Raymond Counterbalanced Forklift 4250

Warning: This maintenance check requires trained personnel with PPE!

If forklift is not operational, report the issues to the maintenance team and stop the procedure

Forklift passed the post-maintenance test?

Sign off on the forklift maintenance

Hydraulic Reservoir - Change fluid and filter

Power Amplifiers - Torque power cable terminal bolts to 95 to 105 in. lb. (10.7 to 11.8 Nm)

Sign off on the forklift maintenance

Check the weight stamped on the battery in the lift truck against the minimum and maximum allowable weights on the spec tag for the lift truck. Report any lift trucks that are running with batteries under the minimum or over the maximum allowable weight. Inspect all battery connectors and leads for damage and cuts in protective coatings. Make sure battery gates are in place and not damaged. Make sure the battery has no more than 0.5 in. (13 mm) free play in any direction.

In an open area, measure stopping distance. Traveling 2 to 3 mph (3.2 to 4.8km/h) empty, push the EPO switch; the empty lift truck should stop within 2 to 4 feet (0.6 to 1.2 m). During normal operation, with a rated load and traveling at top speed, the lift truck should stop within approx. one and one-half truck lengths. Stopping distance depends on the load, floor, and tire condition. Examine for signs of oil on the friction disk. If oil is present, disassemble brake, clean rotor, and replace pads.

Measure for correct gap: Check the gap between the armature disc and the brake coil. The gap should measure between 0.008 and 0.016in. (0.2 and 0.4 mm). If gap exceeds 0.016in. (0.4 mm), remove and disassemble the brake assembly to check components. Failure to keep brakes adjusted causes premature disk and rotor wear and excessive motor heat. Refer to Brakes on page7-48.

Check the gap between the brake coil and armature disk. The gap should measure 0.008 and 0.016 in. (0.2 and 0.4 mm). If gap exceeds 0.016 in. (0.4 mm), remove and disassemble the brake assembly to check components.

A drive tire fender kit is available for trucks that operate in dusty or dirty environments. Refer to the Parts Manual.

Warning: This maintenance check requires trained personnel with PPE!

Forklift operational in current environment?

Sign off on the forklift maintenance

Hydraulic Reservoir: Change fluid and filter

Pump Couplings: Separate pump and motor. Apply Molybdenum Anti-Seize Compound (P/N 990-638) to the splines

Lift Motor: Caution: Discharge the power amplifiers energy storage capacitors before removing any large fuse or motor cable for service. To discharge, turn the key switch OFF, disconnect the battery, and manually push in the plungers on all three contactors.

Lift Motor: Turn the key switch OFF and disconnect the battery connector

Lift Motor: Remove the three front covers

Lift Motor: Remove the power cables, labeling if necessary for reinstallation. Use two wrenches to avoid twisting the terminal studs

Lift Motor: Model 4250 only: Disconnect speed sensor (JPL2) and temperature sensor (JPL3)