Run Testp. 135
Diagnosis and Repairp. 135
+Test A08 – Traction Motor Temperaturep. 136
Limitsp. 136
Run Testp. 136
Diagnosis and Repairp. 136
+Test A09 – Lift Motor Temperaturep. 137
Limitsp. 137
Run Testp. 137
Diagnosis and Repairp. 137
+Test A10 – TPA Temperaturep. 138
Limitsp. 138
Run Testp. 138
Diagnosis and Repairp. 138
+Test A11 – Traction Motor Currentp. 139
Limitsp. 139
Run Testp. 139
Diagnosis and Repairp. 139
+Test A12 – APA Temperature (AC Aux)p. 140
Limitsp. 140
Run Testp. 140
Diagnosis and Repairp. 140
+Test A13 – Pressure Sensor Voltagep. 141
Run Testp. 141
Diagnosis and Repairp. 141
+Test A14 – +12VDC Power Supplyp. 142
Run Testp. 142
Diagnosis and Repairp. 142
+Test A15 – Battery Voltagep. 143
Run Testp. 143
Diagnosis and Repairp. 143
+Test A16 – Aux Motor Temperature (AC Aux)p. 144
Limitsp. 144
Run Testp. 144
Diagnosis and Repairp. 144
+Test A18 – Aux Motor Current (AC Aux)p. 145
Limitsp. 145
Run Testp. 145
Diagnosis and Repairp. 145
+Test A19 – LPA Tempp. 146
Limitsp. 146
Run Testp. 146
Diagnosis and Repairp. 146
+Test A20 – Lift Motor Currentp. 147
Limitsp. 147
Run Testp. 147
Diagnosis and Repairp. 147
+Test A22 – Traction Throttle (VR1) Requestp. 148
Run Testp. 148
Diagnosis and Repairp. 148
+Test A23 – Lift Throttle (VR2) Requestp. 149
Run Testp. 149
Diagnosis and Repairp. 149
+Test A26 – +5VDC Power Supplyp. 150
Run Testp. 150
Diagnosis and Repairp. 150
+Test A31 – Solenoid 5T (AUX1) Current (DC Aux)p. 151
Run Testp. 151
Diagnosis and Repairp. 151
+Test A32 – Solenoid 5B (AUX2) Current (DC Aux)p. 152
Run Testp. 152
Diagnosis and Repairp. 152
+Test A33 – Aux Dump (SOL6)/Main Relief Dump (SOL3) Currentp. 153
Run Testp. 153
Diagnosis and Repairp. 153
+Test A34 – Lower Current (SOL2)p. 154
Run Testp. 154
Diagnosis and Repairp. 154
+Test A35 – Brake Armaturep. 155
Run Testp. 155
Diagnosis and Repairp. 155
+Test A36 – Ambient Air Temp Sensorp. 156
Run Testp. 156
Diagnosis and Repairp. 156
+Test A37 – Steer Power Amp Currentp. 157
Run Testp. 157
Diagnosis and Repairp. 157
+Test A39 – Analog Reference Voltagep. 158
Run Testp. 158
Diagnosis and Repairp. 158
+Test A40 – Handle Heater Reference Voltage (optional)p. 159
Run Testp. 159
Diagnosis and Repairp. 159
+Test A41 – Emergency Power Off (EPO) Switchp. 160
Run Testp. 160
Diagnosis and Repairp. 160
Test A42 – Travel Pot LEARN Valuep. 161
Test A43 – Lift Pot LEARN Valuep. 162
Test A96 – BSM Currp. 163
Test A97 – BSM Voltp. 164
Test A98 – BSM Tempp. 165
Test A99 – H2O Snsep. 166
Test A100 – BSM Commp. 167
+Input Testsp. 169
+Test I00 – Deadman Switch (DS1)p. 170
Run Testp. 170
Diagnosis and Repairp. 170
+Test I01 – Nested Switch (S14)p. 171
Run Testp. 171
Diagnosis and Repairp. 171
+Test I02 – 1st Speed Limiting Switch (S12)p. 172
Run Testp. 172
Diagnosis and Repairp. 172
+Test I06 – Reach Switch (S4)p. 173
Run Testp. 173
Diagnosis and Repairp. 173
+Test I07 – Retract Switch (S5)p. 174
Run Testp. 174
Diagnosis and Repairp. 174
+Test I08 – Tilt Up Switch (S6)p. 175
Run Testp. 175
Diagnosis and Repairp. 175
+Test I09 – Tilt Down Switch (S7)p. 176
Run Testp. 176
Diagnosis and Repairp. 176
+Test I10 – Sideshift Right Switch (S9)p. 177
Run Testp. 177
Diagnosis and Repairp. 177
+Test I11 – Sideshift Left Switch (S8)p. 178
Run Testp. 178
Diagnosis and Repairp. 178
+Test I14 – Steering Fuse (FU1)p. 179
Run Testp. 179
Diagnosis and Repairp. 179
+Test I15 – Horn Switch (S3)p. 180
