Raymond Forklift EASi Orderpicker Maintenance Instructions Manual SN 9000 and Up - PDF DOWNLOAD

Maintenance Instructions

Model: EASi Orderpicker

PDMM# 0032

Serial No. 9000 and Up

Date: 11/01/94 Revised 05/01/95

RAYMOND SERVICE INFORMATION

The Raymond Corporation Corporate Headquarters P O Box 130 Greene, New York 13778-0130

RSI MUL-15-008

Models

October 1, 2015

Multiple

SUBJECT:

New Pump Spline Lubricant

GENERAL INFORMATION:

A new lubricant (P/N 1223184) has been approved for use on motor and pump spline joints for all trucks. This new lubricant replaces Anti-Seize Compound P/N 990-638 for pump spline applications only.

SERVICE INFORMATION:

Separate the motor and pump. Clean old grease off the splines. Fill the motor cavity (including the space below the splines) to within 0.5 in. (12.7 mm) of the top of the cavity (see figure below). Assemble the motor and pump.

PARTS AVAILABILITY:

Now available through the Parts Distribution Center.

FILING INSTRUCTIONS:

File this notice in the appropriate Maintenance Manuals next to the Scheduled Maintenance Section.

®

Raymond is a registered trademark of The Raymond Corporation 2015 The Raymond Corporation.

FOTP-0060/1-7-15/F

RSI MUL-15-008 Page 1 of 1

RAYMOND SERVICE INFORMATION

The Raymond Corporation Corporate Headquarters P O Box 130 Greene, New York 13778-0130

RSI MUL-15-006

Model

June 29, 2015

Multi Product

SUBJECT:

Updated Torque Check Procedures

GENERAL INFORMATION:

Updates are being made to the procedures for checking bolt torque during scheduled maintenance.

SERVICE INFORMATION:

When a fastener requires a torque check after the initial 90 day/250 HD Maintenance, there are now two procedures that can be used.

•

If the fastener was previously marked with a paint pen when torqued, look at the markings to verify the fastener has not moved. If the fastener has moved or is in question, remove the fastener, clean the threads, and apply the appropriate thread locker. Install the fastener and torque to the proper value, turning it in the tightening direction. Use a paint pen and mark the fastener for future inspections.

•

If the fastener was not previously marked with a paint pen, determine the proper torque value. Set the torque wrench to 85% of the required torque value and check the torque of the fastener, turning it in the tightening direction. If the fastener does not move, use a paint pen and mark the fastener for future inspections. If the fastener moves, remove the fastener, clean the threads, and apply the appropriate thread locker. Install the fastener and torque to the proper value. Use a paint pen and mark the fastener for future inspections.

PARTS AVAILABILITY:

N/A

FILING INSTRUCTIONS:

File this notice in all Maintenance Manuals next to the 180 day or 500 HD Scheduled Maintenance chart.

®

Raymond is a registered trademark of The Raymond Corporation 2015 The Raymond Corporation.

FOTP-0060/1-7-15/F

RSI MUL-15-006 Page 1 of 1

RAYMOND SERVICE BULLETIN

The Raymond Corporation Corporate Headquarters P O Box 130 Greene, New York 13778-0130

RSB OPR-06-002

Models

March 10, 2006

EASi™ OPR 9000 –14999 and EASi OPR 15000 and up

SUBJECT:

EASi OPR Carriage Control Card Software Version 7.2

DESCRIPTION:

If codes F1 and F2 appear on the display during power up, use the remedy and procedures below to correct the condition.

REMEDY:

There are two software kits involved with this notice. Order and install the appropriate kit by determining the serial number range of the truck you are working on. To help make that determination refer to the procedures below.

PROCEDURES:

1. Order and install software kit P/N 114-900-928/110 in trucks with serial numbers 9000 through 14999.

2. Order and install software kit P/N 114-900-928/012 in trucks with serial numbers 15000 and up.

PARTS AVAILABILITY:

Parts are now available through the Parts Distribution Center.

WARRANTY:

Within normal Raymond policy guidelines.

