Raymond Forklift 8210 & 8250 Pallet Trucks Maintenance Manual 1146945-001D – PDF DOWNLOAD

Description

Raymond Forklift 8210 & 8250 Pallet Trucks Maintenance Manual 1146945-001D – PDF DOWNLOAD

FILE DETAILS:

Raymond Forklift 8210 & 8250 Pallet Trucks Maintenance Manual 1146945-001D – PDF DOWNLOAD

Language : English
Pages : 321
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Raymond Forklift 8210 & 8250 Pallet Trucks Maintenance Manual 1146945-001D – PDF DOWNLOAD

Serial Numbers

8210 821-15-00100 & Up
8250 825-17-00001 & Up

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:

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Raymond Forklift 8210 & 8250 Pallet Trucks Maintenance Manual 1146945-001D – PDF DOWNLOAD

Page Revision Record xiii
Document Revision History xiii
Service Information Documents Included xiv
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
Lead Acid Battery Safety 2-5
Lithium-Ion Battery Safety 2-8
Jacking Safety 2-11
Fork Section 2-11
Tractor Section 2-11
Towing 2-12
Transport 2-13
Static Safety 2-14
Welding Safety 2-15
Systems Overview 3-1
Introduction 3-2
Truck Model Identification 3-3
Lift Truck Specifications 3-4
Operator Display and Programming 3-5
Special Truck Mode 3-5
Hour Meter (H) 3-6
Error Codes (E) 3-6
Error Code History 3-6
Changing Truck Parameters (P) 3-6
Programming Truck Parameters 3-6
Programming Service Parameters 3-8
Parameter Displays 3-8
Setting Individual PIN-key Codes 3-8
Display Part Numbers (Pn) 3-16
Display Test (d) 3-16
Service Display 3-17
Digital Inputs/Outputs from Traction Amplifier and VM 3-17
Traction Amplifier Inputs 3-18
Traction Amplifier Outputs 3-18
Digital Input from Vehicle Manager Control Sensors 3-19
Digital Input from Vehicle Manager Control Sensors 3-19
Typical Power Amplifier Status 3-20
Special Tools 3-21
Service Key 3-21
Programmable Maintenance Tool 3-21
Table of Contents Model 8210/8250 Maintenance Manual
ii Publication:1146945/001, Revised: 25 Sep 2018
Monitor Mode 3-22
Faults Mode 3-23
Information Mode 3-23
Programmer Mode 3-23
FlashWare 3-25
Overview 3-25
Requirements 3-25
Installing FlashWare on PC 3-25
Connecting PC to Truck 3-25
Starting FlashWare 3-25
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 (HD) 4-4
Every 360 Days or 2000 Deadman Hours (HD) 4-6
Grease Fittings 4-7
Pin Locations 4-8
Troubleshooting 5-1
List of Troubleshooting Charts and Tables 5-2
Electrical Troubleshooting Guidelines 5-5
General 5-5
Shorts to Frame 5-5
Shorts to Frame Test 5-6
DC Electric Motors 5-8
DC Motor Types 5-8
Inspection 5-8
Service 5-9
Open Circuit Motor Test 5-12
Grounded Motor Test 5-12
Short-Circuited Armature 5-12
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 Table: Electrical System 5-16
BDI Does Not Reset to 100% 5-16
Horn Does Not Sound When Horn Button Pushed
No Fault Codes 5-16
Green/Red LED on Keypad Not Illuminated When Key Pressed 5-17
Symptom Tables: Lift/Lower System 5-18
No Lift, Lift Motor Does Not
Run, Travel is OK 5-18
No Lift or Slow Lift, Lift Motor Does Run 5-19
No Lower, Lift and Travel OK 5-19
Unable to Pick Up a Load 5-20
Slow Lower 5-20
Load Drifting/Settling 5-20
No Lift or Lower No Fault Codes 5-21
Model 8210/8250 Maintenance Manual Table of Contents
Publication:1146945/001, Revised: 25 Sep 2018 iii
Symptom Tables: Travel (Forward/Reverse) System 5-22
Slow Travel, Lift/Lower OK No Fault Codes 5-22
Truck Does Not Accelerate Correctly 5-22
No Travel Mode No Fault Codes 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
