Raymond Forklift 4760 Maintenance Manual 1451076_001A

Description

Contents:
1. GENERAL

1.1 VEHICLE EXTERIOR VIEW​

1.2 LIFT TRUCK MODELS​

1.3 FRAME NUMBER​

1.4 HOW TO USE THIS MANUAL​

1.4.1 EXPLANATION METHOD​

1.4.2 TERMINOLOGY​

1.4.3 ABBREVIATIONS​

1.5 OPERATING TIPS​

1.5.1 JACK-UP POINT​

1.5.2 HOISTING THE VEHICLE​

1.6 CIRCUIT TESTER​

1.6.1 Digital vs. Analog Multimeter​

1.6.2 Meter Type Affect on Results​

1.6.3 How Range Can Affect the Measurement Result (Analog Type)​

1.7 STANDARD BOLT & NUT TIGHTENING TORQUE​

1.7.1 BOLT STRENGTH CLASS IDENTIFICATION METHOD​

1.8 PRECOATED BOLTS​

1.9 HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE​

1.10 COMPONENT WEIGHTS​

1.11 RECOMMENDED LUBRICANT QUANTITY & TYPES​

1.11.1 Hydraulic Oil Requirement by Lifting Height​

1.12 LUBRICATION CHART​

1.13 PERIODIC MAINTENANCE TABLE​

1.14 PERIODIC REPLACEMENT TABLE​

1.15 VEHICLE DELIVERY NOTES​

1.15.1 Hour Meter Start​2. BATTERY

2.1 BATTERY COMPARTMENT AND REQUIRED WEIGHT​

2.1.1 Battery Compartment Shape​

2.2 SERVICE STANDARDS​

2.3 BATTERY LIST​

2.4 DISPLAY​

2.5 TROUBLESHOOTING​

2.6 BATTERY ASSEMBLY​

2.6.1 REMOVAL AND INSTALLATION​

2.6.2 INSPECTION​

2.6.3 REPLACING BATTERY PLUG TERMINAL​

2.6.4 BATTERY STOPPER​

2.6.5 [OPT] Battery Slide-out / Roll-out Battery Compartment​3. MOTOR

3.1 DRIVE MOTOR​

3.1.1 GENERAL​

3.1.2 SPECIFICATIONS​

3.1.3 COMPONENTS​

3.1.4 REMOVAL·INSTALLATION​

3.1.5 DISASSEMBLY·INSPECTION·REASSEMBLY​

3.2 PUMP MOTOR​

3.2.1 GENERAL​

3.2.2 SPECIFICATIONS​

3.2.3 COMPONENTS​

3.2.4 REMOVAL·INSTALLATION​

3.2.5 DISASSEMBLY·INSPECTION·REASSEMBLY​4. DRIVE UNIT

4.1 DRIVE MOTOR​

4.2 SPECIFICATIONS​

4.3 COMPONENTS​

4.4 DRIVE UNIT ASSY​

4.4.1 REMOVAL · INSTALLATION​

4.4.2 DISASSEMBLY · INSPECTION · REASSEMBLY​

4.5 DIFFERENTIAL CASE ASSY​

4.5.1 DISASSEMBLY · INSPECTION · REASSEMBLY​5. FRONT AXLE

5.1 GENERAL​

5.2 SPECIFICATIONS​

5.3 COMPONENTS​

5.4 FRONT AXLE SHAFT • AXLE HUB​

5.4.1 REMOVAL • INSTALLATION​

5.5 FRONT AXLE BRACKET • AXLE HOUSING​

5.5.1 REMOVAL • INSTALLATION​6. REAR AXLE

6.1 GENERAL​

6.2 SPECIFICATIONS​

6.3 COMPONENTS​

6.4 REAR AXLE ASSY​

6.4.1 REMOVAL AND INSTALLATION​

6.5 STEERING KNUCKLE​

6.5.1 REMOVAL AND INSTALLATION​

6.6 STANDARD REAR AXLE CYLINDER​

6.6.1 REMOVAL AND INSTALLATION​

6.6.2 DISASSEMBLY, INSPECTION, AND REASSEMBLY​

6.7 ELECTRONIC POWER STEERING ACTUATOR​

6.7.1 REMOVAL AND INSTALLATION​7. STEERING

7.1 GENERAL​