Flat Rate Book Reference EASi OPR Model 9980 Code .050 Time

FILING INSTRUCTIONS:

File copies of this notice in Maintenance Manuals PDMM–0101, PDMM–0032A and PDMM-032 in the front portion of the book.

®

Raymond is a registered trademark of The Raymond Corporation © 2006 The Raymond Corporation.

FOTP-0006/mlc/01-01-03/C

RSB OPR-06-002 Page 1 of 1

RAYMOND PRODUCT IMPROVEMENT NOTICE

The Raymond Corporation Corporate Headquarters P O Box 130 Greene, New York 13778-0130

RPIN OPR-05-R005

Model

October 18, 2005

EASi™ Orderpicker S/N 9000 - 14,999

SUBJECT:

New Electric Steer Manager

DESCRIPTION:

The electric steer manager (P/N 154-012-335/002) was redesigned because one of its components became obsolete.

REMEDY:

When you have to replace an old electric steer manager, order the new, redesigned version (P/N 154-012-335/003).

PROCEDURES:

Order and install a new electric steer manager, and use a M3X16 screw (P/N 1018204/013) to secure the daughter card to the standoff.

PARTS AVAILABILITY:

Parts will be available as of October 30, 2005 through the Parts Distribution Center.

FILING INSTRUCTIONS:

File this notice in Maintenance Manual PDMM-0032 at page 337.

®

Raymond is a registered trademark of The Raymond Corporation © 2005 The Raymond Corporation.

FOTP-0005/mlc/01-01-03/C

RPIN OPR-05-R005 Page 1 of 1

RAYMOND PRODUCT IMPROVEMENT NOTICE

The Raymond Corporation Corporate Headquarters P O Box 130 Greene, New York 13778-0130

RPIN OPR-05-R007

Models

November 29, 2005

520, 540, 560 and All EASi™ OPR Models

SUBJECT:

New Handle and Improved Handle Horn Switch

DESCRIPTION:

The horn switch can fail causing the horn not to function.

IMPROVEMENT:

A new handle has been released that is equipped with a solid-state horn switch with increased reliability. For older style handles a new mechanical switch is available with increased reliability.

PROCEDURES:

The handle cover and housing have been modified to allow use of the new switch. Field upgrades use the mechanical switch or the entire handle is replaced with a solid-state switch equipped version.

The parts listed below and the instructions allow the more reliable mechanical switch to be installed in existing handles in the field: Qty. 1 1 1 2.5 in.

Description Switch Handle Cover Handle Housing Shrink Tubing

Part Number 1013006/002 1047003 1047004 611-069/002

®

Raymond is a registered trademark of The Raymond Corporation © 2005 The Raymond Corporation.

FOTP-0005/mlc/01-01-03/C

RPIN OPR-05-R007 Page 1 of 2

1. Disassemble the handle.

PROCEDURES (Cont’d.)

2. Temporarily label each wire at the horn switch and lift pot to avoid confusion when re-assembling the handle.

3. Unsolder all wires at the horn switch and lift pot and pull them through the opening of the handle housing.

4. Remove and discard the horn switch, metal pin, compression spring, and plastic spring button.

5. Assemble the new switch to the new handle cover using the lock washer and nut that comes with the switch.

6. Route the horn switch and lift pot wires through the opening in the new handle housing.

7. Solder the wires to the horn switch and lift pot and cover each terminal with 1/2 in. of shrink tubing.

8. Remove the temporary wire labels and assemble the handle.

PARTS AVAILABILITY:

The following new handles are available with the solid-state horn switch.

114-120-264/004 114-120-264/005 114-120-264/006

Raymond Standard Raymond Cold Storage 24V Raymond Cold Storage 36V

All are now available through the Parts Distribution Center.

Note:

FILING INSTRUCTIONS:

Any horn switch under warranty requires a handle replacement.

File a copy of this notice in the following Maintenance Manuals and page locations: PDMM-0032 after page 372 PDMM-0029 after page 443 PDMM-0101 after page 7-28

®

Raymond is a registered trademark of The Raymond Corporation © 2005 The Raymond Corporation.