No Travel, No Lift/Lower TA Flash Code 3,1 Operator Display
May Indicate Error Code E106 5-23
No Travel, Main Contactor Does Not Close TA Flash Code 3,9
Operator Display Indicates Error Code E107 5-23
No Travel, No Lift/Lower TA Flash Code 1,3 Operator Display
Indicates Error Code E202 5-24
No Travel, No Lift/Lower TA Flash Code 1,2 Operator Display
Indicates Error Code E201 5-24
No Truck Functions Active TA Flash Code 1,7, (Low Battery
Voltage) Operator Display May Indicate E221 5-24
No Truck Functions Active TA Flash Code 1,8, (Excessive
Battery Voltage) Operator Display May Indicate E222 5-24
Charger Troubleshooting 5-25
Lithium-ion Battery Troubleshooting 5-26
Messages and Codes 6-1
List of Messages and Codes 6-2
Messages and Caution Codes 6-5
Code ‘GATE’ 6-5
Code ‘TEST’ 6-5
Code ‘SLO’ 6-5
Code ‘Sro’ (C14) 6-6
Code ‘LoGn’ (C15) (iWAREHOUSE® Only) 6-6
Code br_o (C16) 6-6
Code C19 6-7
Code HPd (C20) 6-7
Code C26 6-7
Code C27 6-8
Code C30 6-8
Code C31 6-8
Code C32 6-9
Code C33 6-9
Code C35 6-9
Code Lo (C41) 6-10
Code Hi (C42) 6-10
Code Cold (C43) 6-11
Code Hot1 (C44) 6-11
Code Hot2 (C45) 6-12
Code C46 (iWAREHOUSE® Only) 6-12
Code C47 (iWAREHOUSE® Only) 6-12
Code C48 6-13
Code C57 6-13
Code C60 6-13
Code C61 6-14
Code C62 6-14
Code C64 6-14
Table of Contents Model 8210/8250 Maintenance Manual
iv Publication:1146945/001, Revised: 25 Sep 2018
Code C66 6-15
Code C67 6-15
Code C68 6-15
Code C70 6-16
Code C71 6-16
Code C72 6-16
Code 075 6-17
Code AC (C256) 6-17
Code C257 6-17
Code C258 6-17
Code C259 6-18
Code C380 6-18
Code C382 6-18
Code C383 6-19
Code C384 6-19
Code C385 6-19
Code C395 6-20
Code C405 6-20
Error Codes 6-21
Code E101 6-21
Code E106 6-21
Code E107 6-22
Code E108 6-22
Code E109 6-22
Code E140 6-23
Code E141 6-23
Code E142 6-23
Code E150 6-24
Code E151 6-24
Code E152 6-24
Code E157 6-25
Code E159 6-25
Code E160 6-25
Code E201 6-26
Code E202 6-26
Code E203 6-26
Code E220 6-27
Code E221 6-27
Code E222 6-27
Code E223 6-28
Code E224 6-28
Code E225 6-28
Code E228 6-29
Code E230 6-29
Code E232 6-29
Code E233 6-30
Code E235 6-30
Code E236 6-30
Code E248 6-31
Code E249 6-31
Code E250 6-31
Code E251 6-32
Model 8210/8250 Maintenance Manual Table of Contents
Publication:1146945/001, Revised: 25 Sep 2018 v
Code E254 6-32
Code E690 6-32
Code E691 6-33
Code E700 6-33
Code E901 6-33
Code E996 6-34
Code E997 6-34
Code E998 6-34
Code E999 6-35
Code BTLR 6-35
8250 Messages and Caution Codes 6-36
Code AC 6-36
Code b_Lo (C500) 6-36
Code bYE (C360) 6-36
Code C501 6-37
Code C502 6-37
Code C503 6-37
Code C504 6-38
Code C505 6-38
Code C506 6-38
Code C507 6-39
Code Hot3 (C508) 6-39
Code Cold (C509) 6-39
Code C510 6-40
Code C511 6-40
Code C512 6-40
Code C513 6-41
Code C514 6-41
Code C515 6-41
Code C516 6-42
Code C517 6-42
Code C518 6-42
Code C519 6-43
Code E751 6-43
Traction Amplifier Flash Codes 6-44
Delta-Q Charger Codes 6-46
Component Procedures 7-1
List of Component Procedures by Component System 7-2
Component Location Photos 7-5
Finish and Accessories 7-7
Tractor Covers 7-8
Tractor Cover Removal 7-8
Lower Cover Removal 7-8
Grille Cover Removal 7-9
Upper Cover Removal 7-9
Console Cover Removal 7-9
Tractor Cover Installation 7-10
Console Cover Installation 7-10
Upper Cover Installation 7-10
Grille Cover Installation 7-11
Lower Cover Installation 7-11
Table of Contents Model 8210/8250 Maintenance Manual
vi Publication:1146945/001, Revised: 25 Sep 2018
Tractor Bumper 7-13
Bumper Removal 7-13
Bumper Installation 7-13
Steering and Controls 7-15
Control Handle Head 7-16
Control Handle Disassembly 7-17
