Raymond Forklift 7400 7420 7440 Reach-Fork® Truck With The ACR System™ Maintenance Manual 1026304C – PDF DOWNLOAD

Description

Raymond Forklift 7400 7420 7440 Reach-Fork® Truck With The ACR System™ Maintenance Manual 1026304C – PDF DOWNLOAD

FILE DETAILS:

Raymond Forklift 7400 7420 7440 Reach-Fork® Truck With The ACR System™ Maintenance Manual 1026304C – PDF DOWNLOAD

Language : English
Pages :624
Downloadable : Yes
File Type : PDF
Size: 30.7 MB

DESCRIPTION:

Raymond Forklift 7400 7420 7440 Reach-Fork® Truck With The ACR System™ Maintenance Manual 1026304C – PDF DOWNLOAD

This manual is designed with the following objectives in mind:

The two-line running page header at the top of each page tells you:

This manual consists of the following sections:

1. •How to Use This Manual Explains the manual format and design, as well as abbreviations and symbols used.
2. •Safety Explains warning and caution notes and general safety rules, as well as safety rules for batteries, static, jacking, and welding.
3. • Systems Overview Includes general lift truck specifications, programming instructions, and configuration menu.
4. • Scheduled Maintenance :Outlines the recommended schedule of preventive services to keep your lift truck working most efficiently.
5. • Troubleshooting Guides the user from fault symptoms to a specific sequence of tests in order to isolate a failing component.
6. •Messages, Codes, and Tests  Lists the electrical fault codes and procedures for running firmware-based electrical tests.
7. • Component Procedures Gives step-by-step procedures for testing, removing, replacing, and servicing individual lift truck components. Components are grouped by lift truck system. To find a component procedure, you may use one of three methods:
8. •Theory of Operation  Explains signal flow within the electrical and hydraulic systems for various conditions of lift truck operation. This section also contains a detailed connection point table (Pinout Matrix) designed to assist in testing and troubleshooting the lift truck.

TABLE OF CONTENTS:

Raymond Forklift 7400 7420 7440 Reach-Fork® Truck With The ACR System™ Maintenance Manual 1026304C – PDF DOWNLOAD

