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Maintenance Manual
4-Wheel Sit-Down Counterbalanced Lift Truck

Models Serial No.

DSD30 S30R-20001-Up/40001-Up
DSD35 S35R-40001-Up
DSD40 S40R-20001-Up/40001-Up
DSD50 S50R-20001-Up/40001-Up
DSD5E S5ER-20001-Up/40001-Up
DSD60 S60R-40001-Up

PDMM-0115 Issued: 07/31/2002

This publication, PDMM-0115, applies to the Raymond DSD 4-Wheel Sit-Down Counterbalanced Lift
Truck, S/N 40001 and Up, and to all subsequent releases of this product until otherwise indicated in
new editions or bulletins. Changes occur periodically to the information in this publication.

Technical changes or additions to the text and illustrations are indicated by a vertical line to the left of
the change.

To order additional copies of this manual, contact your local authorized Raymond Dealer.

If you need assistance with your lift truck, contact your local authorized Raymond Dealer.

To locate a dealer, go to www.raymondcorp.com.

© 2002 The Raymond Corporation.

The following terms are trademarks of The Raymond Corporation: Raymond and Safety On The Move.
All other brand and product names are trademarks or registered trademarks of their respective
companies.
Raymond ® DSD Maintenance Manual Table of Contents

Table of Contents 1:

Electrical Control System

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1
Raymond ® Lift Trucks Important Safety Information . . . . . . . . . . . . . . . . . . . .. S-2
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. S-3
General Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. S-3
Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. S-4
Static Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. S-6
Jacking Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. S-8
Tie-down for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. S-8
Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. S-9

General Information & Features . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. . .. .. . . . 1-2
Motor Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. . .. .. . . . 1-6
Nameplate and Serial Number Locations . . . . . . . . . . . . . . . . .. .. .. . .. .. . . . 1-7
Before Servicing Lift Truck . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. . .. .. . . . 1-7
Features of the GE SX Control System . . . . . . . . . . . . . . . . . .. .. .. . .. .. . . . 1-8
Run-time Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. . .. .. . . . 1-8
Fault Code Display Sequence . . . . . . . . . . . . . . . . . . . . . . .. .. .. . .. .. . . . 1-8
Programmable Truck Operating Modes. . . . . . . . . . . . . . . .. .. .. . .. .. . . . 1-9
Basics of Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. . .. .. . . 1-10
Motor Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. . .. .. . . 1-10
Solid-State Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. . .. .. . . 1-11
Flexible System Application . . . . . . . . . . . . . . . . . . . . . . . .. .. .. . .. .. . . 1-11
More Features with Fewer Components . . . . . . . . . . . . . . .. .. .. . .. .. . . 1-12
Features of SX Family of Transistor Motor Controllers . . . .. .. .. . .. .. . . 1-12
Standard Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. . .. .. . . 1-12
Creep Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. . .. .. . . 1-12
Control Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. . .. .. . . 1-12
Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. . .. .. . . 1-12
Regenerative Braking to Zero Speed . . . . . . . . . . . . . . .. .. .. . .. .. . . 1-13
Pedal Position Regenerative Braking . . . . . . . . . . . . . . .. .. .. . .. .. . . 1-13
Auto Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. . .. .. . . 1-13
Field Weakening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. . .. .. . . 1-13
Speed Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. . .. .. . . 1-13
Ramp Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. . .. .. . . 1-13
Roll-Back Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. . .. .. . . 1-14
Steer Pump Contactor Time Delay. . . . . . . . . . . . . . . . .. .. .. . .. .. . . 1-14
Static Return to Off (SRO) . . . . . . . . . . . . . . . . . . . . . . .. .. .. . .. .. . . 1-14
Accelerator Volts Hold Off . . . . . . . . . . . . . . . . . . . . . . .. .. .. . .. .. . . 1-14
Pulse Monitor Trip (PMT). . . . . . . . . . . . . . . . . . . . . . . .. .. .. . .. .. . . 1-14

PDMM-0115 Issued: 07/31/2002 i

Table of Contents Raymond ® DSD Maintenance Manual

Thermal Protector (TP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Systems Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Standard Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Stored Status Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Remoter Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Maintenance Alert & Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Battery Discharge Indication (BDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Internal Resistance Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Display Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Circuit Board Coil Driver Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Truck Management Module (TMM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Hydraulic Pump Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
GE Information for Separately Excited Controls. . . . . . . . . . . . . . . . . . . . . . 1-18
Standard Display Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Premium Display Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Battery Discharge Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Mode/Fault History Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
History Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Fault Code Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Monitoring System Action Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Premium Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Battery Discharge Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Time Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Speed Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
History Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Left Mode Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Right Mode Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Fault Code Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Monitoring System Action Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Setup Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Brush Wear Indicator Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Vehicle Monitoring System—Action Lights . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Traction Controller & Pump Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Traction Control Logic Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Troubleshooting the SX Motor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
Cabling for Vehicle Field Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
RF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
Recommended Lubrication of Pins and Sockets Prior to Installation . . . . . . 1-32
General Troubleshooting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
BDI Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Function 14 Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34

ii PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Table of Contents

Handset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General Information . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . . 2-2
Handset Functions . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . . 2-3
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . . 2-3
Function Set-Up Procedures. . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . . 2-4
Accessing Stored Fault Codes. . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . . 2-5
Set-up Functions for Traction Controller . . . . . . .. .. . .. .. . .. .. .. . .. .. . . . 2-6
Internal Resistance Compensation Table . .. .. . .. .. . .. .. .. . .. .. . . . 2-9
Dash Display Modes . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-12
Set-up Functions for Hydraulic Pump Control . . .. .. . .. .. . .. .. .. . .. .. . . 2-15
Dash Display Modes. . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-17
Traction Controller Settings. . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-19
Pump Controller Settings . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-29
Memory Maps . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-37

Checks & Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Contactor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Brush Wear Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Motor Thermal Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Truck Management Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Thermal Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Why is Thermal Transfer important? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
What determines “Good” Thermal Transfer? . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Insuring Proper Thermal Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Mounting Instructions for Motor Controls . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Necessary Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
The Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Vehicle Mounting Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Application of Thermal Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Mounting the Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Traction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Troubleshooting Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Unsatisfactory Brush Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
TABLE ONE: Primary Sources of Unsatisfactory Brush Performance . . . 3-14
TABLE TWO: Indications Appearing at Brushes . . . . . . . . . . . . . . . . . . 3-16
TABLE THREE: Indications Appearing as Heating . . . . . . . . . . . . . . . . . 3-18
TABLE FOUR: Indications Appearing at Commutator Surface . . . . . . . . 3-19
Commutator Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

PDMM-0115 Issued: 07/31/2002 iii

Table of Contents Raymond ® DSD Maintenance Manual

SX Control Connections & Troubleshooting by Symptom . . . . . 4-1

SX Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Instructions for Removal of SX Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Failures Causing Reduced or No Motor Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Mis-operation of Other Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Traction Bypass with Pump Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Pump Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Traction Bypass with Pump Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Traction Bypass with Pump Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Pump Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Traction Motor Controller with Pump Motor Controller and Bypass . . . . . . . . . 5-13
TMM7A (Truck Management Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Pump Driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Pump Time Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Diagnostic Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Basic Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Display Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Chassis and Mast

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. .. . 1-2
Truck Models Covered . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. .. . 1-2
Nameplate and Serial Number Locations . . . .. .. . .. .. . .. .. . .. .. .. . .. .. . 1-3
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. .. . 1-4
Dimensions Chart . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. .. . 1-5
General Information (Standard Models) . . . . .. .. . .. .. . .. .. . .. .. .. . .. .. . 1-6

Front Axle & Reduction Differential. . . . . . . . . . . . . . . . . . . . . . 2-1

Front Axle . . . . . . . . . . . . . .. . .. .. . .. .. . .. . . . .. .. . .. .. . .. .. .. . .. .. . 2-2
Description . . . . . . . . . . .. . .. .. . .. .. . .. . . . .. .. . .. .. . .. .. .. . .. .. . 2-2
General Information . . . .. . .. .. . .. .. . .. . . . .. .. . .. .. . .. .. .. . .. .. . 2-2
Removal, Front Wheels . .. . .. .. . .. .. . .. . . . .. .. . .. .. . .. .. .. . .. .. . 2-3
Removal Sequence . . .. . .. .. . .. .. . .. . . . .. .. . .. .. . .. .. .. . .. .. . 2-3
Suggestions . . . . . . . .. . .. .. . .. .. . .. . . . .. .. . .. .. . .. .. .. . .. .. . 2-3
Method 1 . . . . . . . . . .. . .. .. . .. .. . .. . . . .. .. . .. .. . .. .. .. . .. .. . 2-4
Method 2 . . . . . . . . . .. . .. .. . .. .. . .. . . . .. .. . .. .. . .. .. .. . .. .. . 2-4
Method 3 . . . . . . . . . .. . .. .. . .. .. . .. . . . .. .. . .. .. . .. .. .. . .. .. . 2-4

iv PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Table of Contents

Installation . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . . 2-5
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . . 2-6
Sequence . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . . 2-6
Start By . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . . 2-6
Suggestions . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . . 2-7
Removing Front Wheel Hub. . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . . 2-7
Inspection after Disassembly . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . . 2-8
Axle Shafts . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . . 2-8
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . . 2-9
Axle Housing. . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . . 2-9
Front Wheel Hub . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . . 2-9
Hub Bearing Preload . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-10
Installation and Setting Preload . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-10
Reduction Differential . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-11
Sequence . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-11
Start By . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-11
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-12
Suggestions . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-12
Removing Bearing Inner Races . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-12
Inspection after Disassembly . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-13
Reduction Gear . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-13
Differential . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-13
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-14
Sequence . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-14
Suggestions . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-15
Inspection and Adjustment . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-16
Side Bearing Preload . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-16
Reduction Gear Backlash . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-16
Reduction Gear Face Runout . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-17
Tooth Contact . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. .. . .. .. . . 2-17
Tooth Contact Adjustment (DSD30 – 35) . .. .. . .. .. . .. .. .. . .. .. . . 2-18
Tooth Contact Adjustment (DSD40 – 60) . .. .. . .. .. . .. .. .. . .. .. . . 2-19

Transfer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. 3-2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. 3-3
Start by . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. 3-3
Disassembly sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. 3-3
Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. 3-4
Inspection after Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. 3-6
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. 3-7
Reassembly sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. 3-7
Suggestions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. 3-8

PDMM-0115 Issued: 07/31/2002 v

Table of Contents Raymond ® DSD Maintenance Manual

Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . . 4-2
Rear Wheels . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . . 4-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . . 4-3
Removal Sequence . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . . 4-3
Suggestions. . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . . 4-3
Steering Cylinder . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . . 4-4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . . 4-5
Installation . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . . 4-5
Reference value . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . . 4-6
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . . 4-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . . 4-8
Sequence . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . . 4-8
Start By . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . . 4-8
Suggestions . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . . 4-9
Installation . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . . 4-9
Adjusting Bearing Support Clearance. .. .. . .. .. . .. .. . .. .. .. . .. . . . 4-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-10
Disassembly sequence . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-10
Suggestions . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-11
Inspection after Disassembly. . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-12
Tie Rods and Pins . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-12
Kingpins . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-12
Kingpin Bearings . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-12
Knuckles . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-12
Cylinder Rod . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-12
Seals and O-rings . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-12
Hydraulic Pipes . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-12
Tires . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-12
Reassembly . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-13
Assembly sequence . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-13
Suggestions . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-14
Reassembling Rear Axle Hub . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-16
Inspection and Adjustment. . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-18
Minimum Turning Radius Adjustment . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-18
Steering Cylinder . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-19
Disassembly. . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-19
Disassembly sequence . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-19
Suggestions . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-20
Reassembly . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-21
Assembly sequence . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-21
Suggestions . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. .. . .. . . 4-21

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Raymond ® DSD Maintenance Manual Table of Contents

Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Automatic Adjusting Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Master Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Inspection after Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Brake Fluid Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Return Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Primary Cup, Secondary Cup, and Valve . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Master Cylinder Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Disassembly (DSD30 – 35) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Disassembly (DSD40 – 60) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Start By . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Inspection after Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Backing Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Shoes and Linings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Brake Drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Adjusting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Parking Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Reassembly (DSD30 – 35) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Reassembly (DSD40 – 60) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Wheel Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Inspection after Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Cylinder Bodies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Piston Cups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Brake Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Bleeding Air Out of Brake Fluid Line . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

PDMM-0115 Issued: 07/31/2002 vii

Table of Contents Raymond ® DSD Maintenance Manual

Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Steering System . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . . 6-2
Description . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . . 6-2
Oil Flow Sequence . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . . 6-2
General Information . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . . 6-2
Steering Gear . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . . 6-3
Steering Wheel . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . . 6-3
Sequence . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . . 6-3
Removal . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . . 6-3
Installation . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . . 6-3
Steering Gear . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . . 6-4
Sequence . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . . 6-4
Inspection after Removal . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . . 6-5
Installation . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . . 6-5
Disassembly. . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . . 6-6
Sequence . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . . 6-6
Working Rules and Tips . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . . 6-7
Suggestions . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . . 6-7
Inspection after Disassembly . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . . 6-7
Reassembly . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . . 6-8
Sequence . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . . 6-8
Suggestions: . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . . 6-9
Steer Pump . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 6-10
Removal . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 6-10
Sequence . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 6-10
Start By . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 6-10
Suggestions . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 6-10
Installation . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 6-10
Disassembly . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 6-11
Sequence . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 6-11
Working Rules and Tips . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 6-12
Suggestions . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 6-12
Inspection after Disassembly. . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 6-14
Reassembly . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 6-15
Sequence . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 6-15
Suggestions . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 6-15
Inspection after Reassembly . . . . . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 6-17

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Schematic for Trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

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Raymond ® DSD Maintenance Manual Table of Contents

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Lift and Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Down Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Valve Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Start By . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Disassembly – Premium Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Start By . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Disassembly – Standard Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Working Rules and Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Inspection after Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Mounting Flange Face. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Reassembly – Trucks with Standard Hydraulic Pump . . . . . . . . . . . . . . . . . 7-19
Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Start By . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Reassembly – Trucks with Premium Hydraulic Pump . . . . . . . . . . . . . . . . . 7-20
Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Start By . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Inspection after Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Start By . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Lift and Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Lift Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

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Table of Contents Raymond ® DSD Maintenance Manual

Tilt Cylinder Removal . . . . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-33

Suggestions . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-34
Lift Cylinder Disassembly . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-35
Sequence . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-35
Suggestions . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-35
Tilt Cylinder Disassembly . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-36
Sequence . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-36
Suggestions . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-36
Flow Regulator Valve . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-37
Disassembly . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-37
Sequence . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-37
Inspection after Disassembly . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-37
Inspection after Disassembly. . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-38
Lift and Tilt Cylinders . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-38
Precautions for Reassembly. . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-38
Inspection and Adjustment. . . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-39
Hydraulic Tank . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-39
Hydraulic Oil . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-39
Hydraulic Tank Refill Capacities. . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-39
Suction Strainer. . . . . . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-39
Return Filter . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-39
Control Valve . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-40
External Leakage . . . . . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-40
Internal Leakage . . . . . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-40
Main Relief Valve Adjustment . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-41
Auxiliary Relief Valve Adjustment. .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-41
Lift and Tilt Cylinders. . . . . . . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-42
Mast Tilt Angle Adjustment . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-42
Lift Cylinder Stroke Adjustment . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-42
Adjusting Method. . . . . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-43
Flow Regulator Valve . . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-43
Testing . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-44
Lift Cylinder Drift Test . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-44
Tilt Cylinder Drift Test . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-44
Piping . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. . . 7-44

Mast and Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Description . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. . . . . . . . . . . 8-2
Components. . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. . . . . . . . . . . 8-2
Removal and Installation . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. . . . . . . . . . . 8-3
Mast and Lift Bracket Assembly . . .. .. . .. .. . .. .. . .. .. . .. . . . . . . . . . . 8-3
Sequence . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. . . . . . . . . . . 8-3
Suggestions . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. . . . . . . . . . . 8-3
Disassembly . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. . . . . . . . . . . 8-5
Sequence . . . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. . . . . . . . . . . 8-5
Suggestions . . . . . . . . . . . . . . . .. .. . .. .. . .. .. . .. .. . .. . . . . . . . . . . 8-6
Inspection after Disassembly. . . . . .. .. . .. .. . .. .. . .. .. . .. . . . . . . . . . . 8-7

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Raymond ® DSD Maintenance Manual Table of Contents

Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . . . 8-7
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . . . 8-9
Adjusting Mast and Lift Bracket Clearance . .. . .. .. . .. .. .. . .. .. . . . 8-9
Cylinder Clamps . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . . . 8-9
Mast Supports . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . . . 8-9
Precautions for Installing Chain Anchor Kit. .. . .. .. . .. .. .. . .. .. . . 8-10
Inspection and Adjustment . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . . 8-11
Chain Tension Adjustment . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . . 8-12
Clearance Adjustment on Lift Bracket . . . . . .. . .. .. . .. .. .. . .. .. . . 8-13
Mast Clearance Adjustment . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . . 8-16
Main Roller Shim Replacement . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . . 8-18
Mast Strip Adjustment . . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . . 8-18
Tilt Angle Adjustment . . . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . . 8-19
Lift Cylinder Stroke Adjustment . . . . . . . . . .. . .. .. . .. .. .. . .. .. . . 8-19
Bleeding Lift Cylinders . . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . . 8-20
Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . . 8-21
Service Data. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . . 8-22
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . . 8-24

Troubleshooting Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Front Axle and Reduction Differential Troubleshooting . . . . . . . . . . . . . . . . . . . 9-2
Brake System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Steering System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Hydraulic System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Rear Axle Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Mast and Forks Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

Maintenance Service Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Front Axle and Reduction Differential . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . . 10-2
Hubs and Wheels . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . . 10-2
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . . 10-4
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . . 10-5
Brake System–Brake Pedal . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . . 10-7
Brake System–Master Cylinder . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . . 10-8
Brake System–Wheel Cylinder . . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . . 10-9
Brake System–Wheel Brakes . . . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . 10-10
Brake System–Service Brakes . . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . 10-11
Brake System–Parking Brake . . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . 10-12
Steering System–Steering Gear . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . 10-13
Steering System–Steering Cylinder . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . 10-14
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . 10-15
Mast and Forks (Simplex Mast) . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . 10-18
Mast and Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . 10-20
Tightening Torques for Standard Bolts and Nuts . . .. . .. .. . .. .. .. . .. .. . 10-21
Service Data: General . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . 10-25
Maintenance Chart . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. .. . .. .. . 10-25

PDMM-0115 Issued: 07/31/2002 xi

Table of Contents Raymond ® DSD Maintenance Manual

Periodic Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35

Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
Fuel and Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
Weight of Major Components (Approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
Special Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
Special Tool Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41
Inspection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

xii PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Safety Precautions

Safety Precautions S:

PDMM-0115 Issued: 07/31/2002 S-1

Safety Precautions Raymond ® DSD Maintenance Manual

Raymond ® Lift Trucks Important Safety Information

Raymond ® Lift Trucks Important Safety Information

Most accidents involving product operation, The Raymond Corporation cannot anticipate
maintenance and repair are caused by failure to every possible circumstance that might involve
observe basic safety rules and precautions. An a potential hazard. The warnings in this
accident can often be avoided by recognizing publication and on the product are therefore
potentially hazardous situations before an not all-inclusive. If a tool, procedure, work
accident occurs. A person must be alert to method, or operating technique that is not
potential hazards. This person should also have specifically recommended by The Raymond
the necessary training, skills, and tools to Corporation is used, you must satisfy yourself
perform these functions properly. that it is safe for you and others. You should
also ensure that the product will not be
Improper operation, lubrication, maintenance,
damaged or made unsafe by the operation,
or repair of this product can be dangerous and
lubrication, maintenance, or repair procedures
could result in injury or death.
you choose.
Do not operate or perform any lubrication,
The information, specifications, and
maintenance, or repair on this product, until
illustrations in this publication are on the basis
you have read and understood the operation,
of information available at the time it was
lubrication, maintenance, and repair
written. The specifications, torques, pressures,
information.
measurements, adjustments, illustrations, and
Safety precautions and warnings are provided other items can change at any time. These
in this manual and on the product. If these changes can affect the service given to the
hazard warnings are not heeded, bodily injury product. Obtain the complete and most current
or death could occur to you or other persons. information before starting any job.
The hazards are identified by the “Safety Alert Raymond lift truck Dealers have the most
Symbol” and followed by a “Signal Word” such current information available.
as “CAUTION” or “WARNING” as shown below.

! WARNING

The meaning of this “Safety Alert Symbol” is as

follows:
Attention! Become Alert! Your Safety is involved.
The message that appears under the warning
explains the hazard and can be either written
or pictorially presented.
Operations that may cause product damage
are identified by NOTICE labels on the product
and NOTE labels in this publication.

S-2 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Safety Precautions

Definitions

Definitions General Safety

Throughout this manual, you will see two kinds • Do NOT operate or work on this lift truck
of safety reminders: unless you are trained, qualified, and
authorized to do so, and have read the
Owner/Operator Manual.
! WARNING
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury.

! CAUTION
Indicates a potentially hazardous 198B15004D.EPS

situation which, if not avoided, may • Know the lift truck’s controls and what they
result in minor or moderate injury. It do.
can also be used to alert against • Do NOT operate this lift truck if it needs
unsafe practices. repair or if it is in any way unsafe.
• Operate this lift truck only from the
operator’s position.
• Before working on this lift truck, always
turn the key switch OFF and disconnect the
lift truck’s battery connector (unless this
manual tells you otherwise).
• Do NOT wear watches, rings, or jewelry
when working on this lift truck.

19jewelry.eps

• Follow the scheduled lubrication,

maintenance and inspection steps.

19schedmnt.eps

PDMM-0115 Issued: 07/31/2002 S-3

Safety Precautions Raymond ® DSD Maintenance Manual

Battery Safety

• Follow exactly the safety and repair Battery Safety

instructions in this manual. Do NOT take
“shortcuts.”
! WARNING
As a battery is charged, an explosive
gas mixture forms within and
around each cell. If the area is not
properly ventilated, this explosive
gas can remain in or around the
battery for several hours after
198b15008d.eps
charging. Make sure there are no
open flames or sparks in the
• Do NOT use an open flame near the lift charging area. An open flame or
truck.
spark can ignite this gas, resulting in
• Do NOT use gasoline or other flammable serious damage or injury.
liquids for cleaning parts.
• Clean up any hydraulic fluid, oil, or grease
that has leaked or spilled on the floor.
! WARNING
Battery electrolyte is a solution of
sulfuric acid and water. Battery acid
causes burns. Should any electrolyte
come in contact with your clothing or
skin, flush the area immediately with
cold water. Should the solution get
19spills.eps
on your face or in your eyes, flush
the area with cold water and get
• Always park this lift truck indoors. medical help immediately.
• Do NOT wash this lift truck with a hose.
• Do NOT add to or modify this lift truck until
• Read, understand and follow procedures,
you contact your local Raymond Dealer to
recommendations, and specifications in the
receive written manufacturer approval.
battery and battery charger manufacturer’s
• Do NOT park this lift truck in a cold storage manuals.
area overnight.

1925l6s014.eps

S-4 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Safety Precautions

Battery Safety

• Wear personal protective equipment to • Keep the charging area well-ventilated to

protect eyes, face and skin when checking, avoid hydrogen gas concentration.
handling or filling batteries. This equipment
includes goggles or face shield, rubber
gloves (with or without arm shields), and a
rubber apron.

1904g6s058.eps

• Turn the key switch OFF before

disconnecting the battery from the lift truck
at the battery connector. Do NOT break live
1925L6S016.eps
circuits at the battery terminals. A spark
• Make sure a shower and eyewash station often occurs at the point where a live circuit
are nearby in case of an accident. is broken.
• Do NOT lay tools or metal objects on top of
the battery. A short circuit or explosion
could result.

1904G6S059.eps

• A battery gives off explosive gases. NEVER

smoke, use an open flame, or use anything
that gives off sparks near a battery. 1904g6s057.eps

• Keep batteries clean. Corrosion causes

shorts to the frame and possibly sparks.
• Keep plugs, terminals, cables and
receptacles in good condition to avoid
shorts and sparks.

1923L6S012.eps

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Safety Precautions Raymond ® DSD Maintenance Manual

Static Precautions

• Keep filler plugs firmly in place at all times

except when the electrolyte level is checked,
Static Precautions
when water is added to the cells or when Electronic circuit boards and devices used on
the specific gravity is checked. the Raymond RTW lift truck can be damaged by
the discharge of static electricity, called
electrostatic discharge.
Static charges can accumulate from normal
operation of the lift truck as well as movement
or contact between non-conductive materials
(plastic bags, synthetic clothing, synthetic soles
on shoes, styrofoam coffee cups, etc.)
Accumulated static can be discharged through
human skin to a circuit board or component by
touching the parts. Static discharge is also
possible through the air when a charged object
is placed close to another surface at a different
electrical potential. Static discharge can occur
1927Y7S013.tif without your seeing or feeling it.
• Make sure the vent holes in the filler plugs Whenever working on or near static-sensitive
are open to allow the gas to escape from the electronics, always use static discharge
cells. precautions.
1. Place a static discharge wrist strap around
Vent your wrist. Connect the ground lead to the
Hole wrist strap connector. The wrist strap
should be equipped with a 1 megohm
resistor to protect against shock hazard.
2. Connect the ground clamp to an unpainted,
grounded surface on the truck frame.
3. Handle circuit boards by edges only. Avoid
touching edge connectors.
4. If you are removing or installing
static-sensitive components, place them on
a properly grounded static mat.
1909g6s047.tif 5. To transport static-sensitive components,
including failed components being
• Do NOT allow cleaning solution, dirt or any
returned, place the components in an
foreign matter to enter the cells.
antistatic bag or box (available from your
• Make sure you install the correct size Raymond Dealer).
battery. A smaller or lighter weight battery
could seriously affect lift truck stability. See Test the wrist strap and associated accessories
the lift truck’s specification plate for more monthly. A wrist strap that is not working
information. properly will not alert you that it is bad.
• NEVER plug a battery charger into the lift
truck’s battery connector. Plug the battery
charger only into the battery connector
from the battery.

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Raymond ® DSD Maintenance Manual Safety Precautions

Static Precautions

19mat2.tif

Figure S-1: Anti-Static Kit with Wrist Strap and Mat

Figure S-1 shows the components of the

Raymond antistatic field service kit, part
number 1-187-059. The kit includes a wrist
strap, ground cord, and static-dissipative work
surface (mat). Follow the instructions packaged
with this kit.
Wrist straps are available in quantities of 25, as
part number 1-187-058/001.
A wrist strap tester is available as part number
1-187-060.
Contact your local authorized Raymond Dealer
for information.

PDMM-0115 Issued: 07/31/2002 S-7

Safety Precautions Raymond ® DSD Maintenance Manual

Jacking Safety

Jacking Safety To elevate the lift truck:

1. Place a suitable jack as close as possible to
Sometimes you may need to jack the lift truck
the lifting channels on the truck frame. See
off the floor to perform maintenance
Figure S-2.
procedures. When doing so, observe the proper
safety precautions: NOTE: A standard mechanical jack (railroad
jack) is not a suitable jack because of
1. Lower the forks completely. Remove any
the curved design of the truck.
load.
2. Place all controls in neutral. 2. Lift the truck only as far as required to
perform the procedure.
3. Set the parking brake and block the wheels
3. Securely block the lift truck in place.
to prevent movement of the vehicle.
4. Turn the key switch OFF and disconnect It is possible to elevate the front of the lift truck,
the battery connector. without using a jack.

5. Place the jack under the designated jacking 1. Block the steerable wheels with chocks.
points. See Figure S-2. 2. Tilt the mast back and place blocks on the
floor under the mainframe.
3. Tilt the mast forward, lifting the truck off
! WARNING the floor.
Use extreme care whenever the lift
truck is jacked up. Never block the
lift truck between the telescopic and Tie-down for Transport
the floor. Use a suitable hoist to
stabilize the mast. Keep hands and To transport your lift truck in an over-the-road
feet clear from vehicle while jacking vehicle or rail car, follow these steps:
the lift truck. After the lift truck is 1. Lower the forks and locate the lift truck in
jacked, place solid blocks or jack the center of the transport vehicle.
stands beneath it to support it. DO 2. Position an adjustable chain over and
NOT rely on the jack alone to through the fork carriage.
support the lift truck. 3. Position an additional adjustable chain over
the counterweight.
4. Secure the ends of the chain over the
counterweight toward the front of the
Jack only in
these areas transport vehicle bed. Secure the chain
ends of the other chain to the back of the
vehicle bed and draw taut.
NOTE: This will secure the lift truck to the
vehicle bed and prevent tipping and
forward or backward movement.

19toyrch_t.eps

Figure S-2: Correct Jacking Locations

S-8 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Safety Precautions

Welding Safety

Welding Safety ! CAUTION

Disconnect the battery before you
attempt to inspect, service, or repair
! WARNING the lift truck.
Flame cutting or welding on painted
surfaces may produce potentially • Check for shorts to frame. If you detect any
harmful fumes, smoke and vapors. shorts, correct them before you proceed
Prior to performing flame cutting or with the welding operation.
welding operations, it is • Clean the area to be welded.
recommended that the coating be • Protect all lift truck components from heat,
removed in the vicinity where the weld spatter and debris.
operation(s) will be performed. • Attach the ground cable as close to the weld
area as possible.
Coating removal may be by • Disconnect all electrical circuit cards before
mechanical methods, chemical doing any type of electric resistance
methods or a combination of welding.
methods. Perform flame cutting • Do not perform any welding operations
and/or welding operations only in near the electrical components.
well ventilated areas. Use local • If you must do welding near the battery
exhaust if necessary. compartment, remove the battery from the
lift truck.
• When you are finished welding, re-install
Before working on this lift truck, make sure
circuit cards and perform all ground tests
that:
and electrical inspections before operating
• Fire protection equipment is nearby. the lift truck.
• You know where the nearest eyewash • Short B+ and B- on the traction and pump
station is. power amplifiers.

1904G6S059.eps

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Safety Precautions Raymond ® DSD Maintenance Manual

Welding Safety

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Raymond ® DSD Maintenance Manual General Information & Features

General Information & Features 1:

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General Information & Features Raymond ® DSD Maintenance Manual

Glossary

Glossary

Accelerator. A device that converts Circuit. A way for current to go from the
mechanical movement into a voltage pattern to positive (+) side of an electrical power source to
the logics for variable drive motor speed. the negative (–) side of an electrical power
source. This can be through wires and electrical
Activate. A word used with a component or components.
circuit. To change from the normal condition to
the “activated” condition because of an Closed Circuit. Wiring or components in a
application of force or electricity. circuit that have continuity.
Ammeter. An electric meter used to measure Coil. A component made from many circles or
current flow in amperes. turns of wire used to concentrate a magnetic
field.
Ampere (or Amp). The unit of measure of
current flow. The amount of current that one Commutator. An armature component used
volt can push through a resistance of one ohm. to transfer current from the brushes to the
armature windings.
Anode. The positive (+) side of a diode.
Compound Motor. A motor which has a field
Armature. The rotating portion of an electric winding in series with the armature and a
motor or generator.
shunt field winding in parallel with the series
Battery. Two or more cells connected together winding and armature.
for a supply of electric current.
Conduct. To allow the flow of current.
BDI (Battery Discharge Indicator). An Conductor. A material that provides a path for
electrically controlled display showing the
current flow.
operator the state of battery charge.
Connector. Part of a wire assembly or harness
BJT (Bipolar Junction Transistor). A that connects with another wire assembly or
transistor that is used to control voltage going
harness. Used for ease of assembly and
to a motor or other electrical device.
disassembly.
Brush. A conductor, normally a block of Contact Tips or Contacts. The portion of a
carbon, that makes sliding contact between the
switch, relay, or contactor where the circuit can
stationary and moving part of the motor or
be opened or closed.
generator.
Contactor Assembly. An electrical
Bus Bar. A heavy electrical conductor that component consisting of an electromagnetic
carries high current from one point to another
coil and a set of heavy contact tips. Control
and to which other smaller wires are connected.
current passes through the coil, building a
Bypass (1A) Contactor, Traction. Switch magnetic field that closes or opens the contact
that connects A2 traction motor cable to battery tips.
negative and bypasses the main power
Contactor Coil. An electromagnet used to
MOSFETs.
close or open contact tips in a contactor
Capacitor. Device used to store electrical assembly.
energy for short periods of time.
Continuity. Having the ability to allow
Cathode. The negative (–) side of a diode. current flow.

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Glossary

Control Circuits. The wires and components Electromagnet. A coil of wire, most often
carrying low current used to signal the logics wound on an iron core, that produces a strong
unit, turn on main components, or support magnetic filed when current is sent through the
auxiliary circuits (indicated by thin lines on a coil.
schematic).
Electromotive Force (EMF). The force that
Counter Electromotive. An opposing causes an electric current to flow in a circuit.
voltage set up by a collapsing or increasing This force is measured in volts.
magnetic field within a Force (CEMF) coil.
Field Windings. The stationary coils that
Current. The movement or flow of electricity produce a magnetic field in motors and
through a conductor. A circuit must be complete generators.
for current to flow.
Filter. An electrical device or component for
Current Limit. The maximum allowable restriction or suppression of undesired voltage
current of a stalled drive motor. spikes.
Current Sensor. A hall-effect sensor in the Fuse. A component in an electrical circuit that
motor circuit that produces an increasing will open the circuit if too much current goes
voltage output as the motor current increases. through it.
Current Shunt. A precision low-value resistor Gate. Terminal of a MOSFET to which voltage
connected in series with the armature of a is applied to turn the MOSFET on and off.
motor. The logics uses the measured voltage
drop across the shunt to control maximum
Generator. A device that transforms
non-electric energy (such as mechanical,
current allowed in selected power circuits.
thermal, etc....) into electrical energy.
Deactivate. To change from the activated
condition back to the normal (deactivated)
Grounded. A wire or wires that are in contact
with the metal chassis of the vehicle (ground).
condition. It can be caused by the application of
Can be caused by a loss of insulation from the
force, the removal of force, or the removal of
wire, or by connecting the wire to the vehicle.
electricity.
Digital Signal. A signal in which the elements Harness. An assembly made of two or more
wires that are held together.
may be either of two distinct values. For
example high voltage, low voltage. Heat Sink. A mounting frame used for
semiconductor cooling.
Diode. A semiconductor device that allows
current to flow in one direction, from the anode Heat Sink Pad. Thin metal sheet sandwiched
to the cathode. between the heatsink of a controller and the
frame of the lift truck used to better transfer the
Display. An electrical device that converts
heat away from the controller.
voltage inputs to a visual output.
Drain. Terminal of a MOSFET through which Hour Meter. An electrically activated device
used to record the amount of usage a truck
the main current flows.
receives.
Electric Motor. A device that changes
electrical energy into mechanical energy to do
work.
Electrical Braking. Electrically trying to
rotate the drive motor opposite to the direction
of truck movement.

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General Information & Features Raymond ® DSD Maintenance Manual

Glossary

Horse Power. A measure of the time-rate of MOSFET. (Metal Oxide Semiconductor Field
doing work. 1 HP is defined as the equivalent of Effect Transistor)
raising 33,000 pounds, one foot, in one minute.
A fast switching transistor that is used to
Linear Measure: control voltage going to a motor or other
electrical device.
HP = Force x Distance
33,000 x Time Normal Condition. Words used with a
switch or relay. Their normal condition is
• Force in Pounds
their condition when they are not controlled by
• Distance in Feet the application of force, temperature, pressure,
• Time in Minutes or electricity.
• 33,000 is a Constant Normally Closed (N.C.). A switch or relay
Rotational Measure: whose contacts are closed in the normal
condition.
HP = Torque x Speed
5252 Normally Open (N.O.). A switch or relay
whose contacts are open in the normal
• Torque in Foot - Pounds condition.
• Speed in revolutions per minute (RPM) OFF-Time. The amount of time a current does
• 5252 is a Constant not flow through a semiconductor.
IGBT. (Insulated Gate Bipolar Transistor) A Ohm. The unit of measurement of resistance.
fast switching transistor capable of handling The amount of resistance that will let one volt
high current required to power an electric push only one ampere of current through it.
motor.
ON-Time. The amount of time current flows
Indicator. A lamp or LED that gives an through a transistor.
indication of some vehicle condition when it
turns on or flashes. Open Circuit. Wiring or components of a
circuit that have no continuity.
Input. A voltage change at the incoming
connection of a component. Optical Switch. An electronic device made
up of an infrared light signal generator and
Insulator. A material that has a very large photosensitive signal receiver that changes an
resistance so that it will not let current flow input digital voltage into an electrically isolated
through it. digital voltage output.
LED. Light Emitting Diode - a diode that emits Output. The current flow from a component
light (lights) when current flows in the forward which initiated from a voltage change at the
direction. component’s input.
Logics or Logic Unit. The main printed PTC (Positive Thermal Coefficient
circuit board containing a microprocessor and Resistor). A resistor that is used in parallel
circuits to condition the voltage signals that go with the tips of the line contactor to allow the
into or come out of the logics. It electronically main capacitors in the controller to charge
monitors and controls the truck’s functions. quicker after the battery is plugged in. As the
Magnetic Field. The area around a magnet PTC conducts current, it heats up and its
where magnetic forces are detected. resistance increases. Each controller has an
internal PTC that will slowly charge the main
Microprocessor. A small computer integrated capacitors if the external PTC fails.
circuit (IC) pre-programmed to control the
various electrical functions of a lift truck.

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Glossary

Resistance. Opposition to the flow of current Volt. The unit of measurement of electromotive
in a circuit. The unit of electrical resistance is force. One volt is the force needed to make one
the OHM. The lower the resistance, the greater ampere of current flow through one ohm of
the current flow for a given voltage. resistance in a circuit.
Silicon Controlled Rectifier (SCR). A Watt. The unit of measurement of power. The
diode that can be turned on and off so that it amount of power used when one volt pushes
allows current flow in only one direction or it one ampere of current through a resistance of
blocks current flow in both directions. one ohm. The result of amperes (current)
multiplied by volts (voltage) is watts (power).
Source. Terminal of a MOSFET through which
the main current flows. Wire. A conductor used to provide a path for
current to flow to and from electrical
Terminal. An electrical connection point on an components.
electrical component.
Wiring Diagram. A drawing using visual
Transistor. A semiconductor device used as representation of components to depict the way
an electronic switch.
they actually look. It is used to show the
Torque. The turning force or effect required to locations of components and the connections
do work. between them.
Torque = Force x Distance Zener Diode. A special diode used to regulate
voltage or as an over voltage protector.
• Force in Pounds
• Distance in Feet to center of rotation
Varistor. An electrical filter that is usually
terminated across the horn connections of a
mechanical horn to eliminate voltage spikes
when the horn is activated.

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General Information & Features Raymond ® DSD Maintenance Manual

Motor Options

Motor Options

Hydraulic Pump
Model Serial #
Motor

DSD30 S30R-20001-up 6.6"

DSD30 S30R-40001-up 8"

DSD35 S35R-40001-up 8"

DSD40 S40R-20001-up 8"

DSD40 S40R-40001-up 9"

DSD50 S50R-20001-up 8"

DSD50 S50R-40001-up 9"

DSD5E S5ER-20001-up 8"

DSD5E S5ER-40001-up 9"

DSD60 S60R-40001-up 9"

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Raymond ® DSD Maintenance Manual General Information & Features

Nameplate and Serial Number Locations

Nameplate and Serial Number Locations

Nameplate

Chassis Mast Serial

Serial Number
Number

Traction Motor Hydraulic Motor Power Steering Motor

Serial Number Serial Number Serial Number

Before Servicing Lift Truck

! WARNING
Before doing any maintenance or
adjustments on the lift truck, make
sure to always use correct blocks to
prevent the unit from rolling or
falling. Raise the drive wheels off the
ground. This can be done by tilting
the mast all the way back, placing
solid blocks under the mast then
tilting the mast forward. Securely
support with blocks.

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General Information & Features Raymond ® DSD Maintenance Manual

Features of the GE SX Control System

Features of the GE SX Control System

The GE SX control monitors over seventy

different system functions. Run-time fault
conditions, when sensed, are indicated on the
steering console display.

Mode/Fault Code Buttons

Mode/Fault
Code Button

Fault Code Display Sequence

Run-time Diagnostics When the truck key is switched OFF, the
During truck start up or operation, a diagnostic display shows truck hours, drive motor hours,
code could appear on the display instead of the and pump motor hours for four seconds each.
battery state of charge. If the GE SX Control At this point, use the mode buttons to activate
System detects a prob-lem, the ! symbol glows in the display sequence of faults that caused the
the monitoring system action lights at the same lift truck to shut down. For details, see
time. The codes indicate an improper operating instrument panels sections for both standard
sequence or a defect in the truck electrical and premium displays.
system.
Run-time diagnostics cover the following areas
of truck operation and protection:
• Drive motor and pump motor hours
• Service reminder hours
• Battery discharge level
• Motor brush wear (Premium Display Only)
• Stall protection
• Overtemperature protection of drive motor,
pump motor, and the control panel
• Brake fluid level

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Raymond ® DSD Maintenance Manual General Information & Features

Programmable Truck Operating Modes

Mode/Fault Code Buttons

Programmable Truck Operating

Modes
The GE SX Control System also allows users to
modify how the truck operates for conditions
where the truck is used. The operator can select
from four operating modes:
1. Economy – slowest travel speed and
acceleration.
2. Moderate – travel speed and acceleration
somewhat slower than standard.
3. Standard – travel speed and acceleration
suitable for the broadest range of
applications.
4. High – Highest travel speed and
acceleration.
Each time the key is switched OFF then ON
again, the controller remains in the previously
selected mode.
Operating Mode details differ depending on the
display type. See the sections on Standard and
Premium Instrument Panels for more
information.

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General Information & Features Raymond ® DSD Maintenance Manual

Basics of Circuit Operation

Basics of Circuit Operation

Motor Characteristics current to increase, providing the greater

torque needed to drive the increased
Historically, most electric vehicles have relied mechanical load. If the mechanical load is
on series motor designs because of their ability decreased, the process reverses. The motor
to produce very high levels of torque at low speed and the back EMF increase, while the
speeds. But, as the demand for high efficiency armature current and the torque developed
systems increases (for example: systems that decrease. Thus, whenever the load changes, the
are more closely applied to customers’ specific speed changes also, until the motor is again in
torque requirements) shunt motors are now electrical balance.
often being considered over series motors. In
most applications, by independently controlling In a shunt motor, the variation of speed from no
the field and armature currents in the load to normal full load on level ground is less
separately excited motor, the best attributes of than 10%. For this reason, shunt motors are
both the series and the shunt wound motors considered to be constant speed motors
can be combined. (Figure 2).

As shown in the typical performance curves of

Figure 1, the high torque at low speed
characteristic of the series motor is evident. SPEED

NO LOAD CURRENT

LOAD CURRENT

STARTING
CURRENT
FULL
NO LOAD CURRENT

SPEED
TORQUE
LOAD CURRENT

STARTING
CURRENT
FULL

ARMATURE CURRENT
Figure 2
TORQUE
1

Figure 1-2: Armature Current in a Shunt Motor

ARMATURE CURRENT
Figure 1
1
In the separately excited motor, the motor is
Figure 1-1: Armature Current in a Series Motor operated as a fixed field shunt motor in the
normal running range. However, when
additional torque is required (for example, to
In a shunt motor, the field is connected directly climb non-level terrain, such as ramps and the
across the voltage source and, therefore, is like) the field current is increased to provide the
independent of variations in load and armature higher level of torque. In most cases, the
current. If field strength is held constant, the armature to field ampere turn ratio can be very
torque developed will vary directly with the similar to that of a comparable size series motor
armature current. If the mechanical load on the (Figure 3.)
motor increases, the motor slows down,
reducing the back EMF (which depends on the
speed, as well as the constant field strength).
The reduced back EMF allows the armature

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Raymond ® DSD Maintenance Manual General Information & Features

Solid-State Reversing

LINE POS

SPEED FUSE

Q3 Q5

LOAD CURRENT
A1 +
NO LOAD CURRENT

ARM F1 F2

FULL
CAP Q2
A2 -

STARTING
Q4 Q6

CURRENT
Q1

TORQUE

ARMATURE CURRENT NEG

Figure 4
Figure 3
1
1 Figure 1-4: Solid State Reversing
Figure 1-3: Armature Current in a
Separately Excited Motor
By energizing the transistors in pairs, current
can be made to flow in either direction in the
Aside from the constant horsepower field. The armature control circuit typically
characteristics described, there are many other operates at 12 kHz to 15 kHz, a frequency range
features that provide increased performance normally above human hearing. This high
and lower cost. The following description frequency coupled with the elimination of
provides a brief introduction to examples of directional contactors, provides very quiet
some of these features. vehicle operation. The field control circuits
typically operate at 2 kHz.
Solid-State Reversing The line contactor is normally the only
The direction of armature rotation on a shunt contactor required for the shunt motor traction
motor is determined by the direction in which circuit. This contactor is used for both
current flows through the field windings. pre-charge of the line capacitors and for
Because the shunt motor field only typically emergency shut down of the motor circuit, in
requires about 10% of the armature current at case of problems that would cause a full motor
full torque, it is normally cost effective to torque condition. The line can be energized and
replace the double-pole, double-throw reversing de-energized by the various logic combinations
contactor with a low power transistor H-Bridge of the vehicle, for example, activate on key, seat,
circuit (Figure 4). or start switch closure, and de-energize on time
out of idle vehicle. Again, these options add to
the quiet operation of the vehicle.

Flexible System Application

Because the shunt motor controller has the
ability to control both the armature and field
circuits independently, the system can
normally be adjusted for maximum system
efficiencies at certain operating parameters.
Generally speaking, with the ability of
independent field and armature, the motor
performance curve can be maximized through
proper control application.

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General Information & Features Raymond ® DSD Maintenance Manual

More Features with Fewer Components

More Features with Fewer weakening level in order to set the top speed of
the motor. This top speed function (Minimum
Components Field Current) is enabled when the armature
Field weakening with a series wound motor is current is less than the value set by Function
accomplished by placing a resistor in parallel 24 and the accelerator pedal is fully depressed.
with the field winding of the motor. Bypassing Top Speed can be adjusted by Function 7 of the
some of the current flowing in the field into the Handset or a trimpot.
resistor causes the field current to be less, or The percent on-time has a range of
weakened. With the field weakened, the motor approximately 0 to 100%. The SX controllers
speed will increase, giving the effect of operate at a constant frequency and the percent
“overdrive”. To change the “overdrive speed”, it on-time is controlled by the pulse width of the
is necessary to change the resistor value. In a voltage/current applied to the motor circuits.
separately excited motor, independent control of
the field current provides for infinite
adjustments of “overdrive” levels between motor Creep Speed
base speed and maximum weak field. The
With the accelerator at minimum volts, the
desirability of this feature is enhanced by the
creep speed can be adjusted by Function 2 of
elimination of the contactor and resistor
the Handset. At creep speed, the ON time can
required for field weakening with a series motor.
decrease to approximately 5%, with the OFF
With a separately excited motor, overhauling time at approximately 95%. At full transistor
speed limit, or downhill speed, will also be more operation, this condition will be reversed (short
constant. By its nature, the shunt motor will try OFF time, long ON time). This variation of ON
to maintain a constant speed downhill. This and OFF time of the oscillator varies the voltage
characteristic can be enhanced by increasing applied to the motor, thereby varying the speed
the field strength with the control. Overhauling of the motor for a given load.
load control works in just the opposite way of
field weakening, armature rotation slows with Control Acceleration
the increase of current in the field.
This feature allows for adjustment of the rate of
Regenerative braking (braking energy returned
time it takes for the control to accelerate to
to the battery) may be accomplished completely
100% applied battery voltage to the motor on
with solid-state technology. The main
hard acceleration. Armature C/A is adjusted by
advantage of regenerative braking is increased
Function 3 from 0.1 to 22 seconds.
motor life. Motor current is reduced by 50% or
more during braking while maintaining the
same braking torque as electrical braking with Current Limit
a diode clamp around the armature. The lower
This circuit monitors motor current by utilizing
current translates into longer brush life and
sensors in series with the armature and field
reduced motor heating. Solid state regenerative
windings. The information detected by the
braking also eliminates a power diode, current
sensor is fed back to the card so that current
sensor, and contactor from the circuit.
may be limited to a pre-set value. If heavy load
currents are detected, this circuit overrides the
Features of SX Family of oscillator and limits the average current to a
Transistor Motor Controllers value set by Function 4 and Function 8 of the
Handset. The C/L setting is based on the
maximum thermal rating of the control.
Standard Operation Because of the flyback current through Q2, the
With the accelerator at maximum ohms or volts, motor current is usually greater than battery
the creep speed can be adjusted by Function 2 current, except at 100% ON time.
of the Handset or a trimpot. The field control
section allows the adjustment of the field

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Raymond ® DSD Maintenance Manual General Information & Features

Features of SX Family of Transistor Motor

Regenerative Braking to Zero Speed Auto Braking

This feature is enabled by initiating a “neutral
position” using either the directional switch or
the accelerator switch. Once activated, Auto
Braking operates similar to Pedal Position
Regenerative Braking and is adjusted by using
Q2
Function 21 of the Handset.
ARM

Field Weakening
This function allows the adjustment of the field
Q1
weakening level in order to set the top speed of
Figure 5 the motor. The function is enabled when the
armature current is less than the value set by
1 Function 24 and the accelerator pedal is fully
Figure 1-5: Armature Circuit for Regenerative Braking depressed. It is important to note that this
function is used to optimize motor and control
performance, and this setting will be
Slow down is accomplished when reversing
determined by RAYMOND engineers at the time
direction by providing a small amount of
of vehicle development. Field personnel must
retarding torque for deceleration. If the vehicle
not change this setting without prior written
is moving, and the directional lever is moved
permission from the manufacturer.
from one direction to the other, the regen signal
is initiated. Once the regen signal is initiated,
the field current is increased (armature circuit Speed Limits
shown in Figure 5). Armature current is
This feature provides a means to control speed
regulated to the regen current limit as set by
by limiting motor volts utilizing three
Function 9. As the vehicle slows down, the field
“adjustable” speed limits. This motor volt limit
current continues to increase, and transistor
regulates top speed of the transistor controller,
Q2 begins to chop. The field current increases
but actual truck speed varies at any set point
until it reaches a preset value set by Function
depending on the loading of the vehicle. Each
10, and transistor Q2 on-time increases until it
speed limit is adjustable with the Handset
reaches 100% on-time. Once both of these
using Functions 11, 12, and 13.
conditions are met, and regen current limit can
no longer be maintained, the braking function
is canceled. The fields reverse, and the control Ramp Start
reverts back to motoring.
This feature provides maximum control torque
Part of the energy produced by the motor during to restart a vehicle on an incline. The memory
regen is returned to the battery, and part is for this function is the directional switch. When
dumped in the motor as heat. stopping on an incline, the directional switch
must be left in its original or neutral position to
Pedal Position Regenerative Braking allow the control to initiate full power when
restarted. The accelerator potentiometer input
This feature allows control of the stopping will modulate ramp start current.
distance based on pedal position when there
has been a “directional switch” change. Pedal
position reduces the regenerative current as the
accelerator is returned to the creep speed
position. Maximum regenerative current is
obtained with the accelerator in the top speed
position.

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Roll-Back Control

Roll-Back Control Pulse Monitor Trip (PMT)

This feature provides retarding torque to limit The PMT design contains three features which
rollback speed in the non-travel direction when shut down, or lock out, control operation if a
the accelerator pedal is released when stopping fault conditions occurs that would cause a
on a grade, or when the brake pedal is released disruption of normal vehicle operation:
when starting on a grade. This feature forces
• Look ahead
the vehicle to roll very slowly down the grade
when the accelerator or brake is released. • Look again
Because the vehicle can gain significant speed • Automatic look again and reset
during roll-back, the torque needed to re-start
on the ramp is lower than an unrestricted The PMT circuit will not allow the control to
roll-back speed. start under the following conditions:
• The control monitors both armature and
Steer Pump Contactor Time Delay field FET's at start-up and during running.
• The control will not allow the line contactor
This feature provides two options for SP time
to close at start-up, or will drop it out
delay. Option 1 provides a 0.5 to 63 second time
during running, if either the armature or
delayed drop out of the steer pump contactor
field FET's are bad, so as to cause
when the Forward or Reverse directional switch
uncontrolled truck movement.
is opened. This is the default option for
Function 18. Option 1 is overridden by a 1.5
second time delayed drop out whenever the seat Thermal Protector (TP)
switch is opened. Option 2 provides a 0.5 to 63
This temperature sensitive device is mounted to
second time delayed drop out of the SP
the heat sink of the power transistor (Q1). If the
contactor when the seat switch is opened.
transistor's temperature begins to exceed the
design limits, the thermal protector lowers the
Static Return to Off (SRO) maximum current limit, and maintains the
transistors within their temperature limits.
This inherent feature of the control is designed
Even at a reduced current limit, the vehicle will
to require the driver to return the directional
normally reach sufficient speed. As the control
lever to the neutral position anytime the
cools, the thermal protector automatically
operator leaves the vehicle and returns.
resets, returning the control to full power.
Additionally, if the seat switch or key switch is
opened, the control shuts off and cannot be
restarted until the directional lever is returned Low Voltage
to neutral. A time delay of approximately 2
Batteries under load, particularly if undersized
seconds is built into the seat switch input to
or more than 80 percent discharged, will
allow momentary opening of the seat switch, if a
produce low voltages at the control terminals.
bump is encountered.
The SX control is designed for use down to 50
percent of a nominal battery voltage of 36-84
Accelerator Volts Hold Off volts, and 75 percent of a nominal battery
voltage of 24 volts. Lower battery voltage may
This feature checks the voltage level at the
cause the control to operate improperly;
accelerator input whenever the key switch or
however, the resulting PMT should open the
seat switch is activated. If, at start up, the
Line contactor in the event of a failure.
accelerator is calling for more than 20% of full
speed, the control will not operate. This feature
assures that the control is calling for low speed
operation at start up.

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Systems Diagnostics

Systems Diagnostics Remoter Readings

The control detects the system's present This feature displays the recorded hours of use
operating status and is displayed to either the of the traction and pump control or contactor to
Dash Display or the Handset. There are the Dash Display each time the key switch is
currently over 70 status codes available with SX turned OFF.
systems using Traction and Pump controls and
Truck Management Module (TMM). Along with Maintenance Alert & Speed Limit
the status code display from the TMM, the SX
control is capable of reducing the current to the This feature is used to display Status Code 99
motor, alerting the operator of a critical fault and/or activate a speed limit when the vehicle
condition. operating hours match the hours set into the
maintenance alert register. This feature is set
Standard Status Codes with the Handset using Functions 19 and 20.
The operator is alerted that maintenance on the
The SX traction control has over 30 Status vehicle is required. This function is disabled by
Codes that assist the service technician and setting Functions 19 and 20 to a value of 255.
operator in troubleshooting the vehicle. If
mis-operation of the vehicle occurs, a status Battery Discharge Indication (BDI)
code is displayed on the Dash Display for
vehicles so equipped, or is available by plugging The latest in microprocessor technology is used
the Handset into the “P2 or P4” plug of the logic to provide accurate battery state of charge
card. information and to supply passive and active
warning signals to the vehicle operator.
With the status code number, follow the
Features and functions:
procedures outlined in DIAGNOSTIC STATUS
CODES to determine the problem and a • Displays 100 to 0 percent charge.
solution. • Display blinks with 20% charge. Disables
NOTE: The Status Code Instruction Sheets do pump circuit with 10% charge. Auto
not claim to cover all possible causes of ranging for 36/48 volt operation.
the display of a “status code”. They Adjustable for use on 24 to 80 volts.
provide instructions for checking the
most direct inputs that can cause status Internal Resistance Compensation
codes to appear.
This feature is used when the Battery Discharge
Indicator is present. Adjustment of this
Stored Status Codes
function improves the accuracy of the BDI.
This feature records the last 16 “Stored Status Improper adjustment can cause the battery to
Codes” that have caused a PMT controller shut be over-discharged.
down and¤or disrupted normal vehicle
operation. (PMT type faults are reset by cycling
the key switch). These status codes, along with
the corresponding BDI and remoter readings,
are accessed with the Handset, or by using the
RS 232 communications port and dumping the
information to a Personal Computer terminal.

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Display Modes

Display Modes designed to detect a “worn out brush” and

display a fault code on the Dash Display to
The Dash Display allows the operator to select warn maintenance personnel that the motor
the best vehicle performance for changing brushes needs replacing before they wear to the
application (task) conditions. There are four (4) point of causing destructive damage to the
modes that are selected by depressing a push motor commutator surface.
button on the dash display.
(See Section On Display)
Hydraulic Pump Control
From the Display, the operator may select any
of four pre-set interactive modes consisting of The hydraulic motor controller consists of the
(4) Controlled Acceleration levels, (4) Auto following features:
Regen levels, (4) Lever Regen levels, and (4) • Four speeds, adjustable from 0 to 100%
Speed Limits. motor volts. Fixed speeds actuated by
These interactive modes are “pre-set” using the switch closure to negative.
Handset (Functions 48 through 63) or a • Current limit and controlled acceleration
personal computer (Functions 97 through 112). adjustable.
This feature allows the operator to select the • Battery Discharge Indicator interrupt
best vehicle performance for changing compatible.
application (task) conditions.
Operation of voltage regulator card: This card
provides the basic functions required for
Circuit Board Coil Driver Modules
controlling the pump control, optional
Coil drivers are internal to the control card, and contactors, and PMT functions. Battery positive
are the power devices that operate the Line and is applied through a main control fuse to the
SP contactor coils. On command from the key switch, energizing the control card power
control card, these drivers initiate opening and supply input to P1.
closing the contactor coils. All driver modules When a pump line contactor (PL) is used, PMT
are equipped with reverse battery protection, operation is the same as outlined for the
such that, if the battery is connected traction controllers.
incorrectly, the contactors can not be closed
electrically. The four speed (motor volts) reference points
P12, P19, P20, and P21 are selected by
connecting these points independently to
Truck Management Module (TMM)
battery negative.
The Truck Management Module is a The speed for the Auxiliary functions
multifunction accessory card, or an integral (Aux1¤Aux2) is obtained by closing Speed Limit
function of the GE Pump controls when used 1 (SL1) at P1-12 to control negative. SL1 is
with the SX Traction control. The Module adjustable using the Handset and Function 11
provides the OEM the ability to initiate status to adjust motor voltage from 0 to 100%. The
codes or operator warning codes to be displayed specified motor volts are regulated; however, the
on the Dash Display, whenever a normally open magnitude of motor current varies depending
switch or sensor wire provides a signal to the on the loading of the vehicle.
Module.
The speed for the first lift function (Lift0) is
The TMM Module is used to display a separate obtained by closing Speed Limit 2 (SL2) at
status code indicating overtemperature of P1-19 to control negative. SL2 is adjusted using
traction motors, hydraulic motors, or any other the Handset and Function 12, similar to SL1.
device or system that can activate a switch that
closes. The speed for the tilt function (Tilt) is obtained
by closing Speed Limit 3 (SL3) at P1-20 to
The TMM Module is also used as a Brush Wear control negative. SL3 is adjusted using the
Indicator (BWI). The Brush Wear Indicator is Handset and Function 13, similar to SL1.

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Display Modes

The speed for the second Lift function (Lift1) is

obtained by closing Speed Limit 4 (SL4) at
P1-21 to control negative. SL4 is adjusted using
the Handset and Function 14, similar to SL1.
If more than one Speed Limit is activated, the
selected speed with the highest motor volts will
override the low motor volt speed. The current
limit circuit is adjustable and operates the
same as the traction current limit.
The controlled acceleration circuit is adjustable
and operates the same as the traction circuit.
Adjustment range is from 0.1 to 22.0 seconds.
The Battery Discharge Indicator (BDI) interrupt
disables the hydraulic controller if the
connection at P10 loses the 12 volt signal from
the traction control. BDI interrupt is disabled
by Function 17 using the Handset. Select card
type with or without BDI function.

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GE Information for Separately Excited Controls

GE Information for Separately

Excited Controls
Each section of the GE controller part number
has a particular meaning. Table 1-1 explains
each portion of the controller part number.

Controller Part Number IC3645 SR 4 D 33 2 C3

Part Number Section 01 02 03 04 05 06 07

Section 01
Section 01 defines the basic electric vehicle control number.
SP = Series Control (Pump)
Section 02
SH = Separately Excited Control (Plugging)
Section 02 defines the control type.
SR = Separately Excited Control (Regen to Zero)
1 = 120 volts
2 = 24 volts
3 = 36 volts
Section 03
4 = 48 volts
Section 03 defines the operating voltage.
5 = 36/48 volts
6 = 24/36 volts
7 = 72/80 volts
D = 6.86” x 6.67”

Section 04 R = 6.86” x 8.15”

Section 04 defines the package size. U = 8.66” x 8.13”
W = 8.66” x 10.83”
22 = 220 Amps
Section 05 33 = 330 Amps
Section 05 defines the armature current
(2 characters). 40 = 400 Amps
etc.
2 = 20 Amps
Section 06 3 = 30 Amps
Section 06 defines the field current
(1 character). 4 = 40 Amps
etc.
Section 07 A1 = Customer A/Revision 1
Section 07 defines the customer with an B1 = Customer B/Revision 1
alpha digit and the revision with a
numeric digit. etc.

Table 1-1: Controller Part Number Definition

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Standard Display Operation

Standard Display Premium Display

Operation Operation

1 1

All segments on the display should turn ON and All segments on the LCD display and the
the Vehicle Monitoring System Action Lights Vehicle Monitoring System Action Lights should
should light in a left to right chaser pattern. The light in a chaser pattern from left to right. The
seat belt icon should flash for 10 seconds seat belt icon should flash for 10 seconds
(regardless of whether the seat belt is fastened (regardless of whether the seat belt is fastened
or not). The 7-segment display should show the or not). The time display area should show the
currently selected operating mode level. currently selected operating mode for the drive
motor controller and pump motor controller.

The 7-segment display should read the battery

state of charge in percentage format. This is a The battery charge display area should show
numeric value between zero and one hundred the battery state of charge, and the time display
using the 3 rightmost digits. area should display either the time or date,
NOTE: When the battery reaches a 20% state of whichever is selected.
charge, the battery action light flashes NOTE: When the battery reaches a 20% state of
continuously. At 10% charge, the light charge, the battery action light flashes
remains ON. continuously. At 10% charge, the light
remains on.
For both the Premium and Standard display options, if the display shows a fault code instead of the
battery state of charge, this means a run-time fault was detected. The fault must be corrected
before you use the lift truck. See the sections on the Premium and Standard Displays for more
information on run-time fault codes.

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Standard Display

Standard Display

Battery Discharge
Indicator/Indicator Monitoring
(for Run-time System
Diagnostics) Action Lights

Mode/Fault
History
Button

Battery Discharge Indicator Mode/Fault History Button

The 7-segment Light-Emitting Diode (LED) Pressing and holding this button with the key
numeric display indicates the percentage of switch ON accesses the performance mode. For
battery charge. When the number “100” the first 2 seconds the button is held, the
appears, the battery is fully charged. current operating mode is displayed in “Lx”
format using the 2 right most digits, where “x”
Hour Meter is a numeric value between one and four. If the
performance mode received from the controller
Immediately after the key is turned to the OFF is outside this range, the mode is displayed as
position, the numeric display enters the Hour “L=”. If the mode cannot be read at all, the mode
Display Mode for 12 seconds. Truck hours, is displayed as “LC.” Continuing to hold the
drive motor hours, and pump motor hours are button will cycle the display through the 4
consecutively displayed for 4 seconds each. performance levels. To select a new mode,
Once the Hour Meter display cycle is complete, release the button when the desired mode is
the display goes blank and enters Silent Mode. displayed. This button is also used to access
and navigate History Mode.

