Raymond Forklift Pallet Trucks with Delta-Q Chargers SERVICE INFORMATION Manual

RAYMOND SERVICE INFORMATION

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

RSI PLT-18-007

Model

October 16, 2018

Pallet Trucks with Delta-Q Chargers

SUBJECT:

Delta-Q Charger Hardware

GENERAL INFORMATION:

B+/B– terminal hardware is available for the Delta-Q Chargers.

SERVICE INFORMATION:

Part Number 1190648/03 1190648/04

Description Nut Screw

Qty. per Charger 2 2

Refer to Figure 1.

Figure 1: B+ and B– Terminal Hardware Location 1. Tighten to 40 in. lbs. (4.5 Nm).

2. Use care to prevent cross-threading the screw and nut. Cross-threading can cause the B+/B– connections to have a poor/loose connection.

PARTS AVAILABILITY:

Now available through the Parts Distribution Center.

FILING INSTRUCTIONS:

File this notice in the appropriate Maintenance Manual.

®

Raymond is a registered trademark of The Raymond Corporation 2018 The Raymond Corporation.

1306777/001A

RSI PLT-18-007 Page 1 of 1

RAYMOND SERVICE INFORMATION

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

RSI MUL-18-002

Model(s)

March 9, 2018

FlashWare

SUBJECT:

FlashWare 7.8 Functionality and Enhancements

GENERAL INFORMATION:

Highlights of FlashWare 7.8 1. New OPR Carriage Control Card P/N 1275051/001 load/upload functionality.

2. New Guidance Manager P/N 1268588/001 support.

3. Correct “Flash Erase Error” message when trying to connect to a VM with a Boot Block version of 1.0.

4. New Windows 10 compatible Drivers for Silver Box P/N 230489-001 USB/CAN Interface Module.

SERVICE INFORMATION:

Download the current version from the Raymond Portal.

1. There are two separate selections: • “FlashWare Application Package” includes FlashWare and all truck files.

• “FlashWare Application” includes the FlashWare application only.

2. The user will have the ability to select “Run” or “Save.”

• Choose “Run” to automatically extract the file into the C:\Download folder.

• Choose “Save” to launch the application at a later time.

3. After the version downloads, launch the self-extracting Zip file. This will install the files into the C\:Download folder. Open the Readme.txt file located in the C:\Download folder and follow the instructions.

Customers must contact their local Raymond Sales and Service Center to obtain the current FlashWare version.

PARTS AVAILABILITY:

Now available through the Parts Distribution Center.

FILING INSTRUCTIONS:

File this notice in the Appendix of all applicable maintenance manuals.

®

Raymond is a registered trademark of The Raymond Corporation 2018 The Raymond Corporation.

FOTP-0060/1-2-17/H

RSI MUL-18-002 Page 1 of 1

RAYMOND SERVICE INFORMATION

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

RSI MUL-18-001

Models

March 12, 2018

Multiple

SUBJECT:

Cold Storage Hydraulic Fluid Part Number Change

GENERAL INFORMATION:

A new cold storage hydraulic fluid, P/N 1266010 is available to replace P/N 1017238.

Note: These fluids can be mixed with each other.

SERVICE INFORMATION:

Refer to the following chart:

®

Raymond is a registered trademark of The Raymond Corporation 2018 The Raymond Corporation.

FOTP-0060/1-2-17/H

RSI MUL-18-001 Page 1 of 2

PARTS AVAILABILITY:

Now available through the Parts Distribution Center.

FILING INSTRUCTIONS:

File this notice in the Appendix of all applicable maintenance manuals.

®

Raymond is a registered trademark of The Raymond Corporation 2018 The Raymond Corporation.

FOTP-0060/1-2-17/H

RSI MUL-18-001 Page 2 of 2

RAYMOND SERVICE INFORMATION

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

RSI PLT-17-010

Models

December 19, 2017

8210, 6210

SUBJECT:

NEXSYS Battery Parameter Settings

GENERAL INFORMATION:

Improper setting of Parameter 21 may cause the truck BSOC to display differently than the charge in the NEXSYS battery.

SERVICE INFORMATION:

NEXSYS Battery Size 5.0 inch (12NXS85-1) 7.5 inch (12NXS137-1) 8.5 inch (12NXS85-2)

Parameter 21 Setting 4 (Model 8210) 3 (Models 8210, 6210) 1 (Models 8210, 6210)

Note: Setting 4 of Parameter 21 was added in VM Software version 2.4.

PARTS AVAILABILITY: FILING INSTRUCTIONS:

®

Now available through the Parts Distribution Center.

File this notice in Maintenance Manuals: • 6210: 1146947B next to page 3-15 • 8210/8250: 1146945C next to page 3-11.

Raymond is a registered trademark of The Raymond Corporation 2017 The Raymond Corporation.

FOTP-0060/1-2-17/H

RSI PLT-17-010 Page 1 of 1

RAYMOND SERVICE INFORMATION

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

RSI MUL-17-001

Models

August 15, 2017

Multiple

SUBJECT:

Scheduled Maintenance Changes

GENERAL INFORMATION:

The Initial 90 Day/250 Deadman Hour Hydraulic Reservoir oil change is no longer required for the following models: • • • • • • • •

4150/4250 5200 5400/5500/5600 7200/7300/7310 7500/7520 7700/7720 9300/9400 9600/9700

Note: The filter change is still required at the Initial 90 Day/250 Deadman Hour service interval.

The Initial 90 Day/250 Deadman Hour Drive Unit oil change is no longer required for the models listed below: • • • • • • • • • • • •

®

3010/3020 4150/4250 5200 5400/5500/5600 7200/7300/7310 7500/7520 7700/7720 6210 8210/8250 8310/8410/8510/8610/8900 9600/9700 9800

Raymond is a registered trademark of The Raymond Corporation 2017 The Raymond Corporation.

FOTP-0060/1-2-17/H

RSI MUL-17-001 Page 1 of 2

PARTS AVAILABILITY:

N/A

FILING INSTRUCTIONS:

File this notice in the following maintenance manuals:

®

• • • • • • • • • • • • • •

1134255A next to page 4-3 (3010/3020) 1193671B next to page 4-5 (4150/4250) 1043922B next to page 4-3 (5200) 1031794C next to page 4-5 (5400/5500/5600) 1146947B next to page 4-3 (6210) 1188937A next to page 4-5 (7200/7300/7310) 1112860E next to page 4-5 (7500/7520) 1137893E next to page 4-5 (7700/7720) 1146945B next to page 4-3 (8210/8250) 1152122C next to page 4-3 (8310/8410/8510/8610) 1087856D next to page 4-3 (8900) 1089026A next to page 4-3 (9300/9400) 1089040C next to page 4-5 (9600/9700) 1203870A next to page 4-1 (9800)

Raymond is a registered trademark of The Raymond Corporation 2017 The Raymond Corporation.

FOTP-0060/1-2-17/H

RSI MUL-17-001 Page 2 of 2

RAYMOND SERVICE INFORMATION

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

RSI MUL-17-002

Models

August 8, 2017

Multiple

SUBJECT:

Elimination of 90 Day Inspection

GENERAL INFORMATION:

As announced at the 2017 Summit meeting, the requirement for a 90 Day Inspection has been eliminated. See below.

SERVICE INFORMATION:

Service Centers may still choose to use the 90 Day Inspection process as a tool to complete follow-up calls on their customers, however you are no longer required to enter the completion of this activity into SAP. NOTE: This does not change the requirement for the Initial 90 Day/250 Deadman Hours Maintenance, which is addressed in RSI MUL-17-001.

Please contact Warranty Administration at warrantyinfo@raymondcorp.com with any questions about this new process, or call Amber Fogarty at 607-656-2811.

PARTS AVAILABILITY:

N/A

FILING INSTRUCTIONS:

File this notice in the Warranty Administration Guide.

®

Raymond is a registered trademark of The Raymond Corporation 2017 The Raymond Corporation.

FOTP-0060/1-2-17/H

RSI MUL-17-002 Page 1 of 1

PARTS AVAILABILITY:

N/A

FILING INSTRUCTIONS:

File this notice in the following maintenance manuals:

®

• • • • • • • • • • • • • •

1134255A next to page 4-3 (3010/3020) 1193671B next to page 4-5 (4150/4250) 1043922B next to page 4-3 (5200) 1031794C next to page 4-5 (5400/5500/5600) 1146947B next to page 4-3 (6210) 1188937A next to page 4-5 (7200/7300/7310) 1112860E next to page 4-5 (7500/7520) 1137893E next to page 4-5 (7700/7720) 1146945B next to page 4-3 (8210/8250) 1152122C next to page 4-3 (8310/8410/8510/8610) 1087856D next to page 4-3 (8900) 1089026A next to page 4-3 (9300/9400) 1089040C next to page 4-5 (9600/9700) 1203870A next to page 4-1 (9800)

Raymond is a registered trademark of The Raymond Corporation 2017 The Raymond Corporation.

FOTP-0060/1-2-17/H

RSI MUL-17-001 Page 2 of 2

RAYMOND SERVICE INFORMATION

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

RSI PLT-17-005

Models

June 27, 2017

6210/8210

SUBJECT:

Delta Q Charger Software 4.5.1

GENERAL INFORMATION:

A Delta Q Charger Software update (version 4.5.1) is available.

SERVICE INFORMATION:

Delta Q Software version 4.5.1 is available with the following changes: Fixed unexpected charger lockup.

Download version 4.5.1 from the Raymond Portal, onto a blank Flash drive. Use P/N 990-1203 right angle USB adapter if a longer Flash drive is being used.

PARTS AVAILABILITY: FILING INSTRUCTIONS:

®

Now available on the Raymond Portal.

File this notice in Maintenance Manual 1146945A (Model 8210) next to page xii, and 1146947A (Model 6210) next to page ix.

Raymond is a registered trademark of The Raymond Corporation 2017 The Raymond Corporation.

FOTP-0060/1-2-17/H

RSI PLT-17-005 Page 1 of 1

RAYMOND SERVICE INFORMATION

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

RSI PLT-17-003

Models

May 3, 2017

8210, 6210

SUBJECT:

Delta Q Charger Algorithm #1, version 1.13.

GENERAL INFORMATION:

Delta Q Charger Algorithm #1, version 1.13 (P/N 1263444/001) is available with the following enhancements.

• Fixes unintended repeated Equalization charging of batteries, caused by brief discharging and charging of the battery.

• Thermistor P/N 1192068 is necessary for the Delta Q software to operate properly.

®

Raymond is a registered trademark of The Raymond Corporation 2017 The Raymond Corporation.

FOTP-0060/1-2-17/H

RSI PLT-17-003 Page 1 of 6

SERVICE INFORMATION:

Download the Delta Q Algorithm #1, version 1.13 (P/N 1263444/001) onto a blank flash drive, and load it into the Delta Q charger. A right angle flash drive adaptor P/N 1218263-001 may be needed to insert a longer flash drive into the Delta Q charger.

Install thermistor P/N 1192068 as outlined below.

USB SUPPORT HARDWARE: USB FLASH MEMORY DRIVE AND ADAPTOR • Physical Flash Drive end-to-end max. length: 1.5 inches o Recommended: Kingston DTMCK/8GB o Min. memory size: 2 MB • Right Angle Flash Drive Adaptor o P/N 1218263-001 (L-COM P/N UADAA90-2) o To allow use of any Flash Drive length ALGORITHM PREPARATION: DOWNLOAD TO PC • Acquire new Algorithm #1 zip file (CHARGER_Add_Alg#1.zip \ Password: chargers), as noted in “Parts Availability”, and load unzipped file ‘CHARGER’ into clean Flash Drive.

REQUIRED CHARGER ACCESSORY FOR ALGO #1: BATTERY TEMPERATURE SENSOR • The following Delta-Q Charger Temperature Compensation Sensor is required to allow Algo #1 to function properly. o Raymond P/N: 1192068 Thermistor Assembly o Sensor connected from the Charger’s DC Port ‘C1’ (Neg.) and ‘C2’ (Pos.) to any Battery Post.

REQUIRED BATTERY SET FOR ALGO #1: 24VDC LEAD ACID WET CELL MAINTENANCE TYPE • Algo #1 must be matched with the following Batteries, to allow proper charging operation. o Raymond P/N: 27234-00 o Mfr.: Trojan, Mfr. P/N: T-605 REQUIRED TRUCK SOFTWARE FOR ALGO #1: -023 • The Truck must have Software suffix -023, to allow Truck setting, acceptance, and operation of Algo #1. o Raymond Truck Software P/N: 1209060-023 TRUCK PRELIMINARY SETUP FOR ALGO #1: -023 (or greater) • Set each of the following Parameters, 21 and 46 Settings, to 3 as shown below.

Parameter 21: Battery Type 1: Industrial 2: AGM Charging Profile 3: Wet Cell (4 Pack) Parameter 46: CAN Communication Enabled HF Charger 0: Disabled (Default) 1: AGM Charging Profile 2: Wet Cell Charging Profile 3: Charger Detected • This allows the Truck to detect and communicate with the CAN enabled Charger.

• This Truck SW Setting combination will NOT allow the Truck to automatically set the

®

Raymond is a registered trademark of The Raymond Corporation 2017 The Raymond Corporation.

FOTP-0060/1-2-17/H

RSI PLT-17-003 Page 2 of 6

Charger’s active Algo ID to #1.

• Utilizing this Setting combination will ONLY allow Algo 1 to be Set within the Charger using the following two methods. o By Downloading the respective Algo #1 file, as instructed in this RSI, or o By Manually Selecting and Setting the Chargers ‘charging profile’ to Algo #1, per RSI PLT-15-016 • This is only a Temporary workaround SW Setting at the moment, to allow a nonrecognized Algo, not listed within the Truck SW, to be utilized. (Currently listed and recognized Algo’s within Truck SW are #73 and #43) PRE-CHECK: CHARGING ALGORITHM\CHARGE PROFILE • Place the truck Main ON/OFF switch in the OFF position.

• Make sure the onboard Charger is NOT connected to an AC power source and is NOT charging.

• Verify Charger power source, Truck Battery Pack, is approximately 24VDC. • Read and note active Algorithm ID. Press the Charger utility button (tool image).

• Verify the correct active Charging Algorithm ID number displayed on Charger is set to match supported Battery Mfr. and Model. o P232. displayed for Algo ID #232 (version 1.02) for Wet Cell: Trojan model T-605 o P073. displayed for legacy Algo ID #73 (version 1.43) for Wet Cell: Trojan model T-605 o [P001. displayed for new Algo ID #1 (version 1.13) for Wet Cell: Trojan model T-605 ] this RSI CHARGING ALGORITHM: DOWNLOAD TO CHARGER • This Algo only download will not affect present Charger SW or Algo’s, other than Algo #1 will be added to the existing available Algo’s list, and will automatically set Algo #1 as the active charging Algorithm within the Charger.

• Place the truck Main ON/OFF switch in the OFF position • Make sure the onboard Charger is NOT connected to an AC power source and is NOT charging • Insert the USB Flash Drive into the Charger USB port, with only the downloadable Algorithm File present on the flash drive. o The Algorithm File is located within the acquired CHARGER root directory.  CHARGER\FILES\ALGOS\A_1_13_1_0.bin  CHARGER\FILES\SW\ <should be blank> • The Charger display will scroll U S b. and upper triangular light (USB Indicator) will flash green.

• Wait approximately 1 to 2 minutes for the flashing green light to become solid green, indicating the download is complete.

• Remove the USB Flash Drive from the Charger.

• The green light USB Indicator will turn OFF, indicating the USB link\session end.

IF CHARGER ERROR: If Error amber light is produced: • Record the Error Code displayed • Write down the Charger nonconformance symptoms • For Error Code description and Troubleshooting, reference RSI PLT-15-016 • Note all recovery actions taken o For Example: Cycle VDC, disconnect-connect o For Example: Cycle VAC, disconnect-connect • Reattempt the Algorithm download ®

Raymond is a registered trademark of The Raymond Corporation 2017 The Raymond Corporation.

FOTP-0060/1-2-17/H

RSI PLT-17-003 Page 3 of 6

POST-CHECK: CHARGER ALGORITHM • Repeat “PRE-CHECK: CHARGING ALGORITHM\CHARGE PROFILE” steps. o Make sure the Charger’s active Algorithm ID is 1. o If needed, the Charge Profile\Algorithm ID #1 can be selected manually.

