Raymond EASi Reach-Fork EZ-C EZ-D EZ-CD EZ-DD Maintenance Manual 2013

Description

The Raymond EASi Reach-Fork EZ-C EZ-D Maintenance Manual is the consolidated 458-page service reference for the EASi Reach-Fork lift truck family running the ACR System — Series EZ-C, EZ-CD (previously DZ-C), EZ-D, and EZ-DD (previously DZ-D) — from serial number 00001 and up. Published by The Raymond Corporation as document 1119847A on 02 Jan 2013, this is the manual that replaced the earlier EASI Reach-Fork maintenance manuals #1019428A (EZ-C/DZ-C) and PDMM-0109 (EZ-D/DZ-D), making it the single source for the whole 36V AC traction line.

If you maintain, service, or repair one of these reach-fork trucks, this manual gives you the procedures, specifications, diagnostic routines, and theory you actually need. Every procedure is written against the EZ-C and EZ-D platforms — nothing generic, nothing borrowed from another truck.

File Details

• Manual type: Maintenance / Service Manual
• Manufacturer: The Raymond Corporation
• Series covered: EZ-C, EZ-CD, EZ-D, EZ-DD (EASi Reach-Fork with ACR System)
• Document number: 1119847A
• Issue date: 02 Jan 2013
• Language: English
• Page count: 458 pages
• File format: PDF
• Serial coverage: S/N 00001 and up

Chapters Covered

• Section 1 — How to Use This Manual: manual design, IETM usage, abbreviations and symbols
• Section 2 — Safety: general safety, battery safety, static precautions, jacking safety, tie-down for transport, welding safety
• Section 3 — Systems Overview: lift truck specifications, model and mast designations, battery specifications, FlashWare, operator display, modes of operation, passwords, Configure Mode menu
• Section 4 — Scheduled Maintenance: maintenance guidelines, Maintenance Minder tool, initial 90-day / 250 HD service, 180-day / 500 HD service, 360-day / 2000 HD service, lubrication points, contactor tip inspection, chain and fork inspection
• Section 5 — Troubleshooting: electrical troubleshooting, shorts to frame, battery state-of-charge, fuses and connectors, DC and AC motor testing, hydraulic troubleshooting guidelines and symptom tables
• Section 6 — Messages, Codes, and Tests: power amplifier LED diagnostics, full message and fault code listing, analog tests, input tests, output tests
• Section 7 — Component Procedures: special tools, decals and chassis, steering and controls, drive and brake, electrical components, hydraulic components, hydraulic cylinders, mast / chain / hose / cable, cold storage conditioning, fork height-tilt indicator
• Section 8 — Theory of Operation: traction system, lift/aux system (AC and DC lift), thermal cut-back, steering system, HTI operation, full pinout matrix
• Appendix A: lubrication specification chart, thread adhesives and sealants, component-specific service/torque chart, standard and metric torque charts, hydraulic fitting torques, straight thread face seal O-ring torques, decimal equivalent chart, standard/metric conversions
• Index: alphabetical subject index

Read together, these sections take a technician from a dead lift truck through to a completed repair. Section 3 explains how the truck is built and configured, Section 4 lays out what to service and when, Section 5 narrows a symptom down to the failing circuit, Section 6 goes further with specific fault codes and live diagnostic tests you run through the operator display, Section 7 walks you through removal, installation, and adjustment of serviceable components, and Section 8 explains the electrical and hydraulic logic so you understand why a test behaves the way it does. That structure is what separates a real maintenance manual from a parts list.

Systems and Components Covered in Depth

The EZ-C and EZ-D trucks are covered as complete systems, not isolated parts. The drive and brake section walks through the drive unit — set-up, radial ring inspection, disassembly, assembly, backlash measurement, and shim formulas — plus traction motor removal and installation, brake adjustment, upper brake pad replacement, O-ring seal replacement, brake bleeding, and the deadman (brake) pedal and master cylinder. Steering and controls covers the steering shaft and gear, caster assembly, steerable caster adjustment, and both the Fore/Aft Stance and Dockstance control handles down to the throttle pot (VR1), lift/lower pot (VR2), tilt/sideshift switch card, and horn and reach/retract switches.

