Raymond Forklift 6210 Maintenance Manual SN 621-15-00100 and up – PDF DOWNLOAD

Description

Raymond Forklift 6210 Maintenance Manual SN 621-15-00100 and up – PDF DOWNLOAD

FILE DETAILS:

Raymond Forklift 6210 Maintenance Manual SN 621-15-00100 and up – PDF DOWNLOAD

Language : English
Pages :291
Downloadable : Yes
File Type : PDF
Size:18.7 MB

DESCRIPTION:

Raymond Forklift 6210 Maintenance Manual SN 621-15-00100 and up – PDF DOWNLOAD

User Manual Design

This manual is designed to give personnel, with an expected level of expertise, the technical information necessary to maintain, troubleshoot, and repair a Raymond product. The two-line running page header at the top of each page contains the name of the manual, the title of the current section, and the topic of the current page.

This manual includes the following sections:

TABLE OF CONTENTS:

Raymond Forklift 6210 Maintenance Manual SN 621-15-00100 and up – PDF DOWNLOAD

Service Information Documents Included ix
Page Revision Record x
Document Revision History x
Section 1: How to Use This Manual 1-1
Manual Design 1-2
Interactive Electronic Technical Manuals 1-3
Abbreviations and Symbols 1-4
Section 2: Safety 2-1
Definitions 2-2
General Safety 2-3
Battery Safety 2-5
Jacking Safety 2-8
Elevate Rear of Truck 2-8
Elevate Either Side of the Truck 2-9
Tie-Down for Transport 2-10
Towing 2-10
Static Safety 2-11
Welding Safety 2-12
Section 3: Systems Overview 3-1
Introduction 3-2
General System Data 3-3
Lift Truck Specifications 3-4
Special Tools 3-6
Programmable Maintenance Tool 3-7
Service Key 3-7
Lift/Lower Pendant 3-7
Operator Display and Programming 3-8
Special Truck Mode 3-8
Hour Meter (H) 3-8
Error Codes (E) 3-9
Changing Truck Parameters (P) 3-10
Programming Service Parameters 3-12
Parameter Display 3-12
Setting Individual PIN-Key Codes 3-13
Display Part Numbers (Pn) 3-19
Display Test (d) 3-19
Service Input/Output Display 3-20
Digital Inputs/Outputs from Traction Amplifier and VM 3-21
Traction Amplifier System Mode 3-23
Modes of Operation 3-24
Programmable Maintenance Tool (PMT) 3-24
Monitor Mode 3-24
Faults Mode 3-25
Clear 3-25
Information Mode 3-25
Programmer Mode 3-25
Table of Contents Model 6210 Maintenance Manual
ii Publication: 1146947, Revised: 12 Jan 2017
FlashWare 3-27
Overview 3-27
Requirements 3-27
Installing FlashWare on PC 3-27
Connecting PC to Truck 3-27
Starting FlashWare 3-27
Section 4: Scheduled Maintenance 4-1
Scheduled Maintenance Guidelines 4-2
Initial 90 Day/250 Deadman Hour (HD) Maintenance 4-3
Every 180 Days or 500 Deadman Hours (HD) 4-4
Every 360 Days or 2000 Deadman Hours (HD) 4-6
Lubrication Points 4-7
Chain Maintenance 4-8
Fork Inspection 4-9
Section 5: Troubleshooting 5-1
List of Troubleshooting Charts and Tables 5-2
Electrical Troubleshooting Guidelines 5-1
General 5-1
Shorts to Frame 5-1
DC Electric Motor 5-4
DC Motor Types 5-4
Inspection 5-4
Servicing 5-4
Open Circuit Motor Test 5-7
Grounded Motor Test 5-7
Short-Circuited Armature 5-7
Short-Circuited Winding 5-8
AC Electric Motors 5-9
AC Motor Type 5-9