Reference RSI PLT-15-016, or respective IC650 Charger Manual.

CHARGER SETTING: VERIFICATION • Key Truck Power, On & Off o This will verify the Charger’s new Algo #1 will remain set in the Charger, and will not change with the truck ability to remotely change the Charger’s Algo to something other than Algo #1.

• Press the Charger’s ‘utility’ button to read the Algorithm ID #.

• Repeat: Re-key the Truck again, to re-read and make sure the active Algo #1 is still set.

ACCEPTABLE TRUCK ERROR • After the new Algo #1 is loaded and Truck operation is engaged, the following Error will be produced. o Error Code: C395  Description: Unexpected battery charger communication  This is associated with Par. 21 set to 3 and Par. 43 set to 3 • This error is expected, will clear, and will not hinder Truck operation.

CHARGING AND DRIVE AWAY PROTECTION FUNCTIONAL CHECK • Leave the truck Main ON/OFF switch in the OFF position.

• Connect to an AC power source to verify Charger will charge.

• Make sure the Truck Handle displays “AC” (truck disabled), and Charger is charging.

• Turn the truck Main ON/OFF switch to the ON position. Make sure the Truck will not move. Turn the truck Main ON/OFF switch to the OFF position.

• Disconnect from the AC power source to stop the charging cycle.

• Functional Check complete.

TRUCK FUNCTIONAL CHECK • Make sure the onboard Charger is NOT connected to an AC power source, and is NOT charging.

• Turn the truck Main ON/OFF switch to the ON position/ • Perform a couple basic Truck functional operations. o For Example: Raise\lower and travel.

• Turn the truck Main ON/OFF switch to the OFF position.

CHARGER Algo #1 ADDITION COMPLETION

• Mark the charger with permanent marker dot, or sticker, to indicate Algo #1 Loaded.

• Algo #1 Addition, Time Stamp, & Summary, log\record …. o Algo #1 Version loaded (v1.13) o Marking method (sticker? marker? color? alphanumeric?) o Date and Time Algo #1 loaded o Charger S/N o Truck S/N • Charger Algo #1 Download Process complete o Make sure the USB Flash Drive has been removed, and the USB Port Cover is closed\inserted.

®

Raymond is a registered trademark of The Raymond Corporation 2017 The Raymond Corporation.

FOTP-0060/1-2-17/H

RSI PLT-17-003 Page 4 of 6

PC - SUCCESSFUL ALGO DOWNLOAD VERIFICATION • Insert the USB Flash Drive used to download Algo #1 into the Charger, and still contains only this file, into a PC. • Open Windows Explorer (File Manager.)

• Copy and paste the CHARGER file into the desired respective subdirectory.

• Navigate as follows to make sure of a Successful Download. o CHARGER\RESP\DQ_ _ _ _ _ _ _ _ _ _ _ _ _ _\syslog\syslog.txt o This TXT file will show previously active Algo version, new active Algo, and valid Algo ID #1.

Example text: C 0033512427.763 BKGND :Active alg from: ID73.v1.43 to ID1.v1.13 C 0033512427.823 BKGND :Valid alg 1 1.13.0 • If not successful, retry the Algo #1 download process.

OPTIONAL: UPLOAD\CHECK NEW CHARGER DATA • Place the truck Main ON/OFF switch in the OFF position.

• Make sure the onboard Charger is NOT connected to an AC power source and is NOT charging • Insert a clean USB flash drive into the Charger USB port, and automatically upload the Charger data history.

• The Charger display will scroll U S b. and the upper triangular green light (USB Indicator) will flash.

• Wait approximately 1 to 2 minutes for the flashing green light to become solid Green, indicating the upload is complete.

• Remove the USB Flash Drive from the Charger.

• The green light USB Indicator will turn OFF, indicating the USB link\session end.

OPTIONAL: VIEWING CHARGER DATA The uploaded data (CHARGER file) can be referenced to view Charger Configuration content and Charging History.

• PC File Manager Tool: o The following TXT files can be viewed via Microsoft Explorer, Microsoft Notepad, or any file manager or text editor.  CHARGER\RESP\DQ_ _ _ _ _ _ _ _ _ _ _ _ _ _\SETTING\Setting.txt  CHARGER\RESP\DQ_ _ _ _ _ _ _ _ _ _ _ _ _ _\syslog\syslog.txt  CHARGER\RESP\DQ_ _ _ _ _ _ _ _ _ _ _ _ _ _\syslog\000000_ _.txt (size 36KB or smaller) • Delta-Q Charger Tool o The entire CHARGER file can be imported into either of the two Delta-Q Tools.

The Delta-Q “Simple IDAT Tool” can be used to view basic charging data, for example: Charging Cycles & Amp Hrs Returned.  The Tool and User Guide can be downloaded from the following link. http://delta-q.com/software-accessories/

o

•

®

The Delta-Q “IC Programmer and Data Analysis Tool” can be used to view detailed charging data, graphs, and profiles, for example: Current, Voltage, Temperature, and so forth.  The Tools can be downloaded from Delta-Q Support link upon special request. https://delta-q.com/support/

Raymond is a registered trademark of The Raymond Corporation 2017 The Raymond Corporation.

FOTP-0060/1-2-17/H

RSI PLT-17-003 Page 5 of 6

OPTIONAL: ALGO REMOVAL (if required) In order to remove an Algo from the Charger, a Charger SW set, with its Algo’s present, must be reloaded.

PARTS AVAILABILITY: FILING INSTRUCTIONS:

®

Now available through The Raymond Portal.

File this notice in the following Maintenance Manuals: • 1146945B (Model 8210) next to page 7-44 (to charge a battery).

• 1146947B (Model 6210) next to page 7-44 (to charge a battery).

Raymond is a registered trademark of The Raymond Corporation 2017 The Raymond Corporation.

FOTP-0060/1-2-17/H

RSI PLT-17-003 Page 6 of 6

RAYMOND SERVICE INFORMATION

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

RSI PLT-16-010

Models

January 3, 2017

6210, 8210

SUBJECT:

Delta Q Charger DC Reset Procedure

GENERAL INFORMATION:

Before replacing the charger, perform the steps on the following pages, if the charger is not charging, or the blue light is lit with the AC power disconnected, even if version 3.0.8.2 software is installed.

®

Raymond is a registered trademark of The Raymond Corporation 2016 The Raymond Corporation.

FOTP-0060/1-7-16/G

RSI PLT-16-010 Page 1 of 5

SERVICE INFORMATION:

Follow the actions below to perform the DC Reset.

SUPPORT HARDWARE\TERMINAL INFORMATION: • Trojan T-605:  Wrench: 9/16 inch  Nut Size: 1/2 inch (Battery post stud: 5/16 – 18)  Torque: 95 to 105 in. lbs. (10.7 to 11.9 Nm) • Discover EVGC6A-A:  Wrench: 14 mm  Nut Size: M8 (Battery post stud: 5/16 – 18)  Torque: 62 to 75 in. lbs. (7.0 to 8.5 Nm) PRE-CHECK: CHARGING ALGORITHM\CHARGE PROFILE (if possible) • Place the truck Main ON/OFF switch in the OFF position.

• Make sure the onboard Charger is NOT connected to an AC power source and is NOT charging.

• Verify the Charger power source, Truck Battery Pack, is approximately 24VDC. Note: This can be measured at Battery Pack’s main connector, SB-175.

• Read and note the active Algorithm ID. Press the Charger utility button (tool image).

• Verify the correct active Charging Algorithm ID number displayed on the Charger is set to match the supported Battery Mfr. and Model. ­ P073. is displayed for Algo ID #73 (version 1.40) for Wet Cell: Trojan model T-605 ­ P043. is displayed for Algo ID #43 (version 1.16) for AGM: Discover model EVGC6A-A BATTERY PACK COVER REMOVAL • Place the truck Main ON/OFF switch in the OFF position.

• Make sure the onboard Charger is NOT connected to an AC power source and is NOT charging.

• Remove the Battery Pack Cover.  Remove the two threaded screw Knobs located on the top center of the Cover surface.  Lift the Cover straight up by the Handle and set aside on a solid, flat, stable surface (floor) in a safe location.  Position the removed Cover either in a standing position or lying flat on the solid, flat, stable surface.  For Pallet Trucks with a Load Backrest, the upper portion of the Cover must be tilted forward, towards the forks, when lifting it out. Avoid scraping the Cover outer surface against the Backrest rails.

CAUTION: The Cover may be heavy. Safely lift and set aside.

®

Raymond is a registered trademark of The Raymond Corporation 2016 The Raymond Corporation.

FOTP-0060/1-7-16/G

RSI PLT-16-010 Page 2 of 5

CHARGER DC DISCONNECTION (RESET): • Find the Charger’s DC Positive ring-terminal with a yellow insulator. This is located on upper left battery, right forward positive post.

• Lift the terminal’s rubber insulation Boot’s front edge. Slide the Boot away from the battery terminal. You may need to pinch and push down on the center of the Boot, and rock it back-and-forth to slide it along the cable.

• Use a wrench to remove the Nut (and Washer) from the threaded battery post stud\terminal.

• Lift and disconnect (move) the yellow terminal from the battery’s positive post.

Note: The large positive Battery Cable terminal lug does not need to be disconnected.

• Wait 1 to 2 minutes.

• Re-install the Positive ring terminal on the respective battery positive post.

• Re-install the Nut (and Washer), and torque as indicated.

• Boot re-installation, similar method as install, to avoid snagging onto large lug terminal external edge.

CHARGER AC INITIALIZATION: • After disconnecting DC and re-connecting.

• Make sure the truck Main ON/OFF switch is in the OFF position.

• Re-check the respective terminal to make sure it has been correctly re-assembled and secured.

• Apply an AC power source to the Charger.

• Wait approximate 1 minute for the Charger to Initialize and start charging (flashing green lights).

• Remove the AC power source from the Charger to end/stop the charging cycle.

• AC Initialization is now complete.

(IF AC INITIALIZATION IS UNSUCCESSFUL): • If DC Reset and AC Initialization is not successful.  Repeat previous DC (“Charger DC Disconnection”) and AC (“Charger AC Initialization”) actions.  If still unsuccessful, the Charger may need to be replaced.

POST-CHECK: CHARGING ALGORITHM\CHARGE PROFILE • Repeat the “PRE-CHECK: CHARGING ALGORITHM\CHARGE PROFILE” steps.

• Verify the Charger’s Algorithm ID # matches the Battery type installed after the DC Reset.

• If needed, the Charging Profile\Algorithm ID can be reselected Automatically, as noted in “AUTO-SELECT ALGORITHM” or set the Algorithm manually. Refer to RSI PLT-15-016.

AUTO-SELECT ALGORITHM • Turn the truck Main ON/OFF switch ON and OFF. • This automatically re-sets the Charger charging Algorithm ID to match the Truck software charging Algorithm ID. Note: This may have to be repeated, if the Algorithm ID # does not match the Battery type.

®

Raymond is a registered trademark of The Raymond Corporation 2016 The Raymond Corporation.

FOTP-0060/1-7-16/G

RSI PLT-16-010 Page 3 of 5

CHARGING FUNCTIONAL RE-CHECK • Leave the truck Main ON/OFF switch in the OFF position.

• Connect an AC power source to verify the Charger will charge with the correct active Algorithm. ­ Momentarily turn the main ON/OFF switch to ON, then OFF, to make sure the Truck Handle displays “AC” and disables all truck functionality when the main ON/OFF switch is in the ON position.

• If charging is OK, remove the AC power source to stop the charging cycle.

TRUCK FUNCTIONAL CHECK • Make sure the onboard Charger is NOT connected to an AC power source and is NOT charging.

• Place the truck Main ON/OFF switch in the ON position.

• Perform a couple basic Truck functional operations. ­ For example: Raise\lower and travel.

• Place the truck Main ON/OFF switch in the OFF position.

OPTIONAL: CHARGER DATA\HISTORY UPLOAD • Place the truck Main ON/OFF switch in the OFF position.

• Make sure the onboard Charger is NOT connected to an AC power source and is NOT charging.

• Insert a clean USB flash drive into the Charger USB port to automatically upload Charger data history.

• The Charger display will scroll U S b. and the upper triangular green light (USB Indicator) will flash.

• Wait approximately 1 to 2 minutes for the flashing green light to become a solid Green, indicating the upload is complete.

• Remove the USB Flash Drive from the Charger.

• The green USB Indicator light will turn OFF, indicating the USB link session has ended.

OPTIONAL: VIEWING CHARGER DATA The uploaded data (CHARGER file) can be used to view Charger Configuration and Charging History.

• PC .txt File Manager Tool: ­ The following .txt files can be viewed via MS Explorer, MS Notepad, or other text viewer\editor.  CHARGER\RESP\DQ_ _ _ _ _ _ _ _ _ _ _ _ _ _\SETTING\Setting.txt  CHARGER\RESP\DQ_ _ _ _ _ _ _ _ _ _ _ _ _ _\syslog\00000000.txt • Delta-Q Charger Tool ­ The entire CHARGER file can be imported into either of the two Delta-Q Tools. ­ The Delta-Q “Simple IDAT Tool” can be used to view basic charging data.

For example: Charging Cycles.  The Tool and User Guide can be downloaded from the following link. http://delta-q.com/software-accessories/ ­ The Delta-Q “IC Programmer and Data Analysis Tool” can be used to view detailed charging data, graphs, and profiles. For example: Current, Voltage, Temperature, and so forth.  The Tools can be downloaded from Delta-Q Support link upon special request. https://delta-q.com/support/

®

Raymond is a registered trademark of The Raymond Corporation 2016 The Raymond Corporation.

FOTP-0060/1-7-16/G

RSI PLT-16-010 Page 4 of 5

PARTS AVAILABILITY: FILING INSTRUCTIONS:

®

Not Applicable File this notice in Maintenance Manuals: • 1146945A (Model 8210) next to page 6-33 • 1146947A (Model 6210) next to page 6-35.

Raymond is a registered trademark of The Raymond Corporation 2016 The Raymond Corporation.

FOTP-0060/1-7-16/G

RSI PLT-16-010 Page 5 of 5

RAYMOND SERVICE INFORMATION

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

RSI PLT-16-007

Models

October 25, 2016

6210, 8210

SUBJECT:

ETAC Loses Power

GENERAL INFORMATION:

The ETAC may lose power due to a harness short.

SERVICE INFORMATION:

1. Remove five screws to disassemble the lower and upper cover.

2. Place Kapton disc (P/N 1256355/001) at the location identified in the graphic below.

®

Raymond is a registered trademark of The Raymond Corporation 2016 The Raymond Corporation.

FOTP-0060/1-7-16/G

RSI PLT-16-007 Page 1 of 3

3. Wrap any extra Kapton material around to the other side of the flex cable.

4. Place the ETAC board in the upper cover. Make sure that the ETAC board display connector guide pins are mated to the holes in the display. (Refer to 1, 2, and 3 in the illustration below.)

5. While holding the ETAC board in place, carefully position the lower cover on the upper cover. (Refer to 4 in the illustration above.)

6. Make sure the ETAC board did not change position.

®

Raymond is a registered trademark of The Raymond Corporation 2016 The Raymond Corporation.

FOTP-0060/1-7-16/G

RSI PLT-16-007 Page 2 of 3

7. Make sure the screws have a rubber washer.

8. Tighten the five screws for the lower cover in the sequence noted in the graphic below. Tightening force is 10 in. lbs. (1.15 Nm).

PARTS AVAILABILITY: FILING INSTRUCTIONS:

®

Now available through the Parts Distribution Center.

File this notice in the following Maintenance Manuals: • 1146945A (Model 8210) next to page 5-1 • 1146947A (Model 6210) next to page 5-1

Raymond is a registered trademark of The Raymond Corporation 2016 The Raymond Corporation.

FOTP-0060/1-7-16/G

RSI PLT-16-007 Page 3 of 3

RAYMOND SERVICE INFORMATION

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

RSI PLT-16-006

Models

October 24, 2016

6210, 8210

SUBJECT:

Delta Q Charger Software Release 3.0.2.8

GENERAL INFORMATION:

Delta Q Software version 3.0.2.8 is available for download.

