Raymond Walkie Stacker RCS20 to RRS30 Maintenance Manual 1010298-2 2006

Description

Contents:
Ordering Spare Parts
Standard Codes
Warning Symbols
Warning Levels
Prohibitory Symbols
Ordinance Symbols
Safety
General Safety
Battery Safety
Static Discharge Precautions
Welding Safety
Introduction, Service Manual
Contents, Section M
Machine Information
General Product Information
Presentation of Walkie Trucks
Truck Side Views
Intended Truck Application
Prohibited Truck Application
Truck Data
RCS20 Dimensions
RCS30 Dimensions
RCS40 Dimensions
RSS22 Dimensions
RSS30 Dimensions
RSS40 Dimensions
RRS30 Dimensions
Data Plate
Main Components
Inch (SAE) and Metric Fasteners
Introduction
Nomenclature, Threads
Strength Identification
Truck Torque Specifications
Conversion of Metric and English Units
Technical Service Data
Contents, Section P
Planned Maintenance
Introduction, Maintenance
Jacking Truck Off The Floor
Elevate Rear of Truck
Elevate Either Side of Truck
Lubricants
Standard Conditioning
Corrosion Conditioning
Cold Storage Conditioning
Service Schedule
Planned Maintenance Schedule
Planned Maintenance Procedures
Services Performed Daily or Every 8 Operating Hours
Services Performed Weekly or Every 30 Operating Hours
Services Performed Monthly or Every 120 Operating Hours
Services Performed Quarterly or Every 360 Operating Hours
Services Performed Semi-Annually or Every 720 Operating Hours
Services Performed Annually or Every 1440 Operating Hours
Lubrication Chart
Oil and Grease Specifications
Approved Oils and Grease
RCS Grease & Mast Adjustment Points Location
RSS Grease & Mast Adjustment Points Location
RRS Grease & Mast Adjustment Points Location
Contents, Section S
Service Instructions
Frame/Chassis
Theory of Operation
Maintenance
Troubleshooting
Repair and Rebuild
Inspection Covers
Theory of Operation
Maintenance
Troubleshooting
Repair and Rebuild
Battery Compartment
Theory of Operation
Maintenance
Troubleshooting
Repair and Rebuild
Operator Controls
Theory of Operation
Maintenance
Troubleshooting
Repair and Rebuild
Control Handle, One Spool Valve
Control Handle, Two Spool Valve
Control Handle
Decals
Decal with Protective Sheet
Decal without Protective Sheet
Electric Motors
Theory of Operation
Maintenance
Troubleshooting
Repair and Rebuild
Pump Motor
Drive Motor
Brush Replacement
Transmission
Theory of Operation
Maintenance
Fluid Changing
Troubleshooting
Repair and Rebuild
Transmission Disassembly
Axle Seal
Parking Brake System
Theory of Operation
Maintenance
Brake Adjustment
Troubleshooting
Repair and Rebuild
Brake Shoe
Drive Wheel
Theory of Operation
Maintenance
Troubleshooting
Repair and Rebuild
Support/Swivel Wheel
Theory of Operation
Maintenance
Caster Adjustment
Troubleshooting
Repair and Rebuild
Load Wheels
Theory of Operation
Maintenance
Troubleshooting
Repair and Rebuild
Caster Assembly
Theory of Operation
Maintenance
Inspection
Troubleshooting
Repair and Rebuild
Steering Arm/Wheel, Tiller Arm
Theory of Operation
Maintenance
Inspection
Troubleshooting
Repair and Rebuild
Steering Arm/Wheel, Head
Theory of Operation
Maintenance
Troubleshooting
Repair and Rebuild
Steering Bearing
Theory of Operation
Maintenance
Troubleshooting
Repair and Rebuild
Electrical Functions
Theory of Operation
Key Switch S17 in ON Position
Operating Arm in Drive Position, S10, Brake Switch Closed
Travel Request, Forks-first
Travel Request, Tractor-first
Reversing/Motor Brake Forks-first to Tractor-first Direction
Reversing/Motor Brake Tractor-first to Forks-first Direction
Reverser switch
Lifting Forks
Lowering Forks
Horn
Lifting Forks, Manual Valve
Tilting Forks (RCS/RRS)
Side Shifting Forks (Optional)
Extend/Retract Forks (RRS30)
Electrical Schematic 1(5)
Electrical Schematic 2(5)
Electrical Schematic 3(5)
Electrical Schematic 4(5)
Electrical Schematic 5(5)
Maintenance
Wiring
Troubleshooting
Troubleshooting Chart Index
Troubleshooting Charts
Battery
Theory of Operation
Maintenance
Inspection and Care
Battery Exterior Cleaning
Charging
Storage
Battery History Record
Troubleshooting
Repair and Rebuild