Open Winding 5-9
Shorted Winding 5-9
Hydraulic Troubleshooting Guidelines 5-10
Symptom Tables: Travel System (Forward/Reverse) 5-11
No travel in either direction, lift/lower okay
(Code E106, Digital output overcurrent) 5-11
No travel in either direction, lift/lower okay
(Code E201, M-error) 5-11
No travel in either direction, lift/lower okay
(Code E214, Traction Amplifier CAN timeouts) 5-12
Slow travel, lift/lower okay No fault codes 5-12
No travel 5-12
Slow or no travel (Code C41, Battery under-voltage warning) 5-12
Slow or no travel (Code C43, Traction Amplifier
thermal cutback) 5-13
No travel (Code C42, Battery over-voltage warning) 5-13
Truck does not accelerate correctly 5-14
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) 5-14
No Travel, No Lift/Lower TA Flash Code 3,1
Operator Display May Indicate Error Code E106 5-14
Model 6210 Maintenance Manual Table of Contents
Publication: 1146947, Revised: 12 Jan 2017 iii
No Travel, Main Contactor Does Not Close TA Flash Code 3,9
Operator Display Indicates Error Code E107 5-15
No Travel, No Lift/Lower TA Flash Code 1,2
Operator Display Indicates Error Code E201 5-15
No Travel, No Lift/Lower TA Flash Code 1,3
Operator Display Indicates Error Code E202 5-15
No Truck Functions Active TA Flash Code 1,7, (Low
Battery Voltage) Operator Display May Indicate E221 5-15
No Truck Functions Active TA Flash Code 1,8, (Excessive
Battery Voltage) Operator Display May Indicate E222 5-16
Symptom Tables: Wiring System 5-17
Truck functions partially, some functions do work
when commanded 5-17
Symptom Tables: Electrical Problems 5-18
Green and red LEDs on keypad do not light when a
button on the keypad is pushed (keypad option only) 5-18
Horn does not sound when horn button is pushed 5-18
Battery discharge indicator (BDI) will not reset to 100% 5-18
Charger Troubleshooting 5-19
Section 6: Messages and Codes 6-1
List of Messages and Codes 6-2
Caution and Error Codes 6-5
Messages and Caution Codes 6-6
Code ‘GATE’ 6-6
Code ‘TEST’ 6-6
Code ‘SLO’ 6-6
Code ‘Sro’ (C14) 6-7
Code ‘LoGn’ (C15) (iWAREHOUSE Only) 6-7
Code br_o (C16) 6-7
Code C19 6-8
Code HPd (C20) 6-8
Code C26 6-8
Code C27 6-9
Code C30 6-9
Code C31 6-9
Code C32 6-10
Code C33 6-10
Code C35 6-10
Code Lo (C41) 6-11
Code Hi (C42) 6-11
Code Cold (C43) 6-12
Code Hot1 (C44) 6-12
Code Hot2 (C45) 6-13
Code C46 (iWAREHOUSE® Only) 6-13
Code C47 (iWAREHOUSE® Only) 6-13
Code C48 6-14
Code C57 6-14
Code C60 6-14
Code C61 6-15
Code C62 6-15
Code C64 6-15
Code C66 6-16
Table of Contents Model 6210 Maintenance Manual
iv Publication: 1146947, Revised: 12 Jan 2017
Code C67 6-16
Code C68 6-16
Code C70 6-17
Code C71 6-17
Code C72 6-17
Code 075 6-18
Code C95 6-18
Code C96 6-18
Code C97 6-19
Code C98 6-19
Code AC (C256) 6-19
Code C257 6-20
Code C258 6-20
Code C259 6-20
Code C380 6-21
Code C381 6-21
Code C382 6-21
Code C383 6-22
Code C384 6-22
Code C385 6-22
Code C386 6-23
Code C395 6-23
Code C405 6-23
Error Codes 6-24
Code E101 6-24
Code E106 6-24
Code E107 6-25
Code E108 6-25
Code E109 6-25
Code E140 6-26
Code E141 6-26
