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Raymond 8300 8400 8500 8600 Pallet Truck and Tow Tractor Maintenance Manual - PDF Download

Raymond 8300 8400 8500 8600 Pallet Truck and Tow Tractor Maintenance Manual – PDF Download

Name: Raymond 8300 8400 8500 8600 Pallet Truck and Tow Tractor Maintenance Manual - PDF Download
SKU: RYM-8300-8600-MM-1106240D-HD
Availability: InStock

Original price was: $39.95.Current price is: $23.95.

Complete Raymond maintenance manual (publication 1106240D) for Model 8300, 8400, and 8500 pallet trucks and the Model 8600 tow tractor, covering troubleshooting, fault codes, hydraulic and electrical service, and component procedures.

SKU: RYM-8300-8600-MM-1106240D-HD Category: Material Handling Equipment Manuals Tags: Raymond 1106240D PDF, Raymond 8300 8400 8500 8600 manual, Raymond pallet truck maintenance manual, Raymond tow tractor service manual Vendor: Welder Service Docs

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Description

Raymond 8300 8400 8500 8600 Pallet Truck and Tow Tractor Maintenance Manual

This is the complete Raymond maintenance manual for the Model 8300, 8400, and 8500 pallet trucks and the Model 8600 tow tractor, published as document 1106240D. It is the same service reference used to diagnose faults, remove and install components, adjust assemblies, and verify specifications across all four machines. The manual applies to serial numbers 830-09-83001, 840-09-83001, 850-09-83001, and 860-09-83001 and up. Every major system is covered: traction and travel control, lift and lower hydraulics, power-assisted and electric power steering, the brake, drive unit, battery and charging, wiring harness, and the CAN bus that links the Vehicle Manager and Traction Amplifier.

File Details

Manual type: Maintenance Manual
Brand: Raymond (The Raymond Corporation)
Models covered: Model 8300, 8400, and 8500 pallet trucks; Model 8600 tow tractor
Serial numbers: 830-09-83001, 840-09-83001, 850-09-83001, and 860-09-83001 and up
Publication number: 1106240D
Reissued: 27 Jan 2012
Language: English
File format: PDF
Page count: 373 pages
Electronic format: Interactive Electronic Technical Manual (IETM) with linked navigation

Chapters Covered

Section 1 – How To Use This Manual: Manual Design, Interactive Electronic Technical Manuals, Abbreviations and Symbols, START Page
Section 2 – Safety: Definitions, General Safety, Battery Safety, Jacking Safety (Tractor Section and Fork Section), Tie-Down for Transport, Towing, Static Safety, Welding Safety
Section 3 – Systems Overview: Truck Model Identification, Lift Truck Specifications, Special Tools and Service Key, Operator Display and Programming, FlashWare overview and installation
Section 4 – Scheduled Maintenance: Maintenance Guidelines, Initial 90 Day or 250 Deadman Hours (HD) Maintenance, Every 180 Days or 500 Deadman Hours, Every 360 Days or 2000 Deadman Hours, Contactor Tip Inspection, Grease Fittings (all models and trucks without composite bushings)
Section 5 – Troubleshooting: Troubleshooting Flowcharts (TS1 START, GEN1 General, END1 End Procedure), Electrical Troubleshooting Guidelines, CAN Bus Troubleshooting, Shorts to Frame Test, Fuses, DC Electric Motors, AC Electric Motors, Hydraulic Troubleshooting Guidelines, Lift/Lower Symptom Tables, Travel (Forward/Reverse) Symptom Tables, Wiring System Symptom Tables
Section 6 – Messages and Codes: Traction Amplifier LED Diagnostics, Traction Amplifier Flash Codes, Caution Codes (C-series), Error Codes (E-series), Power Assisted Steering Caution Codes, Electric Power Steering Caution Codes
Section 7 – Component Procedures: Steering and Controls, Power Assisted Steering, Electric Power Steering, Control Handle Assemblies, Drive and Brake, Drive Unit, Steering Bearing, Drive Wheel, Casters (with and without springs), Brake, Electrical Components, Battery, Power Cables, Wiring Harness, AMP Water-Resistant Connectors, Traction Amplifier, Motors, Traction Motor, Lift Motor, Hydraulic Components, Hydraulic Unit, Hydraulic Reservoir, Hydraulic Pump, Hydraulic Ram, Hydraulic Cylinder Seals, Top Linkage Subassembly, Pull Rod Subassembly, Load Wheels, Pallet Entry Sliders, Pallet Entry Rollers, Fork Height Adjustment, Cold Storage Conditioning
Section 8 – Theory of Operation: Definitions, Traction System (Vehicle Manager and Traction Amplifier), Lift/Lower System, Power Assisted Steering, Electric Power Steering, Pinout Matrix (standard, power assisted steering, electric power steering)
Appendix: Lubrication Equivalency Chart, Thread Adhesives, Sealants, and Lubricants, Component Specific Service/Torque Chart, Torque Chart Standard (Ferrous), Torque Chart Standard (Brass), Torque Chart Metric, Torque Chart Thread-Forming Screws, Decimal Equivalent Chart, Standard/Metric Conversions
Index and Schematics: Alphabetical index plus the schematics publication (1123028C) covering Models 8300, 8400, 8500, and 8600 with and without power steering, the options sheet, component legend, power distribution diagram, and hydraulic schematic

