RAYMOND 21I TRACTOR SCR & RESISTOR PARTS CATALOG MAANUAL - PDF DOWNLOAD

MODEL21I TRACTOR SCR & RESISTOR PARTS CATALOG SIN 4,000 THRU 6,147

PDPM-0088 DATED: AUG 13, 1992

MODEL /211 TABLE OF CONTENTS S/N - 0211- 4000 AND UP 211813

Page 1 Of 5

Description

Date: August 13, 1992 Serial No.

POWER Power Section Basic (Model 211) - #828-001-040 / (A) ..................................

4000 to 4549 Power Section Standard (Model 21i) - #828-001-043/ (A) Sh. 1...................

4000 to 4151 Power Section Standard (Model 21Q - #828-001-043/ (A) Sh.2....................

4000 to 4151 Power Section Standard (Model 21 Q - #828-001-043/ (C) Sh.1 ..•...•.••.•••••...

4152 to 4549 Power Section Standard (Model 211) -#828-001-043/ (C) Sh.2...................

4152 to 4549 Cover Assembly- Standard - #812-004-078 ...•••...•.•••.•....•.•......•.....••.............29000/4000 to 29360/4151 Cover Assembly- Standard - #812-004-223 (A) ...•....•.•...•........•....•...............•29361 /4152 & Up Cover Assembly- 40 - #828-001-041/ (C) .....................................................29000/4000 & Up Finish Instructions - #828-001-067/ (D) ..........................................................29000/4000 & Up Bilingual Finish Instructions - #828-001-068/ (E) ...•••.....................................29000/4000 & Up Finish Instruction Alteration - #154-008-794/ ....•.••.•.•.•...................................29000/4000 & Up Caster-Aux. Hyd. & Elect. -3000# - #828-001-044/ ....................................29000/4000 & Up Caster-Aux. Hyd. & E!ect.-4000#-#828-001-045/(A), 812-001-443/(D) ....... 29000/4000 & Up Trac-Oualizer Installation (Model 21 i) - #812-005-067 / (H) ...........................

4000 to 5211 Trac-Oualizer Installation (Model 21 i) - #828-001-144/ .................................

5212 & Up Caster Assembly- #812-005-148/.(F) .....•.....•..•..••...•.•...........................•.......

4000 to 5211 Caster Assembly- #828-001-145/ (C)............................................................

5212 & Up Trac-Oualizer Assembly- #812-005-087 (A)...................................................

4000 & Up Power Section Basic (Model 211)- #828-001-077/ ..•......................................

4550 to 4799 Power Section Basic (Model 21i)- #828-001-123/ .........................................

4800 to 5499 Power Section Basic (Model 211)- #828-001-123/ (A)...................................

5500 to 5569 Power Section Basic (Model 211)- #828-001-200/ .........................................

5570 to 5685 Power Section Basic (Model 211)- #828-001-239/ (A)...................................

5686 & Up Power Section Standard (Model 21 I) - #828-001-078/ (C) Sh.1 ...................

4550 to 5569 Power Section Standard (Model 21 Q- #828-001-078/ (C) Sh.2 ...................

4550 to 5569 Power Section Standard (Model 21Q -#828-001-199/ Sh.1..........................

5570 to 5685 Power Section Standard (Model 211) - #828-001-199/ Sh.2..........................

5570 to 5685 Power Section Standard (Model 21 i) - #828-001-238 / (B) Sh.1....................

5686 to 6003 Power Section Standard (Model 21 I) - #828-001-238/ (B) Sh.2....................

5686 to 6003 Power Section Standard (Model 211) - #828-001-238/ (C) Sh.1 ................•..

6004 & Up Power Section Standard (Model 21 I) - #828-001-238/ (C) Sh.2 .................•.

6004 & Up Power Section to Mast - #812-000-008/ (K) ...................................................29000/4000 & Up Power Section to Mast - #828-003-278/...•.....•.•.•.••••••....••.....•..•.•........•.....•....