Horn Button/Switch Replacement 7-18
Lift/Lower Button Replacement 7-18
Push Button Replacement 7-18
Emergency Reverse Replacement 7-19
Keypad 7-20
Keypad Removal 7-20
Keypad Installation 7-21
Control Arm Assembly 7-23
Control Arm Removal 7-24
Control Arm Installation 7-24
Drive and Brake 7-27
Drive Unit Assembly 7-28
Drive Unit 7-30
Drive Unit Removal 7-30
Drive Unit Disassembly 7-31
Drive Unit Assembly 7-31
Drive Unit Installation 7-32
Drive Unit Housing Lubrication 7-33
Gear Oil Level Check 7-33
Changing Gear Oil 7-33
Drive Wheel 7-34
Drive Wheel Removal 7-34
Tire Replacement 7-34
Drive Wheel Installation 7-35
Electromagnetic Brake Assembly 7-36
Brake Disc Location 7-36
Air Gap Inspection 7-36
Friction Disc Replacement 7-36
Electric Brake Release 7-37
Mechanical Brake Release 7-37
Electrical Components 7-39
Lead Acid Battery 7-40
Swing-out Battery Pack 7-40
Removal (entire battery pack) 7-40
Installation (entire battery pack) 7-41
Removal (single battery) 7-41
Installation (single battery) 7-41
Charger Replacement 7-42
Battery Maintenance 7-43
Battery Exterior Cleaning 7-43
To Charge a Battery 7-44
To Charge a Raymond Battery Pack (Option) 7-45
To Add Water to a Battery 7-45
Battery Specific Gravity 7-46
Specific Gravity Check 7-46
Model 8210/8250 Maintenance Manual Table of Contents
Publication:1146945/001, Revised: 25 Sep 2018 vii
Battery Voltage Check 7-46
Battery Storage 7-46
Lithium-Ion Battery 7-47
Battery Removal 7-48
Battery Installation 7-48
Lithium-Ion Battery Covers 7-49
General Information 7-49
Top Cover 7-49
Top Cover Removal 7-49
Top Cover Installation 7-49
Front Cover 7-50
Front Cover Removal 7-50
Front Cover Installation 7-50
Cell Module Assembly, Battery Monitoring Unit, and
Cell Module Assembly Fuse 7-51
Cell Module Assembly, Battery Monitoring Unit, and
Cell Module Assembly Fuse Removal 7-51
Cell Module Assembly, Battery Monitoring Unit, and
Cell Module Assembly Fuse Installation 7-52
Battery Management Controller 7-54
BMC Removal 7-54
BMC Installation 7-55
BMC Fuse 7-56
BMC Fuse Removal 7-56
BMC Fuse Installation 7-56
Charger 7-56
Charger Removal 7-56
Charger Installation 7-57
Charger Cord 7-57
Charge Cord Removal 7-57
Charge Cord Installation 7-57
Lithium-ion Battery User Interface (HUD) 7-58
Lithium-ion Battery Display Removal 7-58
Lithium-ion Battery Display Installation 7-58
Wire Harness 7-58
Wire Harness Removal 7-58
Wire Harness Installation 7-59
Counterweight 7-60
Counterweight Removal 7-60
Counterweight Installation 7-60
Cooling Fan 7-61
Cooling Fan Removal 7-61
Cooling Fan Installation 7-61
SBX Cable Assembly 7-61
SBX Cable Assembly Removal 7-61
SBX Cable Assembly Installation 7-62
Specification and Warning Labels 7-63
Label Removal 7-63
Label Installation 7-63
Battery Connector 7-64
Inspection 7-64
Battery Connector Access and Removal 7-64
Table of Contents Model 8210/8250 Maintenance Manual
viii Publication:1146945/001, Revised: 25 Sep 2018
Cable Removal, Replacement, and Installation 7-65
Power Cables 7-66
Power Cable Repair 7-66
Wiring Harness 7-68
Wiring Harness Terminology 7-68
Wiring Harness Inspection 7-68
Wiring Harness Repair 7-69
Wiring Harness Soldering Procedures 7-69
Main Harness Bracket Removal 7-70
Main Harness Installation 7-70
Fuses 7-72
Fuse Test/Inspection 7-72
Horn 7-73
Horn Removal 7-73
Horn Installation 7-73
Traction Amplifier 7-74
To Clean the Traction Amplifier 7-74
Traction Amplifier Removal 7-74
Traction Amplifier Installation 7-74
Contactors 7-76
Resistance Testing 7-76
Contactor Removal 7-76