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Standard Display

History Mode Fault Code Indicator

While in Silent Mode, the user can access the A fault code is displayed if a run-time fault is
history of the last 16 truck faults by pressing detected by the monitoring system. In addition,
and holding the Mode/Fault History Button. the Fault Code Indicator lights.
Unit behavior is then dependent on whether the
A drive controller fault is displayed in an “-xx”
truck is equipped with a pump controller or not.
format (where “x” is a number from 0 to 9). A
If so, holding the button cycles through a
pump controller fault is displayed in a “-1xx”
display of “d”, “P”, and a blank screen.
format. If the fault code received is out of range
Releasing the button on the “d” or “P” accesses
“===” is displayed.
the history folder for either the drive controller
or pump controller respectively. If the Drive
Controller History folder is selected, the fault Monitoring System Action Lights
code, battery state of charge, and truck power
These symbols light when specific problems are
steering pump hours are displayed for 3
detected. Stop the truck and take corrective
seconds each. If the Pump Controller History
action immediately. These lights are identical
Folder is selected, the display cycles through
for both the Standard and Premium Instrument
the fault code and pump controller hours for
Panels and are detailed later.
three seconds each. Pressing the Mode/Fault
History Button cycles the display to the next
fault. The displayed item blinks briefly (to
acknowledge the button was depressed) before
changing to the next fault. Releasing the button
when the display is blank or turning the key
switch to the ON position, exits History Mode. If
a pump controller is not installed, holding the
button switches the display between “d” and a
blank screen. Accessing the history folder for
the drive controller and exiting History Mode
require the same actions as if the unit was
equipped with a pump controller.

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General Information & Features Raymond ® DSD Maintenance Manual

Premium Display

Premium Display

Drive Motor Pump Motor Brush Wear

Icon Icon Indicator

Battery Discharge
Indicator/Indicator
(for Run-time Speed Display/
Diagnostics) Performance Mode
Indicator/Fault
Code Indicator

Truck Icon

Monitoring
System Action
Lights
History/Date/
Time Display

Right Mode
Left Mode Button
Button

Battery Discharge Indicator Speed Display

The Battery Charge Display Area shows the The Speed Display Area shows the current
current battery state of charge on its bar graph speed in either MPH or KPH depending on the
in 10% increments. unit mode. The appropriate MPH or KPH
symbol also lights to indicate the active mode.
Time Display For details on how to select a desired system of
units, see the Setup Mode section.
The Time Display Area shows either the time or
the date. Simultaneously depressing both Mode Hour Meter
Buttons switches the display between the time
and date. For details on how to set the time and Immediately after the key is turned to the OFF
date, see the Setup Mode section. position, the numeric display enters the Hour
Display Mode for 12 seconds. Truck hours,
drive motor hours, and pump motor hours are
consecutively displayed along with their
corresponding icon for 4 seconds each.

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Premium Display

History Display several other functions described in other

sections.
After the hour display cycle is complete, the
truck enters Silent Mode. No activity is shown
Right Mode Button
on the display or indicators when the truck is in
this mode. By pressing the left or right buttons, This button allows the user to change the
History Display is accessed for either the drive current performance mode. By holding down
motor control or the pump motor control this button while in either the drive
respectively. The corresponding motor icon performance display mode, or pump
illuminates to indicate which history folder is performance display mode the unit will cycle
being accessed. Regardless of which is through each available mode. Releasing the
accessed, the display behaves the same way. button while the desired mode is displayed
The Speed Display Area displays the most switches the unit to that mode. This button has
recent fault code. The time display area cycles several other functions described in other
through 4 different items: battery state of sections.
charge, truck or pump hours, time, and date of
the displayed fault. Pressing either button will
Fault Code Indicator
cycle to the next fault in the history folder. The
display will blink briefly each time a button is A fault code is displayed in the Speed Display
pressed. Area if a run-time fault is detected by the
monitoring system. In addition, the Fault Code
Start-Up Indicator and any applicable icons will light.

Once the key is turned ON, the display enters a

Monitoring System Action Lights
self test mode. All segments on the Liquid
Crystal Display (LCD) and indicators are turned These symbols light when specific problems are
on in a left-to-right chaser pattern. After the self detected. Stop the truck and take corrective
test is complete, the seat belt light will blink for action immediately. These lights are identical
10 seconds regardless of whether the seat belt for both the Standard and Premium Instrument
is fastened. Also, the currently selected drive Panels and are detailed on page 1-25.
controller and pump controller performance
modes are displayed in an “dx_Py” format where
Setup Modes
“x” and “y” are numeric values between 1 and 4.
If the performance mode information from Setup Mode is accessed by pressing both mode
either controller is outside of this range, “=” is buttons simultaneously while the display is in
displayed instead of a number. If the Silent Mode. If the buttons are released within
performance mode information cannot be read, 10 seconds, Regular Setup Mode is accessed. If
“dC” or “PC” is displayed. the buttons are held for longer than 10 seconds,
the display blanks for 5 seconds and then
Left Mode Button enters Speed Sensor Setup Mode.

Pressing this button accesses the drive In Regular Setup Mode the units system
performance display mode. The drive motor (imperial or metric) and the date and time are
icon illuminates and the current drive motor set. Pressing the right button toggles between
mode is displayed in the Speed Display Area. metric (indicated by KPH icon) and imperial
Pressing this button a second time within 4 (MPH icon). Pressing the left button selects the
seconds accesses the pump performance currently flashing mode and advances to the
display mode, and lights the pump motor icon. time setup mode. The time is displayed in the
To return to normal operating mode press this Time Display Area with the hours flashing. The
button again. After 4 seconds, the performance right mode button changes the hour and the left
display mode is exited automatically if no other mode button accepts the currently displayed
buttons are depressed. This button also has hour. The minutes will then flash and are set in
the same manner. AM and PM are set next if the

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General Information & Features Raymond ® DSD Maintenance Manual

Premium Display

unit is in imperial mode. Once the time is set,

the display switches to the current date. Date
setup is identical to time setup, cycling through
year, month, and day respectively. To exit
Regular Setup Mode, press both the left and
right buttons simultaneously.
In Speed Sensor Setup Mode the current speed
sensor setting flashes in the Speed Display
Area. To scroll through the available speed
settings, press and release the right mode
button. Press the left mode button when the
desired speed setting is displayed. The selected
setting will stop flashing and both mode
buttons must then be depressed to select the
setting.
Adjust the Speed Sensor mode according to the
gear ratio and tire diameter. Settings 1 through
12 are for the 2 or 3 ton gear ratio and settings
14 through 25 are for the 1 ton gear ratio. If the
truck has new, standard tires with no wear yet,
use a setting of 5 on 2 or 3 ton trucks and a
setting of 18 on 1 ton trucks.

Brush Wear Indicator Icon

This icon lights if the system detects that either
the drive or pump motor brushes are worn and
need replacing. The corresponding motor icon
(drive or pump) is illuminated with this icon.

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Vehicle Monitoring System—Action Lights

Vehicle Monitoring System—

Action Lights

1 2 3 4 5 6 7

1. Service Due Action Light 4. Battery Charge Action Light

The wrench symbol lights when it is time for The battery symbol flashes if the battery
planned maintenance. The maintenance reaches the 20% charge level. If the charge level
interval is programmed into the GE SX Control drops below 10%, the symbol glows solid.
System to provide reduced drive performance Reduced truck drive and/or lift performance is
when activated. programmed into the GE SX Control System.
2. Seat Belt Warning Action Light 5. Brake Fluid Action Light
The seat belt symbol flashes for the first 10 The brake fluid symbol lights if the brake fluid
seconds after the key is turned ON, regardless reaches a predetermined low level.
of whether the seatbelt is fastened.
6. Park Brake Action Light
3. Overtemperature Action Light
The park brake symbol lights when the park
The thermometer symbol glows if an brake is applied. Do not drive the lift truck with
overtemperature condition develops in the drive the park brake applied.
motor, pump motor, or the controller. Reduced
7. Fault Detection Light
truck drive performance can be programmed
into the GE SX Control System. The fault code symbol lights whenever a fault
code is displayed. When some faults are
detected, the truck shuts downs and cannot be
operated until the cause of the fault is repaired.

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Traction Controller & Pump Controller

Traction Controller & Pump Controller

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Traction Control Logic Flow Chart

Traction Control Logic Flow Chart

Connect
Battery
Power steer
contactor
closes
Battery
Positive @
P1-1
Depress
accelerator which
closes accelerator
start switch
Close Key
Switch

Voltage from
accelerator
Battery potentiometer is
Positive @ applied to
P1-2 controller

Close Seat
Switch The appropriate
H-bridge
transistors are
turned on to
apply voltage to
Line Contactor the field
closes and battery
positive @ control
P, A1, A2, and F1
Q1 transistor
turns on and
voltage is applied
Circuit is to the armature
energized to
allow inputs from
direction lever
and accelerator
Truck moves
in chosen
direction
Select
forward or
reverse

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General Information & Features Raymond ® DSD Maintenance Manual

Troubleshooting the SX Motor Controller

Troubleshooting the SX Motor Controller

If mis-operation of the vehicle occurs, a Status

Code is displayed on the Dash Display or by
plugging a Handset into the P2 or P4 location on
the controller and then reading the status code.
With the Status Code Number, follow the
procedures outlined in the Status Code Section
of this manual to determine the problem.
Checking and replacement of components are
also outlined in this manual. Please refer to this
section as needed.
Important Note: Due to the interaction of the
controller with all vehicle functions, almost any
status code could be caused by the controller.
After all other status code procedures are
followed and no problem is found. Replace the
controller as the last option to correct the
problem.
The same device designations were maintained
on different controls but the wire numbers may
vary. Refer to the elementary and wiring
diagrams for your specific control. The wire
number shown on the schematic will have
identical numbers on the corresponding wiring
diagrams for a specific truck.

! WARNING
Before troubleshooting, jack up
wheels, disconnect the battery and
discharge the capacitors. To
discharge the capacitors, connect a
150 ohm, 25 watt resistor (Part No.
223-012-200) between the positive
and negative terminals on the control
panel for at least 20 seconds.
Reconnect the battery as needed for
the specific check.

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Troubleshooting the SX Motor Controller

CONNECTIONS TO MAIN PLUG (23 PIN) and P2 or P4 PLUG (12 PIN)

PIN TRACTION INPUT/OUTPUT (P1) PUMP INPUT/OUTPUT (P5)

1 Battery volts from battery Battery volts from battery

2 Battery volts from key Battery volts from key

3 Battery volts from start switch Status code 93 input

4 Battery volts from forward switch Status code 93 input

5 Battery volts from reverse switch Status code 94 input

6 Battery volts from seat switch Status code 94 input

7 Accelerator input voltage signal Potentiometer input voltage signal

8 Accelerator negative Status code 95 input

9 Accelerator pot +5 volts supply Status code 95 input

10 BDI interrupt for lift lockout Pump Enable signal 12 VDC

11 1A Driver signal Status code 91 input

12 Optional switched speed limit set by Function 11 Speed limit #1 input

13 Not used TMM brushwear indicator output

14 Hydraulic switch sensor TMM overtemperature output

15 Not used Status code 92 input

16 Not used Status code 90 input

17 Line contactor driver and suppression Line contactor driver

18 Steer pump control driver and suppression 1 A contactor driver

19 TMM +5 volt supply Speed limit #2 input

20 Not used Speed limit #3 input

21 Remoter input for pump contactor Speed limit #4 input

22 Not used Not used

23 Not used Not used

1 2 3 4 5 6 1 2 3 4 5 6 6 8

9 10 11 12 13 14 15
7 8 9 10 11 12
16 17 18 19 20 21 22 23

WIRE HARNESS VIEW P2 or P4 WIRE HARNESS VIEW- MAIN PLUG

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General Information & Features Raymond ® DSD Maintenance Manual

Troubleshooting the SX Motor Controller

1 2 3 4 5 6 1 2 3 4 5 6 6 8

9 10 11 12 13 14 15
7 8 9 10 11 12
16 17 18 19 20 21 22 23

WIRE HARNESS VIEW P2 or P4 WIRE HARNESS VIEW- MAIN PLUG

Pin Traction P2 “Y” Plug Input/Output Pump “P4” Plug Input/Output

1 Not used Not used

2 Not used Not used

3 Not used Not used

4 Negative Negative

5 +5 volt supply +5 volt supply

6 Cont/Store (in) Handset Cont/Store (in) Handset

7 Not used Not used

8 Value Not used

9 Function Not used

10 Not used Not used

11 Serial Receive Serial Receive

12 Serial Transmit Serial Transmit

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Raymond ® DSD Maintenance Manual General Information & Features

General Maintenance Instructions

General Maintenance Instructions

The transistor control, like all electrical

apparati, does have some thermal losses. The ! CAUTION
semiconductor junctions have finite Do not use Electric braking when the
temperature limits, above which these devices vehicle is jacked up and the drive
may be damaged. For these reasons, normal wheels are in a free wheeling
maintenance should guard against any action
that will expose the components to excessive
position. The higher motor speeds
heat and/or those conditions that will reduce can create excessive voltages that
the heat dissipating ability of the control, such are harmful to the control.
as restricting air flow.
The following Do’s and Don’t’s should be Do not hipot (or megger) the control.
observed:
Use a lead-acid battery with the voltage and
Any controls that are applied in ambient ampere hour rating specified for the vehicle.
temperatures over 100°F (40°C) should be Follow normal battery maintenance procedures,
brought to the attention of RAYMOND Service recharging before 80% discharged with periodic
Engineering. equalizing charges.
All external components having inductive coils Visual inspection of GE contactors contained in
must be filtered. Refer to vehicle manufacturer the traction and pump systems is
for specifications. recommended to occur during every 160 hours
of vehicle operation. Inspection is recommended
The wiring should not be directly steam
to verify that the contactors are not binding and
cleaned.
that the tips are intact and free of
In dusty areas, blow low-pressure air over the contaminants.
control to remove dust. In oily or greasy areas,
It is not recommend to perform any type of
use a mild solution of detergent or denatured
welding on the vehicle after the installation of
alcohol to wash the control, and then use
the control(s) in the vehicle. The Raymond
low-pressure air to completely dry the control.
Corporation will not honor control failures
For the control to be most effective, it must be during the warranty period when such failures
mounted against the frame of the vehicle. The are attributed to welding while the control is
metal vehicle frame, acting as an additional installed in the vehicle.
heat sink, gives improved vehicle performance
by keeping the control package cooler. Apply a
thin layer of heat-transfer grease (such as Dow
Cabling for Vehicle Field Repairs
Corning 340) and a metal heatsink pad between If an additional control or electronic device is
the control heat sink and the vehicle frame. added to the vehicle in the field, use only
RAYMOND recommended wires and cables.
Control wire plugs and other exposed transistor
control parts should be kept free of dirt and
paint that might change the effective resistance RF Interference
between points.
To prevent radio frequency (RF) interference,
take care when routing power cables in the
vicinity of radio-controlled devices.

Suppression suppression (for example, a snubber) is

required on all inductive devices. This
Unless specifically noted otherwise,

PDMM-0115 Issued: 07/31/2002 1-31

General Information & Features Raymond ® DSD Maintenance Manual

Recommended Lubrication of Pins and Sockets Prior to Installation

suppression minimizes noise and prevents recommended contact cleaner and lubricant
damage caused by electrical surges. that provides a high degree of environmental
and fretting protection.
Recommended Lubrication of New and re-manufactured control plugs are
Pins and Sockets Prior to cleaned and lubricated prior to shipment from
Installation the factory. However, in applications where
severe vibration or high temperature cycling
and excessive humidity (such as freezers) are
present, it is recommended that the plug
! WARNING terminals are cleaned and lubricated every year,
Before conducting maintenance on per these instructions. In normal applications,
perform plug maintenance every two years,
the vehicle, jack up the drive wheels, unless intermittent problems arise with the
disconnect the battery and discharge plugs, requiring more immediate attention.
the capacitors. To discharge the
capacitors, connect a 150 ohm, 25
watt resistor (Part No. 223-012-200) ! WARNING
between the positive and negative
Do not use any other cleaners or
terminals on the control panel for at
lubricants other than the ones
least 20 seconds.
specified.

Cleaner and lubricant are provided in the

1. Disconnect plug from controller or mating
terminal maintenance kit 223-012-220.
plug.
Fretting occurs during microscopic movement
2. Locate the plug that contains the socket
at the contact points of the connection. This
(female) terminals. Perform maintenance
movement exposes the base metal of the
only on the plug containing the socket
connector pin which, when oxygen is present,
(female) type terminals. Reconnecting the
allows oxidation to occur. Sufficient build up of
plugs lubricates the pin (male) terminals.
the oxidation can cause intermittent contact
and intermittent vehicle operation. This can 3. Clean each terminal using contact cleaner
occur at any similar type of connection, as shown in Figure 1-6.
whether at the control or in any associated
vehicle wiring, and the resultant intermittent
contact can provide the same fault indication as
actual component failure.
The addition of lubricant prevents the oxidation ane
r
e
t cl
process by eliminating the access of oxygen to c on
t ac
r

the contact point. Add lubricant to the 12 pin

ane

and 23 pin plugs of all new SX controls at the

le

time of their installation into a vehicle

C

When servicing existing vehicles exhibiting

symptoms of intermittent mis-operation or
shutdown by the control, add lubricant to all 12 1
and 23 pin plugs, after proper cleaning of the Figure 1-6: Cleaning Terminals
connectors, as a preventative measure to insure
fretting is not an issue before control
replacement. Also, for long term reliable control
operation, the plug terminals must be
maintained per these instructions with the

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Raymond ® DSD Maintenance Manual General Information & Features

General Troubleshooting Instructions

4. Lubricate each terminal using lubricant as NOTE: Status code numbers from 00 to 99 are
shown in Figure 1-7. Apply enough traction control status codes. Status
lubricant to each terminal opening to codes with the prefix 1 (101 to 199) are
completely fill the openings to a minimum pump control status codes.
depth of 0.125 inches.
With the status code number, follow the
procedures outlined in the status code
instruction sheets to determine the problem.
Important Note: Due to the interaction of the
logic card with all vehicle functions, almost any
status code or control fault could be caused by
LU
B
R
IC

the logic card. After all other status code

A
N
T

procedures are followed and no problem is

found, replace the controller as the last option
to correct the problem.
The same device designations were maintained
on different controls but the wire numbers may
vary. Refer to the schematic for your specific
1 control. The wire numbers shown on the
Figure 1-7: Lubricating Terminals schematic have identical numbers on the
corresponding wiring diagrams for a specific
5. Reconnect plugs. vehicle.
Check resistance on R x 1000 scale from frame
General Troubleshooting to power and control terminals. A resistance of
Instructions less than 20,000 ohms can cause misleading
symptoms. Correct resistance of less than 1000
Troubleshooting the SX control should be quick ohms first.
and easy when following the instructions
outlined in the status code instruction sheets. Before proceeding, visually check for loose
wiring, mis-aligned linkage to the accelerator
switch, signs of overheating of components, etc.
! WARNING Tools and test equipment required are: clip
leads, volt-ohm meter (20,000 ohms per volt)
Before troubleshooting, jack up the and basic hand tools.
drive wheels, disconnect the battery,
and discharge the capacitors. BDI Operation
Discharge capacitors by connecting a
BDI is only monitored by the GE Traction
150 ohm, 25 watt resistor (Part No
controller, not the pump controller. The
223-012-200) between the positive separate pump controller has no way of
and negative terminals on the control tracking the charge of battery. In order to tell
panel for at least 20 seconds. the truck display what the state of charge of the
Reconnect the battery as needed for battery is so that it can show the operator, the
specific checks. traction controller uses a specific algorithm to
more accurately determine the voltage on the
battery. The information sent to the display is
If mis-operation of the vehicle occurs, a status just a percentage value, but this percentage is
code will display on the Dash Display or is linked to a specific battery voltage by the
available by plugging a Handset into the plug controller.
P2 location and reading the status code.

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General Information & Features Raymond ® DSD Maintenance Manual

General Troubleshooting Instructions

The GE controller uses a value of 2.14 volts per charge by 1%. This means that it will take a
cell or higher to indicate a fully charged battery minimum of 4 minutes for the BDI to drop 10%
(100%) and a value of 1.94 volts per cell or
lower to indicate a fully discharged battery (0%). Function 14 Setting
As an example, a 36V battery with 18 cells
would have a fully charged voltage of 38.52V In order for the controller to know what the true
and a fully discharged voltage to a percentage state of discharge of the battery is by measuring
value that is then sent to the display. the voltage while the battery is supplying
current, there must be a relationship
The controller must know how many cells are
established that gives the static voltage of the
present to properly make this association, so
battery based on the voltage of the battery
there is a setting (setting number 15) that can
under a load. This relationship is based on the
be adjusted to do this. Because the voltage
internal resistance of the battery and can vary
difference is great enough between a 36V and
between different batteries based on battery
48V battery, there is a value that setting
quality, capacity, and voltage. This
number 15 can be set to that allows the
compensation factor is adjusted using
controller to determine which of these two
Setting 14 in the GE traction controller.
voltages is connected. If this setting is used, the
controller can sometimes be fooled by a 36V See Function 14 in the Handset section, there is
battery with a high surface voltage (generally a table titled Internal Resistance Compensation
present just after the battery is unplugged from Table. This table gives the appropriate setting
the charger) or an over discharged 48V battery. for a given voltage drop. This voltage drop value
Another problem can arise if a battery is is the difference between the voltage on the
plugged into the truck that has a different battery while providing 0 amps of current (static
voltage than the previous battery, without voltage) and the voltage on the battery while
letting the head capacitors in the controller providing 100 amps of currents. From this
discharge. Until the capacitors completely given voltage, the logic in the controller can
discharge, the controller still holds memory of determine the static voltage of the battery when
the voltage of the first battery and will not the traction motor current is at any value
automatically adjust to the new particular between 50 amps and 400 amps.
voltage of the battery to be used in the truck.
To obtain the correct voltage drop for the
Whenever the controller is powered up and the function 14 table, subtract the battery voltage
key switch is turned ON after having the when the battery current is 100 amps from the
capacitors completely discharged, the controller static battery voltage. A true static voltage of the
must start with a new battery discharge level battery is difficult to obtain if there is some
based on the voltage that is measured at that surface charge still on the battery right after
time. This discharged voltage is stored and sent charging or if the battery voltage is still rising
to the display to be shown to the operator. after heavy usage. In addition, getting the
current to be exactly 100 amps out of the
Once the controller knows how many cells the
battery can be difficult as well. Because getting
battery has and the current discharge state of
this information is difficult, it can sometimes
the battery, it must then start taking samples of
cause the voltage measurement to be off by as
the battery voltage to monitor any changes in
much as a couple of volts.
the battery’s state of charge. These samples are
taken only during operation of the traction A simpler method of obtaining the correct
motor by the traction controller and only when values that are at least 100 amps apart and
the current in the traction motor is between 50 extrapolate. The voltage drop that is given in the
amps and 400 amps. Each sample is at least 4 Function 14 table is based on the assumption
seconds apart. As the values of the sample that the voltage and battery current are linear.
voltages start changing, the controller waits Once the current and voltage are known for any
until the measured voltage value is lower than 2 points, any third point on the same line can
the stored voltage value 6 times in a row before be calculated. If the third point is chosen as
it will decrement the stored battery state of being exactly 100 amps above or below one of

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Raymond ® DSD Maintenance Manual General Information & Features

General Troubleshooting Instructions

the other points, then the voltage difference

between should work for the Function 14 table.
Example:
Operate unloaded lift greater than 36.5
volts on the battery with 120 amps out
of the battery
Operate loaded lift greater than 34.4 volts
on the battery with 275 amps out of the
battery
Find the voltage difference (X) for a current
difference of 100 amps.
Slope =
voltage difference/current difference =
(36.5-34.4)/(275-120) = 0.0135 = X/100
X = 0.0135 * 100 = 1.35
Since 1.35 is between a setting of 16 (1.43) and
17 (1.34), choose the higher setting (17) to be
sure that the battery is not over-charged.
Adjust the setting for Function 14 for each
different battery that is used in a truck to
insure the proper amount of discharge per
cycle. If a battery is not being discharged
properly (over or under discharged), even after
properly adjusting Function 14, the
Function 14 setting is raised to decrease the
depth of discharge or lowered to increase the
depth of discharge.

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General Information & Features Raymond ® DSD Maintenance Manual

General Troubleshooting Instructions

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Raymond ® DSD Maintenance Manual Handset

Handset 2:

PDMM-0115 Issued: 07/31/2002 2-1

Handset Raymond ® DSD Maintenance Manual

General Information

General Information

The Handset is a multifunctional tool used with

the SX series motor controllers. The Handset is
1
used to access the memory elements called
HANDSET
“Registers” which have electronic data stored in
them to control an operation. There are 128
Registers in the SX series of Control Cards. The
2 Handset accesses the registers for the traction
or pump motor functions, indicates Status
Codes (possible faults), and makes adjustments
to the operating limits set in the Control Cards.
Some of the registers in the “SX” series of
3 control cards can not be accessed with the
Handset. The Handset can access the registers
CONT STORE that control the operation of the lift truck. The
values for the limits on the control card
1 2 3 4
PLUG WIRING functions are set with either the Handset or a
5 6 7 8 PC. The Handset has a Light Emitting Diode
MOD. PLUG
9 10 11 12 PLUG P2 or P4
(LED) display, a keypad for data entry, and an
1 9 adjustment knob for changing function values.
13 14 15 2 6 See Figure 2-1.
3 3 NOTE: The vehicle will operate with the
4 4
Handset connected, however, the
5 5
6 8
adjustment knob MUST BE SET FULLY
7 1 CLOCKWISE to make sure the control
8 2 can operate at maximum speed.
This section has the control card checks and
adjustments that are made using the Handset.
The control card checks and adjustments are
usually made with the controller installed in the
lift truck. Bench checks and adjustments can
also be made with the control card connected as
shown in FIGURE 4. The checks show the
stored setting numbers that were stored for the
different controller functions. This section also
includes a description of each of the different
1. Adjustment 4. Coil Cord functions. Use the adjustment knob on the
Knob Handset to adjust the function settings. See
5. Plug P2 or P4
Figure 2-1.
2. LED Display (12 Pin)
3. Keypad 6. Modular Plug The Handset with a cord is available through
(8 Pin Hand Set) your lift truck dealer under part #223-012-198.
The handset is the same for all GE controls;
2 however, the cord is different for the SX series
Figure 2-1: Handset motor controllers. The SX controller Handset
cord is available from The Raymond Parts
Distribution Center or your local authorized
dealer under part #223-012-199.

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Raymond ® DSD Maintenance Manual Handset

Handset Functions

Handset Functions

The purpose of the Handset is to permit At the Traction Controller, unplug the “P2 plug”
authorized personnel to perform checks and and plug in the Handset to the plug location P2
adjustments: on the controller. After installing the Handset
tool, plug in the battery and turn ON the key
• Monitor existing system fault codes for both
switch. The following start-up display sequence
traction and pump controllers
occurs:
• Monitor intermittent random status codes
• Monitor battery state of charge
Start-Up Display Sequence
• Monitor hour meter reading on traction and
pump controllers
• Monitor or adjust these control functions: Key Switch ON
• Creep speed
• Controlled acceleration and 1A time Verify each LED Segment 8888
• Armature and field current limit
• Steer pump time delay and define signal
input (seat switch or directional switch) If Maintenance
If Maintenance
• Regenerative braking current limit Code is Active Code is
Not Active
• Speed limit points (SL1, SL2, and SL3)
• Truck management fault speed limit
Display Code -99 for four
• Internal resistance compensation for seconds and activate
battery state of charge indication speed limit (if selected)

• Battery voltage (36/48 volts can be auto

ranging) BDI Display Diagnostics
override with
• Selection of card operation type: fault
• Standard traction card selection:
• 1A enabled/disabled Run Mode

• Auto braking enabled/disabled BDI Display Diagnostics

override with
fault
Operation
Key Switch OFF

! WARNING
Display steer pump hour meter
Before connecting or disconnecting for four seconds
the Handset tool, 1) Jack up the drive
wheels of the vehicle, 2) Turn OFF the Display traction hour meter
for four seconds
key switch, 3) Unplug the battery
and 4) Discharge the capacitors.
Display pump hour meter
for four seconds
2

Figure 2-2: Start-up Display

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Handset Raymond ® DSD Maintenance Manual

Function Set-Up Procedures

There are 15 numbers on the keypad but many

! WARNING more functions available. For the first 15
functions on the keypad simply press the
Before making any adjustments to appropriate number. To access Functions 16
the control, consult the function through 30 press the CONT button and the
settings on page 4. Failure to use the appropriate number on the keypad at the same
proper settings could result in time. For the traction controller, the seat switch
must be open and for the pump controller, the
misoperation or damage to the
key switch must be ON.
control system.
Example for Function 16:
CONT and keypad #1
Function Set-Up Procedures Example for Function 18:
With the Handset connected, hold down the CONT and keypad #3
CONT button while turning ON the key switch. To access Functions 48 and up, the seat switch
The Handset will show the segment checking must be closed for the traction controller, and
display. This accesses the set up mode, ready to the key switch turned OFF for the pump
monitor or adjust control function settings. If a controller. Press the CONT button and the
fault code is displayed, simply push the CONT appropriate number on the keypad at the same
button to clear. time.
Push down one of the function numbers on the Example for function 48:
keypad to check that setting. For example, CONT and keypad #1
push down on function key ⑤: the
corresponding function code is displayed. When programming is finished, press the ESC
button when the (8888) is showing and press it
Example: U 05 again for 1 second. The display now shows the
After one second, we will see the value that is battery state of charge. This means the control
stored under this function: is in run mode.

Example: 105 NOTE: For bench checks and adjustments,

please see the GE Sentry for Windows
If this value needs resetting, push again on the section
CONT button and the value will blink. The
number on the Handset will no longer be the
original value but will correspond to the
position where the adjustment knob was left.
Turn the adjustment knob to the desired setting
(the values will continue to blink). When the
desired setting is reached, push STORE. The
value displayed will no longer blink. Next, push
the ESC button and get the Segment Check
display again. This indicates the programming
mode is still accessed. Continue this process to
check or set all the functions. Each time a value
is changed, go back and verify that the setting
is correct. The value adjustment range available
on the Handset is 0 to 255. However, some
functions do not use the entire range.

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Raymond ® DSD Maintenance Manual Handset

Accessing Stored Fault Codes

Accessing Stored Fault Codes the ON position. The first of the 16 status codes
will be overwritten each time a new status code
The SX Traction and Pump Motor Controllers occurs. The stored status is cleared from the
have function registers (31 through 47) that register by using the Handset. Use the
store the last 16 Status Codes that caused the procedure in Figure 2-3 to access and clear
operation of the lift truck to stop, the battery the fault code registers for the traction and
charge, and the power steer hours at the time pump controllers with the Handset.
the fault occurred. A PMT fault is reset by
turning the key to the OFF position and then to

Key to OFF position

Push ESC and CONT at

the same time

Release ESC and CONT

Status Code Displayed Push ESC to erase Hold both the ESC and
stored data CONT keys down to
erase all 16 stored codes

Push CONT Key

Displays Battery Push ESC to erase

State-of-Charge When stored data
Fault occurred

Push CONT Button

Display hour meter Push ESC to erase

reading when fault stored data
occurred

Push CONT Button

Figure 2-3: Accessing Fault Codes

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Handset Raymond ® DSD Maintenance Manual

Set-up Functions for Traction Controller

FUNCTION 2. Creep Speed (Push 2)

! WARNING This function allows for the adjustment of the
Please contact RAYMOND before creep speed of the vehicle. Creep speed can add
13% to the percent on-time at the slowest speed
making changes to any function
range.
settings. Failure to properly adjust
the settings could result in Range: 2% to 15% on-time
misoperation or damage to the Set: 0 to 255
motor and/or controller. Resolution: 0.05% per set unit
Example: Setting of 20 = 3% on time
FUNCTION 3. Armature Controlled
Acceleration (Push 3)
LX
HANDSET

This function allows for the adjustment of the

g EVC
rate of time it takes for the control to accelerate
to 100% applied battery voltage to the motor on
hard acceleration. This function is changed by
the Dash Display mode selection button.
Range: 0.025 to 6.3 seconds
Set: 0 to 255
Resolution: 0.025 seconds per set unit
CON T ST ORE Example: Setting of 20 = 0.5 seconds
FUNCTION 4. Armature Current Limit
1 2 3 4 (Push 4)
+ + This function should always remain set at 255
(maximum current limit) for this family of
5 6 7
controls.

9 10 11 12 FUNCTION 5. Counter EMF Trip Point for

Auto Braking (Push 5)
This function allows for the adjustment of the
13 14 15 ESC
speed at which the truck will activate auto
braking, after the accelerator pedal is released.
The truck speed correlates to the amount of
voltage produced by the traction motor when it
2
is coasting. The setting of this function
represents the motor voltage.

Set-up Functions for Range: 0 to 100 volts

Traction Controller Set: 0 to 255

Resolution: 0.392 volts per set unit
FUNCTION 1. Mile per Hour Scaling (Push 1)
Example: Setting of 20 = 7.84 volts
This function is not used. If the premium
display option is used, the speedometer is
adjusted through the display.
Factory Default Value 16

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Raymond ® DSD Maintenance Manual Handset

Set-up Functions for Traction Controller

FUNCTION 6. Auto Calibration of Accelerator FUNCTION 9. Regen Braking Current Limit

Potentiometer (Push 6) (Push 9)
This function allows for the auto calibration of This function allows for the adjustment of the
the accelerator potentiometer. Leave this maximum current seen by the motor during
function set to a value of zero during normal regenerative braking; the higher the current,
truck operation. To activate the auto calibration the shorter the stopping distance. This function
routine, set this function to a value between 15 is changed using the Dash Display mode
and 20, and refer to the truck setup section of selection button.
this manual for detailed instructions covering
the auto calibration procedure.
Resolution Example
Important Note: Use this function to Volts Min Max Set per Unit if set at
Value 100
recalibrate the accelerator every time the
traction controller or accelerator is replaced. 36/46 182 591 0 to 1.625 344
A A 255 amps amps
FUNCTION 7. Min Field Current (Push 7)
72/80 52A 409 32 to 1.625 162
This function allows the adjustment of the field A 255 amps amps
weakening level in order to set the top speed of
the motor.
REGEN BRAKE IA = (VAL X 1.625) + 182
at 36/48 volts
Resolution Example
Volts Min Max Set per Unit if set at REGEN BRAKE IA = (VAL X 1.625)
Value 71 at 72/80 volts

36/46 0 20 51 to 0.314 6.28 A FUNCTION 10. Max Field Current During

115 amps Regen (Push 10)
72/80 0 17 51 to 0.269 5.38 A This function allows for the adjustment of the
114 amps maximum field current attainable during the
regenerative braking mode.
MIN IF = (VAL-51) X 0.314 (at 36¤48
VOLTS)
Resolution Example
MIN IF = (VAL-51) X 0.269 (at 72¤80 Volts Min Max Set per Unit if set at
Value 220
VOLTS)
Important Note: This function is used to 36/46 0 64 51 to 0.314 53 amps
255 amps
optimize motor and control performance, and
this setting was determined by RAYMOND 72/80 0 55 51 to 0.269 45 amps
engineers at the time of vehicle development. 255 amps
Field personnel must not change this setting
without prior written permission from the IF = (VAL-51) x 0.314 (at 36/48 volts)
manufacturer.
IF = (VAL-51) x 0.269 (at 72/80 volts)
FUNCTION 8. Max Field Current (Push 8)
Important Note: This function is used to
This function allows for the adjustment of the optimize motor and control performance and
maximum field current in order to obtain the this setting was determined by Raymond
maximum torque of the motor. Always set this engineers at the time of vehicle development.
function to 255. Field personnel must not change this setting
without prior written permission from the
manufacturer.

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Handset Raymond ® DSD Maintenance Manual

Set-up Functions for Traction Controller

FUNCTION 11. Auxiliary Speed Limit FUNCTION 13. Maintenance and Truck
(Push 11) Management Speed Limit (Push 13)
This function allows for the adjustment of the This function is the same as Function 11;
motor speed limit (maximum battery volts to the however, it is active based on maintenance
motor) based on the state of pin P1-12 of the hours (Function 19 and 20), or traction motor
controller. If pin P1-12 is pulled to battery volts, overheating (Status Code 90), or on low BDI
the speed limit is deactivated. If pin P1-12 is value.
allowed to float, the speed limit is active.
Range: 100% to 0% battery volts
Range: 100% to 0% battery volts
Set: 46 to 180
Set: 46 to 180
Resolution: 0.75% per set unit
Resolution: 0.75% per set unit
Example: Setting of 80 = 75% of battery
Example: Setting of 80 = 75% of battery volts
volts
SPEED LIMIT = 100% - [(VAL-46) x 0.75%]
Factory Default Value: 0
FUNCTION 14. Internal Resistance
SPEED LIMIT = 100% - [(VAL-46) x 0.75%] Compensation (Push 14)
FUNCTION 12. Top Speed Limit (Push 12) This function is used when the Battery
Discharge Indicator is present. Adjustment of
This function allows for the adjustment of the
this function improves the accuracy of the BDI.
motor speed limit (maximum battery volts to the
In order to determine this setting, the voltage
motor). This speed limit is the same as Function
drop of the battery under load must first be
11; however, it is always active. This function is
calculated.
changed using the Dash Display mode selection
button. 1. On a fully charged battery, record the open
circuit voltage (Vo) by measuring the voltage
Range: 100% to 0% battery volts
at the control positive and negative power
Set: 46 to 180 terminals.
Resolution: 0.75% per set unit 2. Load the traction motor to 100 amps in the
battery cable and record the voltage (VL) at
Example: Setting of 80 = 75% of battery the control positive and negative power
volts terminal.
Factory Default Value: 0 3. Calculate voltage drop (VDrop) as follows:
SPEED LIMIT = 100% - [(VAL-46) x 0.75%] VDrop = Vo – VL
4. Use the table below to determine the
appropriate setting. Use the calculated
VDrop as a reference.
(See Function 14 settings in General
Information & Features)

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Raymond ® DSD Maintenance Manual Handset

Internal Resistance Compensation Table

Internal Resistance Compensation NOTE: The following functions have function

Table numbers larger than the numbers on
the Handset keypad. To access these
functions. Push the CONT key and the
Setting VDrop Setting VDrop number shown in the instructions at the
same time. THE SEAT SWITCH MUST
2 11.44 17 01.34 BE OPEN.
3 07.60 18 01.27 FUNCTION 16. Stall Protection % On-time
Trip Point (Push CONT 1)
4 05.72 19 01.20
This function allows for the adjustment of the
5 04.57 20 01.14 stall motor protection, as well as the display
6 03.81 21 01.09 and storing of an 82 fault code. This function
adjusts the percent on time at which the fault
7 03.27 22 01.04 occurs when the accelerator is calling for
greater than 50% speed and the armature
8 02.86 23 00.99 current is above 500 amps at 36/48V (or above
9 02.54 24 00.95 370 amps at 72/80V).
Range: 100% to 0% battery volts
10 02.28 25 00.91
Set: 46 to 180
11 02.08 26 00.88
Resolution: 0.75% per set unit
12 01.90 27 00.85
Example: Setting of 125 = 41% on-time
13 01.76 28 00.82
% ON TIME = 100% - [(VAL-46) x 0.75%]
14 01.63 29 00.79 Important Note: This function is used to
15 01.52 30 00.76 optimize motor and control performance, and
this setting will be determined by Raymond
16 01.43 31 00.74 engineers at the time of vehicle development.
Field personnel must not change this setting
FUNCTION 15. Battery Volts (Push l5) without prior written permission from the
manufacturer.
This function allows for the adjustment of
voltage range. In order for the BDI to operate
properly, the setting as shown in the table must
be entered:

Battery
Set units
volts

Between 32 and 44 FACTORY

36
DEFAULT

48 Between 45 and 69

72 Between 70 and 80

80 Between 81 and 183

36/48 Between 184 and 250

No BDI Between 251 and 255

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Handset Raymond ® DSD Maintenance Manual

Internal Resistance Compensation Table

FUNCTION 17. Card Type Selection • Pick up steer pump contactor on directional
(Push CONT 2) switch closure and drop out steer pump
contactor on directional switch opening,
This function allows the user to enable or
after a delay determined by the following:
disable the vehicle’s auto braking routine by
setting the function within the ranges outlined Range: 0.5 to 63 seconds
in the chart.
Setting: Between 128 and 255
Control Function Setting Resolution: 0.5 seconds per set unit

740A, 1A enabled, auto Example: Setting of 149 = [(149-128) x 0.5]

128 to 255 + 1.5 = 11.5 seconds
36/48V braking enabled
NOTE: If the seat switch opens, the steer pump
740A, 1A enabled, auto
64 to 127 contactor will open immediately. If a foot
36/48V braking disabled
directional control option is installed on
740A, Without 1A, auto a truck, use only the settings for the
50 to 63 seat switch input.
36/48V braking enabled

740A, Without 1A, auto FUNCTION 19. Maintenance Code Tens and
0 to 49 Units Hours Set (Push CONT 4)
36/48V braking disabled

600A, Auto braking This function allows for the adjustment of the
50 to 255 tens and units hours of the maintenance code
36/48V enabled
activation time.
600A, Auto braking
0 to 49 Range: 0 to 99
36/48V disabled
Set: 0 to 99
450A, Auto braking
50 to 255 Example: 9999 Hours
72/80V enabled

450A, Auto braking Disabled: 255

0 to 49
72/80V disabled FUNCTION 20. Maintenance Code Thousands
and Hundreds Hours Set (Push CONT 5)

FUNCTION 18. Steer Pump Time Delay This function allows for the adjustment of the
(Push CONT 3) thousands and hundreds hours of the
maintenance code activation time.
This function allows for the selection of steer
pump contactor pick up input, either seat Range: 0 to 240
switch or directional switch closing, as well as Set: 0 to 240
the adjustment of the time delay for the
contactor drop out. Example: 9999 Hours

• Pick up steer pump contactor on seat Disabled: 255

switch closure and drop out steer pump
contactor on seat switch opening, after a
delay determined by the following:
Range: 1.5 to 65 seconds
Setting: Between 0 and 127
Resolution: 0.5 seconds per set unit
Example: Setting of 20 = (20 x 0.5) + 1.5 =
11.5 seconds

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Internal Resistance Compensation Table

FUNCTION 21. Auto Regen Braking Current without prior written permission from the
Limit (Push CONT 6) manufacturer.
This function allows for the adjustment of the FUNCTION 25. Monitor (Push CONT 10)
braking torque applied when the start or
This function is not used. To ensure optimum
directional switch is opened, and the counter
operation of the control, leave this function with
EMF is above the setting of Function 5. A higher
zero stored in the register.
current correlates to a shorter stopping
distance. This function is changed using the FUNCTION 26. Field to Armature Current
Dash Display mode selection button. Ratio (Push CONT 11)
Current = (Value of Setting/4) x 6.5 This function sets the ratio between armature
and field current when operating below the
NOTE: If the result is less than 52 amps, the
maximum field current and above the Field
control will default to 52 amps.
Weakening Start point. The setting represents
FUNCTION 22. Not Applicable the quantity of field current changed for each 1
amp of armature current changed.
This value changes with operating mode
selected, and should not be adjusted in the For a 36/48V control:
field.
Range: 0 to 0.314 field amps/armature
FUNCTION 23. Regen Cancel Current amp
(Push CONT 8)
Setting: 0 to 13
This function allows for the adjustment of the
Resolution: 0.024 field amps/armature
armature current at which regenerative braking
amp
cancels, and is specific to each motor design.
Example: Setting of 10 = 0.24 field
Important Note: This function is used to
amps/armature amp
optimize motor and control performance, and
this setting will be determined by Raymond For a 72¤80V control:
engineers at the time of vehicle development.
Range: 0 to 0.269 field amps/armature
Field personnel must not change this setting
amp
without prior written permission from the
manufacturer. Setting: 0 to 13
FUNCTION 24. Field Weakening Start Resolution: 0.021 field amps/armature
(Push CONT 9) amp
This function allows for setting the armature Example: Setting of 10 = 0.20 field
current at which minimum field current is amps/armature amp
achieved. Important Note: This function is used to
Range: 0 to 414 Amps optimize motor and control performance, and
this setting will be determined by Raymond
Setting: 0 to 255 engineers at the time of vehicle development.
Resolution: 1.625 per set unit Field personnel must not change this setting
without prior written permission from the
Example: Setting of 20 = 32.5 amps manufacturer.
I motor FWS = VAL. x 1.625
FUNCTION 27. Minutes Register
Important Note: This function is used to (Push CONT 12)
optimize motor and control performance, and
This register is only intended for storage of the
this setting will be determined by Raymond
minutes value for proper operation of the hour
engineers at the time of vehicle development.
meter and is not adjustable.
Field personnel must not change this setting

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Handset Raymond ® DSD Maintenance Manual

Internal Resistance Compensation Table

FUNCTION 28. Stored Status Code Count FUNCTION 48. Mode 1 Armature Controlled
Pointer (Push CONT 13) Acceleration (Push CONT 1)
This register contains the location of the last This function allows for the adjustment of the
stored status code recorded of the 16 stored rate of time it takes for the control to accelerate
status codes. These stored status codes have to 100% applied battery voltage to the motor on
caused a PMT controller shutdown and/or hard acceleration.
disruption of normal vehicle operation.
Range: 1.0 to 25.5 seconds
To determine which stored status code was the
Set: 10 to 255
last one recorded, read the number stored in
Function 28. Using the Memory Map, match Resolution: 0.10 seconds per set unit
the "stored status code pointer number" [the
Example: Setting of 20 = 2.0 seconds
number shown in the HS (Handset) number
column] on the memory map, with the number This C/A takes effect when the Mode 1 settings
obtained from Function 28. This is the last are called for by the Dash Display.
stored status code recorded.
FUNCTION 49. Mode 1 Regen Current Limit
NOTE: When scrolling through the stored (Push CONT 2)
status code register, the register always
This function allows for the adjustment of the
starts at status code 1 and scrolls to
maximum current seen by the motor during
status code 16.
regenerative braking; the higher the current,
FUNCTION 29. Power Steering Hours (Ones the shorter the stopping distance.
and Tens) (Push CONT 14)
This register is only intended for storage of the Reso-
ones and tens values of the hours of operation lution Example
Volts Min Max Set Per If set at
of the power steering motor and is not
unit 100
adjustable. value
FUNCTION 30. Power Steering Hours 0 to 344
(Hundreds and Thousands) (Push CONT 15) 36/48 182 A 591 A 1.625
255 amps

This register is only intended for storage of the 32 to 162

72/80 52 A 409 A 1.625
hundreds and thousands values of the hours of 255 amps
operation of the power steering motor and is not
adjustable. REGEN BRAKE IA = (VAL X 1.625) + 182 at
36/48 volts
Dash Display Modes REGEN BRAKE IA = (VAL X 1.625) at 72/80
The following functions (functions 48 through volts
63) are mode settings that are activated from This REGEN CURRENT LIMIT takes effect when
the Dash Display. the Mode 1 settings are called for by the Dash
NOTE: The following functions have function Display.
numbers larger than the numbers on
the Handset keyboard. To access these
functions. Push the CONT key and the
number shown in the instructions at the
same time. THE SEAT SWITCH MUST
BE CLOSED.

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Raymond ® DSD Maintenance Manual Handset

Internal Resistance Compensation Table

FUNCTION 50. Mode 1 Auto Regen Current This AUTO REGEN CURRENT LIMIT takes
Limit (Push CONT 3) effect when the Mode 2 settings are called for by
the Dash Display.
This function allows for the adjustment of the
braking torque applied when the start or FUNCTION 55. Mode 2 Speed Limit
directional switch is opened, and the counter (Push CONT 8)
EMF is above the setting of Function 5. A higher
Same as Function 51.
current correlates to a shorter stopping
distance. This SPEED LIMIT 2 takes effect when the Mode
2 settings are called for by the Dash Display.
Current = (Value of Setting/4) x 6.5
NOTE: If the result is less than 52 amps, the
FUNCTION 56. Mode 3 Armature Controlled
Acceleration (Push CONT 9)
control will default to 52 amps.
Same as Function 48.
This AUTO REGEN CURRENT LIMIT takes
effect when the Mode 1 settings are called for by This C/A takes effect when the Mode 3 settings
the Dash Display. are called for by the Dash Display.
FUNCTION 51. Mode 1 Speed Limit FUNCTION 57. Mode 3 Regen Current Limit
(Push CONT 4) (Push CONT 10)
This function allows for the adjustment of the Same as Function 49.
motor speed limit (maximum battery volts to the
This REGEN CURRENT LIMIT takes effect when
motor).
the Mode 3 settings are called for by the Dash
Range: 100% to 0% battery volts Display.
Set: 46 to 180 FUNCTION 58. Mode 3 Auto Regen Current
Resolution: 0.75% per set unit Limit (Push CONT 11)

Example: Setting of 80 = 75% of battery Same as Function 50.

volts This AUTO REGEN CURRENT LIMIT takes
SPEED LIMIT = 100% - [(VAL-46) x 0.75%] effect when the Mode 3 settings are called for by
the Dash Display.
This speed limit takes effect when the Mode 1
settings are called for by the interactive Dash FUNCTION 59. Mode 3 Speed Limit 2
Display. (Push CONT 12)

FUNCTION 52. Mode 2 Armature Controlled Same as Function 51.

Acceleration (Push CONT 5) This speed limit takes effect when the Mode 3
Same as Function 48. settings are called for by the Dash Display.

This C/A takes effect when the Mode 2 settings FUNCTION 60. Mode 4 Armature Controlled
are called for by the Dash Display. Acceleration (Push CONT 13)

FUNCTION 53. Mode 2 Regen Current Limit Same as Function 48.

(Push CONT 6) This C/A takes effect when the Mode 4 settings
Same as Function 49. are called for by the Dash Display.

This REGEN CURRENT LIMIT takes effect when FUNCTION 61. Mode 4 Regen Current Limit
the Mode 2 settings are called for by the Dash (Push CONT 14)
Display. Same as Function 49.
FUNCTION 54. Mode 2 Auto Regen Current This REGEN CURRENT LIMIT takes effect when
Limit (Push CONT 7) the Mode 4 settings are called for by the Dash
Same as Function 50. Display.

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Handset Raymond ® DSD Maintenance Manual

Internal Resistance Compensation Table

FUNCTION 62. Mode 4 Auto Regen Current FUNCTION 63. Mode 4 Speed Limit 2 (Push
Limit (Push CONT 15) CONT ESC)
Same as Function 50. Same as Function 51.
This AUTO REGEN CURRENT LIMIT takes This speed limit takes effect when the Mode 4
effect when the Mode 4 settings are called for by settings are called for by the Dash Display.
the Dash Display.

The "maximum field current " setting is

adjusted by Function 8. This function, along
with the "armature current limit" , Function 4,
sets the maximum torque of the motor.

MAXIMUM

The " ratio " setting is adjusted by Function 26.

This function sets the ratio between armature
and field current when operating, IMOTOR is
above FWS and less than the full load
transistion point. Setting is the value of field
current changed for each 100 amps of
armature current changed.
FIELD CURRENT

The " minimum field

current " setting is adjusted
by Function 7. The function
sets the top speed of the
motor.

The " field weakening start "

setting is adjusted by Function
24. This function sets the
armature current at which
minimum field current will be
achieved .

ZERO
ARMATURE CURRENT
MAXIMUM
ZERO

The "full load transition point "

The "armature current limit "

setting is adjusted by Function 4.
The function along with the
"maximum field current",
Function 8, sets the maximum
torque of the motor.

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Raymond ® DSD Maintenance Manual Handset

Set-up Functions for Hydraulic Pump Control

Set-up Functions for until the total IR compensation voltage is

added.
Hydraulic Pump Control Range: 0.0015 to 0.383 seconds
FUNCTION 1. Not Applicable Setting: 0 to 255
This function is not applicable to this type of Resolution: 0.0015 seconds per set unit
control and is not adjustable.
Example: Setting of 20 = 0.032 seconds
FUNCTION 2. Internal Resistance For example, if you select 2.08 volts from
Compensation Start (Push 2) Function 16 to add to the motor, it takes 0.18
This function allows for the adjustment of the seconds to add a total of 2.08 volts.
current level at which the internal resistance (2.08/0.375) = 0.032
compensation feature (Function 16) will take
FUNCTION 11. Aux 1/Aux 2 Speed Limit 1
effect.
(SL1) (Push 11)
Range: 0 to 1325 amps
This function allows for the adjustment of the
Setting: 52 to 255 speed limit (maximum battery volts to the
motor) when the SL1 limit switch input signal is
Resolution: 6.5 amps per set unit
received by the control card at pin P1-12. SL1
Example: Setting of 72 = (72-52) x 6.5 = limit switch is a normally open switch
130 amps connected to battery negative, the switch
closing enables speed limit.
FUNCTION 3. Controlled Acceleration
(Push 3) Range: 0 volts to 96 volts
This function allows for the adjustment of the Setting: 0 to 255
rate of time it takes for the control to accelerate Resolution: 0.375 volts per set unit
to 96% applied battery voltage to the motor on
hard acceleration. Example: Setting of 50=18.75 volts
Range: 0.1 to 5.5 seconds FUNCTION 12. Lift 1 Speed Limit 2 (SL2)
(Push 12)
Setting: 0 to 255
Same as Function 11 except using SL2 limit
Resolution: 0.021 seconds per set unit
switch for input to control card at pin P1-19.
Example: Setting of 20 = 0.52 seconds C/A
FUNCTION 13. Tilt Speed Limit 3 (SL3) (Push
FUNCTION 4. Armature Current Limit 13)
(Push 4)
Same as Function 11 except using SL3 limit
This function allows for the adjustment of the switch for input to control card at pin P1-20.
current limit of the control. The setting for this
FUNCTION 14. Lift 2 Speed Limit (SL4)
function should always remain at 255 for this
(Push 14)
family of controls to achieve maximum current
limit. Same as Function 11 except using SL4 limit
switch for input to control card at pin P1-21.
FUNCTION 7. Internal Resistance
Compensation Rate (Push 7) FUNCTION 15. Not Applicable
This function allows for the adjustment of the This function is not applicable to this type of
rate of time it takes for the control to add the control and is not adjustable.
internal resistance compensation voltage that is
applied to the motor. This function adds 0.375
volts to the motor at the rate of time adjusted

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Handset Raymond ® DSD Maintenance Manual

Set-up Functions for Hydraulic Pump Control

NOTE: The following functions have function FUNCTION 17. Card Type Selection
numbers larger than the numbers on (Push CONT 2)
the Handset keypad. To access these
Set this function in accordance with the control
functions, push the CONT key and the
type in use in the vehicle:
number shown in the instructions at the
same time. THE KEY SWITCH MUST BE
ON. Function Setting
FUNCTION 16. Speed/Torque Compensation Std C/L BDI Lockout 54 to 62
(Push CONT 1)
High C/L BDI Lockout 63 to 71
This function is used to stabilize pump speed at
heavy loads. The voltage selected is added to the
motor at each 100 amp increment starting at BDI Lockout means that presence of the BDI
the value set in Function 2. The voltage signal from the traction control is required in
compensation selected will be added in order for the pump control to operate. This
increments of 0.375 volts until the entire control will stop operation when the battery
voltage is added. For example, a setting of 2 is state of charge reaches 9%.
added in 30 steps of 0.375 volts each: whereas, Settings for these functions should be made in
a setting of 4 is added in 15 steps of 0.375 volts between the values shown.
each.

Setting
Voltage
Setting
Voltage ! WARNING
Drop Drop
Field personnel must not change this
2 11.44 17 1.34 setting without prior written
3 7.60 18 1.27
permission from the manufacturer.
Card type selection must be made
4 5.72 19 1.20 within the capabilities of the
5 4.57 20 1.14 TRANSISTOR control panel used and
the supporting electro-mechanical
6 3.81 21 1.09 devices. Failure to comply with
7 3.27 22 1.04 proper application standards could
result in mis-operation or damage to
8 2.86 23 0.99
the control and/or motors.
9 2.54 24 0.95

10 2.28 25 0.91 FUNCTION 28. Fault Count Pointer

(Push CONT 13)
11 2.08 26 0.88
This register contains the location of the last
12 1.90 27 0.85 stored status code recorded of the 16 stored
status codes. These stored status codes have
13 1.76 28 0.82
caused a PMT controller shutdown and¤or
14 1.63 29 0.79 disruption of normal vehicle operation.

15 1.52 30 0.76 To determine which stored status code was the

last one recorded, read the number stored in
16 1.43 31 0.74 Function 28. Using the Memory Map, match
the “stored status code pointer number” in
Table 2-1: Speed/Torque Compensation Table
the HS (Handset) number column) on the
memory map, with the number obtained from

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Raymond ® DSD Maintenance Manual Handset

Dash Display Modes

Function 28. This is the last stored status code FUNCTION 50. Mode 1 – Tilt Speed Limit
recorded. (SL3) (Push CONT 3)
NOTE: When scrolling the stored status code This function allows for the adjustment of the
register, the register always starts at speed limit (maximum battery volts to the
status code 1 and scrolls to status code motor) when the SL3 limit switch input signal is
16. received by the control card. SL3 limit switch is
a normally open switch connected to battery
Dash Display Modes negative, the switch closing enables speed limit.
Range: 0 volts to 96 volts
Functions 48 through 63 are mode settings that
are activated from the Dash Display. Setting: 0 to 255
NOTE: The following functions have function Resolution: 0.375 volts per set unit
numbers larger than the numbers on
Example: Setting of 50 = 18.75 volts
the Handset keypad. To access these
functions, push the CONT key and the FUNCTION 51. Mode 1 – Lift 2 Speed Limit
number shown in the instructions at the (SL4) (Push CONT 2)
same time. THE KEY SWITCH MUST BE
OFF. This function allows for the adjustment of the
speed limit (maximum battery volts to the
FUNCTION 48. Mode 1 – Controlled motor) when the SL4 limit switch input signal is
Acceleration (Push CONT 1) received by the control card. SL4 limit switch is
a normally open switch connected to battery
This function allows for the adjustment of the
negative, the switch closing enables speed limit.
rate of time it takes for the control to accelerate
to 96% applied battery voltage to the motor on Range: 0 volts to 96 volts
hard acceleration.
Setting: 0 to 255
Range: 0.1 to 22.0 seconds
Resolution: 0.375 volts per set unit
Setting: 0 to 255
Example: Setting of 50 = 18.75 volts
Resolution: 0.084 seconds per set unit
FUNCTION 52. Mode 2 – Controlled
Example: Setting of 20 = 1.8 seconds C/A Acceleration (Push CONT 5)
FUNCTION 49. Mode 1 – Lift 1 Speed Limit Same as function 48.
(SL2) (Push CONT 2)
FUNCTION 53. Mode 2 – Lift 1 Speed Limit
This function allows for the adjustment of the (SL2) (Push CONT 6)
speed limit (maximum battery volts to the
motor) when the SL2 limit switch input signal is Same as Function 49.
received by the control card. SL2 limit switch is FUNCTION 54. Mode 2 – Tilt Speed Limit
a normally open switch connected to battery (SL3) (Push CONT 7)
negative, the switch closing enables speed limit.
Same as Function 50.
Range: 0 volts to 96 volts
FUNCTION 55. Mode 2 – Lift 2 Speed Limit
Setting: 0 to 255 (SL4) (Push CONT 8)
Resolution: 0.375 volts per set unit Same as Function 51.
Example: Setting of 50 = 18.75 volts FUNCTION 56. Mode 3 – Controlled
Acceleration (Push CONT 9)
Same as Function 48.

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Handset Raymond ® DSD Maintenance Manual

Dash Display Modes

FUNCTION 57. Mode 3 – Lift 1 Speed Limit

(SL2) (Push CONT 10)
Same as Function 49.
FUNCTION 58. Mode 3 – Tilt Speed Limit
(SL3) (Push CONT 11)
Same as Function 50.
FUNCTION 59. Mode 3 – Lift 2 Speed Limit
(SL4) (Push CONT 12)
Same as Function 51.
FUNCTION 60. MODE 4 – Controlled
Acceleration (Push CONT 13)
Same as Function 48.
FUNCTION 61. Mode 4 – Lift 1 Speed Limit
(SL2) (Push CONT 14)
Same as Function 49.
FUNCTION 62. Mode 4 – Tilt Speed Limit 3
(SL3) (Push CONT 15)
Same as Function 50.
FUNCTION 63. Mode 3 – Lift 2 Speed Limit
(SL4) (Push CONT ESC)
Same as Function 51.

