Raymond Forklift Walkie Counterbalanced RCS20 30 40 RSS22 30 40 RRS30 Maintenance Manual – PDF DOWNLOAD

Description

Raymond Forklift Walkie Counterbalanced RCS20 30 40 RSS22 30 40 RRS30 Maintenance Manual – PDF DOWNLOAD

FILE DETAILS:

Raymond Forklift Walkie Counterbalanced RCS20 30 40 RSS22 30 40 RRS30 Maintenance Manual – PDF DOWNLOAD

Language : English
Pages :466
Downloadable : Yes
File Type : PDF
Size:33.6 MB

DESCRIPTION:

Raymond Forklift Walkie Counterbalanced RCS20 30 40 RSS22 30 40 RRS30 Maintenance Manual – PDF DOWNLOAD

User 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 running page header at the top of each page contains the name of the manual, the title of the current section, and the topic of the current page.

This manual includes the following sections:

TABLE OF CONTENTS:

Raymond Forklift Walkie Counterbalanced RCS20 30 40 RSS22 30 40 RRS30 Maintenance Manual – PDF DOWNLOAD

Ordering Spare Parts 1
Standard Codes 3
Warning Symbols 15
Warning Levels 15
Prohibitory Symbols 16
Ordinance Symbols 16
Safety 17
General Safety 17
Battery Safety 21
Static Discharge Precautions 26
Welding Safety 28
Introduction, Service Manual 31
Contents, Section M 33
Machine Information 33
General Product Information 35
Presentation of Walkie Trucks 35
Truck Side Views 36
Intended Truck Application 36
Prohibited Truck Application 36
Truck Data 37
RCS20 Dimensions 38
RCS30 Dimensions 39
RCS40 Dimensions 40
RSS22 Dimensions 41
RSS30 Dimensions 42
RSS40 Dimensions 43
RRS30 Dimensions 44
Data Plate 45
Main Components 46
Inch (SAE) and Metric Fasteners 49
Introduction 49
Nomenclature, Threads 50
Strength Identification 51
Truck Torque Specifications 57
Conversion of Metric and English Units 58
Technical Service Data 61
Publication: #1010298-2, Issued: 22 Dec 2006 5
6
RCS
Table of Contents
Contents, Section P 65
Planned Maintenance 65
Introduction, Maintenance 67
Jacking Truck Off The Floor 68
Elevate Rear of Truck 68
Elevate Either Side of Truck 68
Lubricants 69
Standard Conditioning 69
Corrosion Conditioning 69
Cold Storage Conditioning 70
Service Schedule 71
Planned Maintenance Schedule 71
Planned Maintenance Procedures 75
Services Performed Daily or Every 8 Operating Hours 75
Services Performed Weekly or Every 30 Operating Hours 76
Services Performed Monthly or Every 120 Operating Hours 77
Services Performed Quarterly or Every 360 Operating Hours 78
Services Performed Semi-Annually or Every 720 Operating Hours 79
Services Performed Annually or Every 1440 Operating Hours 81
Lubrication Chart 83
Oil and Grease Specifications 84
Approved Oils and Grease 84
RCS Grease & Mast Adjustment Points Location 85
RSS Grease & Mast Adjustment Points Location 86
RRS Grease & Mast Adjustment Points Location 87
Contents, Section S 89
Service Instructions 89
Frame/Chassis 91
Theory of Operation 91
Maintenance 91
Troubleshooting 91
Repair and Rebuild 92
Inspection Covers 95
Theory of Operation 95
Maintenance 95
Troubleshooting 95
Repair and Rebuild 96
Battery Compartment 103
Theory of Operation 103
Maintenance 103
Troubleshooting 103
Publication: #1010298-2, Issued: 22 Dec 2006
RCS
Table of Contents
Repair and Rebuild 104
Operator Controls 109
Theory of Operation 109
Maintenance 109
Troubleshooting 109
Repair and Rebuild 11 O
Control Handle, One Spool Valve 115
Control Handle, Two Spool Valve 116
Control Handle 118
Decals 121
Decal with Protective Sheet 121
Decal without Protective Sheet 121
Electric Motors 123
Theory of Operation 123
Maintenance 123
Troubleshooting 124
Repair and Rebuild 125
Pump Motor 125
Drive Motor 131
Brush Replacement 133
Transmission 135
Theory of Operation 135
Maintenance 135
Fluid Changing 135
Troubleshooting 136
Repair and Rebuild 137
Transmission Disassembly 140
Axle Seal 145
Parking Brake System 14 7