Read together, the manual forms a complete service loop. A technician can identify the truck and its options, find the right scheduled-maintenance interval, run a symptom or fault code through the troubleshooting tables, pull the affected component procedure with its torque values and thread-locking compound part numbers, and confirm operation against the theory-of-operation and pinout references. Maintenance intervals are broken out by operating condition – light to moderate, severe, and extreme – so the same truck can be serviced correctly for its working environment. The appendix consolidates lubrication, sealant, and torque data in one place, and the schematics publication rounds out the wiring and hydraulic side.

Diagnostics and Fault Codes

Section 5 and Section 6 are the diagnostic core. The symptom tables address no lift, slow lift, no lower, inability to pick up a load, slow lower, load drifting, no travel, slow travel, no emergency reverse, no rabbit speed, and jog speed faults, each with possible causes and the matching action. The traction amplifier LED display modes and flash codes are documented, and the caution and error codes are listed individually with the system response, the reason the code sets, the tests to run, and how to clear it. Codes C14 through C90 and E101 through E253 are covered, including the power-assisted steering set for the 8400 and the electric power steering set for the 8500 and 8600.

Component Service, Hydraulics, and Drive Unit

The component procedures section is where the manual earns its keep on a shop floor. It walks through power-assisted and electric power steering service, control handle removal and repair, drive unit removal and gear assembly with shim-pack measurement, steering bearing replacement, brake rotor replacement and gap checking, caster shimming and adjustment, battery removal with and without gates and rollers, power cable repair with the manual crimp tool, AMP water-resistant connector pin extraction and insertion, traction amplifier removal and installation, traction motor disassembly and reassembly with torque sequences, lift motor removal, hydraulic unit, reservoir, pump, ram, and cylinder seal service, top linkage and pull rod subassembly work, load wheel replacement, and fork height adjustment with the eccentric pin settings. Torque values, thread-locking compound numbers, and adjustment tolerances are given at each step.

Complete PDF Bookmark Tree

Complete Bookmarks

The complete bookmarks in the “Raymond 8300 8400 8500 8600 Pallet Truck and Tow Tractor Maintenance Manual – PDF Download” are as follows:

Cover Pagep. 1

Table of Contentsp. 3

Page Revision Recordp. 13

Document Revision Historyp. 13

Section 1. How To Use This Manualp. 17

Manual Designp. 18

Interactive Electronic Technical Manualsp. 19

Abbreviations & Symbolsp. 20

START Pagep. 22

Section 2. Safetyp. 25

Definitionsp. 26

General Safetyp. 27

Battery Safetyp. 30

Jacking Safetyp. 33

Tractor Sectionp. 33

Figure 2-1. Tractor Section Jacking Pointsp. 33

Fork Sectionp. 33

Tie-Down for Transportp. 34

Figure 2-2. Tie-Down for Transportp. 34

Towingp. 35

Static Safetyp. 36

Figure 2-3. Anti-Static Kit (P/N 1-187-059) With Wrist Strap and Matp. 36

Welding Safetyp. 37

Section 3. Systems Overviewp. 39

Introductionp. 40

Truck Model Identificationp. 41

Figure 3-1. Model 8300p. 41

Figure 3-2. Model 8400p. 41

Figure 3-3. Model 8500 with Electric Power Steerp. 41

Figure 3-4. Model 8500 with Spring-Loaded Handlep. 41

Figure 3-5. Model 8600 with Electric Power Steerp. 41

Figure 3-6. Model 8600 with Spring-Loaded Handlep. 41

Lift Truck Specificationsp. 42

Figure 3-7. Lift Truck Specification Plate – Models 8300, 8400, and 8500 Pallet Trucksp. 42

