Raymond Order Picker Forklift 5400

Measure and mark a 12 in. (305 mm) length that has operated over the pulley sheave.

Stretch the chain; if more than 1/3 in. (8.5 mm) play is detected, replace the chain.

Wipe piston with clean kerosene or suitable industrial solvent

Inspect all surfaces for galling or heavy scratches

Inspect all parts: replace as necessary

Remove snap rings, seals, retaining ring and brass adapter

Dip all packings in clean hydraulic fluid

Turn the key switch OFF and disconnect the battery connector.

Remove electrical over-the-mast cable from bottom pulley on carriage.

Disconnect cable tension spring from carriage.

Disconnect JPC8 and JPC9 from carriage manager and cut cable tie from tractor side.

Feed cable through carriage to tractor.

Use 90° snap ring pliers to remove snap ring holding chain rocker assembly to center cylinder.

Attach a suitable hoist to carriage and lift approximately 1 ft. (30.5 cm).

Turn the key switch OFF and disconnect the battery connector.

Remove the steer motor/gearbox.

Remove the B side end bell and brush retainers.

Remove the A side end bell bolts and pull the end bell and rotor from the motor housing.

Loosen the two phillips head screws that are used with the small clips to retain the bearing in the A side end bell.

Remove the A side end bell from the rotor.

Use a press to remove the old bearing.

Press on the new bearing and reassemble the motor.

Torque the bolts holding the motor to the gear reducer to approximately 85 in. lbs.

Warning: This maintenance check requires trained personnel with PPE!

Turn the key switch OFF and disconnect the battery connector.

Remove brake assembly including the rotor hub nut and rotor hub.

Note the number of spacers used.

Identify and remove power cables from drive motor.

Remove the drive motor retaining screws.

Clean motor mounting flange and drive unit. Install a new gasket.

Clean screws. Apply thread-locking compound (P/N 990-536) to screws and torque equally to 13 ft. lb. (18 N.m).