RAYMOND 8310 8410 8510 Pallet Trucks and 8610 Tow Tractor Maintenance Manual 1152122B – PDF DOWNLOAD

Description

RAYMOND 8310 8410 8510 Pallet Trucks and 8610 Tow Tractor Maintenance Manual 1152122B – PDF DOWNLOAD

FILE DETAILS:

RAYMOND 8310 8410 8510 Pallet Trucks and 8610 Tow Tractor Maintenance Manual 1152122B – PDF DOWNLOAD

Language : English
Pages : 473
Downloadable : Yes
File Type : PDF
Size: 34.6 MB

DESCRIPTION:

RAYMOND 8310 8410 8510 Pallet Trucks and 8610 Tow Tractor Maintenance Manual 1152122B – PDF DOWNLOAD

Serial Numbers:
8310 831-12-10001 and up
8410 841-12-10001 and up
8510 851-12-10001 and up
8610 861-12-10001 and up

Manual Design

The Raymond® Pallet Trucks and Tow Tractor Maintenance Manual is designed with the following objectives in mind:

The two-line running page header at the top of each page tells you:

• Look up the component name in the list of Component Procedures.
• Find the component in the Component Locator Photographs.
• Look up the component name in the Index.
• Section 8. Theory of Operations explains flow within hydraulic and electrical systems for various conditions of lift truck operation. This section also contains a pinout matrix chart that lists functions and normal voltages of terminals and harness connector pins.
• Appendix contains reference information such as torque values, lubricants, and standard/metric conversions.
• Index lists subjects alphabetically.

TABLE OF CONTENTS:

RAYMOND 8310 8410 8510 Pallet Trucks and 8610 Tow Tractor Maintenance Manual 1152122B – PDF DOWNLOAD