Figure 3-8. Lift Truck Specification Plate – Model 8600 Tow Tractorp. 42

Special Toolsp. 43

Service Keyp. 43

Figure 3-9. Service Keyp. 43

Operator Display and Programmingp. 44

Figure 3-10. Operator Displayp. 44

Special Truck Modep. 44

Hour Meter (H)p. 44

Error Codes (E)p. 44

Error Code Historyp. 44

Changing Truck Parameters (P)p. 45

Programming Operator Parametersp. 45

Programming Service Parametersp. 47

Service Parameter Display (Keypad Only)p. 47

Setting Individual PIN-Key Codes (Keypad Only)p. 47

Display Part Numbers (Pn)p. 51

Diagnostic Test Display (D)p. 51

Service Input/Output Displaysp. 52

Figure 3-11. Service Key Connection Pointp. 52

Figure 3-12. Operator Displayp. 52

Digital Inputs/Outputs from Traction Amplifier and VMp. 53

Traction Amplifier Inputsp. 53

Traction Amplifier Outputsp. 53

Digital Input From VM Control Sensorsp. 54

FlashWarep. 55

Overviewp. 55

Requirementsp. 55

Installing FlashWare on PCp. 55

Connecting PC to Truckp. 55

Starting FlashWarep. 55

Figure 3-13. Truck Opening Screen with Menup. 55

Configuration and Truck Setup Optionsp. 56

Figure 3-14. Typical Truck Setup Screenp. 56

Changing Truck Parameters:p. 56

Figure 3-15. Change Parameterp. 57

Figure 3-16. Send Changes Buttonp. 57

Software Managementp. 58

Figure 3-17. Truck Setup Screen Software Buttonp. 58

Figure 3-18. Truck Software Windowp. 59

Erase Vehicle Managerp. 59

Figure 3-19. Erase Vehicle Manager Software Screenp. 59

Reset Defaultsp. 59

Diagnosticsp. 60

Figure 3-20. Truck Diagnostics Screenp. 60

Error Logp. 60

RE_Read Truck Settingsp. 60

SAVE Settings to Filep. 60

SEND Changes to Truckp. 60

Section 4. Scheduled Maintenancep. 61

Maintenance Guidelinesp. 62

Initial 90 Day/250 Deadman Hours (HD) Maintenancep. 63

Every 180 Days or 500 Deadman Hoursp. 64

Every 360 Days or 2000 Deadman Hours (HD)p. 66

Contactor Tip Inspectionp. 67

Grease Fittings (All Models)p. 68

Figure 4-1. Caster Grease Fittingsp. 68

Figure 4-2. Load Wheel Grease Fittingsp. 68

Grease Fittings (Trucks without Composite Bushings Only)p. 69

Figure 4-3. Upper Bell Crank Grease Fittings (Between Tractor and Fork Section)p. 69

Figure 4-4. Lower Bell Crank Grease Fittings-left side shown (Between Tractor and Fork Section)p. 69

Figure 4-5. Lower Bell Crank Grease Fittings-left side shown (Between Tractor and Fork Section)p. 69

Figure 4-6. Fork Grease Fittings (Top View)p. 69

Section 5. Troubleshootingp. 71

How to Use This Sectionp. 72

Troubleshooting Flowchartsp. 73

TS1: START TROUBLESHOOTINGp. 73

Figure 5-1. TS1: START TROUBLESHOOTINGp. 73

GEN1: General Troubleshootingp. 74

Figure 5-2. GEN1: General Troubleshootingp. 74

END1: End of Troubleshooting Procedurep. 75

Figure 5-3. END1: End of Troubleshooting Procedurep. 75

Electrical Troubleshooting Guidelinesp. 76

Troubleshooting the CAN Busp. 76

Test the Main Wire Harnessp. 77

Test the Stem Harnessp. 77

Test the Grab Railp. 77

Test the Traction Amplifier and Vehicle Managerp. 77

Shorts to Frame Testp. 78

Fusesp. 81

Figure 5-4. Fuse Locationp. 81

Test/Inspectionp. 81

DC Electric Motorsp. 82

DC Motor Typesp. 82

Figure 5-5. Motor Circuitsp. 82

Inspectionp. 82

Servicep. 82

Open Circuit Motor Testp. 84

Grounded Motor Testp. 85

Short-Circuited Armaturep. 85

Short-Circuited Windingp. 85

AC Electric Motorsp. 86

AC Motor Typep. 86

Figure 5-6. AC Traction Motor circuit – Phase Ap. 86

Figure 5-7. AC Traction Motor circuit – Phase Bp. 86

Open Windingp. 86

Shorted Windingp. 86

Hydraulic Troubleshooting Guidelinesp. 87

Symptom Tables: Lift/Lower Systemp. 88

No Lift, Lift Motor Does Not Run, Travel is OK (From control handle or grab rail switch)p. 88

No Lift or Slow Lift, Lift Motor Does Runp. 89

No Lower, Lift and Travel OKp. 89

Unable to Pick Up a Loadp. 90

Slow Lowerp. 90

Load Drifting/Settlingp. 90

Symptom Tables: Travel (Forward/Reverse) Systemp. 91

No Travel, Lift/Lower OK. Main Contactor Does Not Close. TA Amber LED is Flashing Once Every 2 Secondsp. 91

No Travel, No Lift/Lower. TA Flash Code 3,1. Operator Display May Indicate Error Code E106p. 91

No Travel, No Lift/Lower. TA Flash Code 1,3. Operator Display Indicates Error Code E202p. 92