Contactor Installation 7-76
Lift Motor Solenoid 7-78
Switches (General) 7-79
Testing/Inspecting Switches 7-79
Main ON/OFF Switch 7-79
Main ON/OFF Switch Inspection 7-79
Main ON/OFF Switch Removal 7-79
Main ON/OFF Switch Installation 7-79
2-Position Keyed Switch (Optional) 7-80
Replacement 7-80
Arm Angle Proximity Switch 7-80
Replacement 7-80
Arm Angle Proximity Switch Adjustment 7-81
Lift Cutout Proximity Switch 7-82
Replacement 7-82
DC Motors, General 7-83
Motor Brush Inspection 7-83
Motor Brush Replacement 7-83
Motor Brush Spring Tension 7-84
Brush Spring Tension Inspection 7-84
Terminal Nuts 7-85
Polishing the Commutator 7-85
Traction Motor 7-86
Traction Motor Disassembly 7-88
Traction Motor Assembly 7-88
Speed Sensor (Encoder) Replacement 7-89
Terminal Block Replacement 7-90
Model 8210/8250 Maintenance Manual Table of Contents
Publication: 1146945/001, Revised: 25 Sep 2018 ix
Lift Motor 7-91
Lift Motor Removal 7-91
Lift Motor Installation 7-91
Lift Motor Brush Replacement 7-91
Hydraulic Components 7-92
Hydraulic Components 7-93
General Guidelines 7-93
Hydraulic Unit Torque Specifications 7-93
Hydraulic Fluid 7-94
Hydraulic Fluid Level Check 7-94
Changing Hydraulic Fluid 7-94
Hydraulic Unit 7-96
Hydraulic Unit Removal 7-97
Hydraulic Unit Installation 7-97
Hydraulic Reservoir 7-99
Reservoir Removal 7-99
Reservoir Installation 7-99
Filter Screen and Inlet Tube 7-100
Filter Screen and Inlet Tube Removal 7-100
Filter Screen and Inlet Tube Installation 7-100
Hydraulic Pump 7-101
Hydraulic Pump Removal 7-101
Hydraulic Pump Installation 7-101
Hydraulic Pump Pressure Relief Valve Adjustment 7-102
Relief Valve Settings 7-102
Relief Valve Setting Check 7-102
Relief Valve Setting Adjustment 7-102
Hydraulic Cylinder 7-103
Cylinder Removal 7-103
Cylinder Disassembly 7-104
Cylinder Inspection 7-104
Cylinder Assembly 7-104
Cylinder Installation 7-105
Hydraulic Solenoid 7-106
Solenoid Removal 7-106
Solenoid Installation 7-106
Mast 7-109
Pallet Forks and Load Wheels 7-110
Load Wheels – Single 7-110
Removal and Replacement 7-110
Load Wheels – Dual 7-111
Removal and Replacement 7-111
Load Wheel Pull Rod 7-114
Removal and Replacement 7-115
Carrier Frame Linkage 7-115
Downstops 7-116
Lower Link Fork Heel Inspection 7-116
Downstop Adjustment 7-116
Skid Shoe Blocks 7-118
Skid Shoe Adjustment 7-118
Table of Contents Model 8210/8250 Maintenance Manual
x Publication: 1146945/001, Revised: 25 Sep 2018
Options 7-119
Cold Storage Conditioning 7-120
Cold Storage Hydraulic Fluid 7-120
Accessory Bar, Load Backrest Mounted 7-121
Accessory Bar 7-123
LED Work Light Installation 7-125
Operator Fan Installation 7-126
Casters 7-127
Caster Removal 7-127
Wheel Replacement 7-127
Caster Installation 7-127
Static Strap Replacement 7-128
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 (Neutral Braking) 8-3
Emergency Reverse 8-3
Fault Codes 8-3
High Pedal Disable (HPD) 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
Static Return to Off (SRO) 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
Truck Starting 8-5
Traction System 8-6
Vehicle Manager 8-6
Traction Amplifier 8-6
Direction/Speed Control 8-6
Control Handle Positioning 8-6
Travel Request 8-6
Emergency Reverse 8-7
Electric Brake Release Switch 8-7
Lift/Lower System 8-8
Lift 8-8
Lower 8-8
Pinout Matrix 8-9
Model 8210/8250 Maintenance Manual Table of Contents
Publication: 1146945/001, Revised: 25 Sep 2018 xi
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
Index I-1

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