Raymond Forklift 9600 9700 Swing-Reach® Lift Truck Maintenance Manual 1089040 – PDF DOWNLOAD

Description

Raymond Forklift 9600 9700 Swing-Reach® Lift Truck Maintenance Manual 1089040 – PDF DOWNLOAD

FILE DETAILS:

Raymond Forklift 9600 9700 Swing-Reach® Lift Truck Maintenance Manual 1089040 – PDF DOWNLOAD

Language : English
Pages :471
Downloadable : Yes
File Type : PDF
Size:12.0 MB

DESCRIPTION:

Raymond Forklift 9600 9700 Swing-Reach® Lift Truck Maintenance Manual 1089040 – PDF DOWNLOAD

Serial Numbers
9600 960-09-00001 and Up
9700 970-09-00001 and Up

Manual Design

• 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.

This manual consists of the following sections:

TABLE OF CONTENTS:

Raymond Forklift 9600 9700 Swing-Reach® Lift Truck Maintenance Manual 1089040 – PDF DOWNLOAD

Document Revision History v
Service Information List vi
How to Use This Manual 1-1
Manual Design 1-2
Interactive Electronic Technical Manuals 1-3
Abbreviations, Acronyms, and Symbols 1-4
Safety 2-1
Definitions 2-2
General Safety 2-3
Battery Safety 2-5
Static Precautions 2-8
Jacking Safety 2-9
Blocking and Lifting Safety 2-10
Welding Safety 2-11
Systems Overview 3-1
Introduction 3-2
Lift Truck Specifications 3-3
General Information 3-4
Truck Installation 3-5
FlashWare 3-6
Operator Displays 3-8
Modes of Operation 3-10
Scheduled Maintenance 4-1
Scheduled Maintenance Guidelines 4-2
Maintenance Minder ™ Tool 4-3
Initial 90 Day/250 Deadman Hour (HD) Maintenance 4-5
Every 180 days or 500 Deadman Hours (HD) 4-6
Every 360 Days or 2000 HD 4-10
Lubrication Points 4-11
Chain Maintenance 4-14
Fork Inspection 4-15
Troubleshooting 5-1
Electrical Troubleshooting 5-2
Troubleshooting Communication Error Codes (5x Series) 5-21
Wire Guidance Troubleshooting 5-23
Troubleshooting Steering Fault Codes (G Series) 5-25
Hydraulic Troubleshooting Guidelines 5-26
Symptom Tables: Hydraulic System 5-27
Symptom Tables: Travel Problems 5-34
Symptom Tables: Electrical Problems 5-36
Messages, Codes, and Tests 6-1
Messages and Codes Summary List 6-2
Messages and Codes 6-5
Electrical Test Summary List 6-35
Analog Tests 6-39
Input Tests 6-77
Output Tests 6-127
Table of Contents Model 9600/9700 Swing-Reach® Lift Truck
ii Publication: 1089040, Issued: 08 Apr 2016
Component Procedures 7-1
List of Component Procedures 7-2
Component Locator Photos 7-3
Special Tools, Decals, and Chassis 7-11
Special Tools 7-12
Lift/Lower Pendant 7-13
Decals and Plates 7-14
Steering and Controls 7-19
Steer Motor 7-20
Control Handle Assembly 7-22
EPO Switch 7-29
Drive and Brake 7-31
Drive Unit 7-32
Drive Tire Pressing 7-35
Brake 7-36
Electrical Components 7-39
Battery Procedures 7-40
Wiring and Harness Connectors 7-42
Power Cables 7-50
Motors 7-52
Guidance Manager Firmware Replacement 7-56
Mini-Mast Height Proximity Sensor 7-58
Rotate Position Feedback Pot (VR6) 7-63
Traverse Position Feedback Pot (VR5) 7-64
Slack Chain Switch Adjustment 7-65
Cold Storage Conditioning 7-66
Hydraulic Components 7-67
Lift/Lower Pump 7-68
Manifolds 7-70
Bleeding the Hydraulic System 7-74
Lift Pressure Adjustment 7-76
Load Handler Pressure Adjustment 7-77
Traverse Pressure Adjustment 7-78
Main Lift Cylinders (9700) 7-79
Main Lift Cylinders (9600) 7-81
Main Lift Cylinder Shimming 7-83
Flow Limiters 7-84
Mast, Chain, Hose, Cable 7-87
Main Mast 7-88
Main Lift Chains (9600) 7-92
Main Lift Chains (9700) 7-94
Main Mast Lateral Bearing Adjustment (9600) 7-96
Main Mast Lateral Bearing Adjustment (9700) 7-97
Carriage 7-98
Telescopic Removal and Mast Puck/Bearing Replacement (9600) 7-100
Telescopic Removal and Mast Bearing Replacement (9700) 7-101
Height Encoder Belt Replacement 7-102
Mini-Mast and Load Handler 7-103
Load Handler 7-106
Traverse Gear Shaft 7-109
Load Handler Lift Chain 7-111
Mini-Mast Pucks 7-112
Model 9600/9700 Swing-Reach® Lift Truck Table of Contents
Publication: 1089040, Issued: 08 Apr 2016 iii
Fork Height and Lift Chain Adjustment 7-114
Theory of Operation 8-1
System Architecture 8-2
Functional Operation 8-6
Hydraulic Components 8-12
Pinout Matrix 8-15
Appendix A-1
Lubrication Specification Chart A-2
Adhesives and Sealants A-3
Component Specific Service/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 Chart A-13
Standard/Metric Conversions A-15
Index I-1
Schematics

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