Mech. Overhead Guard Posts Installation - #828-000-889/ (A) ....................29000/4000 &"l.Jp Mech. Overhead Guard Posts Installation - #828-003-869/ ..........................33607/6148 & Up Fire Extinguisher Installation - #828-001-436/ .....•....•......•.............................29000/4000 & Up Back Guard Installation (Rear Guard) -#812-004-175/ (E) ...........................29000/4000 & Up Back Guard Installation (Full Length) - #100-014-333 (G) .............................29000/4000 & Up Rear View Mirror Installation - #828-001-302/ ......•....•....................................29000/4000 & Up Battery Roller Assembly - #828-001-430/ (A) .......•.........................................33372/6004 & Up Fire Extinguisher Installation - #828-003-727 / .....•.........................................33607 /6148 & Up

Page 100

107 109 111 109.1 111.1 113 113.1 115 117 119 121 123 125 127 127.1 129 129.1 131 135 135.1 135.2 135.3 135.4 137 139 137.1 139.1 137.2 139.2 137.3 139.3 141 (Page) 143 143.1 145 147 149 151 163 165

MODEL /211 TABLE OF CONTENTS S/N-021I-4000 ANO UP Date: August 13, 1992

Page 2 Of 5

Serial No.

Description

BRAKE ANO STEERING Mech. Steer Control Assembly - Reverse - #812-004-016 (E) .......................29000 / 4000 to 32087/ 4549 Mech. Steer Control Assembly- Forward - #812-004-017 (F) .......................29000/4000 to 32087/4549 Mech. Steer Control Assembly- 40 Reverse - #812-004 018 (E) ..................29000/4000 to 32087/4549 Mech. Steer Cantrel Assembly - 40 Forward - #812-004-019 (E) .................29000/4000 to 32087/4549 Brake & Motor Assembly (Modet 21ij - #812-005-006/ (B) ......................-...

4000 to 4549 Brake Assembly- #812-001-541 (C), 400-037•••- ••- .......................................29000/4000 to 34040/6281 Brake Assembly - #828-001-544, 400-060 ......................................................34041 /6282 & Up Steering Wheel Assembly- #812-004-150..............................;.......................29000/4000 t o _ Steering Wheel Assembly- #828-001-212 (C) ............................................... _ & Up Mech. Steer Control Assembly - Reverse - #828-001-079 (A) .......................

4550 to 5499 Mech. Steer Control Assembly - Reverse - #828-001-265 5500 & Up Mech. Steer· Contra Assembly - Forward - #828-001-080 4550 to 5499 Mech. Steer Control Assembiy- Forward - #828-001-266 (A).......................

5500 & Up Mech. Steer Contra Assembly - 40 Reverse- #828-001-081 (A) ..................

4550 to 5499 Mech. Steer Contra Assembiy-40 Reverse - #828-001-267 (A).................

5500 & Up Mech. Steer Contra Assembly - 40 Forward - #828-001-082 (A).................

4550 to 5499 Mech. Steer Control Assembly - 40 Forward - #828-001-268 (A).................

5500 & Up Brake & Motor Assembly (Model 21 ij - #828-001-089/ (B) ......:....................

4550 & Up Master Cytfnder Assembly- #812-002-052.....................................................29000/4000 & Up Brake & Motor Assembly (Model 21 EE) - #828-001-490 (A) ......-.................

4000 & Up Steer Assembly Retrofit Kits - #828-900-003, 004, 005, 006 ..........................29000/4000 & Up

(A).......................

(A).......................

DRIVE UNIT Drive Unit Assembly (Model 21 ij - #812-005-007/ (0) ...................................

4000 to 4549 Drive Unit Assembly (Model 21 i) - #828-001-088/ .........................................

4500 to 5211 Drive Unit Assembly (Model 21 ij - #828-001-088/ (C) ...................................