No Travel, No Lift/Lower. TA Flash Code 1,2. Operator Display Indicates Error Code E201p. 92

No Travel, Main Contactor Does Not Close. TA Flash Code 3,9. Operator Display Indicates Error Code E107p. 92

No Travel or Slow Travel. Main Contactor Does Close. TA Flash Code 2,1. Operator Display Indicates Error Code Cold (C43)p. 93

Slow Travel, Lift/Lower OK. No Fault Codesp. 93

No Emergency Reverse, Travel/Lift/Lower OK. No TA Flash Codesp. 93

No Rabbit Speed, Travel/Lift/Lower OK. No Fault Codesp. 93

No Truck Functions Active. TA Flash Code 1,8, (Excessive Battery Voltage). Operator Display May Indicate E222p. 94

No Truck Functions Active. TA Flash Code 1,7, (Low Battery Voltage). Operator Display May Indicate E221p. 94

No Travel or Slow Travel. TA Flash Code 2,2, (Thermal Cutback) Heatsink Temperature Exceeded 185°F (85°C). Operator Display May Indicate Hot2 (C45)p. 94

No Travel. Static Return to OFF (SRO) Fault. Display may indicate ‘Sro’ and Error and Parameter Control Indicators Blinkingp. 95

No Travel. High Pedal Disable Fault. Display may indicate ‘HPd’ and Error and Parameter Control Indicators Blinkingp. 95

Truck Does Not Accelerate Correctlyp. 95

Jog Speed Does Not Activate and Handle Does Not Stay in Coast Position. Lift and Travel OK. (Model 8400 with Coast PRO ™)p. 96

Jog Speed Does Not Activate. Lift and Travel OK. (Center Rider Models Only with Fixed-Position Handle)p. 96

Jog Speed Does Not Function, Handle Does Stay in Coast Position. Lift and Travel OK (Model 8400 with Coast PRO ™)p. 96