7.2 SPECIFICATIONS​

7.3 COMPONENTS​

7.4 STEERING WHEEL AND MAST JACKET​

7.4.1 REMOVAL AND INSTALLATION​

7.4.2 DISASSEMBLY, INSPECTION AND REASSEMBLY​

7.5 HYDROSTATIC STEERING VALVE ASSY​

7.5.1 TROUBLESHOOTING​

7.5.2 REMOVAL AND INSTALLATION​

7.5.3 DISASSEMBLY, INSPECTION AND REASSEMBLY​

7.6 RELIEF PRESSURE INSPECTION AND ADJUSTMENT​8. BRAKES

8.1 GENERAL​

8.2 SPECIFICATIONS​

8.3 COMPONENTS​

8.4 DRUM BRAKE​

8.4.1 DISASSEMBLY, INSPECTION AND REASSEMBLY​

8.5 BRAKE AIR BLEEDING​

8.6 BRAKING FORCE INSPECTION AND ADJUSTMENT​

8.7 BRAKE MASTER CYLINDER​

8.7.1 REMOVAL AND INSTALLATION​

8.8 ELECTROMAGNETIC BRAKE​

8.8.1 DISASSEMBLY, INSPECTION, AND REASSEMBLY​

8.9 ELECTROMAGNETIC BRAKE INSPECTION AND ADJUSTMENT​

8.10 BRAKE PEDAL ADJUSTMENT​

8.11 URGENT ELECTROMAGNETIC BRAKE RELEASE​

8.11.1 USING ANALYZER FUNCTION IN THE DISPLAY​9. BODY & FRAME

9.1 COMPONENTS​

9.2 BATTERY HOOD ASSY​

9.2.1 REMOVAL AND INSTALLATION​

9.3 COUNTERWEIGHT​

9.3.1 REMOVAL AND INSTALLATION​

9.4 OPERATOR’S SEAT​

9.4.1 REMOVAL AND INSTALLATION​

9.5 SEAT BELT​

9.5.1 REMOVAL AND INSTALLATION​

9.6 FUSE REPLACEMENT​10. MATERIAL HANDLING SYSTEM

10.1 HYDRAULIC CIRCUIT​

10.2 COMPONENTS​

10.3 COMPONENT REMOVAL • INSTALLATION​

10.3.1 RETURN FILTER​

10.3.2 SUCTION FILTER​

10.4 NATURAL DROP TEST​

10.5 NATURAL FORWARD TEST​

10.6 OIL LEAK TEST​

10.6.1 LIFT CYLINDER​

10.6.2 TILT CYLINDER​11. MAST

11.1 TNMAST ASSY​

11.1.1 COMPONENTS​

11.1.2 TN REMOVAL AND INSTALLATION (W/OUT LIFT BRACKET)​

11.1.3 TN REMOVAL AND INSTALLATION (W/LIFT BRACKET)​

11.1.4 TN MAST ASSY, DISASSEMBLY, INSPECTION, AND REASSEMBLY​

11.1.5 TN LIFT BRACKET DISASSEMBLY, INSPECTION, AND REASSEMBLY​

11.1.6 TN MAST – ADJUSTMENT​

11.1.7 MAST ROLLER REMOVAL AND INSTALLATION​

11.2 TF, TT, QM MAST ASSY​

11.2.1 COMPONENTS​

11.2.2 MAST ADJUSTMENT (TF, TT, QM)​

11.3 CHAIN​

11.3.1 INSPECTION​

11.3.2 REASSEMBLY​

11.3.3 ADJUSTMENT​

11.4 FORK​

11.4.1 REMOVAL​

11.4.2 INSTALLATION​

11.4.3 INSPECTION​

11.5 LOAD BACKREST INSPECTION​

11.6 LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN LIFTING)​12. CYLINDER

12.1 LIFT CYLINDER (TN), REAR LIFT CYLINDER (TF • TT • QM)​

12.1.1 GENERAL​

12.1.2 SPECIFICATIONS​

12.1.3 COMPONENTS​

12.1.4 REMOVAL AND INSTALLATION​

12.1.5 DISASSEMBLY, INSPECTION AND REASSEMBLY​

12.2 SAFETY DOWN VALVE​

12.2.1 REMOVAL AND INSTALLATION​

12.3 FRONT LIFT CYLINDER (TF, TT-OV, QM)​

12.3.1 GENERAL​

12.3.2 SPECIFICATIONS​

