Raymond Forklift 8300 8400 & 8500 Pallet Trucks & 8600 Tow Tractor Maintenance Manual – PDF DOWNLOAD

Description

Raymond Forklift 8300 8400 & 8500 Pallet Trucks & 8600 Tow Tractor Maintenance Manual – PDF DOWNLOAD

FILE DETAILS:

Raymond Forklift 8300 8400 & 8500 Pallet Trucks & 8600 Tow Tractor Maintenance Manual – PDF DOWNLOAD

Language : English
Pages : 402
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Raymond Forklift 8300 8400 & 8500 Pallet Trucks & 8600 Tow Tractor Maintenance Manual – PDF DOWNLOAD

Models: Serial Numbers:
8300 830-09-83001 and up
8400 840-09-83001 and up
8500 850-09-83001 and up
8600 860-09-83001 and up
Publication: 1106240D
Publication: 1106240C

Manual Design:

The Raymond® Pallet Trucks and Tow Tractor Maintenance Manual is designed with the following objectives in mind:
• Provide technical coverage for expected levels of user expertise
• Anticipate your needs and reduce your decisions regarding maintenance
• Reduce page flipping thru a “one-stop shopping” approach
The two-line running page header at the top of each page tells you:
• Name of the manual: Raymond® Pallet Trucks and Tow Tractor Maintenance Manual
• Current section title: Section 1. How to Use This Manual
• Current topic: Manual Design

This manual contains the following sections:
• Section 1. How to Use This Manual contains descriptive information in Manual Design, Abbreviations & Symbols, and a START Page. The START Page asks a few questions to guide you to the correct section.
• Section 2. Safety contains definitions of warning and caution notes, explains general safety rules and safety rules for battery safety, jacking safety, tie-down for transport, towing, welding safety, and static safety.
• Section 3. Systems Overview contains general information on truck specifications, operation, programming, and details for modes of operation.
• Section 4. Scheduled Maintenance outlines the recommended schedule of preventive services to keep your truck working most efficiently.
• Section 5. Troubleshooting is a set of general troubleshooting guidelines, a troubleshooting task flow, and a set of troubleshooting tables for symptoms not accompanied by a fault code.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Raymond Forklift 8300 8400 & 8500 Pallet Trucks & 8600 Tow Tractor Maintenance Manual – PDF DOWNLOAD