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Raymond ® DSD Maintenance Manual Handset

Traction Controller Settings

Traction Controller Settings

Traction Controller Settings for DSD30 and DSD35

Traction Motor Diameter: 9"

Setting Description SET# 36V 48V

MPH Scaling 1 16 16

Creep Speed 2 87 87

Controlled Acceleration 3 24 33

Armature Current Limit 4 255 255

Counter EMF Trip Point for Auto Regen 5 15 25

Auto Calibration of Accel. Potentiometer 6 255 255

Min Field Current 7 88 88

Max Field Current 8 255 255

Regen Current Limit 9 0 0

Max Field Current for Regen 10 201 201

Speed Limit from Pin 12 on Negative (SL1) 11 0 0

Max Armature % On (SL2) 12 0 0

Speed Limit from Trac Mtr Temp/Maint/BDI 13 113 113

Internal Resistance Compensation 14 24 16

Battery Voltage 15 36 48

Traction Motor Stall Protection 16 120 120

Card Type Selection 17 57 57

Steer Motor Time Delay 18 149 149

Maint Code Hrs Tens and Ones 19 255 255

Maint Code Hrs Thousands and Hundreds 20 255 255

Auto Regen Current Limit 21 0 10

Truck Mode Set by Display 22 183 183

Regen Cancel Current 23 30 30

Field Weakening Start 24 100 100

Monitor 25 0 0

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Handset Raymond ® DSD Maintenance Manual

Traction Controller Settings

Traction Controller Settings for DSD30 and DSD35

Traction Motor Diameter: 9"

Setting Description SET# 36V 48V

Field to Armature Current Ratio 26 6 6

Minutes Register for Hourmeter 27 0 0

Stored Fault Count Pointer 28 0 0

P¤S Hourmeter Storage Register 29 0 0

P¤S Hourmeter Storage Register 30 0 0

MODE 1 - Controlled Acceleration [#3] 48 36 50

MODE 1 - Regen Current Limit [#9] 49 0 0

MODE 1 - Auto Regen Current Limit [#21] 50 0 0

MODE 1 - Max Armature % On (SL2) [#12] 51 80 80

MODE 2 - Controlled Acceleration [#3] 52 36 50

MODE 2 - Regen Current Limit [#9] 53 0 0

MODE 2 - Auto Regen Current Limit [#21] 54 0 0

MODE 2 - Max Armature % On (SL2) [#12] 55 0 0

MODE 3 - Controlled Acceleration [#3] 56 24 33

MODE 3 - Regen Current Limit [#9] 57 0 0

MODE 3 - Auto Regen Current Limit [#21] 58 0 10

MODE 3 - Max Armature % On (SL2) [#12] 59 0 0

MODE 4 - Controlled Acceleration [#3] 60 18 25

MODE 4 - Regen Current Limit [#9] 61 0 0

MODE 4 - Auto Regen Current Limit [#21] 62 0 20

MODE 4 - Max Armature % On (SL2) [#12] 63 0 0

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Raymond ® DSD Maintenance Manual Handset

Traction Controller Settings

Traction Controller Settings for DSD40, DSD50 and DSD5E

Traction Motor Diameter: 11"

Setting Description SET# 36V 48V

MPH Scaling 1 16 16

Creep Speed 2 60 60

Controlled Acceleration 3 20 27

Armature Current Limit 4 255 255

Counter EMF Trip Point for Auto Regen 5 15 15

Auto Calibration of Accel. Potentiometer 6 255 255

Min Field Current 7 79 80

Max Field Current 8 255 255

Regen Current Limit 9 35 25

Max Field Current for Regen 10 255 255

Speed Limit from Pin 12 on Negative (SL1) 11 0 0

Max Armature % On (SL2) 12 0 0

Speed Limit from Trac Mtr Temp/Maint/BDI 13 113 113

Internal Resistance Compensation 14 24 16

Battery Voltage 15 36 48

Traction Motor Stall Protection 16 130 130

Card Type Selection 17 57 57

Steer Motor Time Delay 18 149 149

Maint Code Hrs Tens and Ones 19 255 255

Maint Code Hrs Thousands and Hundreds 20 255 255

Auto Regen Current Limit 21 30 25

Truck Mode Set by Display 22 183 183

Regen Cancel Current 23 50 50

Field Weakening Start 24 100 100

Monitor 25 0 0

Field to Armature Current Ratio 26 3 5

Minutes Register for Hourmeter 27 0 0

Stored Fault Count Pointer 28 0 0

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Handset Raymond ® DSD Maintenance Manual

Traction Controller Settings

Traction Controller Settings for DSD40, DSD50 and DSD5E

Traction Motor Diameter: 11"

Setting Description SET# 36V 48V

P¤S Hourmeter Storage Register 29 0 0

P¤S Hourmeter Storage Register 30 0 0

MODE 1 - Controlled Acceleration [#3] 48 30 40

MODE 1 - Regen Current Limit [#9] 49 0 0

MODE 1 - Auto Regen Current Limit [#21] 50 0 0

MODE 1 - Max Armature % On (SL2) [#12] 51 80 80

MODE 2 - Controlled Acceleration [#3] 52 30 40

MODE 2 - Regen Current Limit [#9] 53 18 13

MODE 2 - Auto Regen Current Limit [#21] 54 0 0

MODE 2 - Max Armature % On (SL2) [#12] 55 0 0

MODE 3 - Controlled Acceleration [#3] 56 20 27

MODE 3 - Regen Current Limit [#9] 57 35 25

MODE 3 - Auto Regen Current Limit [#21] 58 30 25

MODE 3 - Max Armature % On (SL2) [#12] 59 0 0

MODE 4 - Controlled Acceleration [#3] 60 15 20

MODE 4 - Regen Current Limit [#9] 61 70 50

MODE 4 - Auto Regen Current Limit [#21] 62 60 50

MODE 4 - Max Armature % On (SL2) [#12] 63 0 0

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Traction Controller Settings

Traction Controller Settings for DSD60

Traction Motor Diameter: 11"

Setting Description SET# 36V 48V

MPH Scaling 1 16 16

Creep Speed 2 60 60

Controlled Acceleration 3 20 27

Armature Current Limit 4 255 255

Counter EMF Trip Point for Auto Regen 5 15 15

Auto Calibration of Accel. Potentiometer 6 255 255

Min Field Current 7 80 80

Max Field Current 8 255 255

Regen Current Limit 9 35 35

Max Field Current for Regen 10 255 255

Speed Limit from Pin 12 on Negative (SL1) 11 0 0

Max Armature % On (SL2) 12 0 0

Speed Limit from Trac Mtr Temp/Maint/BDI 13 113 113

Internal Resistance Compensation 14 24 16

Battery Voltage 15 36 48

Traction Motor Stall Protection 16 130 130

Card Type Selection 17 135 135

Steer Motor Time Delay 18 149 149

Maint Code Hrs Tens and Ones 19 255 255

Maint Code Hrs Thousands and Hundreds 20 255 255

Auto Regen Current Limit 21 30 25

Truck Mode Set by Display 22 183 183

Regen Cancel Current 23 50 50

Field Weakening Start 24 100 100

Monitor 25 0 0

Field to Armature Current Ratio 26 5 5

Minutes Register for Hourmeter 27 0 0

Stored Fault Count Pointer 28 0 0

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Handset Raymond ® DSD Maintenance Manual

Traction Controller Settings

Traction Controller Settings for DSD60

Traction Motor Diameter: 11"

Setting Description SET# 36V 48V

P¤S Hourmeter Storage Register 29 0 0

P¤S Hourmeter Storage Register 30 0 0

MODE 1 - Controlled Acceleration [#3] 48 30 40

MODE 1 - Regen Current Limit [#9] 49 0 0

MODE 1 - Auto Regen Current Limit [#21] 50 0 0

MODE 1 - Max Armature % On (SL2) [#12] 51 80 80

MODE 2 - Controlled Acceleration [#3] 52 30 40

MODE 2 - Regen Current Limit [#9] 53 18 18

MODE 2 - Auto Regen Current Limit [#21] 54 0 0

MODE 2 - Max Armature % On (SL2) [#12] 55 0 0

MODE 3 - Controlled Acceleration [#3] 56 20 27

MODE 3 - Regen Current Limit [#9] 57 35 35

MODE 3 - Auto Regen Current Limit [#21] 58 30 25

MODE 3 - Max Armature % On (SL2) [#12] 59 0 0

MODE 4 - Controlled Acceleration [#3] 60 15 20

MODE 4 - Regen Current Limit [#9] 61 70 70

MODE 4 - Auto Regen Current Limit [#21] 62 60 50

MODE 4 - Max Armature % On (SL2) [#12] 63 0 0

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Traction Controller Settings

Traction Controller Settings For UL EE Closed Motor Option DSD30 and DSD35
Traction Motor Diameter: 9"

Setting Description SET# 36V 48V

MPH Scaling 1 16 16

Creep Speed 2 87 87

Controlled Acceleration 3 27 33

Armature Current Limit 4 255 255

Counter EMF Trip Point for Auto Regen 5 20 25

Auto Calibration of Accel. Potentiometer 6 255 255

Min Field Current 7 88 88

Max Field Current 8 255 255

Regen Current Limit 9 25 0

Max Field Current for Regen 10 170 170

Speed Limit from Pin 12 on Negative (SL1) 11 0 0

Max Armature % On (SL2) 12 110 110

Speed Limit from Trac Mtr Temp/Maint/BDI 13 113 113

Internal Resistance Compensation 14 24 16

Battery Voltage 15 36 48

Traction Motor Stall Protection 16 160 160

Card Type Selection 17 57 0

Steer Motor Time Delay 18 149 149

Maint Code Hrs Tens and Ones 19 255 255

Maint Code Hrs Thousands and Hundreds 20 255 255

Auto Regen Current Limit 21 35 0

Truck Mode Set by Display 22 183 183

Regen Cancel Current 23 30 30

Field Weakening Start 24 112 100

Monitor 25 0 0

Field to Armature Current Ratio 26 8 9

Minutes Register for Hourmeter 27 0 0

Stored Fault Count Pointer 28 0 0

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Handset Raymond ® DSD Maintenance Manual

Traction Controller Settings

Traction Controller Settings For UL EE Closed Motor Option DSD30 and DSD35
Traction Motor Diameter: 9"

Setting Description SET# 36V 48V

P¤S Hourmeter Storage Register 29 0 0

P¤S Hourmeter Storage Register 30 0 0

MODE 1 - Controlled Acceleration [#3] 48 40 50

MODE 1 - Regen Current Limit [#9] 49 0 0

MODE 1 - Auto Regen Current Limit [#21] 50 0 0

MODE 1 - Max Armature % On (SL2) [#12] 51 130 130

MODE 2 - Controlled Acceleration [#3] 52 40 50

MODE 2 - Regen Current Limit [#9] 53 13 0

MODE 2 - Auto Regen Current Limit [#21] 54 0 0

MODE 2 - Max Armature % On (SL2) [#12] 55 110 110

MODE 3 - Controlled Acceleration [#3] 56 27 33

MODE 3 - Regen Current Limit [#9] 57 25 0

MODE 3 - Auto Regen Current Limit [#21] 58 35 0

MODE 3 - Max Armature % On (SL2) [#12] 59 110 110

MODE 4 - Controlled Acceleration [#3] 60 20 25

MODE 4 - Regen Current Limit [#9] 61 50 0

MODE 4 - Auto Regen Current Limit [#21] 62 70 0

MODE 4 - Max Armature % On (SL2) [#12] 63 110 110

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Traction Controller Settings

Traction Controller Settings for UL EE Closed Motor Option DSD40, DSD5E, DSD50
and DSD60 Traction Motor Diameter: 11"

Setting Description SET# 36V 48V

MPH Scaling 1 16 16

Creep Speed 2 60 60

Controlled Acceleration 3 27 27

Armature Current Limit 4 255 255

Counter EMF Trip Point for Auto Regen 5 20 20

Auto Calibration of Accel. Potentiometer 6 255 255

Min Field Current 7 80 90

Max Field Current 8 255 255

Regen Current Limit 9 25 0

Max Field Current for Regen 10 255 255

Speed Limit from Pin 12 on Negative (SL1) 11 0 0

Max Armature % On (SL2) 12 80 90

Speed Limit from Trac Mtr Temp/Maint/BDI 13 113 113

Internal Resistance Compensation 14 24 16

Battery Voltage 15 36 48

Traction Motor Stall Protection 16 160 160

Card Type Selection 17 57 0

Steer Motor Time Delay 18 149 149

Maint Code Hrs Tens and Ones 19 255 255

Maint Code Hrs Thousands and Hundreds 20 255 255

Auto Regen Current Limit 21 35 0

Truck Mode Set by Display 22 183 183

Regen Cancel Current 23 50 50

Field Weakening Start 24 100 100

Monitor 25 0 0

Field to Armature Current Ratio 26 8 7

Minutes Register for Hourmeter 27 0 0

Stored Fault Count Pointer 28 0 0

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Handset Raymond ® DSD Maintenance Manual

Traction Controller Settings

Traction Controller Settings for UL EE Closed Motor Option DSD40, DSD5E, DSD50
and DSD60 Traction Motor Diameter: 11"

Setting Description SET# 36V 48V

P¤S Hourmeter Storage Register 29 0 0

P¤S Hourmeter Storage Register 30 0 0

MODE 1 - Controlled Acceleration [#3] 48 40 40

MODE 1 - Regen Current Limit [#9] 49 0 0

MODE 1 - Auto Regen Current Limit [#21] 50 0 0

MODE 1 - Max Armature % On (SL2) [#12] 51 100 110

MODE 2 - Controlled Acceleration [#3] 52 40 40

MODE 2 - Regen Current Limit [#9] 53 13 0

MODE 2 - Auto Regen Current Limit [#21] 54 0 0

MODE 2 - Max Armature % On (SL2) [#12] 55 80 90

MODE 3 - Controlled Acceleration [#3] 56 27 27

MODE 3 - Regen Current Limit [#9] 57 25 0

MODE 3 - Auto Regen Current Limit [#21] 58 35 0

MODE 3 - Max Armature % On (SL2) [#12] 59 80 90

MODE 4 - Controlled Acceleration [#3] 60 20 20

MODE 4 - Regen Current Limit [#9] 61 50 0

MODE 4 - Auto Regen Current Limit [#21] 62 70 0

MODE 4 - Max Armature % On (SL2) [#12] 63 80 90

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Pump Controller Settings

Pump Controller Settings

Pump Controller Settings for DSD30 and DSD35

SN Prefix: S30R4 or S35R4
Pump Motor Diameter: 8"

Setting Description SET# 36V¤48V

N/A 1 0

Internal Resistance Compensation Start 2 66

Controlled Acceleration 3 20

Armature Current Limit 4 255

N/A 5 255

N/A 6 255

Internal Resistance Compensation Rate 7 100

N/A 8 255

N/A 9 255

N/A 10 255

Aux1/Aux2 Speed Limit (SL1) 11 50

Lift 1 Speed Limit (SL2) 12 45

Tilt Speed Limit (SL3) 13 38

Lift 2 Speed Limit (SL4) 14 96

N/A 15 255

Speed Torque Compensation 16 20

Card Type Selection (500A/600A) 17 58

N/A 18 255

N/A 19 255

N/A 20 255

N/A 21 255

Truck Mode Set by Display 22 183

Minutes 23 0

Minutes seconds 24 0

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Handset Raymond ® DSD Maintenance Manual

Pump Controller Settings

Pump Controller Settings for DSD30 and DSD35

SN Prefix: S30R4 or S35R4
Pump Motor Diameter: 8"

Setting Description SET# 36V¤48V

N/A 25 0

Monitor 26 0

N/A 27 255

Stored Fault Count Pointer 28 0

Pump Hourmeter Storage Register 29 0

Pump Hourmeter Storage Register 30 0

MODE 1 - Controlled Acceleration [#3] 48 27

MODE 1 - Lift 1 Speed Limit (SL2) [#12] 49 34

MODE 1 - Tilt Speed Limit (SL3) [#13] 50 31

MODE 1 - Lift 2 Speed Limit (SL4) [#14] 51 67

MODE 2 - Controlled Acceleration [#3] 52 27

MODE 2 - Lift 1 Speed Limit (SL2) [#12] 53 45

MODE 2 - Tilt Speed Limit (SL3) [#13] 54 38

MODE 2 - Lift 2 Speed Limit (SL4) [#14] 55 80

MODE 3 - Controlled Acceleration [#3] 56 20

MODE 3 - Lift 1 Speed Limit (SL2) [#12] 57 45

MODE 3 - Tilt Speed Limit (SL3) [#13] 58 38

MODE 3 - Lift 2 Speed Limit (SL4) [#14] 59 96

MODE 4 - Controlled Acceleration [#3] 60 20

MODE 4 - Lift 1 Speed Limit (SL2) [#12] 61 67

MODE 4 - Tilt Speed Limit (SL3) [#13] 62 50

MODE 4 - Lift 2 Speed Limit (SL4) [#14] 63 255

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Pump Controller Settings

Pump Controller Settings for DSD40, DSD50, DSD5E, and DSD60

SN Prefix: S40R4, S50R4, S5ER4 or S60R0
Pump Motor Diameter: 9"

Setting Description SET# 36V¤48V

N/A 1 0

Internal Resistance Compensation Start 2 66

Controlled Acceleration 3 20

Armature Current Limit 4 255

N/A 5 255

N/A 6 255

Internal Resistance Compensation Rate 7 100

N/A 8 255

N/A 9 255

N/A 10 255

Aux1/Aux2 Speed Limit (SL1) 11 50

Lift 1 Speed Limit (SL2) 12 45

Tilt Speed Limit (SL3) 13 38

Lift 2 Speed Limit (SL4) 14 96

N/A 15 255

Speed Torque Compensation 16 20

Card Type Selection (500A/600A) 17 67

N/A 18 255

N/A 19 255

N/A 20 255

N/A 21 255

Truck Mode Set by Display 22 183

Minutes 23 0

Minutes seconds 24 0

N/A 25 0

Monitor 26 0

N/A 27 255

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Handset Raymond ® DSD Maintenance Manual

Pump Controller Settings

Pump Controller Settings for DSD40, DSD50, DSD5E, and DSD60

SN Prefix: S40R4, S50R4, S5ER4 or S60R0
Pump Motor Diameter: 9"

Setting Description SET# 36V¤48V

Stored Fault Count Pointer 28 0

Pump Hourmeter Storage Register 29 0

Pump Hourmeter Storage Register 30 0

MODE 1 - Controlled Acceleration [#3] 48 27

MODE 1 - Lift 1 Speed Limit (SL2) [#12] 49 34

MODE 1 - Tilt Speed Limit (SL3) [#13] 50 31

MODE 1 - Lift 2 Speed Limit (SL4) [#14] 51 67

MODE 2 - Controlled Acceleration [#3] 52 27

MODE 2 - Lift 1 Speed Limit (SL2) [#12] 53 45

MODE 2 - Tilt Speed Limit (SL3) [#13] 54 38

MODE 2 - Lift 2 Speed Limit (SL4) [#14] 55 80

MODE 3 - Controlled Acceleration [#3] 56 20

MODE 3 - Lift 1 Speed Limit (SL2) [#12] 57 45

MODE 3 - Tilt Speed Limit (SL3) [#13] 58 38

MODE 3 - Lift 2 Speed Limit (SL4) [#14] 59 96

MODE 4 - Controlled Acceleration [#3] 60 20

MODE 4 - Lift 1 Speed Limit (SL2) [#12] 61 67

MODE 4 - Tilt Speed Limit (SL3) [#13] 62 50

MODE 4 - Lift 2 Speed Limit (SL4) [#14] 63 255

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Raymond ® DSD Maintenance Manual Handset

Pump Controller Settings

Pump Controller Settings for UL EE Closed Motor Option DSD30 and DSD35
SN Prefix: S30R4 or S35R4
Pump Motor Diameter: 8"

Setting Description SET# 36V¤48V

N/A 1 0

Internal Resistance Compensation Start 2 66

Controlled Acceleration 3 40

Armature Current Limit 4 255

N/A 5 255

N/A 6 255

Internal Resistance Compensation Rate 7 100

N/A 8 255

N/A 9 255

N/A 10 255

Aux1/Aux2 Speed Limit (SL1) 11 50

Lift 1 Speed Limit (SL2) 12 45

Tilt Speed Limit (SL3) 13 38

Lift 2 Speed Limit (SL4) 14 96

N/A 15 255

Speed Torque Compensation 16 20

Card Type Selection (500A/600A) 17 58

N/A 18 255

N/A 19 255

N/A 20 255

N/A 21 255

Truck Mode Set by Display 22 183

Minutes 23 0

Minutes seconds 24 0

N/A 25 0

Monitor 26 0

N/A 27 255

PDMM-0115 Issued: 07/31/2002 2-33

Handset Raymond ® DSD Maintenance Manual

Pump Controller Settings

Pump Controller Settings for UL EE Closed Motor Option DSD30 and DSD35
SN Prefix: S30R4 or S35R4
Pump Motor Diameter: 8"

Setting Description SET# 36V¤48V

Stored Fault Count Pointer 28 0

Pump Hourmeter Storage Register 29 0

Pump Hourmeter Storage Register 30 0

MODE 1 - Controlled Acceleration [#3] 48 53

MODE 1 - Lift 1 Speed Limit (SL2) [#12] 49 34

MODE 1 - Tilt Speed Limit (SL3) [#13] 50 31

MODE 1 - Lift 2 Speed Limit (SL4) [#14] 51 67

MODE 2 - Controlled Acceleration [#3] 52 53

MODE 2 - Lift 1 Speed Limit (SL2) [#12] 53 45

MODE 2 - Tilt Speed Limit (SL3) [#13] 54 38

MODE 2 - Lift 2 Speed Limit (SL4) [#14] 55 80

MODE 3 - Controlled Acceleration [#3] 56 40

MODE 3 - Lift 1 Speed Limit (SL2) [#12] 57 45

MODE 3 - Tilt Speed Limit (SL3) [#13] 58 38

MODE 3 - Lift 2 Speed Limit (SL4) [#14] 59 96

MODE 4 - Controlled Acceleration [#3] 60 40

MODE 4 - Lift 1 Speed Limit (SL2) [#12] 61 67

MODE 4 - Tilt Speed Limit (SL3) [#13] 62 50

MODE 4 - Lift 2 Speed Limit (SL4) [#14] 63 255

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Raymond ® DSD Maintenance Manual Handset

Pump Controller Settings

Pump Controller Settings for UL EE Closed Motor Option

DSD40, DSD50, DSD5E, and DSD60
SN PREFIX: S40R4, S50R4, S5ER4 or S60R0
Pump Motor Diameter: 9"

Setting Description SET# 36V¤48V

N/A 1 0

Internal Resistance Compensation Start 2 66

Controlled Acceleration 3 40

Armature Current Limit 4 255

N/A 5 255

N/A 6 255

Internal Resistance Compensation Rate 7 100

N/A 8 255

N/A 9 255

N/A 10 255

Aux1/Aux2 Speed Limit (SL1) 11 50

Lift 1 Speed Limit (SL2) 12 45

Tilt Speed Limit (SL3) 13 38

Lift 2 Speed Limit (SL4) 14 96

N/A 15 255

Speed Torque Compensation 16 20

Card Type Selection (500A¤600A) 17 67

N/A 18 255

N/A 19 255

N/A 20 255

N/A 21 255

Truck Mode Set by Display 22 183

Minutes 23 0

Minutes seconds 24 0

N/A 25 0

Monitor 26 0

PDMM-0115 Issued: 07/31/2002 2-35

Handset Raymond ® DSD Maintenance Manual

Pump Controller Settings

Pump Controller Settings for UL EE Closed Motor Option

DSD40, DSD50, DSD5E, and DSD60
SN PREFIX: S40R4, S50R4, S5ER4 or S60R0
Pump Motor Diameter: 9"

Setting Description SET# 36V¤48V

N/A 27 255

Stored Fault Count Pointer 28 0

Pump Hourmeter Storage Register 29 0

Pump Hourmeter Storage Register 30 0

MODE 1 - Controlled Acceleration [#3] 48 53

MODE 1 - Lift 1 Speed Limit (SL2) [#12] 49 34

MODE 1 - Tilt Speed Limit (SL3) [#13] 50 31

MODE 1 - Lift 2 Speed Limit (SL4) [#14] 51 67

MODE 2 - Controlled Acceleration [#3] 52 53

MODE 2 - Lift 1 Speed Limit (SL2) [#12] 53 45

MODE 2 - Tilt Speed Limit (SL3) [#13] 54 38

MODE 2 - Lift 2 Speed Limit (SL4) [#14] 55 80

MODE 3 - Controlled Acceleration [#3] 56 40

MODE 3 - Lift 1 Speed Limit (SL2) [#12] 57 45

MODE 3 - Tilt Speed Limit (SL3) [#13] 58 38

MODE 3 - Lift 2 Speed Limit (SL4) [#14] 59 96

MODE 4 - Controlled Acceleration [#3] 60 40

MODE 4 - Lift 1 Speed Limit (SL2) [#12] 61 67

MODE 4 - Tilt Speed Limit (SL3) [#13] 62 50

MODE 4 - Lift 2 Speed Limit (SL4) [#14] 63 255

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Raymond ® DSD Maintenance Manual Handset

Memory Maps

Memory Maps

Traction Control

E2 Func No. HS No. Traction Control Function Access By Restrictions

0 1 1 MPH Scaling HS or PC None

1 2 2 Creep HS or PC None

2 3 3 Controlled Acceleration HS or PC None

3 4 4 Armature Current Limit HS or PC None

Counter EMF Trip Point for

4 5 5 HS or PC None
Auto Braking

Auto Calibration of Accelerator

5 6 6 HS or PC None
Pot

Minimum Field Current Contact Service

6 7 7 HS or PC
Engineering

7 8 8 Maximum Field Current HS or PC None

8 9 9 Regen Current Limit HS or PC None

9 10 10 Field Current for Regen HS or PC None

10 11 11 Speed Limit 1 HS or PC None

11 12 12 Top Speed Limit HS or PC None

Maintenance & Truck Mgmt

12 13 13 HS or PC None
Speed Limit

13 14 14 IR Compensation HS or PC None

14 15 15 Battery Volts Select HS or PC None

Stall Protection and % ON-Time

15 16 16 HS or PC None
Trip

16 17 17 Card Type Select HS or PC None

17 18 18 Steer Pump Time Delay HS or PC None

Maintenance Code HM
18 19 19 HS or PC None
(Tens/Units)

Maintenance Code HM
19 20 20 HS or PC None
(Thou/Hun)

Auto Regen Braking Current

20 21 21 HS or PC None
Limit

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Handset Raymond ® DSD Maintenance Manual

Memory Maps

Traction Control

E2 Func No. HS No. Traction Control Function Access By Restrictions

Mode Storage For DD on

21 22 22 HS or PC
power-up

22 23 23 Regen Cancel Current HS or PC None

FW Start Contact Service

23 24 24 HS or PC
Engineering

24 25 25 Monitor HS or PC Temporary Storage

Ratio Contact Service

25 26 26 HS or PC
Engineering

26 27 27 Steer Pump Minutes HS or PC Temporary Storage

27 28 28 Fault Count Pointer HS or PC None

28 29 29 Steer Pump Hours (Tens/Ones) HS or PC None

29 30 30 Steer Pump Hours (Thou/Hun) HS or PC None

30 31 Traction Hours (Tens/Ones) PC Only None

31 32 Traction Hours (Thou/Hun) PC Only None

32 33 (18) Stored Status Code #1 PC Only Reset to Zero Only

33 34 BDI 1 PC Only Reset to Zero Only

34 35 Hours (Tens/Ones) 1 PC Only Reset to Zero Only

35 36 Hours (Thou/Hun) 1 PC Only Reset to Zero Only

36 37 (20) Stored Status Code #2 PC Only Reset to Zero Only

37 38 BDI 2 PC Only Reset to Zero Only

38 39 Hours (Tens/Ones) 2 PC Only Reset to Zero Only

39 40 Hours (Thou/Hun) 2 PC Only Reset to Zero Only

40 41 (22) Stored Status Code #3 PC Only Reset to Zero Only

41 42 BDI 3 PC Only Reset to Zero Only

42 43 Hours (Tens/Ones) 3 PC Only Reset to Zero Only

43 44 Hours (Thou/Hun) 3 PC Only Reset to Zero Only

45 46 BDI 4 PC Only Reset to Zero Only

46 47 Hours (Tens/Ones) 4 PC Only Reset to Zero Only

47 48 Hours (Thou/Hun) 4 PC Only Reset to Zero Only

48 49 (26) Stored Status Code #5 PC Only Reset to Zero Only

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Raymond ® DSD Maintenance Manual Handset

Memory Maps

Traction Control

E2 Func No. HS No. Traction Control Function Access By Restrictions

49 50 BDI 5 PC Only Reset to Zero Only

50 51 Hours (Tens/Ones) 5 PC Only Reset to Zero Only

51 52 Hours (Thou/Hun) 5 PC Only Reset to Zero Only

52 53 (28) Stored Status Code #6 PC Only Reset to Zero Only

53 54 BDI 6 PC Only Reset to Zero Only

54 55 Hours (Tens/Ones) 6 PC Only Reset to Zero Only

55 56 Hours (Thou/Hun) 6 PC Only Reset to Zero Only

56 57 (30) Stored Status Code #7 PC Only Reset to Zero Only

57 58 BDI 7 PC Only Reset to Zero Only

58 59 Hours (Tens/Ones) 7 PC Only Reset to Zero Only

59 60 Hours (Thou/Hun) 7 PC Only Reset to Zero Only

60 61 (32) Stored Status Code #8 PC Only Reset to Zero Only

61 62 BDI 8 PC Only Reset to Zero Only

62 63 Hours (Tens/Ones) 8 PC Only Reset to Zero Only

63 64 Hours (Thou/Hun) 8 PC Only Reset to Zero Only

64 65 (34) Stored Status Code #9 PC Only Reset to Zero Only

65 66 BDI 9 PC Only Reset to Zero Only

66 67 Hours (Tens/Ones) 9 PC Only Reset to Zero Only

67 68 Hours (Thou/Hun) 9 PC Only Reset to Zero Only

68 69 (36) Stored Status Code #10 PC Only Reset to Zero Only

69 70 BDI 10 PC Only Reset to Zero Only

70 71 Hours (Tens/Ones) 10 PC Only Reset to Zero Only

71 72 Hours (Thou/Hun) 10 PC Only Reset to Zero Only

72 73 (38) Stored Status Code #11 PC Only Reset to Zero Only

73 74 BDI 11 PC Only Reset to Zero Only

74 75 Hours (Tens/Ones) 11 PC Only Reset to Zero Only

75 76 Hours (Thou/Hun) 11 PC Only Reset to Zero Only

76 77 (40) Stored Status Code #12 PC Only Reset to Zero Only

77 78 BDI 12 PC Only Reset to Zero Only

PDMM-0115 Issued: 07/31/2002 2-39

Handset Raymond ® DSD Maintenance Manual

Memory Maps

Traction Control

E2 Func No. HS No. Traction Control Function Access By Restrictions

78 79 Hours (Tens/Ones) 12 PC Only Reset to Zero Only

79 80 . Hours (Thou/Hun) 12 PC Only Reset to Zero Only

80 81 (42) Stored Status Code #13 PC Only Reset to Zero Only

81 82 BDI 13 PC Only Reset to Zero Only

82 83 Hours (Tens/Ones) 13 PC Only Reset to Zero Only

83 84 Hours (Thou/Hun) 13 PC Only Reset to Zero Only

84 85 (44) Stored Status Code # 14 PC Only Reset to Zero Only

85 86 BDI 14 PC Only Reset to Zero Only

86 87 Hours (Tens/Ones) 14 PC Only Reset to Zero Only

87 88 Hours (Thou/Hun) 14 PC Only Reset to Zero Only

88 89 (46) Stored Status Code # 15 PC Only Reset to Zero Only

89 90 BDI 15 PC Only Reset to Zero Only

90 91 Hours (Tens/Ones) 15 PC Only Reset to Zero Only

90 91 Hours (Tens/Ones) 15 PC Only Reset to Zero Only

91 92 Hours (Thou/Hun) 15 PC Only Reset to Zero Only

92 93 (48) Stored Status Code #16 PC Only Reset to Zero Only

94 95 Hours (Tens/Ones) 16 PC Only Reset to Zero Only

95 96 Hours (Thou/Hun) 16 PC Only Reset to Zero Only

96 67 48 Dash Display CA-1 HS or PC None

97 98 49 Dash Display Regen C/L-1 HS or PC None

98 99 50 Dash Display Auto Regen C/L-1 HS or PC None

99 100 51 Dash Display Speed Limit 2 - 1 HS or PC None

100 101 52 Dash Display CA-2 HS or PC None

101 102 53 Dash Display Regen C/L-2 HS or PC None

102 103 54 Dash Display Auto Regen C/L-2 HS or PC None

103 104 55 Dash Display Speed Limit 2 - 2 HS or PC None

104 105 56 Dash Display CA-3 HS or PC None

105 106 57 Dash Display Regen C/L-3 HS or PC None

106 107 58 Dash Display Auto Regen C/L-3 HS or PC None

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Raymond ® DSD Maintenance Manual Handset

Memory Maps

Traction Control

E2 Func No. HS No. Traction Control Function Access By Restrictions

107 108 59 Dash Display Speed Limit 2 - 3 HS or PC None

108 109 60 Dash Display CA-4 HS or PC None

109 110 61 Dash Display Regen C/L-4 HS or PC None

110 111 62 Dash Display Auto Regen C/L-4 HS or PC None

111 112 63 Dash Display Speed Limit 2 - 4 HS or PC None

Secure HM (Tens/Ones) Steer

112 113 PC Only Read Only
Pump

Secure HM (Thou/Hun) Steer

113 114 PC Only Read Only
Pump

114 115 Secure Aux HM (Tens/Ones) PC Only Read Only

115 116 Secure Aux HM (Thou/Hun) PC Only Read Only

116 117 Reserved PC Only GE Future Use

117 118 Reserved PC Only GE Future Use

118 119 Reserved PC Only GE Future Use

119 120 Reserved PC Only GE Future Use

120 121 Truck Minutes PC Only None

121 122 Pump Minutes PC Only None

122 123 Pump Hours (Tens/Ones) PC Only None

123 124 Pump Hours (Thou/Hun) PC Only None

124 125 OEM Use PC Only None

125 126 OEM Use PC Only None

Accelerator Auto Calibration

126 127 PC Only None
Slope

Accelerator Auto Calibration

127 128 PC Only None
Y-Intercept

PDMM-0115 Issued: 07/31/2002 2-41

Handset Raymond ® DSD Maintenance Manual

Memory Maps

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Raymond ® DSD Maintenance Manual Checks & Repairs

Checks & Repairs 3:

PDMM-0115 Issued: 07/31/2002 3-1

Checks & Repairs Raymond ® DSD Maintenance Manual

General Information

General Information

Pump Fuse
(350 Amperes)

Traction Fuse

Figure 3-1: Traction and Power Amplifier Fuse Locations

Traction Fuse
(350 Ampere for 600 Amp control)
(500 Ampere for 740 Amp control)
Traction and Pump Ampere rating is identified
by the 11th, 12th and 13th digit of the part
number
Example: 606 = 600 and 746 = 740 marked on
the bottom of the controller by the buses or bus
bars.

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Raymond ® DSD Maintenance Manual Checks & Repairs

Fuses

NOTE: The electronic controller in these lift

! WARNING trucks can not be seen from the operator
area. Some checks and adjustments are
Some adjustments in this section difficult to do unless another person can
must be done with the battery operate the controls.
connected and power applied to the NOTE: The bolts and screws connected to the
controller. When making these electronic components are normally
adjustments, make sure the drive metric sizes. Make sure that the correct
wheels are raised from the floor. fastener for the part that has been
Some voltage measurements must be disassembled is used.
made with the SRO circuit complete.
Make sure the drive wheels are
raised from the surface before doing Fuses
troubleshooting. If working alone,
put a weight in the seat to close the The fuses are found on the SX control panel.
The value of the power fuse for the traction
seat switch. However, this should
controller is 350 amps for the 600 amp
only be done when necessary to controller and 500 amps for the 740 amp
perform adjustments requiring that controller. The value of the power fuse for the
the seat switch is closed. Put the hydraulic pump controller is 350 amps and the
voltmeter so that you can see it from value for the hydraulic pump contactor is 500
the operator area. This will allow the amps. The value of the power fuse for the power
steering motor is 60 amps. The condition of the
controls to be operated while taking
fuses is determined by looking at them or
voltage measurements. checking with an ohmmeter. The location of the
fuses is shown in Figure 3-1.

! WARNING
Make sure to disconnect the battery
and separate the connector before
disassembling any part of the
controller. The capacitor stores
electrical energy and can cause
injury if a person discharges a
capacitor through parts of the body.
AFTER the battery is disconnected,
make sure to also discharge the
capacitor by using a p/n
223-012-200 Resistor across the
positive and negative terminals on
the control panel for at least 20
seconds.

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Fuses

Contactor Line

1 Contactor

2 Washer, Plain

3 Tip, Spring Top

4 Tip, Spring

5 Tip, Spring Seat

6 Tip, Movable

7 Clamp, Bus

8 Screw

9 Washer, Lock

10 Tip, Carrier

11 Bushing, Plunger

12 Tip, Stationary

15 Base, Bus

16 Armature

17 Spring, Armature

18 Frame

19 Coil

20 Magnet Base Assy

21 Kit, Service Tip

22 Nut

3 3

Figure 3-2: Typical Contactor Assembly-Exploded View Figure 3-3: Typical Contactor Assembly

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Contactor Repair

Contactor Repair

Make a location identification for the wires and

cables then disconnect from the contactor
assembly. Remove the mounting screws and Coil Resistance Test Specifications
remove the contactor assembly.
Line, Traction Line and
Contactor Contacts. The contacts in a 59 ohms ± 10%
Pump Line (36/48V)
contactor are made of special silver alloy. The
contacts will look black and rough from normal Line and Power Steering
161 ohms ± 10%
operation. This condition does not cause (72/80V)
problems with the operation of the lift truck.
Power Steering (36/48V) 77 ohms ± 10%
Cleaning is not necessary. DO NOT USE A FILE
ON THE CONTACTS. DO NOT LUBRICATE THE Pump and 1A Bypass
CONTACTS. 33 ohms ±10%
(36/48V)

! WARNING
ALWAYS replace all of the contacts in
a contactor at the same time. Replace
the contacts in the contactor for the
hydraulic pump after 1000 hours of
operation. Replace the contacts in the
other contactors when the thickness
of any area of a contact is less than
30% of the thickness of a new
contact or if there is any transfer of
contact material.

Coil. Check the coil with an ohmmeter for an

open circuit or a short-circuit. Replace if
damaged. Reconnect again to the correct
terminals. The coils in the contactors for the
hydraulic pump and 1A have an external
suppressor. The coil and the suppressor can be
checked separately with an ohmmeter. [A
suppressor diode (and sometimes a resistor in
series) is part of the coil. The diode will cause the
ohmmeter to indicate a difference in resistance in
one direction. Reverse the probes of the
ohmmeter to the opposite terminals and
measure the resistance. Use the highest
resistance].

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Brush Wear Indicators

Brush Wear Indicators Motor Thermal Switches

The brush wear indicator will illuminate on the Replace the thermal switch if it is damaged.
premium display only when the motor brushes However, motor disassembly is required to
need replacement. The sensor is located on the replace the thermal switch.
brush carrier and will come in contact with the
brush holder when the brushes have passed a
serviceable limit. When the brush wears within ! WARNING
approximately 1.5 mm (0.060 in.) of the brush
lead, the connection between the brush and the To prevent damage and injury if the
sensor causes the indicator to illuminate on the lift truck moves. Raise the drive
premium display. wheels from the floor during these
Check the operation of the brush wear tests.
indicators during periodic maintenance. Remove
the battery from the lift truck for access to the
motors. Use a jumper cable to connect the battery for
operation of the motors. See Figure 3-4.
Use a jumper cable to connect the battery for Disconnect the sensor wires from outside of
operation of the motors. See Figure 3-4. the motor case. Touch the ends of the sensor
Disconnect the sensor wires from the outside of wire together. The warning light will illuminate
the motor case. Touch the ends of each sensor if the circuit is operating correctly.
wire to the A1 terminal of the motor while it is
in operation. The warning light will illuminate if
the truck has a premium display and if the
circuit is operating correctly.

Figure 3-4: Connect Battery to Operate Motor

1. Raise Drive Wheels

2. Jumper
3. Battery
Connect the battery to operate the motor.
Remove the battery for access to the motor. Use
a jumper cable to connect the battery to the lift
truck. Raise the drive wheels. See “Before
Servicing Lift Truck” in the GENERAL
INFORMATION Section.

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Truck Management Module

Truck Management Module

The Truck Management Module is a maintenance personnel that the motor brushes
multi-function accessory card or an auxiliary need replacement before they wear to the point
function of the SX Pump control used with the of causing destructive damage to the motor
SX series Traction controls. The TMM card is commutator surface. The BWI is a sensor that
able to provide the status codes or operator short circuits to the motor armature to signal
warning codes that are displayed on the dash limits of brush wear.
display whenever a normally open switch or
NOTE: Motor armature must be in the positive
sensor wire provides a signal to the TMM
side of the battery circuit.
accessory card. The TMM is used to display
overtemperature of motors, hydraulic systems,
or any other device or system than can activate Installation
a thermostat type switch that closes at the
desired temperature. Status code 90 not only
displays the status code to the dash display, ! WARNING
but when activated is programmed with the
Handset to reduce the speed of the truck from Before adjusting, servicing, or
100% to 0% percent on-time. The TMM is also making contact with working
used to monitor and display motor brush wear components, raise the truck wheels
warnings on the premium display when the off the floor, disconnect the battery,
motor brushes require replacement.
and discharge the capacitor in the
traction and pump controls.
Operation
The TMM card utilizes up to 6 input points and 3
output points (See Wiring Section for
connections). The 3 output points connect to
the “P2” plug on the Traction Controller. The
input to the TMM card is a switch wire closure
to battery negative or positive.
The instructions for adjustment of the speed
limit function of status code 90 is described in
detail in the instructions for the Handset. The
speed limit function is enabled when the input
switch supplies a negative signal to TB1.
NOTE: The microprocessor only checks for
TMM status codes 94 and 95 when a
neutral signal is present (for example:
open start switch or open F/R switch),
the status code is displayed and the
speed limit is enabled when the control
is returned to the run mode.
The TMM is also used as a Brush Wear
Indicator (BWI) when the truck is equipped with
a premium display. The Brush Wear Indicator is
designed to detect a worn-out brush and
display a fault code on the dash display to warn

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Thermal Transfer

Thermal Transfer

Why is Thermal Transfer “Good” thermal transfer is thus dependent on 3

factors:
important?
1. Proper heat sinking.
Solid-state electronic devices are often
considered “lossless” as compared to their 2. Proper mechanical mating (mounting).
electro-mechanical counterparts. However, 3. Optimum surface contact.
these devices are not entirely 100% efficient and
losses exist in the form of generated heat that
must be dissipated properly to insure Insuring Proper Thermal
long-term reliability and performance. Transfer
The Control incorporates solid-state devices
throughout. It also incorporates heat sinking to Mounting Instructions for Motor
provide proper dissipation of the generated heat Controls
through these heat sinks to the control base
In the design of this
that is eventually dissipated in the vehicle
family of motor controls,
control mounting structure (for example,
performance
bulkhead).
assumptions were made
The Control heat sinks are designed to provide based on heat transfer
relief from short-term thermal peak overloads, between the control and
but long-term cooling is dependent on proper the ambient
thermal transfer from the heat sink to the environment. The
vehicle frame. vehicle mounting
surface acts as a heat
What determines “Good” sink, which increases the effective surface area
for heat dissipation. If this assumed heat
Thermal Transfer? transfer is not achieved during control
The primary factor for insuring “good” thermal installation and operation, the controllers will
transfer is a good mechanical fall short of their anticipated performance. It
surface-to-surface interfacing for flat and should be noted that the condition of the
threaded surface mating. The effectiveness of mounting surface, and the quality of the
the thermal transfer is a function of the amount resulting interface between the control and the
of actual surface contact there is between a vehicle, can significantly hinder heat transfer
heat “source” and a properly selected heat from the control. This why each control has a
“sink”. thin sheet of copper between the control and
the frame of the truck. The presence of
While most commercially prepared surfaces contaminants, or of air voids created by surface
appear flat and smooth, good thermal transfer inconsistencies in either the vehicle or the
of the heat generated in solid-state devices control, degrade the control’s capacity for heat
requires the optimum in surface contact. The transfer. The control’s performance is de-rated
smallest amount of surface irregularity is proportionally as its own thermal sensors
detrimental as it adds to the thermal reduce its operation to protect it from damage
resistivity between the two surfaces and limits due to excessive heating.
thermal transfer.
Contained within the software of the controls
are several diagnostic status codes related to
controller thermal performance. Failure to
follow these mounting recommendations

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Vehicle Mounting Surface

increases the likelihood of encountering these Vehicle Mounting Surface

status codes.
The quality of the vehicle mounting surface is
Careful surface preparation, including critical for the optimum heat transfer between
adequate application of thermal compound, as the control and the ambient environment.
detailed in the following paragraphs, must be Conduction through the base of the control is
completed during the installation of the the control’s only means of heat rejection. While
controls. There are many techniques for the controls are highly efficient, a few percent of
applying thermal compound, and one approach the electrical energy will be converted into heat.
is outlined below that has shown to apply a As previously mentioned, if this energy is not
consistent thickness of material. dissipated through the base of the control, a
thermal protector will reduce the performance
Necessary Tools of the control until the temperature stabilizes.
For optimal heat transfer from control to
Recommended use of the following components, vehicle, the flatness of the vehicle mounting
or equivalent substitutions, during the control surface should be equivalent to the flatness of
installation process: the control surface (0.005 inch per linear inch).
a. Thermal compound, (223-012-221), Use a straight edge or dial indicator to verify the
maintained per the manufacturer’s mounting surface.
recommendations and free of The biggest hindrance to heat transfer is the
contaminants presence of rust, scale, weld splatter, or paint
b. 3/32” notched trowel, such as a on the vehicle mounting surface. If any of these
adhesive spreader, model 223-012-222 items are noted, prepare the surface per the
following guidelines:
c. Calibrated torque wrench (0 to 15 ft-lbs)
a. Clean the mounting surface with a
The Controls rotary wire brush until the metal
surface is exposed.
During the manufacture of the control, the
b. Using 80-100 grit emery paper, sand the
surface flatness is maintained at 0.005 inch per
surface until the metal shines.
linear inch (not to exceed 0.025 inch per 10.0
inches). The surface finish of the control has an c. Flush the surface clean with an
Ra (average roughness) of 64 (microinches), or appropriate liquid de-greaser or parts
better. This finish is consistent with cold rolled cleaner.
or extruded aluminum.
Always take care in the handling and storage of
controllers. Make sure the base of the control is
free from nicks, bumps, protrusions, or any
other foreign object that would prevent the
control from sitting flush with the vehicle
mounting surface. Examine the base of the
control to verify that it is in good condition and
free from damage or contamination.

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Application of Thermal Compound

Application of Thermal Compound a. Prepare the two mounting surfaces

(control and vehicle) as indicated
Due to the minute differences in the control previously.
mounting surface and the vehicle mounting
b. Using a triangular notched trowel of
surface, small pockets of air are created. These
3/32” (0.09” ± 0.01), apply the grease to
air pockets will add to the overall thermal
the vehicle mounting surface.
resistance of the interface. To avoid these air
pockets and improve thermal conductivity, c. Use straight, non-crossing strokes of the
apply thermal compound between the control trowel to apply the compound.
base plate and the vehicle mounting surface. d. Make multiple vertical passes until a
The function of this compound is to conform to uniform consistency is achieved.
surface discrepancies, filling gaps and
optimizing the metal-to-metal contact of the
control and the vehicle.

Adhesive Spreader Vehicle surface after proper

grease application
3

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Application of Thermal Compound

Mounting the Control

8 5
a. After control mounting surface is
prepared with heat sink grease, place 4 5
the copper heat conducting pad on heat
2 3
sink grease, and align holes as
positioned.
2 1
b. After placing the copper pad, apply heat
4 1
sink grease to the exposed side of the
pad using the same method as before.
c. Prepare mounting surface of truck. 6 3
6 7

d. Place the control unit with desired 3

orientation on mounting surface of Figure 3-6: Proper sequence for use in tightening
truck with mounting holes aligned. hardware during control mounting
e. Move the control slightly in all directions
Maintenance
to eliminate voids and enhance the
distribution of the thermal compound. If it is necessary to remove the control, give
f. Insert all of the mounting hardware (6 or careful consideration to removing the old
8 bolts, M6, necessary for the mounting thermal compound from the control and
of the respective control). mounting surface, prior to replacement of the
unit. Never re-use thermal compound. Use a
g. Tighten these bolts (as per sequence putty knife or similar straight edge to carefully
shown in Figure 3-6) to half of the remove all thermal compound residue without
nominal torque value (7.5 lb-ft). damaging either mounting surface. Flush the
h. Lastly, tighten the bolts to the nominal surfaces with a liquid de-greaser or parts
torque value (15 lb-ft), following the cleaner and allow them to dry, before
same sequence. re-applying the thermal compound and
mounting the control. Take care not to
contaminate the surfaces with hydraulic fluid
or battery acid.
If the copper heat conducting pad between the
control and the truck shows signs of corrosion
that cannot be cleaned, then replace the copper
pad. Otherwise, carefully remove the old
thermal compound and reapply it before
3 installing the new control.
Figure 3-5: Calibrated torque wrench for hardware
installation

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Traction Control

Traction Control

1 Traction Ctrl

2 Pad, Tr Heats

3 Bolt, Washer Assy

4 Washer, Plain

5 Bolt, Washer Assy

6 Washer, Plain

7 Fuse

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Troubleshooting Tips

Troubleshooting Tips

Successful Commutation Requirements Armature Winding Problems

• Good contact between commutator and • Open Circuit
brush • Thin red sparks encircling commutator
• Mechanically true commutator • Blackens or flattens commutator bars,
• Brushes free to move in holders especially at edges
• Copper-Oxide-Carbon film (as opposed to • Short Circuit
pure copper surface) noted by color • Blue spark in vicinity of brush holder
variations
• Commutator bars oxidize or burn
• Commutator surface is clean and smooth
• Grounded
• Clean commutator
• High current draw
NOTE: Refer to the charts beginning on
• Rapid brush wear
page 3-14 for “Unsatisfactory Brush
Performance” and the illustrations
beginning on page 3-21 for “Commutator
Surfaces” that show the main patterns
of film build-up on commutators, and
indicate the type of brush/commutator
interaction that give rise to each pattern.
Sparking at Brushes
• Commutator in poor condition
• Eccentric or rough commutator
• Excessive vibration
• Broken or sluggish spring
• Brushes to short
• Machine overloaded
• Short circuit in armature
Insulation System
• Insulation resistance - 0.10 megohm (or
greater)
• Less than 0.10 megohm, investigate:
• Excessive dirt
• Moisture
• Insulation break down
For moisture, bake in an oven at 90°C (190°F)
• 600V - 60HZ - 1 minute
• Test old motors at 75% of above values

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Unsatisfactory Brush Performance

Unsatisfactory Brush Performance

TABLE ONE: Primary Sources of Unsatisfactory Brush Performance

• Poor operation of commutator surface
• High mica
Preparation and Care of Motor • Side mica
• Need for periodic cleaning
• Clogged ventilating ducts

• Brushes tight in holders

• Brushes too loose in holders
• Brush holders loose at mounting
Mechanical Fault in Motor • Loose pole pieces
• Loose or worn bearings
• Dynamic imbalance
• Variable angular velocity

• Open or high resistance connection at commutator

• Connection at series terminal
Electric Fault in Motor • Short circuit in field or armature winding
• Ground in field or armature winding
• Reversed polarity on main pole

• Overload
• Dynamic braking
• Low average current density in brushes
• Contaminated atmosphere
• “Contact positions”
Load or Service Condition
• Oil on commutator or oil mist in air
• Abrasive dust in air
• Humidity too high
• Humidity too low
• Silicone contamination

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Unsatisfactory Brush Performance

TABLE ONE: Primary Sources of Unsatisfactory Brush Performance (Cont’d)

• Loose or damaged motor mounting
• External source of vibration
• External short circuit
• Contact drop of brushes too high
Disturbing External Condition • Contact drop of brushes too low
• Lack of film-forming properties in brush
• Lack of polishing action in brush
• Brushes too abrasive
• Lack of carrying capacity

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Unsatisfactory Brush Performance

TABLE TWO: Indications Appearing at Brushes

Indication Immediate Causes Primary Faults

• Poor operation of commutator surface

• High mica
• Side mica
• Low average current density in brushes
Commutator surface • Contaminated atmosphere
condition • Contact positions
• Oil on commutator or oil mist in air
• Humidity too low
• Lack of film-forming properties in brush
• Lack of polishing action in brush

• Clogged ventilating ducts

• Brushes tight in holders
• Brushes too loose at mounting
Mechanical fault in
• Loose pole pieces
motor
• Loose or worn bearings
Sparking • Dynamic unbalance
• Incorrect spring tension

• Open or high resistance

• Connection at commutator
Electrical fault in
• Short circuit in field or armature winding
motor
• Ground in field or armature winding
• Reversed polarity on main pole

• Overload
Bad load condition
• Rapid change of load

• Loose or damaged motor mountings

Vibration
• External source of vibration

Chattering of brushes • See Chattering or Noisy Brushes

Wrong brush grade for • Lack of film-forming properties in brush

application

Other • Silicone contamination

Etched or Burned • See Copper in Brush Face

Bands on Brush Embedded copper
Face

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Unsatisfactory Brush Performance

TABLE TWO: Indications Appearing at Brushes (Cont’d)

Indication Immediate Causes Primary Faults

Commutator surface • See specific surface fault in evidence

condition • Silicone contamination

Severe sparking • See Sparking

• Incorrect spring tension

• Brushes tight in holders
Rapid Brush Wear • Brushes too loose in holders
Imperfect contact
with commutator • Brushes holders loose at mounting
• Loose or damaged motor mountings
• External source of vibration

Wrong brush grade • Lack of film-forming properties in brush

for application

Commutator surface • High mica

condition • Side mica

• Oil on commutator or oil mist in air

Copper in Brush • Abrasive dust in air
Bad service condition
Face • Humidity too high
• Humidity too low

Wrong brush grade • Lack of film-forming properties in brush

for application • Brushes too abrasive

Commutator surface • Raised commutator bars

condition

• Brushes too loose in holders

Looseness in motor • Brushes holders loose at mounting
• Incorrect spring tension
Chattering or
Noisy Brushes • Clogged ventilating ducts
• Contact poisons
High friction
• Humidity too low
• External source of vibration

Wrong brush grade • Lack of film-forming properties in brush

for application

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Unsatisfactory Brush Performance

TABLE THREE: Indications Appearing as Heating

Indication Immediate Causes Primary Faults

• Overload
Severe load condition • External short circuit
• Stalled motor
Heating in Windings
(Field or Armature) • Loose or worn bearings
Unbalanced magnetic
field • Short circuit in field or armature
winding

Lack of ventilation

Severe load condition • Overload

• Contact positions
Severe sparking
• See Sparking

• Incorrect spring tension

• Contact poisons
Heating at High friction • Humidity too low
Commutator
• Lack of film-forming properties in
brush

Poor commutator surface • See specific surface fault in evidence

Depreciation • Clogged ventilating ducts

High contact resistance • Contact drop of brushes too high

Severe load condition • Overload

Faulty motor adjustment • Incorrect spring tension

Severe sparking • See Sparking

Raw streaks on • See Streaking or Threading of

commutator Surface
Heating at Brushes
Embedded copper • See Copper in Brush Face

• Contact drop of brushes too low

• Lack of film-forming properties in
Wrong brush grade brush
for application
• Brushes too abrasive
• Lack of carrying capacity

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Unsatisfactory Brush Performance

TABLE FOUR: Indications Appearing at Commutator Surface

Indication Immediate Causes Primary Faults

Commutator surface • See specific surface fault in evidence

condition

• Brushes too loose in holders

Looseness in motor
• Brushes holders loose at mounting

Vibration • External source of vibration

Brush Chipping
or Breakage Chattering • See Chattering or Noisy Brushes

Sluggish brush movement • Brushes tight in holders

• Poor operation of commutator surface

Rough or uneven surface • High mica
• Side mica

High • Stalled motor

Commutator Sparking
Bar

• High mica
Low
• Open or high resistance connection at
Commutator Sparking
commutator
Bar
• Stalled motor

• Low average current density in brushes

• Contaminated atmosphere
• Contact positions
Sparking
• Oil on commutator or oil mist in air
• Humidity too low
Streaking or • Lack of film-forming properties in brush
Threading of
Surface • High mica
• Side mica
Copper or foreign material • Oil on commutator or oil mist in air
in brush face • Abrasive dust in air
• Humidity too high
• Brushes too abrasive

Bar Etching or • High mica

Sparking
Burning • Side mica

Bar Marking at • Open or high resistance connection at

Pole Pitch Sparking commutator
Spacing

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Unsatisfactory Brush Performance

TABLE FOUR: Indications Appearing at Commutator Surface (Cont’d)

Indication Immediate Causes Primary Faults

Bar Marking at • Lack of polishing action in brush

Slot Pitch Sparking • Lack of film-forming properties in brush
Spacing

• Open or high resistance connection at

Flat Spot Sparking commutator
• Stalled motor

High temperature • See Heating at Commutator

• Contaminated atmosphere
Discoloration Atmospheric condition
• Oil in commutator or oil mist in air
of Surface
Wrong brush grade for • Lack of polishing action in brush
application • Lack of film-forming properties in brush

Embedded copper • See Copper in Brush Face

• Contact positions
Raw Copper Bad service condition • Abrasive dust in air
Surface • Humidity too low

Wrong brush grade for • Lack of film-forming properties in brush

application • Brushes too abrasive

• High mica
Rapid
• Side mica
Commutator Burning
Wear with • Incorrect spring tension
Blackened • Brushes tight in holders
Surface
Severe sparking • See Sparking

• Contact positions
Foreign material in brush • Abrasive dust in air
Rapid
face • Humidity too low
Commutator
Wear with • Brushes too abrasive
Bright Surface
Wrong brush grade for • Brushes too abrasive
application • Lack of film-forming properties

Copper • External source of vibration

Brush Vibration
Dragging • Lack of film-forming properties in brush

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Commutator Surfaces

Commutator Surfaces
UNSATISFACTORY
GOOD CONDITION CONDITION
LIGHT FILM UNEVEN FILM
Uniform coloring indicates Patchy colors of varying
satisfactory operation of densities and shape. Due to
machine and brushes. Film unclean operating conditions
color is largely an effect of or incorrect physical
thickness, therefore provided condition of commutator.
the film is uniform it is
perfectly acceptable.

SATISFACTORY CONDITION
UNSATISFACTORY
LIGHT AND DARK PATTERN CONDITION
This is not a good condition FILM WITH DARK AREAS
but in our experience it is
known that machines having These areas can be isolated or
this commutator pattern regular. Commutator out of
have operated with round. This can be caused
satisfactory results for long by vibration or mechanical
periods of time. This deficiencies in equipment
condition can appear in operation, bearings,
alternating bars as shown or couplings, etc.
every 3rd or 4th bar, etc.
This is related to the winding
design of the armature.
Difficulty caused from split
windings crossing in the
same slot. UNSATISFACTORY
CONDITION
UNSATISFACTORY
CONDITION EXAMPLE OF POOR
COMMUTATOR MACHINING
STREAKY FILM WITH NO
COMMUTATOR WEAR Bars are low on entry and
leaving edges giving rise to
Frequently due to the brushes riding on the
under-loaded operation, middle of the bars.
machine grossly
over-brushed or brush grade
incorrect for particular
machine application.
Atmosphere and
environmental conditions
can contribute.

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Commutator Surfaces

UNSATISFACTORY UNSATISFACTORY
CONDITION CONDITION

EXAMPLE OF POOR BRUSH CONTACT MARK

COMMUTATOR MACHINING
Storage of machines, for
Bars are low in the middle lengthy periods, with
giving rise to the brushes brushes in position. This can
riding on entry and leaving also result from operation
bar edges. This and the of machine in prolonged
previous illustration indicate stall conditions.
the need for better
maintenance.

UNSATISFACTORY UNSATISFACTORY
CONDITION CONDITION

STREAKY FILM WITH BAR EDGE BURNING CAUSE

COMMUTATOR WEAR HIGH MICA

This is a further development Illustration shows high mica

of the third example, in every slot. Same effect can
previous page. Brush grade, occur on one bar only.
machine applications and Similar conditions can be
working environment all caused by a high or low bar.
suspect. Earlier corrective
action should have been
taken.

UNSATISFACTORY UNSATISFACTORY
CONDITION CONDITION

DOUBLE POLE PITCH SMALL BRIGHT SPOTS

Darkening of commutator in Related to over-loaded

sequences two pole pitches machines and low brush
apart is due to armature pressure. Due to sparking
fault, bad coil, riser bars or under brush which gives rise
equalizer connections. to spots being of a random
distribution. If not corrected,
will result in scored
commutator.

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Raymond ® DSD Maintenance Manual SX Control Connections & Troubleshooting by Symptom

SX Control Connections & Troubleshooting

by Symptom 4:

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SX Control Connections & Troubleshooting by Symptom Raymond ® DSD Maintenance Manual

SX Control

SX Control

F1 F2

12 Pin
Y Plug

Negative

23 Pin Main A2
Connector A1
Positive

Figure 4-1: SX Control Connection Points

These troubleshooting instructions are The primary method of diagnosing SX Control

intended as a method to check all outside System faults is to use the diagnostic features
devices and eliminate them as the source of the of the display and Handset. These, along with
problem in order to conclude that the SX the preceding fault code tables, aid in the
Control is faulty. resolution of the majority of faults encountered.
If a problem is readily identified through the
Instructions for Removal of SX built-in diagnostics feature, use the following
Control tables as a secondary guide to aid in the
identification of the fault.
1. Disconnect the battery, discharge the
capacitor, and raise drive wheels off the 1st Check is for shorts to frame. Voltage on
floor. frame may cause many problems and codes.
2. Unplug the main and Y plugs by pressing 2nd Checks are always loose/dirty connections
down on tab and pulling straight out on at controller and harness connections.
connector. Never use wires to pull out
connector.
3. Remove power fuse and all bus or cable
connections from control.

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Raymond ® DSD Maintenance Manual SX Control Connections & Troubleshooting by Symptom

Failures Causing Reduced or No Motor Torque

Failures Causing Reduced or No Motor Torque

Table One: Failures Causing Reduced or No Motor Torque

NOTE: Conduct all testing with truck jacked up.
Symptom Probable Cause
1a. Line Contactor does not pick up. • Check power and control fuses.
No control voltage from positive • Check battery for low specific gravity and
to negative. connections for looseness or broken connector.
1b. Line Contactor does not pick up • Check PTC (Positive Temperature Coeificent) for
with control voltage positive heating. If hot to touch, check for proper battery
to negative. polarity to control panel.
• Plug in the battery with the key switch OFF.
Voltage on should be battery volts at P1-1.
• Close key switch and check volts at P1-2; voltage
should be battery volts. If not, check control fuse
FU2.
• With key switch and seat switch closed, check for
battery volts at P1-6. If zero, check control fuse,
wiring, or faulty key switch. If low, check for volt
drop across circuit from battery positive to P1-6.
• With key switch and seat switch closed, check for
battery volts at P1-2. If zero, check control wire #10
between key switch and seat switch and control
card or fault seat switch. If low, check for volt drop
across circuit to P1-2.
• Check for positive at line contact coil, P10-2
connection. If not battery volts, check line coil for
open or possible loose connections.
• Static Return to Off Fault.
If monitoring system warning light on display (!)
comes on, once the key switch and seat switch are
closed:
• Check for fault in directional control switch.
• Check for fault in wiring to directional control
switch.

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SX Control Connections & Troubleshooting by Symptom Raymond ® DSD Maintenance Manual

Failures Causing Reduced or No Motor Torque

Table One: Failures Causing Reduced or No Motor Torque (Cont’d)

NOTE: Conduct all testing with truck jacked up.
Symptom Probable Cause
1c. Line contact closes, truck does • Check power fuse at positive on control. Should be
not move. battery volts. If not, check power fuse by volt drop
check across fuse.
• Check voltage at A1 and A2, should be battery
volts. If not, check motor cables and volts at A1
and A2 to locate open circuit. Check motor brushes
for sticking.
• Check F1 to F2 for open field circuit (loose
connections).
• Check for voltage on F1 and F2, it should increase
and decrease by pressing accelerator and
releasing.
• Check voltage at P1-7. Should be 0.5 volts with
accelerator at creep speed, increasing to 3.5 volts
or more as the accelerator is pressed down to top
speed. If P1-7 remains at about 0.5 or less volts,
check start switch and accelerator potentiometer.
• Check circuit from accelerator start switch and
potentiometer to traction control for open wires.
• Check motor A1 to A2 for open circuit in motor
armature.
• Check motor F1 to F2 for open circuit in motor
fields.
• Check for direction switch inputs to control at P1-5
and P1-6 for forward and reverse. If voltage not
present, check circuit to accelerator. Positive at
P7-A and check for circuit through switch at P7-B
and P7-C.
• Replace the SX Traction control.
1d. Line contactor closes, display • Check for direction switch positive to control at
powers up, power steering P1-4 and P1-5. If not present, check direction
control does not close. switch and voltage to switch.
• With direction switch input voltage to P1-4 or P1-5,
check for positive voltage to power steering coil at
P10-3 wire 21. If voltage is not present, check coil
for open by resistance check. If low voltage, check
for volt drop across wire 10 from key switch and
across key switch.
• If battery voltage is correct at P10-3 and all other
voltage are correct to traction control, the power
steering driver in the control has failed. Replace the
SX controller.

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Raymond ® DSD Maintenance Manual SX Control Connections & Troubleshooting by Symptom

Mis-operation of Other Features

Mis-operation of Other Features

Table Two: Mis-operation of Other Features

NOTE: Conduct all testing with truck jacked up.
Symptom Probable Cause
1a. 1A Bypass contact does not close (if • Check accelerator voltage to control at P1-7.
equipped). Voltage should start at below 0.5 volt and
increase to above 3.5 volts as accelerator is
depressed.
• Voltage from accelerator must go above 3.5
! WARNING volts at P1-7 to achieve 1A Bypass operation.
• Check battery position voltage at 1A Bypass
Do Not use jumper wire on coil to PID driver terminal 3 wire 30.
coil driver with motor in static • Check for battery negative at PID driver
condition or Severe damage terminal 2.
may occur to motor armature. • Check for signal voltage from control at P1-11
However controller protects to PID driver terminal 1. Voltage should be less
than 12.
against this action and should
• If voltage is 12 or higher at P1-11 or PID driver
produce a code terminal 1, then check for open PID driver.
• If voltage is 2 or less and terminal 2 and 3 do
not complete the circuit the PID driver may be
shorted or open and should be replaced.
2a. 1A Bypass contactor close with key. • Check for short to negative on wire 45 from coil
to driver terminal 3.
• Check for signal voltage at P1-11 if present.
Replace SX controller.
2b. Power steering contact closes with • Check for voltage short to battery negative on
key switch. wire 21 between P10-3 and P1-18.
• Check negative voltage at P10-3. If present,
replace SX controller.
3a. 1A Bypass contactor will not close • Check voltage.
at stall (if equipped). • Check Bypass contactor and driver and wiring.
• Replace SX Controller.
3b. 1A will not open until start switch is • Check voltage at P1-7. Should be near 0.5
opened. volts, or below when accelerator is released. If
not, check accelerator output.
3c. Stiff Regen (severe reversal). • Check Regen adjustment setting on Controller.
• Check controller type setting.
• Replace SX Controller.
3d. Very soft reversal during regen • Check for proper adjustment of regen.
braking mode. • Check controller type setting.
• Replace SX Controller.