On the hydraulic side you get the main manifold for AC and DC lift, reach manifold, tilt/sideshift manifolds, full port torque specifications, lift pressure adjustment, auxiliary system pressure adjustment, bypass flow regulator valve adjustment (FR1), steering system pressure adjustment, proportional lower valve adjustment, and counterbalance valve adjustment. Lift cylinders are covered in complete detail — front cluster, back cylinder with threaded anchor retention, side cylinder seal repacking, front and back cylinder seal repacking, lowering cushion, and flow control. Reach, tilt, and sideshift cylinders each get their own removal, disassembly, reassembly, and installation procedures.

Electrical coverage includes battery procedures, wiring and harness repair, Molex and AMP water-resistant connectors, power cable repair with lug crimping, power cable terminal torques, and both DC and AC motor service. The mast, chain, hose, and cable section covers over-the-mast hose and cable replacement and adjustment, mast shimming, mast bearing shimming, complete mast disassembly and shimming, reach carriage bearings, half shaft bearings, thrust bearings, lift chain adjustment and replacement, reach carriage lift chain anchors, equalization chains and sheaves, mechanical stop adjustment, and mast backlash adjustment.

Fault Codes and Diagnostic Tests

Section 6 is where this manual earns its keep on a modern reach truck. It lists every fault code the Vehicle Manager can display — including traction power amp overtemp (1H), low battery (1T), LPA overtemp (1V), traction motor approaching overtemp (2A), TPA and traction motor temp sensor out-of-range (2C, 2E), traction motor speed sensor failure (2H), TPA failure (2M), contactor codes (42, 43, 44, 45, 4B, 4C, 4D, 4E, 4F, 4G), CAN bus errors (59, 5A, 5B, 5G, 5J, 5L, 5M, 5N, 5P, VC), mast switch codes (61, 63, 6K), lift motor and LPA faults (6F, 6S, 6T, 6V, 6W, 6X, 6Y), throttle and lift pot out-of-range (80, 81, 83, 8F), operator compartment sensor codes (58, 8A), and VM/display faults (A0, AG, AH, AJ, AK, AL, EC, E1, E2, F4, F5, F8, FG, FH).

For each code you get the test to run and the corrective action. The tests themselves — analog, input, and output — are laid out as diagnosis and repair tables with probe points, meter scale, expected readings, and both pass and fail branches. That includes Test A04 throttle pot voltage, A05 lift/lower pot voltage, A08 traction motor temperature, A09 lift motor temperature, A10 TPA temperature, A11 traction motor current, A19 LPA temp, A20 lift motor current, A22 traction throttle request, A23 lift throttle request, A24 TPA internal temperature, A25 LPA internal temperature, A26 +5VDC supply, plus input tests such as the deadman switch (I00), nested switch (I01), speed limiting switches (I02, I03), lift inhibit bypass (I04), lift limit (I05), reach and retract switches (I06, I07), tilt switches (I08, I09), sideshift switches (I10, I11), fuse tests (I13, I14), horn (I15), motor speed sensors (I19, I20), staging switch (I21), lift cutout (I22), CAN bus (I23), and the OCSS upper and lower beam tests (I80, I81). Output tests cover contactors (O00, O01, O02), solenoids (O04 through O12), horn and alarms (O18, O19, O20), fans (O23), lift blocking (O24), aux select (O25), aux boost 1 and 2 (O26, O27), and ramp tests for the lift and traction power amplifiers (O28, O29).