Run Testp. 180
Diagnosis and Repairp. 180
+Test I18 – Aux Motor Encoder (AC Aux)p. 181
Run Testp. 181
Diagnosis and Repairp. 181
+Test I19 – Traction Motor Speed Sensorp. 182
Run Testp. 182
Diagnosis and Repairp. 182
+Test I20 – Lift Motor Speed Sensorp. 183
Run Testp. 183
Diagnosis and Repairp. 183
+Test I22 – Lift Cutout Switch (S27)p. 184
Run Testp. 184
Diagnosis and Repairp. 184
+Test I23 – CAN Bus Testp. 185
Run Testp. 185
Diagnosis and Repairp. 185
+Test I24 – Steer Limit Switch (S11)p. 189
Run Testp. 189
Diagnosis and Repairp. 189
+Test I25 – Steer Motor Encoderp. 190
Run Testp. 190
Diagnosis and Repairp. 190
+Test I26 – Height Indicator Encoderp. 191
Run Testp. 191
Diagnosis and Repairp. 191
+Test I32 – Deadman Switch (DS2)p. 192
Run Testp. 192
Diagnosis and Repairp. 192
+Test I33 – Steer Tiller Encoder 1 Connect Detectp. 193
Run Testp. 193
Diagnosis and Repairp. 193
+Test I34 – Steer Tiller Encoder 2 Connect Detectp. 194
Run Testp. 194
Diagnosis and Repairp. 194
+Test I35 – Steer Tiller Encoder 1 – Channels A & Bp. 195
Run Testp. 195
Diagnosis and Repairp. 195
+Test I36 – Steer Tiller Encoder 2 – Channels A & Bp. 196
Run Testp. 196
Diagnosis and Repairp. 196
+Test I39 – Neutral Pulsesp. 197
Run Testp. 197
Diagnosis and Repairp. 197
+Test I60 – Security Start Switch (S23) (optional)p. 198
Run Testp. 198
Diagnosis and Repairp. 198
+Test I63 – High Speed Travel Switch (S25)p. 199
Run Testp. 199
Diagnosis and Repairp. 199
+Test I80 – OCSS Upper Beamp. 200
Run Testp. 200
Diagnosis and Repairp. 200
+Test I81 – OCSS Lower Beamp. 202
Run Testp. 202
Diagnosis and Repairp. 202
Test I82 – OCSS Cntp. 204
+Test I83 – BatGateLp. 205
Run Testp. 205
Diagnosis and Repairp. 205
+Test I84 – BatGateRp. 206
Run Testp. 206
Diagnosis and Repairp. 206
+Test I86 – Lift Heightp. 207
Run Testp. 207
Diagnosis and Repairp. 207
+Test I90 – Degrees Turned Past Steer Flagp. 208
Run Testp. 208
Diagnosis and Repairp. 208
+Test I91 – iPORT Communication Testp. 209
Run Testp. 209
Diagnosis and Repairp. 209
Test I92 – iPORT Error Bitmapp. 211
+Output Testsp. 213
+Test O00 – Toggle MPC Contactorp. 214
Run Testp. 214
Diagnosis and Repairp. 214
+Test O01 – Toggle STR Contactorp. 215
Run Testp. 215
Diagnosis and Repairp. 215
+Test O03 – Toggle AUX Contactorp. 216
Run Testp. 216
Diagnosis and Repairp. 216
+Test O04 – Toggle AUX1 (SOL5T) Solenoid (AC Aux)p. 217
Run Testp. 217
Diagnosis and Repairp. 217
+Test O05 – Toggle AUX2 (SOL5B) Solenoid (AC Aux)p. 218
Run Testp. 218
Diagnosis and Repairp. 218
+Test O06 – Toggle Reach Solenoidp. 219
Run Testp. 219
Diagnosis and Repairp. 219
+Test O07 – Toggle Tilt Solenoidp. 220
Run Testp. 220
Diagnosis and Repairp. 220
+Test O08 – Toggle the Sideshift Solenoidp. 221
Run Testp. 221
Diagnosis and Repairp. 221
Test O09 – Aux Dump (SOL6)/Main Relief Dump (SOL3)p. 222
+Test O11 – Toggle the Load Hold (SOL1) Solenoidp. 223
Run Testp. 223
Diagnosis and Repairp. 223
Test O12 – Ramp the Proportional Lower (SOL2) Solenoidp. 224
+Test O18 – Toggle Hornp. 225
Run Testp. 225
Diagnosis and Repairp. 225
+Test O19 – Audible Alarmp. 226
Run Testp. 226
Diagnosis and Repairp. 226
+Test O20 – Travel Alarmp. 227
Run Testp. 227
Diagnosis and Repairp. 227
+Test O23 – Toggle Fansp. 228
Run Testp. 228
Diagnosis and Repairp. 228
+Test O27 – Ramp Aux Motor (AC Aux)p. 229
Run Testp. 229
Diagnosis and Repairp. 229