Page Revision Record -xi
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
START Page 1-6
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
Static Safety 2-12
Welding Safety 2-13
Systems Overview 3-1
Introduction 3-2
Truck Model Identification 3-3
Lift 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 3-14
Digital Inputs/Outputs from Traction Amplifier and VM 3-15
FlashWare 3-17
Overview 3-17
Requirements 3-17
Installing FlashWare on PC 3-17
Connecting PC to Truck 3-17
Starting FlashWare 3-17
Configuration and Truck Setup Options 3-18
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) 4-6
Contactor Tip Inspection 4-7
Grease Fittings (All Models) 4-8
Grease Fittings (Trucks without Composite Bushings Only) 4-9
Table of Contents Raymond® Pallet Trucks and Tow Tractor Maintenance Manual
ii Publication: 1106240, Reissued: 27 Jan 2012
Troubleshooting 5-1
How to Use This Section 5-2
Troubleshooting Flowcharts 5-3
TS1: START TROUBLESHOOTING 5-3
GEN1: General Troubleshooting 5-4
END1: End of Troubleshooting Procedure 5-5
Electrical Troubleshooting Guidelines 5-6
Troubleshooting the CAN Bus 5-6
Shorts to Frame Test 5-8
Fuses 5-11
Test/Inspection 5-11
DC Electric Motors 5-12
DC Motor Types 5-12
Inspection 5-12
Service 5-12
Open Circuit Motor Test 5-14
Grounded Motor Test 5-15
Short-Circuited Armature 5-15
Short-Circuited Winding 5-15
AC Electric Motors 5-16
AC Motor Type 5-16
Open Winding 5-16
Shorted Winding 5-16
Hydraulic Troubleshooting Guidelines 5-17
Symptom Tables: Lift/Lower System 5-18
No Lift, Lift Motor Does Not Run, Travel is OK
(From control handle or grab rail switch) 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
Symptom Tables: Travel (Forward/Reverse) System 5-21
No Travel, Lift/Lower OK Main Contactor Does Not Close
TA Amber LED is Flashing Once Every 2 Seconds 5-21
No Travel, No Lift/Lower TA Flash Code 3,1
Operator Display May Indicate Error Code E106 5-21
No Travel, No Lift/Lower TA Flash Code 1,3
Operator Display Indicates Error Code E202 5-22
No Travel, No Lift/Lower TA Flash Code 1,2
Operator Display Indicates Error Code E201 5-22
No Travel, Main Contactor Does Not Close TA Flash Code 3,9
Operator Display Indicates Error Code E107 5-22
No Travel or Slow Travel Main Contactor Does Close
TA Flash Code 2,1 Operator Display Indicates
Error Code Cold (C43) 5-23
Slow Travel, Lift/Lower OK No Fault Codes 5-23
No Emergency Reverse, Travel/Lift/Lower OK
No TA Flash Codes 5-23
No Rabbit Speed, Travel/Lift/Lower OK No Fault Codes 5-23
Raymond® Pallet Trucks and Tow Tractor Maintenance Manual Table of Contents
Publication: 1106240, Reissued: 27 Jan 2012 iii
No Truck Functions Active TA Flash Code 1,8,
(Excessive Battery Voltage)
Operator Display May Indicate E222 5-24
No Truck Functions Active TA Flash Code 1,7,
(Low Battery Voltage) Operator Display May Indicate E221 5-24
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) 5-24
No Travel Static Return to OFF (SRO) Fault Display may
indicate ‘Sro’ and Error and Parameter Control
Indicators Blinking 5-25
No Travel High Pedal Disable Fault Display may indicate
‘HPd’ and Error and Parameter Control Indicators Blinking 5-25
Truck Does Not Accelerate Correctly 5-25
Jog Speed Does Not Activate and Handle Does Not Stay in
Coast Position Lift and Travel OK (Model 8400
with Coast PRO™) 5-26
Jog Speed Does Not Activate Lift and Travel OK
(Center Rider Models Only with Fixed-Position Handle) 5-26
Jog Speed Does Not Function, Handle Does Stay in
Coast Position Lift and Travel OK (Model 8400
with Coast PRO™) 5-26
Symptom Tables: Wiring System 5-27
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
Caution Codes 6-9
Code ‘GATE’ 6-9
Code ‘SLO’ 6-9
Code ‘Sro’ (C14) 6-9
Code C15 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 Lo (C41) 6-15
Code Hi (C42) 6-15
Code Hot1 (C44) 6-16
Code Hot2 (C45) 6-16
Code C46 (iWarehouse Only) 6-16
Table of Contents Raymond® Pallet Trucks and Tow Tractor Maintenance Manual
iv Publication: 1106240, Reissued: 27 Jan 2012
Code C47 (iWarehouse Only) 6-17
Code C50 6-17
Code C51 6-17
Code C52 6-18
Code C57 6-18
Code C60 6-18
Code C61 6-19
Code C62 6-19