Document Revision History. xi
How To Use This Manual 1-1
Manual Design 1-2
Interactive Electronic Technical Manuals 1-3
Abbreviations & Symbols 1-4
Safety 2-1
Definitions 2-2
General Safety 2-3
Battery Safety. 2-6
Jacking Safety 2-9
Tractor Section 2-9
Fork Section 2-9
Tie-Down for Transport. 2-10
Towing 2-11
Without Brake Release Bolts 2-11
With Brake Release Bolts 2-11
Static Safety 2-12
Welding Safety 2-13
Systems Overview 3-1
Introduction 3-2
Truck Model Identification 3-3
Truck Specifications 3-4
Special Tools 3-5
Service Key 3-5
Operator Display and Programming 3-6
Special Truck Mode 3-6
Hour Meter (H) 3-6
Error Codes (E) 3-6
Changing Truck Parameters (P) 3-7
Service Input/Output Displays 3-18
Digital Inputs/Outputs from Traction Amplifier and VM 3-18
FlashWare 3-21
Overview 3-21
Requirements 3-21
Installing FlashWare on PC 3-21
Connecting PC to Truck 3-21
Starting FlashWare 3-22
Scheduled Maintenance 4-1
Maintenance Guidelines 4-2
Initial 90 Day/250 Deadman Hours (HD) Maintenance 4-3
Every 180 Days or 500 Deadman Hours 4-4
Every 360 Days or 2000 Deadman Hours (HD) 4-7
Contactor Tip Inspection 4-8
Grease Fittings (All Models) 4-9
Grease Fittings (Trucks with Steel Bushings Only) 4-10
Undercarriage Pin and Bushing Inspection Points. 4-11
Table of Contents Raymond® Pallet Trucks and Tow Tractor Maintenance Manual
ii Publication: 1152122, Issued: 25 Apr 2013
Troubleshooting 5-1
How to Use This Section. 5-2
Electrical Troubleshooting Guidelines 5-3
General 5-3
Troubleshooting the CAN Bus. 5-3
Shorts to Frame 5-6
Fuses. 5-9
Test/Inspection 5-9
DC Electric Motors 5-10
DC Motor Types 5-10
Inspection 5-10
Service 5-10
Open Circuit Motor Test 5-12
Grounded Motor Test 5-13
Short-Circuited Armature 5-13
Short-Circuited Winding 5-13
AC Electric Motors 5-14
AC Motor Type 5-14
Open Winding 5-14
Shorted Winding. 5-14
Hydraulic Troubleshooting Guidelines 5-15
Symptom Tables: Lift/Lower System 5-16
No Lift, Lift Motor Does Not Run, Travel is OK
(From control handle or grab rail switch) 5-16
No Lift or Slow Lift, Lift Motor Does Run 5-17
No Lower, Lift and Travel OK 5-17
Unable to Pick Up a Load 5-18
Slow Lower 5-18
Load Drifting/Settling. 5-19
Symptom Tables: Travel (Forward/Reverse) System 5-20
No Travel, Lift/Lower OK. Main Contactor Does Not Close.
TA Amber LED is Flashing Once Every 2 Seconds 5-20
No Travel, No Lift/Lower. TA Flash Code 3,1.
Operator Display May Indicate Error Code E106 5-20
No Travel, No Lift/Lower. TA Flash Code 1,3.
Operator Display Indicates Error Code E202 5-21
No Travel, No Lift/Lower. TA Flash Code 1,2.
Operator Display Indicates Error Code E201 5-21
No Travel, Main Contactor Does Not Close. TA Flash Code 3,9.
Operator Display Indicates Error Code E107 5-21
Slow Travel, Lift/Lower OK. No Fault Codes 5-22
No Emergency Reverse, Travel/Lift/Lower OK.
No TA Flash Codes 5-22
No Rabbit Speed, Travel/Lift/Lower OK. No Fault Codes. 5-22
No Truck Functions Active. TA Flash Code 1,8,
(Excessive Battery Voltage). Operator Display
May Indicate E222 5-22
No Truck Functions Active. TA Flash Code 1,7,
(Low Battery Voltage). Operator Display May Indicate E221 5-23
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) 5-23
Raymond® Pallet Trucks and Tow Tractor Maintenance Manual Table of Contents
Publication: 1152122, Issued: 25 Apr 2013 iii
No Travel. Static Return to OFF (SRO) Fault.
Display may indicate ‘Sro’ and Error and Parameter
Control Indicators Blinking 5-23
No Travel. High Pedal Disable Fault.