5212 & Up . Bearing Assembly- #812-001-230 (E), 812-001-231 (0) ...............................29000/4000 & Up Drive Wheel Assembly- #812-000-279 (8), 812-000-299/ (0) ......................29000/4000 to 31507/5211 Drive Wheel Assembly - #828-001-148/ (A) •••••- ••••- ......................................31508/5212 & Up Drive Motor Assembly (Modef 21 ij _- Prestollte - #570-440 ............................

4000 to 4549 Drive Motor Assembly (Modet 211) - Prestollte - #570-251 /200 ....................

4550 & Up Drive Motor Assembly (Modet 21 ij - Prestolfta - #570-251 /201 ....................

4550 & Up Drive Motor Assembly (Model 21 ij - G.E. - #570-251/100.............................

4550 & '1.Jp Drive Motor Assembly (Modet 21 Q-Advanced DC - #570-251 /500.............

4550 & Up Drive Unit Assembly (Model 21EE) - #828-001-489/ (A)...............................

4000 & Up

201 203 205 207 211 213 213.1 215 215.1 217 217.1 219 219.1 221 221.1

223 223 1 225 227 231 233

~

303 303.1 303.2 305.

307 307.1 315 317 317.1 317.2 317.3 321

EL,ECTBICAL Sectrical Symbol_ _ _ _ _ _ ......................................................... , .

Wiring Diagram - #154-008-781 (L) Sh. 1.

2M00/4000 & Up Wiring Diagram - #154-008-781 (L) Sh. 2 291)()()/4000 & Up Wiring Diagram - #154-008-781 (L) Sh. 3..

2M00/4000 & Up Wiring Diagram - #154-008-781 (L) Sh. 4 ••....••..29000/4000 & Up Electrical Schematic· #154-008-782 (K) Sh. 1... ·--·-···············29000/4000 & Up

401 403 405 407 407C 409

MODEL /211 TABLE OF CONTENTS S/N - 0211-4000 AND UP Page 3 Of 5 Description

Date: August 13, 1992 Serial No.

Page

ELECTRICAL (Cont'd.)

Electrical Schematic - #154-008-782 (K) Sh. 2 ...............................................29000/4000 & Up 411 System Electrical - #154-008-780/ (J) Sh. 1 ........•.........................................29000/4000 to 32244/5569 413 System Electrical - #154-008-780/ (J) Sh. 2 ...•..............................................29000/4000 to 32244/5569 415 System Electrical - #154-008-780/ (L) Sh. 1 ........••.................•........•..........•..32245/5570 to 32884/5685 413.1 System Electrical - #154-008-780/ (L) Sh. 2 ..................................................32245/5570 to 32884/5685 415.1 System Electrical - #154-008-780/ (P) Sh. 1 ..••.••.....••...............•..........••........32885/5686 to 33417/6036 413.2 System Electrical - #154-008-780/ (P) Sh. 2 ..................................................32885/5686 to 33417 /6036 415.2 System Electrical - #154-008-780/ (T) Sh. 1 ..................................................33418/6037 & Up 413.3 System Electrical - #154-008-780/ (T) Sh. 2 .........•........................................33418/6037 & Up 415.3 SCR Panel Assembly- #154-008-725/ (G) .....•......•........................................29000/4000 & Up 417 Electrical Power Filter Assembly-#154-008-862 (C) .....................................29000/4000 & Up 419 Electric Control Assembly- #154-008-723/ (8) .............................................29000/4000 to 421 Electric Control Assembly- #154-008-723/ (E) ....•............................•...•....... & U-p421.1 Mechanical Control Assembly- #154-008-724 (H) .............................•.••.......