Symptom Tables: Wiring Systemp. 97

Section 6. Messages and Codesp. 99

List of Messages and Codesp. 100

Traction Amplifier LED Diagnosticsp. 103

Figure 6-1. Traction Amplifier Status Indicator LEDp. 103

Traction Amplifier Flash Codesp. 104

Caution and Error Codesp. 106

Figure 6-2. Operator Displayp. 106

Caution Codesp. 107

Code ‘GATE’p. 107

Code ‘SLO’p. 107

Code ‘Sro’ (C14)p. 107

Code C15p. 108

Code C19p. 108

Code HPd (C20)p. 108

Code C21p. 109

Code C22p. 109

Code C24p. 109

Code C25p. 110

Code C26p. 110

Code C27p. 110

Code C30p. 111

Code C31p. 111

Code C32p. 111

Code C33p. 112

Code C34p. 112

Code C35p. 112

Code Lo (C41)p. 113

Code Hi (C42)p. 113

Code Hot1 (C44)p. 114

Code Hot2 (C45)p. 114

Code C46 (iWarehouse Only)p. 114

Code C47 (iWarehouse Only)p. 115

Code C50p. 115

Code C51p. 115

Code C52p. 116

Code C57p. 116

Code C60p. 116

Code C61p. 117

Code C62p. 117

Code C63p. 117

Code C64p. 118

Code C65p. 118

Code C66p. 118

Code C67p. 119

Code C68p. 119

Code C70p. 119

Code C71p. 120

Code C72p. 120

Error Codesp. 121

Code E101p. 121

Code E106p. 121

Code E107p. 122

Code E108p. 122

Code E140p. 123

Code E141p. 123

Code E150p. 123

Code E157p. 124

Code E159p. 124

Code E160p. 124

Code E201p. 125

Code E202p. 125

Code E203p. 126

Code E220p. 126

Code E221p. 127

Code E222p. 127

Code E223p. 128

Code E224p. 128

Code E225p. 128

Code E228p. 129

Code E230p. 129

Code E232p. 129

Code E233p. 130

Code E235p. 130

Code E252p. 130

Code E253p. 131

Power Assisted Steering Caution Codesp. 132

Code C36p. 132

Code C74p. 132

Code C75p. 132

Code C76p. 133

Code C77p. 133

Code C78p. 133

Code C79p. 134

Code C80p. 134

Code C81p. 134

Code C82p. 135

Code C83p. 135

Code C84p. 135

Code C85p. 136

Code C86p. 136

Code C90p. 136

Electric Power Steering Caution Codesp. 137

Code C36p. 137

Code C74p. 137

Code C75p. 138

Code C76p. 138

Code C77p. 138

Code C78p. 139

Code C79p. 139

Code C80p. 140

Code C81p. 140

Code C82p. 141

Code C83p. 141

Code C84p. 142

Code C85p. 142

Code C86p. 143

Code C87p. 143

Code C88p. 143

Code C89p. 144

Code C90p. 144

Section 7. Component Proceduresp. 145

List of Component Procedures by Truck Systemp. 146

Component Locator Photosp. 149

Figure 7-1. Inside Tractor, Rear Viewp. 149

Figure 7-2. Inside Tractor, Right Sidep. 150

Figure 7-3. Inside Tractor, Left Sidep. 151

Figure 7-4. Model 8400 (Long-John Forks Shown)p. 152

Figure 7-5. Model 8400 Control Handlep. 153

Steering and Controlsp. 155

Power Assisted Steeringp. 156

Replacing the Pinion Gearp. 156

Figure 7-6. Pinion Gear Replacementp. 156

Figure 7-7. Mounting Bolt Detailp. 156

Replacing the Power Steer Unitp. 157

Figure 7-8. Power Steer Unit Replacementp. 157

Removing the Power Steering Sensor Cardp. 158

Figure 7-9. Power Steer Sensor Card Removal/Installationp. 158

Figure 7-10. Lower Cover Removalp. 159

Installing the Power Steering Sensor Cardp. 159

Figure 7-11.p. 159

Learn Steerp. 160

Learning Steer with FlashWarep. 160

Learning Steer with a Service Keyp. 160

Checking the Steer Positionp. 160

Steer Position Check – Method 1p. 160

Steer Position Check – Method 2p. 160

Replacing the Handle Centering Bumpersp. 161

Figure 7-12. Lower Cover Removalp. 161

Figure 7-13. Bumper Removalp. 161

Replacing the Handle Pivot Mechanismp. 162

Figure 7-14. Lower Cover Removalp. 162

Figure 7-15. Upper Cover Removalp. 162

Figure 7-16. Pivot Mechanism Replacementp. 163

Figure 7-17. Pivot Shaft Bearingsp. 164

Electric Power Steeringp. 166

Electric Power Steer Handle and Post Assemblyp. 166

Removing Handle and Postp. 166

Figure 7-18. Post Assembly Mounting Screwsp. 166

Installing Handle and Postp. 166

Handle Height Adjustmentp. 167

Standard Handle Height Adjustmentp. 167

Figure 7-19. Height Adjustment – Standard Handlep. 167

Premium Handle Height Adjustmentp. 167

Figure 7-20. Height Adjustment – Premium Handlep. 167

Control Head – Standard Handlep. 168

Figure 7-21. Control Head/Arm and Post Disassemblyp. 168

Standard Control Head Installationp. 168

Control Head – Premium Handlep. 169

Figure 7-22. Control Head Mounting Screwsp. 169

Premium Control Head Installationp. 169

Offset (Home) Sensor Proximity Switch (SW23)p. 171

Offset Sensor Replacementp. 171

Figure 7-23. Offset Sensor Plate Mounting Screwsp. 171

Figure 7-24. Setting Sensor Gapp. 171

Gas Springsp. 172

Post Gas Spring Replacementp. 172

Figure 7-25. Post Gas Spring Replacementp. 172

Control Handle – Model 8300p. 173

Figure 7-26. Model 8300 Control Head Assembly – Exploded Viewp. 173

Control Handle Disassemblyp. 174

Changing Horn Button/Switchp. 174

Figure 7-27. Horn Button Removalp. 174

Changing Lift/Lower Buttonp. 175

Figure 7-28. Lift/Lower Button Removalp. 175

Changing Push Buttonp. 175

Figure 7-29. Push Button Removalp. 175

Spring-Loaded Handle Designp. 176

Spring-Loaded Handle Removalp. 176

Figure 7-30. Control Handle Base Cover Removalp. 176

Figure 7-31. Control Handle Wire Harnessp. 176

Figure 7-32. Remove Jam Nut at Coast Linkp. 176

Figure 7-33. Return Spring Rod Removalp. 177

Spring-Loaded Handle Installationp. 177

Return Spring Adjustment, Spring-Loaded Handlep. 177

Figure 7-34. Return Spring Adjustmentp. 177

Fixed-Position Handle Design – Models 8500 and 8600p. 179

Fixed-Position Handle Removalp. 179

Fixed-Position Handle Installationp. 179

Control Handle Assembliesp. 180

Figure 7-35. Control Handle and Head Assembly – Model 8400 (Spring-Loaded Handle)p. 180

Figure 7-36. Control Handle with Hand Brake – Model 8500 and 8600 (Fixed Handle)p. 181

Figure 7-37. Control Handle with Deadman Brake – Model 8500 and 8600 (Spring-Loaded Handle)p. 182

Figure 7-38. Control Head Assembly (Models 8400, 8500, and 8600) – Exploded Viewp. 183