FOTP-0005/mlc/01-01-03/C

RPIN OPR-05-R007 Page 2 of 2

RAYMOND PRODUCT IMPROVEMENT NOTICE

The Raymond Corporation Corporate Headquarters PO Box 130 Greene, New York 13778-0130

RPIN OPR-03-R001

Model

February 25, 2003

EASi ™ OPR

NOTE:

This Notice Supercedes Improvement Notice OPR-95-R006A, dated February 14, 1996.

SUBJECT:

Lift pump spline lubricant

DESCRIPTION:

A scheduled maintenance task was created to reduce premature failures of spline drives on lift pumps and motors. The procedure called for disassembling the lift pump and motor and reapplying Molybdenum Type G anti-seize compound (P/N 990-638) every 6 months. Changes in the manufacturing process ensure that all trucks are shipped with Molybdenum G applied to all spline drives. Reapplication on regular intervals is no longer necessary.

REMEDY:

Discontinue the practice of disassembling the lift pump and motor and reapplying Molybdenum every six months as outlined in RPIN-OPR-95-R006A.

PROCEDURES:

There is no longer a scheduled maintenance requirement for spline drives. However, if the lift pump and motor are disassembled for repair or replacement, apply Molybdenum type G to the splines prior to reassembly.

PARTS AVAILABILITY:

Now available through the Parts Distribution Center.

FILING INSTRUCTIONS:

File this notice after page 50 in Maintenance Manual PDMM-0032 & PDMM-0032A.

Raymond ® is a registered trademark of The Raymond Corporation 2003 The Raymond Corporation.

FOTP-0005/mlc/02-13-02/C

RPIN OPR-03-R001 Page 1 of 1

RAYMOND SERVICE BULLETIN

The Raymond Corporation Corporate Headquarters P O Box 130 Greene, New York 13778-0130

RSB No. OPR-01-010A

Model

November 15, 2002 NOTE:

EASi ™ OPR This bulletin supersedes bulletin number OPR-01-010, dated October 16, 2001.

SUBJECT:

Control handle assembly

DESCRIPTION:

A solid state control handle assembly is now available.

REMEDY:

Replace the existing handle with the new handle equipped with non-contact potentiometers. The new control handle benefits from the use of solid state lift and travel potentiometers.

NOTE:

A carriage control card (P/N 154-012-377/xxx) must be installed in the truck for the new handle to function. Cards built prior to 1995 will not allow the handle to function and may damage the solid state potentiometers.

Model EASi OPR

New handle assembly cut in criteria Effective Date Serial Number 10/01/01 OPR-01-AR-29334

Refer to the chart below when replacing handles.

Truck Model

Type

Volts

New Handle

EASi OPR EASi OPR EASi OPR

Non C/S C/S C/S

All 24V 36V

114-120-264/001 114-120-264/002 114-120-264/003

Raymond is a registered trademark of The Raymond Corporation 2002 The Raymond Corporation.

FOTP-0006/mlc/07-11-01/A

RSB No. OPR-01-010A Page 1 of 3

PROCEDURES:

Determine the appropriate replacement handle for the truck you are working on.

IMPORTANT!

PROCEDURES: (cont’d.)

The lift knob on solid state handles should not require any adjustment. The lift potentiometer neutral for (P/N 114-120-264/ALL) handles can be anywhere between 2.0 and 3.0 volts. The lift potentiometer voltage at fully CW (clockwise) (Lower) should be between 3.5 and 4.6 volts. The lift potentiometer voltage at fully CCW (counterclockwise) (Lift) should be between 0.4 and 1.5 volts. If the lift potentiometer voltages are out of range, replace the entire handle, or the lift potentiometer (P/N 1-120-106/001).

If the lift knob breaks or becomes loose, replace it using the following procedure: 1. Rotate lift potentiometer shaft fully CCW. 2. Install lift knob on potentiometer shaft (do not tighten set screws).

3. Rotate lift knob fully CCW and tighten set screws.

4. Verify lift potentiometer voltage readings.

5. Install nylon set screws on lift knobs that are fully threaded electrostatic discharge (ESD) protected.

IMPORTANT!