Display may indicate ‘HPd’ and Error and Parameter
Control Indicators Blinking 5-24
Truck Does Not Accelerate Correctly 5-24
Jog Speed Does Not Activate When Button is Pressed and
Handle Does Not Stay in Coast Position. Lift and
Travel OK. (Model 8410 with Coast PRO™) 5-24
Jog Speed Does Not Activate When Button is Pressed.
Lift and Travel OK. (Center Rider Models Only with
Fixed-Position Handle) 5-25
Jog Speed Does Not Function, Handle Does Stay in
Coast Position. Lift and Travel OK (Model 8410
with CoastPRO™) 5-25
Symptom Tables: Wiring System. 5-26
Messages and Codes 6-1
List of Messages and Codes 6-2
Traction Amplifier LED Diagnostics 6-5
Traction Amplifier Flash Codes 6-6
Caution and Error Codes 6-8
Message and Caution Codes 6-9
Code ‘GATE’ 6-9
Code ‘SLO’ 6-9
Code ‘Sro’ (C14) 6-9
Code ‘LoGn’ (C15) (iWAREHOUSE Only) 6-10
Code C19 6-10
Code ‘HPd’ (C20) 6-10
Code C21 6-11
Code C22 6-11
Code C24 6-11
Code C25 6-12
Code C26 6-12
Code C27 6-12
Code C30 6-13
Code C31 6-13
Code C32 6-13
Code C33 6-14
Code C34 6-14
Code C35 6-14
Code C36 (Model 8410 with Power Assisted Steering) 6-15
Code C36 (Models 8510/8610 with Electric Power Steering) 6-15
Code C38 (Models 8510/8610 with Electric Power Steering) 6-15
Code C39 (Models 8510 with Electric Power Steering and
Orderpicking Option) 6-16
Code Lo (C41) 6-16
Code Hi (C42) 6-16
Code Hot1 (C44) 6-17
Code Hot2 (C45) 6-17
Code C46 (iWAREHOUSE® Only) 6-18
Code C47 (iWAREHOUSE® Only) 6-18
Table of Contents Raymond® Pallet Trucks and Tow Tractor Maintenance Manual
iv Publication: 1152122, Issued: 25 Apr 2013
Code C50 6-19
Code C51 6-19
Code C52 6-19
Code C57 6-20
Code C60 6-20
Code C61 6-20
Code C62 6-21
Code C63 6-21
Code C64 6-21
Code C65 6-22
Code C66 6-22
Code C67 6-22
Code C68 6-23
Code C70 6-23
Code C71 6-23
Code C72 6-24
Code C74 (Model 8410 with Power Assisted Steering) 6-24
Code C74 (Models 8510/8610 with Electric Power Steering) 6-24
Code C75 (Model 8410 with Power Assisted Steering) 6-25
Code C75 (Models 8510/8610 with Electric Power Steering) 6-25
Code C76 (Model 8410 with Power Assisted Steering) 6-25
Code C76 (Models 8510/8610 with Electric Power Steering) 6-26
Code C77 (Model 8410 with Power Assisted Steering) 6-26
Code C77 (Models 8510/8610 with Electric Power Steering) 6-26
Code C78 (Model 8410 with Power Assisted Steering) 6-27
Code C78 (Models 8510/8610 with Electric Power Steering) 6-27
Code C79 (Model 8410 with Power Assisted Steering) 6-27
Code C79 (Models 8510/8610 with Electric Power Steering) 6-28
Code C80 (Model 8410 with Power Assisted Steering) 6-28
Code C80 (Models 8510/8610 with Electric Power Steering) 6-28
Code C81 (Model 8410 with Power Assisted Steering) 6-29
Code C81 (Models 8510/8610 with Electric Power Steering) 6-29
Code C82 (Model 8410 with Power Assisted Steering) 6-29
Code C82 (Models 8510/8610 with Electric Power Steering) 6-30
Code C83 (Model 8410 with Power Assisted Steering) 6-30
Code C83 (Models 8510/8610 with Electric Power Steering) 6-30
Code C84 (Model 8410 with Power Assisted Steering) 6-31
Code C84 (Models 8510/8610 with Electric Power Steering) 6-31
Code C85 (Model 8410 with Power Assisted Steering) 6-31
Code C85 (Models 8510/8610 with Electric Power Steering) 6-32
Code C86 (Model 8410 with Power Assisted Steering) 6-32
Code C86 (Models 8510/8610 with Electric Power Steering) 6-32
Code C87 (Models 8510/8610 with Electric Power Steering) 6-33
Code C88 (Models 8510/8610 with Electric Power Steering) 6-33
Code C89 (Models 8510/8610 with Electric Power Steering) 6-33