Code C63 6-19
Code C64 6-20
Code C65 6-20
Code C66 6-20
Code C67 6-21
Code C68 6-21
Code C70 6-21
Code C71 6-22
Code C72 6-22
Error Codes 6-23
Code E101 6-23
Code E106 6-23
Code E107 6-24
Code E108 6-24
Code E140 6-25
Code E141 6-25
Code E150 6-25
Code E157 6-26
Code E159 6-26
Code E160 6-26
Code E201 6-27
Code E202 6-27
Code E203 6-28
Code E220 6-28
Code E221 6-29
Code E222 6-29
Code E223 6-30
Code E224 6-30
Code E225 6-30
Code E228 6-31
Code E230 6-31
Code E232 6-31
Code E233 6-32
Code E235 6-32
Code E252 6-32
Code E253 6-33
Power Assisted Steering Caution Codes 6-34
Code C36 6-34
Code C74 6-34
Code C75 6-34
Code C76 6-35
Code C77 6-35
Code C78 6-35
Code C79 6-36
Code C80 6-36
Code C81 6-36
Code C82 6-37
Code C83 6-37
Code C84 6-37
Code C85 6-38
Code C86 6-38
Code C90 6-38
Electric Power Steering Caution Codes 6-39
Code C36 6-39
Code C74 6-39
Code C75 6-40
Code C76 6-40
Code C77 6-40
Code C78 6-41
Code C79 6-41
Code C80 6-42
Code C81 6-42
Code C82 6-43
Code C83 6-43
Code C84 6-44
Code C85 6-44
Code C86 6-45
Code C87 6-45
Code C88 6-45
Code C89 6-46
Code C90 6-46
Component Procedures 7-1
List of Component Procedures by Truck System 7-2
Component Locator Photos 7-5
Steering and Controls 7-11
Power Assisted Steering 7-12
Replacing the Power Steer Unit 7-13
Removing the Power Steering Sensor Card 7-14
Installing the Power Steering Sensor Card 7-15
Learn Steer 7-16
Checking the Steer Position 7-16
Replacing the Handle Centering Bumpers 7-17
Replacing the Handle Pivot Mechanism 7-18
Electric Power Steering 7-22
Electric Power Steer Handle and Post Assembly 7-22
Handle Height Adjustment 7-23
Control Head – Standard Handle 7-24
Control Head – Premium Handle 7-25
Gas Springs 7-28
Control Handle – Model 8300 7-29
Control Handle Disassembly 7-30
Changing Horn Button/Switch 7-30
Changing Lift/Lower Button 7-31
Changing Push Button 7-31
Table of Contents Raymond® Pallet Trucks and Tow Tractor Maintenance Manual
vi Publication: 1106240, Reissued: 27 Jan 2012
Spring-Loaded Handle Design 7-32
Spring-Loaded Handle Installation 7-33
Return Spring Adjustment, Spring-Loaded Handle 7-33
Fixed-Position Handle Design – Models 8500 and 8600 7-35
Fixed-Position Handle Installation 7-35
Control Handle Assemblies 7-36
Control Head Removal 7-40
Changing Horn Button/Switch 7-40
Changing Lift/Lower Switch Activator 7-41
Changing the Push Button 7-41
Changing the Jog Switch 7-42
Changing the Jog Button Control and Spring 7-42
Drive and Brake 7-43
Drive Unit 7-44
Removing the Drive Unit 7-44
Steering Bearing 7-45
Removing the Steering Bearing 7-45
Installing the Steering Bearing 7-45
Assembling the Gear 7-46
Checking the Gears 7-49
Adjusting Tooth Pattern of Drive Unit 7-49
Installing the Drive Unit 7-50
Drive Housing Lubrication 7-51
Drive Wheel 7-52
Removing the Drive Wheel 7-52
Cushion Tire Replacement 7-52
Caster Adjustment 7-54
Casters (without Springs) 7-55
Caster Removal 7-55
Wheel Replacement 7-55
Caster Assembly 7-55
Caster Installation 7-56
Casters (Spring-Loaded) 7-57
Spring-Loaded Caster Removal 7-57
Wheel Replacement 7-57
Caster Disassembly 7-58
Caster Assembly 7-59
Wheel Installation 7-59
Spring-Loaded Caster Installation 7-60
Brake 7-61
Spring-Loaded Handle 7-61
Brake Removal, Spring-Loaded Handle 7-61
Brake Installation, Spring-Loaded Handle 7-61
Checking the Gap 7-62
Replacing the Rotor 7-62
Electrical Components 7-63
Battery 7-64
With Battery Gates and Rollers (Optional) 7-64
Battery Gates (Optional) 7-64
Battery Rollers (Optional) 7-64
Without Battery Gates and Rollers 7-64
Battery Exterior Cleaning 7-65
Raymond® Pallet Trucks and Tow Tractor Maintenance Manual Table of Contents
Publication: 1106240, Reissued: 27 Jan 2012 vii
Testing, Charging, and Maintenance 7-65
Maintenance-Free Batteries 7-66
Battery Storage 7-66
Power Cables 7-67
Wiring Harness 7-69
Wiring Harness Terminology 7-69
Inspecting a Wiring Harness 7-69
Repairing a Wiring Harness 7-69
Wiring Harness Soldering Procedures 7-70
AMP Water-Resistant Connectors 7-71
AMP Connector Pin Extraction 7-71
AMP Connector Pin Insertion 7-72
AMP Connector Seals 7-72
AMP Harness/Traction Amplifier Connector 7-74