12.3.3 COMPONENTS​

12.3.4 REMOVAL AND INSTALLATION​

12.3.5 DISASSEMBLY, INSPECTION AND REASSEMBLY​

12.4 TILT CYLINDER​

12.4.1 GENERAL​

12.4.2 SPECIFICATION​

12.4.3 COMPONENTS​

12.4.4 REMOVAL AND INSTALLATION​

12.4.5 DISASSEMBLY, INSPECTION AND REASSEMBLY​

12.5 MAST FORWARD BACKWARD TILT ANGLE ADJUSTMENT​13. OIL PUMP

13.1 GENERAL​

13.2 COMPONENTS​

13.3 REMOVAL AND INSTALLATION​

13.4 DISASSEMBLY, INSPECTION AND REASSEMBLY​

13.5 TEST METHOD​14. OIL CONTROL VALVE

14.1 OIL CONTROL VALVE (Mechanically Controlled Valve)​

14.1.1 GENERAL​

14.1.2 SPECIFICATIONS​

14.1.3 REMOVAL AND INSTALLATION​

14.1.4 DISASSEMBLY, INSPECTION AND REASSEMBLY​

14.2 OIL CONTROL VALVE (Solenoid Controlled Valve)​

14.2.1 GENERAL​

14.2.2 SPECIFICATIONS​

14.2.3 REMOVAL AND INSTALLATION​

14.2.4 DISASSEMBLY, INSPECTION, AND REASSEMBLY​

14.2.5 I-Q PLATE​

14.3 CONTROL VALVE LEVER ASSY​

14.3.1 REMOVAL AND INSTALLATION​

14.4 RELIEF PRESSURE ADJUSTMENT​

14.5 MANUAL DOWN VALVE​

14.6 TROUBLESHOOTING​15. PERFORMANCE STABILITY SYSTEM (PSS)

15.1 GENERAL (PSS)​

15.1.1 System configuration​

15.1.2 Name and Feature of Each Component​

15.2 COMPONENTS​

15.2.1 LIFTING HEIGHT SWITCH (TN)​

15.2.2 LIFTING HEIGHT SWITCH (TF)​

15.2.3 LIFTING HEIGHT SWITCH (TT)​

15.2.4 LIFTING HEIGHT SWITCH (QM)​

15.2.5 PRESSURE SENSOR​

15.2.6 TILT ANGLE SENSOR​

15.2.7 YAW RATE SENSOR​

15.2.8 SWING LOCK CYLINDER​

15.2.9 SPEED SENSOR​

15.3 FOR REPAIR WORK​

15.4 YAW RATE SENSOR​

15.5 Swing Lock Cylinder​

15.6 TILT ANGLE SENSOR​

15.7 LOAD SENSOR​

15.8 SPEED SENSOR​

15.9 MAST LIFTING HEIGHT SWITCH​

15.10 TIRE ANGLE SENSOR​

15.11 TIRE ANGLE SENSOR​

15.12 MATCHING​

15.12.1 STANDARD STATE OF VEHICLE​

15.12.2 AVAILABILITY OF MAST CONTROL IN REFERENCE TO ATTACHMENT WEIGHT​

15.12.3 CAUTIONS ON MODIFYING VEHICLES​

15.13 GENERAL (OPS)​

15.13.1 System Configuration​

15.13.2 Name and Feature of Each Component​

15.14 CONTROL SPECIFICATION​

15.15 RENEWAL OF PSS CAUTION LABEL​16. FINGERTIP CONTROLS

16.1 GENERAL​

16.2 COMPONENTS​

16.3 REMOVAL·INSTALLATION​

16.4 DISASSEMBLY·INSPECTION AND REASSEMBLY​17. CONTROL SYSTEM

17.1 GENERAL​

17.1.1 Controller System Configuration​

17.2 ELECTRICAL COMPONENTS​

17.3 LAYOUT OF CONTROLLER CABLES​

17.4 SPECIFICATIONS​

17.5 BEFORE INSPECTION​

17.6 CONNECTOR INSPECTION​

17.6.1 TO USE SST​

17.6.2 Main Controller​

17.6.3 Motor Controllers​

17.6.4 EPS Controller (Electric Power Steering / Auto Park Brake)​