Key Specifications You Will Find Inside

The Appendix alone is worth the download. The Lubrication Specification Chart lists approved fluids and greases by application — drive unit gear case 75W-90 synthetic gear oil, ISO VG 46 hydraulic fluid for non-cold-storage trucks, ISO VG 32 and MIL-H-5606E for cold storage, NLGI 2 grease for mast uprights and bearings, and Teflon grease for lift chains. The Component Specific Service/Torque Chart gives you the exact torque for hundreds of fasteners — power amplifier cables at 95 to 104 in. lb., traction motor top nut at 204 to 221 in. lb., bottom nut at 128 to 133 in. lb., drive wheel mounting bolts at 170 ft. lb., mast-to-tractor bolts at 165 ft. lb., overhead guard at 130 ft. lb., and so on. Standard and metric torque charts, hydraulic fitting torques, and straight thread face seal O-ring torques are all included, along with decimal equivalents and standard/metric conversions.

Pressure settings are spelled out too. Lift relief pressure is 3200 psi for 1.75 in. cylinders up to 330 in. elevated height, 3500 psi for 1.75 in. cylinders from 331 to 371 in., and 2900 psi for 2.00 in. cylinders up to 421 in. Auxiliary system pressure is 2000 psi on AC lift and 1600 psi on DC lift. Steering system pressure is 1600 psi on AC lift. Battery voltage range is 32 to 39V. Brake gap is 0.008 in. between the adjuster bushing and motor housing. Thermal down-rating tables list the exact temperatures at which the truck reduces performance and shuts down. All values are printed exactly as Raymond specifies them.

Battery specifications for the 36V line are also included — EZ-C and EZ-CD widths of 18.5 and 21.5 in. with weights from 2300 to 2900 lb.; EZ-D widths of 16.5 and 18.5 in. with weights from 2000 to 2600 lb.; EZ-DD widths of 16.5 and 18.5 in. with weights from 1600 to 2600 lb. All series are rated at 6 hours with maximum 1240 amp hours, and the UL note requiring no more than 0.5 in. of horizontal battery movement is stated.

Cold Storage, HTI, and Options

For cold storage operations, the manual documents the required components — heated control handle assemblies, cold storage deadman switch, cold storage contactor/fuse panel, wire mesh mast guard, optional heated floor pad — plus the correct lubricants and sealing treatments. The Fork Height-Tilt Indicator (HTI) gets its own section with component locations, active maintenance mode, cable replacement, encoder assembly, display card, calibrating and setting the height indicator, fork carriage shimming, and the HTI pressure switch.

What This Manual Enables You to Do

With the Raymond EASi Reach-Fork EZ-C EZ-D maintenance manual in hand, you can perform the full scheduled maintenance routine at 90-day, 180-day, and 360-day or 250, 500, and 2000 deadman-hour intervals; diagnose electrical and hydraulic faults down to the individual circuit using Raymond’s own fault codes and test routines; remove, disassemble, reassemble, and reinstall major components including the drive unit, traction motor, brake, steering shaft and gear, control handle, lift cylinders, reach cylinder, tilt cylinder, sideshift cylinder, and mast; adjust pressures, torque values, chain tension, and mast shimming to factory specification; and understand the theory of operation behind the traction, lift/aux, steering, and thermal cut-back systems so you can reason through problems the code list does not cover.

Having the right procedures and the right specifications matters because these trucks run 36V electrical systems with CAN bus communications between the Vehicle Manager and the power amplifiers, hydraulic pressures up to 3500 psi, and lift capacities from 2500 to 4500 lb. Guessing at a torque value, a pressure setting, or a fault-code corrective action is how a repair turns into a return visit. This manual removes the guesswork.

IMAGES PREVIEW

Delivery is instant. The moment your order completes you get the PDF — no shipping, no waiting, no physical book to keep track of. Download it, open it on any device, and print the pages you need for the job. Whether you are in the shop, on the warehouse floor, or out at a customer site, the complete Raymond EASi Reach-Fork service reference stays with you.