CAUTION:

NOTE:

PARTS AVAILABILITY:

The travel potentiometer neutral for (P/N 114-120-264/ALL) handles can be anywhere between 2.0 and 3.0 volts. The travel potentiometer voltage at fully CW (Forward Travel) should be between 0.4 and 1.5 volts. The travel potentiometer voltage at fully CCW (Reverse Travel) should be between 3.5 and 4.6 volts. If the travel potentiometer voltages are out of range, replace the entire handle, or the travel potentiometer (P/N 1-120-104/002).

The solid state potentiometers used in this handle are ESD sensitive. Use proper static protection.

The following Raymond Service Bulletins, Raymond Product Improvement Notices and Service Manual pages do not apply to the new handles: OPR-95-005, OPR-95-005A, OPR-96-012, OPR-97-R004, OPR-97-005, OPR-97-005A, GEN-98-R006, PDMM-0032 page 204 (“Possible Causes...” section 1), PDMM-0032 page 205 (“Possible Causes...” section 1), PDMM-0032 pages 371-372 (L/L Return Spring Replacement), PDMM-0032A page 207 (“Possible Causes...” section 1), PDMM-0032A page 208 (“Possible Causes...” section 1), PDMM-0032A pages 386-387 (L/L Return Spring Replacement).

Now available through the Parts Distribution Center.

Raymond is a registered trademark of The Raymond Corporation 2002 The Raymond Corporation.

FOTP-0006/mlc/07-11-01/A

RSB No. OPR-01-010A Page 2 of 3

WARRANTY:

Within normal Raymond Policy Guidelines

Flat Rate Book Reference EASi ™ OPR Model 9970 Code 0.7 Time

FILING INSTRUCTIONS:

File this bulletin in Maintenance Manual PDMM-0032, behind page 372.

File this bulletin in Maintenance Manual PDMM-0032A, behind page 386.

Raymond is a registered trademark of The Raymond Corporation 2002 The Raymond Corporation.

FOTP-0006/mlc/07-11-01/A

RSB No. OPR-01-010A Page 3 of 3

RAYMOND SERVICE BULLETIN

The Raymond Corporation Corporate Headquarters P O Box 130 Greene, New York 13778-0130

RSB No. OPR-99-004

Models

November 10, 1999

EASi™ OPR

NOTE:

This Bulletin applies to trucks equipped with Heavy Duty Drive Units.

SUBJECT:

Tightening mounting bolts on the drive unit.

DESCRIPTION:

Mounting bolts may become loose on the larger drive units.

REMEDY:

The addition of a hardened washer, more torque, and stronger thread-locking compound.

PARTS REQUIRED: Part Number 5-002-027 5-018-010 5-016-009 990-554/01 PROCEDURES:

Description Screw-soc head cap Washer-flat m20 Nut-hex, lock m20 Thread-locking compound (Red)

Qty. 3 3 3 AR

1. Block truck prior to removing the drive unit mounting bolts.

2. Remove existing mounting bolts and nuts to install the new mounting bolts.

3. When Installing bolts (P/N 5-002-027) apply thread-locking compound (P/N 990-544), place the washers (P/N 5-018-010) between the bolt head and the top of the drive unit mounting plate.

4. Torque bolts to 325-350ft.lbs 5. Jam nuts (P/N 5-016-009) into the bottom of the drive unit mounting plate.

6. Return truck to service.

Raymond is a registered trademark of The Raymond Corporation Copyright 1999 The Raymond Corporation.

All Rights Reserved.

RSB No. OPR-99-004 Page 1 of 2

PARTS AVAILABILITY:

Parts are now available through the Syracuse Parts Distribution Center

WARRANTY:

Within normal Raymond Policy Guidelines Flat Rate Book Reference Model EASi™ OPR Code 9910 Time 1.0

FILING INSTRUCTIONS:

File in front of OPR maintenance manual PDMM 0032.

Raymond is a registered trademark of The Raymond Corporation Copyright 1999 The Raymond Corporation.

All Rights Reserved.

RSB No. OPR-99-004 Page 2 of 2

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