SERVICE INFORMATION:

Delta Q version 3.0.2.8 is available with the following updates: • Unexpected charger lock up (Blue Light Issue) is fixed • Unexpected charger shutdown is fixed.

• Forces a charger restart at the end of the software download.

Download version 3.0.2.8 from the Raymond Portal. Use a blank USB Drive.

Due to space constraints, a short USB Drive is necessary. If using a longer USB Drive, use USB Adapter P/N 990-1203.

PARTS AVAILABILITY:

FILING INSTRUCTIONS:

®

The USB Drive Adapter is now available through the Parts Distribution Center.

The software download is available from the Raymond Portal.

File this notice in the following Maintenance Manuals: • 1146945A (Model 8210) next to page 5-28 • 1146947A (Model 6210) next to page 6-31

Raymond is a registered trademark of The Raymond Corporation 2016 The Raymond Corporation.

FOTP-0060/1-7-16/G

RSI PLT-16-006 Page 1 of 1

RAYMOND SERVICE INFORMATION

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

RSI PLT-16-005

Models

September 13, 2016

8210, 6210

SUBJECT:

New Software Release

GENERAL INFORMATION:

New Software, VM version 2.3 and Curtis version 30.46, is available. The new software includes the changes noted on page 2.

®

Raymond is a registered trademark of The Raymond Corporation 2016 The Raymond Corporation.

FOTP-0060/1-7-16/G

RSI PLT-16-005 Page 1 of 2

SERVICE INFORMATION:

Note: Load version 2.3 into the VM BEFORE loading version 30.46 into the Curtis. Once version 30.46 is loaded into the Curtis Amplifier, you cannot go back to an earlier Curtis version, or the BSOC will read 9999 on the display, until version 30.46 is reloaded.

• • • • • •

• • • •

• • PARTS AVAILABILITY: FILING INSTRUCTIONS:

®

Brake is released when the handle is down and the throttle is moved.

Improved ramp performance, travel alarm activation, speed of truck startup, and hour meter tracking Code C63 has been changed to C405 (Load Holding Driver).

Nuisance codes E380 and E691 have been addressed.

Changed the default speed for Click-2-Creep to 0.5 MPH from 1.0 MPH and adjusted the acceleration rate.

The issue where interruption of the FlashWare download could cause the Curtis controller to be unusable has been resolved. Take care not to interrupt downloading this version or the Curtis controller may become unusable.

Increased the amount of time the horn will beep after a successful startup Brake Override switch can now be used at Startup. “br_o” is displayed to let the operator know the switch is activated.

Brake is now activated during Motor Stall.

Trucks with Delta Q charger: During Startup, if the VM detects the charger and CAN Enable Parameter 46 are not enabled, Code C395 is displayed. During Run Time, if the VM detects the charger and the CAN Enable Parameter 46 are not enabled, Code E700 is displayed.

VM reboots if the Main ON/OFF switch is ON when the charger cord is disconnected from the AC outlet. iBATTERY Option is available with a FlashWare Passkey.

Now available through the Raymond Portal.

File this notice in the following Maintenance Manuals: • 1149645A (Model 8210) next to the Table of Contents • 1146947A (Model 6210) next to the Table of Contents

Raymond is a registered trademark of The Raymond Corporation 2016 The Raymond Corporation.

FOTP-0060/1-7-16/G

RSI PLT-16-005 Page 2 of 2

RAYMOND SERVICE INFORMATION

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

RSI PLT-16-004

Models

September 12, 2016

102XM, RAS, 8210, 6210

SUBJECT:

Parameter settings when using the Nexus™ battery pack

GENERAL INFORMATION:

The correct parameter settings when using the Nexus™ battery pack has changed with the introduction of the 8210 and 6210.

SERVICE INFORMATION:

PARTS AVAILABILITY: FILING INSTRUCTIONS:

®

Model

Parameter 21

Parameter 46

102XM

2

N/A

RAS

2

N/A

8210

3

0

6210

3

0

N/A

File this notice in the following Maintenance Manuals: • 1010183C (Model 102XM), next to page 3-11 • 1146945A (Model 8210), next to page 3-11 • 1055925B (Model RAS20/25), next to page 3-13 • 1146947A (Model 6210), next to page 3-14

Raymond is a registered trademark of The Raymond Corporation 2016 The Raymond Corporation.

FOTP-0060/1-7-16/G

RSI PLT-16-004 Page 1 of 1

RAYMOND SERVICE INFORMATION

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

RSI PLT-16-003

Models

April 7, 2016

6210, 8210

SUBJECT:

Code C70 Correction

GENERAL INFORMATION:

The Temperature Sensor resistance in code C70 is incorrect.

SERVICE INFORMATION:

PARTS AVAILABILITY: FILING INSTRUCTIONS:

®

Change the resistance reading in the “Reason” section from 591 ohms to the range, “from 990 ohms to 1100 ohms”.

Not Applicable

File this notice in Maintenance Manuals: • 1146947A next to page 6-14 – Model 6210 • 1146945A next to page 6-13 – Model 8210

Raymond is a registered trademark of The Raymond Corporation 2016 The Raymond Corporation.

FOTP-0060/1-7-16/G

RSI PLT-16-003 Page 1 of 1

RAYMOND SERVICE INFORMATION

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

RSI PLT-15-016

Models

February 29, 2016

102XM, RAS20/25, 8210, 6210

SUBJECT:

Delta-Q Charger Troubleshooting

GENERAL INFORMATION:

1190648/001 Delta-Q Charger Troubleshooting Procedures

SERVICE INFORMATION:

The attached pages contain updated Delta-Q charger configuration and troubleshooting procedures.

PARTS AVAILABILITY:

N/A

FILING INSTRUCTIONS:

®

File this notice in Maintenance Manuals: • 1010183C (102XM) next to page 5-13 • 1055925B (RAS20/25) next to page 5-16 • 1146945A (8210) next to page 6-33 (replaces pages 6-33/6-34) • 1146947A (6210) next to page 6-35 (replaces pages 6-35/6-36)

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

FOTP-0060/1-7-15/F

RSI PLT-15-016 Page 1 of 1

Delta-Q IC Series Battery Chargers Installation and Design Guide

IC650

IC900

IC1200

Delta-Q Technologies Corp.

3755 Willingdon Avenue Burnaby, BC V5G 3H3 CANADA

© 2016 Delta-Q Technologies Corp. All rights reserved.

(PN: 710-0143 Rev 4 Date: 26/01/2016)

Web: www.delta-q.com Phone: +1.604.327.8244 E-mail: info@delta-q.com

9.0 Charger Con guration There are two ways to alter the con guration on the IC Series Charger: 1. Use the Select Charge Pro le Button.

2. Use a pre-programmed USB ash drive.

9.1 Selecting A Charge Pro le Using the ‘Select Charge Pro le Button’ 1. Disconnect AC input from the charger, or from the wall outlet. Wait 30 seconds for the input relay to open.

3. Press and release the Select Charge Pro le Button to advance through charging pro les loaded on the charger. The selected charging pro le will be displayed up to three times (e.g. “P-0-1-1” for Pro le 11).*

Disconnect AC input from the charger.

2. While reconnecting AC input, press and hold the Select Charge Pro le Button. Hold the button (approx. 20 seconds) through the light check function, until Error Indicator is on (in amber) and Battery Charging Indicator (in green) starts ashing.

Press the Select Charge Pro le Button to advance through the charge pro les. *Process will time out and pro le will remain unchanged if there is 15 seconds of inactivity, a pro le number is allowed to display three times, or if AC power is cycled.

4. Once the desired charging pro le is displayed, press and hold the Select Charge Pro le button for 10 seconds to con rm selection and exit Pro le Selection Mode. When the charge pro le is con rmed, the Error Indicator and Battery Charging Indicator lights will turn o , while the blue AC Power Indicator remains lit. At this point, the button can be released.

5. Press the Select Charge Pro le Button to check that the desired pro le is selected.

Reconnect AC input while holding the Select Charge Pro le Button.

35

9.2 Con guring the IC Series Charger Using a USB Flash Drive Pre-con gured les for use on a USB drive are available from Delta-Q. To use the USB port, follow these steps: 1. Insert the USB ash drive at any time, but preferably not during a charge cycle. Stop the charge cycle by removing AC power or the DC connection to the batteries. The charger can power the USB port from the AC connection (DC disconnected) or from the DC connection (AC disconnected).

2. If there is enough disk space (about 2 MB), the charger will write charge tracking data to the drive. The Fault / Error / USB Indicator will ash green during Insert the USB ash drive to begin the reprogramming process. When reading and writing. complete, the Fault / Error / USB indicator will be solid green as shown.

3. If the drive contains compatible con guration les, the charger will load them.

4. The IC Series Charger may brie y reset.

5. Remove the drive when the Fault / Error / USB indicator is solid green.

Troubleshooting If the alarm indicator ashes amber, note the error code and retry the update. If there is no response to inserting the USB drive when the charger is being used o -board, check that AC power is available and connected. If the charger is installed on-board, ensure that the charger either has AC power and / or batteries are connected.

Con rming a Software Update After using a USB ash drive to update the charger rmware, the update can be con rmed by reviewing the .txt le written to the ash drive by the charger. It will be located in the folder labelled ‘syslog’ (e.g. F:\ CHARGER\RESP\serialno\syslog\00000000.txt).

Open this le using a text editing program such as Wordpad or Microsoft Word. If the update has been successful, near the end of the text you will see a description resembling “SM Task: Successful upgrade at Major[001].Minor[001].Build[000] variant[008].”

Alternatively, if you are using the IC Programmer and Data Analysis Tool, you will be able to see which software and charging algorithm were used for each charge cycle in the Charger Cycle Summaries.

36

10.0 Troubleshooting The IC Series Charger is continuously monitoring itself and its environment for unusual conditions. There are a few indications that may require the user’s attention.

Symptom

Recommended Action

No indicator lights

Check AC power and connection to batteries.

Only blue AC light on

Charger has AC and is waiting connection to batteries or CAN remote control commands. Battery voltage must rise over 0.2V /cell before charging will begin.

Solid red Fault / Error / USB Indicator

Read fault code (e.g. F-0-0-1) number on the Charge Pro le / Error Display and refer to the fault code table below.

Flashing amber Fault / Error / USB Indicator

Read error code (e.g. E-0-0-1) number on the Charge Pro le / Error Display and refer to the error code table below.

10.1 Charger Fault Codes Code

Description

Troubleshooting / Customer Actions

F-0-0-1

DC-DC failure: LLC excessive leakage fault

F-0-0-2

PFC failure: PFC excessive leakage fault

Internal charger fault. Remove AC and battery for minimum 30 seconds and retry charger. If it fails again, contact the manufacturer of your vehicle or machine / or Delta-Q Technologies.

F-0-0-3

PFC has taken too long to boost

F-0-0-4

The charger has been unable to calibrate the current offset.

F-0-0-5

The voltage drop across the DC relay is too high while the relay is closed.

10.2 Charger Error Codes Code

Description

Solution

E-0-0-1

Battery voltage over limit in software. Typically 2.5V/cell.

•

Check the battery voltage and cable connections.

•

Check charger voltage model is appropriate for batteries.

•

This error will automatically clear once the condition has been corrected.

•

Check the battery voltage and cable connections.

•

Check battery size and condition. Batteries may be overdischarged. Use another charger to bring the batteries above the minimum voltage.

•

This error will automatically clear once the condition has been corrected.

E-0-0-2

Battery voltage too low to start a charge cycle. Algorithm dependent ʹ typically 0.1V/cell.

38

10.2 Charger Error Codes Code

Description

Solution

E-0-0-3

Charge time limit reached.

Algorithm dependent.

•

Charger output reduced due to high temperatures. Operate at lower ambient temperature.

•

Charger output reduced due to low AC voltages. Check AC voltage.

•

Check for shorted or damaged cells.

•

Poor battery health. Replace battery.

•

Very deeply discharged battery. Retry charge.

•

Poorly connected battery. Check connections.

•

Extra loads. Turn o other devices running on the battery

•

This error will automatically clear once the charger is reset by cycling DC or by loss of AC for over 10 minutes.

Battery could not be trickle charged up to the minimum voltage. May also be used for other battery-related errors depending on the algorithm.

•

Check for shorted or damaged cells.

•

Poor battery health. Replace battery.

•

Check DC connections.

•

This error will automatically clear once the charger is reset by cycling DC or by loss of AC for over 10 minutes ͘

Charge amp-hour Limit reached.

Algorithm dependent.

•

Charger output reduced due to high temperatures. Operate at lower ambient temperature

•

Charger output reduced due to low AC voltages. Check AC voltage.

•

Check for shorted or damaged cells.

•

Poor battery health. Replace battery.

•

Very deeply discharged battery. Retry charge.

•

Poorly connected battery. Check connections.

•

Extra loads. Turn o other devices running on the battery

•

This error will automatically clear once the charger is reset by cycling DC or by loss of AC for over 10 minutes.

•

Cool or warm batteries as needed.

•

Check temperature sensor and connections.

•

This error will automatically clear once the condition has been corrected.

•

Battery is connected the wrong way around. Check the battery connections.

•

This error will automatically clear once the condition has been corrected.

•

Check for an electrical device connected between the charger and the battery which passes through voltage but not current (ie. Diode).

•

Some lithium algorithm try to charge without detecting battery voltage and will show this fault if it is not connected. Ensure the charger is properly connected to approved equipment.

•

This error will automatically clear once the charger is reset by cycling DC or AC.

E-0-0-4

E-0-0-7

E-0-0-8

E-0-1-2

E-0-1-3

Battery temperature out of range. Algorithm dependent.

Reverse polarity

Battery does not take current

39

10.2 Charger Error Codes (continued) Code

Description

Solution

E-0-1-6 E-0-1-8

Software upgrade failed

•

Ensure the USB flash drive is properly formatted and is not corrupted.

•

Ensure the USB ash drive does not draw excessive current.

•

Copy the install les to the USB ash drive again ͘

•

Retry the update by reinserting the USB Flash Drive into the charger.

•

If software updates continue to fail, contact Delta-Q.

•

Remove and re-insert the USB Drive.

•

Ensure the USB flash drive is properly formatted and is not corrupted.

•

Ensure the USB ash drive does not draw excessive current.

•

If the condition persists then remove AC and battery for minimum 30 seconds and retry charger.

•

If the problem persists then contact Delta-Q for further help.

E-0-1-7

USB mount/unmount error

E-0-1-9

Hardware build does not support software version

•

The charger hardware does not support the new software version trying to be programmed. Existing SW is left running. Contact Delta-Q.

E-0-2-0

No active algorithm selected

•

Reprogram the charger with its original software, algorithms, and settings.

•

Use the wrench button to select the correct algorithm if still available on the charger.

•

The problem will clear automatically when an available algorithm is set on the charger as default.

•

When already full, some new batteries may exhibit this error. Cycle the batteries and see if it reoccurs.

•

Check battery size and condition. Resistive batteries in poor condition may cause this. Some new batteries if charged when already full will also cause this. Cycle the batteries a few times.

•

Check the battery voltage and cable connections.

•

This error will automatically clear once the condition has been corrected.

•

Another device may be drawing current from the battery.

•

Check the battery voltage and cable connections.

•

Check battery size and condition. Batteries may be over-discharged.

Use another charger to bring the batteries above the minimum voltage.

•

This error will automatically clear once the condition has been corrected.

E-0-2-1

E-0-2-2

High battery voltage while charging.

Algorithm dependent ʹ typically 2.8V/cell

Low battery voltage while charging.

Algorithm dependent ʹ typically 0.1V/cell

E-0-2-3

High AC voltage error (>270VAC)

•

AC voltage is too high. Connect charger to an AC source that provides stable AC between 85 Ͳ 270 VAC / 45-65 Hz. This error will automatically clear once the condition has been corrected.

E-0-2-4

Charger failed to turn on properly

•

Disconnect AC input and battery for 30 seconds. If error persists, contact Delta-Q.

E-0-2-5

AC voltage has dipped below 80VAC 3 times in 30 seconds

•

AC source is unstable. This could be caused by an undersized generator and/or input cables that are too long or too small. Connect charger to an AC source that provides stable AC between 85 Ͳ 270 VAC / 45-65 Hz.

•

This error will automatically clear once the condition has been corrected.