Code C90 (Model 8410 with Power Assisted Steering) 6-34
Code C90 (Models 8510/8610 with Electric Power Steering) 6-34
Code C94 (Models 8510/8610 with Electric Power Steering) 6-34
Error Codes 6-35
Code E101 6-35
Code E106 6-35
Code E107 6-36
Raymond® Pallet Trucks and Tow Tractor Maintenance Manual Table of Contents
Publication: 1152122, Issued: 25 Apr 2013 v
Code E108 6-36
Code E140 6-36
Code E141 6-37
Code E150 6-37
Code E157 6-37
Code E159 6-38
Code E160 6-38
Code E201 6-38
Code E202 6-39
Code E203 6-39
Code E220 6-39
Code E221 6-40
Code E222 6-40
Code E223 6-40
Code E224 6-41
Code E225 6-41
Code E228 6-41
Code E230 6-42
Code E232 6-42
Code E233 6-42
Code E235 6-43
Code E252 6-43
Code E253 6-43
Component Procedures 7-1
List of Component Procedures by Truck System 7-2
Component Locator Photos 7-7
Steering and Controls 7-15
Power Steering 7-16
Replacing the Pinion Gear 7-16
Replacing the Power Steer Unit 7-17
Learn Steer 7-17
Checking the Steer Position 7-18
Steer Home Proximity Sensor (SW23) 7-19
Sensor Replacement 7-19
Sensor Flag Adjustment 7-19
Power Assisted Steering Control Handle 7-20
Removing the Power Steering Sensor Card 7-21
Installing the Power Steering Sensor Card 7-21
Replacing the Handle Centering Bumpers 7-22
Replacing the Handle Pivot Mechanism 7-23
Electric Power Steering 7-26
Electric Power Steer Handle and Post Assembly 7-26
Handle Height Adjustment 7-27
Control Head – Standard Handle 7-28
Control Head – Premium Handle 7-33
Handle Center Switch (SW24) 7-38
Gas Springs 7-39
Control Handle – Model 8310 7-40
Control Handle Disassembly 7-41
Spring-Loaded Handle Design. 7-43
Removal – Model 8410. 7-43
Installation – Model 8410 7-44
Table of Contents Raymond® Pallet Trucks and Tow Tractor Maintenance Manual
vi Publication: 1152122, Issued: 25 Apr 2013
Return Spring Adjustment – Model 8410. 7-44
Removal – Models 8510 and 8610 7-45
Installation – Models 8510 and 8610. 7-46
Return Spring Adjustment – Models 8510 and 8610 7-46
Fixed-Position Handle Design – Models 8510 and 8610. 7-48
Fixed-Position Handle Removal. 7-48
Fixed-Position Handle Installation 7-48
Control Handle Assemblies. 7-49
Control Head Removal 7-53
Changing Horn Button/Switch 7-53
Changing Lift/Lower Switch Activator. 7-54
Changing the Push Button 7-54
Changing the Jog Switch 7-55
Changing the Jog Button Control and Spring 7-55
Throttle Spring Replacement 7-56
Drive and Brake 7-59
Drive Unit 7-60
Removing the Drive Unit. 7-60
Removing the Steering Bearing 7-62
Installing the Steering Bearing 7-62
Disassembling the Drive Unit 7-63
Assembling the Drive Unit 7-64
Checking the Gears 7-66
Adjusting the Tooth Pattern 7-66
Installing the Drive Unit 7-67
Drive Housing Lubrication 7-69
Drive Wheel 7-70
Removing the Drive Wheel 7-70
Cushion Tire Replacement 7-70
Shim Caster Adjustment 7-72
Adjustable Caster Adjustment 7-73
Casters (Poly Block) 7-74
Caster Removal 7-74
Wheel Replacement 7-74
Caster Installation 7-74
Casters (Spring-Loaded) 7-75
Spring-Loaded Caster Removal 7-75
Wheel Removal 7-75
Caster Disassembly 7-76
Caster Assembly. 7-77
Wheel Installation. 7-77
Spring-Loaded Caster Installation. 7-78
Brake. 7-79
Brake Removal 7-79
Brake Installation 7-80
Checking the Gap 7-80
Replacing the Rotor 7-80
Electrical Components 7-81
Battery. 7-82
Trucks With Battery Gates and Rollers (Optional) 7-82
Battery Removal 7-82
Battery Installation. 7-82
Raymond® Pallet Trucks and Tow Tractor Maintenance Manual Table of Contents
Publication: 1152122, Issued: 25 Apr 2013 vii
