Raymond 4760 Maintenance Manual 1451076_001A

Data Size: 123.87 MB 
File Type: PDF 
Language: English 
Manufacturer: Raymond 
Applicable Machine: Forklift 
Document: Maintenance Manual, Electric Diagram 
Machine Model: Raymond 4760-C40, 4760-C40S, 4760-C50, 4760-C50S, 4760-C50L, 4760-C55, 4760-C60, 4760-C65, 4760-C65L 
Serial Numbers: 00001 and Up 
Book Number: 1451076/001A 
Publication Date: 2025 
Page: 1626 Pages

List 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