40

10.2 Charger Error Codes (continued) Code

Description

Solution

E-0-2-6

One or more USB script commands failed

•

Ensure the USB flash drive is properly formatted͘

•

Ensure the right update package is being used ͘

•

Copy the install les to the USB ash drive again ͘

•

Retry the update by reinserting the USB Flash Drive into the charger.

•

If software updates continue to fail, contact Delta-Q.

E-0-2-7

USB overcurrent fault

•

USB hardware overcurrent protection has been tripped. Remove and reinsert USB ash drive. If condition persists, try using a di erent USB ash drive.

E-0-2-8

Attempt to select algorithm incompatible with this software

•

Update charger software, continue to use existing algorithm* or select a di erent charging algorithm that is compatible.

*Notes:

•

If selection of a di erent algorithm, then the existing algorithm will remain in the charger

•

If upgrading existing algorithm then existing algorithm will be deleted, please contact Delta-Q for a software upgrade to run the new algorithm.

E-0-2-9

Cannot transmit on CAN bus

•

Check the physical CAN connector, electrical bus conditions and other CAN modules for correct functioning. For example, check termination resistance is approximately 60 ohms.

E-0-3-0

CAN heartbeat timeout on Battery module

•

May be caused by a missing heartbeat message. Check the CANbus battery module for correct function.

•

This error will automatically clear once the condition has been corrected.

The Vref for the ADC measurements has triggered an alarm

•

Internal charger error. Remove AC and battery for minimum 30 seconds and retry charger.

•

If the problem persists, contact Delta-Q.

•

This error will automatically clear once the condition has been corrected.

Battery temperature sensor is missing or shorted

•

Check if sensor is connected correctly.

•

The charger behavior when this fault occurs can be con gured. OEMs may contact Delta-Q for more information.

•

This error will automatically clear once the condition has been corrected.

CANOpen reprogramming failed

•

Re-try CANOpen download or re-program using the USB

•

This error will automatically clear once reprogramming has completed successfully.

Fan will not turn

(Fan-equipped models only)

E-0-3-1

E-0-3-6

E-0-3-7

E-0-3-8

E-0-4-0

Fan voltage pulled low

•

Check fan connections for loose wires.

•

Check rotor is not locked, or fan is not obstructed. Inspect the fan and clear the blockage.

•

This error will automatically clear once the condition has been corrected.

(Fan-equipped models only)

•

Ensure the fan is not stuck, sticking, or otherwise overloaded.

41

RAYMOND SERVICE INFORMATION

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

RSI MUL-16-001

Models

February 19, 2016

Multi-Product

SUBJECT:

New Horn Available

GENERAL INFORMATION:

A new horn (P/N 1233519/XXX), designed to perform better in cold storage environments, is available to replace horn P/N 1047433/XXX.

SERVICE INFORMATION:

Order and install P/N 1233519/XXX. Refer to Figure 1 for correct bracket configuration.

To install the new horn: Connect Horn(+) and Horn(–) wires to the new horn. Make sure the horn bracket is isolated from the truck frame.

Figure 1 NOTE: If necessary (3-wire to 2-wire conversion), install ½ in. heat shrink tubing (P/N 611-013) over the unused spade connector and wire. Fasten the unused wire back to the harness using a ty-rap (P/N 611-029) or equivalent.

®

Raymond is a registered trademark of The Raymond Corporation 2016 The Raymond Corporation.

FOTP-0060/1-7-15/F

RSI MUL-16-001 Page 1 of 2

PARTS AVAILABILITY:

Now available through the Parts Distribution Center.

FILING INSTRUCTIONS:

File this notice in Maintenance Manuals: • PDMM-0080-01 (EF) next to page 7-109 • PDMM-0092 (TRT) next to page 7-148 • 1010298-2 (RCS20/30/40, RSS22/30/40 & RRS30) next to page 233 • 1031794B (5400/5500/5600) next to page 7-61 • 1031940A (ET-F) next to page 7-53 • 1034066E (8300/8400/8500/8600) next to page 7-45 • 1043922A (5200) next to page 7-47 • 1087856D (8900) next to page 7-3 • 1089026A (9300/9400) next to page 7-41 • 1089040B (9600/9700) next to page 7-39 • 1106240D (8300/8400/8500/8600) next to page 7-63 • 1112860B (7500/7520) next to page 7-69 • 1119828C (4150/4250) next to page 7-51 • 1119847A (EZ-C/EZ-D) next to page 7-77 • 1134255A (3010/3020) next to page 7-45 • 1137893B (7700/7720) next to page 7-59 • 1146947A (6210) next to page 7-54 • 1193671A (4150/4250) next to page 7-49

®

Raymond is a registered trademark of The Raymond Corporation 2016 The Raymond Corporation.

FOTP-0060/1-7-15/F

RSI MUL-16-001 Page 2 of 2

RAYMOND SERVICE INFORMATION

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

RSI PLT-15-015

Models

January 5, 2016

6210, 8210

SUBJECT:

E250 code with Delta Q Charger

GENERAL INFORMATION:

When the Delta Q Charger goes into sleep mode, a Code E250 will be displayed.

SERVICE INFORMATION:

After 18 days of inactivity, the Delta Q charger will go into sleep mode. It must be plugged into AC power in order to function again. When the charger is plugged into AC power, it goes through a Reset. The timer will be set to 490 days instead of 18.

Also, when the charger enters sleep mode, it will not communicate with the lift truck, and it will cause the lift truck to display an E250 code. The E250 code will self-clear when the charger is plugged into AC power, and it resets from sleep mode.

There are two ways to reset the charger: 1. If you wait until the E250 code is displayed, the truck will be inoperable. To reset it, plug the charger into AC power. The code and the timer will be reset.

2. To force a reset before the truck generates the E250 code and shuts down: a. Disconnect one of the battery terminals to the charger for 30 seconds. b. Reconnect the cable. c. Plug the charger into AC power to reset it.

This will force the reset before the truck generates the E250 code.

PARTS AVAILABILITY: FILING INSTRUCTIONS:

®

N/A

File this notice in Maintenance Manuals: • 1146945A (Model 8210) next to page 6-28 • 1146947A (Model 6210) next to page 6-31.

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

FOTP-0060/1-7-15/F

RSI PLT-15-015 Page 1 of 1

RAYMOND SERVICE INFORMATION

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

RSI PLT-15-014

Models

November 30, 2015

3010, 3020, 83x0, 84x0, 85x0, 86x0, 8900, RCS20/30/40, RSS22/30/40, RRS30

SUBJECT:

New Horn Available

GENERAL INFORMATION:

A new horn is available to replace horns P/N 590-643/XXX and 23309-XX. The new horn can be used on 24 – 48 volt trucks.

SERVICE INFORMATION:

When replacing the horn: 1. Order and install the correct horn for the truck model as identified in the following table.

Model Number 3010 3020 83x0 84x0 85x0 86x0 8900 RCS20/30/40 RSS22/30/40 RRS30 2.

3.

4.

5.

®

Old Horn P/N 590-643/104 590-643/104 590-643/104 590-643/104 590-643/104 590-643/104 590-643/104 23309-01 23309-01 23309-01

New Horn P/N 1047433/002 1047433/002 1047433/002 1047433/002 1047433/002 1047433/002 1047433/002 1047433/003 1047433/003 1047433/003

Connect the main harness Horn+ and Horn– terminals to the horn.

Cover the unused harness terminal with ½ inch heat shrink tubing (P/N 611-013).

Secure the unused terminal to the harness using straps (P/N 611-029) or equivalent.

Make sure that the horn bracket is isolated from the frame of the truck (if applicable).

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

FOTP-0060/1-7-15/F

RSI PLT-15-014 Page 1 of 2

PARTS AVAILABILITY: FILING INSTRUCTIONS:

®

Now available through the Parts Distribution Center.

File this notice in Maintenance Manuals and Parts Manuals for each of the models listed at the top of page 1.

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

FOTP-0060/1-7-15/F

RSI PLT-15-014 Page 2 of 2

RAYMOND SERVICE INFORMATION

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

RSI MUL-15-007

Model

September 10, 2015

Multi-Product

SUBJECT:

Electrical Troubleshooting

GENERAL INFORMATION:

Many electrical components are being replaced and, when tested, no problems are found with the component.

SERVICE INFORMATION:

Before replacing an electrical component, disconnect and clean all jack/pin connectors on the component(s) with contact cleaner (P/N 996-600/CC2). Reconnect and retest truck.

PARTS AVAILABILITY:

Now available through the Parts Distribution Center.

FILING INSTRUCTIONS:

File this notice in Maintenance Manuals: • 1010183C (102XM) next to page 5-4 • 1134255A (3010/3020) next to page 5-3 • 1043922A (5200) next to page 5-6 • 1031794B (5400/5500/5600) next to page 5-13 • 1152122B (8310/8410/8510/8610) next to page 5-3 • 1087856D (8900) next to page 5-12 • 1112860B (7500/7520) next to page 5-2 • 1137893B (7700/7720) next to page 5-2 • 1089026A (9300/9400) next to page 5-2 • 1113065A (4450) next to page 5-5 • 1160093A (4700) next to page 5-7 • 1193671A (4150/4250) next to page 5-2 • 1089040B (9600/9700) next to page 5-2 • 1055925B (RAS 20/25) next to page 5-3 • 1010298-2 (RCS20/30/40 RSS22/30/40 RRS30) next to page 198

®

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

FOTP-0060/1-7-15/F

RSI MUL-15-007 Page 1 of 1

RAYMOND SERVICE INFORMATION

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

RSI PLT-15-011

Model

September 1, 2015

RAS

SUBJECT:

Scheduled Maintenance Procedure

GENERAL INFORMATION:

Check the torque of the outrigger assembly adjusting bolts during Scheduled Maintenance (SM).

SERVICE INFORMATION:

On page 4-4 of Publication 1055925B, add outrigger assembly adjusting bolts to the list of components next to hardware. Use the torque wrench check procedures called out in MUL-15-006. If the bolts are loose, refer to the tightening sequence on page 7-72.

The list of hardware to check on page 4-4 is not meant to be all inclusive; all hardware should be checked for correct tightness using the methods described in MUL-15-006.

FILING INSTRUCTIONS:

®

File this notice in Maintenance Manual 1055925B next to page 4-4.

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

FOTP-0060/1-7-15/F

RSI PLT-15-011 Page 1 of 1

RAYMOND SERVICE INFORMATION

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

RSI PLT-15-009

Models

July 27, 2015

102XM, RAS20/25

SUBJECT:

New Battery Pack and Charger

GENERAL INFORMATION:

The production battery packs for the 102XM and RAS20/25 have been changed and no longer use the MAC charger (P/N 1078082). The MAC charger is still available as a service part for packs originally equipped with that charger.

SERVICE INFORMATION:

There is a new battery pack and charger being shipped with the 102XM and RAS. Due to dimensional changes, the new Delta-Q charger (P/N 1190648/001) will not fit in the previous battery packs. To order the new battery pack and charger, use the table below for the correct part number.

Model 102 102 102 RAS RAS RAS

Part Number 1202787/007 1202787/009 1202787/011 1202787/013 1202787/015 1202787/017

Battery Type Wet Cell Wet Cell AGM Wet Cell Wet Cell AGM

Batteries Included No Yes Yes No Yes Yes

Part numbers for replacement parts will be released in the near future.

PARTS AVAILABILITY: FILING INSTRUCTIONS:

®

Now available through the Parts Distribution Center.

File this notice in Maintenance Manuals: • 1010183C (102XM) next to page 7-32 and make a note in the parts manual.

• 1055925B (RAS20/25) next to page 7-34 and make a note in the parts manual.

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

FOTP-0060/1-7-15/F

RSI PLT-15-009 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 INFORMATION

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

RSI PLT-15-004

Model

April 21, 2015

RAS20/25

SUBJECT:

Telescopic Wear

GENERAL INFORMATION:

The RAS20/25 is designed to lift loads that have the center of gravity in line with the center of the carriage. If the truck is used with off-center loads, the carriage guides can wear a groove into the inner telescopic. Should the inner telescopic be damaged, a kit has been developed that adds rollers on either side of the carriage to prevent further damage. All trucks manufactured after serial number RAS-15-07225 have the rollers installed from the factory.

SERVICE INFORMATION:

Some wear is normal on the inner telescopic. The difference between normal wear and damage that requires repair is described on page 2. Repair instructions begin on page 3.

There are two styles of carriages used on the RAS. The serial number for the old carriage that was installed on trucks is approximately RAS-10-03922 and below. The starting serial number for the new carriage installed on trucks is approximately RAS-10-03923. If your truck is near this serial number break, refer to the drawings below to order the correct kit.

“Old Carriage” Use kit P/N 1213813/002 PARTS AVAILABILITY:

®

“New Carriage” Use kit P/N 1213813/001

Now available through the Parts Distribution Center.

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

FOTP-0060/1-7-15/F

RSI PLT-15-004 Page 1 of 6

FILING INSTRUCTIONS:

File this notice in Maintenance Manual 1055925B next to page 7-68.

Mast Inspection During Scheduled Maintenance, inspect the inner rails of the telescopic for wear. Compare the results with the photos below. Take the action noted. Remember to clean and lubricate the mast every Scheduled Maintenance.

Normal operation: The paint is worn; no ridges are felt between the worn area and the rest of the channel.

Lubricate at Scheduled Maintenance

Wear pattern is worn greater than 0.060 in. (1.5 mm) deep. Ridges are forming on the sides of the worn area. Remove the ridges and install the carriage rollers.

Refer to the repair procedure on the following pages.

Wear area shows signs of the carriage guide digging into the channel. Smooth the rail and install the carriage rollers.

®

Refer to the repair procedure on the following pages.

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

FOTP-0060/1-7-15/F

RSI PLT-15-004 Page 2 of 6

Trucks built before approximately serial number RAS-10-03923 have a butterfly shaped carriage which has the carriage bearings closer together than the ITA carriage used on later serial numbers. Identify which kit you need by comparing the carriage to the drawings on page 1.

Serial Number Range Kit Number Kit Contents: Roller Bracket Thin Shim (16 GA) Thick Shim (20 GA) 3/8-16 x 1.5 Socket Head Cap Screw 3/8-16 x 2 Hex Head Cap Screw 3/8-16 Nut

Approximately RAS-10-03922 and Below 1213813/002 Part Number 1213790/001 1213811/002 1213812/003 1213812/004 1133697/004 11143-08 11261-06

Approximately RAS-10-03923 and Above 1213813/001 Part Number 1213790/001 1213811/001 1213812/001 1213812/002 1133697/004 11143-08 11261-06

Quantity 4 2 2 2 4 4 4

Repair Procedure Required Tools and Supplies 9/16 Socket and ratchet 9/16 Wrench 5/8 Hex drive bit.

3/8 Drive torque wrench Electric Drill 1/8 Drill bit 5/16 Drill bit 3/8-16 UNC-2B tap 25/64 Drill bit (Optional but helpful) Center punch Small ball-peen hammer (For center punch) Adjustable square or steel ruler Two large clamps 4” Grinder and medium grit flap disc Shop Towels NLGI-2 grease (P/N 990-620) Thread-Locking Compound (P/N 1013829) Cotter Pin (P/N 810-910) Black touch up paint Railroad jack (or equivalent low profile, high lifting jack)

®

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

FOTP-0060/1-7-15/F

RSI PLT-15-004 Page 3 of 6

Preassemble Bearing Brackets Preassemble the carriage lateral bearing brackets using the 3/8-16 Hex Head Cap Screws, 3/8-16 Nuts, and Rollers.

1. Place the bolt through the roller then through the bracket and fasten with the nut. The rollers will be on opposite sides of the bracket.

2. If the bolts have pre-applied thread-locking compound, torque to 30 ft. lb. (40 Nm), otherwise apply thread-locking compound (P/N 1013829) and torque to 23 ft. lb. (31 Nm).

Note: The left and right brackets, as you are facing the forks, are mirror images of each other.

Refer to the photos below.

Left

Right

Installation Procedure Assemble the brackets to the carriage. The procedure on the following pages assumes that one technician is performing the rework without the use of a hoist. Alternative methods, if a suitable hoist is used, are included.

1. Lower the carriage fully. Use a railroad jack to lift the carriage enough to create slack in the lift chain.

If using a hoist, remove the forks, attach the hoist to the carriage, and lift the carriage with the hoist just enough to create slack on the lift chain.