Battery Connector
Theory of Operation
Maintenance
Inspection
Troubleshooting
Repair and Rebuild
Horn
Theory of Operation
Maintenance
Troubleshooting
Repair and Rebuild
Line Contactor
Theory of Operation
Maintenance
Troubleshooting
Repair and Rebuild
Removal/Replacement of Contact Tips
Hourmeter, BDI/Hourmeter, BDI/Hourmeter/Lift Interrupt
Theory of Operation
Hourmeter
BDI/Hourmeter
BDI/Hourmeter/Lift Interrupt
Maintenance
Discharge Adjustment (Meters with Lockout Interrupt)
Troubleshooting
Battery Discharge Indicator (BDI)
Hourmeter
Switches
Theory of Operation
Maintenance
General Inspection
Key Switch Inspection
Master Control On/Off Switch Inspection
Lift and Lower Switches
Brake Interlock Switch Adjustment
Troubleshooting
Repair and Rebuild
Key Switch
Master Control On/Off Switch
Lift and Lower Switches
Horn Switch
Brake Interlock Switch
Speed Controls
Theory of Operation
Maintenance
Potentiometer Adjustment
Troubleshooting
Repair and Rebuild
Potentiometer Assembly
Rearward and Forward Switches
Reverser Assembly Replacement
Transistor Controller
Theory of Operation
Basics of Circuit Operation
Control Features
Motor Circuit
Control Circuit
Maintenance
Safety
Cleaning
Transistor Adjustable Settings
Definitions
Troubleshooting
Diagnostics and Troubleshooting
Handset Diagnostics
Troubleshooting Chart
Troubleshooting Chart Using Handset
Repair and Rebuild
Hydraulic System
Theory of Operation
Lift (Solenoid valve)
Lift (Mechanical Valve)
Lower (Solenoid Valve)
Lower (Mechanical Valve)
Relief Pressure
Compensating Cylinder
Reach (Solenoid valve)
Tilt (Solenoid valve)
Sideshift (Solenoid valve)
Maintenance
Adjustments
Hydraulic Fluid Check
Changing Hydraulic System Fluid
System Draining
Refilling System
Bleeding Hydraulic System
Troubleshooting
Primary Malfunctions
Auxiliary Function
Repair and Rebuild
Reservoir
Pump and Motor Assembly
Hydraulic Pump Assembly
Spool Control Valves
Theory of Operation
Lift (Mechanical Valve)
Lower (Mechanical Valve)
Maintenance
Troubleshooting
Spool Valve Leaks
Mast Drifts
Repair and Rebuild
One Spool Control Valve
Two Spool Control Valve
Lift Cylinders, Two Stage Mast
Theory of Operation
Maintenance
Inspection
Troubleshooting
Repair and Rebuild
Limited Freelift (LFT) Cylinder, Two Stage Mast
Full Freelift (FFL) Cylinder, Two Stage Mast
FFL Staging Cylinder, Two Stage Mast
Lift Cylinders, Three Stage Mast
Theory of Operation
Maintenance
Inspection
Troubleshooting
Repair and Rebuild
Three Stage Mast Staging Cylinders
Three Stage Mast Freelift Cylinder
Reach Cylinder, RRS30
Theory of Operation
Maintenance
Inspection
Troubleshooting
Repair and Rebuild
Tilt Cylinder
Theory of Operation
Maintenance
Inspection
Troubleshooting
Repair and Rebuild
Tilt Cylinder, RCS20/30/40
Tilt Cylinder, RRS30
Mast, Two Stage
Theory of Operation
Maintenance
Visual Inspection
Lift Chain Inspection
Lift Chain Lubrication
Lift Chain Adjustment
Lift Chain Replacement
Troubleshooting
Repair and Rebuild
Mast, Three Stage
Theory of Operation
Maintenance
Troubleshooting
Repair and Rebuild
Crosshead
Theory of Operation
Maintenance
Troubleshooting
Repair and Rebuild
Sideshifter
Theory of Operation
Maintenance
Periodic Maintenance
Inspection
Troubleshooting
No Sideshifting
Sideshifting Very Slow
Irregular Sideshifting
Repair and Rebuild
Sideshift Carriage
Upper Pad Replacement
Lower Pad Replacement
Cylinder
Single Reach, RRS30
Theory of Operation
Maintenance
Carriage Bumpers
Carriage Roller Bearings
Reach Adjustment
Troubleshooting
Repair and Rebuild
Reach
Forward Frame
Outer Arm
Inner Arm
Rear Frame
Reach Cylinder
Carriage Bearings
Forks
Theory of Operation
Maintenance
Inspection
Troubleshooting
Repair and Rebuild
Load Backrest
Theory of Operation
Maintenance
Troubleshooting
Repair and Rebuild
Warning Lights / Alarm (Optional)
Theory of Operation
Maintenance
Troubleshooting
Repair and Rebuild
Warning Light
Travel Alarm
Electrical Heater (Optional)
Theory of Operation
Maintenance
Troubleshooting
Repair and Rebuild
Version One Handset
Theory of Operation
Version Two Handset
Theory of Operation