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SX Control Connections & Troubleshooting by Symptom Raymond ® DSD Maintenance Manual

Mis-operation of Other Features

4-6 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Wiring

Wiring 5:

PDMM-0115 Issued: 07/31/2002 5-1

Wiring Raymond ® DSD Maintenance Manual

5-2 PDMM-0115 Issued: 07/31/2002

Wiring 5:

Traction Bypass with Pump Contactor

5-3
5-4
Pump Contactor

3 2

Legend:
1. Traction Controller
2. Hydraulic Pump Motor Contactor
3. Fuse (Traction Circuit)
4. Fuse (Hydraulic Pump Circuit)
5. Fuse Panel (FU1, FU2, FU3)
6. Fuse 5 (Steering Circuit)
7. Power Steering Motor Contactor

5-5
5-6
Traction Bypass with Pump Contactor

1
2

2
3

3
8
8 7

7
5

5
4

4
9

9
6

6
Legend:
1. Traction Controller
2. Hydraulic Pump Motor Contactor
3. Fuse 4 (Traction Circuit)
4. Fuse 6 (Hydraulic Pump Circuit)
5. Fuse Panel (FU1, FU2, FU3)
6. Fuse 5 (Steering Circuit)
7. Power Steering Motor Contactor
8. 1A Bypass Contactor
9. Line Contactor

5-7
5-8
Traction Bypass with Pump Control

5-9
5-10
Pump Control
2
2
1
1

8
6
7
8
5
5

6
7
4
4
33

Legend:
1. Traction Controller
2. Pump Controller
3. Line Contactor
4. Power Steering Motor Contactor
5. Fuse Panel (FU1, FU2, FU3)
6. Fuse 5 (Steering Circuit)
7. Fuse 6 (Hydraulic Pump Circuit)

5-11
5-12
Traction Motor Controller with Pump Motor Controller and Bypass

5-13
5-14
Raymond ® DSD Maintenance Manual Wiring

TMM7A (Truck Management Module)

Wiring 5:

TMM7A (Truck
Management Module)

Connector Wire Nominal

Description Condition
Terminal # Voltage
Traction Motor No Fault 5V
1 73 Overtemperature Traction Motor Overtemperature 0V
2 – Not Used
Pump Motor No Fault 5V
3 74 Overtemperature Traction Motor Overtemperature 0V
4 – Not Used
Traction Motor BWI No Fault 5V
5 75
Traction Motor Brushes Worn 0V
Traction Motor BWI No Fault 5V
6 76
Traction Motor Brushes Worn 0V
7 70 P2-9 Traction Card –
Pump Motor BWI No Fault 5V
8 77
Pump Motor Brushes Worn 0V
9 71 P2-9 Traction Card –
Pump Motor BWI No Fault 5V
10 78
Pump Motor Brushes Worn 0V
13 72 P1-19 Traction Card –
14 – Not Used
Battery Negative 0V
15 79
0V

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Wiring Raymond ® DSD Maintenance Manual

TMM7A (Truck Management Module)

Truck Transistor
P11 TMM7A TMM7A
Error Harness Pump Control Description
Pin # Terminal # Wire #
Wire # Pin #
2 None TB7 70 23 P5-14 P2-9 On Traction control
3 None TB9 71 24 P5-13 P2-8 On Traction control
P1-19 On Traction control
with pump contactor
4 None TB13 72 25/17 P5-10
P1-10 On Traction control
with pump control
Traction Motor
5 90 TB1 73 80 P5-16
Overtemperature
Pump Motor
6 92 TB3 74 82 P5-11
Overtemperature
7 94 TB5 75 85 P5-5 Traction BWI
8 94 TB6 76 86 P5-6 Traction BWI
9 95 TB8 77 87 P5-8 Pump BWI
10 95 TB10 78 88 P5-9 Pump BWI

NOTE: TMM7A wires are all black with

numbers stamped in white. Truck
harness wires are multi colored with
wire numbers stamped 10mm from each
terminal. Some TMM7A wire numbers
are exactly the same as truck harness
wire numbers, but the wires are not
connected.

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Raymond ® DSD Maintenance Manual Wiring

Pump Driver

Pump Driver

FUNCTION: Controls the power supply to the

contactor coil according to the control signal
input.

Truck
Terminal Wire Voltage on
Harness Description Condition
# # Terminal
Wire #
Not Activated 0V
1 N/A 52 Control Signal Input
Activated 5V
2 13 13 Battery Negative Always 0V
Contactor Not Activated BV
3 18 50-1 Contactor Coil Input
Contactor Activated 0 - 0.5V
4 N/A Not Used
BV = Battery Volt

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Wiring Raymond ® DSD Maintenance Manual

Pump Time Delay

Pump Time Delay

FUNCTION: Controls the power supply to the

pump driver according to the control signal
input.

Contactor Voltage
Terminal Truck Wire
Panel Description Condition on
# Harness #
Harness # Terminal
Not Activated 0V
1 N/A 52 Control Signal Output
Activated 5V
2 13 13 Battery Negative Always 0V
Control Card Input Contactor Not Activated 12V
3 52 53
to Delay Contactor Activated 11V
BV
4 10 10 Battery Positive Key On
BV
BV = Battery Volt

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Raymond ® DSD Maintenance Manual Diagnostic Status Codes

Diagnostic Status Codes 6:

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Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Basic Checks

Basic Checks

The biggest mistake technicians can make is to Always check each function and write down
assume they know the problem before starting the reading.
to work on a truck. Unfortunately, while
If the programming fails to match the
making our life easier, self-diagnostics also
specifications, reprogram the controller and
make us more susceptible to this type of
check the truck operation before going any
mistake. Never start to fix a truck based solely
further. If repairs are required, turn the key
on the number on the dash or handset display.
switch OFF, then push the CONT and ESC keys
Always follow the basic troubleshooting steps.
at the same time to enter the History Folder.
Talk to the operator Only zero out these codes after the truck is
repaired and running properly.
• Confirm their description of the problem
with an operational check. Utilize the Status Codes in the following pages
• Visually inspect cables, connectors, to find the component or area to check for a
contactor tips, etc. fault. Status Codes the result from a faulty
controller, but perform all voltage checks and
• Perform basic battery cables to frame testing before replacing.
resistance tests. You should have at least
20,000 ohms.
Display Codes
• Check for any voltage on the frame.
• Check the battery condition. Note – Shorts to frame may cause false codes.

Now we are ready to allow the self-diagnostics CCCC – Check for Shorts to frame by volts.
to give us a starting point to repair the truck. PC – Pump controller information data cannot
Turn the key switch ON and check when the be read.
display goes through its boot up sequence to be
sure all of the LEDs or LCD segments are DC – Drive controller information data cannot
functional. At this time, note the status (fault) be read.
code (if any) and then turn the key switch OFF “=” – Data from controller is outside of range
so you can note the hours on the meter.
Disconnect the battery and discharge the Please see Display Section for proper setup of
capacitor with the 150–25 watt resistor between speed sensor.
the positive and negative terminals on the
controller. Remove the P2 plug that connects
the dash display to the card and insert the
handset plug connector. Plug in the battery.
While holding the CONT button down on the
handset, turn on the key switch to enter the
programming mode. When you get the 8888 on
the handset, push down on the key pad #1
button to double check the Status Code stored
in the memory.. This should be the same as the
dash display (if it showed one). Before
proceeding, check the card’s programming.

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Raymond ® DSD Maintenance Manual Diagnostic Status Codes

Status Codes

Status Codes

Status
Description Page
Code

Blank Segments do not illuminate on the Dash Display and/or the Handset. 6-6

-01 No seat switch input (no voltage to P1-6). 6-7

-02 Forward directional switch is closed on initial power-up. 6-8

-03 Reverse directional switch is closed on initial power-up. 6-9

-05 Start switch or brake switch fails to close. 6-10

-06 Accelerator depressed with no direction selected. 6-11

-07 Accelerator input voltage too high. 6-12

-08 Accelerator input speed too high on power-up after initial key switch closure. 6-13

-09 Both the forward and reverse directional switches are closed at the same time. 6-14

-11 Start switch closed on power-up after initial key switch closure. 6-15

-15 Battery voltage is too low or control card is mis-adjusted. 6-16

-16 Battery voltage is too high or control card is mis-adjusted. 6-17

-21 Accelerator voltage is too high. 6-18

-23 Motor field current is too high on start up in the reverse direction. 6-19

-24 Motor field current is too high on start up in the forward direction. 6-20

-27 Control’s internal power supply is less than 10 Volts DC. 6-21

-28 Motor field current is too high during the run mode. 6-22

-41 Shorted thermal protector (TP) or armature transistor overtemperature. 6-22

-42 Motor armature offset voltage is too high. 6-23

-43 Motor armature offset voltage is too low. 6-24

-44 Armature transistor did not turn off properly. 6-25

-45 Armature transistor did not turn off properly. 6-26

-46 “Look Ahead” test for A2 volts less than 12% of battery volts. 6-27

-49 Motor field current is too low during the run mode. 6-28

-51 Capacitor volts are low before the line contactor closes. 6-29

-57 Controller “motor current sensor” input too low during running. 6-30

PDMM-0115 Issued: 07/31/2002 6-3

Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Status
Description Page
Code

-64 The line driver input (P2-17) is less than 12% of battery volts. 6-31

-65 The line coil is too high during the run mode. 6-32

-66 The field current exceeds the current limit on the field transistor. 6-33

-67 The armature current exceeds the armature transistor limit. 6-34

-69 The power steering coil current is too high during the run mode. 6-35

-76 Capacitor (1C) voltage too high. 6-36

-77 Motor current is detected during regenerative braking. 6-37

If the armature motor current is greater than a preset value for longer than 3.5
-82 6-38
sec. the armature motoring current will be turned OFF.

A switch position is incorrect during the accelerator potentiometer

-83 6-39
autocalibration routine.

Accelerator pot values obtained during the autocalibration routine were not
-86 6-40
valid.

Hydraulic lever is activated before the pump is enabled when key switch is
-89 6-41
initially activated.

-89 Hydraulic lever is activated when truck is operating. 6-42

-90 Traction motor temperature has exceeded maximum temperature limit. 6-43

Traction motor temperature has exceeded maximum temperature limit. (with

-90 6-44
pump controller hyd.)

-91 Pump motor temperature has exceeded maximum temperature limit. 6-45

Pump motor temperature has exceeded maximum temperature limit. (with

-91 6-46
pump controller hyd.)

-94 Traction motor brush wear indicator has detected worn brush. 6-47

-94 Traction motor brush wear indicator has detected worn brush. 6-48

-95 Pump motor brush wear indicator has detected worn brush. 6-49

-95 Pump motor brush wear indicator has detected worn brush. 6-50

-99 Maintenance alert and speed limit. 6-51

-117 “Card Type” selection is invalid. 6-52

-127 Control logic card power supply is less than 10 VDC. 6-52

-128 Armature current is too high during the lift mode. 6-53

-141 Pump control is overtemperature. 6-53

-142 Pump Controller “motor current sensor” input is missing. 6-54

6-4 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Diagnostic Status Codes

Status Codes

Status
Description Page
Code

-143 Pump Controller “motor current sensor” input is too low. 6-55

-144 Power Transistor (Q1) did not turn off properly. 6-56

-145 Power Transistor (Q1) did not turn on properly. 6-57

-146 “Look Ahead” test for Pump motor circuit volts less than 12% of battery volts. 6-58

-150 Capacitor volts are low after the line contactor closes. 6-59

Capacitor volts are low before the line contactor closes. (Internal card function
-151 6-60
during pre-charge.)

-157 Controller “motor current sensor” input voltage polarity check. 6-61

-180 Voltage at capacitor (1C) is less than 14 volts. 6-62

-181 Battery voltage is less than 14 volts. 6-63

-189 Input switch closed before pump enable signal is received. 6-64

(*) Not used on all models of lift trucks. Status Codes

in this group will flash on the display.

PDMM-0115 Issued: 07/31/2002 6-5

Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Segments do not illuminate on the No input voltage to the Logic Card or

None Dash Display and/or the Handset. the display unit.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Display screen on Dash Display and/or
Handset is blank.

POSSIBLE CAUSE
Circuits valid Positive or negative control voltage is not
for Traction present.
Controller
• Insure that the key switch is closed and
voltage is present between P1-1 &
battery negative. Also check for
voltage between P1-2 and control
negative.
Open circuit between control card AND the
Dash Display or Handset.
• Check for an open circuit or loose
connection going from the control and
the Dash Display or Handset.
Bad Dash Display or Handset.
• Replace Dash Display or Handset.

6-6 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Diagnostic Status Codes

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

No seat switch input This status code is displayed when

-01 (no voltage to P1-6). P1-6 is less than 50% battery volts.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Control will not operate.

Circuits valid POSSIBLE CAUSE

for Traction Mis-adjusted or bad seat or deadman
Controller switch.
• Check to see that the seat switch closes
properly.
Open circuit between battery positive and
P1-6.
• Check for loose connections or broken
wires:
• Between the seat switch and P1-6.
• Between the key switch and the
battery positive side of the seat
switch.
• Between the seat switch and P1-2.
• On vehicles without a seat/deadman
switch, check for a loose connection or
broken wire from P1-2 and/or P1-6.

PDMM-0115 Issued: 07/31/2002 6-7

Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Forward directional switch is closed This status code is displayed when

-02 on initial power-up. P1-4 is greater than 60% of battery
voltage at initial key switch ON.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Control will not operate because of
Static Return to Off (SRO) lock out.

POSSIBLE CAUSE
Circuits valid Forward directional switch is closed on
for Traction initial start up (for example: closure of
Controller battery, key switch or seat/deadman
switch).
• Return directional switch lever to
neutral and then return lever to
forward position.
Forward directional switch is welded
closed or mis-adjusted to be held closed.
• Replace or adjust directional switch to
insure that it opens when the
directional switch is returned to
neutral.
Malfunctioning control.
• Replace the controller unit.

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Raymond ® DSD Maintenance Manual Diagnostic Status Codes

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Reverse directional switch is closed on This status code is displayed when

-03 initial power-up. P1-5 is greater than 60% of battery
voltage at initial key switch ON.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Control will not operate because of
Static Return to Off (SRO) lock out.

POSSIBLE CAUSE
Circuits valid Reverse directional switch is closed on
for Traction initial start up (for example: closure of
Controller battery, key switch or seat/deadman
switch).
• Return directional switch lever to
neutral and then return lever to reverse
position.
Reverse directional switch is welded closed
or mis-adjusted to be held closed.
• Replace or adjust directional switch to
insure that it opens when the
directional switch is returned to
neutral.
Malfunctioning control.
• Replace the controller unit.

PDMM-0115 Issued: 07/31/2002 6-9

Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Start switch or brake switch fails to This status code is displayed when
close. P1-7 is calling for greater than 40%
-05 speed and P1-3 is less than 60% of
battery volts.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Control will not operate.

POSSIBLE CAUSE
Malfunctioning start switch circuit.
Circuits valid
for Traction • Check start switch to insure closure
with accelerator pedal released.
Controller
• Check for open circuit or loose
connection in wiring from key switch to
start switch and from P1-3 to start
switch.
Malfunctioning accelerator switch.
• Check accelerator switch potentiometer
for proper operation and ohmic value.

6-10 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Diagnostic Status Codes

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Accelerator depressed with no This status code is displayed when

direction selected. P1-4 & P1-5 are less than 60% of
-06 battery volts, and P1-7 is calling for
greater than 40% speed.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Control will not operate.

POSSIBLE CAUSE
Accelerator pedal is depressed before
Circuits valid closing forward or reverse directional
for Traction switch.
Controller
• Status code will disappear when
directional switch is closed or when
accelerator pedal is released.
Malfunctioning directional switch.
• Check forward or reverse switch to
insure closure when direction is
selected.
Open circuit between directional switch(es)
and battery positive or between directional
switch(es) and P1-4 or P1-5.
• Check all control wires and
connections shown in Troubleshooting
Diagram.

PDMM-0115 Issued: 07/31/2002 6-11

Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Accelerator input voltage too high. This status code is displayed when the
accelerator input voltage at P1-7 is 0.7
-07 volts less than the zero speed auto
calibration value for the accelerator.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Control will not operate when
accelerator pedal is depressed or status
code -07 is displayed then disappears
when the vehicle starts to accelerate.
Circuits valid P1-9 P1-7 P1-8
for Traction POSSIBLE CAUSE
Controller Accelerator input mis-adjusted or 56 29 28
malfunctioning.
Open circuit between battery negative and P9-4 P9-1
P1-7 in accelerator input circuit.
• Check for broken wires or loose
P9-3
connections or open
potentiometer/voltage supply. ACC. POT
Short circuit from battery positive to wiring
in accelerator input circuit.

6-12 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Diagnostic Status Codes

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Accelerator input speed too high on This status code is displayed when the
power-up after initial key switch accelerator input voltage at P1-7 is
closure. calling for greater than 20% speed, and
-08 any of the following connections are
opened and closed: battery or key
switch.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Control will not operate.

POSSIBLE CAUSE
Accelerator input mis-adjusted or
Circuits valid P1-9 P1-7 P1-8
malfunctioning.
for Traction
• Input voltage at P1-7 should be more
Controller 56 29 28
than 20% speed. Adjust or replace
accelerator unit to insure that the
voltage at P1-7 is calling for less than P9-4 P9-1
20% before depressing pedal.
• Repeat the auto calibration routine
outlined in Accelerator Controller P9-3
Set-up Procedures of this manual.
ACC. POT
• P1-7 or the accelerator pot negative
have an open circuit.
Malfunctioning control.
• Replace the controller unit.

PDMM-0115 Issued: 07/31/2002 6-13

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Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Both the forward and reverse This status code is displayed when
-09 directional switches are closed at the P1-4 and P1-5 are greater than 60% of
same time. battery volts at the same time.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Control will not operate.

POSSIBLE CAUSE
Forward or reverse directional switch
Circuits valid welded closed or mis-adjusted to be held
for Traction closed.
Controller
• Replace or adjust directional switches to
insure that they open when directional
switch is returned to neutral.
Short circuit between battery positive and
P1-4 and/or P1-5.
• Disconnect wires from P1-4 and P1-5
and check wire for short circuit to
positive side of directional switch.
Malfunctioning card.
• Disconnect wires and measure voltage
at P1-4 and P1-5. Voltage should be
less than 60% of battery volts.

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Raymond ® DSD Maintenance Manual Diagnostic Status Codes

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Start switch closed on power-up after This status code is displayed when P3
-11 initial key switch closure. is greater than 60% of battery voltage
when the key switch is closed.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Control will not operate.

POSSIBLE CAUSE
Start switch input mis-adjusted or
Circuits valid malfunctioning.
for Traction
• Make sure input voltage at P1-3 is less
Controller
than 60% of battery volts at key switch
closing. Adjust or replace accelerator
unit to insure that the voltage at P1-3
is less than 60% of battery volts before
closing the start switch.
Short circuit between battery positive and
P1-3 in start switch input circuit.
• Disconnect wire from P1-3. Check for
short circuit from wire to battery
positive.
Malfunctioning card.
• Disconnect wire from P1-3. Measure
voltage from P1-3 to negative. Voltage
should be zero, if not, replace card.

PDMM-0115 Issued: 07/31/2002 6-15

Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Battery voltage is too low or control This status code is displayed when the
card is mis-adjusted. battery volts are less than 1.95 volts
-15 per cell at initial key switch ON. See
table below.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Control will not operate.

POSSIBLE CAUSE
Discharged battery.
Circuits valid
for Traction • Check battery for proper open circuit
voltage as shown in “Troubleshooting
Controller
Diagram”, charge battery, if required.
Bad battery.
• Check each battery cell for proper
voltage (greater than 1.95 volts at cell).
Replace or repair battery.
Incorrect control card adjustment.
• Check function 15 for proper
adjustment for battery being used. See
Handset instruction sheet for details.
Adjust to proper settings.
Check “minimum” battery volts at P1-1
and NEG.

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Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Battery voltage is too high or control This status code is displayed when the
card is mis-adjusted. battery volts are greater than 2.40
-16 volts per cell at initial key switch ON.
See table below.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Control will not operate. FU1 15A
5

MAXIMUM
POSSIBLE CAUSE NOMINAL
LIMIT VOLTS
BATTERY
AT 2.4 VDC
VOLTAGE
Incorrect control card adjustment. PER CELL
Circuits valid 24 28.8
for Traction • Check function 15 for proper 36 43.2
adjustment for battery being used. See 48 57.6
Controller 72 86.4
Handset instructions for details. Adjust +
P1-1 80 100.8
to proper setting.
Battery over-charged or incorrect battery -

used.
NEG

Traction
Control N
• Check battery for proper open circuit Terminal
voltage per table in “Troubleshooting
Diagram”. If voltage excessive, check
battery charger for proper output
voltage.
Check “maximum” battery volts at P1-1
and NEG.

PDMM-0115 Issued: 07/31/2002 6-17

Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Accelerator voltage is too high. This status code is displayed when the
-21 voltage at P1-7 is greater than 4.5
volts.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Controller will not operate.

POSSIBLE CAUSE
• Verify wire connection between P1-9 P1-7 P1-8
Circuits valid accelerator pot to P1-8.
for Traction • Verify wire connection between P1-7 to
Controller accelerator pot.
56 29 28
• Verify that the accelerator pot is
adjusted properly. P9-4 P9-1

P9-3
ACC. POT

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Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Motor field current is too high on start This status code is displayed when the
up in the reverse direction. current draw in the motor field is too
-23 high at start up in the reverse
direction.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Control will not operate.

POSSIBLE CAUSE
Malfunctioning control.
Circuits valid
for Traction • Replace controller unit.
Controller

PDMM-0115 Issued: 07/31/2002 6-19

Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Motor field current is too high on start This status code is displayed when the
up in the forward direction. current draw in the motor field is too
-24 high at start up in the forward
direction.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Control does not operate.

POSSIBLE CAUSE
Malfunctioning control.
Circuits valid
for Traction • Replace controller unit.
Controller

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Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Control’s internal power supply is less This status code is displayed when the
-27 than 10 Volts DC. control’s power supply is less than 10
volts.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Line contactor opens and closes, then KEY
SWITCH
can only be closed by opening and FU2
12
closing the key switch.
5

Circuits valid POSSIBLE CAUSE FU1

for Traction 10
Discharged Battery.
Controller + 2
• Check battery to insure proper state of
charge. Voltage may be dropping below
10 Volts DC under load.
-
Loose connection at P1-1. P1-1 P1-2
NEG
• Insure that the wire connection at P1-1
is tight. P1-1 should be at battery
voltage.
Malfunctioning control.
• Replace controller unit.

PDMM-0115 Issued: 07/31/2002 6-21

Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Motor field current is too high during This status code is displayed when the
the run mode. current in the motor field is sustained
-28 above a preset limit for longer than 70
seconds.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM THE PRESENCE OF THIS STATUS

Control will not operate. CODE IS NOT NECESSARILY
INDICATIVE OF A CONTROL ISSUE.
POSSIBLE CAUSE IF FUNCTION 7 IS NOT
Continued operation of vehicle in high motor MIS-ADJUSTED, THE STATUS CODE
Circuits valid current condition. INDICATES AN APPLICATION ISSUE
for Traction
• Operate vehicle at lower motor current WHERE A MOTOR IS BEING
Controller
condition for 70 seconds. STALLED, ETC. DISPLAY OF THIS
Function 7 is mis-adjusted to allow higher STATUS CODE SHOULD NOT
than normal motor filed current. TRIGGER THE RETURN OF A
CONTROL FOR REPAIR OR
• Adjust function per OEM instructions.
REPLACEMENT.

Traction
Description of Status Cause of Status Indication
Status Code

Shorted thermal protector (TP) or This status code is displayed when the
-41 armature transistor overtemperature. voltage at the thermal protector is too
low.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM THE PRESENCE OF THIS STATUS

Reduced or no power to traction motor CODE IS NOT NECESSARILY
in SCR range. INDICATIVE OF A CONTROL ISSUE.
IF FUNCTION 7 IS NOT
POSSIBLE CAUSE
MIS-ADJUSTED, THE STATUS CODE
Circuits valid Control is in thermal cut-back. INDICATES AN APPLICATION ISSUE
for Traction
• Allow control to cool, status code WHERE A MOTOR IS BEING
Controller
should disappear. STALLED, ETC. DISPLAY OF THIS
Malfunctioning control. STATUS CODE SHOULD NOT
TRIGGER THE RETURN OF A
• Replace controller unit.
CONTROL FOR REPAIR OR
NOTE: Thermal protector located in REPLACEMENT.
control is not serviceable.

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Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Motor armature offset voltage is too This status code is displayed when the
high. voltage at the current sensor input is
-42 greater than 2.6 volts with no current
flowing in the motor circuit.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Control will not operate.

POSSIBLE CAUSE
Malfunctioning control.
Circuits valid
for Traction • Replace controller unit.
Controller

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Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Motor armature offset voltage is too This status code is displayed when the
low. voltage at the current sensor input is
-43 less than 2.4 volts with no current
flowing in the motor circuit.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Control will not operate.

POSSIBLE CAUSE
Malfunctioning control.
Circuits valid
for Traction • Replace controller unit.
Controller

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Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Armature transistor did not turn off This status code is displayed when,
properly. during control operation, the
-44 armature transistor fails to turn off.
This will result in a PMT condition.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Line contactor opens and then can only
be closed by opening and closing the
key switch.

Circuits valid POSSIBLE CAUSE

for Traction Malfunctioning control.
Controller
• Replace controller unit.

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Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Armature transistor did not turn off This status code is displayed when,
properly. during control operation, the
-45 armature transistor fails to turn on
properly. This will result in a PMT
condition.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Truck will not operate.

POSSIBLE CAUSE
Malfunctioning control.
Circuits valid
for Traction • Replace controller unit.
Controller

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Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

“Look Ahead” test for A2 volts less This status code is displayed when the
-46 than 12% of battery volts. voltage at A2 is less than 12% of
battery volts.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Line contactor will open.

POSSIBLE CAUSE
Check for short circuit from the motor
Circuits valid armature to the frame of the vehicle.
for Traction
Check for welded 1A contactor (if used).
Controller
Malfunctioning control.
• Replace controller unit.

PDMM-0115 Issued: 07/31/2002 6-27

Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Motor field current is too low during This status code is displayed when the
-49 the run mode. current draw in the motor field is too
low during the run mode.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Control will not operate.

POSSIBLE CAUSE
Malfunctioning control or connection.
Circuits valid
for Traction • Replace controller unit.
Controller • Open motor field winding.

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Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Capacitor volts are low before the line This status code is displayed during
contactor closes. “key on” when the capacitor volts is
-51 less than 85% of battery volts at initial
key switch ON.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Line contactor does not close when
capacitor does not pre-charge.

POSSIBLE CAUSE
Circuits valid • Welded 1A contactor (if used).
for Traction • Check PTC for open circuit on line
Controller contactor.
• Check for conductivity across open 1A
contactor.
Wiring error.
• Insure that there is no device
connected to load side of line contactor.
Malfunctioning control.
• Replace controller unit.

PDMM-0115 Issued: 07/31/2002 6-29

Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Controller “motor current sensor” This status code is displayed when the
-57 input too low during running. voltage input from the current sensor
is too low during running.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Control will not operate.

POSSIBLE CAUSE
• Line contactor power tips did not close.
Circuits valid • Volt drop across contactor tips.
for Traction
Malfunctioning control.
Controller
• Replace controller unit.

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Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

The line driver input (P2-17) is less This status code is displayed when the
than 12% of battery volts. control detects that the line driver
-64 input (P2-17) is less than 12% battery
volts when the key switch is turned
ON.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Control does not operate. Line
contactor does not close.

POSSIBLE CAUSE
Circuits valid • Open wire connection to Pin P1-17.
for Traction • Shorted line Driver transistor in
Controller control.
• Possible open circuit in line contactor
coil.
Malfunctioning control.
• Replace controller unit.

PDMM-0115 Issued: 07/31/2002 6-31

Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

The line coil is too high during the run This status code is displayed when the
mode. current limit in the line coil driver is
exceeded during the run mode. The
-65 line contactor will drop out and the
key switch will have to be recycled to
reset the control.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Control does not operate.

POSSIBLE CAUSE
• Shorted line contactor coil.
Circuits valid • Short between wires connected to line
for Traction coil.
Controller
If line coil resistance is correct:
• (59W for 36-48)
• (161W for 80V)
Malfunctioning control.
• Replace controller unit.

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Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

The field current exceeds the current This status code is displayed when the
limit on the field transistor. field transistor exceeds its specific
-66 current limit. The line contactor will
drop out and the key switch will have
to be recycled to restart the control.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Control will not operate.
• Line contactor opens.

POSSIBLE CAUSE
Circuits valid
• Shorted field F1 to F2.
for Traction
Controller • F1 or F2 terminals shorted to battery
positive (B+).
• F1 or F2 Terminals shorted to battery
negative (B-).
(The controller looks for a high change in
current over time to identify a short circuit
in the field or cables.)

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Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

The armature current exceeds the This status code is displayed when the
armature transistor limit. armature transistor exceeds its
-67 specific current limit. The control is
reset by recycling the key switch.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Control will not operate.

POSSIBLE CAUSE
• Shorted motor armature A1 to A2.
Circuits valid • Power cables may be shorted to each
for Traction other (Measure at control terminals).
Controller • A1 to A2 terminals may be shorted to
battery positive or negative.

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Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

The power steering coil current is too This status code is displayed when the
high during the run mode. current in the power steering driver
-69 circuit exceeds current limit during
the run mode. The control is reset by
recycling the key switch.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Control will not operate.

POSSIBLE CAUSE
• Shorted power steering control coil.
Circuits valid • Short between wires connecting to the
for Traction power steering coil.
Controller
If the power steering coil resistance is
correct:
• (59W for 36-48V)
• (161W for 80V)
Malfunctioning control.
• Replace controller unit.

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Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Capacitor (1C) voltage too high. This status code is displayed when the
voltage on the capacitor goes above
-76 limit voltage* during the regenerative
braking cycle.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Line contactor opens and closes, then
opens and can only close by opening
Circuits valid and closing the key switch.
LINE FU4
for Traction
POSSIBLE CAUSE
Controller
• Unplugging the battery connector +

ARMATURE
during regenerative braking.
Battery
• Line contactor bouncing open during

FIELD
-
POS A1 F1
POWER CONNECTIONS
regen.
NEG A2 F2
• Main power fuse opening during regen.
• Intermittent battery plug connection.

Limit Voltage:
Limit Batt.
50V 36V
70V 48V
96V 72/80V

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Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Motor current is detected during This status code is displayed when

-77 regenerative braking. motoring current is detected during
the regenerative braking cycle.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Truck will not operate.

POSSIBLE CAUSE
Malfunctioning control. LINE FU1
Circuits valid
for Traction • Replace controller unit.
+
Controller

ARMATURE
Battery ACC POT

FIELD
-
POS A1 F1
POWER CONNECTIONS
NEG A2 F2

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Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

If the armature motor current is This status code is displayed when the
greater than a preset value for longer armature motor current exceeds a
-82 than 3.5 sec. the armature motoring preset value for 3.5 sec. and the
current will be turned OFF. accelerator pedal is calling for
maximum performance.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM *CODE WARNING*

The Control will not operate, and can
only be reset by cycling the key switch. THE PRESENCE OF THIS STATUS
CODE IS NOT NECESSARILY
POSSIBLE CAUSE:
INDICATIVE OF A CONTROL ISSUE.
Circuits valid • Continued operation of vehicle in high IF FUNCTION 16 IS NOT
for Traction motor current condition.
MIS-ADJUSTED, THE STATUS CODE
Controller • Operating control at stall motor current INDICATES AN APPLICATION ISSUE
for more than 3.5 seconds.
WHERE A MOTOR IS BEING
• Function 16 is incorrectly adjusted for STALLED, ETC. DISPLAY OF THIS
control % on time.
STATUS CODE SHOULD NOT
Adjust function TRIGGER THE RETURN OF A
• Function 16 is adjusted at a level of CONTROL FOR REPAIR OR
130 for all controls except: REPLACEMENT.
• the 9” DSD30 and DSD35 are set to
*Continued occurance of this code could
120
lead to damage to motor assembly.
• the EE’s are all set at 160.
• Possible mechanical resistance to
motor rotation.

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Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

A switch position is incorrect during This status code is displayed when the
the accelerator potentiometer seat switch is open, or the any of the
autocalibration routine. forward, reverse or start switches are
-83 closed at the beginning of the
accelerator potentiometer auto
calibration routine.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
The auto calibration routine outlined in
Section 8 of this manual will not start.

POSSIBLE CAUSE:
Circuits valid • Seat switch is open.
for Traction • Confirm switch wiring, or replace
Controller switch, if required.
• Any of the forward, reverse or start
switches are closed.
• Confirm switch wiring, or replace
switch, if required.

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Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Accelerator pot values obtained Refer to Section 8 of this manual for

-86 during the autocalibration routine possible causes of this status code.
were not valid.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Accelerator potentiometer auto
calibration routine was not successfully
completed.
P1-9 P1-7 P1-8
Circuits valid POSSIBLE CAUSE:
for Traction • Misadjusted or bad accelerator
Controller potentiometer assembly. 56 29 28
• Verify the accelerator potentiometer
operation. P9-4 P9-1
• Open circuit on the accelerator
potentiometer.
P9-3
ACC. POT

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Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Hydraulic lever is activated before the This status code is displayed when the
-89 pump is enabled when key switch is voltage at P14 is greater than 3 volts
initially activated. at pump enable (10ms).

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
The truck will not run or the pump will
not operate.

POSSIBLE CAUSE:
Circuits valid Shorted or welded hydraulic switch.
for Traction
• Verify connections to hydraulic
Controller
switches.
• Verify mechanical operation of
hydraulic switches (check adjustment).
• Check for short between wire 50 and
52.
• Check for shorted switch.

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Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Hydraulic lever is activated when This status code is displayed when the
-89 truck is operating. voltage at P14 is greater than 3 volts
at pump enable (10ms).

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Hydraulic functions do not operate.

POSSIBLE CAUSE:
• Battery voltage has dropped to Lift
Circuits valid Lockout conditions.
for Traction
Controller

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Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Traction motor temperature has This status code is displayed when the
-90 exceeded maximum temperature voltage at the respective terminal of
limit. the Pump Logic Card is at zero volts.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Status code flashes “ON and OFF”.
Action Light flashes.

POSSIBLE CAUSE
Circuits valid User defined status code is displayed by
for Traction switch closure to battery negative.
Motor
• Bad temp switch (shorted). Traction
Temperature
motor.
(Contactor
• Bad TMM card.
Hydraulics)
• Wire 80 shorted to battery NEG.
• Battery Neg @ TMM7A terminal 1
P11-5.

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Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Traction motor temperature has This status code is displayed when the
-90 exceeded maximum temperature voltage at the respective terminal of
limit. (with pump controller hyd.) the TMM is at zero volts.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Status code flashes “ON and OFF”.
Action light flashes.

POSSIBLE CAUSE
Circuits valid User defined status code is displayed by
for Traction switch closure to battery negative.
Motor
• Bad temp switch (shorted). Traction
Temperature
motor.
(With Pump
• Bad pump card.
Controller
• Wire 80 shorted to battery NEG.
Hydraulic)
• Battery Neg @ pump control P5-16.

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Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Pump motor temperature has This status code is displayed when the
-91 exceeded maximum temperature voltage at the respective terminal of
limit. the TMM is at zero volts.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Status Code flashes “ON and OFF”.
Action Light flashes.

POSSIBLE CAUSE
Circuits valid User defined status code is displayed by
for Hydraulic switch closure to battery negative.
Pump
• Battery Neg at TMM7A terminal 3
Temperature
P11-6.
(With
• Wire 82 shorted to battery NEG.
Contactor
• Bad Temp switch (shorted).
Hydraulics)
• Bad TMM card.

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Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Pump motor temperature has This status code is displayed when the
-91 exceeded maximum temperature voltage at the respective terminal of
limit. (with pump controller hyd.) the TMM is at zero volts.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Status Code flashes “ON and OFF”.

POSSIBLE CAUSE
User defined status code is displayed by
Circuits valid switch closure to battery negative.
for Hydraulic
• Bad temp switch (shorted). Pump
Pump
motor.
Temperature
• Bad pump card.
(With Pump
Controller • Wire 82 shorted to battery NEG.
Hydraulic) • Battery Neg at P5-11.

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Raymond ® DSD Maintenance Manual Diagnostic Status Codes

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Traction motor brush wear indicator This status code is displayed when the
-94 has detected worn brush. voltage at terminal 8 and 10 of the
TMM is at zero volts.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Status Code flashes “ON and OFF”.

POSSIBLE CAUSE
User defined status code is displayed by
Circuits valid motor brush sensor closure to battery
for Traction positive.
Motor Brush
• Worn brushes.
Wear Indicator
• Terminal 5 or 6 is shorted to positive
(With Pump
on the TMM7A card.
Contactor
• Bad input switch (shorted) check for
Control
proper adjustment of the BWI T-bar on
Hydraulics)
brush holder.
• Wire 85 or 86 shorted to positive.
• Bad TMM7A card.

PDMM-0115 Issued: 07/31/2002 6-47

Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Traction motor brush wear indicator This status code is displayed when the
-94 has detected worn brush. voltage at the respective terminal of
the Pump Logic Card is at zero volts.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Status Code flashes “ON and OFF”.

POSSIBLE CAUSE
User defined status code is displayed by
Circuits valid motor brush sensor closure to battery
for Traction positive.
Motor Brush
• Worn brushes.
Wear (With
• P5-5 or P5-6 is shorted to positive on
Pump Control
pump control card.
Card
• Bad input switch (shorted). Check for
Hydraulics)
proper adjustment of the BWI T-bar on
brush holder.
• Wire 85 or 86 shorted to positive.
• Bad pump control card.

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Raymond ® DSD Maintenance Manual Diagnostic Status Codes

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Pump motor brush wear indicator This status code is displayed when the
-95 has detected worn brush. voltage at the respective terminal of
the TMM is at battery volts.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Status Code flashes “ON and OFF”.

POSSIBLE CAUSE
User defined status code is displayed by
Circuits valid motor brush sensor closure to battery
for Pump positive.
Motor Brush NEG
• Worn brushes.
Wear Indicator
• Terminal 8 or 10 is shorted to positive
(With
on the TMM7A card.
Contactor
• Bad input switch (shorted). Check for
Control
proper adjustment of the BWI T-bar on
Hydraulics)
brush holder.
• Wire 87 or 88 shorted to positive.

PDMM-0115 Issued: 07/31/2002 6-49

Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Pump motor brush wear indicator This status code is displayed when the
has detected worn brush. voltage at the respective terminal of
-95 the Pump Logic Card is at battery
volts.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Status Code flashes “ON and OFF”.

POSSIBLE CAUSE
User defined status code is displayed by
Circuits valid motor brush sensor closure to battery
for Pump positive.
Motor Brush
• Worn brushes.
Wear Indicator
• P5-8 or 5-9 is shorted to positive.
(With Pump
Control Card • Bad input switch (shorted). Check for
proper adjustment of the BWI T-bar on
Hydraulics)
brush holder.
• Wire 87 or 88 shorted to positive. NEG
• Bad pump control card.

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Raymond ® DSD Maintenance Manual Diagnostic Status Codes

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

Maintenance alert and speed limit. This status code is displayed when the
“normal” hour meter exceeds the
-99 “maintenance alert hours” setting for
the vehicle.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Status code is displayed for 4 seconds
when the key switch is first turned ON,
and/or the vehicle may run at a
reduced speed.
Circuits valid
for Traction CUSTOMER SELECTED SETTING WITH
Controller THE HANDSET:
User defined status code is displayed when NO DIAGRAM
the normal hour meter reading exceeds the
programmed “maintenance alert hours”
setting selected by the user. USER SHOULD PERFORM THE
• Maintenance Code Hour Meter, DESIRED MAINTENANCE
Functions 19 and 20, are programmed FUNCTION
with the Handset and command the
display of status code -99.
• If desired, Maintenance Code Speed
Limit, Function 13, can be
programmed with the Handset.
User should perform the desired
maintenance function. Re-set maintenance
alert hour meter after maintenance is
performed.

PDMM-0115 Issued: 07/31/2002 6-51

Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Traction
Description of Status Cause of Status Indication
Status Code

“Card Type” selection is invalid. This status code is displayed when the
-117 card type selection value is set to an
invalid number.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Control will not operate.

POSSIBLE CAUSE NO
Invalid card type selection.
Circuits valid GRAPHIC
for Pump • Review Function 17 in the Handset
Instruction sheets. Adjust and set card FOR THIS
Controller
type value as instructed by Service
STATUS CODE
Manual.

Hydraulic
Description of Status Cause of Status Indication
Status Code

Control logic card power supply is less This status code is displayed when the
-127 than 10 VDC. logic card power supply is less than
10 volts.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Control will not operate.

POSSIBLE CAUSE
Discharged battery.
Circuits valid
for Pump • Check battery to insure proper state of
charge.
Controller
• Check control fuse FU 11.
Loose connection at P1-1.
• Insure that the wire connection at P1-1
is tight.
• Insure that wire connection at P5-1 is
tight.
• Check for Volt drop across wire 12 and
wire 2.
Bad logic card.
• Replace control.

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Raymond ® DSD Maintenance Manual Diagnostic Status Codes

Status Codes

Hydraulic
Description of Status Cause of Status Indication
Status Code

Armature current is too high during This status code is displayed when the
-128 the lift mode. current in the armature circuit is
sustained above 400A for 70 sec.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM NO
Control will not operate.
GRAPHIC
POSSIBLE CAUSE FOR THIS
Continued operation of vehicle in high motor
Circuits valid current condition. STATUS CODE
for Pump
• Operate vehicle at lower motor current
Controller
condition for 70 seconds.
• Check hydraulic pressure adjustment.

Hydraulic
Description of Status Cause of Status Indication
Status Code

Pump control is overtemperature. This status code is displayed when the

-141 voltage at the thermal protector is less
than 3.8 volts.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Reduced or no power to pump motor in
control range.

POSSIBLE CAUSE
Circuits valid Control is in thermal cut-back.
for Pump
• Allow control to cool, status code
Controller
should disappear.
• Check wire 23, P5-14 and P2-9.
• Check hydraulic pressure adjustment.
NOTE: Pump control thermal protection
is located inside of pump control
and is not serviceable.

PDMM-0115 Issued: 07/31/2002 6-53

Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Hydraulic
Description of Status Cause of Status Indication
Status Code

Pump Controller “motor current This status code is displayed when the
sensor” input is missing. voltage at the current sensor is
-142 greater than 1.6 volts with no current
flowing in the motor circuit.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
No power to pump motor in control
range.

POSSIBLE CAUSE
Circuits valid Control is bad.
for Pump
• Replace controller unit.
Controller
NOTE: Pump motor current sensor is
located inside of pump control and
testing is not possible.

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Raymond ® DSD Maintenance Manual Diagnostic Status Codes

Status Codes

Hydraulic
Description of Status Cause of Status Indication
Status Code

Pump Controller “motor current This status code is displayed when the
sensor” input is too low. voltage at the current sensor is less
-143 than 0.6 volts with no current flowing
in the motor circuit.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
No power to pump motor in control
range.

POSSIBLE CAUSE
Circuits valid Control is bad.
for Pump
• Replace controller unit.
Controller
NOTE: Pump motor current sensor is
located inside of pump control and
testing is not possible.
NOTE: Pump control thermal protection
is located inside of pump control
and is not serviceable.

PDMM-0115 Issued: 07/31/2002 6-55

Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Hydraulic
Description of Status Cause of Status Indication
Status Code

Power Transistor (Q1) did not turn off This status code is displayed when,
-144 properly. during pump control operation, the
transistor fails to turn off.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Control may run continuously.

POSSIBLE CAUSE
Control is bad.
Circuits valid
for Pump • Check switch adjustment.
Controller • Check for shorts to Neg on wires
51,52,53,54.
• Replace controller.

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Raymond ® DSD Maintenance Manual Diagnostic Status Codes

Status Codes

Hydraulic
Description of Status Cause of Status Indication
Status Code

Power Transistor (Q1) did not turn on This status code is displayed when,
-145 properly. during pump control operation, the
transistor fails to turn on.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Control may run continuously.

POSSIBLE CAUSE
Control is bad.
Circuits valid
for Pump • Replace controller unit.
Controller • Check for proper negative voltage at N
terminal on control.
• Check for shorts to Neg on wires
51,52,53,54.
• Check for proper positive voltage to
control at P5-1,19-20, 21 and 12.
• Check for proper positive voltage at
P5-1.
• Check for proper Neg voltage at N
terminal on control.

PDMM-0115 Issued: 07/31/2002 6-57

Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Hydraulic
Description of Status Cause of Status Indication
Status Code

“Look Ahead” test for Pump motor This status code is displayed when the
-146 circuit volts less than 12% of battery voltage in the pump motor is less than
volts. 12% of battery volts.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Pump contactor will operate. FU6
P

POSSIBLE CAUSE
• Check for short circuit from the motor
Circuits valid armature to the frame of the vehicle.
A1
for Pump • Check for open circuit from A1 to A2 on
Controller control through motor.

ARMATURE
A1

P A1 *
Control is bad. PUMP CONTROL
A2
POWER
• Replace controller. CONNECTION
A2
N

FIELD
*

A2

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Raymond ® DSD Maintenance Manual Diagnostic Status Codes

Status Codes

Hydraulic
Description of Status Cause of Status Indication
Status Code

Capacitor volts are low after the line This status code is displayed when the
-150 contactor closes. capacitor voltage is less than 85% of
the battery voltage in the run mode.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Pump control will not operate. 325 amps
FU6
P
POSSIBLE CAUSE
Bad line contactor.
Circuits valid A1

for Pump • Check for open line contactor power

ARMATURE
tips. A1

Controller P A1 *
• Check for volt drop across line PUMP CONTROL
POWER
A2
CONNECTION
contactor. N A2

FIELD
*
• Check for loose or open connections in A2

cables from battery positive to control N

positive circuit.
Bad power fuse.
• Check power fuse for open circuit.
No battery voltage at P5-1.
• Check for battery voltage at POS and
P5-1.
• Check for loose connection at P5-1.

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Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Hydraulic
Description of Status Cause of Status Indication
Status Code

Capacitor volts are low before the line This status code is displayed during
contactor closes. (Internal card “key-on” when the capacitor volts is
-151 function during pre-charge.) less than 85% of battery volts at initial
key switch ON.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Pump control will not operate.

POSSIBLE CAUSE
NOTE: Repeated “charging/discharging”
Circuits valid
the capacitors during
for Pump troubleshooting will cause status
Controller code 51. Also “do not” connect any
loads to the load side of the line
contactor.
• Check battery voltage.
• Check for open PTC resistor.
• Check for battery voltage at P5-1.
Bad control.
• Replace controller unit.
NOTE: PTC resistor is located across the
line contactor that is serviceable.
NOTE: There is also a PTC resistor that is
in the controller and it is not
serviceable.

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Raymond ® DSD Maintenance Manual Diagnostic Status Codes

Status Codes

Hydraulic
Description of Status Cause of Status Indication
Status Code

Controller “motor current sensor” This status code is displayed when the
-157 input voltage polarity check. voltage input to motor current sensor
is of the wrong polarity.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Pump control will not operate.

POSSIBLE CAUSE
Control is bad.
Circuits valid
for Pump • Replace controller unit.
Controller

PDMM-0115 Issued: 07/31/2002 6-61

Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Hydraulic
Description of Status Cause of Status Indication
Status Code

Voltage at capacitor (1C) is less than This status code is displayed when the
14 volts. voltage at P1 is less than 14 volts.
-180 This occurs typically in the run mode
of operation.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Pump Control will not operate.

POSSIBLE CAUSE
(Line contactor controlled by traction
Circuits valid control).
for Pump
Line contactor opened up during run.
Controller
• Check connection from P5-17 to Line
coil (-) for loose connection.
• Check connection from battery (+) to
Line coil (+) for loose connection.
• Check for failed power fuse at pump
control.
• Check for dirty contactor tips.

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Raymond ® DSD Maintenance Manual Diagnostic Status Codes

Status Codes

Hydraulic
Description of Status Cause of Status Indication
Status Code

Battery voltage is less than 14 volts. This status code is displayed when the
-181 battery voltage measured at P1 is less
than 14 volts.

Memory
Corrective Actions Troubleshooting Diagram
Recall

YES SYMPTOM
Pump control will not operate.

POSSIBLE CAUSE
• Check connection from control fuse to
Circuits valid pump P1 for loose connections.
for Pump • Check for low battery volts under load.
Controller • Check for volt drop between pos. and
P5-1.

PDMM-0115 Issued: 07/31/2002 6-63

Diagnostic Status Codes Raymond ® DSD Maintenance Manual

Status Codes

Hydraulic
Description of Status Cause of Status Indication
Status Code

Input switch closed before pump This status code is displayed when pin
-189 enable signal is received. 12,19,20 or 21 is pulled to negative
before pin 10 is greater than 5.0 volts.

Memory
Corrective Actions Troubleshooting Diagram
Recall

NO SYMPTOM
Pump Control will not operate.

POSSIBLE CAUSE
• Hydraulic handle pulled before pump
Circuits valid enable signal given.
for Pump • Shorted hydraulic switch.
Controller • Check Hydraulic switch adjustment.
• Bad control.

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Raymond ® DSD Maintenance Manual General Information

General Information 1:

PDMM-0115 Issued: 07/31/2002 1-1

General Information Raymond ® DSD Maintenance Manual

Scope

Scope

This setion of the service manual deals with all components or systems of Raymond DSD lift trucks,
except for the electrical system, which is covered in a separate section.

Truck Models Covered

Truck Model Serial Number
This service manual furnishes service and
maintenance information for the trucks listed S30R-20001-up
in Table 1-1. DSD30
S30R-40001-up

DSD35 S35R-40001-up

S40R-20001-up
DSD40
S40R-40001-up

S50R-20001-up
DSD50
S50R-40001-up

S5ER-20001-up
DSD5E
S5ER-40001-up

DSD60 S60R-40001-up
Table 1-1: Truck Models Covered

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Raymond ® DSD Maintenance Manual General Information

Nameplate and Serial Number Locations

Nameplate and Serial

Number Locations

Mast serial
number

Power steering
motor serial
number

Chassis Hydraulic Traction Nameplate

serial motor serial motor serial
number number number

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General Information Raymond ® DSD Maintenance Manual

Dimensions

Dimensions

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Raymond ® DSD Maintenance Manual General Information

Dimensions Chart

Dimensions Chart

Ref# Truck Model DSD30 DSD35 DSD40 DSD50 DSD5E DSD60

Maximum Lift 3320 3320 3340 3340 3340 3310

A
(130) (130) (131) (131) (131) (130)

Free Lift 115 115 130 130 130 135

B
(4.5) (4.5) (5.1) (5.1) (5.1) (5.3)

Maximum Fork Spacing 818 818 818 818 818 818

C
(outside to outside) (32.0) (32.0) (32.0) (32.0) (32.0) (32.0)

Fork Length 1070 1070 1070 1070 1070 1070

D
(42) (42) (42) (42) (42) (42)

Tilt Angle
E 5°/6° 5°/6° 5°/6° 5°/6° 5°/6° 5°/6°
(forward/backward)

Overall Length 3050 3050 3152 3152 3252 3325

F
(120) (120) (124) (124) (127.9) (130.8)

Overall Width 945 945 1054 1054 1054 1103

G
(outside of tires) (37.2) (37.2) (41.5) (41.5) (41.5) (43.4)

Overall Height 2105 2105 2110 2110 2110 2110

H
(to top of mast, lowered) (83) (83) (83.5) (83.5) (83.5) (83.5)

Overall Height 2180 2180 2207 2207 2207 2207

I
(to top of overhead guard) (85.8) (85.8) (86.9) (86.9) (86.9) (86.9)

Overall Height 4560 4560 4570 4570 4570 4540

J
(to top of mast, extended) (180) (180) (180) (180) (180) (179)

Tread (front) 793 793 875 875 875 900

K
(31.2) (31.2) (34.4) (34.4) (34.4) (35.4)

Tread (rear) 826 826 897 897 897 897

L
(32.5) (32.5) (35.3) (35.3) (35.3) (35.3)

Wheelbase 1170 1170 1280 1280 1380 1380

M
(46.1) (46.1) (50.4) (50.4) (54.3) (54.3)

Front Overhang 376 376 394 394 394 406

N
(14.8) (14.8) (15.5) (15.5) (15.5) (15.9)

Rear Overhang 434 434 408 408 408 469

O
(17) (17) (16) (16) (16) (18.4)

Underclearance 118 118 124 124 124 124

P
(at center of wheelbase) (4.6) (4.6) (4.9) (4.9) (4.9) (4.9)

Unit: mm (in.)

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General Information Raymond ® DSD Maintenance Manual

General Information (Standard Models)

General Information
(Standard Models)
Truck Model

Units DSD30 DSD35 DSD40 DSD50 DSD5E DSD60

Standard Controller GE SX Controller

Standard Simplex Mast Size meters 3.3 3.3 3.3 3.3 3.3 3.3

Without 2095 2335 2685 2870 2695 3335

Battery (4620) (5140) (5920) (6330) (5940) (7353)
Service Weight
kg (lb.)
(standard axle) With Max 3298 3534 4296 4482 4509 5150
Battery (7270) (7790) (9470) (9880) (9940) (11353)

1500/ 1800/ 2000/ 2500/ 2500/ 3000/

Rated Capacity/ kg/mm 500 500 500 500 500 500
Load Center (lb./in.) (3000/ (3500/ (4000/ (5000/ (5000/ (6000/
24) 24) 24) 24) 24) 24)

Maximum Fork Height 3310

mm (in.) 3320 (130) 3340 (131)
(130)

Lift Speed 36V 0.24 (48) 0.23 (45) 0.31 (61) 0.28 (56) 0.26 (51)
(Rated Load)
Performance

m/sec.
48V 0.34 (67) 0.32 (64) 0.40 (78) 0.38 (74) 0.36 (70)
(fph)
Lowering Speed (rated load) 0.50 (99) 0.50 (98)
Work

Tilt Angle (forward/backward) degrees 5°/6°

Free Lift mm (in.) 115 (4.5) 130 (5.1) 135 (5.3)

Travel Speed 10.8

36V 12.9 (8.0) 11.6 (7.2)
Performance

(Without Load) km/h (6.7)

Traveling

(mph)
14.2
48V DNA 14.8 (9.2)
(8.8)

Minimum Turning Radius 1790 1890 1990 2045

mm (in.)
(70.5) (74.5) (78.5) (80.5)

Traction Motor 36V 8.2 (6.1) 8.3 (6.1)

60 min.
Output HP(kW)
48V DNA 11.7 (8.7)

Transfer Type Spur

Gear
Ratio 3.538 3.067

Reduction Type Bevel

Gear
Ratio 4.571 5.0

Differential Axle Housing Banjo

Power
Train

Gear Type/ Gears Straight Bevel/2

Number
Pinions Straight Bevel/2

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Raymond ® DSD Maintenance Manual General Information

General Information (Standard Models)

Truck Model

Units DSD30 DSD35 DSD40 DSD50 DSD5E DSD60

Type Dynamic Load Sense

Turning Angle Inside 83° 83°

Power Steering

Degrees
Outside 54° 56°

Steering Wheel Diameter mm (in.) 328 (13)

System

Cylinder Minimum kgf/cm2

Test Pressure (psi) 107 (1522) [10,500] 163 (2320) [16,000]
[kPa]

Service Brake Type Self-Adjusting Duo-Servo

Inside Drum
mm (in.) 254 +0 0.13 (10.00 +0 0.0051)
Diameter

Lining
mm (in.) 4.87 (0.19) 6 (0.24)
Thickness

Master
mm (in.) 22.22 (0.8748)
Cylinder ID

Wheel
Brake System

mm (in.) 22.22 (0.8748) 28.58 (1.1252)

Cylinder ID

Park Brake Type Mechanical, Mounted on Front Wheels

Lever kgf 25 to 30
Operating (lbf) (55 to 66)
Effort [N] [245 to 294]

Mounting Front Wheels Fixed Type

Rear Wheels Center Pivot Type

Traveling
System

Wheel Oscillation
3°
Alignment Angle
Degrees
Camber 1°

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General Information Raymond ® DSD Maintenance Manual

General Information (Standard Models)

Truck Model

Units DSD30 DSD35 DSD40 DSD50 DSD5E DSD60

Hydraulic Type Gear

Pump
Make Parker Hydraulics, Inc.

Model 1PX230 1PX290 1SX250

Displace- cc 25
23.0 (1.403)/rev. 29 (1.77)
ment (cu in.) (1.526)

Control Valve Make Husco International

Model 5000CC Sectional Valve

Relief kgf/cm2
(psi) 263 (3750) [25855]
Pressure
[kPa]

Flow Regulator Type Variable

Valve
liter
Regulated 71
(cu.in.)/ 48 (2929) 59 (3600)
Flow Rate (4332)
min
Hydraulic System

Lift Cylinders ID 45 (1.77) 50 (1.97) 55 (2.17)

Stroke 1650 (64.96) 1600 (62.99)

mm (in.)
Tilt Cylinders ID 63 (2.48) 70 (2.75) 80 (3.15)

Stroke 79 (3.11) 81 (3.19)

Hydraulic Tank Capacity liter

8 (4.8) 24 (6.3) 30 (7.9)
(approx) (US gal.)

Mast Roller type CL

Mast 100 x 15 x 12 115 x 20 x 13 115 x 21 x 13

Outer
Dimensions (3.94 x 0.59 x 0.47) (4.53 x 0.79 x 0.51) (4.53 x 0.83 x 0.51)
(Flange
mm (in.)
Inside Width
100 x 17 x 12 115 x 20 x 13
x THK x WEB Inner
(3.94 x 0.67 x 0.47) (4.53 x 0.83 x 0.51)
THK)

Main Rollers Type #6308 Ball Bearing #6309 Ball Bearing

100 x 30 115 x 35 100 x 30

Diameter x Width
(3.94 x 1.18) (4.53 x 1.58) (3.94 x 1.18)

Side Rollers Type Lubricating type needle roller bearing

Diameter x
mm (in.) 42 x 36 (1.65 x 1.42)
Width
Mast and Forks

Lift Chains BL534 BL634 BL834

Forks (Lgth x Wdth x Thk) 1070 x 100 x 35 1070 x 100 x 40 1070 x 125 x 45
(36 x 4 x 1.3) (42 x 3.9 x 1.6) (42 x 5 x 1.8)
mm (in.)
Fork Spacing
min/max 240/818 (9.4/32)
(out to out)

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Raymond ® DSD Maintenance Manual General Information

General Information (Standard Models)

Truck Model

Units DSD30 DSD35 DSD40 DSD50 DSD5E DSD60

Voltage 36/48

Amp Hours (6 hr. rate) 36V 900 1300 1300

48V 700 800 1000

Compartment Height -
598 (23.6)
Dimensions Center

Height -
mm (in.) 592 (23.3)
Edges

Length 708 (27.9) 775 (30.5) 875 (34.4)

Width 906 (35.6) 1003 (39.5

Weight (Min/Max)
1400/
Battery

1000/
750/1200 1315/1600 1800
kg (lb.) 1600
(1650/2650) (2900/3550) (3100/
(2200/
4000)
3550)

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General Information Raymond ® DSD Maintenance Manual

General Information (Standard Models)

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Raymond ® DSD Maintenance Manual Front Axle & Reduction Differential

Front Axle & Reduction Differential 2:

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Front Axle & Reduction Differential Raymond ® DSD Maintenance Manual

Front Axle

Front Axle

Description

6 8
5
7

1
4 3
2

1. Front wheel hub

2. Frame support
3. Axle shaft
4. Axle housing
5. Reduction pinion
6. Reduction gear
7. Differential case
8. Differential carrier

General Information
The frame supports hold the front axle housing
in such a manner as to allow a limited amount
of rotary motion of the housing, the rotary
sliding surfaces being lubricated with grease.
The cushion tire is press-fitted to the outer ring
of the wheel hub.

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Raymond ® DSD Maintenance Manual Front Axle & Reduction Differential

Removal, Front Wheels

Removal, Front Wheels Suggestions

1. Park the truck on level floor with the
parking brake applied, the direction lever in
! WARNING neutral, the forks lowered, and the key
Be sure to use the same size and switch OFF.
brand tire for replacement. 2. Prepare tools, jacks, and wheel blocks.
3. Block the rear wheels.
Removal Sequence 4. Loosen the wheel nuts about two turns.

Wheel
2 nut

2
2

1. Wheel Nuts NOTE: Loosen, but do not remove, the wheel

nuts.
2. Front Wheel
5. Raise the front end of the truck. Use one of
the three methods described on page 2-4.

! WARNING
To prevent possible injury, do not
replace the tire when the truck is
loaded.

Dismount the truck before raising the

front tire.

To prevent possible personal injury,

raise the truck only until the tire just
clears the ground.

Do not put any portion of your body

under the truck. Securely support the
truck on blocks after raising it.

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Front Axle & Reduction Differential Raymond ® DSD Maintenance Manual

Method 1

Method 1 Method 3
Position the jack under the frame and raise the Fasten a hoist to the mast and lift the front end
truck until the tire clears the floor. of the truck as shown.

2
Jack Capacities 6. Remove the wheel nuts (loosened in Step 4.)
DSD30 - 35 3000 kgf (6700 lbf)

DSD40 - 60 5000 kgf (12,000 lbf) ! CAUTION

Be careful not to damage the bolt
threads when removing the wheel.
Method 2
Tilt the mast all the way back, place solid 7. Remove the wheel.
blocks under the mast, and tilt the mast
forward. NOTE: Service Limit For Cushion Tires
Replace the tire if the height of the solid
rubber portion is 25.4 mm (1 in.) or less.
! CAUTION For tire replacement, consult your Lift
After raising the front end, securely Truck Dealer.
support it by blocks.

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Raymond ® DSD Maintenance Manual Front Axle & Reduction Differential

Installation

Installation
To install, reverse the removal sequence and do Tightening Torque For Wheel Nuts
the following steps.
DSD30 – 35 DSD40 – 60
! CAUTION 16 kgf•m 38.5 kgf•m
Use the same size and brand of tire. (116 lbf•ft) (278 lbf•ft)

[157 N•m] [378 N•m]

Make sure the clamping surfaces of
the wheel nuts and counterbores in
the rim are free of dirt.

1. Install the tire and tighten the wheel nuts.

Tighten each nut until its tapered portion is
in full-face contact with the counterbore in
the rim.

Wheel Nut

Counterbore

2. Lower the truck until the tire touches the

floor. Then tighten the wheel nuts in
numbered sequence shown below, in two or
three steps, to the specified torque.

6
3

5
2

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Front Axle & Reduction Differential Raymond ® DSD Maintenance Manual

Disassembly

Disassembly

6
7

Sequence Start By
1. Axle shaft 1. Remove the mast. (For replacement of the
front axle housing and disassembly of the
2. Lock nut, lock washer, oil seal, and tapered
differential, refer to section, “Mast and
roller bearing (inner bearing)
Forks” on page 8-1.)
3. Hub & drum assembly [Front wheel hub,
2. Jack up the truck.
brake drum, wheel bolts, drum nuts, and
tapered roller bearing (outer bearing)] 3. Support the front end of the truck at both
4. Tapered roller bearing (outer bearing), oil sides with blocks or stands to keep the
seal, and oil deflector truck in a horizontal position.
4. Remove the front wheels.
5. Tapered roller bearing (inner bearing), and
seal retainer NOTE: It is not necessary to remove the axle
6. Brake assembly housing or drain the oil for removal of
the shaft only.
7. Frame support and axle housing

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Raymond ® DSD Maintenance Manual Front Axle & Reduction Differential

Suggestions

Suggestions Removing Bearings

The inner race of the tapered roller bearing
Removing the Lock Nut remains in the axle housing when the hub is
Use a lock nut wrench (Special Tool). drawn out. Remove this race together with the
seal retainer with a bearing puller.

Tool DSD30 – 35 DSD40 – 60

Lock Nut
223-012-169 223-012-170
Wrench

Special Tool

Removing Front Wheel Hub

Use a wheel hub puller (Special Tool).

Tool DSD30 – 35 DSD40 – 60

Wheel Hub
223-012-171
Puller 223-012-173
(223-012-172)
(puller seat)

NOTE: It is not necessary to remove the oil seal

from the hub or to disassemble the oil
deflector unless the seal is bad.

Special Tool

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Inspection after Disassembly

Inspection after Disassembly Runout

Set a dial indicator at the middle part of the
Axle Shafts axle shaft. Turn the shaft and read the
indicator to find runout.
Looseness of Mating Splines
Mount the differential bevel gear on the splined
end of the shaft and set a dial indicator as Runout of shaft
shown below. Turn the bevel gear and read the
indicator.

