Raymond Forklift RCS20 30 40 RSS22 30 40 RRS30 Maintenance Manual SN01000 - Up

Front Cover

Maintenance Manual Walkie Counterbalanced RCS20/30/40

Walkie Straddle RSS22/30/40

Walkie Reach RRS30

Model RCS20/30/40 RSS22/30/40 RRS30

Serial Numbers 01000 - Up

Publication: #1010298-2

Issued: 22 Dec 2006

Raymond Raymond

www.raymondcorp.com

Raymond

Always follow the warnings given in this Service Manual and on the truck to avoid accidents from occurring.

Warns that an accident will occur if the instructions are not followed.

The consequences are serious personal injury or possibly death, and/or extremely large material damage.

Warns that an accident can occur if the instructions are not followed.

The consequences are serious personal injury or possibly death, and/or large material damage.

Warns that an accident can occur if the instructions are not followed.

The consequences are personal injury and/or material damage.

Marks the risk of an accident or breakdown if the instructions are not followed.

If smoking occurs in situations where a restriction against smoking is stated, a serious accident can occur.

If open flames are used in situations where open flames are prohibited, a serious accident can occur.

If the prohibition is ignored, a serious accident can occur.

When the directive for safety shoes is given, safety shoes shall always be worn to avoid personal injury.

When the directive for protective glasses is given, protective glasses shall always be worn to avoid personal injury.

±

.

VOLTAGE

CURRENT

MODEL

SERIAL

A.

V.

−

−

−

−

…

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-15-014

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 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-14-003

Models

April 21, 2014

RRS / RCS / RSS

SUBJECT:

Motor Controller Changes

GENERAL INFORMATION:

The Motor Controllers were changed to P/N 1148211/001 (200 amp) and P/N 1148775/001 (300 amp) in March and April of 2012. When these changes were made, all of the parameters that could be adjusted on the previous controllers were not accessible with a User Handset. The changes cut into production with serial numbers RSS-12-40391, RCS-12-01554, and RRS-12-02022.

SERVICE INFORMATION:

Both the 200 amp and 300 amp controllers have since been updated to /002 which will allow access to all of the parameters that were originally available. If a truck needs to have the travel speeds changed, it will require the installation of the 1148211/002 (200 amp) or 1148775/002 (300 amp) controller for the model being serviced.

See page 2 for details on parameter settings.

All EE rated trucks were changed to use the 300 amp electrical system which includes the controller, contactor, larger drive motor, fuses, larger cables, hardware, and brake push rod at the serial number breaks listed above. When ordering parts for these EE trucks, use the parts information for the RCS30/40.

PARTS AVAILABILITY:

Now available through the Parts Distribution Center.

FILING INSTRUCTIONS:

File this notice in Maintenance Manual 1010298 next to page 275.

®

Raymond is a registered trademark of The Raymond Corporation 2014 The Raymond Corporation.

FOTP-0060/1-8-14/E

RSI PLT-14-003 Page 1 of 2

200 AMP RCS20, RSS22/30/40, RRS30 Controller Parameter Settings Parameter

Range

Units

Description

50 to 200

Standard Setting 200

M1 Braking Current Limit M1 Acceleration Rate M1 Deceleration Rate

Amps

0.1 to 3

1

Seconds

0.1 to 10

3

Seconds

0 to 100

100

%

0 to 100

100

%

Maximum Mode 1 Braking Current Limit Time it takes to accelerate from 0 to Mode 1 full speed Time it takes to decelerate in Mode 1 to the new throttle request when the throttle is reduced or released to neutral.

Maximum Mode 1 forward travel speed Maximum Mode 1 reverse travel speed

M1 Max Forward Speed M1 Max Reverse Speed

300 AMP RCS30/40 Controller Parameter Settings Parameter

Range

M1 Braking Current Limit M1 Acceleration Rate M1 Deceleration Rate

M1 Max Forward Speed M1 Max Reverse Speed

®

Units

Description

50 to 300

Standard Setting 300

Amps

0.1 to 3

0.5

Seconds

0.1 to 10

3

Seconds

0 to 66

66

%

0 to 66

66

%

Maximum Mode 1 Braking Current Limit Time it takes to accelerate from 0 to Mode 1 full speed Time it takes to decelerate in Mode 1 to the new throttle request when the throttle is reduced or released to neutral.

