Raymond Forklift WALKIE 101-F40L Maintenance Instruction Manual SN 101-93-03000 & Up – PDF DOWNLOAD

Description

Raymond Forklift WALKIE 101-F40L Maintenance Instruction Manual SN 101-93-03000 & Up – PDF DOWNLOAD

FILE DETAILS:

Raymond Forklift WALKIE 101-F40L Maintenance Instruction Manual SN 101-93-03000 & Up – PDF DOWNLOAD

Language : English
Pages : 110
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Raymond Forklift WALKIE 101-F40L Maintenance Instruction Manual SN 101-93-03000 & Up – PDF DOWNLOAD

PREFACE:

This manual includes information required for maintenance, troubleshooting, and repair of the Model 101-F40L The object is to insure safe maintenance and repair practices and procedures for this Raymond product.

MANUAL OVERVIEW:

• This manual consist of both the Maintenance section and the Parts Catalog (P/C) for the specific equipment listed on the cover.
• The Table of Contents provides easy location of all subject matter within the manual.
• The following symbols are used throughout this manual to represent a condition or hazard of which the operator should be aware.

TABLE OF CONTENTS:

Raymond Forklift WALKIE 101-F40L Maintenance Instruction Manual SN 101-93-03000 & Up – PDF DOWNLOAD

Manual Overview
General Maintenance Instructions
Maintenance Practices
Specifications
Hydraulic
Component Identification
Standard Torque Data For Bolts
Conversion Table
Decimal Equivalent Chart
Planned Maintenance (PM)
Inspection Form
PM Schedule and Procedure
Daily Inspection
Monthly PM Service (or 100 Hrs )
Semi Annual Service (or 500 Hrs )
Annual PM Service (or 1000 Hrs)
Lubrication Points
Fill Points
Scheduled Maintenance
Batteries
Battery Cleaning
Electrolyte Process
Battery Cleaning Procedure
WALKIE 101-F40L
Table Of Contents
Battery Electrical Leakage To Frame Test
Battery Charging
Charging Process
Hydrometer Use
Voltage Check
Adding Water To Battery
Guidelines
Battery History Record
Motors
Motor Cleaning
Brush Care
Maintenance Schedule
Motor Maintenance Inspection Chart
Brush Replacement
Motor Overheating
Motor Test for Open Circuit
Motor Open Circuit Test Procedure
Short Circuit Test – Motors
Short Circuit Test
Armature Shorts
Motor Grounds Test
Grounds – General
PDMM-0030
l a 9§
2
3
3
4
4
5
8
9
10
11
11
11
11
12
12
12
13
14
17
17
17
17
17
18
18
18
’19
19
20
20
20
21
21
22
22
22
24
25
26
26
27
27
27
28
28
Subiect
Hydraulic •• •
Oil Selection •
Changing Reservoir Fluid
Power Section • • • •
Special Tools • • • • •
Flush Grease Fitting Adaptor
Battery-Pak Lifter •
Bearing Installation Tool
Control Handle • •
Removal and Installation
Head Unit Removal
Control Handle Removal
Travel Control Switches
Horn, Lift/Lower Switches
Load Wheel
Repair and Replacement
WALKIE 101-F40L
Table Of Contents
Pull Rod Bushings Removal and Replacement
Carrier Frame Linkage and Bushings
Drive Wheel
Removal
Installation
Drive Unit
Removal
Installation
Drive Unit Pivot Bearing Adjustment
Axle Seal Removal
Installation •
Drive Unit Assembly
Drive Unit Disassembly
Drive Unit Assembly
Drive Motor
Removal
Drive Motor Brush Replacement
Drive Motor Disassembly
Drive Motor •
Installation • • •
Battery Replacement
Battery Wiring Hookup
Brake • ••
Brake Adjustment
Brake Interlock Switch
Linkage Removal
Installation
Brake Shoe Removal and Installation
PDMM-0030 ii
J!ggt
29
29
29
30
30
30
30
30
31
31
31
31
32
32
33
33
34
34
35
35
36
37
37
38
38
39
39
40
41
42
43
43
43
43
44
44
46
47
48
48
49
49
49
50
WALKIE 101-F40L
Table Of Contents
Subiect
Lift/Lower
Description
Theory of Operation
Lift
Electrical
Control Circuits
Power Wiring
Lower
Hydraulic and Electrical
Equipment Recommended for Normal Servicing
Pump and Motor
Removal and Installation
Pump Motor Brush Removal
Relief Valve
Removing Solenoid Operated Release Valve
Installing Solenoid Operated Release Valve
Removing Pump and Motor Assembly
Removing Reservoir
Removing the Pump
Installing the Pump
Installing the Reservoir
Check Valve
Cylinder Assembly Removal Installation
Cylinder Removal
Hydraulic Cylinder
Cylinder Disassembly
Inspection
Cylinder Assembly
Cylinder Installation
Lift Limit Switch
Troubleshooting
No Lift
Forks do not lower
Forks will not hold load
PDMM-0030 Ill
eq
51
51
51
51
52
52
52
53
53
54
55
55
55
57
57
57
57
57
57
58
58
58
58
58
59
59
59
60
61
61
62
62
64
64
WALKIE 101-F40L
Table Of Contents
Subiect
Traction System
Outline
Preparing to Travel
First Speed Forward
Control Circuit
Power Circuit
Second Speed Forward
Control Circuit
Power Circuit
Third Speed Forward First Speed Reverse
Contactor Tip/Bar Replacement
Troubleshooting
Truck is dead – nothing operates
No travel – horn and lift/lower operates OK
No forward travel – forward contactor does not energize
No forward travel – forward contactor closed
No reverse travel – reverse contactor does not energize, forward travel operates
No reverse travel – reverse contactor closed
No second speed, forward and reverse travel operates correctly
No third speed – forward, reverse travel and second speed operate correctly
No Emergency Reverse
Troubleshooting
Wiring Inspection Procedure
Battery Charger
Electrical Testing
Equipment Required
Instructions
Acceptable Charge Values
Open Circuit Voltage Test
Short Circuit Amperage Test
Diodes
Capacitor
Timer
Overcharging Problems
Charger and Battery not Properly Matched
Defective Battery or Poor DC Connection
Battery Charts
Appendix
Hydraulic Schematic
Electrical Scematic
Alphabetical Index

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