Face runout of flange

DSD30 – 35 DSD40 – 60

Runout of axle 0.5 (0.020) 1.0 (0.039)

2 A
shaft (1/2 of maximum maximum
dial indicator
0.07 to 0.17 reading) B 1.0 (0.039) 2.0 (0.079)
Free movement A
(looseness of (0.0028 to 0.0067)
Unit: mm (in.)
splines) B 0.5 (0.020) A = Assembly Standard
B = Repair or Service Limit
Unit: mm (in.)
A = Assembly Standard
B = Repair or Service Limit
Set a dial indicator against the flange of the axle
shaft as shown. Turn the shaft and read the
indicator to find face runout.
Axle Housing
1. Check the surfaces of axle housing in
contact with the mast bearing for damage. Face runout of axle A 0.05 (0.0020)
2. Check the entire axle housing for shaft flange B 0.5 (0.020)
distortion, dents, and other defects paying
particular attention to the welds to see if Unit: mm (in.)
any weld is cracked. A = Assembly Standard B = Repair or
Service Limit
Oil Seals and Retainers
1. Check the outer surface of the oil seal
retainer for wear or damage.
2. Check the outer and inner oil seals for wear
and damage.

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Raymond ® DSD Maintenance Manual Front Axle & Reduction Differential

Reassembly

Reassembly Front Wheel Hub

To reassemble, reverse the steps of the 1. Fill the front wheel hub, especially the roller
disassembly sequence and do the following holder and oil seal lip groove, with grease.
steps.
NOTE: Be careful not to apply grease to the
brake drum.
Axle Housing
1. Install the O-ring in the outer groove (of the
two grooves in the bore of each frame
support).
2. Apply grease to the surfaces A of the
support and axle housing.

Frame support
O-ring A

2. Install the inner race and oil seal retainer of

the wheel hub bearing with an installer
(Special Tool).

Special tool

Tool DSD30 – 35 DSD40 – 60

Installer 223-012-174 223-012-175

3. Apply retaining compound to the flange

surfaces of the axle shafts.

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Front Axle & Reduction Differential Raymond ® DSD Maintenance Manual

Hub Bearing Preload

Hub Bearing Preload Installation and Setting Preload

Tighten the inner nut to produce the required 1. Fill the hub with the recommended grease
preload. Tighten the outer nut to the specified as listed in the service manual.
torque and check the preload. Make sure that 2. Pack the inner and outer bearing with the
the preload noted after tightening the outer nut recommended grease.
meets the specification. This step is for new
bearings. Where the bearings removed in 3. Install the inner bearing to the back side of
disassembly are reused, try to produce the the hub.
preload at the lower side of the range. 4. Install the inner seal.
5. Clean the lining surface of the drum.
5 to 50 kgf•cm 6. Install the hub onto the axle.
Preload for hub bearing (0.4 to 3.6 lbf•ft)
7. Install the outer bearing, grease seal, and
[0.5 to 4.9 N•m]
preload nut.
20 kgf•m 8. If the bearings are being reused, try to
Tightening torque for
(145 lbf•ft) produce the lower side of the applied force
lock nuts
[196 N•m] in tangential direction.
9. For new bearings, tighten the preload nut
to 14 kgf•m (101 lbf•ft) [137 N•m]. Slowly
rotate the hub slightly more than 3 turns,
back the nut off 80°, and set the applied
force in tangential direction.
10. For models with an outer lock nut, torque
the nut to 20 kgf•cm (145 lbf•ft) [196 N•m].
After torquing the lock nut, check the force
applied in tangential direction again to
Inner
insure the preload did not change.
Outer
nut nut
2
Bar

Spring
balancer

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Raymond ® DSD Maintenance Manual Front Axle & Reduction Differential

Reduction Differential

Reduction Differential

Description

4 5 2 1

Sequence Start By
1. Lock plates Remove the differential carrier from the
2. Side bearing nuts transmission case.

3. Differential carrier assembly (lock washers,

side bearing caps, and differential carrier)
4. Reduction gear and differential gear
assembly (spring pins, pinion shafts,
differential pinions, differential bevel gear,
washers, and differential case)
5. Tapered roller bearings

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Front Axle & Reduction Differential Raymond ® DSD Maintenance Manual

Disassembly

Disassembly Removing Bearing Inner Races

Use a bearing puller to remove the inner races
Suggestions from the differential case.
1. Before removing the differential carrier
from the transmission case, measure the
gear backlash to aid in obtaining correct
backlash at the time of reassembly.

Backlash between
0.15 to 0.25
reduction gear
(0.0059 to 0.0098)
and pinion

Unit: mm (in.)

2. Put a mark across the bearing cap,

adjusting screw, and carrier on each side.
The caps are not interchangeable.

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Raymond ® DSD Maintenance Manual Front Axle & Reduction Differential

Inspection after Disassembly

Inspection after Disassembly

Reduction Gear
Check the teeth for wear, pitting, flaking, or
chipping. Minor flaws on the tooth surface can
be repaired by grinding with an oil stone or a
hand grinder. Check the teeth for contact. If the
gear is badly damaged and requires
replacement, replace the pinion too. Reduction
gear and pinion are a matched set and must be
changed at the same time.

Differential
1. Check the differential cases for damage.
Check in particular the seat formed on each
case for carrying the side bearing inner race
to see whether the seat surface is galled or
not.
2. Check the sliding surfaces of the thrust
washers and gears for wear or damage.
3. Check the teeth of the differential pinions
and bevel gears for wear, pitting, chipping,
or galling.
4. Check the fit of each pinion on the spider.

0.02 to 0.07
Fit of differential A
(0.0008 to 0.0028)
pinions on spider
B 0.35 (0.0138)

Unit: mm (in.)
A = Assembly Standard
B = Repair or service limit

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Reassembly

Reassembly

4 1

3 2

Sequence
1. Tapered roller bearings
2. Differential gear assembly [differential case,
thrust washers, bevel gears, pinions, and
pinion shaft]
3. Spring pin
4. Reduction gear
5. Differential carrier assembly [carrier, side
bearing caps, side bearing nuts, and lock
washers]

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Suggestions

Suggestions Reassembling Differential Case

After putting the case assembly in place on the
Reassembling Differential Pinions carrier, install the bearing caps tentatively by
Use the thrust washers of the differential gears making the cap bolts snug tight. Tightly secure
for adjusting the backlash between the the caps after the bearing preload has been
differential gears and pinions. Measure the adjusted.
backlash and, if it exceeds the limit, replace the
thrust washers. Installing Bearing Caps
Make sure to know which are the left and right
caps and to put each cap in place correctly.
Backlash between 0.18 to 0.23
A
differential gears (0.0071 to 0.0091)
and pinions B 0.5 (0.020) 12.8 kgf•m
Tightening torque for
(93 lbf•ft)
bearing cap bolts
Unit: mm (in.) [126 N•m]
A = Assembly Standard
B = Repair or service limit

Installing Reduction Gear

Apply thread-locking compound (LOCTITE No.
271 or equivalent) to the bolts for holding the
reduction gear to the case. Make sure to tighten
these bolts evenly so as not to strain the gear.

12.0 kgf•m
Tightening torque for
(87 lbf•ft)
reduction gear bolts
[118 N•m]

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Inspection and Adjustment

Inspection and Adjustment Reduction Gear Backlash

Adjust the backlash between the reduction gear
Side Bearing Preload and pinion after installing the differential
Tie a wire on the reduction gear tooth and hook carrier assembly to the transmission case. To
a spring scale to the wire. Tighten the side measure the backlash, set a dial indicator with
bearing nuts, while reading the spring scale, its spindle pointing squarely to the tooth face of
until the specified preload is obtained. the reduction gear. With the pinion held, move
the gear back and forth to read the indicator.
NOTE: Before measuring the preload, tap the Adjust the backlash using the left and right side
back of the reduction gear with a copper bearing nuts and pinion shims.
hammer while rotating the gear to center
between bearing.
Backlash between
0.15 to 0.25
reduction gear and
15 to 30 kgf (0.0059 to 0.0098)
pinion
Min. (1.1 to 2.2 lbf)
[1.5 to 2.9 N] Unit: mm (in.)
Preload for
1.32 to 2.5 kgf•cm
differential
(2.9 to 5.5 lbf•ft)
case side
[13 to 25 N•m]
bearings Max.
As force applied to
reduction gear in
tangential direction.

Backlash
Increase
Decrease
2
Decrease

Increase
Increase

Backlash Decrease

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Tooth Contact

Reduction Gear Face Runout Tooth Contact

Using a dial indicator, check the reduction gear Check the gear reduction tooth contact. To
for face runout at the maximum radius position check, apply a thin coat of bluing to several
in back of the gear. If the runout exceeds the gear teeth on both drive and coast sides. Press
limit, check the reduction gear bolts for forward on the reduction pinion and rotate the
tightness; retighten if necessary. Check the reduction gear back and forth until a contact
condition of the tapered roller bearings. pattern is noted on both concave and convex
Readjust or replace them if necessary. faces of the gear teeth. To adjust the tooth
contact, refer to the chart on page 2-18.

0.05 (0.0020)
A
Face runout of maximum
reduction gear 0.05 (0.0020)
B
maximum

Unit: mm (in.)
A = Assembly Standard
B = Repair or Service Limit

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Tooth Contact Adjustment (DSD30 – 35)

Tooth Contact Adjustment

(DSD30 – 35)

Tooth Contact Adjustment

Extends from toe to

middle portion,
1 covering not less Correct tooth contact
than 50% of tooth
length.

1. Move gear away from pinion.

2. Move pinion toward gear by
Short contact at increasing shim thickness to
2 secure correct backlash.
toe of tooth.

1. Move gear toward pinion.

2. Move pinion away from gear by
Short contact at decreasing shim thickness to
3 secure correct backlash.
heel of tooth.

1. Move pinion toward gear by

increasing shim thickness.
Heavy contact on 2. Move gear away from pinion to
4 face or upper secure correct backlash.
portion of tooth.

1. Move pinion away from gear by

decreasing shim thickness.
Heavy contact on 2. Move gear toward pinion to
5 flank or lower secure correct backlash.
portion of tooth.

Repeat the above adjustment until the correct

tooth contact is obtained.

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Tooth Contact Adjustment (DSD40 – 60)

Tooth Contact Adjustment

(DSD40 – 60)

Tooth Contact Adjustment

Extends from toe

to middle portion,
1 covering not less Correct tooth contact
than 50% of
tooth length.

1. Move pinion toward gear by

increasing shim thickness.
Short contact at 2. Move gear away from pinion to
2 secure correct backlash.
toe of tooth.

1. Move pinion away from gear by

decreasing shim thickness.
Short contact at 2. Move gear toward pinion to
3 secure correct backcklash.
heel of tooth.

1. Move pinion toward gear by

increasing shim thickness.
Heavy contact on 2. Move gear away from pinion to
4 face or upper secure correct backlash.
portion of tooth.

1. Move pinion away from gear by

decreasing shim thickness.
Heavy contact on 2. Move gear toward pinion to
5 flank or lower secure correct backlash.
portion of tooth.

Repeat the above adjustment until the correct

tooth contact is obtained.

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Tooth Contact Adjustment (DSD40 – 60)

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Raymond ® DSD Maintenance Manual Transfer Assembly

Transfer Assembly 3:

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Transfer Assembly Raymond ® DSD Maintenance Manual

Description

Description
Front axle center

1 8 2

6 Traction motor

5 9 4 6
3

Main component The transfer assemblies of all the 1 ton, 2 ton,

and 3 ton class trucks share completely
1. Transfer case
identical components except the different bevel
2. Transfer cover gear sets as shown below.
3. Input gear (13T)
No. of teeth
4. Output gear (48T) No. of teeth
on bevel
on bevel gear
5. Bevel gear set pinion
6. Taper roller bearing 1 ton class
7 32
7. Lock nut trucks

8. Ball bearing 2 and 3 ton

7 35
class trucks
9. Plug (standard) or pulse generator (option)

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Raymond ® DSD Maintenance Manual Transfer Assembly

Disassembly

Disassembly

Start by 3. Remove the traction motor, reduction and

differential assembly, and transfer
1. Remove the drain plug on the front axle assembly as one unit, from the front axle
housing to let the oil drain out. housing.
2. Disconnect the connectors of the traction 4. Separate the three assemblies removed in
motor harnesses and pulse generator step (3) from each other.
harness.

3 15 Liquid gasket
2

18 1

14
17
Plug (standard)
or 16
Pluse generator (option)

Staked
7

4
6

8 9

13 11 10 12
3

Disassembly sequence 9. Bearing cone

10. Output gear
1. Bolt
11. Spacer
2. Transfer cover
3. Side cover with pulse generator, or plug 12. Bearing cup
13. Bearing cup
4. Nut
14. Snap ring
5. Shim
Remove parts 15 to 17 as a unit.
Remove parts 6 and 8 as a unit.
15. Input gear
6. Bevel pinion shaft
7. Shim 16. Ball bearing
17. Ball bearing
8. Bearing cone
18. Transfer case

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Suggestions for Disassembly

Suggestions for Disassembly

Shaft locking
15 bar fixing bolt
Shaft locking
bar
18 Special
tool

Staked 3

Special tool needed

4
5 Bevel pinion puller 223-012-177
9
8 12 d. If the bearing cone [8] needs to be
13 10
removed, use a bearing puller and a
3
press to pull it from the bevel pinion
1. Remove the bevel pinion shaft [6] as follows: [6].
a. Using a chisel, cut the staked portion e. If the bearing cups [12] and [13] need
of the nut [4], taking care not to to be removed, use a bearing cup
damage the bevel pinion shaft. puller to pull them out of the transfer
b. Hold the input gear [15] with the case [18].
special tool to prevent the bevel pinion NOTE: The taper roller bearing cup and cone
[6] from rotating, then remove the nut are an exclusive pair. If either the cup or
[4] and shims [5]. cone of a pair is faulty, replace them as a
Special tool needed set.
The removed shims should be kept
together until they are reinstalled. (This
Transfer bearing tool 223-012-176 only applies when the bevel pinion
and/or taper roller bearing are/is
c. Using the bevel pinion puller (special reused.)
tool), pull the bevel pinion [6] out of the
bearing cone [9]. The bevel pinion and bevel gear are an
exclusive pair. If either of them is
damaged, replace them as a set.

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Suggestions for Disassembly

M14 × 1.5
17 Thread 18

14

15
Rod of sliding
hammer

16
3

2. Remove the input gear as follows:

a. Remove the snap ring [14].
b. Using a sliding hammer, pull the input
gear [15], complete with the ball
bearings out of the case [18].
c. If the ball bearings [16] and [17] need
to be removed, use a puller to pull
them out. Do not attempt to tap them
out.

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Transfer Assembly Raymond ® DSD Maintenance Manual

Inspection after Disassembly

Inspection after Disassembly

1. Check the output gear [10] and the input

gear [15] for damaged/worn teeth and worn
splines.
2. Check the bearings for wear or damage.
Make sure that they rotate freely without
making noise.
3. Check the transfer case for cracks or other
damage.
4. Check the bevel pinion and the bevel gear
for incorrect tooth contact, damage, and
wear.

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Reassembly

Reassembly

Follow the disassembly sequence in reverse.

2 4 5
1
17

3
18

16 19

13
10

8 Staked

14

15

6 11 12 7
3

Reassembly sequence
1. Transfer case 9. Shim

Assemble the parts 2 to 4 first, then install 10. Bearing cone

the assembly into the case 1. 11. Spacer
2. Input gear 12. Output gear
3. Ball bearing 13. Bearing cone
4. Ball bearing 14. Shim
5. Snap ring 15. Nut
Press-fit the parts 6 and 7 into the case 1. 16. Side cover with pulse generator (option)
6. Bearing cup 17. Liquid gasket
7. Bearing cup 18. Transfer cover
Assemble the parts 8, 9 and 10. 19. Bolt
8. Bevel pinion shaft

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Suggestions for Reassembly

Suggestions for Reassembly

Mark “b” is indicated here.

! CAUTION

Axle center
Ball bearings and taper roller
bearings can be fitted onto shafts
more easily when they are warmed
in hot oil. However, do not increase
the oil temperature above 120°C
(250°F).

1. Install the input gear [2] as follows:

a. Press-fit the ball bearings [3] and [4]
into the input gear [2]. Force the
assembly into the transfer case [1].
B
b. Install the snap ring [5].
A
2. Sub-assemble the bevel pinion shaft [8] as
follows:
a. Place shim stock [9] and bearing cone Mark “a” is indicated here.
[10] on the bevel pinion [8], then install 3

these into place using a press.

Calculate the thickness C of shims [9] NOTE: When installing shim stock [9], make
using the following equation. sure to locate the 1.0 mm (0.04 in.) thick
shim closest to the bevel pinion.
C = 1.8 + a/100 - b (unit: mm)
a = Machining error in the differential
carrier dimension A
b = Machining error in the bevel pinion
dimension B
The machining error “a” is stamped on
the top surface of the differential
carrier. (No stamping is present if the
error is within ± 0.05 mm.)
The machining error “b” is marked on
the end surface of the bevel pinion
using electric marking pen. No mark is
1.0 mm (0.04 in.)
present if the error “b” is ± 0.
thick shim Standard shim
C stock thickness
1.8 mm (0.071 in.)
3

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Suggestions for Reassembly

b. While inserting the bevel pinion shaft e. With the special tool installed on the
sub-assembly into the case, install the input gear [2], measure the preload of
spacer [11], output gear [12], bearing the taper roller bearing on the bevel
cone [13], and shim stock [14]. Reuse pinion gear shaft [8]. The preload is
the originally installed shim stock [14]. measured in terms of the tangential
force required to start the input gear
Preload adjustment of taper roller bearing
[2] rotating. The measurement should
c. Hold the input gear [2] to prevent the meet the following specified value.
bevel pinion shaft [8] from rotating.
Special tool needed
Tangential force 54 to 81 N
required to start input (5.5 to 8.3 kgf)
Transfer bearing tool 223-012-176
gear [2] rotating [12.1 to 18.26 lbf]

d. Install a new nut [15] on the bevel f. Adjust the preload as required by
pinion shaft [8]. Tighten and loosen the increasing or decreasing the thickness
nut several times, each time after of the shim stock [14]. The greater the
rotating the shaft a little, so that the shim stock thickness, the smaller the
bearing cups and cones settle preload. The smaller the shim stock
completely on each other. Finally, thickness, the greater the preload.
tighten the nut to the torque shown Repeat the steps (d) and (e) until the
below. Do not give the bearings too specified preload is obtained.
much preload.
g. After the specified preload is obtained,
lock the nut [15] on the bevel pinion
shaft [8] by staking to prevent it from
294 ± 20 N·m
Tightening torque loosening.
(30.0 ± 2.0 kgf·m)
of nut [15]
[217 ± 14.5 lbf·ft]
(1) Stake the nut completely against the
bottom of the groove on the bevel pinion.
(2) The staked portion should have a flat of
Attach spring φ 4 mm (φ 0.16 in.) or more.
2
scale hook here
to measure the
tangential force.

Special
tool
8

Staking tool needed A screwdriver is not

appropriate for staking.
14

15

13 R R
12 φ 4 to 6 mm
11 (φ 0.16 to 0.24 in.)
3 3

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Transfer Assembly Raymond ® DSD Maintenance Manual

Suggestions for Reassembly

3. Tighten the bolts to the torques indiated in

the table below the illustration.

Apply liquid gasket onto

the face of flange.

Tightening Torque

Item No. Description N·m kgf·m lbf·ft

1 Cover-to-traction motor 33 ± 2 3.4 ± 0.2 24.6 ± 1.4

2 Side cover 39.2 ± 3.9 4.0 ± 0.4 29.0 ± 2.9

3 Plug or pulse generator 54.0 ± 4.9 5.5 ± 0.5 39.7 ± 3.6

4 Case-to-cover 39.2 ± 3.9 4.0 ± 0.4 29.0 ± 2.9

5 Lock nut 294 ± 20 30.0 ± 2.0 217 ± 14.5

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Raymond ® DSD Maintenance Manual Rear Axle

Rear Axle 4:

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Rear Axle Raymond ® DSD Maintenance Manual

Description

Description

1. Rear axle The truck is steered by the rear wheels. The

2. Steering cylinder rear axle is connected to the frame by its center
pivot shaft. Because of the center pivoting
3. Steer knuckles feature, the rear axle can oscillate up to 3° in
4. King pins each direction.

5. Tie rods
6. Wheel rims
7. Shims

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Raymond ® DSD Maintenance Manual Rear Axle

Rear Wheels

Rear Wheels

Removal Suggestions
1. Park the truck on level floor with the
! CAUTION parking brake applied, the direction lever in
neutral, the forks lowered, and the key
Use the same size and brand of tire switch OFF.
for replacement.
2. Prepare the tools, parts, jack, and wheel
blocks.
Tools Needed: Spring scale, bearing
installer, and puller.
10 Parts Needed: Lock washer [3]; oil seal [7];
cap [1] (when required); bearings [5, 8, 9,
and 10] (when required); wheel assembly
[6].
A 3. Cap [1] is press-fitted to the rim. Pry it off
A
using a chisel and hammer as shown.
9 Discard the removed cap. Use a new cap
5 when installing a replacement wheel.
4
3
7
2
8 1

Removal Sequence
1. Cap 4

2. Outer nut 4. Bend down lock washer [3].

3. Lock washer 5. Loosen nut [2].
4. Inner nut 6. Raise the wheels.
5. Inner race bearing
6. Wheel assembly Hoist Capacities
7. Oil seal
3000 kgf
8. Outer race bearing DSD30–35
(6700 lbf)
9. Outer race bearing
5000 kgf
DSD40–60
10. Inner race bearing (12,000 lbf)

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Rear Axle Raymond ® DSD Maintenance Manual

Steering Cylinder

Steering Cylinder

*: Parts contained in seal kit

12
* 14
11
*
*
17 13 6
*

9
10 8

16 7
*

2 * 1
3
15 4

1. Cylinder tube 10. Stopper ring

2. Piston rod 11. Wiper
3. Cylinder head 12. U-seal
4. Cylinder head 13. O-ring
5. Pivot joint 14. O-ring
6. Snap ring 15. Guide ring
7. Tie rod 16. Piston seal
8. Nut 17. Bushing
9. Spring washer Double-action cylinder is used.

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Raymond ® DSD Maintenance Manual Rear Axle

Inspection

7. Block the front wheels. 1. Using a puller, install bearings (outer) [8]
and [9] to the new wheel assembly [6].
8. Fasten a hoist to the counterweight and lift
the rear end of the truck. 2. Install oil seal [7] to the new wheel
assembly [6].
9. Place the solid blocks under the side frames
to support the truck (with the left and right
rear wheels slightly clearing the floor).
10

A
A

9
5
4
3
7
2
8 1
4
6
10. Remove nut [2], lock washer [3] and nut [4].
11. Remove wheel assembly [6] from the rear 4
axle. Use care not to cause damage to the
oil seal fitted to the rim. After removing the
assembly, raise the counterweight to a position
400 to 500 mm (16 to 20 in.) from the floor.
12. Using a puller, remove outer race bearings
[8] and oil seal [7] from the wheel assembly.
NOTE: Replace the cap and bearings (inner and
outer) if bad. 25.4 mm
(1 inch)

Inspection
1. Oil seal
Check the oil seal of the rim for excessive
4
wear or damage.
2. Tires
Check the height of the solid rubber portion
and, if worn down to 25.4 mm (1 in.),
replace the tire.
NOTE: Replace all tires if one tire is damaged. If
new and used tires are mixed, rapid tire
wear will result.

Installation
To install, follow the reverse the removal
sequence:

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Rear Axle Raymond ® DSD Maintenance Manual

Installation

3. Fill the rim and oil seal with grease. Do not

overfill the oil seal to prevent leakage. Bar

Oil seal

Spring scale

4
Fill with
grease
DSD30, DSD40, DSD50,
DSD35 DSD5E, DSD60

Tangential 33.1 to 86 26.7 to 69.6

force (3.38 to 8.78) (2.73 to 7.10)
4 N (kgf) [lbf] [7.4 to 19.3] [6.0 to 15.6]
4. Tighten nut [4] to 137 N·m (14 kgf·m) Tighten the inner nut to achieve the specified
[101 lbf·ft] torque and back it off 80°, then value.
put lock washer [3]. Install nut [2],
tightening it to 157 N·m (16 kgf·m)
[116 lbf·ft] torque. Check the hub bearing Reference value
preload, making sure it is 2.5 to 6.4 N·m
(25 to 65 kgf·cm) [1.8 to 4.7 lbf·ft]. If the
preload is correct, bend lock washer [3]. 2.5 to 6.4 N·m
Preload for hub
(25 to 65 kgf·cm)
bearings
[1.8 to 4.7 lbf·ft]
Bar
6. After adjusting the preload, tighten a new
lock washer [3] and an outer nut [2] to the
specified torque.

Inside
nut

Outside
nut

5. Check to make sure the preload is correct.

Insert a 24mm round bar into the cast hole
4
of the rim. Attach a spring balance to the
round bar, and measure the tangential
force. 157 N·m
Tightening torque for
(16 kgf·m)
outer (lock) nut
[116 lbf·ft]

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Raymond ® DSD Maintenance Manual Rear Axle

Installation

7. Bend the lock washer to both sides (inward

and outward).

8. Fill the cap with grease, and install the cap

[1].
9. Raise the rear end of the truck and remove
the blocking from the side frames.
10. Lower the truck until the rear wheels just
touch the floor.

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Rear Axle Raymond ® DSD Maintenance Manual

Rear Axle

Rear Axle

Removal

Sequence 2. Raise the rear end of the truck with a jack

and place solid blocks under the side
1. Cap frames (with the left and right rear wheels
2. Nut and washer slightly clearing the floor).

3. Bearing NOTE: A hoist may be used in place of the jack

to raise the rear end (counterweight).
4. Rim and tire
5. Drag link
6. Bearing support and bolts
7. Rear axle assembly

Start By
1. Apply the parking brake and block the front
wheels.

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Raymond ® DSD Maintenance Manual Rear Axle

Installation

Suggestions Installation
To install, reverse the removal sequence and do
Removing Rear Axle Assembly the following steps.

Adjusting Bearing Support Clearance

! WARNING
Adjust the longitudinal clearance to 0.8 mm
Make sure the pressure in the (0.031 in.) with the thrust washer and tighten
hydraulic system is released before the bolts holding the bearing support to the
any lines or hoses are disconnected. specified torque.

1. Put identification marks on the hoses, then 14.8 kgf•m

disconnect them. Tightening torque for
(107 lbf•ft)
bearing support bolts
2. Support the rear axle at its center with a [145 N•m]
garage jack.
3. Loosen and remove the axle mounting
bolts.

Weight of Rear Axle

DSD30–35 60 kg [132 lb.]

DSD40–60 85 kg [187 lb.]

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Rear Axle Raymond ® DSD Maintenance Manual

Disassembly

Disassembly

17
16

15
2
15 4
14
17
19

13
11
2
10

9 3

18
9

5 10 1

12

Disassembly sequence
9. Taper roller bearing
1. Taper roller bearing (inner), Retainer
10. Oil seal
2. Tie rod pin, Bolt, Spring washer, Plain
washer, Collar, Grease nipple 11. Cover, Retainer
3. Spherical bushing, Ring, Retainer, Dust 12. Boot
seal
13. Cover
4. Tie rod
14. Clamp, Bolt, Spring washer
5. Kingpin plate, Shim 15. Pipe (L.H., R.H.)
6. Kingpin, O-ring
16. Steering cylinder [Bolt, Spring washer, Nut]
Remove parts 7 through 12 as an assembly. 17. Elbow, O-ring
7. Knuckle 18. Stopper bolt, Lock nut
8. O-ring 19. Rear axle housing

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Raymond ® DSD Maintenance Manual Rear Axle

Disassembly

Suggestions Mark Cylinder End Caps

Mark the cylinder end caps for proper
Removing Retainer and Bearing alignment before they are disassembled from
Use a puller to remove the retainer and inner the cylinder.
bearing from the knuckle.

4
4

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Rear Axle Raymond ® DSD Maintenance Manual

Inspection after Disassembly

Inspection after Disassembly Hydraulic Pipes

Inspect the hydraulic pipes for cracks,
Tie Rods and Pins especially at the joints with the end fittings.
1. Make sure that the pins are free of any Check for leaks.
surface flaws such as grooving or stepped
wear. Examine the keeper plate weld for Tires
cracking.
Check the height of the solid rubber portion
2. Examine the bearings for wear or damage. and, if worn down to 25.4 mm (1 in.), replace
3. Examine the tie rods for damage and the tire.
alignment. Inspect the welds for signs of NOTE: Replace all tires even if only one tire is
cracks. damaged. If new and used tires are
NOTE: If pin replacment is necessary, replace mixed, rapid tire wear will result.
its bearing as well.

Kingpins
Check the kingpins for any surface flaws such
as grooving or stepped wear. Inspect the pins
for cracks at the bearing shoulder.
25.4 mm
(1 inch)
Kingpin Bearings
Examine the rollers and bearing races for
grooving, abrasive wear, pitting, bruising, or
corrosion. Replace both the cup and cone of
damaged bearings. 4

Knuckles
Inspect the inside of each knuckle for wear or
damage. Be sure to examine for casting cracks.
Check the tie rod pin hole. Examine the wheel
nut threads for damage.

Cylinder Rod
Examine the rod for surface or plating damage.
Inspect the rod for straightness. Examine the
piston for damage. Check the tie rod pin hole
for damage or wear.

Seals and O-rings

Examine all seals and O-rings for damage such
as cuts and tears. Replace seals that show signs
of aging.

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Raymond ® DSD Maintenance Manual Rear Axle

Reassembly

Reassembly

3
2

4
17
4 16
5
3
1

15
11
17
10

9 7

13
18
9

14 10 19

12

Assembly sequence
11. Cover, Retainer
1. Rear axle housing
2. Steering cylinder [Bolt, Spring washer, Nut] 12. Boot
13. Kingpin, O-ring, Bolt, Spring washer
3. Elbow, O-ring
14. Kingpin plate, Shim, Bolt, Spring washer
4. Pipe (L.H., R.H.)
5. Clamp, Bolt, Spring washer 15. Cover
16. Tie rod
6. Knuckle
17. Tie rod pin, Bolt, Spring washer, Plain
7. Spherical bushing, Ring, Retainer, Dust
washer, Collar, Grease nipple
seal
8. O-ring 18. Stopper bolt, Lock nut
19. Retainer, Taper roller bearing
9. Taper roller bearing
10. Oil seal

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Rear Axle Raymond ® DSD Maintenance Manual

Reassembly

Suggestions 4. Pressure test cylinder reassembly for leaks.

Reassembling Steer Cylinder

DSD30–35 DSD40–60
1. Replace all seals and O-rings when
reassembling the steer cylinder. Lubricate 107 163
Minimum test
seals and O-rings lightly with hydraulic (1522) (2320)
pressure
fluid. [10,500] [16,000]
2. Assemble wiper seal and U-seal as shown. Unit: kgf/cm2 (psi) [kPa]

5. Use an alternating tightening pattern to

tighten the mounting bolts when attaching
the cylinder assembly to the axle beam.

DSD30–35 DSD40–60

17.9 kgf•m 26.7 kgf•m

Tightening
(130 lbf•ft) (193 lbf•ft)
torque for bolts
[176 N•m] [262 N•m]
Wiper seal U-Seal

Reassembling Knuckles
4

3. Align marks on the end caps to marks on 1. Insert bearing cups into knuckles.
the cylinder body. Tighten nuts. Adequately fill bearing cages with grease.
Apply a coat of grease to the oil seal groove.
Insert the bearing cages in the knuckles
2.1 ± 0.2 kgf•m and apply additional grease as required to
Tightening torque for meet the recommended amount.
(15.5 ± 1.5 lbf•ft)
cylinder nuts
[21 ± 2 N•m]

DSD30–35 DSD40–60

Quantity of 40cc 80 cc
grease (2.44 in3) (4.88 in3)

2. Reassemble remaining components (seals,

O-rings, covers, and boots).
3. Assemble parts, knuckle [6] through Boot
[12], and insert this sub-assembly into the
rear axle housing.

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Raymond ® DSD Maintenance Manual Rear Axle

Reassembly

Reassembling Kingpins 3. Measure the tangential force at point “C”.

When the tangential force is larger than the
1. Install the kingpins and measure the values shown in the table below, add
distances “A” on both the left and right shims. When the tangential force is smaller
kingpins. than the values shown in the table below,
remove shims. Repeat this procedure until
the values in the table are attained.

DSD30–35 DSD40–60

1.6 to 2.6 kgf 2.5 to 4.5 kgf

Tangential
(3.5 to 5.7 lb.) (5.5 to 9.9 lb.)
force
[15.7 to 25.5 N] [24.5 to 44.1 N]

2. Add shims to each side to within 0.1 mm

(0.004 in.) of the measured distance “A”
and tighten bolt “B”.

4. Tighten kingpin keeper plate bolts.

Keeper
Kingpin Bolt
Plate Bolts

1.7 kgf•m 3.4 kgf•m

Tightening
(12.3 lbf•ft) (24.6 lbf•ft)
torque for bolts
[16.7 N•m] [33.4 N•m]

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Rear Axle Raymond ® DSD Maintenance Manual

Reassembly

Reassembling Tie Rods 3. Reassemble rear axle hubs. Drive the inner
race of the inner bearing onto the shaft
Replace dust seals. Tighten tie rod pin bolts to using a special tool as shown below.
the specified torque. Grease the joints using the
grease zerks.

0.7 kgf•m
Tightening torque
(5 lbf•ft)
for bolts
[6.9 N•m]

4. There is space between the two tapered

roller bearings inside the rear axle hub.
Make sure to fill this space with grease.
4
Grease the oil seal lip groove and roller
retainers, too. Do not overfill the oil seal lip
groove as this can cause leakage.
Reassembling Rear Axle Hub
1. Using Installation Tool #223-012-178 or
#223-012-179, install inner bearing races.
Using Tool #223-012-188 or 223-012-189,
install outer bearing races.

DSD30–35 DSD40–60

Bearing
223-012-178 223-012-179
installer

2. Pack bearing cones.

5. Install wheel assembly carefully so as not to

damage the bearing or seal.
6. Install outer bearing and nut [4].

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Raymond ® DSD Maintenance Manual Rear Axle

Reassembly

7. Tighten nut [4] to 14 kgf•m (101 lbf•ft) 8. Check to make sure the preload is correct.
[137 N•m] torque and back it off to 80°, then
place lock washer [3].
25 to 65 kgf•cm
Install nut [2], tightening it to 16 kgf•m Preload for hub
(1.8 to 4.7 lbf•ft)
(116 lbf•ft) [157 N•m] torque. bearings
[2.5 to 6.4 N•m]
Check the hub bearing preload, making
sure it is 25 to 65 kgf•cm (1.8 to 4.7 lbf•ft)
[2.5 to 6.4 N•m].
Bar
If the preload is correct, bend lock washer
[3].

Inside
nut

Outside
nut

Bar

25 to 65 kgf•cm
Preload for hub bearings Spring
(1.8 to 4.7 lbf•ft)
Tangential Force scale
[2.5 to 6.4 N•m]

16 kgf•m 101653
Tightening torque for
(116 lbf•ft)
outer lock nut 9. Install cap [1].
[157 N•m]
10. Raise the rear end of the truck and remove
NOTE: Preload for bearing is given in tangential the blocking from the side frames.
force measurement and must be
11. Lower the truck until the rear wheels are on
measured with a spring scale. Apply
the floor.
force to spring scale as shown in graphic
#101653, read scale. Adjust nut [4] to
achieve correct preload.

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Rear Axle Raymond ® DSD Maintenance Manual

Inspection and Adjustment

Inspection and Adjustment

Minimum Turning Radius

Adjustment
1. Using a turning radius gauge, measure the
angular swing of rear wheels.
2. Setting the turning angle of each rear wheel
to the specification is not enough. Drive the
truck to make the sharpest possible turn to
either side, and measure the radius of the
track left behind by the outer wheel for
confirmation. The standard minimum
turning radius is indicated below.

DSD30–35 DSD40–60

Steering Angle Turning radius [Unit: mm (in.)]

Inside 83° 83°
Outside 54° 56°

Tightening torque 6.8 kgf•m

for knuckle stopper (49 lbf•ft)
bolt lock nut [67 N•m]

3. Drive the lift truck at low speeds in such a

way as to make the sharpest possible turn
to either side. Measure the radius of the
track left by the outer wheel.
4. The minimum turning radius, R, is the
distance from the turning center to the
center of tire contact with the surface while
the truck is executing its sharpest turn,
plus the rear overhang (distance from
center of rear tire to the outermost end of
the counterweight).

DSD30 1787 (70.4)

DSD35 1787 (70.4)

DSD40 1890 (74.4)

DSD50 1890 (74.4)

DSD5E 1991 (78.4)

DSD60 2045 (80.5)

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Raymond ® DSD Maintenance Manual Rear Axle

Steering Cylinder

Steering Cylinder
Disassembly

*: Parts contained in repair kit 10

*

11
9

A
11
3
*
4
5 2

* 1 7
6 * 6
*
7 *
A

5
2
4
1 *
3

8
1

Disassembly sequence
8. Cylinder tube
1. Nut, Spring washer, Tie rod
9. Piston rod
Remove parts 7 through 11 as assembly.
10. Guide ring, Piston seal
2. Cylinder head
11. Stopper ring
3. O-ring
NOTE: Do not remove bushing [5] from the
4. Snap ring
cylinder head [2] if acceptable.
5. Bushing
Do not remove bearing [11] from piston
6. Wiper rod [9] if acceptable.
7. U-seal

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Rear Axle Raymond ® DSD Maintenance Manual

Steering Cylinder

Suggestions Inspection and Repair

1. Cylinder tube [8]:
Mark Cylinder End Caps
Check for wear, damage or rust inside the
Mark the cylinder end caps for proper cylinder.
alignment before they are disassembled from
2. Piston rod [9]:
the cylinder.
Check for rust, damage, scratches or
impact marks on the rod surface.
Mark 3. Rings and gaskets:
Replace the entire seal kit.

Mark

DSD30–35 DSD40–60

Internal
diameter of A 63 (2.480) 75 (2.953)
cylinder tube [1]

External
diameter of A 40 (1.575) 50 (1.968)
piston rod [2]

A: Standard value
Unit: mm (in.)

2 1

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Raymond ® DSD Maintenance Manual Rear Axle

Suggestions

Reassembly

5 5
13
4
1 2 14
12
16

9
15 8
6
11 3
7 10
4

Assembly sequence Suggestions

1. Piston rod 1. Replace all seals and O-rings whenever
reassembling steer cylinder. Lubricate seals
2. Piston seal
and O-rings lightly with hydraulic fluid.
3. Guide ring
2. Assemble wiper seal and U-seal as shown.
4. Cylinder tube
5. Cylinder head
6. Bushing
7. Snap ring
8. U-seal
9. Wiper
10. O-ring
11. O-ring
12. Tie rod
Wiper U-seal
13. Spring washer
4
14. Nut
15. Pivot joint
16. Stopper ring

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Rear Axle Raymond ® DSD Maintenance Manual

Suggestions

3. Align marks on the end caps to marks on

the cylinder body. Tighten nuts.

Mark

Mark

Tightening torque for 21 ± 2

cylinder nuts (2.1 ± 0.2)
N·m (kgf·m) [lbf·ft] [15.5 ± 1.5]

Unit: N·m (kgf·m) [lbf·ft]

4. Pressure test cylinder reassembly for leaks.

DSD30–35 DSD40–60

10500 16000
Minimum
(107) (163)
test pressure
[1522] [2320]

Unit: kPa (kgf/cm2) [psi]

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Raymond ® DSD Maintenance Manual Brake System

Brake System 5:

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Brake System Raymond ® DSD Maintenance Manual

Description

Description

Automatic Adjusting Device

General Information
This device adjusts the drum-to-lining
clearance automatically. As the clearance
increases due to lining wear, the lever
mechanism of this device turns the adjusting
screw by one notch or tooth to reposition the
shoes closer to the drum. This corresponds to
1/24 of one rotation or 15°. In the course of
usage, the adjusting process repeats itself at
long intervals.

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Raymond ® DSD Maintenance Manual Brake System

Master Cylinder

Master Cylinder

Disassembly

9
8

4 7
10
6
5

*3

223-010-356 DSD30 – 35

1 223-010-262 DSD40 – 60

1. Taper plug
2. Master cylinder body
3. Repair kit
4. Cap assembly
5. Level sensor
6. Oil tank assembly
7. Push rod
8. Jam nut
9. Clevis
10. Push rod assembly
NOTE: Change these parts (*) periodically. They
are included in the Repair Kit.

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Brake System Raymond ® DSD Maintenance Manual

Inspection after Disassembly

Inspection after Disassembly Return Spring

Replace the return spring every year.
Brake Fluid Level Sensor
1. Fill the reservoir with brake fluid. Connect Primary Cup, Secondary Cup, and
the fill level sensor connector at the bottom Valve
of the fluid reservoir and turn the key to
ON. Check these rubber parts for swelling, tearing,
and deterioration from aging. Replace them
every year.

Reassembly
To reassemble, reverse the procedure for
disassembly and do the following steps.
1. Clean all metal parts with a volatile
DOWN = ON UP = OFF cleaning solvent. Dry them with pressure
air.
5
2. Apply a thin coat of rubber grease (Metal
2. The sensor is satisfactory if the brake fluid Rubber #20) or brake fluid to the piston
level warning lamp on the monitor flashes cups and the cylinder bore.
when the reservoir filler is in the DOWN
position and goes off when it is in the UP Master Cylinder Adjustment
position.
Adjust master cylinder only after pedal height
Cylinder Body adjustment has been made (See page 5-15).
With master cylinder installed and push rod
1. Check the bore of the cylinder for rust, connected to brake pedal, use the clevis pin to
corrosion, and scoring. adjust the master cylinder push rod so there is
2. Check the inlet port and relief ports for 0.5 to 2.8 mm of free play between the end of
cleanliness. Also check the threads in the the push rod and cylinder position contact.
screw connection of each joint for damage. Tighten jam nut on push rod clevis assembly.
Make sure the boot is free from defects.

Piston
Replace the piston if it is damaged. Check the
piston clearance in the cylinder body. Replace
the cylinder body and piston if the clearance is
in excess of the service limit.

Clearance 0.020 to 0.105

A
between piston (0.00079 to 0.00413)
and cylinder B 0.2 (0.008)

Unit: mm (in.)
A = Assembly Standard
B = Repair or Service Limit

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Raymond ® DSD Maintenance Manual Brake System

Service Brakes

Service Brakes

Disassembly (DSD30 – 35)

2
16 23 3 24 13 9 9 21

20

19

7
22
6
26
4 10
27 17
15
11
14

18 25
8
12

Components
14. Cup
1. Service brake assembly
2. Wheel cylinder assembly 15. Spring
16. Pin
3. Backing plate
17. Spring
4. Primary shoe and lining assembly
5. Secondary shoe and lining assembly 18. Strut
19. Spring washer
6. Parking lever
20. Retainer
7. Adjusting screw
8. Adjusting lever 21. Bolt with washer
22. Snap ring
9. Spring
23. Cover
10. Cable guide
11. Fitting cable 24. Parking cable assembly
25. Spring
12. Spring
26. Spring washer
13. Shoe guide plate
27. Bolt

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Disassembly (DSD40 – 60)

Disassembly (DSD40 – 60)

2
16 23 10 3 24 13 27 28 29 21

26
9
20
19

7
22
6
31
30 4
14 17
15
14
18 11

12 8 25

Components
1. Service brake assembly 16. Pin
17. Spring
2. Wheel cylinder assembly
18. Strut
3. Backing plate
19. Spring washer
4. Primary shoe and lining assembly
5. Secondary shoe and lining assembly 20. Retainer
21. Bolt with washer
6. Parking lever
22. Snap ring
7. Adjusting screw
8. Adjusting lever 23. Cover
24. Parking cable assembly
9. Spring
25. Spring
10. Self-locking nut
11. Fitting cable 26. Spring
27. Pin
12. Spring
28. Sheave
13. Shoe guide plate
14. Cup 29. Plain washer
30. Bolt
15. Spring
31. Spring washer

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Disassembly (DSD40 – 60)

Start By Removing Hold-Down Springs

1. Remove the front wheel. Use a special tool to remove the hold-down
springs.
2. Remove the wheel hub and brake drum.
3. Separate the parking brake lever and cable
at the bottom of the wheel brake. Special Tool Part Number
4. Disconnect the brake pipe from the wheel Spring remover 223-012-181
brake assembly.

Suggestions

Removing Return Springs

Use a special tool to remove the return springs.

Special Tool Part Number

Spring remover 223-012-180

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Brake System Raymond ® DSD Maintenance Manual

Inspection after Disassembly

Inspection after Disassembly Brake Drums

Check the inside (friction) surface of the drum
Backing Plate for abnormal wear, grooving, and other defects.
1. Check the backing plate for cracks. Minor grooving can be removed by grinding,
provided that the service limit on the inside
2. Tighten the backing plate mounting bolts to diameter is not exceeded.
the specified torque.

DSD30–35 DSD40–60
Tightening torque for 16 kgf•m
backing plate (116 lbf•ft) Inside 254 + 0.13 0 310 + 0.15 0
mounting bolts [157 N•m] diameter A
(10.0 + 0.0051 0) (12.2 + 0.0059 0)
of brake
drum B 256 (10.08) 312 (12.28)
Shoes and Linings
Unit: mm (in.)
1. Check each shoe and lining for cracks. A = Assembly Standard
B = Repair or Service Limit
2. Replace the lining if it is dirty, greasy,
burnt, or glazed.
3. Check the thickness of the lining. Replace Adjusting Screws
the lining if it exceeds the service limit.
Check the wheel teeth for wear. Turn the screw
by hand to ensure its rotating parts turn freely.

5
Parking Brake Cable
Replace a cable if it is permanently stretched,
rusted, or damaged.
DSD30–35 DSD40–60

Lining A 4.87 (0.19) 6 (0.24) Other

thickness B 2.5 (0.10) 3 (0.12) 1. Check the return springs for cracks or
fatigue.
Unit: mm (in.)
A = Assembly Standard 2. Check the adjusting springs for cracks or
B = Repair or Service Limit fatigue.
3. Check the fitting cables for stretching.

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Reassembly (DSD30 – 35)

Reassembly (DSD30 – 35)

10
6 3
A
12
1

8 12

13
5

8
4
7 1
11

14

16
A 2
15
Section A-A

Sequence
1. Backing plate 9. Pin, hold-down spring, and cup
10. Shoe guide plate
2. Parking brake cable
11. Fitting cable
3. Wheel cylinder
4. Parking brake lever 12. Return spring
13. Cable guide
5. Shoe and primary lining
14. Adjusting lever and adjusting spring
6. Retainer and washer
7. Shoe and secondary lining 15. Adjusting screw
16. Return spring
8. Strut and anti-rattle spring

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Brake System Raymond ® DSD Maintenance Manual

Reassembly (DSD40 – 60)

Reassembly (DSD40 – 60)

3 A 11
9
6

1
13

7
4

10
10

12

16
14
15 2 A
Section A-A

Sequence
1. Backing plate 9. Strut and anti-rattle spring
10. Pin, hold-down spring, and cup
2. Parking brake cable
11. Shoe guide plate
3. Wheel cylinder
4. Parking brake lever 12. Fitting cable
13. Return spring
5. Shoe and primary lining
14. Adjusting lever and adjusting spring
6. Retainer and washer
7. Pin, sheave, and washer 15. Adjusting screw
16. Return spring
8. Shoe and secondary lining

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Raymond ® DSD Maintenance Manual Brake System

Reassembly (DSD40 – 60)

Suggestions Installing Return Springs

1. Use a special tool to install the return
Installing Wheel Cylinder springs to the backing plate pins.
Apply retaining compound to the mounting face
of the wheel cylinder before positioning the
cylinder in place. Secure it by tightening to the Special Tool Part Number
specified torque: Spring installer 223-012-182

DSD30–35 DSD40–60

Tightening 0.8 to 1.2 1.8 to 2.7

torque for (6 to 9) (13 to 20)
wheel cylinder [8 to 12] [18 to 26]

Unit: kgf•m (lbf•ft) [N•m]

Installing Automatic Adjusting Device

1. Clean the adjusting screw and associated
parts, then grease the screw threads and
screw socket. Be sure the screw turns freely
when rotated by hand. If the screw is hard
5 to turn, replace it.
Greasing 2. The right and left adjusting screws are
color-coded.
Apply a thin coat of the specified brake grease
to each of the following parts. • Right-hand adjusting screw and lever
(left-hand thread) is yellow.
1. Shoe ledges (6 places):
• Left-hand adjusting screw and lever
The ledges are the portions of the backing
(right-hand thread) is white.
plate in contact with the shoe.
2. Anchor pin surface in contact with the shoe
ends.

Installing Shoes
1. Make sure that each push rod of the wheel
cylinder is snugly fitted to its shoe web.

NOTE: After reassembly, bleed air out of the

brake fluid lines. (Reference “Air
Bleeding Operation Procedure” on
page 5-15.)

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Wheel Cylinders

Wheel Cylinders

Disassembly

10

6
12
5 11

9
3 8

4
*
2

Sequence
8. Spring
1. Connecting link
9. Cup
2. Boot
3. Piston 10. Piston
11. Boot
4. Piston cup
12. Connecting link
5. Body
6. Bleeder screw NOTE: Change the parts (*) periodically. They
are included in the repair kit.
7. Cap

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Inspection after Disassembly

Inspection after Disassembly Piston Cups

Check for swelling or other defects. Replace the
Cylinder Bodies cups at the time of overhaul and every year.
1. Check the bore for rusting, corrosion, and
scoring. Boots
2. Check the threads of the bleeder screw and Replace the boots if they are hardened,
oil pipe for damage. damaged, or otherwise deteriorated.

Pistons Reassembly
1. Check the sliding surface for rusting or To reassemble, reverse the procedure for
scratching. disassembly and do the following:
2. Check the piston clearance in the cylinder 1. Coat the piston cups and the cylinder bore
body. Replace the cylinder body and piston with brake fluid.
if the clearance exceeds the service limit.
2. Be careful not to damage the lips of the
cups.

DSD30–35 DSD40–60

Clearance 0.040 to 0.125 0.020 to 0.105

between A (0.00157 to (0.00079 to
piston and 0.00492) 0.00413)
cylinder B 0.15 (0.0059)

Unit: mm (in.)
A = Assembly Standard
B = Repair or Service Limit

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Brake System Raymond ® DSD Maintenance Manual

Inspection and Adjustment

Inspection and Adjustment 3. When the automatic adjusting device is

suspected of malfunctioning during normal
use of the machine, check for the following
Automatic Adjusting Device causes:
1. Have the service brake properly set with the • Adjusting spring is not correctly hooked
drum-to-lining clearance adjusted to to the primary shoe.
specification. Pull the adjusting lever by
giving a push to the cable, as shown, to see • Any one of these parts is in bad
if the lever turns the adjusting screw by one condition and needs replacing:
tooth and, as the push is released, returns a. fitting cable
to its original position. If it does, the device
is in satisfactory condition. b. adjusting lever
c. adjusting screw

Manual Adjustment
1. The drum-to-lining clearance is adjusted by
rotating the adjusting screw with a
screwdriver on to the toothed wheel. Insert
the screwdriver tip through the hole in the
backing plate.

2. If the lever fails or is sluggish to turn the

adjusting screw in the above test, the likely
cause is that the lever is not properly
positioned relative to the toothed wheel. Be
sure that the lever is positioned so that its
actuating tip touches the toothed wheel at
about 9 mm (0.35 in.) under the center line
of the screw, as shown below. 5

9 mm
(0.35 in.)

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Raymond ® DSD Maintenance Manual Brake System

Brake Pedal Adjustment

Brake Pedal Adjustment Bleeding Air Out of Brake Fluid Line

Set the dimensions A, B, and C to the specified Whenever any part of the brake fluid line is
values. disconnected in servicing work, an air bleeding
operation must be performed to complete the
After the shoe linings have been replaced, turn
job. Air trapped in any part of the fluid line will
the adjusting screw as far as it will go (until the
cause the brake pedal to feel spongy.
clearance becomes zero) and back it off by the
amount of rotation shown below.
Air Bleeding Operation Procedure
1. Tie a flexible tube, such as a vinyl pipe, to
DSD30 – 35 19 clicks
the bleeder screw on the wheel cylinder.
DSD40 – 60 16 clicks Insert the free end of the tube into a vessel
filled with brake fluid.
2. Pump the brake pedal and depress it all the
Height from floor 98 mm ± 3 mm 1 ton way. While keeping the pedal depressed,
to pedal (A) 80 mm ± 3 mm 2/3 ton loosen the bleeder screw. When air bubbles
cease to come out, tighten the screw.
Stroke (to a point Repeat this process until nothing but brake
where brakes start 3 to 10 (0.12 to 0.4) fluid flows into the vessel.
to apply) (B)
3. Repeat procedure at each wheel brake, and
Clearance between fill up the brake fluid reservoir to level.
piston and push 0.5 to 2.8 (0.02 to 0.11)
rod (C)

Unit: mm (in.)

Push rod

NOTE: Make sure that the reservoir never

becomes empty of fluid at any time during
the procedure.
Use specified brake fluid. Avoid mixing
different brands of brake fluid before
and after filling up the reservoir.

Stop bolt
Brake Test
After completion of necessary adjustments, test
5
the brake force by operating the truck at a
speed of 10 km/h (6.2 mph). Refer to Manual
Adjustment for necessary readjustment.

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Brake System Raymond ® DSD Maintenance Manual

Brake Pedal Adjustment

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Raymond ® DSD Maintenance Manual Steering System

Steering System 6:

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Steering System Raymond ® DSD Maintenance Manual

Steering System

Steering System

Description

Oil Flow Sequence General Information

1. From hydraulic tank This steering system is an open-center type,
where the steering fluid is provided by a
2. Steering pump
dedicated steering pump. The oil is constantly
3. Steer gear available and flows through the steer gear and
4. Steering cylinder back to the tank via the mast operating valve.

5. Mast operating valve In this type of steering system, only the small
dedicated steer pump is pressurized, providing
6. To hydraulic tank
an efficient, energy-conservative system.

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Steering Gear

Steering Gear

Steering Wheel

Sequence Installation
1. Nut, washer To install, follow the reverse of the removal
sequence.
2. Wheel

Removal
Use a special tool.

Special Tool Part Number

Wheel puller 223-012-183

Wheel puller

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Steering System Raymond ® DSD Maintenance Manual

Steering Gear

Steering Gear

Sequence
! WARNING
1. Column & kick cover mounting hardware
2. Column & kick covers
Hydraulic pressure can cause
personal injury. Before any steering
3. Hoses, connectors and O-rings
system hydraulic lines or
4. Steer column mounting bolts components are disconnected, make
5. Steer column sure all hydraulic pressure is
6. Steer gear released in the steering system.
Move the steer wheels to the left and
right, then straight.

NOTE: For servicing the steer cylinder, see

“Steering Cylinder” on page 4-19.

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Raymond ® DSD Maintenance Manual Steering System

Inspection after Removal

Inspection after Removal

Inspect the grommets for cracks or tears in the
rubber or for signs of aging. Check the O-rings
for damage.

Installation
To install, follow the reverse order of the
removal sequence. Tighten bolts to the specified
torque.

2.9 ± 0.3 kgf•m

Tigntening torque
(20.9 ± 2.1 lbf•ft)
for bolts
[28.4 ± 2.9 N•m]

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Steering System Raymond ® DSD Maintenance Manual

Disassembly

Disassembly

Sequence
9. Centering springs
1. Mounting cap, cap screws, dust seal
2. Pressure seal 10. O-ring
11. Gerotor
3. Thrust races, thrust bearings & retaining
ring 12. O-ring
4. Spool 13. Housing
5. Long drive pin 14. O-ring
6. Drive tube 15. Tank plug
7. Short drive pin 16. Manual steering balls
8. Sleeve

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Raymond ® DSD Maintenance Manual Steering System

Working Rules and Tips

Working Rules and Tips IMPORTANT: Before you begin disassembly,

scribe a line across housing gerotor and
The steering gear, complete with the control mounting cap for reference alignment when
valve, is a precision-machined component. As reassembling the unit.
such, it must be handled with extreme care.
Cleanliness is imperative: work in a clean place 1. Remove the five cap screws and the end
and use clean tools. cap. Remove the dust and pressure seals
from the end cap using a thin-bladed
1. Clean the disassembled parts with a volatile screwdriver.
solvent such as trichlene or chlorobenzene,
2. Remove the O-ring from the groove in the
and dry them with compressed air. This
housing.
does not apply to rubber parts.
2. Oil seals, O-rings, and the like are rubber 3. Remove the Gerotor to gain access to the
other O-ring; remove.
parts. Never clean them with solvent. Blow
dirt off rubber parts with compressed air 4. Slide the Thrust Races and Bearing off the
and keep them immersed in a pool of spool.
hydraulic oil until they are ready for 5. Replace the worn components. See
reassembly. A rubber part showing even “Inspection after Disassembly” section.
slight wear and tear must be replaced.
Rubber parts are expendable components 6. Reassemble the components from items 1-3
that should be replaced once a year. per the instructions given in the
“Reassembly” section.
3. Parts to be installed by pressing or forcing
need special treatment. 7. Remove the Tank Plug using Special Tool
223-012-184.
a. Oil Seals
8. Remove and, if necessary, replace the
Oil seals, once removed, must not be O-ring.
reused. After disassembly, examine the
oil seals in place (in the gear box and
side cover). If they are in good
Inspection after Disassembly
condition, leave them in place. When 1. Check all mating surfaces. Replace any
installing a replacement oil seal, be parts that have scratches or burrs that
careful not to score or scratch the lip could cause leaks.
area.
2. Clean all metal parts in clean solvent. Blow
dry with air. Do not wipe dry with cloth or
Suggestions paper towels because lint or other matter
The Steer Gear is designed with very few can get into the hydraulic system and
serviceable components. Only disassemble the cause damage. Do not use a coarse grit or
steer gear if you plan to replace one of the try to file or grind these parts.
following:
1. Dust seal
2. Pressure seal
3. O-rings
4. Thrust race and/or bearings
If replacing these parts does not improve
performance, you must replace the entire steer
gear assembly. Refer to your Parts Manual for
ordering information.

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Steering System Raymond ® DSD Maintenance Manual

Reassembly

Reassembly

Sequence
10. Spool
1. O-ring
2. Tank plug 11. Sleeve
12. Centering springs
3. Housing
13. Short drive pin
4. O-ring
5. Gerotor 14. Drive tube
15. Long drive pin
6. Mounting cap
16. Retaining ring
7. Pressure seal
8. Dust seal 17. Thrust bearing and races
18. Cap screws
9. Manual steering balls

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Raymond ® DSD Maintenance Manual Steering System

Suggestions:

Suggestions: 1. Install O-ring (82.6 [3.25] OD) on tank plug.

2. Assemble tank plug into housing. Torque
NOTE: These instructions are more in depth
tank plug to 47.5 Nm [35 lb-ft].
than routine service should require.
DO NOT disassemble the steer gear 3. Install O-ring (82.6 [3.25] OD) into groove.
further than required to replace 4. Lay gerotor on the housing, lining up bolt
serviceable components. Doing so may holes, check alignment per scribed (mark)
result in replacing entire gear. line.
5. Install pressure seal into inside cavity of
mounting cap (25.4 [1.00] OD x 3.2 [0.12]
W).
6. Install dust seal (25.4 [1.00] OD x 3.2 [0.12]
W) into mounting cap.
7. Install manual steering balls (9) into spool.
Grease balls to retain in holes.
8. Insert spool into sleeve, lining up the spring
slots.
9. Insert smaller centering spring onto
spool/sleeve assembly.
10. Install larger centering spring onto
spool/sleeve assembly.
11. Insert shorter drive pin.
12. Install drive tube assembly, wider groove
downward.
13. Slide spool/sleeve/tube assembly into
housing bore, through the gerotor star.
Before spool/sleeve/tube reaches the tank
plug, line up pin slot in gerotor with pin slot
in drive tube, insert longer drive pin, then
continue to slide spool/sleeve/tube into
housing until the pin sets into the gerotor.
14. Install the retaining ring into groove on
spool.
15. Install bearing race-bearing-bearing race
onto the retaining ring.
16. Grease O-ring (82.6 [3.25] OD) and install
into mounting cap.
17. Carefully install mounting cap over spool so
as not to cut or damage seals. Lining up
bolt holes, check alignment per scribed
6 (mark) line.
18. Install 5 bolts. Torque to 23 Nm [200 in-lb].

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Steer Pump

Steer Pump
Removal

4
6

Sequence Suggestions
1. Motor mounting bracket
Removing the Motor and Pump
2. Motor mounting hardware Assembly
3. Motor
After disconnecting the steer pump hoses,
4. Pump mounting hardware motor cables, and harness leads, remove the
5. Pump pump and motor assembly by removing the
motor bracket mounting hardware where the
bracket is bolted to the frame.
Start By
1. Remove the battery. Removing the Pump
2. Remove the acid tray. Remove the pump from the motor.
3. Disconnect the cables and wires from the
steer pump motor. Mark the wire leads and Installation
cables so they can be correctly reconnected.
To install, reverse removal sequence.
4. Disconnect the hydraulic lines from the
pump.

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Disassembly

Disassembly

4
2

6 7

3
5
1

Sequence
5. Rotor and vanes
1. Cover and mounting bolts
2. O-ring 6. Retaining ring
7. Shaft and bearing
3. Spring and pressure plate
8. Body, O-ring, and seal
4. Ring and locating pins

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Steering System Raymond ® DSD Maintenance Manual

Working Rules and Tips

Working Rules and Tips Suggestions

The steer pump is a precision-machined
component and must be handled with extreme Removing the Motor and Pump
care. Cleanliness is imperative: use clean tools Assembly
and work in a clean place. Disconnect the steer pump hoses, motor cables,
1. Clean the disassembled parts with a volatile and harness leads. Remove the pump and
solvent such as trichlene or chlorobenzene motor assembly by removing the motor bracket
and dry them with compressed air. This mounting hardware where the bracket is bolted
does not apply to rubber parts. to the frame.

2. Oil seal, O-rings, and the like are rubber

parts. Never wash them with solvent. Blow Removing the Pump
dirt off rubber parts with compressed air Remove the pump from the motor.
and keep immersed in a pool of hydraulic
oil until they are ready for reassembly. A
Removing the Pump Cover
rubber part showing even slight wear and
tear must be replaced. Rubber parts are Remove the four bolts holding the rear cover on
expendable components and should be the pump. Remove the cover. Remove the O-ring
replaced yearly. located in the groove of the cover.
3. Parts to be installed by pressing or forcing
need special treatment.
Oil Seals
An oil seal, once removed, must not be
reused. After disassembly, examine the oil
seal in place (in the housing) and, if in
sound condition, leave it in place. When
installing a replacement oil seal, be careful
not to score or scratch its lip portion.

Removing the Spring

Lift the spring off the pressure plate.

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Suggestions

Removing the Pressure Plate Removing the Retaining Ring

Lift the pressure plate off of the ring and remove The shaft and bearing assembly is held in place
the two locating pins from the ring. by an internal retaining ring on the driven end
of the pump. Remove the retaining ring using a
standard retaining ring tool.

Removing the Rotor and Vanes

Remove the rotor and the vanes. Take care not
to lose any of the vanes. Retaining
Ring

Removing the Ring

Lift the ring off of the pump body.

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Steering System Raymond ® DSD Maintenance Manual

Inspection after Disassembly

Removing the Shaft and Bearing Inspection after Disassembly

1. Tap the end of the shaft very lightly to 1. Check all mating surfaces. Replace any
remove it from the pump body. Take parts that have scratches or burrs that
extreme care not to damage the end of the could cause leaks.
shaft.
2. Clean all metal parts in clean solvent. Blow
2. Remove the external retaining ring from the dry with air. Do not wipe dry with cloth or
shaft to allow removal of the bearing. Tap paper towels because lint or other matter
the end of the shaft very lightly to separate can get into the hydraulic system and cause
the bearing from the shaft. Take extreme damage. Do not use a coarse grit or try to
care not to damage the end of the shaft. file or grind these parts.

Removing the Seal and O-ring

1. Examine the shaft seal in place in the
housing. Remove it. Instead, use it as part
of the rebuilt unit. If there is any damage to
the seal, remove it and do not reuse it.
2. Remove the O-ring from the slot in the
body.