- - & Up 421.2 Handle Assembly- #154-002-542/ (L) .....••..••.....•.•••...•..•.•.••••..•...••.••....•.•••.•..29000/4000 to 423 Handle Assembly - #812-010-201 / (8) ........................................................... _ & Up-423.1 Panel Assembly- #812-004-146 (C) ......................•....•...................................29000/4000 & Up 425 Elect. Batt. Conn. Installation - #154-008-790/ (B) ........................................29000/4000 & Up 427 Elec. Connector Assembly- #154-008-n5/ (C) ............................................29000/4000 & Up 429 Indicator Light Assembly - #154-008-950/ (A) ...............................................29000/4000 & Up 431 Switch Assembly- #154-008-960/......•.........•.................................................29000/4000 & Up 433 Meter Installation -Curtis Fuel Gauge - #154-008-787 (C) ............................29000/4000 & Up 435 Back-Up Lamp Assembly- #154-008-958/ ....................................................29000/4000 & Up 437 Light Rework - #154-007-255 (RIE1), 154-008-963 ........................................29000/4000 & Up 439 System Elect Supplement Remote - #154-008-785/ (G) ..............................29000/4000 & Up 441 Remote Assembly- #154-010-023 ..................................................................29000/4000 & Up 441.1 Wiring Supplement- #154-010-024 ....•...................•.......................................29000/4000 & Up 441.2 Discharge Indicator Installation - #154-008-955/. ..........................................29000/4000 & Up 443 Working Light Installation - #154-008-965/ (A) ......•.••.•..........................•.......29000/4000 & Up 445 Light Assembly- #812-002-021 (A), 812-005-080 ..•...••......•.....•.....................29000/4000 & Up 447 EE Conversion Kit Installation - #828-001-055/ (8) ....•.......•.••.•.............•.••••..29000/4000 to 32884/5685 449 EE Conversion Kit Installation - #828-001-055/ (0) ..........·---···········32aas/5686 & Up 449.1 Limit Switch Install. - 24• High Speed R.H. - #154-007-235/ (RIE3) •••......•....29000/4000 & Up 451 Limit Switch Install. -24• High Speed LH. -#154-007-236/ (RIE3) ..••••.••.....29000/4000 & Up 453 Limit Switch Install. - 20• High Speed R.H. - #154-007-237/ (RIE3) ..•....•..••.. 29000/4000 & lJp 455 Limit Switch Install. - 20• High Speed LH. - #154-007-238/ (RIE3) ..............29000/4000 & Up 457 Elec. Limit Switch Installation - #625-000-260/ (RIE3) ...................................29000/4000 & Up 459 Contactor Assembly-36V Remote- #1-105-079...........................................

4000 & Up 463 Contactor Assembly (M, P, X) 36V - #154-008-740/......................................

4000 to 5569 465 Contactor Assembly (M, P, X) 36V - #154-010-740/......................................

5570 & Up 465.1 Contactor Assembly (F & R) 36V- #154-008-742/ ........................................

4000 to 5569 469 Contactor Assembly (F & R) 36V - #154-010-742/ ..........•...........•.................

5570 & Up 469.1 Resistor Assembly Installation - #828-000-980/ (G) ......................................29000/4000 & Up 481 Resistor Assembly- EE - #812-002-915/ (A) ............•..............•......................29000/4000 & Up 483 Resistor Assembly- E - #812-002-905 (8) .........•.....•................................•.....29000/4000 & Up 485 Electric Fan Installation - #828-001-437/ (A) ..................................................29000/4000 & Up 487 Heavy Duty Traction Motor- #812-900-200/ (A)...........................................

4000 & Up 489 Working Lights Installation - #828-003-n3/ ..................................................33607 /6148 & Up 491 Light Rework - #828-003-728/ ........................................................................33607 /6148 & Up 493 495 Strobe Light Installation - #828-003-n5/ .......................................................33607 /6148 & Up

MOOEL /21i TABLE OF CONTENTS S/N - 0211- 4000 ANO UP Cate: August 13 1992

Page 4 Of 5 Description

Serial No.

ELECTRICAL (Cont'd.)