Theory of Operation 14 7
Maintenance 14 7
Brake Adjustment 147
Troubleshooting 148
Repair and Rebuild 149
Brake Shoe 151
Drive Wheel 153
Theory of Operation 153
Maintenance 153
Troubleshooting 153
Repair and Rebuild 154
Support/Swivel Wheel 157
Theory of Operation 157
Publication: #1010298-2, Issued: 22 Dec 2006 7
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RCS
Table of Contents
Maintenance 157
Caster Adjustment 157
Troubleshooting 158
Repair and Rebuild 159
Load Wheels 163
Theory of Operation 163
Maintenance 163
Troubleshooting 163
Repair and Rebuild 164
Caster Assembly 169
Theory of Operation 169
Maintenance 169
Inspection 169
Troubleshooting 170
Repair and Rebuild 170
Steering Arm/Wheel, Tiller Arm 173
Theory of Operation 173
Maintenance 173
Inspection 173
Troubleshooting 173
Repair and Rebuild 17 4
Steering Arm/Wheel, Head 177
Theory of Operation 177
Maintenance 177
Troubleshooting 177
Repair and Rebuild 178
Steering Bearing 181
Theory of Operation 181
Maintenance 181
Troubleshooting 181
Repair and Rebuild 182
Electrical Functions 185
Theory of Operation 185
Key Switch S 17 in ON Position 185
Operating Arm in Drive Position, S10, Brake Switch Closed 185
Travel Request, Forks-first 185
Travel Request, Tractor-first 186
Reversing/Motor Brake Forks-first to Tractor-first Direction 186
Reversing/Motor Brake Tractor-first to Forks-first Direction 186
Reverser switch 186
Lifting Forks 187
Lowering Forks 187
Horn 187
Publication: #1010298-2, Issued: 22 Dec 2006
RCS
Table of Contents
Lifting Forks, Manual Valve 187
Tilting Forks (RCS/RRS) 187
Side Shifting Forks (Optional) 187
Extend/Retract Forks (RRS30) 188
Electrical Schematic 1 (5) 189
Electrical Schematic 2(5) 190
Electrical Schematic 3(5) 191
Electrical Schematic 4(5) 192
Electrical Schematic 5(5) 193
Maintenance 198
Wiring 198
Troubleshooting 204
Troubleshooting Chart Index 205
Troubleshooting Charts 206
Battery 225
Theory of Operation 225
Maintenance 225
Inspection and Care 225
Battery Exterior Cleaning 226
Charging 226
Storage 227
Battery History Record 228
Troubleshooting 228
Repair and Rebuild 229
Battery Connector 231
Theory of Operation 231
Maintenance 231
Inspection 231
Troubleshooting 231
Repair and Rebuild 232
Horn 233
Theory of Operation 233
Maintenance 233
Troubleshooting 233
Repair and Rebuild 234
Line Contactor 237
Theory of Operation 237
Maintenance 237
Troubleshooting 237
Repair and Rebuild 238
Removal/Replacement of Contact Tips 239
Hourmeter, BDI/Hourmeter, BDI/Hourmeter/Lift Interrupt 241
Theory of Operation 241
Hourmeter 241
Publication: #1010298-2, Issued: 22 Dec 2006 9
10
RCS
Table of Contents
BDI/Hourmeter 241
BDI/Hourmeter/Lift Interrupt 243
Maintenance 245
Discharge Adjustment (Meters with Lockout Interrupt) 245
Troubleshooting 24 7
Battery Discharge Indicator (BDI) 247
Hourmeter 249
Switches 251
Theory of Operation 251
Maintenance 251
General Inspection 251
Key Switch Inspection 251
Master Control On/Off Switch Inspection 251
Lift and Lower Switches 252
Brake Interlock Switch Adjustment 252
Troubleshooting 252
Repair and Rebuild 253
Key Switch 254
Master Control On/Off Switch 254
Lift and Lower Switches 255
Horn Switch 256
Brake Interlock Switch 257
Speed Controls 259
Theory of Operation 259
Maintenance 259
Potentiometer Adjustment 259
Troubleshooting 261
Repair and Rebuild 261
Potentiometer Assembly 265
Rearward and Forward Switches 267
Reverser Assembly Replacement 268
Transistor Controller 269
Theory of Operation 269
Basics of Circuit Operation 269
Control Features 271
Motor Circuit 272
Control Circuit 273
Maintenance 27 4
Safety 274
Cleaning 27 4
Transistor Adjustable Settings 275
Definitions 27 6
Troubleshooting 276
Diagnostics and Troubleshooting 276
Handset Diagnostics 277
Troubleshooting Chart 279