17.6.5 Contactor Panel Assembly​

17.6.6 Color Multi-Function Display​

17.7 SERVICING THE CONTROL PANEL​

17.7.1 Disassembly Procedure​

17.7.2 Caution for Part Replacement​

17.8 Main Controller Removal and Installation​

17.8.1 Removal and Installation​

17.9 Drive Motor and Pump Motor Controllers​

17.10 STEER-BY-WIRE (SxW) CONTROLLER​

17.10.1 Removal and Installation​

17.11 SERVICING THE CONTACTOR PANEL​

17.11.1 Contactor Panel Removal and Installation​

17.12 COMBINATION SWITCH​

17.12.1 REMOVAL AND INSTALLATION​

17.12.2 DISASSEMBLY, INSPECTION AND REASSEMBLY​

17.13 ACCELERATOR SENSOR (POTENTIOMETER)​18. COLOR DISPLAY

18.1 GENERAL​

18.2 GENERAL FUNCTIONS​

18.2.1 General Function List​

18.2.2 Initial screen after key-on​

18.2.3 ADMINISTRATOR FUNCTIONS​

18.2.4 Password Entry Procedure​

18.3 SERVICE FUNCTIONS​

18.3.1 GENERAL​

18.3.2 THE SERVICE MENU SCREEN PREPARATION​

18.3.3 SERVICE PASSWORD​

18.3.4 SERVICE MENU SCREEN​

18.3.5 ANALYZER​

18.3.6 ANALYZER MENU screen​

18.3.7 IN/OUT MONITOR FUNCTION (I/O MONITOR)​

18.3.8 PROGRAM VERSION (VERSION)​

18.4 TUNING​

18.4.1 Tuning Item List​

18.4.2 ONLY WITH ELECTRIC POWER STEERING SPECIFICATION​

18.4.3 TUNING MENU SCREEN​

18.4.4 GENERAL (TUNING GENERAL)​

18.4.5 LIFT LEVER (TUNING LIFT LEVER)​

18.4.6 TILT LEVER (TUNING TILT LEVER)​

18.4.7 ATT1 LEVER (TUNING ATT1 LEVER)​

18.4.8 ATT2 LEVER (TUNING ATT2 LEVER)​

18.4.9 TUN EPS (TUNING EPS)​

18.5 OPTION SET​

18.6 MATCHING​

18.6.1 MATCHING MENU SCREEN​

18.6.2 DRIVE (MATCHING DRIVE)​

18.6.3 PSS (MATCHING PSS)​

18.6.4 LEVER (MATCHING LEVER)​

18.6.5 LOAD METER​

18.6.6 TIRE DATA​

18.6.7 MAT EPS​

18.7 etc. MENU​

18.7.1 HOUR METER START “METER START”​

18.7.2 DEMO MODE “DEMO MODE”​

18.7.3 DEFAULT SET “TO DEFAULT SET”​

18.7.4 ECU INFO CLEAR “TO DEFAULT SET”​

18.7.5 Secondary Service Password “MASK PASSWORD”​

18.7.6 SECONDARY MANAGER PASSWORD DELETION “MANAGER PASS CLR”​

18.7.7 RENTAL HOUR METER (RENT TIME)​

18.7.8 Light Sensitivity Detection (LIGHT DETECT)​

18.8 COLOR MULTI-FUNCTION DISPLAY ASSY​

18.8.1 REMOVAL AND INSTALLATION​19. TROUBLESHOOTING

19.1 BEFORE TROUBLESHOOTING​

19.1.1 CONNECTOR HANDLING​

19.1.2 WIRE HARNESS AND CONNECTOR INSPECTION PROCEDURE​

19.2 ALL TRUCK INSPECTION​

19.3 USING SPECIAL SERVICE TOOLS (SSTs)​

19.4 DIAGNOSTIC CODE LIST​

19.5 WHEN A DIAGNOSTIC CODE IS DISPLAYED​

19.1 WHEN NO DIAGNOSTIC CODE IS DISPLAYED​i. APPENDIX