Control Head Removalp. 184

Changing Horn Button/Switchp. 184

Figure 7-39. Horn Button Removalp. 185

Changing Lift/Lower Switch Activatorp. 185

Figure 7-40. Lift/Lower Button Removalp. 185

Changing the Push Buttonp. 185

Figure 7-41. Push Button Removalp. 185

Figure 7-42. Handle with Jog Optionp. 186

Changing the Jog Switchp. 186

Changing the Jog Button Control and Springp. 186

Drive and Brakep. 187

Drive Unitp. 188

Removing the Drive Unitp. 188

Figure 7-43. Drive Unit Fill Plugp. 188

Figure 7-44. Drive Unit Drain Plugp. 188

Figure 7-45. Drive Unit Mounting (Traction Motor Removed)p. 188

Steering Bearingp. 189

Removing the Steering Bearingp. 189

Figure 7-46. Drive Unit (Shown installed in Tractor Frame)p. 189

Figure 7-47. Drive Unit Bottom Viewp. 189

Figure 7-48. Drive Unit, Steering Bearing Removedp. 189

Installing the Steering Bearingp. 189

Figure 7-49. Main Case Cover, Six Hole-Type, Installedp. 190

Figure 7-50. Gear Housing and Coverp. 190

Assembling the Gearp. 190

Figure 7-51. Lower Drive Unit, Cross-Sectional Viewp. 192

Checking the Gearsp. 193

Adjusting Tooth Pattern of Drive Unitp. 193

Figure 7-52. Drive Unit Gear Tooth Patternp. 193

Installing the Drive Unitp. 194

Figure 7-53. Drive Unit Gauge and Shimming Locationsp. 194

Figure 7-54. Drive Unit Mounting Screw Torque Sequencep. 195

Figure 7-55. Drive Unit Drain Plugp. 195

Drive Housing Lubricationp. 195

Drive Wheelp. 196

Removing the Drive Wheelp. 196

Figure 7-56. Drive Wheel and Tirep. 196

Cushion Tire Replacementp. 196

Figure 7-57. Cushion Tire Replacementp. 196

Caster Adjustmentp. 198

Figure 7-58. Drive Tire on Platep. 198

Casters (without Springs)p. 199

Caster Removalp. 199

Figure 7-59. Removing Caster Wheel Assemblyp. 199

Wheel Replacementp. 199

Figure 7-60. Caster Assembly, Disassembledp. 199

Caster Assemblyp. 199

Figure 7-61. Caster Assembly, Assembledp. 200

Caster Installationp. 200

Figure 7-62. Securing Caster To Tractorp. 200

Adjustable Caster Adjustmentp. 200

Figure 7-63. Adjustable Caster Adjustmentp. 200

Casters (Spring-Loaded)p. 201

Spring-Loaded Caster Removalp. 201

Figure 7-64. Removing Spring-Loaded Casterp. 201

Wheel Replacementp. 201

Figure 7-65. Removing Tension Pinp. 201

Figure 7-66. Removing Axle Shaftp. 201

Figure 7-67. Removed Wheel and Shimsp. 201

Caster Disassemblyp. 202

Figure 7-68. Compressing Caster Springsp. 202

Figure 7-69. Relieving Pivot Tensionp. 202

Figure 7-70. Removing Pivot Pin Retainer Screwp. 202

Figure 7-71. Removing Pivot Pinp. 202

Figure 7-72. Separated Casterp. 202

Caster Assemblyp. 203

Figure 7-73. Removing Bolts from Springsp. 203

Wheel Installationp. 203

Figure 7-74. Installing New Wheelp. 203

Figure 7-75. Installing Axle Shaftp. 203

Figure 7-76. Installing Tension Pinp. 203

Spring-Loaded Caster Installationp. 204

Figure 7-77. Caster, Shims and Mounting Boltsp. 204

Figure 7-78. Securing Caster To Tractorp. 204

Brakep. 205

Spring-Loaded Handlep. 205

Figure 7-79. Brake Release Bolt Storage Locationp. 205

Brake Removal, Spring-Loaded Handlep. 205

Figure 7-80. Brake Release Bolts, Installedp. 205

Figure 7-81. Brake Release Bolts, Installedp. 205

Brake Installation, Spring-Loaded Handlep. 205

Checking the Gapp. 206

Figure 7-82. Measuring Brake Gapp. 206

Replacing the Rotorp. 206

Electrical Componentsp. 207

Batteryp. 208

With Battery Gates and Rollers (Optional)p. 208

Battery Removalp. 208

Battery Installationp. 208

Battery Gates (Optional)p. 208

Battery Gate Inspectionp. 208

Battery Rollers (Optional)p. 208

Battery Roller Inspectionp. 208

Battery Roller Replacementp. 208

Without Battery Gates and Rollersp. 208

Battery Removalp. 208

Battery Installationp. 208

Battery Exterior Cleaningp. 209

Figure 7-83. Battery Filler Plugs and Vent Holesp. 209

Testing, Charging, and Maintenancep. 209

Maintenance-Free Batteriesp. 210