Publication: #1010298-2, Issued: 22 Dec 2006
RCS
Table of Contents
Troubleshooting Chart Using Handset 281
Repair and Rebuild 282
Hydraulic System 283
Theory of Operation 283
Lift (Solenoid valve) 283
Lift (Mechanical Valve) 283
Lower (Solenoid Valve) 283
Lower (Mechanical Valve) 283
Relief Pressure 283
Compensating Cylinder 284
Reach (Solenoid valve) 284
Tilt (Solenoid valve) 284
Sideshift (Solenoid valve) 284
Maintenance 289
Adjustments 289
Hydraulic Fluid Check 289
Changing Hydraulic System Fluid 289
System Draining 290
Refilling System 291
Bleeding Hydraulic System 291
Troubleshooting 293
Primary Malfunctions 294
Auxiliary Function 295
Repair and Rebuild 296
Reservoir 302
Pump and Motor Assembly 302
Hydraulic Pump Assembly 305
Spool Control Valves 309
Theory of Operation 309
Lift (Mechanical Valve) 309
Lower (Mechanical Valve) 309
Maintenance 309
Troubleshooting 309
Spool Valve Leaks 309
Mast Drifts 309
Repair and Rebuild 31 O
One Spool Control Valve 312
Two Spool Control Valve 314
Lift Cylinders, Two Stage Mast 317
Theory of Operation 317
Maintenance 317
Inspection 317
Troubleshooting 317
Repair and Rebuild 318
Limited Freelift (LFT) Cylinder, Two Stage Mast 322
Full Freelift (FFL) Cylinder, Two Stage Mast 324
Publication: #1010298-2, Issued: 22 Dec 2006 11
12
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Table of Contents
FFL Staging Cylinder, Two Stage Mast 325
Lift Cylinders, Three Stage Mast 327
Theory of Operation 327
Maintenance 327
Inspection 327
Troubleshooting 327
Repair and Rebuild 328
Three Stage Mast Staging Cylinders 328
Three Stage Mast Freelift Cylinder 331
Reach Cylinder, RRS30 335
Theory of Operation 335
Maintenance 335
Inspection 335
Troubleshooting 335
Repair and Rebuild 336
Tilt Cylinder 341
Theory of Operation 341
Maintenance 341
Inspection 341
Troubleshooting 342
Repair and Rebuild 342
Tilt Cylinder, RCS20/30/40 343
Tilt Cylinder, RRS30 348
Mast, Two Stage 353
Theory of Operation 353
Maintenance 353
Visual Inspection 353
Lift Chain Inspection 353
Lift Chain Lubrication 358
Lift Chain Adjustment 360
Lift Chain Replacement 360
Troubleshooting 360
Repair and Rebuild 360
Mast, Three Stage 369
Theory of Operation 369
Maintenance 369
Troubleshooting 369
Repair and Rebuild 369
Crosshead 377
Theory of Operation 377
Maintenance 377
Troubleshooting 377
Repair and Rebuild 378
Publication: #1010298-2, Issued: 22 Dec 2006
RCS
Table of Contents
Sideshifter 381
Theory of Operation 381
Maintenance 381
Periodic Maintenance 381
Inspection 382
Troubleshooting 384
No Sideshifting 384
Sideshifting Very Slow 384
Irregular Sideshifting 385
Repair and Rebuild 386
Sideshift Carriage 387
Upper Pad Replacement 388
Lower Pad Replacement 388
Cylinder 390
Single Reach, RRS30 391
Theory of Operation 391
Maintenance 391
Carriage Bumpers 392
Carriage Roller Bearings 392
Reach Adjustment 393
Troubleshooting 396
Repair and Rebuild 397
Reach 399
Forward Frame 399
Outer Arm 400
Inner Arm 401
Rear Frame 402
Reach Cylinder 403
Carriage Bearings 404
Forks 405
Theory of Operation 405
Maintenance 405
Inspection 405
Troubleshooting 406
Repair and Rebuild 406
Load Backrest 409
Theory of Operation 409
Maintenance 409
Troubleshooting 409
Repair and Rebuild 409
Warning Lights / Alarm (Optional) 411
Theory of Operation 411
Maintenance 411
Troubleshooting 411
Repair and Rebuild 411
Publication: #1010298-2, Issued: 22 Dec 2006 13
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RCS
Table of Contents
Warning Light 411
Travel Alarm 411
Electrical Heater (Optional) 413
Theory of Operation 413
Maintenance 413
Troubleshooting 413
Repair and Rebuild 413
Version One Handset 415
Theory of Operation 415
Version Two Handset 423
Theory of Operation 423
Publication: #

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