AMP Harness Connector Components 7-74
AMP Harness Connector Disassembly (Contact Removal) 7-74
AMP Harness Connector Contact Insertion 7-74
AMP Harness Connector Assembly 7-75
Testing AMP Harness Connectors 7-76
Brake Potentiometer (VR1) 7-77
Removing VR1 7-77
Installing VR1 7-77
Lift-Limit Switch (SW8) 7-78
Adjusting the Limit Switch 7-78
Grab Rail Switches – Model 8400 7-79
Removing Grab Rail Switches 7-79
Installing Grab Rail Switches 7-79
Load Backrest Switches – Model 8500 Option 7-80
Removing Load Backrest Switches 7-80
Installing Load Backrest Switches 7-80
Hydraulic Solenoids 7-81
CoastPRO™ Solenoid – Model 8400 Option 7-82
Removing the CoastPro Solenoid 7-82
Installing the CoastPro Solenoid 7-83
Coast Solenoid Switch/Spring 7-83
CoastPRO Canister 7-83
Traction Amplifier 7-86
Removing the Traction Amplifier 7-86
Installing the Traction Amplifier 7-86
Programming the Traction Amplifier 7-87
Motors, General 7-88
Terminal Nuts 7-88
Traction Motor 7-89
Removing the Traction Motor 7-89
Lift Motor 7-96
General Data 7-96
Removing the Lift Motor 7-96
Installing the Lift Motor 7-96
Hydraulic Components 7-99
Hydraulic Components 7-100
General Guidelines 7-100
Table of Contents Raymond® Pallet Trucks and Tow Tractor Maintenance Manual
viii Publication: 1106240, Reissued: 27 Jan 2012
Hydraulic Fluid 7-101
Checking Hydraulic Fluid Level 7-101
Hydraulic Unit 7-102
Removing the Hydraulic Unit 7-102
Installing the Hydraulic Unit 7-102
Hydraulic Reservoir 7-103
Removing the Hydraulic Reservoir 7-103
Installing the Hydraulic Reservoir 7-103
Filter Screen and Suction Tube 7-104
Removing Filter Screen and Suction Tube 7-104
Installing Filter Screen and Suction Tube 7-104
Hydraulic Pump 7-105
Removing the Pump 7-105
Installing the Pump 7-105
Adjusting Hydraulic Pump Relief Valve Pressure 7-106
Checking Relief Valve Setting 7-106
Alternate Method Using Rated Load on Pallets 7-106
Hydraulic Ram 7-108
Inspecting Hydraulic Ram 7-108
Removing Hydraulic Ram 7-108
Installing Hydraulic Ram 7-110
Hydraulic Cylinder Seals 7-111
Disassembling the Cylinder 7-111
Assembling the Cylinder 7-112
Mast 7-115
Top Linkage Subassembly 7-116
Removing the Top Linkage Subassembly 7-116
Installing the Top Linkage Subassembly 7-117
Pull Rod Subassembly 7-119
Removing the Pull Rod Subassembly 7-119
Installing the Pull Rod Subassembly 7-120
Load Wheels 7-122
Single Load Wheels – Models 8300, 8400, and 8500 7-122
Tandem Load Wheels – Models 8400 and 8500 7-122
Suspension Wheel – Model 8600 7-123
Pallet Entry Sliders 7-125
Pallet Entry Rollers 7-126
Fork Height Adjustment 7-127
Downstop Installation 7-128
Pallet Entry/Exit Enhancements 7-129
Options 7-131
Cold Storage Conditioning 7-132
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
Raymond® Pallet Trucks and Tow Tractor Maintenance Manual Table of Contents
Publication: 1106240, Reissued: 27 Jan 2012 ix
Emergency Reverse (Models 8300 and 8400) 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
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 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 8400 only) 8-7
Emergency Reverse (Model 8300 and 8400) 8-8
Jog Button Controls Mode (Model 8500 only) 8-8
Coast Mode 8-9
Lift/Lower System 8-10
Lift 8-10
Lower 8-10
Theory of Operation – Power Assisted Steering 8-11
Power Steering Sensor Card 8-11
PSU: Power Steering Unit 8-11
Steering 8-11
Theory of Operation – Electric Power Steering 8-12
Power Steering Potentiometers 8-12
Floor Mat Switch (SW25) – Model 8500 only 8-12
Premium Control Handle – Model 8500 only 8-12
Travel Speed Reduction 8-12
PSU: Power Steering Unit 8-12
Steering 8-13
Pinout Matrix 8-14
Pinout Matrix – Power Assisted Steering 8-19
Pinout Matrix – Electric Power Steering 8-21
Table of Contents Raymond® Pallet Trucks and Tow Tractor Maintenance Manual
x Publication: 1106240, Reissued: 27 Jan 2012
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-7
Torque Chart – Standard (Brass) A-8
Torque Chart – Metric A-9
Torque Chart – Thread-Forming Screws A-10
Decimal Equivalent Chart A-11
Standard/Metric Conversions A-13
Index I-1

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