2. Remove the lift chain cotter pin from the lift chain at the carriage. Remove the lift chain anchor pin.

Note: When lifting the telescopic, take care that the lift chain does not feed all the way through the pulley.

3. Carefully raise the mast until the telescopic just clears the upper carriage bearings.

If using a hoist, lower the carriage onto the floor prior to raising the telescopic.

Note: It may be difficult to guide the chain anchor bracket past the lower telescopic cross tie. You may need to pry the bottom of the carriage forward and the telescopic back. If necessary, a slight bevel may be ground on the top of the cross tie. Only remove enough material as necessary.

4. Back the truck away from the carriage.

Suggestion: If you are doing the work on the floor, leave the forks on the carriage so that the carriage sits upright. This makes it easier to drill and tap the mounting holes. If you are moving the carriage to a suitable work surface, tip the carriage onto its back and remove the forks first. Use a hoist to move the carriage.

5. Lay the carriage fork-side down on a suitable work surface. ®

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

FOTP-0060/1-7-15/F

RSI PLT-15-004 Page 4 of 6

6. Clean the carriage bearing assemblies and mounting plate. Remove and discard the guides and wave washers from all four bearings, items 13 (P/N 1084997) and 18 (P/N 22707) in the illustration below.

7. Use the bearing mounting bracket as a guide to mark the locations for the holes to be drilled and tapped. a. Position the bearing mounting bracket so that the 3/4 inch surface of the bearing mounting bracket on the carriage bearing plate is centered between the two carriage bearings and 1 inch from the back edge of the carriage bearing plate.

b. Clamp in place.

8. Center punch the holes.

Note: It may be helpful to use a 25/64 drill bit and lightly tap the end with a hammer while rotating the bit to mark the location.

9. Remove the brackets and center punch the marks after removing the bracket.

10. Drill out the mounting holes with a 5/16 bit. It may be helpful to first drill a 1/8 pilot hole. Take care to make sure the hole is perpendicular to the bearing plate. If working on the carriage in an upright position, stuff a shop towel behind the lower bearing.

11. Tap the drilled holes using a 3/8-16 UNC-2B tap.

12. Repeat steps 9 through 11 on the other side.

13. Clean and de-burr the holes if needed. Clean up any metal shavings.

14. Install each carriage bearing bracket with one thick shim using the 3/8-16 socket head cap screws. Position the bracket so that the top roller is toward the forks and the bottom roller is toward the tractor.

15. If the screws have pre-applied thread-locking compound, torque to 30 ft. lb. (40 Nm), otherwise apply thread-locking compound (P/N 1013829) and torque to 23 ft. lb. (31 Nm).

16. Clean the inside of the telescopic of old grease.

17. Using the flap disc, clean off the sharp edges on the groove in the telescopic if necessary. ®

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

FOTP-0060/1-7-15/F

RSI PLT-15-004 Page 5 of 6

18. Grease the inside of the telescopic.

19. If not using a hoist and the forks were previously removed, place the carriage so that the fork-side is facing up and reinstall the forks. Then tilt the carriage upright.

20. Position the carriage under the telescopic so the bearings line up with the telescopic.

21. Slowly lower the telescopic onto the carriage, a small amount at a time, to make sure that the bearings go into the telescopic.

Note: If the lower cross tie is catching on the chain anchor block, it may be necessary to pry the carriage forward and the telescopic back. If necessary a slight bevel may be ground on the bottom of the cross tie.

Only remove enough material as necessary.

22. When the telescopic is fully lowered, raise the carriage with the railroad jack (or with the hoist) enough to install the lift chain. Install a new lift chain cotter pin.

23. Lift the carriage slowly to the full elevated height. Make sure the carriage does not bind at full extension.

24. Lower the carriage to approximately waist height and manually rock the carriage.

25. If the carriage is too tight at full extension, the shims must be changed to the thin shims or removed entirely.

If the carriage is loose at full extension and rocks excessively at waist level, install the remaining two shims from the kit.

26. To add or remove the shims, remove the carriage using steps 1 through 3. Working one side at a time, remove the carriage lateral bearing mounting brackets and add or remove one shim on each side.

27. Reinstall the carriage using steps 22 through 24.

28. Install a new cotter pin on the lift chain anchor. Adjust the fork height if necessary.

29. Touch up the paint as necessary.

30. Retest the carriage to verify correct operation.

31. Test all truck functions and return to service.

®

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

FOTP-0060/1-7-15/F

RSI PLT-15-004 Page 6 of 6

RAYMOND SERVICE INFORMATION

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

RSI PLT-13-001

Models

March 21, 2013

RAS20/25

SUBJECT: GENERAL INFORMATION:

Tiller Switch Arm Failures

If operating in applications that are subject to sticky substances, such as soda, fruit juices and syrups, a number of things have been seen.

1. The switch arm may become stuck in the open or closed position, by contamination.

2. The arm may remain free, but switch button actuation may be blocked by contamination.

3. The roller may fail to roll/slide on the cam and actuating slopes damaging the arm.

4. Corrosion may interfere with the connection between the switch and the harness.

Any of these circumstances may lead to a code C14 and/or E112, or possibly only allow slow travel speed without any code.

Note: The RAS20 and RAS25 are not designed or intended for use in freezer applications. They are only rated down to 32ºF (0ºC) and no cold storage option is available.

Raymond is a registered trademark of The Raymond Corporation 2013 The Raymond Corporation.

FOTP-0060/1-23-12/C ®

RSI PLT-13-001 Page 1 of 3

SERVICE INFORMATION:

For any truck operating in the application described, use the steps below.

1. On serial numbers between RAS-11-04254 and RAS-07-02436: Follow PLT-11-003 installation instructions for the plastic switch bridge replacement.

On serial numbers below RAS-07-02436: If the steps below do not correct the issues, the new tiller must be installed prior to performing the update in PLT-11-003. See page 3 to identify which tiller arm the truck has.

2. To help with switch arm and button protection, apply Dow Corning Electrical Compound (P/N 302249-000) around the switch arm as shown in Figure 1.

3. For further protection, apply Electrical Compound to the surface that the switch arm roller rides on.

4. For terminal protection, apply a generous coating Electrical Compound, enough so some squeezes out when the harness is connected, to the switch terminals before installing the harness connectors. Make sure the connectors are well seated, as this material is an insulator rather than a conductor.

CAUTION: Do not use the Dow Corning Electrical Compound in dusty environments. The compound may retain powder contamination and interfere with switch actuation.

Figure 1: Switch with Electrical Compound Applied

PARTS AVAILABILITY:

Now available through the Parts Distribution Center.

FILING INSTRUCTIONS:

File this notice in Maintenance Manual 1055925A next to page 6-22. Make a note on pages 5-14 and 5-10.

Raymond is a registered trademark of The Raymond Corporation 2013 The Raymond Corporation.

FOTP-0060/1-23-12/C ®

RSI PLT-13-001 Page 2 of 3

Raymond is a registered trademark of The Raymond Corporation 2013 The Raymond Corporation.

FOTP-0060/1-23-12/C ®

RSI PLT-13-001 Page 3 of 3

RAYMOND SERVICE INFORMATION

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

RSI PLT-12-005

Models

April 19, 2012

RRS, RCS, RSS

SUBJECT:

Scheduled Maintenance Information Update

GENERAL INFORMATION:

Restatement of Scheduled Maintenance tasks in Maintenance Manual 1010298-2.

SERVICE INFORMATION:

Place the information in the information on pages 2 thru 12 next to the page 71 and cross out the previous information on the Planned Maintenance chart. Also cross out the information on page 405 for fork inspection and make a note to reference the attached document.

PARTS AVAILABILITY:

NA

FILING INSTRUCTIONS:

File this notice in Maintenance Manual 1010298-2 as described above.

Raymond ® is a registered trademark of The Raymond Corporation 2012 The Raymond Corporation.

FOTP-0060/1-23-12/C

RSI PLT-12-005 Page 1 of 12

Scheduled Maintenance Guidelines Following a regularly scheduled maintenance program: •

promotes maximum truck performance

•

prolongs truck life

•

reduces costly down time

•

avoids unnecessary repairs

Scheduled maintenance includes: •

Lubrication

•

Cleaning

•

Inspection

•

Service

Perform all of the scheduled checks and maintenance during the suggested intervals. The time intervals given in this guide are based on Deadman Hours (HD) under normal operating conditions.

When operating under Severe or Extreme conditions, perform these services more often as indicated in the chart below.

Operating Conditions

Working Environment

Service Frequency

Light to Moderate

An eight hour shift of basic material handling

180 days or 500 hours, whichever comes first

Severe

• Extended heavy duty operation

250 hours

• Freezer operation • Sudden temperature changes such as going from freezer to room temperature Extreme

• All UL Type EE rated lift trucks

100 hours

• Dusty or sandy conditions such as in cement plants, lumber or flour mills, coal dust or stone-crushing areas • High temperature areas such as in steel mills, foundries, enclosed (Type EE) applications • Corrosive atmosphere such as in chlorine or salt-sea air environments

Raymond ® is a registered trademark of The Raymond Corporation 2012 The Raymond Corporation.

FOTP-0060/1-23-12/C

RSI PLT-12-005 Page 2 of 12

Initial 90 Day/250 Deadman Hour (HD) Maintenance Perform the following maintenance tasks 90 days or 250 HD after the truck was put into service, whichever comes first.

Component

Task

Drive Unit

Change fluid.

Hydraulic Tank

Change fluid and clean filter screen and magnet.

Raymond ® is a registered trademark of The Raymond Corporation 2012 The Raymond Corporation.

FOTP-0060/1-23-12/C

RSI PLT-12-005 Page 3 of 12

Every 180 days or 500 Deadman Hours (HD) Perform the following maintenance tasks every 180 days or 500 HD, whichever comes first.

Component

Task

Battery

Check the weight stamped on the battery in the lift truck against the minimum and maximum allowable weights on the spec tag for the lift truck. Report any lift trucks that are running with batteries under the minimum or over the maximum allowable weight. Inspect all battery connectors and leads for damage and cuts in protective coatings. If equipped, make sure the battery gates are in place and not damaged. Make sure the battery has no more than 0.5 in. (13 mm) free play in any direction.

Brakes

In an open area, measure stopping distance. (See Brake Adjustment on page 147). Stopping distance depends on the load, floor, and tire condition. Remove brake drum and examine for signs of oil on the shoes or drum. If oil is present, disassemble and clean the drum, and replace the shoes.

Measure thickness of pad and replace shoes when worn to the thickness of the steel backing plate or when the stopping distance cannot be obtained.

Caster Wheel(s)

Examine for bond failure, chunking, and excessive or uneven wear. Inspect bearings for binding or excessive play. Check adjustment of caster wheel(s). (See page 159.)

Contactor (Not Sealed)

Inspect contactor tips for burnt or pitted surfaces. Failure to replace the tips may prevent the contactor from opening or closing causing unscheduled downtime. With the key switch OFF and the battery disconnected, check the plunger for smooth operation with no binding. If binding occurs, the lift truck may malfunction or exhibit intermittent fault codes.

Controls

Verify lift/lower function is smooth and controllable. Verify travel function is smooth and responsive through full range of motion. Check for play in the center position of travel control. Verify no codes on display. Verify function of all switches. Verify the control arm returns to the full upright position when released. Test the operation of all other controls/functions; verify they are smooth and controllable. Check that steering system function is smooth and responsive. Inspect pivot points and bearing.

Drive Unit

Check oil level. Inspect for leaks. Check drive axle for play.

Electrical Cables

Inspect all power cables for nicks or cuts. Give special attention to those cables that are not stationary, for example, cables to the drive motor. Replace any cable that is damaged or shows signs of excessive heat. Failure to do so may cause intermittent system shutdowns and/or electronic failures. Check the tension of the over-the-mast pulley cables. Set tension so the cables just stay on the pulleys. Higher tension will cause premature failure. Make sure over-the-mast pulleys spin freely and show no signs of wear.

Forks

Inspect following the inspection procedures on page 7 of this document.

Frame and Baseleg Checks

General visual inspection of structural members for cracks, including but not limited to baselegs, main frame and tractor.

Hardware

Check bolt torque of major components (drive motor, brake, mast-to-tractor mounting bolts, hydraulic pump and motor assembly, and so forth). Tighten any loose hardware. Replace any broken or missing hardware. See Torque Specs on pages 56 and 57.

Horn

Check that horn sounds when activated.

Raymond ® is a registered trademark of The Raymond Corporation 2012 The Raymond Corporation.

FOTP-0060/1-23-12/C

RSI PLT-12-005 Page 4 of 12

Hydraulic Hoses

Inspect all hydraulic hoses for leaks, nicks, cut, chafing, and bulges. Replace damaged hoses as soon as possible. Inspect all fittings for leaks. Repair any leaks immediately. Inspect over-the-mast hoses for correct tension. Make sure over-the-mast pulleys spin freely and show no signs of wear.

Hydraulic Reservoir

Check fluid level.

Lift Chains

Check adjustment. Inspect for excessive stretch or wear (tool P/N 950-350/CG). Lubricate.

Lubrication

Lubricate all grease points. Lubricate fork positioning locks. Lubricate all pivoting shafts on control arm with spray lube. Lubricate the upper and lower bar where the pads slide on the sideshifter. See pages 85 thru 87.

Mast

Wipe old grease off mast uprights and apply new grease. Examine mast bearings. Inspect mast and carriage stops for tightness and wear. Inspect rails for abnormal wear, metal flakes, or shavings.

Motors

DC - Visually inspect the brushes for excessive heat (discoloration of the pigtails). If excessive heat is evident, inspect the armature circuit for loose connections. Check condition of commutator. Find the shortest brush in the holder. Remove the brush and check the overall dimension as listed in the charts on pages 63 and 65. Inspect the brush for even wear over the full surface of the brush. If the brush is not contacting the complete surface, replace the brushes. Inspect the brush rigging for damage or loose brush holders. Make sure that the connections on the brush leads are tight. Check brush spring tension (pages 63 and 65). Blow out the inside of the motor with compressed air. Check the cable lugs to make sure they are right to the terminal studs. Both the inside and outside nut should be torqued to the values listed. Replace any cable that shows signs of excessive heat.

Shorts to Frame

Check for electrical shorts to frame per page 201. Wipe compartments clean.

Sideshift

Make sure cap screws securing the lowering mounting hooks to the carriage bar are tight. Inspect upper and lower bearing segments per page 381. If segments measure less than (1.5 mm), replace them. Replace segments as a set on the top or bottom as required.

Switches

Check all switches for correct operation and adjust as needed.

Warning Decals

Replace any illegible or damaged decals.

Wheels and Tires

Examine for bond failure, chunking, and excessive or uneven wear. Inspect load wheel bearings for binding or excessive play.

Raymond ® is a registered trademark of The Raymond Corporation 2012 The Raymond Corporation.

FOTP-0060/1-23-12/C

RSI PLT-12-005 Page 5 of 12

Every 360 Days Perform the following maintenance tasks every 360 days.

Component

Task

Drive Unit

Change fluid.

Hydraulic Tank

Change hydraulic fluid and clean the filter screen/magnet, and flush the tank.

4

Raymond ® is a registered trademark of The Raymond Corporation 2012 The Raymond Corporation.

FOTP-0060/1-23-12/C

RSI PLT-12-005 Page 6 of 12

Fork Inspection The following tools are required to perform fork inspection: •

Fork Wear Caliper (P/N 922-369)

•

Tape Measure or ruler

•

24 in. Framing Square

•

4 ft. Level

Do the following when performing Scheduled Maintenance.

Surface Inspection Remove the forks from the carriage. Visually inspect all fork surfaces for signs of damage, including, but not limited to: •

cracks

•

excessive wear

•

excessive heat

•

deformation

•

unauthorized modifications

Pay special attention to the heel and welds attaching mounting components. If any damage is found, remove the fork from service.

Straightness of Blade and Shank Note: This measurement can be done with the forks on or removed from the carriage.

1.

Measure the length of the blade and the height of the shank. See Figure 1-1.

Figure 1-1. Measuring Fork Blade and Shank

Shank Blade

4forkFacts1.svg

2.

Multiply these numbers by 0.5%. The smallest number is your maximum deviation.

• Length of blade _____ x 0.5% = ______ • Height of shank _____ x 0.5% = ______

3.

