Raymond Forklift 5400 5500 5600 High-Level Orderpicker Maintenance Manual 1031794D – PDF DOWNLOAD

Description

Raymond Forklift 5400 5500 5600 High-Level Orderpicker Maintenance Manual 1031794D – PDF DOWNLOAD

FILE DETAILS:

Raymond Forklift 5400 5500 5600 High-Level Orderpicker Maintenance Manual 1031794D – PDF DOWNLOAD

Language : English
Pages : 481
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Raymond Forklift 5400 5500 5600 High-Level Orderpicker Maintenance Manual 1031794D – PDF DOWNLOAD

Models Serial Numbers
5400, 5500, 5600 00100 and Up

• This manual is designed to give personnel with an expected level of expertise the technical information necessary to maintain, troubleshoot, and repair a Raymond product.
• The two-line header at the top of each page contains the name of the manual, the title of the current section, and the topic contained on the page.

TABLE OF CONTENTS:

Raymond Forklift 5400 5500 5600 High-Level Orderpicker Maintenance Manual 1031794D – PDF DOWNLOAD

Document Revision History 1-v
Service Information List 1-v
How to Use This Manual 1-1
Manual Design1-2
Interactive Electronic Technical Manuals 1-3
Abbreviations and Symbols1-4
Safety2-1
Definitions2-2
General Safety 2-3
Battery Safety 2-5
Static Precautions 2-8
Jacking2-9
Emergency Lower Valve 2-10
Tie-Down for Transport 2-11
Towing 2-12
Welding Safety 2-13
Systems Overview3-1
Introduction 3-2
Lift Truck Specifications 3-3
General Information 3-4
Installation3-6
Operator Display 3-7
Modes of Operation3-8
FlashWare3-27
Wire Guidance 3-29
Cold Storage 3-30
Storage 3-31
UL Label “EE”3-32
Scheduled Maintenance 4-1
Maintenance Guidelines 4-2
Maintenance Minder ™ Tool4-3
Initial 90 Day/250 Deadman Hours (HD) Maintenance4-5
Every 180 Days or 500 Deadman Hours (HD) 4-6
Every 360 Days or 2000 Deadman Hours (HD) 4-10
Chain Maintenance 4-11
Troubleshooting 5-1
Electrical Troubleshooting 5-2
Drive Unit Troubleshooting 5-22
Troubleshooting Aisle Exit Error Code J25-24
Symptom Tables: Hydraulic Functions 5-25
Symptom Tables: Travel Functions 5-28
Symptom Tables: Electrical Symptoms 5-29
Messages, Codes, and Tests 6-1
Power Amp LED Diagnostics 6-2
Summary List 6-3
Messages and Codes 6-9
Analog Input Tests 6-43
Input Tests 6-69
Output Tests6-113
Table of Contents Models 5400/5500/5600 Maintenance Manual
ii Publication: 1031794D, Revised: 10 Jan 2018
Component Procedures 7-1
List of Component Procedures 7-2
Component Locator Photos 7-5
Special Tools and Decals7-11
Special Tools 7-12
Decals and Tags 7-13
Steering and Controls 7-17
Steer Motor/Gearbox 7-18
Home Proximity Sensor Adjustment 7-20
Control Handle 7-21
Deadman Pedal 7-27
Drive and Brake 7-29
Traction Motor7-30
Drive Unit – Standard7-31
Drive Unit – Heavy Duty 7-50
Brake7-62
Drive Wheel 7-66
Electrical Components 7-69
Battery Procedures 7-70
Power Cables7-72
Motors7-74
AC Motor Service 7-77
Power Amplifiers 7-80
Horn 7-81
Carriage Control Card Replacement 7-82
EPROM/Microprocessor Removal/Replacement 7-83
Wiring and Harness Repair 7-85
Hydraulic Components 7-93
Flow Sensor Service Notes7-94
High Pressure Relief Valve Adjustment7-97
Lift/Lower and Load Holding Valves 7-98
Bleeding Lift Cylinders7-99
Lift Pump and Motor7-100
Pressure Switch Adjustment7-101
Side Lift Cylinder7-102
Center Lift Cylinder 7-106
Mast Section 7-109
Carriage 7-110
Mast Shimming 7-113
Upper Mast Bearing Replacement 7-115
Lift Chains, Three-Stage7-120
Center Cylinder Ride Spring Chain Anchors 7-122
Forks 7-123
Pallet Clamp7-124
Load Wheels7-125
Skid Pads 7-126
Lift Chain 7-127
Theory of Operation 8-1
System Architecture 8-2
Traction System 8-6
Steering System 8-8
Lift/Lower System8-10
Models 5400/5500/5600 Maintenance Manual Table of Contents
Publication: 1031794D, Revised: 10 Jan 2018 iii
Wire Guidance System8-13
Pin-Out Matrix 8-19
AppendixA-1
Lubrication Specification ChartA-2
Thread Adhesives, Sealants, and Lubricants A-3
Component Specific Torque Chart A-4
Torque Chart – Hydraulic Fittings A-6
Torque Chart – Straight Thread Face Seal O-Rings A-7
Torque Chart – Standard (Ferrous) A-8
Torque Chart – Metric (Ferrous)A-9
Torque Chart – Standard (Brass) A-10
Torque Chart – Metric (Brass)A-11
Torque Chart – Thread-Forming Screws A-12
Decimal Equivalent ChartA-13
Standard/Metric ConversionsA-15
Index I-1

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