Battery Storagep. 210

Power Cablesp. 211

Power Cable Repairp. 211

Figure 7-84. Short Barrel Terminalp. 211

Figure 7-85. Long Barrel Terminalsp. 212

Wiring Harnessp. 213

Wiring Harness Terminologyp. 213

Inspecting a Wiring Harnessp. 213

Repairing a Wiring Harnessp. 213

Wiring Harness Soldering Proceduresp. 214

AMP Water-Resistant Connectorsp. 215

Figure 7-86. AMP Water-Resistant Connectorp. 215

AMP Connector Pin Extractionp. 215

Figure 7-87. AMP Pin Extractionp. 215

Figure 7-88. Removing Wirep. 216

AMP Connector Pin Insertionp. 216

Figure 7-89. Wire Sealp. 216

Figure 7-90. Wire Insertionp. 216

AMP Connector Sealsp. 216

Figure 7-91. Sealing Plugp. 216

Figure 7-92. Interface Sealp. 217

Figure 7-93. Latching AMP Connectorp. 217

AMP Harness/Traction Amplifier Connectorp. 218

AMP Harness Connector Componentsp. 218

Figure 7-94. JPT1 Connector Componentsp. 218

AMP Harness Connector Disassembly (Contact Removal)p. 218

Figure 7-95. AMP Connector (JT1 or JL1)p. 218

AMP Harness Connector Contact Insertionp. 218

AMP Harness Connector Assemblyp. 219

Figure 7-96. Contact Insertionp. 219

Figure 7-97. Wedge Lock Latchesp. 220

Figure 7-98. Wedge Lock Flush With Housingp. 220

Testing AMP Harness Connectorsp. 220

Brake Potentiometer (VR1)p. 221

Removing VR1p. 221

Figure 7-99. Pot Cover Screw Locationsp. 221

Figure 7-100. Brake Control Assembly – Exploded Viewp. 221

Installing VR1p. 221

Lift-Limit Switch (SW8)p. 222

Figure 7-101. Lift-Limit Switchp. 222

Adjusting the Limit Switchp. 222

Grab Rail Switches – Model 8400p. 223

Removing Grab Rail Switchesp. 223

Figure 7-102. Grab Rail Switch Removal, Left Sidep. 223

Figure 7-103. Grab Rail Switch Removal, Right Sidep. 223

Installing Grab Rail Switchesp. 223

Load Backrest Switches – Model 8500 Optionp. 224

Removing Load Backrest Switchesp. 224

Figure 7-104. Load Backrest Switches, Detail Viewp. 224

Figure 7-105. Load Backrest Switches, Cover Plate Openp. 224

Installing Load Backrest Switchesp. 224

Hydraulic Solenoidsp. 225

Figure 7-106. Hydraulic Solenoids (typical unit)p. 225

Coast PRO ™ Solenoid – Model 8400 Optionp. 226

Removing the CoastPro Solenoidp. 226

Figure 7-107. Coast PRO Solenoid Locationp. 226

Figure 7-108. Socket Head Cap Screwsp. 226

Figure 7-109. Removed Solenoid Mechanismp. 226

Installing the CoastPro Solenoidp. 227

Figure 7-110. Install Ball Bearingsp. 227

Coast Solenoid Switch/Springp. 227

Removing Coast Solenoid Switchp. 227

Installing Coast Solenoid Switch/Springp. 227

Coast PRO Canisterp. 227

Removing the CoastPro Canisterp. 227

Installing the CoastPro Canisterp. 227

Figure 7-111. Canister Spacingp. 227

Repairing the CoastPro Canisterp. 228

Figure 7-112. Special Compression Toolp. 228

Figure 7-113. Cylinder Secured In Hydraulic Pressp. 228

Figure 7-114. Removing Snap Ringp. 228

Figure 7-115. Coast PRO Canister Componentsp. 228

Figure 7-116. Assembling Coast PRO Canisterp. 229

Traction Amplifierp. 230

Figure 7-117. Traction Amplifier Locationp. 230

Removing the Traction Amplifierp. 230

Figure 7-118. Removing the Traction Amplifierp. 230

Installing the Traction Amplifierp. 230

Programming the Traction Amplifierp. 231

Motors, Generalp. 232

Terminal Nutsp. 232

Figure 7-119. Traction Motor Terminal Connectionsp. 232

Figure 7-120. Lift and Auxiliary Motor Terminal Nutsp. 232

Traction Motorp. 233

Removing the Traction Motorp. 233

Figure 7-121. Control Handle Base Cover Removalp. 233

Figure 7-122. Control Handle Base Cover Removalp. 234

Figure 7-123. Traction Motor Power Cablesp. 234

Figure 7-124. Traction Motor Removalp. 235

Figure 7-125. Drive Unit Pinion Gearp. 235

Installing the Traction Motorp. 235

Figure 7-126. Main Case Locationp. 235

Installing Temperature Sensorp. 236

Figure 7-127.p. 236

Figure 7-128.p. 236

Terminal Board Removal and Replacementp. 236

Figure 7-129.p. 237

Motor Disassemblyp. 237