Strobe Light Assembly - #828-003-730/............. _ _ _ _ _ 33607/6148 & Up Warning Lights Installation - #828-003-nS/ (A) ..................--············33607/6148 & Up Warning Ught Installation - #154-005-638/ ....................................................33607/6148 & Up Back-Up Alarm Installation - #828-003-780/ ..................................................33607/6148 & Up Back-Up Ughts Installation - #828-003-786/ ..................................................33607/6148 & Up All Travet Alann lnstalJatfon • #828-003-788/ .................................................33607/6148 & Up Fan Assembly· #828-003-796/....................................................................... 33607/6148 & Up

497

499 4101 4103 4105 4107 4109·

HYORAULJC Standard Hydraulic Symbas...........................................................................

501 Hydraulic Schematic - #812-004-134 (C) .......................................................29000/4000 to 30664/4799 503 Hydraulic Schematic - #828-001-121 (8) .......................................................30665/4800 & Up 503.1 System Hydraulic - #828-001-051 / (0) ...........................................................29000/4000 to 30664/4799 505 System Hydraulic - #828-001-120/ (G) :.........................................................

4800 & Up 507 System Hydraulic - Straddle w/Aux. - #828-001-053/ (C) ............................29000/4000 to 30664/4799 509 Manifold Assembly- #812-004-166/ (G) ........................................................29000/4000 to_:_ 511 Manifold Assembly - #812-004-166/ (H) ........................................................ _ & Up 511.1 Lift/Lower Manifold - #520-825/ ......................................................................29000/4000 to 513 Lift/Lower Manifold • #520-845/ ..................................................................... & Up 513.1 Auxiliary Valve Assembly- 1 Spool· #812-002-169 (F) .................................29000/4000 & Up 515 Valve Assembly- 2 Spool - #828-001-049 (C)·---········........................29000/4000 & Up 517 Valve Assembly-3 Spool - #828-001-050 (8) ................................................29000/4000 & Up 519 521 Valve Assembly· #828-001-000/ (A)--·····..···············----····.29000/4000 & Up 523 Auxiliary Valve Assembly - 2 Spool - #812-002-170 (D)---··············.29000/4000 & Up Auxiliary Valve Assembly - 3 Spool - #828-001-038 (A) .................................29000/4000 & Up 525 Control Valve Assembly· 1 Spool - #520-075 ................................................29000/4000 & Up 521 Control Valve Assembly- 2 Spool - #520-076/520-078.................................29000/4000 & Up 529 Control Valve Assembly- 3 Spool - #520-077/520-079.................................29000/4000 & Up 531 Control Valve Assembly (Lift) - #812-004-141 (C) ..........................................29000/4000 & Up 533 Auxiliary Pump and Motor Assembly - (Modal 21 Q - #812-005-010 (E) ........

4000 & Up 537 Auxiliary Motor Assembly- (Modal 21Q -Prestollte- #570-442/100.............

4000 & Up 547 Auxiliary Motor Assembly - (Modal 21 ij - Warfield - #570-442/150...............

4000 & Up 547.1 Auxiliary Motor Assembly - (Modal 21 ij - G.E. - #570-442/200 .....................

4000 & tJp 547.2 Auxiliary Pump Assembly- #500-417/100 .....................................................29000/4000 & Up 549 Auxiliary Pump Assembly- #500-417/200 .....................................................29000/4000 & Up 551 Auxiliary Pump Assembly - #500-417/201 .....................................................29000/4000 & Up 553 Lift Pump and Motor Assembly- EE - #812-002~4 (E) ...............................29000/4000 to 32884/5685 555 Lift Pump and Motor Assembly - (Modal 21 Q - #812-005-009 (E) .................

4000 to 4549 559 Lift Motor Assembly - G.E. - #570-427/101 ....................................................29000/4000 to 32884/5685 561 Lift Motor Assembly- Prestolite - #570-427/201 ............................................29000/4000 to 32884/5685 563 Lift Motor Assembly- Hitachi- #570-427/400.................................................29000/4000 to 32884/5685 565 567 Lift Motor Assembly - G.E. - (Model 21 Q #570-217/100 · · · · · · - - - - · 4000 to 5685 Lift Motor Assembly - Prestolite - (Model 211) #570-217/200 · · · · - - - · • 4000 to 5685 569 Lift Motor Assembly - Warfield - (Model 211) #570-217/150 ········--4000 to 5685 569.1 Lift Motor Assembly - Advanced DC- (Mode 21 i) - #570-257/500 ...............