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Reassembly

Reassembly

Sequence Reassembling the Shaft Seal

1. Body and seal 1. Install the seal in the housing, orienting the
seal lip as shown. Take care not to damage
2. Shaft and bearing the seal during installation.
3. Retaining ring 2. The seal must be bottomed against the
4. Ring shoulder when installed.
5. Rotor and vanes
6. Pressure plate
7. Spring
8. Cover

Suggestions
NOTE: Replace all old seals with new seals.
Lubricate all seals with clean petroleum
jelly such as Vaseline.

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Steering System Raymond ® DSD Maintenance Manual

Reassembly

Reassembling the Shaft and Bearing Reassembling the Ring

Press the bearing onto the shaft and secure it Press the O-ring into the groove in the body.
with the external retaining ring. Place the ring on the body, aligning the bolt
holes and the pin holes. Install the two pins
through the ring and into the body.

Reassembling the Shaft and Body

Install the shaft and bearing assembly into the
body, taking care not to damage the shaft seal
during installation. Secure the shaft by
installing the retainer ring.
6

Reassembling the Rotor and Vanes

Slip the rotor over the splined portion of the
shaft. Insert a vane in each of the slots in the
rotor.

Retaining
Ring

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Inspection after Reassembly

Reassembling the Pressure Plate Reassembling the Cover

Install the pressure plate by slipping it over the 1. Press the O-ring into the groove in the
two pins cover. Place the cover on the ring and align
the four bolt holes. Take care to properly
orient the discharge port to its original
position prior to assembly.
2. Install and tighten the cover bolts.

Reassembling the Spring 6

Slip the spring over the spring seat of the

pressure plate.
4.8 to 6.2 kgf•m
Tightening torque
(35 to 45 lbf•ft)
for cover bolts
[47 to 61 Nm]

Inspection after Reassembly

Check the pump for smooth, free rotation.
Check for leaks after reinstallation in the truck.

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Inspection after Reassembly

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Raymond ® DSD Maintenance Manual Hydraulic System

Hydraulic System 7:

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Hydraulic System Raymond ® DSD Maintenance Manual

Hydraulic System

Hydraulic System

Description
Schematic for Trucks

1. Hydraulic tank General Information

2. Hydraulic lift pump The hydraulic pump draws oil from the oil tank
3. Steer pump and delivers it to the main control valve, where
it is dispensed for lift and tilt functions.
4. Steer gear
5. Main control valve The steer gear is covered on page 6-3. The steer
pump is covered on page 6-10. The steering
6. Flow regulator valve cylinder is covered on page 4-19.
7. Down safety valve
8. Lift cylinder
9. Tilt cylinder
10. Steering cylinder

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Hydraulic Tank

Hydraulic Tank

1. Cap General Information

2. Oil level gauge
The tank contains internal filtering means
3. Drain plug including a strainer on the suction line and a
filter on the return line.
4. Return line filter
5. Suction line strainer The lift cylinder return pipe allows the cylinders
to draw fluid when they retract, providing the
6. Lift cylinder pipe bore walls with oil which inhibits corrosion.

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Hydraulic System Raymond ® DSD Maintenance Manual

Hydraulic Pump

Hydraulic Pump

General Information
This gear pump is capable of developing very
high pressure on its discharge side. A special
arrangement is incorporated in the pump
construction for the purpose of keeping the side
clearances minimized between bushings on the
one side and pump gears on the other. Note, in
illustration 203585 (page 7-5), that discharge
pressure is applied to the back of each bushing
through internal oilways.

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Hydraulic Pump

Hydraulic Pump Operation Pressure Loading Principle

Essentially the pump consists of two gears—the This pump is a self-balanced type based on the
drive gear and the driven gear—closely fitted in principle of pressure loading, balancing for
the housing. The oil is carried around the equal pressure on all sides of the revolving gear.
periphery of the revolving gears from the This reduces bushing and gear wear. In
suction to the discharge side. The teeth operation, the high-pressure oil on the
meshing between the two gears prevents the discharge side is fed back to the suction side.
return of oil from the discharge to the suction On the suction side, pressure is exerted equally
side. on both sides of the gears and shafts, thereby
cancelling out unequal pressure to balance the
pump.
Driven Gear

Clearance

Drive Gear

203585

Discharge side

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Control Valve

Control Valve

7 8

1 9

3
12

11 5 10

1. Inlet spool General Information

2. Lift spool The control valve consists of three valve blocks,
3. Tilt spool all spool-type. The spools are finished by
lapping for their respective blocks and their
4. Auxiliary attachment spool
combination should not be changed. The lift
5. Flow control screws valve assembly has a built-in load check valve.
6. Pump port The tilt valve spool has a built-in tilt lock valve.
When necessary, the attachment valve
7. From steering control valve assembly has a built-in overload relief valve. If
8. To tank the overload relief valve is not used, a shutoff
valve is installed.
9. Main relief valve, auxiliary valve
10. Tie bolt
11. Nut
12. Switches

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Lift and Tilt Cylinders

Lift and Tilt Cylinders

General Information
The left and right lift cylinders are single-acting
type.
The left and right tilt cylinders are
double-acting type. The piston rod carries a
screw-on socket. The socket is repositioned as
necessary by turning when the cylinder is
connected to the outer mast. This feature allows
the tilt cylinders to move in unison.
The tilt angle is increased or decreased with the
spacer and shim of each cylinder.

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Flow Regulator Valve

Flow Regulator Valve

From control valve To control valve

To lift cylinder From lift cylinder

General Information
The flow regulator valve is located between each
lift cylinder and control valve. It limits the flow
of oil forced out of the cylinder when the loaded
forks are lowered to keep a safe constant
lowering speed regardless of load.

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Down Safety Valve

Down Safety Valve

Burst

Normal When hose burst

7

General Information
The down safety valve is built in the oil pipe
joint at the bottom end of the lift cylinder. This
valve is internally provided with an orifice to
prevent stress when the valve is closed. In the
valve having no orifice, the oil leaks around the
valve to prevent shock.

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Down Safety Valve

Valve Types
Down safety valves are available in six types
differing in terms of shutoff flow and identified
by the number punched on the flat (indicated
as “a” on illustration 201731A). The numbers
are: 50, 70, 90, 100, 120, and 150. No. 90 and
No. 120 valves each come in two kinds differing
in screw thread size.

Dual-stage full Triple-stage full

free-lift panoramic free-lift panoramic
Dual stage
Truck
panoramic
1st lift 2nd lift 1st lift 2nd lift
cylinder cylinder cylinder cylinder

DSD30-35 70 90 70 90 70

DSD40-5E 70 120 70 120 70

DSD60 90 90 120 120 90

201731A
Top View:
• Dual-stage panoramic lift cylinder
• Dual-stage full free-lift panoramic, 1st and
2nd cylinders
• Triple-stage full free-lift panoramic, 2nd lift
cylinder
Bottom View:
• Triple-stage full free-lift panoramic 1st lift
cylinder

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Removal and Installation

Removal and Installation

! WARNING
Hydraulic oil under pressure can
remain in the hydraulic system after
the truck and pump have been
stopped. To avoid personal injury,
this pressure must be released
before any work is done on the
hydraulic system.

To prevent possible injury, lower the

lift bracket to the ground, turn the
truck OFF, and move the control
levers to make sure all hydraulic
pressure is released before any
fitting, plug, or hose is loosened,
tightened, removed, or adjusted.

Always move the lift truck to a clean

and level location away from the
path of other machines.

Make sure that no personnel are

near the lift truck when it is running
and tests or adjustments are being
made.

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Hydraulic Pump

Hydraulic Pump
Removal

Sequence Start By
1. Hardware 1. Disconnect the battery from the truck.
2. Pump 2. Disconnect the hoses attached to the pump
fittings.
3. Disconnect the power cables and wire leads
from the pump motor.
4. Raise the truck enough to allow the pump
and motor assembly to be removed from
below the truck. Make sure that the truck
is stable in the raised position.
5. Secure the motor from above with a crane,
hoist, or other adequate device, or support
it at its center with a garage jack.
6. Remove the motor and pump assembly
from the truck.
7. Remove the hydraulic fittings from the
pump.

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Installation

Installation
1. To install, follow the reverse sequence of
the disassembly procedure. Before
installing hydraulic fittings in the pump,
inspect all O-rings for damage or aging and
replace them as required.
2. Tighten hose to the following specifications.

Tightening Torque for Hose

DSD30–35 DSD40–60

Supply hose
from pump 6.5 ± 0.7 kgf•m 10.3 to 11.7 kgf•m
to mast (48 ± 5 lbf•ft) (74 to 85 lbf•ft)
operating [65 ± 7 N•m] [101 to 115 N•m]
valve

3. Lube pump splines before installing into

pump motor. Use molybdenum disulfide
grease.

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Disassembly – Premium Pump

Disassembly – Premium Pump

1 3

9
7

Sequence Start By
1. End cover Externally clean the pump to make sure that it
is free of all matter that may contaminate the
2. O-ring, bush seal, and backup seal
pump parts during disassembly, inspection, or
3. Flange reassembly.
4. Shaft seal and retainer ring
5. O-ring, bush seal, and backup seal
6. Front bushes
7. Drive shaft
8. Gear pack
9. Body and rear bushes

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Disassembly – Standard Pump

Disassembly – Standard Pump

2
8

7 5 3

9
6

Sequence Working Rules and Tips

1. End cover The hydraulic pump is a precision-machined
component and as such must be handled with
2. O-ring, bush seal, and backup seal
extreme care. Cleanliness is imperative: use
3. Flange clean tools and work in a clean place.
4. Shaft seal and retainer ring 1. Clean the disassembled parts with a volatile
5. O-ring, bush seal, and backup seal solvent such as trichlene or chlorobenzene
and dry them with compressed air. This
6. Front bushes does not apply to rubber parts.
7. Drive shaft 2. Oil seals, O-rings, and the like are rubber
8. Gear pack parts. Never clean them with solvent. Blow
dirt off rubber parts with compressed air,
9. Body and rear bushes
and keep them immersed in hydraulic oil
until they are ready for reassembly. A
rubber part showing even slight wear and
tear must be replaced. Rubber parts are
expendable items that should be replaced
once a year.
3. Parts that are installed by pressing or
forcing need special treatment.
Oil Seal
An oil seal, once removed, must not be
reused. After disassembly, examine the oil
seal in place (in the pump flange) and, if in
good condition, leave it in place. When
installing a replacement oil seal, be careful
not to score or scratch its lip portion.

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Suggestions

Suggestions Removing the Shaft Seal

Remove the internal retaining clip in the front of
Removing the End Cover the flange. Push the shaft seal squarely out of
1. Lightly mark the end cover, pump body, the mounting flange.
and mounting flange to ensure proper
reassembly.
2. Remove the rear bolts, spring washers, and
the end cover.

Removing the Seals

Remove the O-ring from the pump body.
Remove the bush seal and the backup seal from
the rear bushings.

Removing the O-ring and Seals

Remove the O-ring from the groove in the body
of the pump. Remove the bush seal and the
backup seal from the front bushings.

Removing the Flange

Turn the unit over and lightly tap the mounting
flange to disengage it from the locating dowels.
Slide the flange squarely off the shaft.

Removing the Bushings

Before removing the internal components, mark
the bushings to denote the location in the body
on a plain area away from the seal location
mark.

FD = Bush on flange end of the drive shaft

FI = Bush on flange end of idler shaft
7 Bush on the cover of priority valve
CD =
end of the drive shaft
Bush on the cover end of the idler
CI =
shaft

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Suggestions

Removing the Drive Shaft

With the unit lying on its side, hold the drive
shaft and pull it squarely out of the body,
bringing with it the bushings and the complete
gear pack.

Separating the Gear Pack

1. Separate the gears, key, and balance plate
from the drive shaft and driven idler shaft.
2. Note the position of the balance plate to
ensure proper location during reassembly.

Removing the Rear Bushes

Remove the remaining rear bushes from the
body bore.

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Inspection after Disassembly

Inspection after Disassembly 2. Often, the tips of the opposing gears have
wiped an overlap in a half-moon shape.
There must be no noticeable wear step as it
Body is critical that the bush side face and
1. Inspect the body bore cut-in where gears balance plate are completely flat to the gear
wipe into the body. side face.

2. The body can only be reused if the cut-in is 3. The bush bearing liners are acceptable if
bright and polished in appearance and the they are not scored or do not show other
depth does not exceed 0.08 mm. damage. The general outside area of the
bush should not show any prominent signs
3. Replace the body if the surface is scored, of wear.
has a matte appearance, or shows signs
that the tips of the gears have dug in and
torn away the surface material. Gears
4. Inspect the body to ensure that there is no 1. Examine the gear side faces for bushing or
superficial damage which may adversely scoring. Often operation on contaminated
affect performance or sealing. Pay fluid shows scoring between the root of the
particular attention to the port threads and gear and the journal, which leaves a wear
body O-ring seal recesses. step. If a wear step can be felt, coincidental
with the root diameter, by drawing a
Mounting Flange Face sharp-pointed tool across the surface from
the journal outwards towards the tip of the
1. Inspect the inner surfaces to ensure that gear, then the gear must be replaced.
there is no unusual wear or scoring in the 2. Carefully examine the gear teeth to ensure
regions where the body O-rings and bush that there are no signs of bruising or
seals contact that could result in external pitting.
leakage.
3. The journal bearing surfaces should be
2. Check the shaft seal recess for scoring or completely free from scoring or bruising.
damage that could result in oil leakage The surface should be highly polished and
around the outer diameter of the shaft seal. smooth to the touch.
A replacement shaft seal can be refitted with
Loctite hydraulic sealant to overcome slight 4. Examine the area where the shaft seal lips
damage in this area. run on the drive shaft. This shows up as
polished ring or rings. If a noticeable groove
can be felt, or if there is scoring, replace the
Bushes and Balance Plate shaft.
1. The side faces that abut the gears should 5. Examine drive keyway in driveshaft journal
be perfectly flat and show no signs of extension to ensure it is not damaged or
scoring. Characteristically there are bright chipped.
polished areas on this surface caused by
loading against the gear side faces. This is 6. If the driveshaft is not damaged from the
often more pronounced on the low-pressure drive coupling and the gears are not
side. Replace these if there is any general harmed as described above, then the gears
scoring or fine scoring with a matte can be reused. If the gears are damaged,
appearance or tearing of the surface replace them as a matched set.
material. 7. As a matter of good practice, when pumps
are dismantled, replace all the seals.

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Reassembly – Trucks with Standard Hydraulic Pump

Reassembly – Trucks with

Standard Hydraulic Pump

2
8

7 5 3

9
6

Sequence Start By
1. End cover Ensure that all parts are perfectly clean.
Lubricate the bushes and gears with clean
2. O-ring, bush seal, and backup seal
hydraulic fluid. Ensure that the O-ring recess
3. Flange and end faces of the body remain dry. This will
4. Shaft seal and retainer ring assist the assembly of the components with the
body bores.
5. O-ring, bush seal, and backup seal
6. Front bushes
7. Drive shaft
8. Gear pack
9. Body and rear bushes

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Reassembly – Trucks with Premium Hydraulic Pump

Reassembly – Trucks with

Premium Hydraulic Pump

1 3

9
7

Sequence Start By
1. End cover Ensure that all parts are perfectly clean.
2. O-ring, bush seal, and backup seal Lubricate the bushes and gears with clean
hydraulic fluid. Ensure that the O-ring recess
3. Flange and end faces of the body remain dry. This will
4. Shaft seal and retainer ring assist the assembly of the components with the
body bores.
5. O-ring, bush seal, and backup seal
6. Front bushes
7. Drive shaft
8. Gear pack
9. Body and rear bushes

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Start By

Reassembling the Rear Bushes Fixturing with the End Cover

1. Install the rear bushes (marked CD and CI) Use the end cover to temporarily fixture the
into the undowelled end of the body. parts as they are reassembled. Place the end
cover on its back and set the undowelled end of
the body against it so that the dowels are
pointing up.

Reassembling the Balance Plate

1. Hold the driveshaft and driven gear of the
idler shaft together and refit the balance
plate in its original position.
2. The two grooves in the plate must be to the
low-pressure side of the pump (the side
where the body bores meet in a point). With
the drive shaft nearest to you, these grooves
7 will be on the left-hand side as shown for
the counterclockwise rotation.
2. The C-shaped cutout in the bushes must be
to the side of the body with the cusp
removal flat.
3. The diagram below shows the location of
the driveshaft and the front bushes and
seals installed.

Flange end
Location
dowels

Cusp
Removal
7

Inlet

Position of
driveshaft

Counterclockwise Rotation

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Start By

Reassembling the Gear Pack Reassembling the O-ring and Seals

1. Fit the key into the keyway in the driveshaft 1. Fit a new O-ring, bush seal and backup
and then carefully fit the gear over the key. seal, ensuring that the seals locate correctly
Fit the second gear on the idler shaft. in the seal grooves.
2. Keeping the gear pack together, carefully feed
the assembly into the body bores with the
driveshaft positioned as previously shown.

Premium pump
configuration

7
7

Reassembling the Shaft Seal

1. Fit a new shaft seal into the recess in the
mounting flange with the “garter” spring
facing into the pump.
2. If the seal recess was scored, then Loctite
hydraulic sealant must be applied to the
outer diameter of the seal.
Standard pump configuration 3. Apply a coat of high-melting-point grease to
7 the shaft seal lips.

Reassembling the Front Bushes 4. Reinstall the retaining ring. Ensure that it
is located in its groove.
Refit the front bushes (FD and FI) into their
original bores, remembering that the C-cutout
must be to the side of the body with the cusp
removal flat. They must match the rear end
bushes.

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Start By

Reassembling the Flange Reassembling the End Cover

Slip the shaft seal and flange assembly over the Replace end cover and refit the bolts and
driveshaft and carefully refit the mounting washers. Tighten the bolts.
flange, ensuring that it is positioned squarely
onto the dowels in the body.

End
cover

Reassembling the Rear O-ring and Seals DSD30–35 DSD40–60

1. Hold the whole unit together and carefully Tightening 4.7 to 5.2 kgf•m 9.0 to 10.4 kgf•m
turn it over. Ensure that it is supported on torque (34 to 38 lbf•ft) (65 to 75 lbf•ft)
for bolts [46 to 51 N•m] [88 to 102 N•m]
the mounting flange, not the driveshaft.
2. Remove the end cover and install a new
O-ring, bush seal, and backup seal. NOTE: Lube splines before installing in pump
motor. Use molybdenum disulfide
grease.

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Inspection after Reassembly

Inspection after Reassembly wipings from the body cut-in can be arrested by
filters.
Pour a small amount of clean hydraulic fluid
into a port and check that the shaft can be It is recommended that, initially, the unit is
rotated without undue force using a run-in at 1500 rpm at zero pressure for one
smooth-jawed vise. minute. Increase the pressure in intervals of 35
bars a minute until maximum pressure is
reached. Check the system temperature
Running In After Reassembly frequently, ensuring that it does not exceed the
A unit which has been reassembled with either maximum permissible temperature of 80°C. If
new gears, bushes, or body, must be carefully the temperature exceeds the system or unit
run-in before it is subjected to full working specification, the test must be delayed and
conditions. operated off-load until the temperature is
lowered to an acceptable range. Typical pump
Ideally, this should be done on a test rig, where
ratings are shown in the table below.
pressure can be applied gradually and any

Typical performance applicable when using

ISOVG 32 at 40°C (104°F)

Max.
Pump Part Test Flow
Continuous
Number Speed Rate
Pressure

[185 bar]
1500 9.11 GPM
223-011-756 (2683 psi)
rpm 34.5 l/min
204 kg/cm2

[190 bar]
1500 9.91 GPM
223-011-758 (2755 psi)
rpm 37.5 l/min
209 kg¤/cm2

[247 bar] 11.49

1500
223-011-938 (2900 psi) GPM
rpm
220 kg/cm2 43.5 l/min

[185 bar] 11.49

1500
223-011-520 (2683 psi) GPM
rpm
204 kg/cm2 43.5 l/min

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Control Valve

Control Valve
Removal

Sequence Start By
1. Auxiliary lines, connectors, and O-rings 1. Remove the floorplates and the dashboard
cover.
2. Steering return hose and connector
3. Lift pipe 2. Tilt the mast to vertical position, lower the
forks all the way, and relieve the pressure
4. Delivery hose, connector, and O-ring in the hydraulic lines.
5. Tilt lines, connectors, and O-rings 3. Disconnect the battery.
6. Return hose 4. Disconnect the wire leads to the valve
7. Control valve switches.

8. Switches

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Installation

Installation

1. To install, follow the reverse of the

disasembly sequence. Before installing Tightening Torque for Hoses
hydraulic fittings in the pump, inspect all
25 ± 0.5 N•m
O-rings for damaging or aging and replace
A Tilt hoses 2.5 ± 0.5 kgf•m
them as required.
18 ± 3.6 lbf•ft
2. Tighten hoses to the specifications shown
in the chart. 65 ± 7 N•m
Delivery hose
B 6.5 ± 0.7 kgf•m
DSD30–35
47 ± 5.1 lbf•ft
100 ± 10 N•m
Delivery hose
C 10 ± 0.1 kgf•m
DSD40–60
72 ± 7.21 lbf•ft
50 ± 7 N•m
D Left Pipe 5.0 ± 0.7 kgf•m
36 ± 5.1 lbf•ft
48 ± 5 N•m
E Aux. Hoses 5.0 ± 0.5 kgf•m
32.6 ± 3.6 lbf•ft
25 ± 5 N•m
Steer Gear
F 2.5 ± 0.5 kgf•m
Return Hose
18 ± 3.6 lbf•ft
100 ± 10 N•m
G Return Hose 10 ± 0.1 kgf•m
72 ± 7.2 lbf•ft

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Disassembly

Disassembly

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Disassembly

Sequence 37. O-ring

38. Cap screws
1. Aux relief valve
2. Main relief valve 39. Cap
40. Switch assy
3. Tie rod nuts
41. Screws
4. Tie rod nuts
5. Second auxiliary spool section 42. Seals
43. Plugs
6. Spring and poppet
44. O-rings
7. O-ring
8. Cap screws 45. Connector

9. Cap 46. Inlet section spool

47. Plug
10. Switch assy
48. O-ring
11. Screws
12. Seals 49. Plug
50. O-ring
13. Flow control screw
51. Tie rods
14. Seals
15. Auxiliary spool section NOTE: Do Not remove spools from housing!

16. Spring and poppet

Suggestions
17. O-ring
18. Cap screws Main Relief Valve
19. Cap NOTE: To remove main relief valve for cleaning
20. Switch assy or inspection, loosen its plug. Loosening
the lock nut will disturb the pressure
21. Screws setting.
22. Seals
Do not remove the main relief valve unless it is
23. Flow control screw bad. This also applies to the shut-off valve
24. Seals assembly.

25. Tilt spool section

26. Spring and poppet
Plug
27. O-ring
28. Cap screws
29. Cap
30. Switch assy
31. Screws Lock nut

32. Seals
33. Flow control screw
34. Seals
7
35. Lift spool section
36. Spring and poppet

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Reassembly

Auxiliary Relief Valve c. Place first spool section (O-ring side

up) on inlet section, position O-ring
NOTE: To remove auxiliary relief valve for and insert load check poppet (nose
cleaning or inspection, loosen its plug. down) and spring (behind poppet) into
Loosening the lock nut will disturb the the load check cavity as shown. Repeat
pressure setting. this procedure for each spool section;
Do not remove the auxiliary relief valve unless it the load check springs are compressed
is bad. This also applies to the shut-off valve by the following sections during
assembly. assembly.
d. Position end section on last spool
section and hand tighten tie rod nuts.
Plug The end section is a “turn around”
section without ports. Universal
outlet/power beyond section and
power beyond and closed center
sections are also used as end sections.
These end sections do not have O-ring
grooves.
Lock nut
e. Position valve assembly with the
mounting pads of the end sections on
a flat surface. To obtain proper
alignment of end sections relative to
the spool sections apply downward
7
pressure to the end sections; snug tie
Reassembly rod nuts to about 10 ft-lb.
Final torque the two 1.2” nuts to 14
Before Reassembly;
ft-lb; final torque the 9¤16” nut to 33
1. Wash all parts except for O-rings with ft-lb. Check for proper spool
solvent. movement.
2. Apply hydraulic oil to O-rings when f. Install auxiliary valves and plugs and
installing them. torque to proper specifications.
3. Make sure that each spool moves freely.
a. Lay out valve components on a clean,
flat working surface. The inlet
assembly will include an O-ring, and
the spool sections include an O-ring, a
load check poppet and a load check
spring. Tools required for basic valve
assembly include 1/2” and 9/16” open
or box end wrenches and a torque
wrench with thin wall sockets.
b. Assemble tie rod nuts to one end of
each tie rod with one or two threads
showing. Insert rods through tie rod
holes of inlet (larger tie rod at top). Lay
inlet on end with tie rods up, place
O-ring into position.

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Lift and Tilt Cylinders

Lift and Tilt Cylinders

Lift Cylinder Removal

5
2

Sequence
1. Hose guard
2. High-pressure hose
3. Set bolt and shims
4. Cylinder clamp (cushion, collar, and shims)
5. Lift cylinder and bracket

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Suggestions

Suggestions Removing Set Bolts

1. Removing hose guard: 1. Remove the set bolt at the top of each lift
cylinder. Lift the inner mast to separate the
With the lift bracket raised to the maximum cylinder rod ends. To lift the inner mast,
height, remove each hose guard from the clove-hitch a sling to the mast with
front side of the mast. protective wad.

! CAUTION
Be careful not to touch the lift control
lever.

2. Lowering lift bracket:

Lower the lift bracket by carefully operating
the lift control lever.
3. Disconnecting high-pressure hoses:
Disconnect the high-pressure hoses at the
joints indicated by arrows. Use a container
to catch oil flowing out of the hoses.
7

NOTE: The rod end of either lift cylinder is

Left-hand cylinder Right-hand cylinder shim-adjusted to eliminate the
difference in stroke between the
cylinders. Before removing the stopper
bolts, record the number of shims and
the cylinder to which the shims are
fitted.
2. Place solid blocks under the inner mast and
detach the sling. Use blocks strong enough
to support the mast.

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Lift Cylinder Installation

Removing Lift Cylinders Lift Cylinder Installation

Attach a lift sling to the lift cylinder from the To install, reverse the removal sequence and do
rear side of the mast and remove the cylinder. the following steps.
Attach the sling before removing the cylinder
clamp. 1. Extend and retract the lift cylinders several
times under no-load conditions to expel air
from the cylinder circuits and to make sure
the cylinders move smoothly.
2. Check the oil level in the hydraulic tank
with the oil level gauge.
3. Check that the lift height is correct.
4. After the lift cylinders or piston rods have
been replaced, check for difference in
stroke between the two cylinders (refer to
Mast and Forks).

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Tilt Cylinder Removal

Tilt Cylinder Removal

1 3

Sequence Suggestions
1. Tilt socket pin (spacer) 1. Retracting piston rod:
2. Rubber hose (O-ring) Remove tilt cylinder pin (item 1), and
retract the piston rod all the way.
3. Cylinder pin (spacer)
4. Tilt cylinder 2. Disconnecting hoses:
Disconnect hoses (item 2) from the cylinder
Start By: at the connectors. Use a container to catch
oil from flowing out of the cylinder. Attach
1. Lower the forks all the way and tilt the mast caps to the connectors of the cylinder to
fully forward. protect the threads of the connectors and to
2. Hitch lifting slings to the top crossmember prevent oil from flowing out of the cylinder
of the outer mast by passing them through when the cylinder is removed.
the round holes. Take up the weight of the
mast with a hoist.

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Hydraulic System Raymond ® DSD Maintenance Manual

Tilt Cylinder Removal

Suggestions

Removing Tilt Socket

Later Version

! WARNING
When removing both tilt cylinders at
the same time, make sure that the
mast is held either by a hoist or is
securely supported and held in place
by blocks.

1
4

2
3

1. Rubber hose
2. Tilt socket pin, bolt, washer
3. Tilt cylinder pin, bolt, washer
4. Tilt cylinder
NOTE: When replacingt the tilt cylinders, it is
necessary to adjust the cylinder stroke
and tilt.

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Lift Cylinder Disassembly

Lift Cylinder Disassembly

Sequence Suggestions
1. Bracket assembly
Removing Piston Rod
2. Holder, wiper ring, U-ring, and O-ring
Draw the piston rod out gently, taking care not
3. Bushing and bearing to damage the sealing members fitted to the
4. Piston rod, snap ring, holder, U-ring, nylon piston.
heel, and piston ring
5. Cylinder tube

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Hydraulic System Raymond ® DSD Maintenance Manual

Tilt Cylinder Disassembly

Tilt Cylinder Disassembly

✱ Parts contained in seal kit

4

1
7

Sequence Suggestions
1. Tilt socket, bushing, bolt, washer, nut, and
grease fitting Removing Bushing
2. Bushing, O-ring, dust seal, packing and 1. Wrap the cylinder with a wad of cloth and
buffer ring hold it in a vise. Using a wrench, remove
the bushing from the cylinder.
3. Piston rod, piston seal, and nut
2. When removing the bushing from the
4. Cylinder tube and bushing piston rod, be careful not to rub the buffer
NOTE: Do not remove the tilt socket and ring, packing, etc., against the threads of
cylinder tube bushing unless they are the piston rod.
damaged.

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Flow Regulator Valve

Flow Regulator Valve

Disassembly

1
5

Sequence Inspection after Disassembly

1. Lock nut 1. Check the springs for fatigue.
2. Plug and O-ring 2. Check the valve seats for damage. Check
the sliding surfaces for evidence of binding
3. Spring and shims
and repair as necessary.
4. Piston, pin, washer, spring, and valve
3. Check the sliding surfaces of the piston and
5. Valve body valve body for damage.
NOTE: Replace the flow regulator valve as an
assembly if any part is malfunctioning
or damaged.

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Inspection after Disassembly

Inspection after Disassembly Precautions for Reassembly

1. Wash all parts clean, making sure that each
Lift and Tilt Cylinders part is clear of any gritty particles.
2. Before inserting the piston rod complete
Cylinder Tube with the piston, apply hydraulic oil to the
1. Check the bore wall for wear, grooving, bore wall of the cylinder tube and to the
scratch marks, and rusting. sealing parts: O-rings, U-rings, wiper rings,
nylon heels, piston seals, dust seals, and
2. Check the welds for cracks. packings—so they will slide smoothly into
the bore.
Piston Rod
3. When clamping the cylinder tube in the vise
1. Check for deflection in the manner shown. in order to run the head into the cylinder
tube, be careful not to distort the tube #4
and #117. Before fitting the piston seal to
the tilt cylinder piston, squeeze the seal by
hand 5 or 6 times to soften it. Hold the
piston steady by clamping the rod in a vise
and apply a small amount of hydraulic oil
to the seal. Fit a portion of the seal to the
groove and push the rest of the seal into
place a little at a time until the seal is in the
groove.
4. Be sure to torque the nut, not the bolt when
re-installing the tilt cylinder.
Torque to 108 to 118 N•m; 11 to 12 kgf•m.
7

2. Check for surface flaws such as grooving,

scratch marks, rusting, and wear. Replace
the rod if its threads show signs of stripping
or any other damage.

Packings and Rings

1. Check the packings and the lips of dust
seals for damage, distortion, and
deterioration due to aging.
2. Check each ring for deterioration due to
7
aging.

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Inspection and Adjustment

Inspection and Adjustment

Hydraulic Tank Hydraulic Tank Refill Capacities

Hydraulic Oil
DSD30 – 35 DSD40 – 50 DSD5E – 60
1. Check the hydraulic oil in the tank for
cleanliness. Oil appearing dirty or whitish 18 (4.8) 24 (6.3) 30 (7.9)
(showing more or less emulsification) must
Unit: liter (U.S. gal)
be changed.
2. Refill capacities in the amount of oil NOTE: A general rule: in any lift truck,
required. regardless of the mast-and-attachment
combination, the oil level should not be
above the “H” mark on the level gauge
! WARNING when the mast is all the way down.
Remove the hydraulic tank filler cap
Suction Strainer
only after the truck has been stopped
and the fill cap is cool enough to Check the suction strainer for clogging or
remove with your bare hand. damage.

Return Filter
Check the return filter for clogging or damage.

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Control Valve

Control Valve 2. Quickly disconnect the oil return hose and

start collecting the oil coming out of the
valve from the oil return port A.
External Leakage
1. Check for oil leaks from the joint between
adjacent valve housings sealed by O-ring. A

2. Check for oil leaks from the scrapers sealed

by O-rings.
3. Check for oil leaks from the screw
connections.

Internal Leakage
It is not practical to check the control valve
alone for internal leakage. The correct way to
check the control valve in place under normal 7
operating conditions follows.
The internal leakage to be checked includes Amount of oil collected 500 cc (30.5 cu. in.)
leakage occurring at the lift spool, tilt spool, tilt for 15 minutes maximum
lock valve, and check valves.
[Test oil temperature: approx. 50°C (122°F)]
3. If the tilt cylinders or lift cylinders drift (the
1. Pick up a load equal to the rated capacity. mast tilts forward or the fork lowers)
Lift it approximately 1 meter (3 ft) high. Tilt excessively even though the amount of oil
the mast forward 3° to 4° and stop the collected in 15 minutes is less than 500 cc
truck. (30.5 cu. in.), measure the internal leakage
of each cylinder. (The measurement is the
assembly standard and not the service
3° to 4° limit.)

approx.
1 meter
(3 feet)

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Main Relief Valve Adjustment

Main Relief Valve Adjustment Auxiliary Relief Valve Adjustment

1. Screw in special tool (223-012-197) 1. Screw in special tool (223-012-197)
pressure port with O-ring into delivery hose pressure port with O-ring into delivery hose
port on valve (B). port on valve (B).
2. Attach a pressure gauge capable of 2. Attach a pressure gauge capable of
measuring up to 250 kgf•cm2 (3555 psi) measuring up to 250 kgf•cm2 (3555 psi)
[25,000 kPa] to the pressure port. [25,000 kPa] to the pressure port.
3. Start the truck and move the control lever 3. Start the truck and move the Auxiliary 1
to the backward tilt position and hold. If the control lever to the far right position and
relief pressure reading is hold. If the relief pressure reading is
185 ± 5 kgf/cm2 158 ± 5 kgf/cm2
(2631 ± 71 psi) (2250 ± 71 psi)
[18,142 ± 490 kPa] [15,513 ± 490 kPa]
when the tilt cylinders reach the end of the auxiliary relief valve setting is correct.
their stroke, the main relief valve setting is
correct.
B

Auxiliary
relief valve
Main relief 7
valve 4. If the setting is incorrect, loosen the lock
7
nut of the adjusting screw and, while
4. If the setting is incorrect, loosen the lock observing the pressure gauge reading,
nut of the adjusting screw and, while slowly turn the adjusting screw in either
observing the pressure gauge reading, direction until the gauge indicates the
slowly turn the adjusting screw in either prescribed set value.
direction until the gauge indicates the
5. While holding the adjusting screw, tighten
prescribed set value.
the lock nut to secure the adjusting screw.
5. While holding the adjusting screw, tighten
6. After securing the adjusting screw, recheck
the lock nut to secure the adjusting screw.
the setting.
6. After securing the adjusting screw, recheck
the setting.
158 ± 5 kgf/cm2
Auxiliary relief
(2250 ± 71 psi)
valve setting
185 ± 5 kgf/cm2 [15,513 ± 490 kPa]
Main relief
(2631 ± 71 psi)
valve setting
[18,142 ± 490 kPa]

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Lift and Tilt Cylinders

Lift and Tilt Cylinders Lift Cylinder Stroke Adjustment

1. Slowly raise the inner mast and check the
Mast Tilt Angle Adjustment stopping manner of the left and right piston
rods at the moment the inner mast reaches
1. Place machine in a horizontal position. its maximum lift height.
2. Tilt the mast all the way backward, and
stop the truck.
3. Measure the tilt angle of the mast at both
sides.
4. To adjust the tilt angle, loosen bolt A of the
tilt cylinder socket, and adjust the cylinder
stroke by turning the rod on either cylinder
so that there is no difference in stroke
between the cylinders.

2. If the top of the mast rocks at that moment,

it should be adjusted with shims. Abnormal
conditions will appear as a time lag in
7
stopping between right- and left-hand
piston rods and rocking of the rod with a
127 to 152 longer cylinder stroke.
Tightening torque for tilt
(13 to 15.5)
cylinder socket bolt
[94 to 112]

NOTE: It is not necessary to adjust the forward

tilt angle, provided that the backward
tilt angle is properly adjusted.

Forward/backward tilt angle 5° to 6°

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Adjusting Method

Adjusting Method Flow Regulator Valve

1. Raise the inner mast, place solid blocks Measure the lowering speed with rated load. If
under the right and left sides of the mast, the speed is out of specification, repair or
and lower the mast until it rests on the replace the flow regulator valve. For the
blocks. specification of lowering speed, refer to
page 10-15.

2. Remove the stopper bolt at the top of the lift 7

cylinder which stopped first, retract the
piston rod, and insert the shims at the top
of the piston rod end.

Stopper bolt

Shims

NOTE: To retract the piston rod, move the lift

control lever to the lowering position to
let the oil escape from the lift cylinder.
3. Extend the piston rod and tighten the
cylinder stopper bolt. Remove the blocks
from under the inner mast.
4. Slowly lower the inner mast all the way to
make sure that the piston rods move
smoothly.

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Testing

Testing Tilt Cylinder Drift Test

1. Pick up a load equal to the rated value, tilt
Lift Cylinder Drift Test the mast to the vertical position, raise the
1. Pick up a load equal to the rated value, tilt forks about 50 cm (20 in.) and stop the
the mast to the vertical position, raise the truck.
forks 1 to 1.5 m (3.3 to 4.9 ft) and stop the 2. Measure the drift extension of the tilt
truck. cylinder for (extension) 15 minutes.
2. Scribe a line on the mast column and
measure the drift of the lift cylinder (drop
for 15 minutes).

DSD30–35 DSD5E DSD60

Tilt cylinder
20 (0.8) 15
7
drift 22 (0.9)
max. (0.6)
(rated load)

Unit: mm (in.)/15 min

DSD30 – 5E DSD60

Lift cylinder drift 50 (2.0)

40 (1.6)
(rated load) maximum
Piping
Unit: mm (in.)/15 min
1. Check each hydraulic circuit for leaks.
2. Check to make sure that each hose is free
from twisting or excessive loops.

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Raymond ® DSD Maintenance Manual Mast and Forks

Mast and Forks 8:

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Description

Description

G
1

2
Forward Forward
3

Detail of A Detail of F
B

D
Forward
Forward
C
Detail of B, C Detail of D
E

4
F Forward

5 Detail of E Detail of G
8

Components The simplex mast features two lift cylinders

placed behind the mast columns, right and left,
1. Inner mast to provide maximum forward visibility.
2. Outer mast Mast strips are fitted to the top end parts of
3. Lift chain outer mast. These strips are for backing up the
inner mast when the mast is tilted backward.
4. Lift bracket
5. Mast support bearing cap
a. Main roller Diam. of
DSD30 – 35 DSD40/5E/60
main roller
b. Main roller
S 99 (3.90) 113.8 (4.48)
c. Main roller
M 100 (3.94) 115 (4.53)
d. Side roller
e. Main roller L 101 (3.98) 116 (4.57)

f. Main roller LL 102 (4.016) 117 (4.606)

g. Mast strip Unit: mm (in.)

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Removal and Installation

Removal and Installation

Mast and Lift Bracket Assembly

6
1
8

Sequence Suggestions
1. Nut
Removing Lift Bracket
2. Forks and lift bracket
1. Tilt the mast forward, and lower the inner
3. High-pressure hose for lift cylinders mast all the way. Slacken the lift chains, and
4. Tilt socket pins remove the nuts from the anchor bolts.
5. Tilt cylinders 2. Tilt the mast back to vertical position.
Secure the lift bracket to prevent it from
6. Mast-support bearing caps and bushing
falling over. Raise the inner mast until the
lift bracket becomes free. Then, back the
truck away, leaving the lift bracket and fork
assembly standing on the floor.

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Suggestions

Removing Lift Cylinder High-Pressure 2. Remove the tilt socket pins, and separate
Hoses the masts from the tilt cylinders.

With the mast in the lowest position, disconnect

the hoses at the flow regulator valve.

Removing Tilt Cylinders

1. Attach a sling to the holes, left and right in
the top cross member of the mast, and lift
the mast with a hoist.

Tilt
socket
pin

Removing Mast Support Bearing Caps

1. Scribe marks on the bearing caps before
removing them.

NOTE: Make sure to use a hoist having a

capacity enough to carry the weight of
the mast assembly.

Weight of Components
Marks
DSD40
DSD30
DSD50 DSD60
DSD35
DSD5E

Gross (Simplex 520 725 830 8

3.3 m mast) (1150) (1600) (1830)
2. Remove the cap bolts and lift off the mast
Unit: kg (lb) assembly, laying it down flat on a level floor.
NOTE: Lay the mast assembly on a floor large
enough for disassembly.

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Disassembly

Disassembly

12 10
15
3

11
10

13
9
2
16 17

8
2

6 14

1
4
5

Sequence
10. Cylinder clamp, seat, shims, cushion, collar
1. Nut
and bolts
2. Forks and lift bracket
11. Bolt and shims
3. Backrest
12. Mast strip and shims
4. Main roller and shims
13. Main roller and shims
5. Main roller and shims
14. Main roller and shims
6. Side roller, bracket, and shims
15. Inner mast
7. Hose guard
16. Lift cylinders
8. Lift hose (high pressure) (Rubber hose,
17. Outer mast
T-joint and down safety valve)
9. Snap ring and chain wheel

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Suggestions

Suggestions

Removing Mast Strips and Main Rollers

Remove bolts [10, 11] to free lift cylinder [16].
Cross the tops of the two lift cylinders. Slide
inner mast [15] toward the bottom of outer mast
[17], and remove main rollers [13, 14] and mast
strips [12].

Removing Inner Mast

After removing the main rollers, attach a sling to
the inner mast crossmember and slide the inner
mast toward the top of the outer mast until it gets
clear of the outer mast roller shafts. Sling the
inner mast again and remove it from the outer
mast.

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Inspection after Disassembly

Inspection after Disassembly Lift Bracket

1. Check the main rollers and side rollers for
Mast smoothness of rotation. Inspect each roller
for wear and cracks.
1. Check each roller for wear, binding, or
other defects. 2. Check the welds of the bracket for cracks.

2. Check each roller for flat spots on rolling 3. Check the finger bar for bend or distortion.
surface.
3. Check the mast member and the welds of
crossmembers, shafts, and supports for
cracks.
4. Check the mast support bushings for wear Finger
or other damage. bar

Distortion of 5 mm (0.2 in.)

A
finger bar maximum
A = Assembly standard

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Inspection after Disassembly

Lift Chains, Chain Wheels, and Chain

Wheel Supports
1. Measure the length of each chain to make
sure that the two chains are equal in
length. Also check the chains for wear,
evidence of breakage, link binding, and
twist.
2. Check each chain anchor bolt for cracks or
damaged thread.
3. Check each chain wheel support and chain
wheel for crack or wear. Check to be sure that
the wheels are capable of smooth rotation.
4. Measure sections of chain that travel over
the chain wheel.

Length of Chain (Per 20 Links)

DSD30–35 DSD40–5E DSD60

A 318 (12.52) 381 (15.00) 508 (20.00)

B 327 (12.87) 392 (15.43) 523 (20.59)

Unit: mm (in.)
A= Assembly standard
B= Repair or service limit

Mast Strips
Check the mast strips for damage, wear, or
distortion.

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Reassembly

Reassembly Cylinder Clamps

To reassemble, follow the reverse of Install each lift cylinder in place (in vertical
disassembly sequence and do the following position) by fitting to the support, and see if
steps: there is any clearance between the outer mast
and cylinder. Reduce the clearance, if any, to
Adjusting Mast and Lift Bracket zero by shimming.
Clearance
Rollers for mast and lift bracket are available in
three sizes (diameters) for selective use. Select
the size that will provide a longitudinal
clearances of 1 mm (0.04 in.) and less.

Shims
Clearance

Clearance
8

Mast Supports
1. Check mast support bushing for wear.
Replace if worn.
Lower roller Upper/middle roller 2. Apply grease to the inside surfaces and
grooves of the caps.
8
3. Install mast support bushings and caps
with beveling toward the center of truck
Roller Sizes respectively. Greasing will be facilitated if
the mast is lifted by placing solid blocks
Diameter of under it.
DSD30–35 DSD40/5E/60
main roller

S 99 (3.90) 113.8 (4.48)

Mast cap
M 100 (3.94) 115 (4.53)
Bushing
L 101 (3.98) 116 (4.57)

LL 102 (4.016) 117 (4.606)

Unit: mm (in.)

Apply grease

Side with wider cut

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Precautions for Installing Chain Anchor Kit

Precautions for Installing Chain

Anchor Kit
Use care not to install the center plate in the
position for link plate.

2
3

4 Stamped mark
8

1. Link plate (marked)

2. Center plate (not marked)
3. Link
4. Split pin

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Inspection and Adjustment

Inspection and Adjustment 3. Check the fork blade (D). Withdraw the fork
from service if the thickness is reduced to
less than the tolerant thickness.
Forks
Check the heel of fork. Fork blade length
1. Carefully inspect the forks for cracks. may also be reduced by wear, especially on
Special attention should be given to the tapered forks and platens. Remove the
heel section (A), all weld areas, and forks from service when the blade length is
mounting brackets (B). no longer adequate for the intended loads.
Remove all forks with cracks from service.
“Wet Test” magnetic particle inspection is
generally preferred due to its sensitivity and
the ease of interpreting the results.

D Toe

A Heel
8

Tolerant
8 Standard Limit
Thickness
2. Check the difference in height of one fork
tip to the other when mounted on the fork DSD30 40 (1.6) 31 (1.2)
carrier. A difference in fork tip height can
DSD35 40 (1.6) 33 (1.3)
result in uneven support of the load and
cause problems when entering loads. DSD40 45 (1.8) 36 (1.4)
The maximum allowable difference in fork
DSD50/5E 45 (1.8) 39 (1.5)
tip elevation (C) is 5 mm (0.20 in.) for pallet
forks. DSD60 45 (1.8) 40 (1.57)
Replace one or both forks when the
Unit: mm (in.)
difference in fork tip height exceeds the
maximum allowable difference.

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Inspection and Adjustment

Chain Tension Adjustment

Tightening Torque

! WARNING DSD30/35/40/50/5E DSD60

Personal injury canmay result from Nut 2

57 84
sudden movement of the mast and (5.8) (8.6)
Nut 3
lift bracket. Use blocks to prevent the [42.0] [62.2]
mast and lift bracket from any 98 147
movement while making Nut 1 (10) (15.0)
adjustments. Keep hands and feet [72.3] [108.5]
clear of any parts that can move. Unit: N•m (kgf•m) [lbf•ft]

1. Have the truck standing on a level floor,

with the mast vertical and the forks lowered 6. Adjust until tension is equal on both
to the floor. Check to be sure that the lift chains.
cylinders are fully retracted.
2. Set the anchor bolts with nut 3.
3. Raise the forks slightly and push the chains
inward midway between the chain wheel
and anchor alternately to check the
tension. When adjusting the chains by
means of the nut 3, tilt the mast forward to
slacken the chains to facilitate adjustment.
4. Turn nut 3 to adjust the chain tension.
Then, hold the anchor bolt in place with a
wrench and tighten nut 2 to the specified
torque.
5. Hold nut 3 in place with a wrench, and
tighten nut 1 to the specified torque.

Anchor bolt

2 nut

3 nut

1 nut
8

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Clearance Adjustment on Lift Bracket

Clearance Adjustment on Lift Bracket

Roller Sizes
Longitudinal Clearance Adjustment on
Lift Bracket Main Rollers Diameter of
DSD30–35 DSD40/5E/60
main roller
1. Raise the forks a little from the floor.
2. Insert a bar between the upper part of lift S 99 (3.90) 113.8 (4.48)
bracket and the inner mast, and push the M 100 (3.94) 115 (4.53)
inner mast to one side. Using a feeler
gauge, measure the clearance (F) between L 101 (3.98) 116 (4.57)
the main roller and inner mast on the
opposite side. LL 102 (4.016) 117 (4.606)

Unit: mm (in.)

F
4. Lift bracket main rollers (upper and center
rollers).
The upper rollers should be the same in
size or 1-rank larger than the center rollers.

F
8

0.1 to 1.0 mm
Clearance F
(0.0004 to 0.0039 in.)

3. If the clearance (F) is out of specification,

use oversize rollers.

Lower roller Upper/middle roller

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Mast and Forks Raymond ® DSD Maintenance Manual

Clearance Adjustment on Lift Bracket

Lateral Clearance Adjustment on Lift

Bracket Main Rollers and Side Rollers 1 1
1. Raise the mast all the way.
2. Set a dial indicator on the inner mast with G1
its contact point rested on the side of the
lift bracket.
2
3. Go over to the opposite side of the mast,
and push the lift bracket to one side with a
2
bar. Set the indicator to zero.
4. Insert a bar between the inner mast and lift
bracket on the indicator side, and push the
lift bracket to the opposite side.

For the lift bracket upper main roller or center

main roller, to extend 0.5 mm (0.02 in.), insert a
0.5 mm (0.02 in.) shim (a) on the inside and
remove the 0.5 mm (0.02 in.) shim (b) from the
lower stopper, then tighten the bolts.

Inner mast

Shims (b)

8 Shims (a)
5. Read the indicator.

0.1 to 0.5 mm
Clearance G
(0.004 to 0.020 in.)
8

6. Adjust clearance (G1) between the middle

main roller and weld plate [2] at the
maximum lift position by increasing or
decreasing the thickness of the shim.

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Clearance Adjustment on Lift Bracket

7. Lower the lift bracket slightly below its 8. With the lift bracket at the maximum lift
maximum lift position, then adjust position, adjust clearance (G3) with shims.
clearance (G2) between the side roller and
mast by increasing or decreasing the
thickness of the shim.

G2 Side
roller

Side
roller

G3

Adjust the side roller clearance by adding shims

under the roller bracket.

Shims

Shims

Roller

Bracket

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Mast and Forks Raymond ® DSD Maintenance Manual

Mast Clearance Adjustment

Mast Clearance Adjustment Lateral Clearance Adjustment on Inner

Mast Main Rollers
Longitudinal Clearance Adjustment on 1. Raise the mast all the way.
Mast Main Rollers
2. Set a dial indicator on the inside of the
1. Tilt the mast all the way backward. outer mast with its contact point rested on
2. Using a feeler gauge, measure the clearance the inner mast.
H between the inner mast lower roller and 3. Go over to the opposite side of the mast,
the outer mast. and push the inner mast against the outer
mast. Set the indicator to zero.

0.1 to 1.0 mm
Clearance H
(0.004 to 0.039 in.)

3. If the clearance (H) is out of specification,

use oversize rollers.

Roller Sizes

Diameter of
DSD30–35 DSD40/5E/60
main roller
J
S 99 (3.90) 113.8 (4.48)

M 100 (3.94) 115 (4.53) 8

L 101 (3.98) 116 (4.57) 4. Insert a bar between the outer and inner
masts on the indicator side, and push the
LL 102 (4.016) 117 (4.606) inner mast to the opposite side.
Unit: mm (in.) 5. Read the indicator.

0.1 to 0.5 mm
Clearance J
(0.004 to 0.020 in.)

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Raymond ® DSD Maintenance Manual Mast and Forks

Mast Clearance Adjustment

6. If the clearance (J) is out of specification,

adjust it by using shims.

Shims

K
8

NOTE: Refer to Main Roller Shim Replacement

on page 8-18.

Lateral Clearance Adjustment on Outer

Mast Main Rollers
1. Raise the mast all the way.
2. Set a dial indicator on the outer mast with
its contact point rested on the inner mast.
3. Go over to the opposite side of the mast,
and push the outer mast against the inner
mast with a bar. Set the indicator to zero.
4. Insert a bar between the outer and inner 8
masts, and push the inner mast to the
opposite side. 6. If the clearance (K) is out of specification,
adjust it by using shims.
5. Read the indicator.

0.1 to 0.5 mm
Clearance K
(0.004 to 0.020 in.)

Shims

NOTE: Refer to Main Roller Shim Replacement

on page 8-18.

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Mast and Forks Raymond ® DSD Maintenance Manual

Main Roller Shim Replacement

Main Roller Shim Replacement Mast Strip Adjustment

1. Remove the lift bracket from the mast. 1. Check the clearance L with the clearance
between the outer mast rollers and inner
NOTE: Refer to Lift Bracket Removal on
mast set to zero (0) in maximum lift
page 8-3.
position.
2. Lower the inner mast below the outer mast
as follows:
L
a. Raise the front end of the machine,
and block that end with a jack stand or
the like.
b. Remove the upper set of bolts from the
lift cylinders, and lift the inner mast
with a hoist. Remove the hose guard.
c. Remove the clamps from the lift
cylinders. Pull the bottom ends of the
cylinders from the outer mast, tilt the
cylinders to the center of the mast, and 8

tie them to the crossmember of outer

mast with rope.
0.1 to 0.5 mm
Clearance L
d. Slowly lower the inner mast until it (0.004 to 0.020 in.)
comes in contact with the lift cylinders.
e. Now the main rollers can be removed 2. If the clearance (L) is out of specification,
from the inner and outer masts. Remove adjust it by means of shims.
the mast strips and shims in advance
because they are apt to come off under NOTE: Refer to Main Roller Shim Replacement
this condition. on page 8-18.
3. After adjusting the all clearance, move the
mast and lift bracket slowly to make sure
that they move smoothly through their full
stroke.

Shims

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Raymond ® DSD Maintenance Manual Mast and Forks

Tilt Angle Adjustment

Tilt Angle Adjustment Lift Cylinder Stroke Adjustment

1. Adjust the tire pressure correctly and keep 1. Slowly raise the inner mast, and check how
the truck level. the piston rods, left and right, stop at the
2. Tilt the mast all the way backward and stop moment the inner mast reaches its
the engine. maximum height.
2. If the top of the inner mast rocks at that
3. Measure the backward tilt angle of the mast
moment, make a shim adjustment.
at both sides.
Abnormal condition can be told by a little
4. To adjust the tilt angle, loosen the bolt of time lag in stopping between the piston
tilt cylinder socket, and adjust the cylinder rods, left and right, and rocking of the rod
stroke by turning the rod on either cylinder with a longer cylinder stroke.
so that there is no difference in stroke
between the cylinders, left and right.

Bolt

8 8

NOTE: It is not necessary to adjust the forward

tilt angle if the backward tilt angle is
properly adjusted.

Forward/backward 5° to 6°
tilt angle (standard)

5. After adjusting the tilt angle, tighten the

socket bolts to the specified torque.

127 to 152
Tightening torque for tilt
(13 to 15.5)
cylinder socket bolt
[94 to 112]

Unit: N•m (kgf•m) [lbf•ft]

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Mast and Forks Raymond ® DSD Maintenance Manual

Bleeding Lift Cylinders

Adjusting Method Bleeding Lift Cylinders

1. Raise the inner mast, place solid blocks When air and oil remaining inside the air
under the left and right sides of the inner chamber of the rod and inside the rod chamber
mast, and lower the mast until it rests on between the tubes are compressed, they open
the blocks. the check valve and flow out of the cylinder.
Therefore, there is no need to bleed the lift
cylinders.

2. Remove the set bolt at the top of lift cylinder

that stopped first, retract the piston rod,
and insert shims at the top of piston rod
end.
3. Extend the piston rod, and tighten the
cylinder set bolt. Remove the blocks from
under the inner mast.

Set bolt

Shims

4. Slowly lower the inner mast all the way to

make sure that the piston rods move
smoothly and that the left and right lift
cylinders come to the end of stroke
simultaneously.

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Raymond ® DSD Maintenance Manual Mast and Forks

Service Data

Service Data

Inner mast
F
L
G1

G3

G2

F
B
Lift Bracket

A C1
K

H E

J
C2

Outer mast

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Mast and Forks Raymond ® DSD Maintenance Manual

Service Data

Service Data
Truck Model
Item
DSD30–35 DSD40–5E DSD60

Difference in height between fork tips A 5 (0.20)

Thickness of forks 100 x 40 100 x 40 125 x 45

A
(width x thickness) (3.9 x 1.6) (3.9 x 1.6) (4.92 x 1.8)
Forks Chains

DSD30 DSD40
100 x 31 100 x 38
125 x 39
(3.9 x 1.2) (3.9 x 1.5)
B (4.92 x
DSD35 DSD50/5E
1.53)
100 x 33 100 x 40
(3.9 x 1.3) (3.9 x 1.57)

Length of tilt chains (per 20 links) A 318 (12.52) 381 (15.00) 508 (20.00)

B 327 (12.87) 392 (15.43) 523 (20.59)

Diameter of main roller S A 99 (3.90) 113.8 (4.48)

M A 101 (3.94) 115 (4.53)

Rollers

L A 101 (3.98) 116 (4.57)

LL A 102 (4.016) 117 (4.606)

Diameter of side roller A 42 (1.65)

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Raymond ® DSD Maintenance Manual Mast and Forks

Service Data

Truck Model
Item
DSD30–35 DSD40–5E DSD60

Distance between outer mast main

A 523 (20.59) 575 (22.64)
rollers (inside to inside) A

Distance between inner mast main

A 581 (22.87) 639 (25.16)
rollers (outside to outside) B

Distance between lift bracket main

A 485 (19.09) 535 (21.06)
rollers (outside to outside) C1

Distance between lift bracket main

A 487 (19.17) 537 (21.14)
rollers (outside to outside) C2

Distance between lift bracket main

A 491 (19.33) 539 (21.22)
rollers (outside to outside) D

Distance between lift bracket side

Mast and Lift Bracket

A 496 (19.53) 546 (21.50)

rollers (outside to outside) E

Longitudinal clearance of lift bracket

middle rollers (with forks slightly A 0.1 to 1.0 (0.004 to 0.039)
lifted) F

Lateral clearance of lift bracket middle

A 0.1 to 0.5 (0.004 to 0.020)
main rollers (fully raised) G1

Lateral clearance of lift bracket side

A 0.1 to 0.5 (0.004 to 0.020)
rollers (fully raised) G2

Lateral clearance of lift bracket lower

A 0.1 to 0.5 (0.004 to 0.020)
main rollers (fully raised) G3

Longitudinal clearance of mast main

A 0.1 to 1.0 (0.004 to 0.039)
rollers (in the whole lift range) H

Lateral clearance of inner mast main

A 0.1 to 0.5 (0.004 to 0.020)
rollers (fully raised) J

Lateral clearance of outer mast main

A 0.1 to 0.5 (0.004 to 0.020)
rollers (fully raised) K

Mast strip clearance (fully raised) L A 0.1 to 0.5 (0.004 to 0.020)

PDMM-0115 Issued: 07/31/2002 8-23

Mast and Forks Raymond ® DSD Maintenance Manual

Troubleshooting

Troubleshooting

Complaint Possible Cause

1. Main rollers and side rollers having no proper clearance

Lift bracket and inner mast will 2. Rollers involved binding on their shafts
not move smoothly 3. Rollers damaged
4. Improper mast-to-strip clearance

1. Too much clearance on side rollers, or side rollers

damaged
Lift bracket or inner mast cocks 2. Lift chains unequally tensioned
3. Shim adjustments unequally made on left and right lift
cylinders (at maximum height)

Mast makes noise Rollers not rotating smoothly on their shafts, or damaged

1. Lift cylinder packing damaged

Load drops (drifts) 2. Lift cylinder bore grooved
3. Control valve faulty

Mast shakes entirely Mast-support bushing worn

Mast is distorted Improper loading or overload

1. Finger bar bent

Fork tips differ in height 2. Forks bent
3. Distortion of mast due to off-center loading

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Raymond ® DSD Maintenance Manual Troubleshooting Section

Troubleshooting Section 9:

PDMM-0115 Issued: 07/31/2002 9-1

Troubleshooting Section Raymond ® DSD Maintenance Manual

Front Axle and Reduction Differential Troubleshooting

Front Axle and Reduction Differential

Troubleshooting

Complaint Possible Cause Remedy

Gear noise comes Teeth worn excessively or tooth contact out of Readjust or replace
out continuously adjustment in spiral bevel drive
during normal
cruising run Bearing preloads too much or too little, or Readjust or replace
bearings are worn excessively

Hub bearings broken Replace

Improper tooth contact between reduction Readjust

pinion (on output shaft) and reduction gear

Irregular noise Bearings associated with spiral bevel drive or Replace

comes out during hub bearings broken
normal travel
Differential side gears have broken teeth, or Replace gears or washer
thrust washers worn

Metal piece in axle housing Clean and replace oil

Bolts securing axle shaft or differential carrier Retighten

are loose

Abnormal noise Fit differential gears in differential case are Replace worn parts
comes out when out of specification due to wear
turning a corner
Broken teeth on differential pinions or side Replace bad parts
gears, or pinions seized on spiders

Differential Bearings broken due to too large a preload Replace bearing and
overheats readjust preload

Backlash between reduction pinion (on output Replace bearings and

shaft) and reduction gear too small readjust preload and
backlash

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Raymond ® DSD Maintenance Manual Troubleshooting Section

Brake System Troubleshooting

Brake System Troubleshooting

Complaint Possible Cause Remedy

Lack of Oil leaking past primary cup in Replace piston cup if cylinder is worn.
braking force master cylinder Replace cup and fluid if the cup is
distorted.

Oil leaking past cups in wheel Replace pipe and connector and
cylinders retighten

Oil leaking from oil pipe Retighten

connection

Shoe linings excessively worn Replace

Linings dirty with oil or grease Clean or replace

Pedal stroke is Air trapped in brake oil line Bleed air at master cylinder and wheel
too large cylinder
Service Brakes

Piston cup bad in master Replace

cylinder

Not enough fluid in reservoir Refill

Push rod-to-piston clearance Readjust

too large in master cylinder

Brake fluid leakage Replace piston cup if cylinder is worn.

Replace the cup and fluid if the cup is
distorted.

Automatic adjusting device out Check cable guide and adjusting

of order spring installation. If they are bad,
replace fitting cable, lever, and
adjusting screw.

Uneven Lining or drum dirty with oil or Clean or replace brake

braking grease in less effective brake
(machine pulls
to one side) Wobbly or loose-mounted drum Replace drum. Readjust and
in less effective brake retighten.

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Troubleshooting Section Raymond ® DSD Maintenance Manual

Brake System Troubleshooting

Complaint Possible Cause Remedy

Brake squeals Linings glazed Replace shoe & lining assembly

Linings badly worn Replace

Service Brakes (Cont’d.)

Backing-plate securing bolts Retighten

loose

Wheel bearings loose Readjust preload and retighten

Brake drum dirty Clean

Brake chatters Anchored ends of shoes rattling Repair or replace

or clatters on anchor

Shoe ledges badly worn Replace backing plate

Piston badly worn in wheel Replace

cylinder

Lever stroke is Lining-to-drum clearance too Readjust

too small small

Squeals during Lining-to-drum clearance too Readjust

traveling small

Brake drum badly distorted Repair or replace

Parking Brake

Will not apply Parking brake cable longer than Check drum-to-lining clearance and,
specified if brake will not apply, turn
adjusting knob clockwise

Linings worn to service limit Replace shoe and lining assembly

Lining-to-drum clearance too Readjust

small

Lack of brake lever operating Readjust to 25 to 30 kgf (55 to 66 lbf)

effort [245 to 294 N]

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Raymond ® DSD Maintenance Manual Troubleshooting Section

Steering System Troubleshooting

Steering System Troubleshooting

Complaint Possible Cause Remedy

Hard steering 1. Overloaded steer axle Reduce load

2. Damaged mechanical linkage Replace

3. Dry mechanical linkage joints Lubricate

4. Mechanical joints too tight Readjust

5. Kingpin bearings improperly preloaded Readjust

Truck wanders 1. Damaged or worn mechanical linkage Replace

2. Loose cylinder piston Replace cylinder rod

Truck drifts 1. Damaged or worn mechanical linkage Replace

2. Tire diameter differs between right and left Replace tire

Erratic steering Loose cylinder piston Replace cylinder rod

Excessive free play Damaged or worn linkage between cylinder and Replace
at steered wheels steered wheels

Axle shimmy 1. Excessive clearance between the kingpin and Repair or replace
its bearings

2. Worn or damaged hub bearing Replace

Rear tires wear Tire on one side differs in kind or brand from that Replace tires
prematurely or on the other side
unevenly

Slow steering, hard Worn or malfunctioning pump Replace

steering, or loss of
steering Malfunctioning relief valve Readjust or replace

Worn or malfunctioning steer gear Replace

Pipe or tube flattened, or restriction in an oil line Clean or replace

Truck wanders Air in system Low level of oil Fill as required

Leaking joint Tighten joint

Pinched pipe or hose Straighten or replace

Worn steer gear Replace

Steering slip Worn steer gear Replace

Leakage of cylinder seals or at lines between steer Repair

gear and cylinder

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Troubleshooting Section Raymond ® DSD Maintenance Manual

Steering System Troubleshooting

Complaint Possible Cause Remedy

Temporary hang-up Thermal issues caused by actuation of hydraulic Correct operating

in steering lift and tilt for long periods of time without procedure
actuation of steering system, creating more
than a 28°C (50° F) temperature differential
between the oil in the tank and the oil in the
steer gear.