+Test O28 – Ramp Lift Motorp. 230
Run Testp. 230
Diagnosis and Repairp. 230
+Test O29 – Ramp Traction Motorp. 231
Run Testp. 231
Diagnosis and Repairp. 231
Test O30 – Toggle Brake Coilp. 232
+Test O32 – Toggle Relays K1, K2, K3, and K4p. 233
Run Testp. 233
Diagnosis and Repairp. 233
+Test O33 – Handle Heaterp. 234
Run Testp. 234
Diagnosis and Repairp. 234
+Test O61 – Custom Outputp. 235
Run Testp. 235
Diagnosis and Repairp. 235
+Section 7. Component Proceduresp. 237
List of Component Proceduresp. 238
+Component Locator Photosp. 241
Tractor and Mastp. 241
Tractorp. 242
Tractor Deckp. 243
Operator Compartmentp. 244
Reach Carriagep. 245
Underside Componentsp. 246
+Special Tools, Decals, and Chassisp. 247
Special Toolsp. 248
Decals and Platesp. 249
+Baselegsp. 254
Removalp. 254
Installationp. 254
+Steering and Controlsp. 257
+Steer Tiller Encoderp. 258
Removalp. 258
Installationp. 258
+Steer Limit Switch (S11)p. 259
Vertical Gap Adjustmentp. 259
Lateral Adjustmentp. 259
+Steerable Casterp. 260
Initial Adjustmentp. 260
Caster Height Adjustmentp. 261
Steering Linkagep. 263
+Control Handlep. 264
Disassemblyp. 264
Travel Pot Repair/Replacementp. 264
Lift Pot Repair/Replacementp. 265
Flex Circuit Repair/Replacementp. 266
Assemblyp. 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. 278
+Brakep. 288
Inspectionp. 288
Brake Removalp. 288
Pad Replacementp. 288
Coil Replacementp. 289
Brake Installationp. 289
Deadman Pedalsp. 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 Amplifierp. 313
Removalp. 313
Installationp. 313
+Cold Storage Conditioningp. 314
Componentsp. 314
Lubricantsp. 314
Sealing Treatmentp. 314
Corrosion Inhibitor Coatingp. 314
+Hydraulic Componentsp. 315
+Hydraulic System Bleedingp. 316
Hydraulic Filterp. 317
Lift Pump Replacement with Regen Lowerp. 318
Lift Pump Priming – Regen Lowerp. 319
Aux Pump Priming – Regen Lower with AC Aux Motorp. 320
+Lift Pressure Adjustmentp. 321
Trucks with Regen Lowerp. 321
+Manual Lowering of Fork Carriagep. 322
Standardp. 322
Regen Lowerp. 322
Proportional Valve Adjustmentp. 323
Auxiliary Pump/Motor Service – AC Auxp. 324
+Auxiliary Pressure Adjustmentp. 325
Auxiliary No-Load Pressure Test (Regen Lower with DC Aux motor only)p. 325
Main Manifold – Standard Lift/Lowerp. 326
Lift/Lower Manifold – HSL/Regen Lowerp. 327
Aux Manifold – HSL/Regen Lowerp. 328
Aux Manifold – AC Auxp. 329
+Aux Manifold – Standard Reach 35.5 in. Wide Mastp. 330
Removalp. 331
Installationp. 331
+Standard Reach Manifold – 32 in. Wide Mastp. 332
Removalp. 333
Installationp. 333
+Deep-Reach® Manifold – 35.5 in. Wide Mastp. 334
Removalp. 334
Installationp. 334
+Deep-Reach® Manifold – 32 in. Wide Mastp. 335
Removalp. 335
Installationp. 335
+Tilt/Sideshift Manifoldp. 336
Removalp. 336
Installationp. 336
+Hydraulic Components, Cylinderp. 337
+Lift Cylinder, Free Lift, Remove/Installp. 338
Model 7700p. 338
Model 7720p. 340
+Lift Cylinder, Free Lift, Seal Repackingp. 342
Disassemblyp. 342
Reassemblyp. 342
+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 Cylindersp. 348
+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 Pads – Model 7700p. 363
Inspection and Adjustmentp. 363
+Carriagep. 364
Removalp. 364
Installationp. 364
+Chain Anchorsp. 365
Main Lift Chain Anchorsp. 365
Free Lift Chain Anchorsp. 366
+Lift Chainsp. 368
Chains, Main Liftp. 368
Chains, Free Liftp. 368
+Height Encoder Beltp. 370
Model 7700p. 370