Place a 24 in. framing square on the blade of the fork, 2 in. away from the heel of the fork. See Figure 1-2.

Raymond ® is a registered trademark of The Raymond Corporation 2012 The Raymond Corporation.

FOTP-0060/1-23-12/C

RSI PLT-12-005 Page 7 of 12

4.

At 21 in., measure the distance between the face of the shank and the framing square. See Figure 1-2.

Figure 1-2. Fork Measurement with Framing Square

4

5.

Compare this measurement, minus 2 in., to the smallest maximum deviation number determined in step 2.

6.

If the maximum deviation number is exceeded, remove the fork from service.

Fork Angle Note: This measurement can be done with the forks on or removed from the carriage.

1.

Place the fork caliper on the blade. Make sure that the two extruded points are touching the blade of the fork.

See Figure 1-3.

2.

Now open and move the caliper so the two extruded points are touching the shank. See Figure 1-3.Error!

Reference source not found.

Figure 1-3. Fork Angle Shank

Indicator Lines Blade

4ForkArmWearCaliperGuide_2.svg

3.

When all four extruded points are in contact with the fork, gently remove the caliper and note the reading on the indicator line, located right above the hinge pin. See Figure 1-3.

Raymond ® is a registered trademark of The Raymond Corporation RSI PLT-12-005 2012 The Raymond Corporation.

Page 8 of 12 FOTP-0060/1-23-12/C

4.

If the deviation is greater than 3° of the original angle, remove the fork from service.

Note: Most forks are manufactured with a 90° angle; therefore, a reading greater than 93° or less than 87° is unacceptable. However, there are some forks that are purposely manufactured to angles greater than or less than 90°.

Fork Tip Height 1.

With forks on the carriage, measure the length of the blade. See Figure 1-1.

• For forks 42 in. (106.7 cm) or less, max. deviation is 0.25 in. (6.3 mm).

• If length of fork is >42 in. (106.7 cm), multiply length of blade by 3%.

Blade length _____in. x 3% = _____in.

This is the maximum deviation.

2.

Elevate forks approx. 4 ft. (1.2 m) off the floor.

3.

Place a 4 ft. level across the tips of the forks. See Figure 1-4.

4.

Raise one end of the level to make it level. See Figure 1-4.

5.

Measure the distance from the tip of the fork. See Figure 1-4.

Figure 1-4. Measuring Fork Tip Height Forks

Distance from tip of fork

Level

Tips 4Fork Inspection.jpg

6.

Compare this measurement to the maximum deviation.

7.

If the maximum deviation number is exceeded, remove the fork from service.

Positioning Locks (if applicable) 1.

With the forks on the carriage, visually inspect the positioning locks for damage.

2.

Test the positioning locks to verify they work correctly.

3.

If the positioning locks are damaged or do not work correctly, remove the fork from service.

Raymond ® is a registered trademark of The Raymond Corporation 2012 The Raymond Corporation.

FOTP-0060/1-23-12/C

RSI PLT-12-005 Page 9 of 12

Wear Fork Blade and Shank 1.

Remove the forks from the carriage.

2.

Approx. half way up the shank, set the front teeth of the jaws of the caliper on the shank. Make sure the caliper is held square across the shank to get an accurate reading. The caliper is now set to measure fork blade wear. Carefully remove the caliper from the shank. See Figure 1-5.

Figure 1-5. Measuring Fork Shank

4Fork Inspection.jpg

3.

Measure 2 in. (50 mm) out from the heel of the fork.

4.

Place the caliper over the flanks of the fork arm blade at this 2 in. (50 mm) point. See Figure 1-6.

Figure 1-6. Measuring Fork Blade Wear

4Fork Inspection.jpg

5.

If the inside teeth of the caliper hit the fork, there is <10% wear. If the inside teeth pass freely over the fork arm, there is >10% wear and the fork must be removed from service.

Raymond ® is a registered trademark of The Raymond Corporation 2012 The Raymond Corporation.

FOTP-0060/1-23-12/C

RSI PLT-12-005 Page 10 of 12

CAUTION: If there is greater than 10% wear of the fork arm, the fork has at least a 20% reduction in capacity.

Note: The caliper is designed to measure forks up to 4 in. (100 mm). It is not to be used on full or lumber tapered forks. For these forks, you must know the original fork blade thickness and take a measurement of the fork arm thickness. If the difference in the measurement exceeds 10% of the original thickness, the fork must be removed from service.

Fork Hooks 1.

Remove the forks from the carriage.

2.

Determine the fork mounting class.

a.

Measure the height of the carriage or the distance between the hooks. See Figure 1-7.

Figure 1-7. Determining Fork Mounting Class Distance between hooks

Carriage Height 4Fork Inspection.jpg

b.

Compare this measurement to the table below.

Fork Mounting Class

Distance Between Hooks in. (mm)

Carriage Height in. (mm)

1

12.05 (306)

13 (331)

2

15.04 (382)

16 (407)

3

18.78 (477)

20 (508)

3.

Locate the correct extruded edge on the caliper for the fork mounting class. See Figure 1-8.

4.

Slide the extruded edge up into the hook pocket. See Figure 1-8.

Raymond ® is a registered trademark of The Raymond Corporation 2012 The Raymond Corporation.

FOTP-0060/1-23-12/C

RSI PLT-12-005 Page 11 of 12

5.

If the caliper’s extruded edge completely slides up into the fork pocket, remove the fork from service. See Figure 1-8.

Figure 1-8. Fork Hook Inspection

Fork Pocket

Fork Mounting Class designation 4Fork Inspection.jpg

Markings Make sure the fork’s marking (individual load rating) is legible (typically located on side of fork). If fork marking is not legible, remove the fork from service.

Raymond ® is a registered trademark of The Raymond Corporation 2012 The Raymond Corporation.

FOTP-0060/1-23-12/C

RSI PLT-12-005 Page 12 of 12

RAYMOND SERVICE INFORMATION

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

RSI PLT-11-003

Models

August 24, 2011

102XM and RAS

SUBJECT:

New Switch Bridge

GENERAL INFORMATION:

Release of new Switch Bridge and mounting hardware for Models 102XM and RAS.

SERVICE INFORMATION:

A new plastic switch bridge (P/N 1128318/001) has been released for use with 1066425 tillers. Use these instructions to replace the current metal switch bridge (P/N 1066427/001).

Note: This bracket is for use only with 1066425 tillers, shipped on trucks built after May 10, 2007. It will not work with 312677 tillers.

1. Bend the two lower terminals (the center terminal and the one under the actuating arm pivot, not the one under the roller) of switch (P/N 308030-000) up (towards the third terminal) about 20º - 30º. The diagonal orientation of the terminals causes them to bend to the side to some extent; do not try to force the terminals to remain centered. The top (unused) terminal may be bent if it is in the way. Do not bend the lower terminals more than necessary to fit in the stem head.

®

Raymond is a registered trademark of The Raymond Corporation 2011 The Raymond Corporation.

FOTP-0060/2-8-11/B

RSI PLT-11-003 Page 1 of 3

SERVICE INFORMATION (CONT.):

2. Place the switch (P/N 308030-000) onto the bracket, with the mounting hole (under the roller) on the molded bracket post. Secure the switch to the bracket using a blunt end self-tapping screw (P/N 1118885/001). Tighten just enough to prevent wiggle in the switch as this screw is going into plastic.

Switches installed on switch bridge with blunt end self-tapping screws

Upper switch hole mounted on molded bracket post

3. Remove the existing switch bridge assembly; do not disconnect the wires.

4. Remove the P-clamp. Reorient the tiller harness to the inboard side of the bolt to clear the switch. Reinstall the P-clamp holding the tiller harness.

P-Clamp

Tiller Harness

Bolt

5. Orient the bridge assembly as it will go in the truck: rollers up and facing the tiller. Remove the wires from the existing switch bridge assembly and install on new switches: the wires must remain on the same sides of the truck. Quick connects from the old middle terminals go on the new middle terminals and those from the old upper terminals go on the new lower terminals (closest to the switch lever pivot). ®

Raymond is a registered trademark of The Raymond Corporation 2011 The Raymond Corporation.

FOTP-0060/2-8-11/B

RSI PLT-11-003 Page 2 of 3

SERVICE INFORMATION (CONT.):

6. Position the bridge assembly on the stem head. Insert the projecting post into one of the tapped holes in the stem head. Make sure it is seated, or the bridge will break. Apply thread-locking compound (P/N 990-536) to the button head screw (P/N 5-007-022). Install screw through the bridge into the other tapped hole in the stem head. Torque to 15 in. lbs. (1.7 Nm). Use care not to over-tighten or you may damage the bridge.

Mounting Post

Button Head Screw Make sure tiller harness is routed under the pivot pin and between the flange on the spring drum and the plastic washer.

7. Test the truck to make sure that top brake, bottom brake, and a speed transition between are functioning correctly before returning the truck to service.

PARTS AVAILABILITY:

Now available through the Parts Distribution Center.

FILING INSTRUCTIONS:

File this notice in Maintenance Manual 1010183B next to page 6-24 for Model 102XM. File this notice in Maintenance Manual 1055925A next to page 6-22 for Model RAS.

®

Raymond is a registered trademark of The Raymond Corporation 2011 The Raymond Corporation.

FOTP-0060/2-8-11/B

RSI PLT-11-003 Page 3 of 3

RAYMOND SERVICE BULLETIN

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

Models

RSB PLT-10-001

102XM/RAS

July 29, 2010 SUBJECT:

Drive Motor Cable Routing

DESCRIPTION:

On some trucks produced between serial numbers RAS-09-03482 through RAS-10-03717 and 102-09-14174 through 102-10-15382, the drive motor cables may be too long and rub on the drive tire.

REMEDY:

Use cable ties and relocate the cables.

PROCEDURE:

Inspect the wires from the terminal block on the drive motor to the motor for damage.

Repair or replace any damaged wires. Verify all terminals on the block are tight. If the wires are near the drive tire, use cable ties to secure them out of the way.

PARTS AVAILABILITY:

Not Applicable.

WARRANTY:

Within normal Raymond policy guidelines.

Flat Rate Book Reference RAS Model 4051 Code 0.2 Time Flat Rate Book Reference 102XM Model 4051 Code 0.2 Time

FILING INSTRUCTIONS:

File this bulletin in Model 102XM Maintenance Manual 1010183B after page 6-10 and in Model RAS Maintenance Manual 1055925A after page 6-8.

®

Raymond is a registered trademark of The Raymond Corporation 2010 The Raymond Corporation.

FOTP-0006/jwr/01-11-10/F

RSB PLT-10-001 Page 1 of 1

RAYMOND PRODUCT IMPROVEMENT NOTICE

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

Models

RPIN PLT-10-R001

102XM / RAS

April 9, 2010 SUBJECT:

New Rocker Switch and PMT Procedures

DESCRIPTION:

Some customers did not want the key pad on Model 102XM and RAS trucks. When connecting a Programmable Maintenance Tool to an RAS20/25 or 102XM truck, the handheld fails to connect and display controller information. The message, “Controller does not support this function” is displayed by the PMT.

REMEDY:

A new double pole, single throw Main ON/OFF switch is now standard in place of a key pad on Models 102XM and RAS. The part number of the new switch is 1040406/001.

PROCEDURE:

With the installation of the new Main ON/OFF switch, the wiring harness changed. Use the schematics on pages 2 and 3 to troubleshoot trucks with the new switch.

The Main ON/OFF switch must be in the ON position for the Programmable Maintenance Tool to display controller information.

Leave the Main ON/OFF switch in the ON position. Turn OFF the truck by using the key switch, key pad, or by disconnecting wire #20 or wire #22 from the “dual” Main ON/OFF rocker switch (for Raymond trucks incorporating a “dual” rocker switch).

When the Programmable Maintenance Tool is connected to the truck and displaying controller information, restart the truck by using the key switch, key pad, or reconnecting wire #20 or #22 to the dual Main ON/OFF rocker switch.

PARTS AVAILABILITY:

Now available through the Parts Distribution Center.

FILING INSTRUCTIONS:

File this notice in Maintenance Manuals 1010183A next to page 5-24 and 1055925A next to page 5-31. Make a note in the Parts Manuals for the new switch part number.

Place the schematic next to page A 10 in Maintenance Manual 1010183A.

Raymond is a registered trademark of The Raymond Corporation 2010 The Raymond Corporation.

FOTP-0005/jwr/01-11-10/F

RPIN PLT-10-R001 Page 1 of 3

Raymond is a registered trademark of The Raymond Corporation 2010 The Raymond Corporation.

FOTP-0005/jwr/01-11-10/F

RPIN PLT-10-R001 Page 2 of 3

Raymond is a registered trademark of The Raymond Corporation 2010 The Raymond Corporation.

FOTP-0005/jwr/01-11-10/F

RPIN PLT-10-R001 Page 3 of 3

RAYMOND PRODUCT IMPROVEMENT NOTICE

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

RPIN GEN-09-R002

Models

October 13, 2009

General

SUBJECT:

Intermittent issues on truck with optional alarms.

DESCRIPTION:

The optional alarm (P/N 590-628/xxx) used on trucks as Travel, Lift/Lower, or other customer requested options has been found to cause intermittent truck issues and codes if not installed correctly.

REMEDY:

Inspect the negative connection on the alarm. If there is a ground strap connected between the connection and the mounting screw that attaches it to the frame, it must be removed. When installing new alarms, remove the grounding strap prior to installing the alarm.

PROCEDURE:

Disconnect the negative wires from the horn and remove the mounting screw that the strap is under. Remove the strap and reinstall the wires and hardware.

PARTS AVAILABILITY:

N/A

FILING INSTRUCTIONS:

File a copy of this Product Improvement Notice or make a note in all current manuals.

®

Raymond is a registered trademark of The Raymond Corporation 2009 The Raymond Corporation.

FOTP-0006/jwr/03-25-09/E

RPIN GEN-09-R002 Page 1 of 1

RAYMOND PRODUCT IMPROVEMENT NOTICE

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

RPIN PLT-08-R013

Models

November 12, 2008

102XM, RAS20/25, 8300, 8400, 8500, and 8600

SUBJECT:

Electronic Tiller Arm Card (ETAC) Ordering

DESCRIPTION:

The ETAC is programmed for specific truck models. Use Table 1. “ETAC Part Numbers” to determine correct ETAC.

REMEDY:

Table 1. ETAC Part Numbers Model 102XM RAS20/25 below S/N 2000 and below RAS20/25 S/N 2001 and above 8300 8400 8500 or 8600 with fixed handle 8500 or 8600 with spring handle

PROCEDURE:

Part Number 851-201-264/102 851-2A1-264/RAS 851-2B1-264/RAS 1053540/019 1053540/020 1053540/021 1053540/022

Replace the ETAC following all safety instructions found in the Maintenance Manual.

When TEST is displayed in the control handle after installing a new ETAC you must program the ETAC using TruckCom. Use the latest version of TruckCom, found on iNet, to program the ETAC.

PARTS AVAILABILITY:

Now available through the Parts Distribution Center.

Raymond ® is a registered trademark of The Raymond Corporation 2007 The Raymond Corporation.

FOTP-0005/jwr/03-16-07/D

RPIN PLT-08-R013 Page 1 of 2

FILING INSTRUCTIONS:

File this notice in the following Maintenance Manuals: Publication Title Number 1010183B Walkie Pallet Truck Model 102XM Serial Number 102-03-00500 – up 1010297A Adjustable Baseleg Walkie Straddle, Models RAS20/25 Serial Number 01000 – up 1034066C Pallet Trucks Models 8300, 8400, 8500, and 8600

Raymond ® is a registered trademark of The Raymond Corporation 2007 The Raymond Corporation.

FOTP-0005/jwr/03-16-07/D

After Page 5-9 4-36 5-36

RPIN PLT-08-R013 Page 2 of 2

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

Models

RSB PLT-08-005A

RRS/RCS/RSS

September 29, 2008

S/N RSS-08-03361 and Below, RRS-08-01552 and Below, and RCS-08-01397 and Below SUBJECT:

Premature Lift Motor Brush Wear

DESCRIPTION:

Brushes may wear quickly, resulting in a damaged motor.

REMEDY:

Replace old brushes with new brushes, P/N 200188/NB. Note: Replacement motors and power units have the new brushes installed and are available through the Parts Distribution Center. The old brush is still available for breakdown orders.