Maximum Mode 1 forward travel speed Maximum Mode 1 reverse travel speed

Raymond is a registered trademark of The Raymond Corporation 2014 The Raymond Corporation.

FOTP-0060/1-8-14/E

RSI PLT-14-003 Page 2 of 2

RAYMOND SERVICE INFORMATION

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

RSI GEN-13-001

Model

June 14, 2013

General

SUBJECT:

Fork Inspection Procedures

GENERAL INFORMATION:

Change to procedure used to inspect forks during Scheduled Maintenance.

SERVICE INFORMATION:

In maintenance manuals containing fork inspection procedures, cross out the existing procedure for checking the straightness of the blade and shank and replace with the following procedure.

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.

Figure 1

2. Multiply these numbers by 0.005) for maximum allowable deviation.

• Length of blade _____ x 0.005 = ______ • Height of shank _____ x 0.005 = ______ 3. Place a straight edge on the blade of the fork, 2 in. away from the heel. Measure any deviation and compare to the number calculated in step 2 for length of blade.

4. Place a straight edge on the shank of the fork, 2 in. away from the heel. Measure any deviation and compare to the number calculated in step 2 for height of shank.

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

PARTS AVAILABILITY:

N/A

FILING INSTRUCTIONS:

File this notice in all Maintenance Manuals that contain fork inspection procedures.

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

FOTP-0060/1-23-12/C ®

RSI GEN-13-001 Page 1 of 1

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

Also see Updated Torque Check Procedures

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 PRODUCT IMPROVEMENT NOTICE

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

Models

RPIN GEN-10-R004

GEN

October 14, 2010 SUBJECT:

Recommended Chain Lubrication

DESCRIPTION:

Scheduled Maintenance of Lift Chains includes conducting an examination for too much stretch and wear, measuring adjustment, and lubrication. The chain lubricant specified in maintenance manuals, P/N 990-652/001, may not adequately penetrate and lubricate the joints of the chain.

REMEDY:

To obtain the complete benefit of Scheduled Maintenance, use P/N 990-500/PL1 when lubricating chains on all trucks.

PROCEDURE:

Use P/N 990-500/PL1 when lubricating chains on all trucks.

PARTS AVAILABILITY:

Available through the Parts Distribution Center.

FILING INSTRUCTIONS:

File this notice in the Appendix of all maintenance manuals next to the lubricant chart.

Cross out the information that calls for the use of Teflon Grease.

®

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

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

RPIN GEN-10-R004 Page 1 of 1

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

Models

RPIN GEN-08-R003

General – See Filing Instructions

June 6, 2008 SUBJECT:

New Cylinder End Cap Wrenches

DESCRIPTION:

New wrenches are now available.

REMEDY:

There are two kits available. Kit P/N 1090889/KIT is for RSS, RRS, and RCS trucks.

Kit P/N 1090761/KIT is for all other Raymond trucks. The part numbers in this RPIN replace all previous part numbers for cylinder end cap tools.

PROCEDURE:

See page 2 for a list of wrenches made for Raymond trucks.

PARTS AVAILABILITY:

Now available through the Parts Distribution Center.

FILING INSTRUCTIONS:

File a copy of this notice in the following Maintenance Manuals: • 1026304B Model 7400, 7420, and 7440 after pages 7-164 and 7-166 • 1031794B Models 5400, 5500, and 5600 after page 7-88 • 1043922A Model 5200 after page 7-78 • 1016335A Model SA/SB next to pages 7-131 and 7-134 • PDMM-0089B Model EASi Pacer™ trucks next to page 7-77 • PDMM-0093-01 Model DSS300/350 next to pages 7-35 and 7-44 ® • PDMM-0049 Gofer Orderpicker after page 7-110 • 1010298-2 Model RCS20/30/40, RSS22/30/40, and RRS30 before pages 317 and 327.