Model 7720p. 370
+Hose and Cable, Over-the-Mastp. 373
Removalp. 374
Installationp. 375
+Cable, Over-the-Mastp. 379
Over-the-Mast Cable Replacementp. 379
+Hose/Tubing, Free Lift Feedp. 382
Removalp. 382
Installationp. 382
+Mast, Model 7700 (Complete Disassembly)p. 383
Separation of Tractor and Mastp. 383
Hose/Cable, Free Lift Cylinder, and Carriage Removalp. 383
Main Lift Chain Removalp. 384
Separation of Telescopicsp. 384
+Mast, Model 7700 (Complete Assembly)p. 387
Assembling and Shimming Outer Telescopic to Main Framep. 387
Assembling and Shimming Inner Telescopic to Outer Telescopicp. 388
Main Lift Chain Installationp. 388
Shimming Carriage to Inner Telescopicp. 389
Carriage, Free Lift Cylinder, and Hose/Cable Installationp. 389
Mating Mast to Tractorp. 392
+Mast, Model 7720 (Complete Disassembly)p. 395
Separation of Tractor and Mastp. 395
Hose/Cable, Free Lift Cylinder, and Carriage Removalp. 395
Main Lift Chain Removalp. 397
Separation of Telescopicsp. 398
+Mast, Model 7720 (Complete Assembly)p. 400
Assembling and Shimming Outer Telescopic to Main Framep. 400
Assembling and Shimming Inner Telescopic to Outer Telescopicp. 401
Main Lift Chain Installationp. 401
Shimming Carriage to Inner Telescopicp. 402
Carriage, Free Lift Cylinder, and Hose/Cable Installationp. 402
Mating Mast to Tractorp. 405
Back Tilt and Lateral Lean Inspectionp. 407
+Section 8. Theory of Operationp. 409
+Traction System Functional Operationp. 410
Battery Connectedp. 410
Key Turned ONp. 410
Deadman Pedal Pressedp. 411
Electric Steeringp. 412
Travel Requestp. 412
Cold Storagep. 414
+Hydraulic System Functional Operation – Standard Lift/Lowerp. 415
System Componentsp. 415
Theory of Lift/Aux Functionsp. 417
+Hydraulic System Functional Operation – Regen Lowerp. 420
+Hydraulic System Functional Operation – Regen Lower/AC Auxp. 425
System Componentsp. 425
Theory of Lift/Aux Functionsp. 427
+Electric Brake Operationp. 430
Overviewp. 430
Brake Releasep. 430
Brake Applicationp. 430
Brake Release Screwsp. 430
Pinout Matrixp. 431
+Section A. Appendixp. 447
Lubrication Specification Chartp. 448
Thread Adhesives, Sealants, and Lubricantsp. 449
Component Specific Service/Torque Chartp. 450
Torque Chart – Hydraulic Fittingsp. 454
Torque Chart – Straight Thread Face Seal O-Ringsp. 455
Torque Chart – Standard (Ferrous)p. 456
Torque Chart – Metric (Ferrous)p. 457
Torque Chart – Standard (Brass)p. 458
Torque Chart – Metric (Brass)p. 459
Torque Chart – Thread Forming Screwsp. 460
Decimal Equivalent Chartp. 461
Standard/Metric Conversionsp. 463
Section I. Indexp. 465
Schematicsp. 479
Instant PDF Delivery
The Raymond 7700 7720 Reach-Fork Trucks Maintenance Manual is delivered as an instant PDF download after purchase. No shipping, no waiting for a physical book. The file can be viewed on a laptop, tablet, or smartphone, and individual pages can be printed for use in the shop. Because it is a searchable PDF, finding a specific torque value or test procedure is a matter of typing a keyword rather than paging through a printed index.
This publication — 1137893E, issued 22 May 2017 — applies to Models 7700 and 7720 Reach-Fork trucks with serial numbers 31,001 and up. If you service, maintain, or repair these trucks, this manual is the reference that keeps your work accurate and your equipment running correctly.
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