Erratic steering Air in system Low level of oil Fill as required

Leaking joint Tighten joint

Pinched pipe or hose Straighten or replace

Thermal damage to steer gear Replace

Spongy or soft Air in system Low level of oil Fill as required

steering
Leaking joint Tighten joint

Pinched pipe or hose Straighten or replace

Air trapped in cylinder Bleed air

Steering wheel turn Problem with steering Column loose or Repair or replace
with no axle column damaged
responses
Column splines Repair or replace
damaged or disengaged
from steer gear

Air in steer gear Starved at startup Temporary

Starved from long period Temporary

of non-use

No flow to steer gear Low oil level Fill as required

Ruptured hose Replace

Thermal damage to steer Replace

gear

Blown piston seal Replace

Steering instability Air in lines Pump sucking air at Check joints

or oscillation inlet

Components or lines Bleed circuit

contain air

Improper relief setting Readjust

Steering wheel turns Lines connected to wrong cylinder ports Correct connections
in wrong direction

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Raymond ® DSD Maintenance Manual Troubleshooting Section

Steering System Troubleshooting

Complaint Possible Cause Remedy

Excessive freeplay At steering wheel Loose steering wheel nut Tighten

Damaged or worn Replace

column shaft

At steered wheels Leaky cylinder seals Replace

Binding or poor Binding or misalignment between column and Readjust steer gear
centering of steer gear mounting bracket
steering or replace rubber
mounting
grommets

High back pressure in tank return line Clear blockages

Contamination in steer gear unit Clean unit

Steer gear locks up Contamination in steer gear unit Clean unit

Insufficient hydraulic power Check pump and

power

Worn or damaged steer gear or steer gear pin Replace

PDMM-0115 Issued: 07/31/2002 9-7

Troubleshooting Section Raymond ® DSD Maintenance Manual

Hydraulic System Troubleshooting

Hydraulic System Troubleshooting

Complaint Possible Cause Remedy

Will not lift or tilt Not enough oil in hydraulic tank Refill

Relief valve out of order because of:

1. Seized main valve Replace
2. Broken valve spring Replace relief valve

Oil pump bad Replace

Control valve switch misaligned or faulty Readjust or replace

Will not lift rated Relief valve out or order because of:
load
1. Too low a relief valve setting Readjust
Lift and Tilt Cylinders

2. Faulty plunger and poppet seat Replace relief valve

3. Weakened spring Replace relief valve
4. Damaged O-ring in valve case Replace O-ring

Oil pump bad Replace

Piston seals worn or damaged Replace

Lift speed is Rpm too low Adjust

too low
Control lever installed loose, resulting in Repair or replace
not enough spool stroke

Tank strainer clogged Clean or replace

Pump not delivering enough oil Repair or replace

Lowering speed is Sleeve seized in flow regulator valve Repair

too low
Dirt in flow regulator valve Clean, repair system,
and replace bad hose

Abnormal resistance to flow due to Replace hose

flattened hose or local clogging

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Raymond ® DSD Maintenance Manual Troubleshooting Section

Hydraulic System Troubleshooting

Complaint Possible Cause Remedy

Cylinder vibrates Piston rod distorted Repair or replace

when actuated
Control lever installed too loose, resulting Repair or replace
in not enough spool stroke

Air in oil circuit Bleed air by operating

cylinder through full
stroke

Not enough oil in hydraulic tank Refill

Load will not hold Control valve spool leaking internally Replace

Lift connector on bottom of control valve Torque to 33 ± 3.5 ft•lbs

not tight
Lift and Tilt Cylinders (Cont’d)

Sliding (inside) surface of cylinder tube Repair or replace

slightly grooved cylinder assembly

Sliding (inside) surface of tube badly Replace

grooved

Piston seals broken or distorted Replace seal kit

Oil leakage from piping Repair or replace

Mast tilts forward Control valve spool leaking internally Replace

(drifts)
Foreign particles lodged between packing Replace packing
and mating surface

Piston seal damaged Repair

Cylinder distorted Repair or replace

Bushing leaks Foreign particles lodged between sealing Replace

members such as oil seals and dust
seals

Oil seals and dust seals bad Replace

O-rings damaged Replace

Cylinder distorted Repair or replace

PDMM-0115 Issued: 07/31/2002 9-9

Troubleshooting Section Raymond ® DSD Maintenance Manual

Hydraulic System Troubleshooting

Complaint Possible Cause Remedy

Hydraulic tank Oil viscosity improper Change oil

heats excessively
Overload Check working
conditions and, if
overloaded, urge the
operator to stay within
the load limit

Local overheating of oil line due to a large Repair or replace

restriction flow
Hydraulic Tank

Relief valve adjustment improper Readjust pressure

setting

Pressure drop due to weakened or broken Repair or replace and

springs readjust

Hydraulic pump worn Replace

Outlet pipe or tube flattened, or Repair or replace

restriction to flow

Cylinders move too Shortage of oil due to a natural loss Refill

slowly
Oil leakage due to damaged oil line seals Repair or replace

Oil viscosity too high Change oil

Cylinders move too Hydraulic pump malfunctioning Check pump and piping;
slowly repair or replace

Oil leakage from oil line Check oil for level and
condition; and/or
change oil

Abnormal rise in oil temperature Check control valve

spools for
misalignment; repair or
Hydraulic Pump

replace

Hydraulic pump leaking internally Replace pump

Noisy Poor pumping Refill

Cavitation 1. Check suction pipe for

any flat portion or
loose connection;
retighten or replace
2. Check shaft oil seal
for airtightness;
replace pump
3. Check pump body for
any outside
interference; repair

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Raymond ® DSD Maintenance Manual Troubleshooting Section

Rear Axle Troubleshooting

Rear Axle Troubleshooting

Complaint Possible Cause Remedy

Hard steering Low pump pressure Check pressure, replace

pump as needed

Damaged mechanical linkage Replace

Dry mechanical linkage joints Lubricate

Mechanical joints too tight Readjust

Kingpin bearings improperly preloaded Readjust

Truck wanders Damaged or worn mechanical linkage Replace

Loose cylinder piston Replace cylinder rod

Truck drifts Damaged or worn mechanical linkage Replace

Tire diameter differs between right and left Replace tire

Erratic steering Loose cylinder piston Replace cylinder rod

Excessive freeplay at Damaged or worn linkage between cylinder Replace

steered wheels and steered wheels

Axle shimmy Excessive clearance between the kingpin and Repair or replace
its bearing

Worn or damaged hub bearing Replace

Rear tires wear Tire on one side differs in kind or brand from Replace tires
prematurely or the other side
unevenly

PDMM-0115 Issued: 07/31/2002 9-11

Troubleshooting Section Raymond ® DSD Maintenance Manual

Mast and Forks Troubleshooting

Mast and Forks Troubleshooting

Complaint Possible Cause

Lift bracket and inner mast Main rollers and side rollers have proper clearance
do not move smoothly
Rollers involved are binding on their shafts

Rollers damaged

Improper mast-to-strip clearance

Lift bracket or inner mast Too much clearance on side rollers, or side rollers are damaged
cocks
Lift chains unequally tensioned

Shim adjustments unequally made on left and right lift cylinders

(at maximum height)

Mast makes noise Rollers not rotating smoothly on their shafts or are damaged

Load drops (drifts) Lift cylinder packing damaged

Lift cylinder bore grooved

Control valve faulty

Entire mast shakes Mast-support bushing worn

Mast is distorted Improper loading or overload

Fork tips differ in height Finger bar bent

Forks bent

Distortion of mast due to off-center loading

9-12 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Maintenance Service Data

Maintenance Service Data 10:

PDMM-0115 Issued: 07/31/2002 10-1

Maintenance Service Data Raymond ® DSD Maintenance Manual

Front Axle and Reduction Differential

Front Axle and Reduction Differential

Hubs and Wheels

Truck DSD40–50
Item DSD30–DSD35
Model DSD60

Face runout of axle shaft flange A 0.05 (0.0020)

B 0.5 (0.020)

Runout of axle shaft A 0.5 (0.020) max 1.0 (0.039) max

(1/2 of dial indicator reading)
B 1.0 (0.039) max 2.0 (0.079)

Preload for hub bearing (1),

A 5 to 50 (0.4 to 3.6) [0.5 to 4.9]
kgf•cm (lbf•ft) [N•m]

Tightening torque Hub bearing lock nuts

A 20 (145) [196]
kgf•cm (outer) (2)
(lbf•ft)
[N•m] Axle shaft bolts (3) A 8.8 (64) [86]

Backing plate bolts (4) A 6 (43) [59] 18.5 (134) [181]

Hub bolt lock nuts (5) A 6 (43) [59] 18.5 (134) [181]

Frame support bolts (6) A 22.9 (166) [225]

Wheel nuts (7) A 16 (116) [157] 38.5 (278) [378]

6 1

7
4

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

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Raymond ® DSD Maintenance Manual Maintenance Service Data

Hubs and Wheels

Truck DSD40–50
Item DSD30–DSD35
Model DSD60

Gear backlash (1) A 0.18 to 0.23 (0.0071 to 0.0091)

B 0.5 (0.020)

Fit of bevel pinion on spider (2) A 0.02 to 0.07 (0.0008 to 0.0028)

B 0.35 (0.0138)

Preload for differential case side bearings (3) 15 to 30 (1.1 to 2.2) [1.5 to 2.9]
kgf•cm (lbf•ft) [N•m]
A 1.3 to 2.5 kgf (2.9 to 5.5 lbf) [13 to 25 N]
as force applied to reduction gear in
tangential direction

Face runout of reduction gear (4) A 0.05 (0.0020) max

B 0.05 (0.0020)

Backlash between reduction gear

A 0.15 to 0.25 (0.0059 to 0.0098)
and pinion (5)

Free movement (looseness) of axle shaft A 0.07 to 0.17 (0.0028 to 0.0067)

splines (6)
B 0.5 (0.020)

Tightening torque Reduction gear bolts (7) A 12 (87) [118]

kgf•cm
(lbf•ft) Side bearing cap bolts
A 12.8 (93) [126]
[N•m] (8)

Carrier bolts (9) A 6.1 (44) [60]

Differential carrier cover

A 3.4 (25) [33]
bolts (10)

6 5 4
10
7
9

8
3
2 1

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

PDMM-0115 Issued: 07/31/2002 10-3

Maintenance Service Data Raymond ® DSD Maintenance Manual

Transfer Case

Transfer Case

N•m kgf•m lbf•ft

1 Cover-to-traction motor 33 ± 2 3.4 ± 0.2 24.6 ± 1.4

2 Side cover 39.2 ± 3.9 4.0 ± 0.4 29.0 ± 2.9

3 Plug or pulse generator 54.0 ± 4.9 5.5 ± 0.5 39.7 ± 3.6

4 Case-to-cover 39.2 ± 3.9 4.0 ± 0.4 29.0 ± 2.9

5 Lock nut 292 ± 20 30.0 ± 2.0 217 ± 14.5

Supply liquid gasket

onto the face of flange.

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

10-4 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Maintenance Service Data

Rear Axle

Rear Axle

Truck
Item DSD30–35 DSD40–60
Model

Oscillating angle A 3°

Toe-in A 0°

Caster A 0°

Camber A 1°

Total fore-aft play of axle at center pin (1) A 0.8 (0.031)

B 1.2 (0.047)

Turning Angle Inside (2) A 83° 83°

Outside (3) A 54° 56°

Tightening torque, Support bolts (4) A 14.8 (107) [145]

kgf•m (lbf•ft)
[N•m] Stopper bolt nuts (5) A 6.8 (49) [67]

Cylinder minimum test pressure, 107 (1522) 163 (2320)

A
kgf•cm2 (psi) [kPa] [10,500] [16,000]

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

PDMM-0115 Issued: 07/31/2002 10-5

Maintenance Service Data Raymond ® DSD Maintenance Manual

Rear Axle

Truck
Item DSD30–35 DSD40–60
Model

Tightening torque Outer locknut (6) A 16 (116) [157]

kgf•m
(lbf•ft) Cylinder nuts (7) A 1.9 to 2.3 (14 to 17) [19 to 23]
[N•m] Cylinder bolts (8) A 17.9 (130) [176] 26.7 (193) [262]

Kingpin bolts (9) A 1.7 (12.3) [16.7] 3.4 (24.6) [33.4]

Tie rod bolts (10) A 0.7 (5) [6.9]

Preload for hub bearing (11)

A 25 to 65 (1.8 to 4.7) [2.5 to 6.4]
kgf•m (lbf•ft) [N•m]

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

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Raymond ® DSD Maintenance Manual Maintenance Service Data

Brake System–Brake Pedal

Brake System–Brake Pedal

Item Truck Model DSD30 – 60

Height of pedal (1) A 89 ± 3 (3.5 ± 0.12)

Stroke (to point where brakes start to apply) (2) A 3 to 10 (0.12 to 0.40)

Clearance between piston and push rod (3) A 0.5 to 2.8 (0.02 to 0.11)

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

PDMM-0115 Issued: 07/31/2002 10-7

Maintenance Service Data Raymond ® DSD Maintenance Manual

Brake System–Master Cylinder

Brake System–Master Cylinder

Truck
Item DSD30–DSD35 DSD40–60
Model

Inside diameter of cylinder 19.05 + 0 0.052 22.22 + 0 0.052

body (1) A
(0.7500 + 0 0.00205) (0.8748 + 0 0.00205)

Diameter of piston (2) 19.05 -0.020 -0.053 22.22 -0.020 -0.053

A
(0.7500 -0.0079 -0.00209) (0.8748 -0.0079 -0.00209)

Clearance between cylinder 0.020 to 0.105 0.020 to 0.105

A
and piston (0.00079 to 0.00413) (0.00079 to 0.00413)

B 0.2 (0.008) 0.2 (0.008)

Diameter of primary cup 20 0

-0.3 23.2 ± 0.25
(lip side) (3) A
(0.79 0
-0.012 ) (0.913 ± 0.0098)

B replace every year replace every year

Diameter of secondary cup 20.2 ± 0.2 23.2 ± 0.25

A
(lip side) (4) (0.795 ± 0.008) (0.913 ± 0.0098)

B replace every year replace every year

Free length of return spring (5) A 46.8 (1.843) 85 (3.35)

B replace every year replace every year

4 2

Earlier Version

1 3 5

2
4
Later Version

1 3 5

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

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Raymond ® DSD Maintenance Manual Maintenance Service Data

Brake System–Wheel Cylinder

Brake System–Wheel Cylinder

Truck
Item DSD30–DSD35 DSD40–60
Model

Inside diameter of cylinder 22.22 + 0.052 28.58 + 0.052

0 0
body (1) A 0.00205 0.00205
(0.8748 - 0 ) (1.1252 + 0 )

Diameter of piston (2) 22.22 - 0.040

28.58 - 0.020
- 0.073 - 0.058
A - 0.00157 - 0.00079
(0.8748 - 0.00287) (1.1252 - 0.00228)

Clearance between cylinder 0.040 to 0.125 0.020 to 0.105

A
and piston (0.00157 to 0.00492) (0.00079 to 0.00413)

B 0.15 (0.0059)

Diameter of piston cup (lip 23.7 ± 0.2 30.5 ± 0.25

A
side) (3) (0.933 ± 0.0079) (1.201 ± 0.0098)

B replace every year

Return Free length A 49.5 (1.95) 58 (2.28)

Spring (4)
Length under
A 20 (0.79) 23 (0.91)
test force

Test force 1.2 ± 0.1 1.3 ± 0.1

kgf (lbf) [N] A (2.6 ± 0.2) (2.9 ± 0.2)
[12 ± 1] [13 ± 1]

B replace every year

Tightening Wheel cylinder 0.8 to 1.2 1.8 to 2.7

torque bolts (5) A (6 to 9) (13 to 20)
kgf•m [8 to 12] [18 to 26]
(lbf•ft)
[N•m] Bleeder screw
A 0.6 to 0.9 (4 to 7) [6 to 9]
(6)

1 6 5

4 3 2

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

PDMM-0115 Issued: 07/31/2002 10-9

Maintenance Service Data Raymond ® DSD Maintenance Manual

Brake System–Wheel Brakes

Brake System–Wheel Brakes

Truck
Item DSD30–DSD35 DSD40–60
Model

Inside diameter of brake drum 254 + 0 1.3 310 + 0 0.15

(1) A
(10.00 + 0 0.0051) (12.20 + 0 0.0059)

B 256 (10.08) 312 (12.28)

Thickness of lining (2) A 4.87 (0.19) 6 (0.24)

B 2.5 (0.098) max 3 (0.118) max

Clearance between drum and 0.2 to 0.5 0.2 to 0.6

A
lining (3) (one side) (0.0079 to 0.0197) (0.0079 to 0.0236)

Return spring Free length Primary: 120 (4.72)

A 102 (4.02)
(4) Secondary: 139.3 (5.48)

Length under Primary: 134 (5.28)

A 111 (4.37)
test force Secondary: 145.4 (5.72)

Test force, 16 ± 1.6 23 ± 2.3

kgf (lbf) [N] A (35 ± 3.5) (51 ± 5.1)
[157 ± 16] [226 ± 23]

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

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Raymond ® DSD Maintenance Manual Maintenance Service Data

Brake System–Service Brakes

Brake System–Service Brakes

Truck
Item DSD30–DSD35 DSD40–60
Model

Adjusting Free length A 79 (3.11) 104 (4.11)

spring (5)
Length under
A 98.5 (3.88) 122 (4.80)
test force

Test force,
A 14 ± 1.4 (31 ± 3) [137 ± 14] 8 ± 0.8 (18 ± 2) [78 ± 8]
kgf (lbf) [N]

Tightening torque for

backing plate bolts (6) A 16 (116) [157]
kgf•m (lbf•ft) [N•m]

1
4

2 6

3
Secondary spring 4

5
Free length

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

PDMM-0115 Issued: 07/31/2002 10-11

Maintenance Service Data Raymond ® DSD Maintenance Manual

Brake System–Parking Brake

Brake System–Parking Brake

Truck
Item DSD30–DSD35 DSD40–60
Model

Locked position of lever A A 4° to 5°

Lever operating effort (F) A 25 to 30 (55 to 66) [245 to 294]

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

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Raymond ® DSD Maintenance Manual Maintenance Service Data

Steering System–Steering Gear

Steering System–Steering Gear

Truck
Item DSD30–DSD35 DSD40–60
Model

Steering effort (at rim with truck on)

A 1.3 (2.9) [12.8]
kgf (lbf) [N]

Tightening torque Tank Plug (1) A 4.8 (35) [47.5]

kgf•cm (lbf•ft) [N•m]
Body cap screws (2) A 2.3 (17) [23]

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

PDMM-0115 Issued: 07/31/2002 10-13

Maintenance Service Data Raymond ® DSD Maintenance Manual

Steering System–Steering Cylinder

Steering System–Steering Cylinder

Truck
Item DSD30-DSD35 DSD40-60
Model

Inside diameter A 63 (2.48) 75 (2.95)

Diameter of piston rod A 40 (1.57) 50 (1.97)

Minimum test pressure for leaks,

A 107 (1522) [10,500] 163 (2320) [16,000]
kgf•cm2 (psi) [kPa]

Tightening torque, Cylinder nuts (1) A 2.1 ± 0.2 (15.5 ± 1.5) [21 ± 2]
kgf•cm
(lbf•ft) Mounting bolts (2)
A 17.9 (130) [176] 26.7 (193) [262]
[N•m]

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

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Raymond ® DSD Maintenance Manual Maintenance Service Data

Hydraulic System

Hydraulic System

Truck
Item DSD30 DSD35 DSD40 DSD5E DSD60
Model

48 volt lift speed (rated load) 0.34 0.32 0.40 0.38

A 0.32 (64)
mm/sec (fpm) (67) (64) (78) (74)

Lowering speed (rated load)

A 0 .58 (115) 0.59 (116) 0.52 (102)
mm/sec (fpm)
Simplex Mast

Forward tilt angle A 5°

Backward tilt angle A 6°

Lift cylinder drift (rated load)

mm (in.)/15 min. A 50 (2.0) max 40 (1.6)
[Oil temperature 45°C (113°F)]

Tilt cylinder drift (forward)

rated load
A 22 (0.9) 15 (0.6)
mm (in.)/15 min. 20 (0.8)
[Oil temperature 45°C (113°F)]

Main relief valve setting,

A SAME
kgf•cm2, (psi) [kPa]

Power steering relief valve setting,

A 51 (725) [5000] 81.5 (1160) [8000]
kgf•cm2, (psi) [kPa]

Output, liter Standard 55.2 (3360) 60 (3913)

A
Hydraulic Pump

(cu. in.)/min 2400 rpm 2400 rpm

69.6 (4549)
Premium 60 (3913) 2400 rpm 69.6
A 2400 rpm (4539)
2400 rpm

Tightening torque for oil pump

A 4.7 to 5.2 (34 to 38) [46 to 51]
bolts kgf•m (lbf•ft) [N•m]

Tightening Tie bolts

Control Valve

A 1.9 (14) [19]

torque kgf•m (1/2 in.)
lbf•ft) [N•m]
Tie bolts
(9/16 in.)
A 4.5 (33) [45]

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

PDMM-0115 Issued: 07/31/2002 10-15

Maintenance Service Data Raymond ® DSD Maintenance Manual

Hydraulic System (Cont’d.)

Hydraulic System (Cont’d.)

Truck DSD30– DSD40–

Item DSD60
Model DSD35 DSD5E

[Piston] 45 + 0 0.2 50 + 0 0.2 55 + 0 0.2

Inside diameter of cylinder tube (1) A
(1.77 + 0 0.008) (1.97 + 0 0.008) (2.17 + 0 0.008)

Diameter of piston ring (2) A 35 (1.38) 40 (1.57) 45 (1.77)

Thread diameter (3) A M49 x 1.5 M54 x 1.5 M59 x 1.5

Tightening torque (4)

170 to 240 200 to 270 270 to 304
A (17.3 to 24.5) (20.4 to 27.5) (27.5 to 31.0)
[125 to 175] [150 to 200] [200 to 225]
Lift Cylinder

N•m (kgf•m) [lbf•ft]

3 2 1

4
Return Filter

Tightening torque
A 49 ± 10 (5 ± 1) [36 ± 7.2]

N•m (kgf•m) [lbf•ft]

Flow Regulator Valve

Flow rate (no load) A 50 (3051) 65 (3967) 75 (4577)

liter (cu. in.)/min.

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

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Raymond ® DSD Maintenance Manual Maintenance Service Data

Hydraulic System (Cont’d.)

Hydraulic System (Cont’d.)

Truck DSD30– DSD40–

Item DSD60
Model DSD35 DSD5E

Inside diameter of cylinder 63 + 0 0.1 70 + 0

0.1
80 + 0
0.1
A
tube (1) (2.48 + 0 0.004) (2.76 + 0
0.004
) (3.15 + 0
0.004
)

B 63.12 (2.4850) 70.12 (2.7606) 80.12 (3.1543)

[Guide bushing] 25 -0.02

30 -0.02
35 -0.052
-0.05 -0.05 -0.064
Diameter of piston rod (2) A -0.0008 -0.0008 -0.00098
(1.0 (1.18 (1.38
-0.0020) -0.0020) -0.00252)

Inside diameter of mast-side -0.012 -0.0005

A 35 0 (1.38 0 )
socket bushing (fitted) (3)
0.085 0.003
Inside diameter of frame-side A 32 + 0 (1.26 + 0 )
head bushing (fitted) (4)
B 32.6 (1.283)

[Guide bushing] thread

A M68 x 2 M75 x 2 M85 x 2
diameter (5)

Tightening torque 265 ± 29 314 ± 31 373 ± 37

A
Tilt Cylinders

N•m (kgf•m) [lbf•ft] (27 ± 3) (32 ± 3.2) (38 ± 3.8)

[195 ± 22] [231 ± 23] [275 ± 27]

[Socket] thread diameter (6) A M24 x 1.5 M27 x 1.5 M30 x 1.5

Tightening Socket bolt (7) A 127 to 152 (13 to 15.5) [94 to 112]
torque
N•m 27 ± 9.8 235 ± 19.6 39.2 ± 25
Self-locking nut
(kgf•m) A (13 ± 1.0) (24 ± 2.0) (40 ± 2.5)
(8)
[lbf•ft] [94 ± 7.2] [174 ± 14.5] [289 ± 18.1]

Clearance between rod and 0.06 to 0.111

0.075 to 0.139
guide bushing (9) A (0.0024 to
(0.0030 to 0.0055)
0.0044)

B 0.35 (0.0138)

3 9
6 4

7 5 1 2 8

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

PDMM-0115 Issued: 07/31/2002 10-17

Maintenance Service Data Raymond ® DSD Maintenance Manual

Mast and Forks (Simplex Mast)

Mast and Forks (Simplex Mast)

Truck DSD30– DSD40–

Item DSD60
Model DSD35 DSD5E

Difference in height between

A 5 (0.20)
fork tips

Thickness of forks 100 x 40 100 x 45 125 x 45

A
(width x thickness) (3.9 x 1.6) (3.9 x 1.8) (4.92 x 1.8)
Forks Chains

DSD30 DSD40
100 x 31 100 x 38
(3.9 x 1.2) (3.9 x 1.5) 125 x 39
B
DSD35 DSD50/5E (4.92 x 1.53)
100 x 33 100 x 40
(3.9 x 1.3) (3.9 x 1.57)

Length of tilt chains A 318 (12.52) 381 (15.00) 508 (20.00)

(per 20 links)
B 327 (12.87) 392 (15.43) 523 (20.59)

Diameter of main roller S A 99 (3.90) 113.8 (4.48)

Rollers

M A 100 (3.94) 115 (4.53)

L A 101 (3.98) 116 (4.57)

LL A 102 (4.016) 117 (4.606)

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

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Raymond ® DSD Maintenance Manual Maintenance Service Data

Mast and Forks (Simplex Mast)

Truck DSD30– DSD40–

Item DSD60
Model DSD35 DSD5E

Diameter of side roller A 42 (1.65)

Distance between outer mast main

A 523 (20.59) 575 (22.64)
rollers (inside to inside) A

Distance between inner mast main

A 581 (22.87) 639 (25.16)
rollers (outside to outside) B

Distance between lift bracket main

A 485 (19.09) 535 (21.06)
rollers (outside to outside) C1

Distance between lift bracket main

A 487 (19.17) 537 (21.14)
rollers (outside to outside) C2

Distance between lift bracket main

A 491 (19.33) 539 (21.22)
rollers (outside to outside) D

Distance between lift bracket side

Mast and Lift Bracket

A 496 (19.53) 546 (21.50)

rollers (outside to outside) E

Longitudinal clearance of lift

bracket middle rollers (with forks A 0.1 to 1.0 (0.004 to 0.039)
slightly lifted) F

Lateral clearance of lift bracket

middle main rollers (fully raised) A 0.1 to 0.5 (0.004 to 0.020)
G1

Lateral clearance of lift bracket side

A 0.1 to 0.5 (0.004 to 0.020)
rollers (fully raised) G2

Lateral clearance of lift bracket

A 0.1 to 0.5 (0.004 to 0.020)
lower main rollers (fully raised) G2

Longitudinal clearance of mast

main rollers (in the whole lift A 0.1 to 1.0 (0.004 to 0.039)
range) H

Lateral clearance of inner mast

A 0.1 to 0.5 (0.004 to 0.020)
main rollers (fully raised) J

Lateral clearance of outer mast

A 0.1 to 0.5 (0.004 to 0.020)
main rollers (fully raised) K

Mast strip clearance (fully raised) L A 0.1 to 0.5 (0.004 to 0.020)

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

PDMM-0115 Issued: 07/31/2002 10-19

Maintenance Service Data Raymond ® DSD Maintenance Manual

Mast and Forks

Mast and Forks

DSD40
Truck
Item DSD30 DSD35 DSD50 DSD60
Model
DSD5E

Inner Mast
F L

G1

G3

G2
B
F

A Lift Bracket
K
C1
H
E
J
C2

Outer Mast

Tightening Mast support bolts A 7.5 (54) [74] 18.2 (132) [178]

Chain wheel support

A 9.9 (72) [97]
bolts

Distortion of finger bar A 5 (0.2)

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

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Raymond ® DSD Maintenance Manual Maintenance Service Data

Tightening Torques for Standard Bolts and Nuts

Tightening Torques for Standard Bolts and Nuts

Tightening Torques for Standard Bolts and Nuts – Fine Thread – With Spring Washer

Nominal
Pitch
Size

mm in. mm in. kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m

6 0.24 1 0.04 0.75 5.4 7.4 0.98 7.1 9.6 1.3 9.4 12.7

8 0.32 1.25 0.05 1.7 12.3 16.7 2.3 16.6 22.6 3.1 22.4 30.4

10 0.39 1.25 0.05 3.5 25.3 34.3 4.6 33.3 45.1 7.1 51.4 69.6

12 0.47 1.25 0.05 6.5 47.0 63.7 8.4 60.8 82.4 12.5 90.4 122.6

14 0.55 1.5 0.06 10.4 75.2 102.0 13.5 97.6 132.4 19.5 141.8 192.2

16 0.63 1.5 0.06 15.8 114.3 154.9 20.6 149.0 202.0 29.3 211.9 287.3

18 0.71 1.5 0.06 22.9 165.6 224.6 29.8 215.5 292.2 42.2 305.2 413.8

20 0.79 1.5 0.06 31.7 229.3 310.9 41.2 298.0 404.0 58.5 423.1 573.7

22 0.87 1.5 0.06 42.2 305.2 413.8 54.8 396.4 537.4 77.8 562.7 763.0

24 0.95 1.5 0.06 55.8 403.6 547.2 72.5 524.4 711.0 102.6 742.1 1006.2

27 1.06 1.5 0.06 81.0 585.9 794.3 105.3 761.6 1032.6 148.0 1070.5 1451.4

30 1.18 1.5 0.06 112.2 811.5 1100.3 145.9 1055.3 1430.8 205.2 1484.2 2012.3

33 1.30 1.5 0.06 149.6 1082.1 1467.1 194.5 1406.8 1907.4 273.3 1976.8 2680.2

36 1.42 1.5 0.06 195.6 1414.8 1918.2 254.3 1839.4 2493.8 356.6 2579.3 3497.1

39 1.54 1.5 0.06 251.0 1815.5 2461.5 326.2 2359.4 3198.9 455.8 3296.8 4469.9

Note
1. The tolerance on these torques is ± 10%.
2. These torques are for “dry” conditions.

PDMM-0115 Issued: 07/31/2002 10-21

Maintenance Service Data Raymond ® DSD Maintenance Manual

Tightening Torques for Standard Bolts and Nuts

Tightening Torques for Standard Bolts and Nuts – Fine Thread – Without Spring Washer

Nominal
Pitch
Size

mm in. mm in. kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m

6 0.24 1 0.04 0.88 6.4 8.6 1.1 8.0 10.8 1.5 10.8 14.7

8 0.32 1.25 0.05 2.0 14.5 19.6 2.7 19.5 26.5 3.7 26.8 36.3

10 0.39 1.25 0.05 4.2 30.4 41.2 5.4 39.1 53.0 8.3 60.0 81.4

12 0.47 1.25 0.05 7.6 55.0 74.5 9.9 71.6 97.1 14.7 106.3 144.2

14 0.55 1.5 0.06 12.2 88.2 119.6 15.9 115.0 155.9 23.1 167.1 226.5

16 0.63 1.5 0.06 18.6 134.5 182.4 24.2 175.0 237.3 34.5 249.5 338.3

18 0.71 1.5 0.06 26.9 194.6 263.8 35.0 253.2 343.2 49.7 359.5 487.4

20 0.79 1.5 0.06 37.3 269.8 365.8 48.5 350.8 475.6 68.8 497.6 674.7

22 0.87 1.5 0.06 49.6 358.8 486.4 64.5 466.5 632.5 91.5 661.8 897.3

24 0.95 1.5 0.06 65.6 474.5 643.3 85.3 617.0 836.5 120.7 873.0 1183.7

27 1.06 1.5 0.06 95.3 689.3 934.6 123.9 896.2 1216.0 174.1 1259.3 1707.3

30 1.18 1.5 0.06 132.0 954.8 1294.5 171.6 1241.2 1682.8 241.4 1746.0 2367.3

33 1.30 1.5 0.06 176.0 1273.0 1726.0 228.8 1654.9 2243.8 321.6 2326.1 3153.8

36 1.42 1.5 0.06 230.1 1664.3 2256.5 299.2 2164.1 2934.1 419.6 3035.0 4114.0

39 1.54 1.5 0.06 295.3 2135.9 2896.0 383.8 2776.0 3763.8 536.2 3878.3 5258.3

Note
1. The tolerance on these torques is ± 10%.
2. These torques are for “dry” conditions.

10-22 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Maintenance Service Data

Tightening Torques for Standard Bolts and Nuts

Tightening Torques for Standard Bolts and Nuts – Coarse Thread – With Spring Washer

Nominal
Pitch
Size

mm in. mm in. kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m

10 0.39 1.5 0.06 3.4 24.6 33.3 4.4 31.8 43.1 6.9 49.9 67.7

12 0.47 1.75 0.07 6.0 43.4 58.8 7.8 56.4 76.5 11.8 85.3 115.7

14 0.55 2 0.08 9.8 70.9 96.1 12.7 91.9 124.5 18.6 134.5 182.4

16 0.63 2 0.08 15.0 108.5 147.1 19.5 141.0 191.2 28.0 202.5 274.6

18 0.71 2.5 0.10 20.7 149.7 203.0 27.0 195.3 264.8 39.1 282.8 383.4

20 0.79 2.5 0.10 29.2 211.2 286.4 37.9 274.1 371.7 54.7 395.6 536.4

22 0.87 2.5 0.10 39.1 282.8 383.4 50.9 368.2 499.2 73.0 528.0 715.9

24 0.95 3 0.12 50.2 363.1 492.3 65.3 472.3 640.4 94.3 682.1 924.8

27 1.06 3 0.12 73.9 534.5 724.7 96.1 695.1 942.2 137.7 996.0 1350.4

30 1.18 3.5 0.14 98.9 715.3 969.9 128.4 928.7 1259.2 188.0 1359.8 1843.7

33 1.30 3.5 0.14 135.5 980.12 1328.8 176.1 1273.7 1727.0 252.6 1827.1 2477.2

36 1.42 4 0.16 170.9 1236.1 1676.0 222.3 1607.9 2180.0 326.3 2360.1 3199.9

39 1.54 4 0.16 226.3 1636.8 2219.2 294.1 2127.2 2884.1 420.0 3037.9 4118.8

42 1.65 4.5 0.18 280.9 2031.8 2754.7 365.2 2641.5 3581.4 523.9 3789.4 5137.7

Note
1. The tolerance on these torques is ± 10%.
2. These torques are for “dry” conditions.

PDMM-0115 Issued: 07/31/2002 10-23

Maintenance Service Data Raymond ® DSD Maintenance Manual

Tightening Torques for Standard Bolts and Nuts

Tightening Torques for Standard Bolts and Nuts – Coarse Thread – Without Spring Washer

Nominal
Pitch
Size

mm in. mm in. kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m

10 0.39 1.5 0.06 4.0 28.9 39.2 5.2 37.6 51.0 8.1 58.6 79.4

12 0.47 1.75 0.07 7.1 51.4 69.6 9.2 66.5 90.2 13.8 99.8 135.3

14 0.55 2 0.08 11.5 83.2 112.8 14.9 107.8 146.1 22.0 159.1 215.7

16 0.63 2 0.08 17.6 127.3 172.6 22.9 165.6 224.6 33.0 238.7 323.6

18 0.71 2.5 0.10 24.4 176.5 239.3 31.8 230.0 311.9 46.0 332.7 451.1

20 0.79 2.5 0.10 34.3 248.1 336.4 44.6 322.6 437.4 64.3 465.1 630.6

22 0.87 2.5 0.10 40.0 289.3 392.3 59.9 433.3 587.4 85.9 621.3 842.2

24 0.95 3 0.12 59.0 426.7 578.6 76.8 555.5 753.2 111.0 802.9 1088.5

27 1.06 3 0.12 86.9 628.5 852.2 113.0 817.3 1108.2 162.0 1171.7 1588.7

30 1.18 3.5 0.14 116.3 841.2 1140.5 151.1 1092.9 1481.8 221.1 1599.2 2168.3

33 1.30 3.5 0.14 159.4 1153.0 1563.2 207.2 1498.7 2031.9 297.3 2150.4 2915.5

36 1.42 4 0.16 201.1 1454.6 1972.1 261.5 1891.4 2564.4 384.0 2777.5 3765.8

39 1.54 4 0.16 266.2 1925.4 2610.5 346.0 2502.6 3393.1 494.1 3573.8 4845.5

42 1.65 4.5 0.18 330.5 2390.5 3241.1 429.5 3107.3 4212.9 616.4 4458.4 6044.8

Note
1. The tolerance on these torques is ± 10%.
2. These torques are for “dry” conditions.

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Raymond ® DSD Maintenance Manual Maintenance Service Data

Service Data: General

Service Data: General

Maintenance Chart Perform service on items at multiples of the

original requirement. For example, at every
Use the service chart to determine servicing 1200 hours or 6 months, also service those
intervals. Calendar intervals shown (weekly, items listed under every 200 hours or monthly,
monthly, etc.) may be used instead of service every 50 hours or weekly and daily (pre-start).
meter intervals if they provide more convenient
servicing schedules and approximate the ● = Check or clean
indicated service meter reading. Recommended ★ = Change or adjust
service should always be performed at the
interval that occurs first.

Maintenance Intervals

Every 1200 hours

Every 2400 hours

Every 200 hours
Daily (pre-start)

Every 50 hours

or 6 months
or monthly
or weekly

or 1 year
How to
Inspection Point Service Data
Check

Motors Bearing Visual Lubricate

lubrication, ● ●
damage

Winding to case Test Resistance is

● ●
resistance greater than
1 ohm
Armature to case Test
● ●
resistance

Brush contact Visual Change brush

● ●
area

Brush length Visual ● ● Change brush

Brush spring Test Change spring

● ●
force

Commutator Visual
surface ● ●
condition

Commutator Visual
● ●
discoloration
Interior, exterior Visual Clean
● ● ●
cleanliness

PDMM-0115 Issued: 07/31/2002 10-25

Maintenance Service Data Raymond ® DSD Maintenance Manual

Maintenance Chart

Maintenance Intervals

Every 1200 hours

Every 2400 hours

Every 200 hours
Daily (pre-start)

Every 50 hours

or 6 months
or monthly
or weekly

or 1 year
How to
Inspection Point Service Data
Check

Steering Free-play, Test

wheel looseness, ● ● ● ● ●
rattling

Operation Test ● ● ● ● ●

Steering Oil leaks Visual ● ● ● ● ●

gear
Mounting bolts, Wrench
● ● ●
tightness
Steering Beam structural Visual
●
linkage damage

Cylinder leaks Visual ● ● ● ● ●

Cylinder Wrench
●
mounting bolts
Tie rod bearings Visual
●
and pins

Kingpin looseness Test ●

Trunnion fore-aft Test Nominal 0.8 mm

looseness ● (0.031 in.)
clearance

Brake pedal Height of pedal Scale 89 ± 3 mm

● ● ● ● ●
above floor (3.5 ± 0.12 in.)

Stroke to point Scale 3 to 10 mm

where brakes ● ● ● ● ● (0.12 to 0.4 in.)
start applying

Parking Performance Test/spring Lever lock position:

brake balancer 4° to 5°
Operating effort: 25
● ● ● ● ●
to 30 kgf
(55 to 66 lb)
[245 to 294 N]

Brake Fluid leaks, Visual

hoses and damage or ● ● ● ● ●
pipes installation

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Raymond ® DSD Maintenance Manual Maintenance Service Data

Maintenance Chart

Maintenance Intervals

Every 1200 hours

Every 2400 hours

Every 200 hours
Daily (pre-start)

Every 50 hours

or 6 months
or monthly
or weekly

or 1 year
How to
Inspection Point Service Data
Check

Brake fluid Level in reservoir Visual ● ● ● ● ★ 103 cc (7.9 cu. in.)

Wheel Master cylinder Overhaul/

brakes and wheel Visual
cylinders— ★
operation, wear
and damage

Brakes Drum-to-lining Feeler gauge DSD30–35

drums clearance 0.2 to 0.5 mm
and shoes (0.01 to 0.02)
● ● ●
DSD40–60
0.2 to 0.6 mm
(0.01 to 0.02)

Sliding surfaces Disassemble DSD30–35

of shoes and /calipers 2.5 mm (0.10 in.)
●
wear of lining DSD40–60
3.0 mm (0.12 in.)

Drum—wear or Visual/scale Service Limit:

damage DSD30–35
254 + 0 0.13 mm
● (10.00 + 0 0.0051 in.)
DSD40–60
310 + 0 0.13 mm
(12.20 + 0 0.0051 in.)

Free length of Scale

●
return springs

Operation of Test
●
shoes

Anchor pins— Visual

●
seizure

PDMM-0115 Issued: 07/31/2002 10-27

Maintenance Service Data Raymond ® DSD Maintenance Manual

Maintenance Chart

Maintenance Intervals

Every 1200 hours

Every 2400 hours

Every 200 hours
Daily (pre-start)

Every 50 hours

or 6 months
or monthly
or weekly

or 1 year
How to
Inspection Point Service Data
Check

Backing Distortion, Dye check

plates cracks, or ●
damage

Fitting cables– Visual/scale

damage and ●
length

Ratchet–wear or Visual
●
damage

Front axle Cracks, Dye check/

distortion, or visual
●
other signs of
damage

Front wheel Spring Hub bearing

bearings– balancer preload
preload ● 5 to 50 kgf
(0.4 to 3.6 lbf•ft)
[0.5 to 4.9 N•m]

Fore-aft play Test ●

Cracks, Visual
distortion, or
●
other signs of
damage

Differential Oil level and oil Visual DSD30–35

leaks 5.7 liters
(1.5 U.S. gal)
● ● ●
DSD40–60
6.1 liters
(1.6 U.S. gal)

Mounting bolts Torque

●
wrench

10-28 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Maintenance Service Data

Maintenance Chart

Maintenance Intervals

Every 1200 hours

Every 2400 hours

Every 200 hours
Daily (pre-start)

Every 50 hours

or 6 months
or monthly
or weekly

or 1 year
How to
Inspection Point Service Data
Check

Rear axle Front wheel Spring Hub bearing

bearings– balancer preload
preload Torque 25 to 65 kgf
wrench (1.8 to 4.7 lbf•ft)
● [2.5 to 6.4 N•m]
Lock Nut (outside)
16 kgf•cm
(116 lbf•ft)
[157 N•m]

Wheels Tires–cuts or Visual

● ● ● ● ●
gouges

Tires–wear Depth gauge ● ● ● ● ●

Tires–imbedded Visual
● ● ● ● ●
objects
Wheel nuts– Torque
● ● ●
tightness wrench

Front Wheel Nuts:

DSD30–35
16 kgf•cm (116 lbf•ft) [157 N•m]
DSD40–60
38.5 kgf•cm (278 lbf•ft) [378 N•m]

Rims–damage Visual ● ● ● ● ●

Hydraulic Oil level and Visual

● ● ● ● ★
tank contamination

Strainer— Visual
★
clogging

Return filter— Visual

★
clogging

Hydraulic Oil leaks or Visual/

● ● ●
pump abnormal noise listen

PDMM-0115 Issued: 07/31/2002 10-29

Maintenance Service Data Raymond ® DSD Maintenance Manual

Maintenance Chart

Maintenance Intervals

Every 1200 hours

Every 2400 hours

Every 200 hours
Daily (pre-start)

Every 50 hours

or 6 months
or monthly
or weekly

or 1 year
How to
Inspection Point Service Data
Check

Control Oil leaks Visual ● ● ● ● ●

valve
Main relief valve Pressure 185 kgf/cm2
setting gauge ● (2631 psi)
[18,142 kPa]

Auxiliary relief Pressure 158 ± 5 kgf/cm2

valve setting gauge ● 2250 ± 71psi
15,513 ± 490 kPa

Overload relief Pressure

●
setting (optional) gauge

Control levers Test

● ● ● ● ●
and links—rattle
Lift Cracks, Visual
cylinders distortion, or
● ● ● ● ●
other signs of
damage

Rod drift (rated Visual/ DSD30–5E

load) watch/ 50 mm (2.0 in.)
scale /15 min
● ● ● ● ●
DSD60
40 mm (1.6 in.)
/15 min

Attachment ● ● ● ● ●

Mounting bolts— Wrench

● ● ●
tightness
Oil Leaks Visual ● ● ● ● ●

Flow Lowering speed Watch/scale Lowering speed

regulator (rated load)
valve DSD30–5E
520 mm/sec
● ● ●
(102 fpm)
DSD60
500 mm/sec
(98 fpm)

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Raymond ® DSD Maintenance Manual Maintenance Service Data

Maintenance Chart

Maintenance Intervals

Every 1200 hours

Every 2400 hours

Every 200 hours
Daily (pre-start)

Every 50 hours

or 6 months
or monthly
or weekly

or 1 year
How to
Inspection Point Service Data
Check

Tilt Cracks, Visual

● ● ● ● ●
cylinders distortion,
Oil leaks Visual ● ● ● ● ●

Forward rod drift Watch/scale DSD30–35

(rated load) 22 mm (0.9 in.)
/15 min
DSD40–5E
● ● ● 20 mm (0.8 in.)
/15 min
DSD60
15 mm (0.6 in.)
/15 min

Mounts—rattle or Visual/free
● ● ● ● ●
damage

Rod socket nut— Torque DSD30 - 35

tightness wrench 15 kgf•m
(108 lbf•ft)
[147 N•m]
● ● ● ● ●
DSD40 - 60
40 kgf•m
(289 lbf•ft)
[392 N•m]

Piping Oil leaks Visual ● ● ● ● ●

Rubber hoses: Visual

● ● ●
damage

Hose reels and Visual

swivel joint—
distortion or ● ● ●
other signs of
damage

PDMM-0115 Issued: 07/31/2002 10-31

Maintenance Service Data Raymond ® DSD Maintenance Manual

Maintenance Chart

Maintenance Intervals

Every 1200 hours

Every 2400 hours

Every 200 hours
Daily (pre-start)

Every 50 hours

or 6 months
or monthly
or weekly

or 1 year
How to
Inspection Point Service Data
Check

Mast Cracks, Visual/dye

and lift distortion, or check
● ● ● ● ●
bracket other signs of
damage

Mast supports—
● ● ●
rattle or damage

Main rollers— Feeler Each roller to mast

clearance, gauge/dial clearance (at max.
damage gauge ● ● ● height):
0.1 to 0.5 mm
(0.004 to 0.020 in.)

Lift chains Length of lift Scale DSD30–35

and chain chains 318 mm (12.5 in.)
wheels (20 links) DSD40–5E
●
381 mm (15.0 in.)
DSD60
508 mm (20.0 in.)

Tension deflection Scale Both chains to

● ● ● ● ●
of lift chains equal in tension

Chains—damaged Visual
● ● ● ● ●
or rusting

Chains wheels— Visual

wear, distortion,
● ● ●
or other signs of
damage

Chain wheel Feel

● ● ●
bearings—rattle

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Raymond ® DSD Maintenance Manual Maintenance Service Data

Maintenance Chart

Maintenance Intervals

Every 1200 hours

Every 2400 hours

Every 200 hours
Daily (pre-start)

Every 50 hours

or 6 months
or monthly
or weekly

or 1 year
How to
Inspection Point Service Data
Check

Forks and Chain anchor Visual

Backrest bolts—distortion ● ● ●
or damage

Forks—wear and Visual/scale Fork thickness—

● ● ● ● ●
distortion refer to Service Data

Forks stopper Visual

pins—damage ● ● ● ● ●
or distortion

Backrest Torque
mounting wrench ● ● ● ● ●
bolts—tightness

Backrest— Visual
distortion or ● ● ● ● ●
damage

Lights Operation Test/visual ● ● ● ● ●

Horn Operation Test ● ● ● ● ●

Turn Operation Test

signals ● ● ● ● ●
(optional)

Rear view Provide vision Visual

mirrors assistance ● ● ● ● ●
(optional)

Overhead Installation and Visual/

● ● ● ● ●
guard damage wrench

PDMM-0115 Issued: 07/31/2002 10-33

Maintenance Service Data Raymond ® DSD Maintenance Manual

Maintenance Chart

Maintenance Intervals

Every 1200 hours

Every 2400 hours

Every 200 hours
Daily (pre-start)

Every 50 hours

or 6 months
or monthly
or weekly

or 1 year
How to
Inspection Point Service Data
Check

Chassis Loosen bolts or Wrench

●
nuts
Operator’s seat— Visual
• damage ● ●
• installation ● ● ●

Lubrication Lubricate Lubricate mast

points ● ● ● supports every 50
hours or weekly

Oil change Inspect ● ● ●

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Raymond ® DSD Maintenance Manual Maintenance Service Data

Periodic Replacement Parts

Periodic Replacement Parts

The parts listed below are important for the safe schedule given here on all trucks brought into
operation of the truck, and especially designed its care.
to be replaced at specified periods. Each service
shop is requested to adhere to the replacement

Period

Periodic 1 1 6
Service 1 year 2 years
Replacement Parts month month months
(2400 (4800
after (200 (1200
hours) hours)
delivery hours) hours)

★Rubber parts for Replace

1 brake master ● ●
cylinder

★Rubber parts for Replace

2 brake wheel ● ●
cylinders

3 ★Hydraulic hoses Replace ● ●

★Hoses for power Replace

4 ●
steering

★Rubber parts for Replace

5 ●
steering cylinder

6 ★Lift chains Replace ●

Hydraulic tank Replace

7 ● ● ● ●
return filter

Drum to lining Check or

8 ● ●
clearance replace

Motor brushes Check or

9 ● ●
replace

★ Indicates important safety-related parts

PDMM-0115 Issued: 07/31/2002 10-35

 Lubrication and Maintenance Chart Be Sure to Perform Service Items Quoted Below

10-36
Lubrication Chart

Check Lubricate

Every 10 Hr. or Daily Multipurpose-type Grease

Every 50 Hr. or Weekly
Specific Gravity of Battery Engine Oil
Maintenance Service Data

Oil Leaks
Bolts, Nuts Every 50 Hr. Or Weekly
Tires, Wheel Nuts Mast Supports
Every 200 Hr. or Monthly Every 200 Hr. or Monthly
Brake Fluid Level
Lubrication Chart

Differential Oil Level Mast Strips, Roller Surfaces

Hydraulic Oil Level (Each Side)
Every 600 Hr. or 3 Months Lift Bracket Side Rollers
Battery Electrolyte Level Contactors (Each Side)
Motor Brushes
Battery Restraint
Lift Chain (Each Side)
Mast, Forks, Lift Chains
Tilt Socket (Each Side)
Seat Belt and Rails Change Front Axle Support
(Each Side)
Steering Oil,
Filter
Service Brakes Tilt Cylinder (Each Side)
Every 1200 Hr. Or 6 Months
Parking Brake Transfer and Differential Oil Brake Pedal
Hydraulic Tank Oil Filter Tie Rod Ends (4 Fittings)
Accelerator Pedal
Horn Rear Axle Center Pin
Every 2400 Hr. or 1 Year (Front/rear)
Dash Monitor Hydraulic Oil
Brake Fluid

NOTE: Reduce Servicing Intervals in Dusty or Severe Conditions. Refer to Operation Manual.

PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual
Raymond ® DSD Maintenance Manual Maintenance Service Data

Fuel and Lubricant Specifications

Fuel and Lubricant Specifications

Recommendation for ambient temperatures [°C (°F)]

Oil Recommendation (-22) (-4) (14) (32) (50) (68) (86)

-30 -20 -10 0 10 20 30

| | | | | | |

Gear oil API service ISO Grade 32 ▲ ISO Grade 68

classification SAE75W SAE80W
multipurpose type AGMA-1EP AGMA-2EP
GL-5 (hypoid gear
oil)
Hydraulic oil SAE 5W -30 to -10 SAE 10W

Brake fluid F.M.V.S.S. No. 116—DOT 3 or DOT4 (SAE J1703)

Grease Wheel NLGI No. 2 grade multipurpose type (lithium base), consistency: 265 - 295
bearings

Chassis NLGI No. 1 grade multipurpose type (lithium base), consistency: 310 - 340

• Avoid mixing lubricants. In some cases, ▲ EP68 Gear oil with borate additives are not
different brands of lubricants are not recommended.
compatible with each other and deteriorate
when mixed. It is best to stick with the
same brand at successive service intervals.

Gear Oil Greases Hydraulic

API service
Specifications NLGI No. 1 NLGI No. 2
classification GL-5
Consistency Consistency
Viscosity SAE90W SAE5W SAE10W
310-340 265-295
Manufacturer
Mobil Grease Mobil Grease JL Hydraulic
Mobil 90 Pegasus Gear Oil —
JL 77 No. 1 77 No. 2 oil 28 LP
Tellus oil
Shell Shell Spirax EP90 Retinax A No. 1 Retinax A No. 2 Tellus oil 22
T-32
Exxon Gear Oil GX 80W90 ---- Ronex MP UNIVISN 22 Nuto H32
Castrol Castrol
Castrol Castrol Spheerol
Castrol Castrol Hypoy Hyspin Hyspin
LM Grease API
AWS32 AWS68
■ Brands of oil are subject to change without notice.
■ When you buy oil, select recommended brands and check specifications.

PDMM-0115 Issued: 07/31/2002 10-37

Maintenance Service Data Raymond ® DSD Maintenance Manual

Weight of Major Components (Approximate)

Weight of Major Components (Approximate)

Component/Model DSD30 DSD35 DSD40 DSD50 DSD5E DSD60

Counterweight 470 625 540 730 540 1060

(1036) (1378) (1190) (1609) (1190) (2337)

Power train (Motor, transfer box,

200 (441) 215 (474) 1060
reduction gear and differential)

Overhead guard 62.7 (138) 67.4 (149) 66.0 (146)

Rear axle 150 (331) 220 (485)

Mast (3.3 m simplex mast) 520 (1146) 725 (1598) 830 (1830)

Outer mast 140 (309) 190 (419) 205 (452)

Inner mast 135 (298) 180 (397) 190 (419)

Lift bracket (including backrest) 105 (231) 150 (331) 175 (386)

Forks (two) 80 (176) 130 (287) 165 (364)

Lift cylinder and related parts 60 (132) 75 (165) 95 (209)

Hydraulic motor 45 (99) 50 (110)

Traction motor 80 (176) 100 (220)

Unit: kg (lb)

10-38 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Maintenance Service Data

Special Service Tools

Special Service Tools

Truck Models
Ref.
Part No. Part Name Application
No. DSD DSD DSD
30–35 40/5E 60

Socket Removal and installation of

1 223-012-185 ● ● ●
wrench rear wheel nuts

223-012-177 Bevel Removal of bevel pinion

2 (or pinion assembly ● ● ●
223-012-186) puller

Gauge kit Measurement of hydraulic

3 223-012-187 ● ● ●
pressure

Socket Removal/installation of front

4 223-012-169 ● ● ●
wrench wheel hub nuts

Socket Removal/installation of front

5 223-012-170 ● — —
wrench wheel hub nuts

Installer Installation of front axle wheel — ● ●

6 223-012-175 bearing inner races
● — —

Installer Installation of rear axle inner

7 223-012-178 ● — —
bearing inner races

Installer Installation of rear axle inner

8 223-012-179 — ● ●
bearing inner races

Installer Install rear axle outer bearing

9 223-012-188 ● — —
inner races

Installer Install rear axle outer bearing

10 223-012-189 — ● ●
inner races

Spring Removal of return spring

11 223-012-180 ● ● ●
remover

Spring Removal/installation of brake

12 223-012-181 ● ● ●
remover shoes

Spring Installation of return spring

13 223-012-182 ● ● ●
hook

Steering Removal of steering wheel

14 223-012-183 wheel ● ● ●
puller

PDMM-0115 Issued: 07/31/2002 10-39

Maintenance Service Data Raymond ® DSD Maintenance Manual

Special Service Tools

Truck Models
Ref.
Part No. Part Name Application
No. DSD DSD DSD
30–35 40/5E 60

Installer Installation of tilt cylinder tube

15 223-012-190 ● ● ●
bushing

223-012-191 Hook Remove/install tilt cylinder ● — —

wrench guide bushing
16 223-012-192 — ● —

223-012-193 — — ●

Pipe Measurement of control valve

223-012-194
connector main relief pressure and
17 or ● ● ●
overload relief pressure
223-012-195
(use with gauge kit)

Spring Install centering spring in steer

18 223-012-196 ● ● ●
installer gear

Wheel Removal of drive wheel hub

19 223-012-171 ● — —
puller

Wheel Removal of drive wheel hub

20 223-012-173 — ● ●
puller

Pressure Main relief valve pressure

21 223-012-197 ● ● ●
port check

Transfer Removal of bevel pinion shaft

22 223-012-176 bearing ● ● ●
tool

Plug assy Torque or steer gear tank

23 223-012-184 ● ● ●
tool

10-40 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Maintenance Service Data

Special Tool Illustrations

Special Tool Illustrations

1 2

46 M10 x 1.5
M14 x 1.5

164
95 17
10
250 22

155
3 4

5 6
90

7 8

PDMM-0115 Issued: 07/31/2002 10-41

Maintenance Service Data Raymond ® DSD Maintenance Manual

Special Tool Illustrations

9 10

ø31
ø48

ø71
ø68
30
40 10

11 12

13 14
M12 x 1.25

M8 x 1.25

45
55

15 16
ø32
ø35

30 45

Flame-hardened HV >500,
depth 2 mm (0.08 in.)

10-42 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Maintenance Service Data

Special Tool Illustrations

17 18

19 20

21 22

23

PDMM-0115 Issued: 07/31/2002 10-43

Maintenance Service Data Raymond ® DSD Maintenance Manual

Inspection Guide

Inspection Guide

Check For (item or condition) How

Antifriction ITEMS Measure inside diameter

bearings 1. Fit on shaft with an indicator hole
gauge and shaft outside
diameter with an
indicating micrometer

2. Fit in housing Measure outside diameter

with an indicating
micrometer and housing
inside diameter with an
indicator hole gauge

3. Preload (small initial load applied to As stated in service manual

absorb initial bearing deformation)

CONDITION As shown
1. High running temperature (caused by
over lubrication)

Radial Thrust
bearing bearing

2. Noise (humming), vibration, or rough

running

3. Creep (marks of circumferential slip on Visually

inner ring’s surface in contact with shaft
or on outer ring’s surface in contact with
housing due to loose fit of bearing)

4. Corrosion Visually

10-44 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Maintenance Service Data

Inspection Guide

Check For (item or condition) How

Antifriction 5. True brineling (caused by careless

bearings installation or removal)
(Cont’d)

6. False brinelling (caused by a constant Visually

vibration or oscillation of non-rotating
bearings through small arc)

7. Cracked race (caused by forcing bearing Visually

or oversize shaft or by cooking race when
installing or removing)

8. Broken separator (caused by dirt, metal Visually

chips, or lack of lubricant)

9. Damaged seal (caused by improper use of Visually

tools)

PDMM-0115 Issued: 07/31/2002 10-45

Maintenance Service Data Raymond ® DSD Maintenance Manual

Inspection Guide

Check For (item or condition) How

Antifriction 10. Spalled race (caused by too loose a fit) Visually

bearings
(Cont’d)

11. Bad discoloration (caused by Visually

overheating due to poor lubrication)

12. Craters (caused by passage of electric Visually

current)

Bushings or sleeve ITEM Determine by measuring

bearings Fit on shaft inside diameter of
bushing and outside
diameter of shaft

CONDITION Hold bushing toward a light

Nicks, burrs, or other flaws on bearing and look through bore
surface

Fasteners CONDITION Visually

1. Striped or otherwise damaged threads
(bolts, nuts, screws, etc.)

2. Distortion or loss of tension (spring lock Examine by compressing

washers, snap rings, etc.)

10-46 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Maintenance Service Data

Inspection Guide

Check For (item or condition) How

Gears ITEM As stated in service manual

1. Fit on bearing, bushing, spline or key

2. Backlash As stated in service manual

CONDITION Visually
1. Excessive wear on teeth, thrust faces,
and end faces on hub

2. Scratching wear (caused by large Visually

particles other than associated with
abrasive wear)

3. Abrasive wear (caused by fine particles Visually

carried in lubricant)

4. Overload wear Visually

5. Pitting Visually

PDMM-0115 Issued: 07/31/2002 10-47

Maintenance Service Data Raymond ® DSD Maintenance Manual

Inspection Guide

Check For (item or condition) How

Gears (Cont’d) 6. Spalling Visually

7. Overload breakage Visually

8. Fatigue breakage Visually

9. Corrosive wear Visually

Keys and keyways Wear on sides making parts not fit tightly Examine by placing

Oil seals Damage to lip Visually

10-48 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Maintenance Service Data

Inspection Guide

Check For (item or condition) How

Roller chains and 1. Wear on pins, bushings, rollers, and Visually

sprockets plates in each link tending to increase in
pitch.

2. Wear on sprocket teeth Visually

Chain
load

Sprocket
Rotation

New Old

Rubber parts Hardening or softening, swelling, tackiness, Visually

tearing, and deterioration due to aging

Splines and ITEM

serrations Fit

CONDITION Visually
1. Nicks, burrs, chips, etc.