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

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

RPIN GEN-08-R003 Page 1 of 2

Wrenches Made for Raymond Lift Trucks Model Position

Wrench P/N

Kit P/N 1090761/KIT

7400 7400 7400 7420 and 7440 7420 and 7440 5200, 5400, 5500, and 5600 SB EASi Pacer Lift Truck EASi Pacer Lift Truck DSS 300/350 EASi Pacer Lift Truck 233 Gofer Lift Truck

Free Lift w/Staging Free Lift w/o Staging Main Lift Cylinder Free Lift Cylinder Main Lift Cylinder Center Lift Cylinder w/Decel and Staging Main Lift Cylinder Main Lift Cylinder Center Free Lift w/Decel Main and Free Lift Cylinder Main Lift Cylinder – Obsolete Main Lift Cylinder – Obsolete

1090761/005 1090761/007 1090761/007 1090761/004 1090761/005 1090761/002 1090761/001 1090761/007 1090761/001 1090761/003 1090761/006 1090761/006

Center Cylinder Main Lift Cylinder Center Cylinder Main Lift Cylinder Center Cylinder Main Lift Cylinder

1090889/002 1090889/004 1090889/002 1090889/004 1090889/002 1090889/004

Kit P/N 1090889/KIT

RSS 22/30/40 RSS 22/30/40 RRS 30 RRS 30 RCS 20/30/40 RCS 20/30/40

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

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

RPIN GEN-08-R003 Page 2 of 2

RAYMOND PRODUCT IMPROVEMENT NOTICE

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

RPIN GEN-08-R001

Model

February 25, 2008

General

SUBJECT:

Warning Light Failures

DESCRIPTION:

There have been a number of warning light assemblies, P/N 591-569/xxx, returned under warranty when only the bulb has failed. This normally happens when the light is described as having intermittent operation or excessive time between the light flashing.

REMEDY:

Troubleshoot the light assembly per the procedure below. Warranty will be denied for warning light assemblies when it is determined that only the bulb has failed. Light bulbs are considered a wearable component as per the Original Equipment Warranty Policy (FOWR-0004) and are only covered for 4 months or 695 hours.

PROCEDURE:

When the light does not function properly, inspect the bulb, P/N 591-569/111, using the attached Figures 1 and 2 as a guide. If the bulb is dark on the end as indicated in Figure 2, measure the voltage as described. If the voltages are correct, only the bulb should be replaced.

PARTS AVAILABILITY:

Now available through the Parts Distribution Center.

FILING INSTRUCTIONS:

File this notice in all manuals that use warning lights.

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

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

RPIN GEN-08-R001 Page 1 of 2

Bulb is clear with no discoloring.

Figure 1: Good Xenon Bulb

Discoloring of bulb typically occurs on this end, above the two pins.

Pin 1

Pin 2

Pin 3

With the bulb removed: Positive lead on Pin 1 and negative lead on Pin 2, reading should be approximately 250 VDC. With the bulb removed: Positive lead on Pin 1 and negative lead on Pin 3, reading should be approximately 250 VDC. Figure 2: Failed Xenon Bulb (burnt on right end)

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

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

RPIN GEN-08-R001 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 GEN-06-R003A

General: All Trucks with Electric Brake

June 6, 2007

SUBJECT:

Updated Scheduled Maintenance Suggested Intervals

DESCRIPTION:

Based on an analysis of field data available from different environments of use, the suggested intervals between scheduled maintenance are extended in some applications to maximize operational efficiencies.

REMEDY:

See page 2 for suggested intervals.

PROCEDURES:

Make a copy of page 2 and insert it in each maintenance manual next to the existing chart.

PARTS AVAILABILITY:

NA

FILING INSTRUCTIONS:

In all current Maintenance Manuals next to the existing interval chart.

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

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

RPIN GEN-06-R003A Page 1 of 2

Suggested Scheduled Maintenance Intervals Operating Conditions Light to Moderate Severe

Extreme

Working Environment An eight hour shift of basic material handling.

Extended heavy duty operations.

Freezer operations.

Sudden temperature changes.

All EE rated lift trucks.

Dusty or sandy conditions, eg…

High temperature areas, eg…

Corrosive atmosphere, eg…

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

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

Service Frequency 180 days or 500 hrs., whichever comes first 250 hrs.

100 hrs.

RPIN GEN-06-R003A Page 2 of 2