PROCEDURE:

Follow the procedure in Maintenance Manual 1010298 for brush replacement.

PARTS AVAILABILITY:

Available through the Parts Distribution Center after November 14, 2008.

WARRANTY:

Within normal Raymond policy guidelines.

Flat Rate Book Reference RRS/RCS/RSS Model 5215 Code 1 Time

FILING INSTRUCTIONS:

File this bulletin in Maintenance Manual 1010298 after page 132.

®

Raymond is a registered trademark of The Raymond Corporation 2008 The Raymond Corporation.

FOTP-0006/jwr/03-16-07/D

RSB PLT-08-005A Page 1 of 1

RAYMOND PRODUCT IMPROVEMENT NOTICE

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

RPIN PLT-07-R009A

Models

December 13, 2007

102XM, RAS20/25

SUBJECT:

Troubleshooting when the BDI does not reset to 100%.

DESCRIPTION:

Once the BDI reaches 0% on the display, the truck will enable lift lock out. This feature conserves the remainder of the battery charge. The truck can then be driven to a designated charging area and plugged in for recharging.

REMEDY:

Use these instructions to determine the cause of the BDI not resetting to 100%.

Refer to PLT-07-R016 for additional information regarding BDI reset (applies to the Model 102XM only).

PROCEDURE:

Use a good, high quality voltmeter. The reset voltage is 25.2 volts. The battery must remain at or above 25.2 volts while driving for 20 seconds.

1. Verify that wire #1 is on the top post of the main contactor and wire #2 is on the bottom post of the main contactor as shown in Figure 1.

2. Measure the static voltage in the battery.

3. If the voltage is below 25.2 volts after a charging cycle, charge the battery pack 5 times consecutively.

4. If the voltage is at or above 25.2 volts and the display still reads 0%, drive the truck with a meter attached and record the voltage drop. If the voltage drops below 25.2 volts, charge the battery pack 5 times consecutively.

5. If the BDI reset to 100% but then dropped back to 0%, drive the truck with a meter attached and record the voltage drop. If the voltage drops below 25.2 volts, charge the battery pack 5 times consecutively.

Note: The voltage must remain at or above 25.2 volts for 20 seconds while driving for the truck to reset and stay at 100%.

Raymond is a registered trademark of The Raymond Corporation PalletPro™ is a trademark of GNB Industrial Power 2007 The Raymond Corporation.

FOTP-0005/jwr/03-16-07/D

RPIN PLT-07-R009A Page 1 of 2

PROCEDURE (CONT.):

6. If the voltage does not stay at or above 25.2 volts for 20 seconds while driving and Step 3 has been completed, proceed to Step 7.

7. If a bad charger or battery is suspected, refer to RPIN PLT-07-R001 “PalletPro™ Field Troubleshooting Guide.”

8. If the voltage remains at or above 25.2 volts while driving for 20 seconds and your BDI does not reset to 100%, proceed to Step 9.

9. Refer to Maintenance Manual 1010183B page 5-21 for the Model 102XM and Maintenance Manual 1055925A page 5-26 for the RAS20/25.

10. Follow the procedures under “Service Display.”

11. Using the table as a reference, toggle through the menu until “BC” is shown. “BC” is represented by the hour glass (B) icon and the parameter control (C) icon lit together.

The control handle will display the voltage received by the ETAC that is approximately equal to battery voltage.

12. If the voltage difference is greater than 0.5 volts and Step 1 has been completed, troubleshoot the wiring between battery (+) and J11-1 on the ETAC card and between B (-) and J11-3 on the ETAC card. Repair as necessary. If no problem is found, replace the ETAC card.

Figure 1 PARTS AVAILABILITY:

Not required.

FILING INSTRUCTIONS:

File this notice in Maintenance Manual 1010183B after page 5-21 for the Model 102XM and Maintenance Manual 1055925A after page 5-26 for the RAS20/25.

Raymond is a registered trademark of The Raymond Corporation PalletPro™ is a trademark of GNB Industrial Power 2007 The Raymond Corporation.

FOTP-0005/jwr/03-16-07/D

RPIN PLT-07-R009A Page 2 of 2

RAYMOND PRODUCT IMPROVEMENT NOTICE

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

RPIN PLT-07-R008A

Models

December 6, 2007

102XM S/N 07-08097 and Below RAS 20/25 SN 07-02435 and Below

SUBJECT:

Handle Stem and Arm Angle Switch Bracket

DESCRIPTION:

A kit has been developed to replace the handle stem and arm angle switch bracket, changing the speed transition points by raising them to a higher position.

REMEDY:

Model 102XM S/N 07-08097 and Below: Replace the old handle stem (P/N 939-353/063) and the old arm angle switch bracket (P/N 939-353/107) with the new kit (P/N 312677/KIT) or new handle stem (P/N 1066425/001) and the new arm angle switch bracket (P/N 1066427/001).

P/N 312677/KIT contains one new handle stem (P/N 1066425/001) and one new arm angle switch bracket (P/N 1066427/001).

Model RAS 20/25 S/N 07-02435 and Below: Replace the old handle stem (P/N 939-353/063) and the old arm angle switch bracket (P/N 1059577/001) with the new kit (P/N 312677/KIT) or new handle stem (P/N 1066425/001) and the new arm angle switch bracket (P/N 1066427/001).

P/N 312677/KIT contains one new handle stem (P/N 1066425/001) and one new arm angle switch bracket (P/N 1066427/001).

Raymond is a registered trademark of The Raymond Corporation 2007 The Raymond Corporation.

FOTP-0005/jwr/03-16-07/D

RPIN PLT-07-R008A Page 1 of 2

PROCEDURE:

Follow the instructions in the Maintenance Manual for removing and replacing the handle stem and arm angle switch bracket.

Note: Continue to service the old arm angle switch bracket with the old or you may

order the new kit (P/N 312677/KIT), which will replace the old handle stem (P/N 939-353/063), and the old arm angle switch bracket (P/N 939-353/107 for the Model 102XM and P/N 1059577/001 for the Model RAS 20/25) with the new. The old handle stem is no longer available. If the old handle stem (P/N 939-353/063) is ordered, it will supersede to the new kit (P/N 312677/KIT).

Note: Do not mix the old style handle stems with the new style arm angle switch

brackets, or the new style handle stems with the old style arm angle switch brackets. Once the truck has been updated, record this change for future reference. Service the new parts only with new parts.

PARTS AVAILABILITY:

Now available through the Parts Distribution Center.

FILING INSTRUCTIONS:

File this notice in Maintenance Manual 1010183B after page 6-17 (Model 102XM) and in Maintenance Manual 1055925A after page 6-22 (Model RAS20/25).

Raymond is a registered trademark of The Raymond Corporation 2007 The Raymond Corporation.

FOTP-0005/jwr/03-16-07/D

RPIN PLT-07-R008A Page 2 of 2

RAYMOND PRODUCT IMPROVEMENT NOTICE

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

Models

RPIN PLT-07-R011 November 13, 2007

102XM S/N 102-07-08742 and Above RRS30 S/N 07-08742 and Above RCS20, 30, 40 S/N 07-01359 and Above RSS20, 30, 40 S/N 07-03033 and Above 8300 S/N 07-69376 and Above 8400 S/N 07-73318 and Above 8500 S/N 07-69386 and Above 019 S/N 07-69113 and Above

SUBJECT:

New Cold Storage Hydraulic Fluid

DESCRIPTION:

Cold storage trucks will be shipped from the factory with a new cold storage hydraulic fluid P/N 1017238. All trucks listed above will have decal P/N 1074515 placed on the hydraulic unit. The decal states, “Reservoir Contains P/N 1017238 Hydraulic Fluid.”

REMEDY:

Use P/N 1017238 in hydraulic units that are cold storage rated.

PROCEDURE:

Above Serial Number Break: When refilling or topping off cold storage hydraulic fluid, use only P/N 1017238.

Below Serial Number Break: If you are changing from any other type of cold storage hydraulic fluid to the new cold storage hydraulic fluid P/N 1017238, please order decal P/N 1074515 and place the decal on the hydraulic unit.

WARNING: Mixing with other types of cold storage fluids can cause “gelling” of the fluid and lead to premature pump failure.

PARTS AVAILABILITY:

Now available through the Parts Distribution Center.

Raymond is a registered trademark of The Raymond Corporation 2007 The Raymond Corporation.

FOTP-0005/jwr/03-16-07/D

RPIN PLT-07-R011 Page 1 of 2

FILING INSTRUCTIONS:

File this notice in Maintenance Manuals 1010183B (102XM) after page 6-55, 1010298B (RRS/RSS/RCS) after page 84, 1055925A (RAS) after page A-15 (or 6-33), 1034066B (8300, 8400, 8500) after page A-2, and PDMM-0091A (019) after page A-2.

Raymond is a registered trademark of The Raymond Corporation 2007 The Raymond Corporation.

FOTP-0005/jwr/03-16-07/D

RPIN PLT-07-R011 Page 2 of 2

RAYMOND PRODUCT IMPROVEMENT NOTICE

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

Models

RPIN PLT-07-R010

8300, 8400, 8500, 8600, 102XM, RAS20/25

July 30, 2007 SUBJECT:

TruckCom – Truck Communications Program

DESCRIPTION:

A new version of TruckCom is available. Enhancements to TruckCom are as follows: 1. USB dongle capability added to the current Parallel Port dongle availability. USB dongle part number is 230489-001.

2. With the USB dongle addition, TruckCom defaults to the last dongle type selected.

3. Parameters missing on some models are added.

4. Parameters missing due to recent truck software changes on some models are added.

5. Unused parameters on some models are removed.

6. Unnecessary or incorrect truck tabs on some models are removed.

7. Parameter adjustment limits on some models are corrected to match truck software specifications.

8. Parameter step values on some models are corrected to match truck software specifications.

9. PC to truck communications improved, resulting in fewer PC operating system error messages and less PC “freeze-ups.”

10. PC operating system error display description better identifies the actual problem.

11. Changes allowing reliable CAN node scanning.

12. Corrected mistakes in the displayed identification of some models.

13. Not defined or incorrectly defined parameters are correctly defined.

14. Improved ease of TruckCom PC installation.

15. Changes correcting TruckCom operational issues.

16. Curtis software download capability on some models removed when not applicable.

Raymond is a registered trademark of The Raymond Corporation 2007 The Raymond Corporation.

FOTP-0005/jwr/03-16-07/D

RPIN PLT-07-R010 Page 1 of 2

REMEDY:

Replace TruckCom version 3.5 with version 3.6.

PROCEDURE:

Uninstall TruckCom version 3.5. Version 3.5 must be removed first. Visit the Raymond iNet and download TruckCom version 3.6. NOTE: Once version 3.6 is installed, version 3.5 cannot be reinstalled even if version 3.6 is uninstalled.

PARTS AVAILABILITY:

Download from iNet.

FILING INSTRUCTIONS:

File this notice in Maintenance Manual 1034066B after page 5-19.

Raymond is a registered trademark of The Raymond Corporation 2007 The Raymond Corporation.

FOTP-0005/jwr/03-16-07/D

RPIN PLT-07-R010 Page 2 of 2

RAYMOND PRODUCT IMPROVEMENT NOTICE

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

Models

RPIN PLT-07-R001 May 7, 2007

101, 102XM, RAS20, and RAS25 Pallet Trucks Equipped with the GNB PalletPro™ Battery Pack

SUBJECT:

Troubleshooting the GNB PalletPro Battery Pack

DESCRIPTION:

GNB has provided documentation to support troubleshooting the PalletPro Battery Pack, which is optional equipment on some Raymond pallet trucks and stackers.

PROCEDURES:

When troubleshooting the GNB PalletPro Battery Pack, refer to the attached information supplied by GNB.

PARTS AVAILABILITY:

Not required.

FILING INSTRUCTIONS:

File this notice in front of all applicable maintenance manuals for trucks that have this optional battery.

Raymond is a registered trademark of The Raymond Corporation PalletPro is a trademark of GNB 2007 The Raymond Corporation.

FOTP-0005/jwr/03-16-07/D

RPIN PLT-07-R001 Page 1 of 7

This page left blank intentionally.

Raymond is a registered trademark of The Raymond Corporation PalletPro is a trademark of GNB 2007 The Raymond Corporation.

FOTP-0005/jwr/03-16-07/D

RPIN PLT-07-R001 Page 2 of 7

GNB Industrial Power 3950 Sussex Avenue Aurora, IL 60504-7932 USA 630.862.2200 tel 800.872.0471 toll free 630.862.2325 fax www.exide.com

PalletPro Field Troubleshooting Guide 1. Upon receipt of a report of poor performance on a GNB PalletPro battery pack, a technician should follow the procedure below to determine the cause of the poor performance.

2. Check overall voltage of the battery pack by measuring the DC voltage at the SB plug with a calibrated DC Volt Meter. a. If the voltage is between 25.33 and 25.8VDC (normal fully charged open circuit voltage (OCV)), proceed to Step 3. b. If the voltage is less than 25.32VDC, the battery is not fully charged. i. Connect the battery to the charger and plug the charger into the AC outlet and allow for a full charge. ii. Recheck voltage after charge is complete and repeat Step 2. c. If after one full charge, the voltage still remains below 25.32V, check individual bloc voltages at open circuit. i. If all blocs are within 0.1 V of each other, proceed to Step 4, Charger Troubleshooting for the charger model that is installed in the PalletPro d. If the blocs vary by more than 0.1VDC, there is a problem with an individual bloc, replace defective bloc(s), record individual OCVs and submit field data to GNB warranty for review.

EXAMPLE 1 EXAMPLE 2 6.30 6.23 6.29 6.22 6.18 Replace 6.10 Replace 6.29 6.19 3. Perform a field load test and check individual bloc voltages. a. Discharge battery using external load or using lifting circuit on vehicle.

Minimum current for load test is 50A. b. If all blocs measure within 0.1V of each other, proceed to Step 4, Charger Troubleshooting. c. If blocs vary by more than 0.1V, there is a problem with an individual bloc, record individual OCVs and load voltages and submit field data to GNB warranty for review.

Page 3 of 7

4. Charger troubleshooting a.

b. c. d.

Saft Model MP750-1225G (Due to Smart Start, battery must be below 80% state of charge. If it is above 80% the charger will shut down protecting the battery from overcharge. The charger applies an initial current to the battery of 4A. If the battery voltage increases to 26.16VDC (2.18VPC) in less than 5 minutes, the charge will terminate. If the battery does not reach this voltage in 5 minutes, the charger initiates a full charge sequence.)

Connect charger to the battery.

Connect the AC plug to the 115V AC outlet Upon startup, check that LED’s are operating as per below: i. Green – SOLID ON ii. Yellow – FLASHING iii. Red –OFF iv. If LED’s are not per above, 1. Check AC voltage supply is at least 105VAC and plug is properly connected.

2. If less than 105VAC, then plug into alternate outlet.

3. If VAC supply is >105VAC and properly connected, contact local GNB service. v. IF LED’s are lit per above, 1. Check output current with Amp meter.

2. Output current should be 25A after 5 minutes. a. If output current is not 25A, contact local GNB service. b. If output current is 25A, charger is operating correctly. vi. Allow charger to complete charge: vii. If RED LED begins to flash, check battery voltage is above 18V. 1. If battery voltage is above 18V, disconnect charger from AC and reconnect. If flashing red continues, contact local GNB service.

2. If battery voltage is below 18V, battery is under voltage.

Check battery.

PalletPro Field Troubleshooting Guide

Page 4 of 7

viii. Proper LED Operation is as follows: LED 80% Charged Cool Down Green Flashing Flashing Yellow Flashing Solid ON Red OFF OFF

Complete Solid ON Solid ON OFF

MAC Model SVR2425125/6 LED Indicators 1. AC Power applied – All 5 LEDs will flash 3 times, then each lamp will flash once individually. Finally all lamps will be off.

2. AC power is applied. Battery is plugged into charger - All 5 LEDs will flash 3 times, then each lamp will flash once individually, checking AC Power. If battery is connected, all 5 LEDs will flash 3 times again. After a 3-5 second delay the charger will turn on.