Figure 7-130.p. 237

Motor Assemblyp. 238

Figure 7-131. Bolt Tightening Sequencep. 239

Lift Motorp. 240

General Datap. 240

Removing the Lift Motorp. 240

Figure 7-132. Bolts Securing Motor To Adapterp. 240

Figure 7-133. Separated Reservoir and Motor (typical)p. 240

Installing the Lift Motorp. 240

Figure 7-134. Coupling Cavityp. 241

Figure 7-135. Indexing Pinp. 241

Hydraulic Componentsp. 243

Hydraulic Componentsp. 244

General Guidelinesp. 244

Figure 7-136. Hydraulic Unit (typical shown)p. 244

Hydraulic Fluidp. 245

Checking Hydraulic Fluid Levelp. 245

Hydraulic Unitp. 246

Removing the Hydraulic Unitp. 246

Figure 7-137. Hydraulic Unit (typical shown)p. 246

Installing the Hydraulic Unitp. 246

Hydraulic Reservoirp. 247

Removing the Hydraulic Reservoirp. 247

Figure 7-138. Adapter Cap Screwsp. 247

Figure 7-139. Removed Reservoirp. 247

Installing the Hydraulic Reservoirp. 247

Filter Screen and Suction Tubep. 248

Removing Filter Screen and Suction Tubep. 248

Figure 7-140. Pump Housing Componentsp. 248

Figure 7-141. Cleaning Filter Screenp. 248

Installing Filter Screen and Suction Tubep. 248

Hydraulic Pumpp. 249

Removing the Pumpp. 249

Figure 7-142. Pump and Adapter Bodyp. 249

Installing the Pumpp. 249

Figure 7-143. Pump Drive Couplingp. 249

Figure 7-144. Installing Pump In Adapterp. 249

Adjusting Hydraulic Pump Relief Valve Pressurep. 250

Figure 7-145. Checking Relief Valve Pressurep. 250

Checking Relief Valve Settingp. 250

Alternate Method Using Rated Load on Palletsp. 250

Hydraulic Ramp. 252

Inspecting Hydraulic Ramp. 252

Removing Hydraulic Ramp. 252

Figure 7-146. Removing Lower Bell Crank Pinsp. 252

Figure 7-147. Disconnecting Upper Clevis Bracketsp. 253

Figure 7-148. Hydraulic Ram Area, Forks Removedp. 253

Figure 7-149. Hydraulic Line Connectionp. 253

Figure 7-150. Vent Hose Connectionsp. 253

Installing Hydraulic Ramp. 254

Figure 7-151. Hydraulic Ram Removal/Installationp. 254

Figure 7-152. Hydraulic Line Connection (installed)p. 254

Hydraulic Cylinder Sealsp. 255

Disassembling the Cylinderp. 255

Figure 7-153. Remove Outer Spiral Lock Ringp. 255

Figure 7-154. Remove the Spacerp. 255

Figure 7-155. Remove Head Lock Ring From Cylinderp. 255

Figure 7-156. Rod and Head Assembly Out of Cylinderp. 255

Figure 7-157. Remove the Piston Jam Nutp. 256

Figure 7-158. Piston Rod Componentsp. 256

Assembling the Cylinderp. 256

Figure 7-159. Correct Piston Seal Orientationp. 256

Figure 7-160. Securing Piston Jam Nutp. 256

Figure 7-161. Installing the Head Lock Ringp. 257

Figure 7-162. Installing the Outer Lock Ringp. 257

Mastp. 259

Put This Raymond Maintenance Manual to Work

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Raymond 8300 8400 8500 8600 Pallet Truck and Tow Tractor Maintenance Manual - PDF Download — PDF page 41 preview

Raymond 8300 8400 8500 8600 Pallet Truck and Tow Tractor Maintenance Manual - PDF Download — PDF page 192 preview

Raymond 8300 8400 8500 8600 Pallet Truck and Tow Tractor Maintenance Manual - PDF Download — PDF page 328 preview

This Raymond 8300 8400 8500 8600 Pallet Truck and Tow Tractor Maintenance Manual gives you the procedures to keep these machines running: diagnose a no-travel or no-lift complaint against the symptom tables, read and clear the C-series caution codes and E-series error codes, service the drive unit and hydraulic ram, adjust fork height and caster shims to the printed tolerances, and torque every fastener to the value the manual specifies. Correct procedures and the right specifications are what keep a pallet truck off the disabled list and away from a repair bill built on guesswork. The manual arrives as an instant PDF download – no shipping and no waiting – and opens on any device so you can print the pages you need for the job or keep it on a laptop in the shop.

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