Battery Gates (Optional) 7-82
Battery Gate Inspection 7-82
Battery Rollers (Optional) 7-82
Battery Roller Inspection. 7-82
Battery Roller Replacement 7-82
Trucks Without Battery Gates and Rollers 7-82
Battery Removal 7-82
Battery Installation 7-82
Battery Exterior Cleaning 7-83
Testing, Charging, and Maintenance 7-84
Maintenance-Free Batteries 7-84
Battery Storage 7-84
Power Cables 7-85
Power Cable Repair 7-85
Wiring Harness. 7-87
Wiring Harness Terminology 7-87
Inspecting a Wiring Harness 7-87
Repairing a Wiring Harness. 7-87
AMP Water-Resistant Connectors 7-89
AMP Connector Pin Extraction 7-89
AMP Connector Pin Insertion 7-90
AMP Connector Seals 7-90
AMP Harness/Traction Amplifier Connector 7-92
AMP Harness Connector Components 7-92
AMP Harness Connector Disassembly (Contact Removal) 7-92
AMP Harness Connector Assembly 7-93
Testing AMP Harness Connectors 7-94
Brake Potentiometer (VR1) 7-95
Removing VR1 7-95
Installing VR1 7-95
Brake Potentiometer Calibration 7-96
Lift-Limit Switch (SW8) 7-98
Adjusting the Limit Switch 7-98
Grab Rail Switches – Model 8410 7-99
Removing Grab Rail Switch Module. 7-99
Installing Grab Rail Switch Module 7-99
Load Backrest Switches – Model 8510 Option 7-100
Removing Load Backrest Switches 7-100
Installing Load Backrest Switches 7-100
Hydraulic Solenoids 7-102
CoastPRO™ Solenoid – Model 8410 Option. 7-103
Removing the CoastPRO Solenoid 7-103
Installing the CoastPRO Solenoid 7-104
Coast Solenoid Switch/Spring 7-105
Removing Coast Solenoid Switch. 7-105
Installing Coast Solenoid Switch/Spring 7-105
CoastPRO Canister. 7-106
Removing the CoastPRO Canister 7-106
Installing the CoastPRO Canister 7-106
Repairing the CoastPRO Canister 7-106
Traction Amplifier. 7-109
Removing the Traction Amplifier 7-109
Table of Contents Raymond® Pallet Trucks and Tow Tractor Maintenance Manual
viii Publication: 1152122, Issued: 25 Apr 2013
Installing the Traction Amplifier 7-110
Programming the Traction Amplifier 7-110
Motors, General 7-111
Terminal Nuts 7-111
Traction Motor 7-112
Removing the Traction Motor – Models 8310/8410 7-112
Removing the Traction Motor – Models 8510 and 8610 7-113
Installing the Traction Motor – Models 8310 and 8410 7-116
Installing the Traction Motor – Models 8510 and 8610 7-117
Temperature Sensor Replacement. 7-118
Terminal Board Removal and Replacement 7-119
Speed Sensor Replacement 7-120
Motor Disassembly 7-121
Motor Assembly 7-123
Lift Motor 7-126
General Data 7-126
Removing the Lift Motor 7-126
Installing the Lift Motor 7-126
Hydraulic Components 7-129
Hydraulic Components. 7-130
General Guidelines 7-130
Hydraulic Fluid 7-131
Checking Hydraulic Fluid Level 7-131
Hydraulic Unit 7-132
Removing the Hydraulic Unit 7-132
Installing the Hydraulic Unit 7-132
Hydraulic Reservoir 7-133
Removing the Hydraulic Reservoir 7-133
Installing the Hydraulic Reservoir 7-133
Filter Screen and Suction Tube 7-134
Removing Filter Screen and Suction Tube. 7-134
Installing Filter Screen and Suction Tube 7-134
Hydraulic Pump 7-135
Removing the Pump 7-135
Installing the Pump 7-135
Adjusting Hydraulic Pump Relief Valve Pressure 7-136
Checking Relief Valve Setting 7-136
Alternate Method Using Rated Load on Pallets 7-137
Hydraulic Ram 7-138
Inspecting Hydraulic Ram 7-138
Removing Hydraulic Ram 7-138
Installing Hydraulic Ram 7-140
Hydraulic Cylinder Seals 7-142
Disassembling the Cylinder 7-142
Assembling the Cylinder 7-143
Cast Hydraulic Cylinder Repair 7-144
Disassembly 7-144
Assembly 7-144
Mast. 7-145