Code E142 6-26
Code E150 6-27
Code E151 6-27
Code E152 6-27
Code E157 6-28
Code E159 6-28
Code E160 6-28
Code E201 6-29
Code E202 6-29
Code E203 6-29
Code E220 6-30
Code E221 6-30
Code E222 6-30
Code E223 6-31
Code E224 6-31
Code E225 6-31
Code E228 6-32
Code E230 6-32
Code E232 6-32
Code E233 6-33
Code E235 6-33
Model 6210 Maintenance Manual Table of Contents
Publication: 1146947, Revised: 12 Jan 2017 v
Code E236 6-33
Code E248 6-34
Code E249 6-34
Code E250 6-34
Code E251 6-35
Code E254 6-35
Code E690 6-35
Code E691 6-36
Code E700 6-36
Code E901 6-36
Code E996 6-37
Code E997 6-37
Code E998 6-37
Code E999 6-38
Code BTLR 6-38
Traction Amplifier Flash Codes 6-39
Delta-Q Charger Codes 6-41
Section 7: Component Procedures 7-1
List of Component Procedures 7-2
Component Locator Photos 7-1
Covers and Finish 7-3
Tractor Covers 7-4
Tractor Cover Removal 7-4
Tractor Cover Installation 7-6
Tractor Bumper 7-9
Bumper Removal 7-9
Bumper Installation 7-9
Steering and Controls 7-11
Control Arm Assembly 7-12
Control Arm Removal 7-13
Control Arm Installation 7-13
Control Head Assembly 7-15
Control Head Removal 7-16
Control Head Installation 7-17
Keypad 7-18
Keypad Removal 7-18
Keypad Installation 7-19
Drive and Brake 7-21
Drive Unit Assembly 7-22
Drive Unit 7-24
Drive Unit Removal 7-24
Drive Unit Disassembly 7-25
Drive Unit Assembly 7-25
Drive Unit Installation 7-26
Drive Unit Housing Lubrication 7-27
Drive Wheel 7-28
Drive Wheel Removal 7-28
Tire Replacement 7-29
Drive Wheel Installation 7-30
Electromagnetic Brake Assembly 7-31
Brake Disc Location 7-31
Table of Contents Model 6210 Maintenance Manual
vi Publication: 1146947, Revised: 12 Jan 2017
Air Gap Inspection 7-31
Friction Disc Replacement 7-31
Electric Brake Release 7-32
Mechanical Brake Release 7-32
Electrical Components 7-33
Battery 7-34
Swing-out Battery Pack 7-34
Charger Replacement 7-36
Removal (Industrial Battery) 7-38
Installation (Industrial Battery) 7-38
Inspection and Care 7-38
Battery Connector 7-43
Inspection 7-43
Cable Removal, Replacement, and Installation 7-43
Power Cables 7-45
Power Cable Repair 7-45
Wiring Harness 7-47
Wiring Harness Terminology 7-47
Wiring Harness Inspection 7-47
Wiring Harness Repair 7-48
Wiring Harness Soldering Procedures 7-48
Fuses 7-49
Fuse Test/Inspection 7-49
Horn 7-50
Horn Removal 7-50
Horn Installation 7-50
Traction Amplifier 7-51
Motor Circuit 7-51
Control Circuit 7-51
Maintenance 7-52
Safety 7-52
Diagnostics and Troubleshooting 7-52
To Clean the Traction Amplifier 7-52
Traction Amplifier Removal 7-53
Traction Amplifier Installation 7-53
Contactors 7-54
Resistance Testing 7-54
Contactor Removal 7-54
Contactor Installation 7-54
Switches 7-55
General 7-55
Testing/Inspecting Switches 7-55
Main ON/OFF Switch 7-55
2-Position Keyed Switch (Optional) 7-56
Arm Angle Proximity Switch 7-56
Converting from Keypad 7-58
DC Motors, General 7-59
Motor Brush Inspection 7-59
Motor Brush Replacement 7-59
Motor Brush Spring Tension 7-60
Terminal Nuts 7-61
Polishing the Commutator 7-61
Model 6210 Maintenance Manual Table of Contents