2. Free movement (looseness) of mating Examine

splines

3. Excessive wear polish on sides (sliding fit Visually

splines)

4. Ridge or edge left between worn and Visually

unworn areas (sliding fit spline)

PDMM-0115 Issued: 07/31/2002 10-49

Maintenance Service Data Raymond ® DSD Maintenance Manual

Inspection Guide

Check For (item or condition) How

Springs ITEMS See specification

1. Type called for

2. Squareness Use a square

3. Free length test Examine

4. Test force

CONDITION Visually
1. Excessive clearance space between coils
(compression springs) in free state

2. Any clearance space between coils

(tension springs) in free state

3. Condition or ends or hooks Visually

4. Cracks or breakage Visually

10-50 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Index

Index I:

PDMM-0115 Issued: 07/31/2002 I-1

Index Raymond ® DSD Maintenance Manual

NOTE: Page references contained in the index Reduction Differential . . . . . . . . M:2-16

use a prefix to direct you to the proper Reduction Differential
section of the manual. The two prefix Tooth Contact . . . . . . . . . . . M:2-17
definitions are: Stroke, Lift Cylinder . . . . . . . . . M:8-19
Tilt Angle . . . . . . . . . . . . . . . . . M:8-19
E: Electrical (Controls Section)
Turning Radius . . . . . . . . . . . . M:4-18
M: Mechanical (Chassis/Mast Section) Ammeter, Definition . . . . . . . . . . . . . E:1-2
Ampere, Abbreviation Amp . . . . . . . . E:1-2
Ampere, Definition . . . . . . . . . . . . . . E:1-2
A Anode, Definition . . . . . . . . . . . . . . . E:1-2
Armature, Definition . . . . . . . . . . . . E:1-2
Accelerator Volts Hold Off, Auto Braking, Description . . . . . . . E:1-13
Description . . . . . . . . . . . . . . . . E:1-14 Auxiliary Relief Valve
Accelerator, Definition . . . . . . . . . . . . E:1-2 Reassembly . . . . . . . . . . . . . . . M:7-29
Activate, Definition . . . . . . . . . . . . . . E:1-2 Removal . . . . . . . . . . . . . . . . . . M:7-29
Adjustment
Auxiliary Relief Valve . . . . . . . . . M:7-41 B
Brake Automatic Adjustment
Device . . . . . . . . . . . . . . . . . M:5-14
Brake Pedal . . . . . . . . . . . . . . . . M:5-15 Backlash, Reduction Gear . . . . . . . M:2-16
Chain Tension . . . . . . . . . . . . . . M:8-12 Battery
Drum to Lining . . . . . . . . . . . . . M:5-14 Safety . . . . . . . . . . . . . . . . . . . . . E:S-4
Fork Carriage Battery Discharge Indication
Clearance . . . . . . . . . . . . . . . M:8-9 (BDI), Description . . . . . . . . . . . E:1-15
Main Roller Lateral Battery Discharge Indicator,
Clearance . . . . . . . . . . . . M:8-14 Definition . . . . . . . . . . . . . . . . . . E:1-2
Main Roller Longitudinal Battery, Definition . . . . . . . . . . . . . . E:1-2
Clearance . . . . . . . . . . . . M:8-13 Bearing Cap Removal . . . . . . . . . . . . M:8-4
Side Roller Lateral Bipolar Junction Transistor,
Clearance . . . . . . . . . . . . M:8-14 Definition . . . . . . . . . . . . . . . . . . E:1-2
Lift Bracket Bleeding
Main Roller Lateral Lift Cylinders . . . . . . . . . . . . . . M:8-20
Clearance . . . . . . . . . . . . M:8-14 Bleeding Brake Lines . . . . . . . . . . . M:5-15
Main Roller Longitudinal Brake
Clearance . . . . . . . . . . . . M:8-13 Testing . . . . . . . . . . . . . . . . . . . M:5-15
Side Roller Lateral Brake Pedal Adjustment . . . . . . . . . M:5-15
Clearance . . . . . . . . . . . . M:8-14 Brake Pedal Specifications . . . . . . . M:10-7
Lift Bracket Clearance . . . . . . . . . M:8-9 Brake Specifications
Lift Cylinder Stroke . . . M:7-42, M:8-19 Parking . . . . . . . . . . . . . . . . . M:10-12
Main Relief Valve . . . . . . . . . . . . M:7-41 Service . . . . . . . . . . . . . . . . . . M:10-11
Mast Clearance . . . . . . . . . . . . . . M:8-9 Brake System
Inner Main Mast Rollers, Automatic Adjusting Device . . . . M:5-2
Lateral . . . . . . . . . . . . . . M:8-16 Automatic Adjusting Device,
Main Mast Rollers, Adjustment . . . . . . . . . . . . . M:5-14
Longitudinal . . . . . . . . . M:8-16 Automatic Adjusting Device,
Outer Main Mast Rollers, Inspection . . . . . . . . . . . . . . M:5-14
Lateral . . . . . . . . . . . . . . M:8-17 Description . . . . . . . . . . . . . . . . . M:5-2
Mast Strip . . . . . . . . . . . . . . . . . M:8-18 Master Cylinder . . . . . . . . . . . . . M:5-3
Mast Tilt Angle . . . . . . . . . . . . . M:7-42 Troubleshooting . . . . . . . . . . . . . M:9-3
Master Cylinder . . . . . . . . . . . . . . M:5-4 Brakes, Service
Rear Axle Bearing Support Adjustment Screw, Inspection . . M:5-8
Clearance . . . . . . . . . . . . . . . M:4-9

I-2 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Index

Automatic Adjusting Device, -06, No direction selected when

Installation . . . . . . . . . . . . .M:5-11 accelerator depressed . . . . . E:6-11
Backing Plate, Inspection . . . . . . .M:5-8 -07, Accelerator input voltage
Disassembly . . . . . . . . . . . . . . . .M:5-5 too high . . . . . . . . . . . . . . . . E:6-12
Drum, Inspection . . . . . . . . . . . . .M:5-8 -08, Accelerator input speed
Greasing . . . . . . . . . . . . . . . . . .M:5-11 to high on power-up . . . . . . E:6-13
Hold-Down Spring, Removal . . . .M:5-7 -09, Both directional switches c
Parking Brake Cable, Inspection .M:5-8 losed . . . . . . . . . . . . . . . . . . E:6-14
Reassembly . . . . . . . . . . . . . . . . .M:5-9 -11, Start switch closed on
Return Spring, Installation . . . .M:5-11 power-up . . . . . . . . . . . . . . . E:6-15
Return Spring, Removal . . . . . . . .M:5-7 -117, Invalid card type
Shoe and Lining, Inspection . . . . .M:5-8 selection . . . . . . . . . . . . . . . E:6-52
Shoe, Installation . . . . . . . . . . .M:5-11 -127, Logic card power supply
Wheel Cylinder, Installation . . . .M:5-11 less than 10 VDC . . . . . . . . E:6-52
Braking, Auto, Description . . . . . . . E:1-13 -128, Armature current too
Braking, Description, Regenerative, high during lift . . . . . . . . . . E:6-53
Pedal Position . . . . . . . . . . . . . . E:1-13 -141,Pump control
Braking, Regenerative, Description . E:1-13 over-temperature . . . . . . . . . E:6-53
Brush Wear Indicators, -142, Pump control current
Checks/Repairs . . . . . . . . . . . . . . E:3-6 sensor input missing . . . . . . E:6-54
Brush, Definition . . . . . . . . . . . . . . . E:1-2 -143, Pump controller motor
Bus Bar, Definition . . . . . . . . . . . . . . E:1-2 current sensor input
Bypass (1A) Traction Contactor, too low . . . . . . . . . . . . . . . . E:6-55
Definition . . . . . . . . . . . . . . . . . . E:1-2 -144, Power transistor did not
turn off properly . . . . . . . . . E:6-56
-145, Power transistor did not
C turn on properly . . . . . . . . . E:6-57
-146, "Look Ahead" test for
Capacitor, Definition . . . . . . . . . . . . . E:1-2 pump motor . . . . . . . . . . . . E:6-58
Cathode, Definition . . . . . . . . . . . . . . E:1-2 -15, Battery voltage too low . . . . E:6-16
Chain Anchor Kit Installation . . . . .M:8-10 -15, Control card mis-adjusted . E:6-16
Precautions . . . . . . . . . . . . . . . .M:8-10 -150, Capacitor volts low after
Chain Tension Adjustment . . . . . . .M:8-12 line contactor closes . . . . . . E:6-59
Chain Wheel Inspection . . . . . . . . . . .M:8-8 -151, Capacitor volts too low . . . E:6-60
Chain Wheel Support Inspection . . . .M:8-8 -157, Controller motor sensor
Checks/Repairs input voltage check . . . . . . . E:6-61
Brush Wear Indicators . . . . . . . . . E:3-6 -16, Battery voltage too high . . . E:6-17
Contactor . . . . . . . . . . . . . . . . . . E:3-5 -16, Control card mis-adjusted . E:6-17
Fuses . . . . . . . . . . . . . . . . . . . . . E:3-3 -180, Voltage at 1C less than
Switches, Thermal, Motor . . . . . . E:3-6 14 volts . . . . . . . . . . . . . . . . E:6-62
Truck Management Module . . . . . E:3-7 -181, Battery voltage less than
Circuit Operation, Basics . . . . . . . . E:1-10 14 volts . . . . . . . . . . . . . . . . E:6-63
Circuit, Definition . . . . . . . . . . . . . . . E:1-2 -189, Input switch closed
Closed Circuit, Definition . . . . . . . . . E:1-2 before pump enable signal
Code received . . . . . . . . . . . . . . . . E:6-64
-01, No seat switch input . . . . . . . E:6-7 -21, Accelerator voltage
-02, Forward switch closed on too high . . . . . . . . . . . . . . . . E:6-18
power-up . . . . . . . . . . . . . . . . E:6-8 -23, Motor field current
-03, Reverse switch closed on too high on reverse
power-up . . . . . . . . . . . . . . . . E:6-9 start-up . . . . . . . . . . . . . . . E:6-19
-05, Start or brake switch fail -24, Motor field current too
to close . . . . . . . . . . . . . . . . E:6-10 high on forward start-up . . . E:6-20

PDMM-0115 Issued: 07/31/2002 I-3

Index Raymond ® DSD Maintenance Manual

-27, Control internal power -91, Pump motor temperature

supply less than out of range (hyd. pump
10 VDC . . . . . . . . . . . . . . . . E:6-21 controller) . . . . . . . . . . . . . . E:6-46
-28, Motor field current too -94, Traction motor brush
high in run mode . . . . . . . . . E:6-22 worn . . . . . . . . . . . . . . . . . . E:6-47
-42, Motor armature offset -94, Traction motor brush worn
voltage too high . . . . . . . . . . E:6-23 (hyd. pump controller) . . . . E:6-48
-43, Motor armature offset -95, Pump motor brush worn . . E:6-49
voltage too low . . . . . . . . . . . E:6-24 -95, Pump motor brush worn
-44, Armature transistor did (hyd. pump controller) . . . . E:6-50
not turn off properly . . . . . . E:6-25 -99, Maintenance alert &
-45, Armature transistor did speed limit . . . . . . . . . . . . . E:6-51
not turn off properly . . . . . . E:6-26 None, Segments do not
-46, "Look Ahead" test for illuminate . . . . . . . . . . . . . . . E:6-6
A2 volts . . . . . . . . . . . . . . . . E:6-27 Coil Driver Modules, Circuit Board,
-49, Motor field current too Description . . . . . . . . . . . . . . . . E:1-16
low during run mode . . . . . . E:6-28 Coil, Definition . . . . . . . . . . . . . . . . . E:1-2
-51, Capacitor volts low before Commutator Surface Conditions . . E:3-21
line contactor closes . . . . . . E:6-29 Commutator, Definition . . . . . . . . . . E:1-2
-57, Controller motor current Compensation Table, Internal
sensor input too low . . . . . . E:6-30 Resistance . . . . . . . . . . . . . . . . . E:2-9
-64, Line driver input less Compound Motor, Definition . . . . . . E:1-2
than 12% of battery voltage . E:6-31 Conduct, Definition . . . . . . . . . . . . . E:1-2
-65, Line coil too high during Conductor, Definition . . . . . . . . . . . . E:1-2
run mode . . . . . . . . . . . . . . . E:6-32 Connections
-66, Field current exceeds Pump Driver Terminals . . . . . . . E:5-17
current limit . . . . . . . . . . . . E:6-33 Pump Time Delay Terminals . . . E:5-18
-67, Armature current SX Motor Controller . . . . . . . . . E:1-29
exceeds limit . . . . . . . . . . . . E:6-34 Truck Management Module
-69, Power steering coil current Terminals . . . . . . . . . . . . . . E:5-15
too high during run mode . . E:6-35 Connector, Definition . . . . . . . . . . . . E:1-2
-76, Capacitor voltage too high . E:6-36 Contact Tips, Definition . . . . . . . . . . E:1-2
-77, Motor current detected Contactor . . . . . . . . . . . . . . . . . . . . . E:3-4
during regenerative Contactor Assembly, Definition . . . . E:1-2
braking . . . . . . . . . . . . . . . . E:6-37 Contactor Coil, Definition . . . . . . . . . E:1-2
-82, Armature motor current Contactor, Repair . . . . . . . . . . . . . . . E:3-5
time out . . . . . . . . . . . . . . . . E:6-38 Contacts, Definition . . . . . . . . . . . . . E:1-2
-83, Incorrect switch position Continuity, Definition . . . . . . . . . . . . E:1-2
during autocalibration . . . . . E:6-39 Control Circuits, Definition . . . . . . . E:1-3
-86, Accelerator pot values Control System Features . . . . . . . . . E:1-8
invalid . . . . . . . . . . . . . . . . . E:6-40 Control Valve . . . . . . . . . . . . . . . . . . M:7-6
-89, Hydraulic lever activated Disassembly . . . . . . . . . . . . . . . M:7-27
before pump enabled . . . . . . E:6-41 Installation . . . . . . . . . . . . . . . . M:7-26
-89, Hydraulic lever activated Removal . . . . . . . . . . . . . . . . . . M:7-25
during truck operation . . . . . E:6-42 Control Valve Specifications . . . . . M:10-15
-90, Traction motor temperature Counter Electromotive, Definition . . . E:1-3
out of range . . . . . . . . . . . . . E:6-43 Creep Speed, Description . . . . . . . . E:1-12
-90, Traction motor temperature Current Limit, Definition . . . . . . . . . E:1-3
out of range (hyd. pump Current Limit, Description . . . . . . . E:1-12
controller) . . . . . . . . . . . . . . E:6-44 Current Sensor, Definition . . . . . . . . E:1-3
-91, Pump motor temperature Current Shunt, Definition . . . . . . . . E:1-3
out of range . . . . . . . . . . . . . E:6-45 Current, Definition . . . . . . . . . . . . . . E:1-3

I-4 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Index

Cylinder Definitions
Lift . . . . . . . . . . . . . . . . . . . . . . .M:7-7 Accelerator . . . . . . . . . . . . . . . . . E:1-2
Bleeding . . . . . . . . . . . . . . . .M:8-20 Activate . . . . . . . . . . . . . . . . . . . E:1-2
Disassembly . . . . . . . . . . . .M:7-35 Ammeter . . . . . . . . . . . . . . . . . . . E:1-2
Drift Test . . . . . . . . . . . . . . .M:7-44 Ampere (Amp) . . . . . . . . . . . . . . . E:1-2
High-Pressure Hose Anode . . . . . . . . . . . . . . . . . . . . . E:1-2
Removal . . . . . . . . . . . . . .M:8-4 Armature . . . . . . . . . . . . . . . . . . E:1-2
Installation . . . . . . . . . . . . .M:7-32 Battery . . . . . . . . . . . . . . . . . . . . E:1-2
Piston Rod Removal . . . . . . .M:7-35 Battery Discharge Indicator
Reassembly Precautions . . . .M:7-38 (BDI) . . . . . . . . . . . . . . . . . . . E:1-2
Removal . . . . . . . . . . . . . . . .M:7-30 Bipolar Junction Transistor
Set Bolt Removal . . . . . . . . .M:7-31 (BJT) . . . . . . . . . . . . . . . . . .. E:1-2
Specifications . . . . . . . . . . .M:10-16 Braking, Electrical . . . . . . . . . .. E:1-3
Stroke Adjustment . . . . . . . .M:8-19 Brush . . . . . . . . . . . . . . . . . . . .. E:1-2
Troubleshooting . . . . . . . . . . .M:9-8 Bus Bar . . . . . . . . . . . . . . . . . .. E:1-2
Master Capacitor . . . . . . . . . . . . . . . . .. E:1-2
Adjustment . . . . . . . . . . . . . .M:5-4 Cathode . . . . . . . . . . . . . . . . . .. E:1-2
Disassembly . . . . . . . . . . . . .M:5-3 Caution . . . . . . . . . . . . . . . . . .. E:S-2
Reassembly . . . . . . . . . . . . . .M:5-4 Circuit . . . . . . . . . . . . . . . . . . .. E:1-2
Steer . . . . . . . . . . . . . . . . . . . . . .M:4-4 Circuit, Closed . . . . . . . . . . . . .. E:1-2
Assembly . . . . . . . . . . . . . . .M:4-21 Circuit, Open . . . . . . . . . . . . . .. E:1-4
Disassembly . . . . . . . . . . . .M:4-19 Coil . . . . . . . . . . . . . . . . . . . . . .. E:1-2
End Cap, Marking . . . . . . . .M:4-20 Commutator . . . . . . . . . . . . . . .. E:1-2
Inspection . . . . . . . . . . . . . .M:4-20 Compound Motor . . . . . . . . . . .. E:1-2
Repair . . . . . . . . . . . . . . . . .M:4-20 Conduct . . . . . . . . . . . . . . . . . .. E:1-2
Specifications . . . . . . . . . . .M:10-14 Conductor . . . . . . . . . . . . . . . .. E:1-2
Tilt . . . . . . . . . . . . . . . . . . . . . . .M:7-7 Connector . . . . . . . . . . . . . . . . .. E:1-2
Bushing Removal . . . . . . . . .M:7-36 Contact Tips . . . . . . . . . . . . . . .. E:1-2
Disassembly . . . . . . . . . . . .M:7-36 Contactor Assembly . . . . . . . . .. E:1-2
Drift Test . . . . . . . . . . . . . . .M:7-44 Contactor Coil . . . . . . . . . . . . . .. E:1-2
Reassembly Precautions . . . .M:7-38 Contactor, Traction
Removal . . . . . . . . . . M:7-33, M:8-4 (1A Bypass) . . . . . . . . . . . . .. E:1-2
Specifications . . . . . . . . . . .M:10-17 Contacts . . . . . . . . . . . . . . . . . .. E:1-2
Tilt Socket Removal . . . . . . .M:7-34 Continuity . . . . . . . . . . . . . . . .. E:1-2
Troubleshooting . . . . . . . . . . .M:9-8 Control Circuits . . . . . . . . . . . .. E:1-3
Wheel Counter Electromotive . . . . . . .. E:1-3
Body Inspection . . . . . . . . . .M:5-13 Current . . . . . . . . . . . . . . . . . . .. E:1-3
Boots Inspection . . . . . . . . .M:5-13 Current Limit . . . . . . . . . . . . . .. E:1-3
Disassembly . . . . . . . . . . . .M:5-12 Current Sensor . . . . . . . . . . . . .. E:1-3
Installation . . . . . . . . . . . . .M:5-11 Current Shunt . . . . . . . . . . . . .. E:1-3
Piston Cups Inspection . . . .M:5-13 Deactivate . . . . . . . . . . . . . . . . .. E:1-3
Piston Inspection . . . . . . . . .M:5-13 Digital Signal . . . . . . . . . . . . . .. E:1-3
Reassembly . . . . . . . . . . . . .M:5-13 Diode . . . . . . . . . . . . . . . . . . . .. E:1-3
Specifications . . . . . . . . . . . .M:10-9 Display . . . . . . . . . . . . . . . . . . .. E:1-3
Cylinder Clamp Installation . . . . . . . .M:8-9 Drain . . . . . . . . . . . . . . . . . . . .. E:1-3
Electric Motor . . . . . . . . . . . . . .. E:1-3
Electrical Braking . . . . . . . . . . .. E:1-3
D Electromagnet . . . . . . . . . . . . . .. E:1-3
Electromotive Force (EMF) . . . .. E:1-3
Dash Display Modes . . . . . . . . . . . . E:2-17 Field Windings . . . . . . . . . . . . .. E:1-3
Deactivate, Definition . . . . . . . . . . . . E:1-3 Field, Magnetic . . . . . . . . . . . . .. E:1-4

PDMM-0115 Issued: 07/31/2002 I-5

Index Raymond ® DSD Maintenance Manual

Filter . . . . . . . . . . . . . . . . . . . . . . E:1-3 Wire . . . . . . . . . . . . . . . . . ... .. E:1-5

Fuse . . . . . . . . . . . . . . . . . . . . . . E:1-3 Wiring Diagram . . . . . . . . ... .. E:1-5
Gate . . . . . . . . . . . . . . . . . . . . . . E:1-3 Zener Diode . . . . . . . . . . . ... .. E:1-5
Generator . . . . . . . . . . . . . . . . . . E:1-3 Definitions, Safety . . . . . . . . . ... .. E:S-3
Glossary of Terms . . . . . . . . . . . . E:1-2 Description
Grounded . . . . . . . . . . . . . . . . . . E:1-3 Hydraulic System . . . . . . . . . . . . M:7-2
Harness . . . . . . . . . . . . . . . . . . . E:1-3 Diagnostic Status Codes
Heat Sink . . . . . . . . . . . . . . . . . . E:1-3 Basic Checks . . . . . . . . . . ... . . E:6-2
Heat Sink Pad . . . . . . . . . . . . . . . E:1-3 See also Codes . . . . . . . . . ... . . E:6-2
Horse Power . . . . . . . . . . . . . . . . E:1-4 Diagnostics, Run-time . . . . . . ... . . E:1-8
Hour Meter . . . . . . . . . . . . . . . . . E:1-3 Digital Signal, Definition . . . . ... . . E:1-3
IGBT . . . . . . . . . . . . . . . . . . . . . . E:1-4 Dimensional Data . . . . . . . . . ... . . M:1-4
Indicator . . . . . . . . . . . . . . . . . . . E:1-4 Diode, Definition . . . . . . . . . . ... . . E:1-3
Input . . . . . . . . . . . . . . . . . . . . . . E:1-4 Display Codes . . . . . . . . . . . . ... . . E:6-2
Insulator . . . . . . . . . . . . . . . . . . . E:1-4 Display Modes, Description . . ... . E:1-16
Light Emitting Diode (LED) . . . . . E:1-4 Display, Definition . . . . . . . . . ... . . E:1-3
Logic . . . . . . . . . . . . . . . . . . . . . . E:1-4 Display, Fault Code . . . . . . . . ... . . E:1-8
Logic Unit . . . . . . . . . . . . . . . . . . E:1-4 Down Safety Valve . . . . . . . . . ... . . M:7-9
Magnetic Fields . . . . . . . . . . . . . . E:1-4 Drain, Definition . . . . . . . . . . ... . . E:1-3
Meter, Hour . . . . . . . . . . . . . . . . . E:1-3 Drum to Lining Adjustment . . ... . M:5-14
Microprocessor . . . . . . . . . . . . . . E:1-4
MOSFET . . . . . . . . . . . . . . . . . . . E:1-4
Motor, Compound . . . . . . . . . . . . E:1-2 E
Motor, Electric . . . . . . . . . . . . . . E:1-3
Normal Condition . . . . . . . . . . . . E:1-4 Electric Motor, Definition . . . . . . . . . E:1-3
Normally Closed (N.C.) . . . . . . . . . E:1-4 Electrical Braking, Definition . . . . . . E:1-3
Normally Open (N.O.) . . . . . . . . . E:1-4 Electromagnet, Definition . . . . . . . . . E:1-3
Note . . . . . . . . . . . . . . . . . . . . . . E:S-2 Electromotive Force, Definition . . . . . E:1-3
OFF-Time . . . . . . . . . . . . . . . . . . E:1-4
Ohm . . . . . . . . . . . . . . . . . . . . . . E:1-4
ON-Time . . . . . . . . . . . . . . . . . . . E:1-4 F
Open Circuit . . . . . . . . . . . . . . . . E:1-4
Optical Switch . . . . . . . . . . . . . . . E:1-4
Fault Code Display . . . . . . . . . . . . . . E:1-8
Output . . . . . . . . . . . . . . . . . . . . E:1-4
Fault Code, Accessing . . . . . . . . . . . E:1-8
Positive Thermal Coefficient
Features, Control System . . . . . . . . . E:1-8
Resistor (PTC) . . . . . . . . . . . . E:1-4
Field Weakening,
Resistance . . . . . . . . . . . . . . . . . . E:1-5
Description . . . . . . . . . . E:1-12, E:1-13
Signal, Digital . . . . . . . . . . . . . . . E:1-3
Field Windings, Definition . . . . . . . . E:1-3
Silicon Controlled Rectifier
Filter Specifications, Return . . . . . M:10-16
(SCR) . . . . . . . . . . . . . . . . . . . E:1-5
Filter, Definition . . . . . . . . . . . . . . . . E:1-3
Source . . . . . . . . . . . . . . . . . . . . E:1-5
Flow Regulator Valve
Switch, Optical . . . . . . . . . . . . . . E:1-4
. . . . . . . . . . . . . M:7-8, M:7-37, M:7-43
Terminal . . . . . . . . . . . . . . . . . . . E:1-5
Disassembly . . . . . . . . . . . . . . . M:7-37
Thermal Transfer . . . . . . . . . . . . E:3-8
Inspection . . . . . . . . . . . . . . . . M:7-37
Torque . . . . . . . . . . . . . . . . . . . . E:1-5
Specifications . . . . . . . . . . . . . M:10-16
Transistor . . . . . . . . . . . . . . . . . . E:1-5
Fluid, Hydraulic . . . . . . . . . . . . . . . M:7-39
Varistor . . . . . . . . . . . . . . . . . . . . E:1-5
Fork Carriage
Volt . . . . . . . . . . . . . . . . . . . . . . . E:1-5
Clearance Adjustment . . . . . . . . M:8-9
Warning . . . . . . . . . . . . . . . . . . . E:S-2
Inspection . . . . . . . . . . . . . . . . . M:8-7
Watt . . . . . . . . . . . . . . . . . . . . . . E:1-5
Main Roller Lateral Clearance
Adjustment . . . . . . . . . . . . . M:8-14

I-6 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Index

Main Roller Longitudinal H

Clearance Adjustment . . . . .M:8-13
Removal . . . . . . . . . . . . . . . . . . .M:8-3
Side Roller Lateral Clearance Handset
Adjustment . . . . . . . . . . . . .M:8-14 Accessing Stored Fault Codes . . . E:2-5
Specifications . . . . . . . . . . . . .M:10-19 Function Set-up Procedures . . . . E:2-4
Fork Chain Specifications . . . . . . .M:10-18 General Information . . . . . . . . . . E:2-2
Fork Inspection . . . . . . . . . . . . . . . .M:8-11 Operation . . . . . . . . . . . . . . . . . . E:2-3
Fork Troubleshooting . . . . . . . . . . .M:9-12 Harness, Definition . . . . . . . . . . . . . . E:1-3
Front Axle Heat Sink Pad, Definition . . . . . . . . . E:1-3
Assembly . . . . . . . . . . . . . . . . . . .M:2-9 Heat Sink, Definition . . . . . . . . . . . . E:1-3
Axle Housing Assembly . . . . . . . .M:2-9 Horse Power
Axle Housing, Inspection . . . . . . .M:2-8 Linear Measure . . . . . . . . . . . . . . E:1-4
Axle Shafts, Inspection . . . . . . . .M:2-8 Rotational Measure . . . . . . . . . . . E:1-4
Bearing Removal . . . . . . . . . . . . .M:2-7 Horse Power, Definition . . . . . . . . . . E:1-4
Description . . . . . . . . . . . . . . . . .M:2-2 Hour Meter, Definition . . . . . . . . . . . E:1-3
Disassembly . . . . . . . . . . . . . . . .M:2-6 Hub and Wheel Specifications . . . . M:10-2
Hub Bearing, Preload . . . . . . . . .M:2-10 Hydraulic Oil . . . . . . . . . . . . . . . . . M:7-39
Hub Removal . . . . . . . . . . . . . . . .M:2-7 Hydraulic Pump . . . . . . . . . . . . . . . . M:7-4
Inspection . . . . . . . . . . . . . . . . . .M:2-8 Balance Plate Assembly . . . . . . M:7-21
Installation . . . . . . . . . . . . . . . .M:2-10 Balance Plate Inspection . . . . . . M:7-18
Lock Nut Removal . . . . . . . . . . . .M:2-7 Body Inspection . . . . . . . . . . . . M:7-18
Oil Seals, Inspection . . . . . . . . . .M:2-8 Bush Inspection . . . . . . . . . . . . M:7-18
Retainers, Inspection . . . . . . . . . .M:2-8 Bushing Removal . . . . . . . . . . . M:7-16
Setting Preload . . . . . . . . . . . . .M:2-10 Drive Shaft Removal . . . . . . . . . M:7-17
Wheel Hub Assembly . . . . . . . . . .M:2-9 End Cover Assembly . . . . . . . . . M:7-23
Front Wheel End Cover Removal . . . . . . . . . . M:7-16
Installation . . . . . . . . . . . . . . . . .M:2-5 Flange Assembly . . . . . . . . . . . . M:7-23
Removal . . . . . . . . . . . . . . . . . . .M:2-3 Flange Removal . . . . . . . . . . . . . M:7-16
Function 14 . . . . . . . . . . . . . . . . . . E:1-34 Front Bushes Assembly . . . . . . M:7-22
Fuse, Definition . . . . . . . . . . . . . . . . . E:1-3 Gear Inspection . . . . . . . . . . . . M:7-18
Fuses, Checks/Repairs . . . . . . . . . . . E:3-3 Gear Pack Assembly . . . . . . . . . M:7-22
Gear Pack Separation . . . . . . . . M:7-17
Inspection, Running In . . . . . . . M:7-24
G Installation . . . . . . . . . . . . . . . . M:7-13
Mounting Flange Face
Inspection . . . . . . . . . . . . . . M:7-18
Gate, Definition . . . . . . . . . . . . . . . . . E:1-3
Operation . . . . . . . . . . . . . . . . . . M:7-5
Gear, Steering . . . . . . . . . . . . . . . . . .M:6-4
O-ring and Seal Assembly . . . . . M:7-22
Disassembly . . . . . . . . . . . . . . . .M:6-6
O-ring and Seal Removal . . . . . . M:7-16
Inspection . . . . . . . . . . . . M:6-5, M:6-7
Premium, Disassembly . . . . . . . M:7-14
Installation . . . . . . . . . . . . . . . . .M:6-5
Premium, Reassembly . . . . . . . . M:7-20
Reassembly . . . . . . . . . . . . . . . . .M:6-8
Pressure Loading . . . . . . . . . . . . M:7-5
General Information,
Rear Bush Assembly . . . . . . . . . M:7-21
Specifications . . . . . . . . . . . . . . .M:1-6
Rear Bush Removal . . . . . . . . . M:7-17
General Maintenance
Rear O-ring and Seal
SX Motor Controller . . . . . . . . . . E:1-31
Assembly . . . . . . . . . . . . . . M:7-23
General Safety . . . . . . . . . . . . . . . . . . E:S-3
Removal . . . . . . . . . . . . . . . . . . M:7-12
Generator, Definition . . . . . . . . . . . . . E:1-3
Seal Removal . . . . . . . . . . . . . . M:7-16
Glossary . . . . . . . . . . . . . . . . . . . . . . E:1-2
Shaft Seal Assembly . . . . . . . . . M:7-22
Grounded, Definition . . . . . . . . . . . . . E:1-3
Shaft Seal Removal . . . . . . . . . . M:7-16
Guide, Inspection . . . . . . . . . . . . .M:10-44

PDMM-0115 Issued: 07/31/2002 I-7

Index Raymond ® DSD Maintenance Manual

Specifications . . . . . . . . . . . . . M:10-15 Rear Axle O-ring . . . . . . . . . . . . M:4-12

Standard, Disassembly . . . . . . . M:7-15 Rear Axle Pin . . . . . . . . . . . . . . M:4-12
Standard, Reassembly . . . . . . . . M:7-19 Rear Axle Seal . . . . . . . . . . . . . M:4-12
Troubleshooting . . . . . . . . . . . . M:9-10 Rear Axle Tie Rod . . . . . . . . . . . M:4-12
Hydraulic Pump Control, Reduction Differential . . . . . . . . M:2-13
Description . . . . . . . . . . . . . . . . E:1-16 Return Filter . . . . . . . . . . . . . . . M:7-39
Hydraulic Schematic . . . . . . . . . . . . . M:7-2 Steer Pump . . . . . . . . . M:6-14, M:6-17
Hydraulic System Suction Strainer . . . . . . . . . . . . M:7-39
Description . . . . . . . . . . . . . . . . . M:7-2 Tires, Rear . . . . . . . . . . . . . . . . M:4-12
Specifications . . . . . . . . . . . . . M:10-15 Transfer Assembly . . . . . . . . . . . M:3-6
Troubleshooting . . . . . . . . . . . . . M:9-8 Inspection Guide . . . . . . . . . . . . . M:10-44
Hydraulic Tank . . . . . . . . . . . . . . . . . M:7-3 Insulator, Definition . . . . . . . . . . . . . E:1-4
Inspection and Adjustment . . . . M:7-39 Internal Resistance
Refill Capacities . . . . . . . . . . . . M:7-39 Compensation, Description . . . . E:1-15
Troubleshooting . . . . . . . . . . . . M:9-10
J
I
Jacking
IGBT, Definition . . . . . . . . . . . . . . . . E:1-4 Method 1 . .. ... ... ... . . . . . . M:2-4
Indicator, Definition . . . . . . . . . . . . . E:1-4 Method 2 . .. ... ... ... . . . . . . M:2-4
Input, Definition . . . . . . . . . . . . . . . . E:1-4 Method 3 . .. ... ... ... . . . . . . M:2-4
Inspection Jacking Safety .. ... ... ... . . . . . . E:S-8
Chain Wheel Supports . . . . . . . . . M:8-8
Chain Wheels . . . . . . . . . . . . . . . M:8-8
Control Valve, L
External Leakage . . . . . . . . . M:7-40
Control Valve, LED, Definition . . . . . . . . . . . . . . . . E:1-4
Internal Leakage . . . . . . . . . M:7-40 Lift Bracket
Cylinder Piping . . . . . . . . . . . . . M:7-44 Inspection . . . . . . . . . . . . . . . . . M:8-7
Flow Regulator Valve . . . . . . . . . M:7-37 Main Roller Lateral Clearance
Fork Carriage . . . . . . . . . . . . . . . M:8-7 Adjustment . . . . . . . . . . . . . M:8-14
Forks . . . . . . . . . . . . . . . . . . . . M:8-11 Main Roller Longitudinal
Hydraulic Pump, Running In . . . M:7-24 Clearance Adjustment . . . . . M:8-13
Lift and Tilt Cylinder Side Roller Lateral Clearance
Cylinder Tube . . . . . . . . . . . M:7-38 Adjustment . . . . . . . . . . . . . M:8-14
Packings and Rings . . . . . . . M:7-38 Lift Bracket Clearance
Piston Rod . . . . . . . . . . . . . . M:7-38 Adjustment . . . . . . . . . . . . . . . . M:8-9
Lift Bracket . . . . . . . . . . . . . . . . . M:8-7 Lift Bracket Removal . . . . . . . . . . . . M:8-3
Lift Chains . . . . . . . . . . . . . . . . . M:8-8 Lift Chain Inspection . . . . . . . . . . . . M:8-8
Mast . . . . . . . . . . . . . . . . . . . . . . M:8-7 Lift Cylinder . . . . . . . . . . . . . . . . . . . M:7-7
Mast Strips . . . . . . . . . . . . . . . . . M:8-8 Bleeding . . . . . . . . . . . . . . . . . . M:8-20
Pump Balance Plate . . . . . . . . . M:7-18 Disassembly . . . . . . . . . . . . . . . M:7-35
Pump Body . . . . . . . . . . . . . . . . M:7-18 Drift Test . . . . . . . . . . . . . . . . . M:7-44
Pump Bushes . . . . . . . . . . . . . . M:7-18 High-Pressure Hose Removal . . . M:8-4
Pump Gears . . . . . . . . . . . . . . . M:7-18 Installation . . . . . . . . . . . . . . . . M:7-32
Pump Mounting Flange Face . . . M:7-18 pecifications . . . . . . . . . . . . . . M:10-16
Rear Axle Cylinder Rod . . . . . . . M:4-12 Piston Rod Removal . . . . . . . . . M:7-35
Rear Axle Hydraulic Pipes . . . . . M:4-12 Reassembly Precautions . . . . . . M:7-38
Rear Axle Kingpin Bearing . . . . . M:4-12 Removal . . . . . . . . . . . . . . . . . . M:7-30
Rear Axle Kingpins . . . . . . . . . . M:4-12 Set Bolt Removal . . . . . . . . . . . M:7-31
Rear Axle Knuckles . . . . . . . . . . M:4-12 Stroke Adjustment . . . . M:7-42, M:8-19

I-8 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Index

Logic Flow Chart, Traction Master Cylinder

Control . . . . . . . . . . . . . . . . . . . E:1-27 Adjustment . . . . . . . . . . . . . . . . . M:5-4
Logic Unit, Definition . . . . . . . . . . . . E:1-4 Body, Inspection . . . . . . . . . . . . . M:5-4
Logics, Definition . . . . . . . . . . . . . . . E:1-4 Cup and Valve, Inspection . . . . . M:5-4
Low Voltage, Description . . . . . . . . . E:1-14 Disassembly . . . . . . . . . . . . . . . . M:5-3
Lubricant Specification Table . . . .M:10-37 Fluid Level Sensor, Inspection . . . M:5-4
Lubrication Chart . . . . . . . . . . . . .M:10-36 Piston, Inspection . . . . . . . . . . . . M:5-4
Reassembly . . . . . . . . . . . . . . . . . M:5-4
Return Spring, Inspection . . . . . . M:5-4
M Specifications . . . . . . . . . . . . . . M:10-8
Memory Maps
Magnetic Field, Definition . . . . . . . . . E:1-4 Traction Control . . . . . . . . . . . . E:2-37
Main Relief Valve Meter, Hour, Definition . . . . . . . . . . . E:1-3
Reassembly . . . . . . . . . . . . . . . .M:7-29 Microprocessor, Definition . . . . . . . . E:1-4
Removal . . . . . . . . . . . . . . . . . .M:7-28 Modes, Dash Display . . . . . . . . . . . E:2-17
Main Roller Shim Replacement . . . .M:8-18 Modes, Programmable . . . . . . . . . . . E:1-9
Maintenance Alert, Description . . . . E:1-15 MOSFET, Definition . . . . . . . . . . . . . E:1-4
Maintenance Interval Chart . . . . . .M:10-25 Motor
Major Component Weight Table . . .M:10-38 Compound, Definition . . . . . . . . . E:1-2
Manual, Models Covered . . . . . . . . . .M:1-2 Motor Characteristics . . . . . . . . . . . E:1-10
Manual, Scope . . . . . . . . . . . . . . . . .M:1-2 Separately Excited Motors . . . . . E:1-10
Mast Series Motors . . . . . . . . . . . . . . E:1-10
Clearance Adjustment . . . . . . . . .M:8-9 Shunt Motors . . . . . . . . . . . . . . E:1-10
Inner Mast Removal . . . . . . . . . . .M:8-6 Motor Control, Mounting
Inspection . . . . . . . . . . . . . . . . . .M:8-7 Instructions . . . . . . . . . . . . . . . . E:3-8
Main Roller Removal . . . . . . . . . .M:8-6 Motor Controller Features . . . . . . . . E:1-12
Mast Strip Removal . . . . . . . . . . .M:8-6 Motor Options, Hydraulic Pump . . . . E:1-6
Mast Support Bearing Motor Thermal Switches,
Cap Removal . . . . . . . . . . . . .M:8-4 Checks/Repairs . . . . . . . . . . . . . E:3-6
Mast and Forks Mounting Instructions,
Description . . . . . . . . . . . . . . . . .M:8-2 Motor Control . . . . . . . . . . . . . . . E:3-8
Mast and Lift Bracket
Disassembly . . . . . . . . . . . . . . . .M:8-5 N
Specifications . . . . . . . . . . . . .M:10-19
Mast Clearance Adjustment
Inner Mast Main Rollers Nameplate, Location . . . . . . . . E:1-7, M:1-3
Lateral Clearance . . . . . . . . .M:8-16 Normal Condition, Definition . . . . . . E:1-4
Mast Main Rollers Normally Closed, Definition . . . . . . . E:1-4
Longitudinal Clearance . . . .M:8-16 Normally Open, Definition . . . . . . . . E:1-4
Outer Mast Main Rollers
Lateral Clearance . . . . . . . . .M:8-17
Mast Roller Specifications . . . . . . .M:10-18 O
Mast Specifications . . . . . . . . . . . .M:10-15
Mast Strip Adjustment . . . . . . . . . .M:8-18 OFF-Time, Definition . . . . . . . . . . . . E:1-4
Mast Strip Inspection . . . . . . . . . . . .M:8-8 Ohm, Definition . . . . . . . . . . . . . . . . E:1-4
Mast Support Installation . . . . . . . . .M:8-9 Oil, Hydraulic . . . . . . . . . . . . . . . . . M:7-39
Mast Tilt Angle Adjustment . . . . . . .M:7-42 ON-Time, Definition . . . . . . . . . . . . . E:1-4
Mast Troubleshooting . . . . . . . . . . .M:9-12 Open Circuit, Definition . . . . . . . . . . E:1-4
Operation
Pump, Hydraulic . . . . . . . . . . . . . M:7-5

PDMM-0115 Issued: 07/31/2002 I-9

Index Raymond ® DSD Maintenance Manual

Operator Display Settings, DSD40/50/5E/60,

Premium 9" EE Motor . . . . . . . . . . . . E:2-35
Battery Discharge Settings, DSD40/50/5E/60,
Indicator . . . . . . . . . . . . E:1-22 9" Motor . . . . . . . . . . . . . . . E:2-31
Brush Wear Indicator . . . . . E:1-24 Set-up Functions,
Fault Code Indicator . . . . . . E:1-23 Description . . . . . . . . . . . . . E:2-15
History Display . . . . . . . . . . E:1-23 Pump Driver
Hour Meter . . . . . . . . . . . . . E:1-22 Terminals . . . . . . . . . . . . . . . . . E:5-17
Identification . . . . . . . . . . . . E:1-22 Pump Motor, Options . . . . . . . . . . . . E:1-6
Left Mode Button . . . . . . . . . E:1-23 Pump Time Delay
Operation . . . . . . . . . . . . . . E:1-19 Terminals . . . . . . . . . . . . . . . . . E:5-18
Right Mode Button . . . . . . . E:1-23 Pump, Hydraulic . . . . . . . . . . . . . . . M:7-4
Setup Modes . . . . . . . . . . . . E:1-23 Installation . . . . . . . . . . . . . . . . M:7-13
Speed Display . . . . . . . . . . . E:1-22 Premium, Disassembly . . . . . . . M:7-14
Start-Up . . . . . . . . . . . . . . . E:1-23 Premium, Reassembly . . . . . . . M:7-20
System Monitoring Lights . . E:1-23 Removal . . . . . . . . . . . . . . . . . . M:7-12
Time Display . . . . . . . . . . . . E:1-22 Standard, Disassembly . . . . . . . M:7-15
Standard Standard, Reassembly . . . . . . . M:7-19
Battery Discharge Troubleshooting . . . . . . . . . . . . M:9-10
Indicator . . . . . . . . . . . . E:1-20 Pump, Steer
Fault Code Indicator . . . . . . E:1-21 Cover Reassembly . . . . . . . . . . M:6-17
Fault History Button . . . . . . E:1-20 Cover Removal . . . . . . . . . . . . . M:6-12
History Mode . . . . . . . . . . . . E:1-21 Disassembly . . . . . . . . . . . . . . . M:6-11
Hour Meter . . . . . . . . . . . . . E:1-20 Inspection . . . . . . . . . . M:6-14, M:6-17
Identification . . . . . . . . . . . . E:1-20 Installation . . . . . . . . . . . . . . . . M:6-10
Mode Button . . . . . . . . . . . . E:1-20 Motor and Pump Assembly
Operation . . . . . . . . . . . . . . E:1-19 Removal . . . . . . . . . . . . . . . M:6-12
System Monitoring Lights . . E:1-21 Pressure Plate Reassembly . . . . M:6-17
Optical Switch, Definition . . . . . . . . . E:1-4 Pressure Plate Removal . . . . . . M:6-13
Output, Definition . . . . . . . . . . . . . . . E:1-4 Reassembly . . . . . . . . . . . . . . . M:6-15
Removal . . . . . . . . . . . . . . . . . . M:6-10
Removal from Motor . . . . . . . . . M:6-12
P Retaining Ring Removal . . . . . . M:6-13
Ring Reassembly . . . . . . . . . . . M:6-16
Parking Brake Ring Removal . . . . . . . . . . . . . . M:6-13
Specifications . . . . . . . . . . . . . M:10-12 Rotor and Vane Reassembly . . . M:6-16
Troubleshooting . . . . . . . . . . . . . M:9-4 Rotor and Vane Removal . . . . . M:6-13
Periodic Replacement Parts . . . . . . M:10-35 Seal and O-ring Removal . . . . . M:6-14
Pin/Socket Lubrication . . . . . . . . . . E:1-32 Shaft and Bearing Reassembly . M:6-16
Positive Thermal Coefficient Shaft and Bearing Removal . . . . M:6-14
Resistor, Definition . . . . . . . . . . . E:1-4 Shaft and Body Reassembly . . . M:6-16
Premium Pump Shaft Seal Reassembly . . . . . . . M:6-15
Disassembly . . . . . . . . . . . . . . . M:7-14 Spring Reassembly . . . . . . . . . . M:6-17
Reassembly . . . . . . . . . . . . . . . . M:7-20 Spring Removal . . . . . . . . . . . . M:6-12
Programmable Modes . . . . . . . . . . . . E:1-9
Pulse Monitor Trip (PMT), R
Description . . . . . . . . . . . . . . . . E:1-14
Pump Controller
Settings, DSD30/35, Ramp Start, Description . . . . . . . . . E:1-13
8" EE Motor . . . . . . . . . . . . . E:2-33 Rear Axle
Settings, DSD30/35, Assembly Removal . . . . . . . . . . . M:4-9
8" Motor . . . . . . . . . . . . . . . E:2-29

I-10 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Index

Bearing Support Clearance, Regulator Valve Specifications,

Adjustment . . . . . . . . . . . . . .M:4-9 Flow . . . . . . . . . . . . . . . . . . . . M:10-16
Bearing, Removal . . . . . . . . . . . .M:4-11 Regulator Valve, Flow
Cylinder End Cap, Marking . . . .M:4-11 . . . . . . . . . . . . M:7-8, M:7-37, M:7-43
Cylinder Rod, Inspection . . . . . .M:4-12 Disassembly . . . . . . . . . . . . . . . M:7-37
Description . . . . . . . . . . . . . . . . .M:4-2 Inspection . . . . . . . . . . . . . . . . . M:7-37
Disassembly . . . . . . . . . . . . . . .M:4-10 Relief Valve
Hub, Assembly . . . . . . . . . . . . .M:4-16 Main, Reassembly . . . . . . . . . . . M:7-29
Hydraulic Pipes, Inspection . . . .M:4-12 Relief Valve, Auxiliary
Kingpin Bearing, Inspection . . . .M:4-12 Adjustment . . . . . . . . . . . . . . . . M:7-41
Kingpin, Assembly . . . . . . . . . . .M:4-15 Reassembly . . . . . . . . . . . . . . . . M:7-29
Kingpin, Inspection . . . . . . . . . .M:4-12 Removal . . . . . . . . . . . . . . . . . . M:7-29
Knuckle, Assembly . . . . . . . . . .M:4-14 Relief Valve, Main
Knuckles, Inspection . . . . . . . . .M:4-12 Adjustment . . . . . . . . . . . . . . . . M:7-41
O-ring, Inspection . . . . . . . . . . .M:4-12 Removal . . . . . . . . . . . . . . . . . . M:7-28
Pin, Inspection . . . . . . . . . . . . . .M:4-12 Remoter Readings, Description . . . . E:1-15
Reassembly . . . . . . . . . . . . . . . .M:4-13 Reservoir
Removal . . . . . . . . . . . . . . . . . . .M:4-8 Hydraulic . . . . . . . . . . . . . . . . . . M:7-3
Retainer, Removal . . . . . . . . . . .M:4-11 Inspection and Adjustment . . . . M:7-39
Seal, Inspection . . . . . . . . . . . . .M:4-12 Refill Capacities . . . . . . . . . . . . M:7-39
Steer Cylinder, Assembly . . . . . .M:4-14 Troubleshooting . . . . . . . . . . . . M:9-10
Tie Rod, Assembly . . . . . . . . . . .M:4-16 Resistance, Definition . . . . . . . . . . . . E:1-5
Tie Rod, Inspection . . . . . . . . . .M:4-12 Return Filter Specifications . . . . . M:10-16
Tires, Inspection . . . . . . . . . . . .M:4-12 RF Interference, Prevention . . . . . . . E:1-31
Troubleshooting . . . . . . . . . . . . .M:9-11 Roll-Back Control, Description . . . . E:1-14
Rear Axle Specifications . . . . . . . . .M:10-5 Run-time Diagnostics . . . . . . . . . . . . E:1-8
Rear Wheel
Hub Bearing, Preload . . . . . . . . . .M:4-6
Inspection . . . . . . . . . . . . . . . . . .M:4-5 S
Installation . . . . . . . . . . . . . . . . .M:4-5
Removal . . . . . . . . . . . . . . . . . . .M:4-3 Safety . . . . . . . . . . . . . . . . . . . . . . . . E:S-2
Reduction Differential Battery . . . . . . . . . . . . . . . . . . . . E:S-4
Adjustment . . . . . . . . . . . . . . . .M:2-16 Definitions . . . . . . . . . . . . . . . . . E:S-3
Bearing Cap, Installation . . . . . .M:2-15 General . . . . . . . . . . . . . . . . . . . . E:S-3
Case Reassembly . . . . . . . . . . . .M:2-15 Jacking . . . . . . . . . . . . . . . . . . . . E:S-8
Description . . . . . . . . . . . . . . . .M:2-11 Static . . . . . . . . . . . . . . . . . . . . . E:S-6
Differential, Inspection . . . . . . .M:2-13 Welding . . . . . . . . . . . . . . . . . . . E:S-9
Disassembly . . . . . . . . . . . . . . .M:2-12 Safety Valve, Down . . . . . . . . . . . . . . M:7-9
Inner Bearing Race Removal . . .M:2-12 SC Controller
Inspection . . . . . . . . . . M:2-13, M:2-16 Connection Points . . . . . . . . . . . . E:4-2
Pinion Reassembly . . . . . . . . . . .M:2-15 Schematic
Reassembly . . . . . . . . . . . . . . . .M:2-14 Hydraulic . . . . . . . . . . . . . . . . . . M:7-2
Reduction Gear Face, Runout . .M:2-17 Pump Contactor . . . . . . . . . . . . . E:5-5
Reduction Gear, Backlash . . . . .M:2-16 Pump Control . . . . . . . . . . . . . . E:5-11
Reduction Gear, Inspection . . . .M:2-13 Traction Bypass with Pump
Reduction Gear, Installation . . .M:2-15 Contactor . . . . . . . . . . E:5-3, E:5-7
Side Bearing, Preload . . . . . . . . .M:2-16 Traction Bypass with Pump
Tooth Contact, Adjustment . . . .M:2-17 Control . . . . . . . . . . . . . . . . . E:5-9
Regenerative Braking, Description . . E:1-13 Traction Motor Controller w/
Regenerative Braking, Pedal Pump Motor Controller
Position, Description . . . . . . . . . E:1-13 & Bypass . . . . . . . . . . . . . . E:5-13
Serial Number Plate, Location . . . . . . M:1-3

PDMM-0115 Issued: 07/31/2002 I-11

Index Raymond ® DSD Maintenance Manual

Serial Number Plates, Location . . . . . E:1-7 Status Codes, Stored,

Service Brake Description . . . . . . . . . . . . . . . . E:1-15
Troubleshooting . . . . . . . . . . . . . M:9-3 Steer Cylinder . . . . . . . . . . . . . . . . . M:4-4
Service Brake Specifications . . . . . M:10-11 Assembly . . . . . . . . . . . . . . . . . M:4-21
Service Data . . . . . . . . . . . . . . . . . . M:8-22 Disassembly . . . . . . . . . . . . . . . M:4-19
Service Interval Chart . . . . . . . . . . M:10-25 Inspection . . . . . . . . . . . . . . . . M:4-20
Shim Replacement, Main Roller . . . M:8-18 Marking End Caps . . . . . . . . . . M:4-20
Silicon Controlled Rectifier, Repair . . . . . . . . . . . . . . . . . . . M:4-20
Definition . . . . . . . . . . . . . . . . . . E:1-5 Specifications . . . . . . . . . . . . . M:10-14
Solid-State Reversing . . . . . . . . . . . E:1-11 Steer Pump
Source, Definition . . . . . . . . . . . . . . . E:1-5 Cover Reassembly . . . . . . . . . . M:6-17
Special Tools . . . . . . . . . . . . . . . . . M:10-39 Disassembly . . . . . . . . . . . . . . . M:6-11
Specifications Inspection . . . . . . . . . . M:6-14, M:6-17
Brake Pedal . . . . . . . . . . . . . . . . M:10-7 Installation . . . . . . . . . . . . . . . . M:6-10
Brake, Parking . . . . . . . . . . . . M:10-12 Motor and Pump Assembly
Brake, Service . . . . . . . . . . . . . M:10-11 Removal . . . . . . . . . . . . . . . M:6-12
Cylinder Pressure Plate Reassembly . . . . M:6-17
Lift . . . . . . . . . . . . . . . . . . M:10-16 Pressure Plate Removal . . . . . . M:6-13
Tilt . . . . . . . . . . . . . . . . . . M:10-17 Pump Cover Removal . . . . . . . . M:6-12
Cylinder, Steer . . . . . . . . . . . . M:10-14 Reassembly . . . . . . . . . . . . . . . M:6-15
Filter, Return . . . . . . . . . . . . . M:10-16 Removal . . . . . . . . . . . . . . . . . . M:6-10
Fork Carriage . . . . . . . . . . . . . M:10-19 Removal from Motor . . . . . . . . . M:6-12
Fork Chain . . . . . . . . . . . . . . . M:10-18 Retaining Ring Removal . . . . . . M:6-13
Hub and Wheel . . . . . . . . . . . . . M:10-2 Ring Reassembly . . . . . . . . . . . M:6-16
Hydraulic System . . . . . . . . . . M:10-15 Ring Removal . . . . . . . . . . . . . . M:6-13
Lubricants . . . . . . . . . . . . . . . M:10-37 Rotor and Vane Reassembly . . . M:6-16
Mast . . . . . . . . . . . . . . . . . . . . M:10-15 Rotor and Vane Removal . . . . . M:6-13
Mast and Lift Bracket . . . . . . . M:10-19 Seal and O-ring Removal . . . . . M:6-14
Mast Roller . . . . . . . . . . . . . . . M:10-18 Shaft and Bearing
Master Cylinder . . . . . . . . . . . . . M:10-8 Reassembly . . . . . . . . . . . . . M:6-16
Pump, Hydraulic . . . . . . . . . . . M:10-15 Shaft and Bearing Removal . . . . M:6-14
Rear Axle . . . . . . . . . . . . . . . . . M:10-5 Shaft and Body Reassembly . . . M:6-16
Service . . . . . . . . . . . . . . . . . . . M:8-22 Shaft Seal Reassembly . . . . . . . M:6-15
Steering Gear . . . . . . . . . . . . . M:10-13 Spring Reassembly . . . . . . . . . . M:6-17
Transfer Case Bolt Torques . . . . M:10-4 Spring Removal . . . . . . . . . . . . M:6-12
Valve, Control . . . . . . . . . . . . . M:10-15 Steer System
Valve, Flow Regulator . . . . . . . M:10-16 Description . . . . . . . . . . . . . . . . . M:6-2
Wheel Brakes . . . . . . . . . . . . . M:10-10 Oil Flow . . . . . . . . . . . . . . . . . . . M:6-2
Wheel Cylinder . . . . . . . . . . . . . M:10-9 Troubleshooting . . . . . . . . . . . . . M:9-5
Speed Limit Steering Gear . . . . . . . . . . . . . . . . . . M:6-4
Description . . . . . . . . . . E:1-13, E:1-15 Disassembly . . . . . . . . . . . . . . . . M:6-6
Standard Pump Inspection . . . . . . . . . . . .M:6-5, M:6-7
Disassembly . . . . . . . . . . . . . . . M:7-15 Installation . . . . . . . . . . . . . . . . . M:6-5
Reassembly . . . . . . . . . . . . . . . . M:7-19 Reassembly . . . . . . . . . . . . . . . . M:6-8
Static Precautions . . . . . . . . . . . . . . . E:S-6 Specifications . . . . . . . . . . . . . M:10-13
Static Return to Off, Description . . . E:1-14 Steering Wheel . . . . . . . . . . . . . . . . . M:6-3
Status Code Table . . . . . . . . . . . . . . . E:6-3 Installation . . . . . . . . . . . . . . . . . M:6-3
See also Codes . . . . . . . . . . . . . . E:6-3 Removal . . . . . . . . . . . . . . . . . . . M:6-3
See also Diagnostics, Stroke Adjustment, Lift Cylinder . . M:8-19
Status Codes . . . . . . . . . . . . . E:6-3 Switches
Status Codes, Standard, Thermal, Motor, Checks/
Description . . . . . . . . . . . . . . . . E:1-15 Repairs . . . . . . . . . . . . . . . . . E:3-6

I-12 PDMM-0115 Issued: 07/31/2002

Raymond ® DSD Maintenance Manual Index

SX Controller Traction Controller

Removal . . . . . . . . . . . . . . . . . . . E:4-2 Memory Maps . . . . . . . . . . . . . . E:2-37
SX Motor Controller Settings, DSD30/35,
Connections . . . . . . . . . . . . . . . E:1-29 9" EE Motor . . . . . . . . . . . . E:2-25
General Maintenance . . . . . . . . . E:1-31 Settings, DSD30/35,
Troubleshooting . . . . . . . . . . . . . E:1-28 9" Motor . . . . . . . . . . . . . . . E:2-19
System Monitoring Lights, Settings, DSD40/50/5E,
Identification . . . . . . . . . . . . . . . E:1-25 11" Motor . . . . . . . . . . . . . . E:2-21
Systems Diagnostics, Settings, DSD40/50/5E/60,
Description . . . . . . . . . . . . . . . . E:1-15 11" EE Motor . . . . . . . . . . . E:2-27
Settings, DSD60, 11" Motor . . . E:2-23
Set-up Functions,
T Description . . . . . . . . . . . . . . E:2-6
Transfer Assembly
Tank, Hydraulic . . . . . . . . . . . . . . . .M:7-3 Bolt Torque Values . . . . . . . . . . M:3-10
Inspection and Adjustment . . . .M:7-39 Description . . . . . . . . . . . . . . . . . M:3-2
Refill Capacities . . . . . . . . . . . . .M:7-39 Disassembly . . . . . . . . . . . . . . . . M:3-3
Tension Adjustment, Chain . . . . . . .M:8-12 Inspection . . . . . . . . . . . . . . . . . . M:3-6
Terminal, Definition . . . . . . . . . . . . . E:1-5 Reassembly . . . . . . . . . . . . . . . . . M:3-7
Test Transfer Case
Cylinder Piping . . . . . . . . . . . . .M:7-44 Bolt Torque Specifications . . . . . M:10-4
Lift Cylinder Drift . . . . . . . . . . .M:7-44 Transistor, Definition . . . . . . . . . . . . E:1-5
Tilt Cylinder Drift . . . . . . . . . . .M:7-44 Troubleshooting
Thermal Protector, Description . . . . E:1-14 Armature Winding Problems . . . E:3-13
Thermal Transfer . . . . . . . . . . . . . . . E:3-8 BDI Operation . . . . . . . . . . . . . . E:1-33
Thermal Transfer, Description . . . . . . E:3-8 Brake System . . . . . . . . . . . . . . . M:9-3
Tilt Angle Adjustment . . . . . . . . . . .M:8-19 Fork Problems . . . . . . . . . . . . . M:8-24
Tilt Cylinder . . . . . . . . . . . . . . . . . . .M:7-7 Forks . . . . . . . . . . . . . . . . . . . . M:9-12
Bushing Removal . . . . . . . . . . . .M:7-36 Front Axle . . . . . . . . . . . . . . . . . . M:9-2
Disassembly . . . . . . . . . . . . . . .M:7-36 General, SX Controller . . . . . . . E:1-33
Drift Test . . . . . . . . . . . . . . . . . .M:7-44 Hydraulic Pump . . . . . . . . . . . . M:9-10
Reassembly Precautions . . . . . .M:7-38 Hydraulic System . . . . . . . . . . . . M:9-8
Removal . . . . . . . . . . . . M:7-33, M:8-4 Hydraulic Tank . . . . . . . . . . . . . M:9-10
Specifications . . . . . . . . . . . . .M:10-17 Indications Appearing
Tilt Socket Removal . . . . . . . . . .M:7-34 as Heating . . . . . . . . . . . . . . E:3-18
Time Delay, Steer Pump Indications Appearing
Contactor, Description . . . . . . . . E:1-14 at Brushes . . . . . . . . . . . . . E:3-16
Tools, Special Service . . . . . . . . . .M:10-39 Indications Appearing
Torque, Definition . . . . . . . . . . . . . . . E:1-5 at Commutator Surface . . . . E:3-19
Torques Insulation System . . . . . . . . . . . E:3-13
Bolt, Coarse Thread w/o Lift Cylinder . . . . . . . . . . . . . . . . M:9-8
Spring Washer . . . . . . . . . .M:10-24 Mast . . . . . . . . . . . . . . . . . . . . . M:9-12
Bolt, Coarse Thread w/ Mast Problems . . . . . . . . . . . . . M:8-24
Spring Washer . . . . . . . . . .M:10-23 Parking Brake . . . . . . . . . . . . . . . M:9-4
Bolt, Fine Thread w/o Rear Axle . . . . . . . . . . . . . . . . . M:9-11
Spring Washer . . . . . . . . . .M:10-22 Reduction Differential . . . . . . . . . M:9-2
Bolt, Fine Thread w/ Reservoir . . . . . . . . . . . . . . . . . M:9-10
Spring Washer . . . . . . . . . .M:10-21 Service Brakes . . . . . . . . . . . . . . M:9-3
Traction Control . . . . . . . . . . . . . . . E:3-12 Sparking at Brushes . . . . . . . . . E:3-13
Steering System . . . . . . . . . . . . . M:9-5

PDMM-0115 Issued: 07/31/2002 I-13

Index Raymond ® DSD Maintenance Manual

SX Controller W
Failures, Reduced or No
Motor Torque . . . . . . . . . . E:4-3
Misoperation of Features . . . . E:4-5 Warning, Preservice . . . . . . . . . . . . . E:1-7
SX Motor Controller . . . . . . . . . E:1-28 Watt, Definition . . . . . . . . . . . . . . . . E:1-5
Tilt Cylinder . . . . . . . . . . . . . . . . M:9-8 Weights, Major Components . . . . . M:10-38
Tips . . . . . . . . . . . . . . . . . . . . . . E:3-13 Welding Safety . . . . . . . . . . . . . . . . . E:S-9
Unsatisfactory Brush Wheel Brake Specifications . . . . . M:10-10
Performance . . . . . . . . . . . . E:3-14 Wheel Cylinder
Truck Management Module Body, Inspection . . . . . . . . . . . . M:5-13
Checks/Repairs . . . . . . . . . . . . . E:3-7 Boots, Inspection . . . . . . . . . . . M:5-13
Connection Terminals . . . . . . . . E:5-15 Disassembly . . . . . . . . . . . . . . . M:5-12
Operation . . . . . . . . . . . . . . . . . . E:3-7 Piston Cups, Inspection . . . . . . M:5-13
Truck Management Module Piston, Inspection . . . . . . . . . . . M:5-13
(TMM), Description . . . . . . . . . . E:1-16 Reassembly . . . . . . . . . . . . . . . M:5-13
Specifications . . . . . . . . . . . . . . M:10-9
Wire, Definition . . . . . . . . . . . . . . . . E:1-5
V Wiring Diagram, Definition . . . . . . . . E:1-5

Valve Z
Auxiliary Relief
Adjustment . . . . . . . . . . . . . M:7-41
Reassembly . . . . . . . . . . . . . M:7-29 Zener Diode, Definition . . . . . . . . . . E:1-5
Removal . . . . . . . . . . . . . . . M:7-29
Control . . . . . . . . . . . . . . . . . . . . M:7-6
Disassembly . . . . . . . . . . . . M:7-27
Installation . . . . . . . . . . . . . M:7-26
Removal . . . . . . . . . . . . . . . M:7-25
Specifications . . . . . . . . . . M:10-15
Down Safety . . . . . . . . . . . . . . . . M:7-9
Flow Regulator
. . . . . . . . . M:7-8, M:7-37, M:7-43
Disassembly . . . . . . . . . . . . M:7-37
Inspection . . . . . . . . . . . . . . M:7-37
Specifications . . . . . . . . . . M:10-16
Main Relief
Adjustment . . . . . . . . . . . . . M:7-41
Reassembly . . . . . . . . . . . . . M:7-29
Removal . . . . . . . . . . . . . . . M:7-28
Varistor, Definition . . . . . . . . . . . . . . E:1-5
Volt, Definition . . . . . . . . . . . . . . . . . E:1-5

I-14 PDMM-0115 Issued: 07/31/2002

PDMM-0115 Printed in the USA