Top Linkage Subassembly 7-146
Removing the Top Linkage Subassembly. 7-146
Installing the Top Linkage Subassembly 7-147
Raymond® Pallet Trucks and Tow Tractor Maintenance Manual Table of Contents
Publication: 1152122, Issued: 25 Apr 2013 ix
Pull Rod Subassembly 7-149
Removing the Pull Rod Subassembly. 7-149
Installing the Pull Rod Subassembly 7-150
Load Wheels 7-152
Tandem Load Wheels – Models 8410 and 8510 7-153
Suspension Wheel – Model 8610 7-154
Pallet Entry Sliders. 7-156
Slider Replacement 7-156
Pallet Entry Rollers. 7-157
Roller Replacement 7-157
Fork Height Adjustment 7-158
Measurement/Adjustment 7-159
Downstop Installation 7-160
Downstop Adjustment. 7-160
Pallet Entry/Exit Enhancements. 7-161
Options. 7-163
Cold Storage Conditioning 7-164
Battery Spacer Kit Installation 7-165
Part Selection 7-166
Installation 7-167
Single Level Accessory Bar Kit Installation 7-168
Truck Modification 7-168
Accessory Bar Installation. 7-169
First Tier Accessory Bar Kit Installation 7-171
Truck Modification 7-171
Accessory Bar Installation. 7-172
Second Tier Accessory Bar Kit Installation 7-174
Accessory Bar Installation. 7-174
Battery Gate Interlock Sensors 7-176
Battery Gate Interlock Sensor Replacement. 7-176
Battery Gate Interlock Sensor Adjustment 7-176
Theory of Operation 8-1
Definitions 8-2
Acceleration Rate 8-2
Brake Lever Potentiometer (VR1)
(Models with Fixed Position Handle) 8-2
Brake (Deadman) Switch (Models with Spring-Loaded Handle) 8-2
Continuity 8-2
Controller Area Network (CAN) 8-2
Current Limiting 8-2
Emergency Reverse (Models 8310 and 8410) 8-2
Fault Codes 8-3
High Pedal Disable (HPD) 8-3
Neutral Plugging Rate (Deceleration) 8-3
Open Circuit 8-3
Overvoltage Cutoff 8-3
PIN-Key Code 8-3
Pulse Width Modulation 8-3
Ramp Shape 8-3
Regenerative Braking 8-3
Sequencing Delay 8-4
Short Circuit or “Short”. 8-4
Table of Contents Raymond® Pallet Trucks and Tow Tractor Maintenance Manual
x Publication: 1152122, Issued: 25 Apr 2013
Speed Limiting 8-4
Static Return To Off (SRO) 8-4
Thermal Cutback (Traction Amplifier) 8-4
Throttle Map. 8-5
Truck Off Delay (Keypad only). 8-5
Undervoltage Cutoff 8-5
VM (Vehicle Manager) 8-5
Walking Speed With Jog Button Controls 8-5
Traction System 8-6
Vehicle Manager (VM) 8-6
Traction Amplifier (TA) 8-6
Battery Plugged In 8-6
Key Switch ON and M1 Energized 8-6
Travel Request, Tractor-First 8-7
Travel Request, Forks-First. 8-7
Strip Curtain Bypass (Model 8410 only) 8-7
Emergency Reverse (Model 8310 and 8410) 8-8
Jog Button Controls Mode (Model 8510 only) 8-8
Coast Mode 8-9
Lift/Lower System 8-10
Lift 8-10
Lower 8-11
Theory of Operation – Power Assisted Steering 8-12
Power Steering Sensor Card 8-12
PSU: Power Steering Unit 8-12
Steering 8-12
Theory of Operation – Electric Power Steering 8-13
Power Steering Potentiometers 8-13
Floor Mat Switch (SW25) – Models 8510 and 8610 8-13
Premium Control Handle – Model 8510 only 8-13
Travel Speed Reduction 8-13
PSU: Power Steering Unit 8-13
Steering 8-14
Pinout Matrix 8-15
Appendix A-1
Lubrication Equivalency Chart A-2
Thread Adhesives, Sealants, and Lubricants A-3
Adhesives. A-3
Component Specific Service/Torque Chart A-5
Torque Chart – Standard (Ferrous) A-9
Torque Chart – Standard (Brass) A-10
Torque Chart – Metric. A-11
Torque Chart – Thread-Forming Screws A-12
Torque Chart – Hydraulic Fittings. A-13
Torque Chart – Straight Thread Face Seal O-Rings A-14
Decimal Equivalent Chart A-15
Standard/Metric Conversions A-17
Index I-1

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