Page Revision Record 1-v
Service Bulletin List 1-vi
Product Improvement Notice List 1-vii
How to Use This Manual 1-1
Map of the Manual 1-2
Manual Design 1-3
Abbreviations and Symbols 1-4
Safety 2-1
Definitions 2-2
General Safety 2-3
Battery Safety 2-5
Static Precautions 2-7
Jacking Safety 2-8
Tie-Down for Transport 2-10
Welding Safety 2-11
Systems Overview 3-1
Introduction 3-2
Lift Truck Specifications 3-3
Model 7400 Series Designation 3-4
Battery Specifications 3-5
FlashWare 3-6
Operator Display 3-15
Modes of Operation 3-16
Scheduled Maintenance 4-1
Maintenance Guidelines 4-2
Maintenance Minder ™ Tool 4-3
Initial 90 Day/250 Deadman Hours (HD) Maintenance 4-5
Every 180 Days or 500 HD 4-6
Every 360 Days or 2000 HD 4-9
Lubrication Points 4-10
Chain Maintenance 4-16
Fork Inspection 4-17
Troubleshooting 5-1
Electrical Troubleshooting 5-2
Hydraulic Troubleshooting Guidelines 5-11
Symptom Tables: Hydraulic Functions 5-13
Symptom Tables: Travel Functions 5-20
Symptom Tables: Electrical Symptoms 5-21
Symptom Tables: Vantage Point System 5-23
Messages Codes and Tests 6-1
Power Amp LED Diagnostics 6-2
Messages and Codes 6-5
Electrical Connections 6-27
Analog Tests 6-33
Input Tests 6-63
Output Tests 6-101
Table of Contents Model 7400/7420/7440 Reach-Fork® Truck
ii Publication: 1026304 Issued: 22 Apr 2009
Component Procedures 7-1
Component Locator Photos 7-3
Special Tools Decals and Chassis 7-13
Special Tools 7-14
Decals and Plates 7-15
Baselegs 7-20
Steering and Controls 7-23
Steer Tiller Encoder (AC Lift) 7-24
Steer Limit Switch (S11) 7-25
Steerable Caster 7-26
Steering Linkage 7-29
Control Handle 7-30
Drive and Brake 7-41
Drive Unit 7-42
Brake (Adjustable) 7-60
Brake (Floating Disk) 7-66
Deadman Switch (S2) 7-68
Inertial Dampener 7-69
Electrical Components 7-73
Battery Procedures 7-74
Wiring and Harness Connectors 7-77
Contactor Panel 7-82
Motors 7-83
AC Motor Service 7-84
Steer Amplifier (AC Lift) 7-92
Cold Storage Conditioning 7-93
Hydraulic Components 7-95
Hydraulic System Bleeding 7-96
Hydraulic Filter 7-97
Lift Pressure Adjustment 7-99
Manual Lowering of Fork Carriage 7-100
Proportional Valve Adjustment 7-101
Auxiliary Pressure Adjustment 7-102
Manifold Main AC Lift Model 7400 7-103
Manifold Main AC Lift Model 7420/7440 7-104
Manifold Main DC Lift Model 7400 7-105
Manifold Auxiliary (Standard Reach) 7-106
Manifold Reach (Deep-Reach ®) 7-108
Manifold Tilt/Sideshift (Deep-Reach ®) 7-110
Manifold Solenoids Fittings and Attachments 7-111
Hydraulic Components Cylinder 7-113
Lift Cylinder Free Lift Remove/Install 7-114
Lift Cylinder Free Lift Exploded Parts Drawing 7-118
Lift Cylinder Free Lift Seal Repacking 7-121
Lift Cylinder Main Remove/Install 7-124
Lift Cylinder Main Lift Exploded Parts Drawing 7-129
Lift Cylinder Main Seal Repacking 7-131
Lift Cylinder Lowering Cushion 7-133
Reach Cylinder 7-136
Tilt Cylinder 7-139
Flow Limiter Main Lift 7-141
Flow Limiter Free Lift 7-142
Model 7400/7420/7440 Reach-Fork® Truck Table of Contents
Publication: 1026304 Issued: 22 Apr 2009 iii
Mast Chain Hose Cable 7-145
Reach Carriage Bearings 7-146
Mast Shimming 7-147
Bow Pads – Model 7400 7-149
Carriage 7-151
Chain Anchors 7-154
Lift Chains 7-160
Height Encoder Belt 7-165
Hose Main Lift 7-169
Hose and Cable Over-the-Mast 7-170
Hose Guard Addition 7-176
Hose/Cable Retainer Upgrade 7-177
Cable Over-the-Mast 7-178
Hose/Tubing Free Lift Feed 7-183
Mast Model 7400 (Complete Disassembly) 7-184
Mast Model 7400 (Complete Assembly) 7-188
Mast Model 7420 (Complete Disassembly) 7-196
Mast Model 7420 (Complete Assembly) 7-201
Mast Model 7440 (Complete Disassembly) 7-207
Mast Model 7440 (Complete Assembly) 7-211
Carriage Free Lift Cylinder and Hose/Cable Installation 7-214
Mating Tractor to Mast 7-218
Theory of Operation 8-1
Traction System Functional Operation 8-2
Cold Storage 8-6
Hydraulic System Functional Operation (AC Lift) 8-7
Hydraulic System Functional Operation (DC Lift) 8-13
Electric Brake Operation 8-18
Pinout Matrix 8-19
Appendix A-1
Lubrication Specification Chart A-2
Thread Adhesives Sealants and Lubricants A-3
Component Specific Service/Torque Chart A-4
Torque Chart – Hydraulic Fittings A-7
Torque Chart – Straight Thread Face Seal O-Rings A-8
Torque Chart – Standard (Ferrous) A-9
Torque Chart – Metric (Ferrous) A-11
Torque Chart – Standard (Brass) A-12
Torque Chart – Metric (Brass) A-13
Decimal Equivalent Chart A-14
Standard/Metric Conversions A-16
Schematics A-17
Index I-1

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