5686 & Up 569.2 Lift Motor Assembly - Prestolite (EE)- (Model 211) - #570-257/200.---5686 & Up 569.3

MODEL 1 • /211 TABLE OF CONTENTS S/N - 0211 - 4000 AND UP

Page 5 Of 5 Description

Date: August 13, 1992 Serial No.

.fw

HYDRAULIC (Cont'd.)

Lift Pump Assembly- EE - 500-344 .................................................................29000/4000 to 32884/5685 Lift Pump Assembly - (Model 21 i) - #500-423/ ..............................................

4000 & Up Reservoir Assembly- #812-004-024 .....................•.........................................29000/4000 to 32884/5685 Reservoir Assembly - #828-001-274 (B) .........................................................32885/5686 & Up Hydraulic Ram Feed Line Installation - #812-005-061/ .................................29000/4000 & Up Hydraulic Ram Feed Line Installation - #812-005-172/ (C) ........................... 29000/4000 to 33606/6147 Hydraulic Ram Feed Line Installation - #828-003-762/ .................................33607 /6148 & Up Motor Steer Assembly- #812-002-623 (F) ..................................................... 29000/4000 to 32087/5499 Motor Steer Assembly - #828-001-254 ...........................................................32088/5500 & Up Lift Pump and Motor Assembly (Model 21 i) - #828-001-085 .........................

4550 to 5685 Lift Pump and Motor Assembly (Model 21 i) - #828-001-223 (D) ...................

5686 & Up Valve Assembly- R/R w/Equalizing - #154-008-971 (A) ...............................30665/4800 & Up Travel R/R Manifold w/Equalizing- #520-840 ...............................................30665/4800 & Up Valve Assembly- R/R w/o Equalizing- #154-008-975 (A) ............................ 30665/4800 & Up Travel R/R Manifold w/o Equalizing- #520-842 ............................................30665/4800 & Up Lift Pump and Motor Assembly- Model 21EE - #828-001-491 (A)................

5686 & Up Auxiliary Pump and Motor Assembly (Model 21 EE) - #828-001-488 ............

5686 & Up

571 575 577 5n.1 579 579.1 579.2 581 581.1 585 585.1 587 589 591 593 597 5101

Introduction to Your Parts Catalog

Introduction

The Raymond Corporation manufactures a variety of lift trucks in both standard and customized configurations. The Parts Catalog is organized into major divisions which cover all areas of the truck. These may include: • Power Unit (if applicable) • Brake and Steering • Drive Unit • Electrical

• Hydraulic (if applicable) • Elevating/Attachments • Contactors • Special Options (if applicable)

Using the Catalog

The catalog contains three elements necessary for effective use, which are: 1. Quality Assurance Sheet gives specific components in a truck and is located at the beginning of the parts catalog.

2. Table of Contents guides the reader to the correct pages.

3. Customized Prints provide special documentation for customized trucks and are located at the end of the parts catalog.

Parts Catalog Overview

• In some cases, large assemblies or installations are broken down over several pages.

Example:

The DRIVE UNIT assembly is shown on one page -- the DRIVE MOTOR for this drive unit on another page -- the DRIVE WHEEL for this unit on another page.

• Drawings of hydraulic hoses and piping do not necessarily conform to exact installation as they appear on the truck.

These illustrations are for part number references only.

• An indented part number indicates the part is a component of the preceding non-indented part and can be ordered separately; however, the component will be included when the non-indented part is ordered.

Example:

570-000 570-000/01 570-000/02

Motor Assembly Armature Field Winding

570-000/01 and 570-000/02 ore parts of Motor 570-000.

• When ordering parts for motors, always include serial number, model number and/or type of motor from data plate on motor, or Quality Assurance Sheet. Always specify truck's serial and model numbers when ordering.

1.