TROUBLESHOOTING ATTENTION!! DO NOT PERFORM REPAIRS ON THE CHARGER THAT ARE HIGHLIGHTED IF CHARGER IS WITHIN 1st YEAR OF WARRANTY SEE BATTERY SERIAL MATRIX AT END OF GUIDE ALL ACTIONS WITH THE EXPCEPTION OF REPLACING THE BREAKER AND/OR THE STOP BUTTON CALLS FOR FULL CHARGER REPLACEMENT Charger will not turn on. Does not go through self test Possible Causes Action Steps Circuit breaker open Check For AC voltage; reset breaker Charger will not turn on after self-test Possible Causes The battery is not plugged into charger Loose connection on circuit board Reverse Polarity

Action Steps Connect battery to charger Check Molex connection Check polarity from battery to charger

Charger is cycling between on and off Possible Causes Loose connection from auxiliary winding of transformer to the circuit board AC Power supply to circuit board is too low Defective circuit board

Action Steps Tighten connection and check for continuity Check AC voltage. Should be within 10% of specified range Contact GNB for replacement

PalletPro Field Troubleshooting Guide

Page 5 of 7

Low charging current Possible Causes AC line voltage too low Trans former Secondary too low Defective SCRs or circuit board Red ABNORMAL LED flashes Possible Causes Output current is too high due to a sudden short circuit at the charger’s output connector SCR Failure Circuit board failure

Red ABNORMAL LED stays lit Possible Causes Battery was not fully charged

Action Steps Check AC voltage. Should be within 10% of specified range Contact GNB for replacement Contact GNB for replacement

Action Steps Check for any possible short circuit. After removing the short circuit condition, press the red STOP button to clear the flashing ABNORMAL LED. Press the STOP button again to restart the charger Contact GNB for replacement Contact GNB for replacement

Action Steps Battery was disconnected from the charger before the charge cycle was complete without pressing the stop button Check batteries

Charger cannot be turned off or will not shut off Possible Causes Action Steps Loose or broken connection between stop Disconnect battery, and remove AC power. button and circuit board Check for continuity and tighten connection Defective Stop button Contact GNB for replacement Stop Button Defective SCR(s) or circuit board Contact GNB for replacement NOTE: DURING THE 1ST YEAR FROM DATE OF SHIPMENT, THE ONLY AUTHORIZED REPAIRS ON MODEL SVR2425125/6 ARE REPLACEMENT OF THE CIRCUIT BREAKER OR STOP BUTTON. ALL OTHER REPAIRS DURING THE 1ST YEAR REQUIRE THE COMPLETE CHARGER TO BE REPLACED.

PalletPro Field Troubleshooting Guide

Page 6 of 7

SERIAL NUMBERS FIRST LETTER IS ALWAYS “C” Second Letter = Month A January B February C March D April E May F June G July H August J September K October L November M December

PalletPro Field Troubleshooting Guide

Third Letter = Year A 1998 B 1999 C 2000 D 2001 E 2002 F 2003 G 2004 H 2005 I 2006 J 2007 K 2008 L 2009 M 2010 N 2011

Page 7 of 7

RAYMOND SERVICE BULLETIN

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

Model

RSB PLT-06-017 April 4, 2007

RAS 20/25 S/N 01000 & Up and S/N 02000 & Up

NOTE:

S/N 01000 & Up is for old version – Maintenance Manual 1010297A. S/N 02000 & Up is for new version – Maintenance Manual 1055975A.

SUBJECT:

Wiring Label

DESCRIPTION:

While wired correctly, the cable between B– and the Traction Power Amplifier B– stud should be labeled as wire 40, but may be labeled as wire 1. Wire 1 is the B+ cable.

REMEDY:

Label the B– cable to the Traction Power Amplifier as wire 40.

PROCEDURES:

When working on the power system of the RAS 20/25, label the B– cable to the TPA as wire 40.

PARTS AVAILABILITY:

N/A

WARRANTY:

Within normal Raymond policy guidelines.

Flat Rate Book Reference RAS 20/25 Model 5086 Code .1 Time

FILING INSTRUCTIONS:

File this bulletin in Maintenance Manual 1055975A after page A-12.

®

Raymond is a registered trademark of The Raymond Corporation 2007 The Raymond Corporation.

FOTP-0006/jwr/03-16-07/D

RSB PLT-06-017 Page 1 of 1

RAYMOND SERVICE BULLETIN

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

Model

RSB PLT-07-001

RSS and RRS Walkie Stackers

February 19, 2007

SUBJECT:

Brake Switch Harness becomes disconnected.

DESCRIPTION:

On some models prior to Serial # 02732, it has been found that when the harness is incorrectly installed, the brake will be applied and the truck will not travel.

REMEDY:

Adjust the harness.

PROCEDURES:

View Figures 1 and 2 on page 2 and adjust the harness accordingly.

PARTS AVAILABILITY:

N/A

WARRANTY:

Within normal Raymond policy guidelines.

Flat Rate Book Reference RSS and RRS Models 4225 Code .1 Time

FILING INSTRUCTIONS:

File in Maintenance Manual 1010298-1 after page 4-85.

®

Raymond is a registered trademark of The Raymond Corporation 2007 The Raymond Corporation.

FOTP-0006/jwr/1-2007/C

RSB PLT-07-001 Page 1 of 2

Figure 1: Before Modification

Figure 2: After Modification

®

Raymond is a registered trademark of The Raymond Corporation 2007 The Raymond Corporation.

FOTP-0006/jwr/1-2007/C

RSB PLT-07-001 Page 2 of 2

RAYMOND PRODUCT IMPROVEMENT NOTICE

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

Models

RPIN PLT-06-R025

RAS20/25

December 21, 2006 SUBJECT:

Pulley Bracket Kit

DESCRIPTION:

A kit has been developed to replace the mast chain yoke assembly. New parts are now available through this kit.

REMEDY:

Replace the mast chain yoke, axle, chain, wheel, and associated hardware with parts from this kit. The chain roller will also have a ball bearing instead of bushings.

PROCEDURES:

Follow the instructions in Maintenance Manual 1055925B, page 6-50 for removing the mast chain yoke. Replace the mast chain yoke, axle, chain wheel, and hardware with parts from the kit (P/N 851-201-621.) See Figure 1.

237737 236150

237907

S22059 (2x)

237738 Figure 1

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

FOTP-0005/jwr/12-2006/C

RPIN PLT-06-R025 Page 1 of 2

PARTS AVAILABILITY:

Parts are now available through the Parts Distribution Center.

FILING INSTRUCTIONS:

File this notice in Maintenance Manual 1055925B after page 6-50.

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

FOTP-0005/jwr/12-2006/C

RPIN PLT-06-R025 Page 2 of 2

RAYMOND PRODUCT IMPROVEMENT NOTICE

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

RPIN PLT-06-R028

Models

December 1, 2006

RAS 20/25

SUBJECT:

Service Parameter #22 Brake Type Setting

DESCRIPTION:

Serial No. Below 2000: Older trucks with a serial number below 2000 are equipped with a mechanical brake switch. New replacement ETAC cards must have Parameter 22 adjusted to 0 to enable the brake switch.

Serial No. 2000 and Up: Parameter 22 on page 5-22 in Maintenance Manual 1055925A is incorrect.

REMEDY:

Serial No. Below 2000: If a new ETAC card is installed into the truck with a serial number below 2000, Parameter 22 must be set to 0.

Serial No. 2000 and Up: Replace information for parameter 22 with the information in this RPIN.

PROCEDURES:

Serial No. Below 2000: Use instructions on page 4-39 in manual 1010297A to access parameter 22. Set parameter 22 to 0.

Parameter 22 should now read: “Brake Type” in the name column.

Range column should be “0 or 1”. Step should be “1” and default should be “1.”

NOTE: Serial No. 2000 and Up trucks use an inductive brake switch and parameter 22 must be set to “1.”

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

FOTP-0005/jwr/12-2006/C

RPIN PLT-06-R028 Page 1 of 2

PARTS AVAILABILITY:

Now available through the Parts Distribution Center.

FILING INSTRUCTIONS:

Serial No. Below 2000: File this notice in Maintenance Manual 1010297A on page 4-40.

Serial No. 2000 and Up: File this notice in Maintenance Manual 1055925A on page 5-22.

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

FOTP-0005/jwr/12-2006/C

RPIN PLT-06-R028 Page 2 of 2

RAYMOND SERVICE BULLETIN

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

RSB PLT-05-005

Models

October 7, 2005

RSS / RRS / RCS Stackers

SUBJECT:

Lift Pump Solenoid

DESCRIPTION:

In some applications, the lift pump solenoid (P/N 851-200-443) may fail prematurely.

REMEDY:

A new solenoid (P/N 851-201-511) has been developed as a replacement for the older solenoid.

PROCEDURES:

When replacing a failed lift pump solenoid, replace it with lift pump solenoid (P/N 851-201-511).

Note:

Verify that the battery is not being over discharged, as this will shorten the life span of the solenoid.

PARTS AVAILABILITY:

Parts are now available through the Parts Distribution Center.

WARRANTY:

Within normal Raymond policy guidelines.

Flat Rate Book Reference RSS / RRS / RCS Model 5075 Code 0.5 Time

FILING INSTRUCTIONS:

File a copy of this bulletin with List 5-4 in the following publications: 1010407-1, 1010383-1, 1010406-1

®

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

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

RSB PLT-05-005 Page 1 of 1

RAYMOND PRODUCT IMPROVEMENT NOTICE

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

RPIN PLT-04-R002 June 14, 2004

Models 102XM and RAS 20/25

SUBJECT:

Programming Operator PIN Codes or Service Parameters

DESCRIPTION:

Setting truck parameters clarification.

REMEDY:

The procedures below are being provided to clarify programming with the Service Key (P/N 851-201-500).

PROCEDURES:

1. Connect the service key to the service key connector on the truck (J41). Make sure the main ON/OFF switch (S21) is in the “|” (ON) position.

2. Turn the truck on while holding the horn button until “P” is displayed (while the horn button is held down, the display will cycle through H, E, P, and Pn). Release the horn button at “P” to enter parameter mode. (If the horn button is released at the wrong time, turn the truck OFF at the keypad and start over.) The parameter symbol on the display is illuminated.

Service Key

Parameter for the sixth driver

3. Rotate the thumbwheel in the fork direction to progress forward through the parameters. While the thumbwheel is held and briefly after it is released, both the parameter number (on the left side of the display, as normal) and the driver number (on the right – only occurs when using service key to display driver’s parameters) are displayed. Stop (release the thumbwheel) at parameter 10 (PIN code) for the first driver; the default value of “1” will be displayed.

4. Press the horn button once to access this parameter. The parameter symbol on the display flashes. Now you can make changes to the value of the first driver’s PIN code.

®

Raymond is a registered trademark of The Raymond Corporation 2004 The Raymond Corporation.

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

RPIN PLT-04-R002 Page 1 of 2

PROCEDURES (Cont’d.)

5. Rotate the thumbwheel in the fork direction to increase the PIN code value, or in the operator direction to decrease it. Holding the thumbwheel in a direction for a time will help quickly advance to larger numbers (for example, codes greater than 100).

The PIN code can be from one to four digits long. Release the thumbwheel when the desired value is reached.

HINT:

For high PIN codes (such as 8000), save time by starting out rotating the thumbwheel towards the operator.

6. Press the horn button again to confirm the new PIN code value. The parameter symbol on the display stops flashing.

NOTE:

Changing the first driver’s PIN code will alter default operation – you will not be able to press “1” and “|” (ON) to power the truck unless a driver’s PIN code is set to a value of “1”.

7. To enable additional drivers: rotate the thumbwheel in the fork direction to roll over to the second driver, and stop at parameter 10. The default value of “0” will be displayed. (By default, all drivers except the first have a PIN code value of 0, which disables that driver.) Follow the steps above for the desired number of different PIN codes you would like to set up. There are a total of ten drivers (1, 2, 3, 4, 5, 6, 7, 8, 9, 0).

NOTE:

Disabling all drivers (all PIN code values = 0) prohibits truck operation without the service key.

PARTS AVAILABILITY:

N/A

FILING INSTRUCTIONS:

File a copy of this notice between pages 5-16 and 5-17 in Model 102XM Maintenance Manual 1010183A. File a copy of this notice between pages 4-38 and 4-39 in Model RAS20/25 Maintenance Manual 1010297.

®

Raymond is a registered trademark of The Raymond Corporation 2004 The Raymond Corporation.

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

RPIN PLT-04-R002 Page 2 of 2

RAYMOND PRODUCT IMPROVEMENT NOTICE

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

RPIN PLT-03-R003

Model

March 27, 2003

RAS20/25

SUBJECT:

Oil leaking through the air filter.

DESCRIPTION:

Reports have been received about oil leaking through the air filter. This occurs during driving with simultaneous lowering of the fork cradle.

REMEDY:

A field solution is now available.

PROCEDURES:

For proper assembly perform the following steps and refer to Figure 1 below.

1. Remove the air filter (C).

2. Install the new filler hose (A) (P/N 209637).

3. Secure the filler hose with cable ties (B) (P/N 20942).

4. Install the air filter (C).

Figure 1 PARTS AVAILABILITY:

Parts will be available as of April 3, 2003 through the Parts Distribution Center.

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

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

RPIN PLT-03-R003 Page 1 of 1

RAYMOND PRODUCT IMPROVEMENT NOTICE

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

RPIN PLT-03-R002

Models

February 25, 2003

DLC Series, DCX Series, DL65/80, DRX30, DTR, DSX, RRS, RCS, RSS

SUBJECT:

Cover plate machine screws on Low-Lift and Walkie Stacker switch housing

DESCRIPTION:

During repair or maintenance activities, overtorquing the machine screws that secure the switch cover plate may cause unwanted internal component interference.

REMEDY:

A field kit has been created to replace the switch housing cover plate machine screws with shorter screws to prevent component interference.

PROCEDURES:

Where this condition exists, replace the six 12 mm machine screws (P/N 301921-012) with six 10 mm machine screws (P/N 301921-010) as outlined in the installation instructions on page 2 of this notice.

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

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

RPIN PLT-03-R002 Page 1 of 2

PROCEDURES: (Cont.)

1. Power the truck down and disconnect the battery.

2. Remove the six, T20, Torx head (12 mm) machine screws from the switch housing cover plate as shown in Figure 1 below.

3. Install the six new (10 mm) machine screws, (P/N 301921-010).

4. Torque to 45 - 50 in. lb. (5 - 6 Nm).

5. Ensure proper operation of the truck and return it to service.

Location of the six machine screws to be replaced.

Figure: 1 PARTS AVAILABILITY:

Order parts as needed through the Parts Distribution Center.

FILING INSTRUCTIONS:

Place copies of this notice in the appropriate Parts Catalog(s) and Maintenance Manual(s) for future reference.

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

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

RPIN PLT-03-R002 Page 2 of 2

RAYMOND PRODUCT IMPROVEMENT NOTICE

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

RPIN No. PLT-00-R003

Models

March 7, 2000

EMB / EMC

SUBJECT:

Louder Horn

DESCRIPTION:

In some applications, the customer may desire a louder horn. A new, louder mechanical horn is now available.

REMEDY:

Install a mechanical horn.

Order: Item 1 2 3 4 5 6

Part Number J28300010 J28409280 J28400780 J28000070 J28000130 J28412900

Description Horn Terminal end Terminal end Wire Assembly Wire Assembly Splice

QTY 1 2 1 1 1 1

PROCEDURES:

1. Disconnect the battery.

(Ref. Page 2)

2. Install the horn using the upper control card mounting bolt.

3. Cut wire F14 at the control card. This is the wire from the horn switch.

4. Using the splice (item 6) connect wire assembly (item 4) to the wire coming from the horn switch and connect the other end to the horn using terminal end (item2).

5. Using Terminal end (item 3), connect wire assembly (item 5) to the B- post on the control card and connect the other end to the horn using terminal end (item 2).

6. Test the truck for proper operation.

PARTS AVAILABILITY:

Now available through the Syracuse Parts Distribution Center.

Raymond is a registered trademark of The Raymond Corporation Copyright 2000 The Raymond Corporation.

All Rights Reserved.

Raymond is a registered trademark of The Raymond Corporation Copyright 2000 The Raymond Corporation.

All Rights Reserved.

6.

.





















þ  þ 

þ  þ 









4.













    





   

























154-010-796









5, 1995

DSW400

Use contact cement to fasten bumper to bulkhead of truck. See figure 1.