Publication: 1146947, Revised: 12 Jan 2017 vii
Traction Motor 7-62
Traction Motor Disassembly 7-64
Traction Motor Assembly 7-64
Lift Motor 7-67
Lift Motor Removal 7-67
Lift Motor Installation 7-67
Lift Motor Brush Replacement 7-67
Hydraulic Components 7-69
Hydraulic System 7-70
Hydraulic Diagram and Components 7-70
Main Components 7-70
Hydraulic Unit Torque Specifications 7-71
Hydraulic Unit 7-72
Reservoir 7-74
Reservoir Removal 7-74
Reservoir Inspection 7-74
Reservoir Installation 7-74
Hydraulic Fluid Level Check 7-75
Changing Hydraulic Fluid 7-75
Hydraulic Pump 7-76
Hydraulic Pump Removal 7-76
Hydraulic Pump Installation 7-76
Filter Screen 7-77
Removal 7-77
Inspection 7-77
Installation 7-77
Lift Cylinder 7-78
Removal 7-78
Disassembly/Assembly 7-78
Installation 7-79
Mast, Chain, Hose, Cable 7-81
Main Mast 7-82
Guidance Damper 7-82
Adjusting Mast Guides/Dampers 7-83
Carriage Removal and Mast Disassembly 7-84
Outrigger Assembly 7-85
General 7-85
Maintenance 7-85
Support Arm Width Adjustment 7-85
Load Wheels 7-88
Load Wheel Removal 7-88
Load Wheel Installation 7-88
Lift Chain 7-90
Lift Chain Adjustment 7-90
Options 7-91
Cold Storage Conditioning 7-92
Cold Storage Hydraulic Fluid 7-92
Travel Alarm 7-93
Flashing Light 7-93
Table of Contents Model 6210 Maintenance Manual
viii Publication: 1146947, Revised: 12 Jan 2017
Section 8: Theory of Operation 8-1
Definitions 8-2
Acceleration 8-2
Arm Angle Proximity Switch 8-2
Click-to-Creep 8-2
Continuity 8-2
Controller Area Network (CAN) 8-2
Creep Speed 8-2
Current Limiting 8-2
Deceleration 8-3
Emergency Reverse 8-3
Fault Codes 8-3
Open Circuit 8-3
Overvoltage Cutoff 8-3
PIN-Key Code 8-3
Pulse Width Modulation 8-3
Regenerative Braking 8-3
Short-Circuit or Short 8-4
Speed Limiting 8-4
Thermal Cutback (Traction Amplifier) 8-4
Tractor 8-4
Truck Off Delay (Keypad only) 8-4
Undervoltage Cutoff 8-4
Vehicle Manager 8-4
Direction/Speed Control 8-5
Control Arm Positioning 8-5
Travel Request, Forks Trailing 8-5
Travel Request, Forks-First 8-5
Emergency Reverse 8-6
Truck Starting 8-6
Lift/Lower System 8-7
Lift 8-7
Lower 8-7
Traction System 8-8
Vehicle Manager 8-8
Traction Amplifier 8-8
Pinout Matrix 8-9
Section A: Appendix A-1
Lubrication Equivalency Chart A-2
Thread Adhesives, Sealants, and Lubricants A-3
Component Specific Service/Torque Chart A-4
Torque Chart – Standard (Ferrous) A-5
Torque Chart – Standard (Brass) A-6
Torque Chart – Metric (Ferrous) A-7
Torque Chart – Metric (Brass) A-8
Torque Chart – Thread Forming Screws A-9
Torque Chart – Hydraulic Fittings A-11
Torque Chart – Straight Thread Face Seal O-Rings A-12
Decimal Equivalent Chart A-13
Standard/Metric Conversions A-15
Section I: Index I-1

IMAGES PREVIEW OF THE MANUAL:

Contact us: [email protected]

https://vimeo.com/837095742?share=copy

PLEASE NOTE:

• This is the SAME MANUAL used by the dealerships to diagnose your vehicle
• No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
• Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
• So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com

S.M