Raymond 3010 Pallet Trucks & 3020 Tow Tractors Maintenance Manual 1134255A – PDF DOWNLOAD
FILE DETAILS:
Raymond 3010 Pallet Trucks & 3020 Tow Tractors Maintenance Manual 1134255A – PDF DOWNLOAD
Language : English
Pages : 377
Downloadable : Yes
File Type : PDF
TABLE OF CONTENTS:
Raymond 3010 Pallet Trucks & 3020 Tow Tractors Maintenance Manual 1134255A – PDF DOWNLOAD
3010 301-14-00001 and up
3020 302-14-00001 and up
Page Revision Recordxi
Document Revision History xi
Service Information Documents Listxii
How To Use This Manual 1-1
Manual Design1-2
Interactive Electronic Technical Manuals 1-3
Abbreviations & Symbols 1-4
Abbreviations and Symbols – Guidance System 1-6
Safety2-1
Definitions2-2
General Safety2-3
Battery Safety2-5
Jacking Safety2-8
Tractor Section2-8
Fork Section 2-8
Tie-Down for Transport 2-9
Towing 2-10
Without Brake Release Bolts 2-10
With Brake Release Bolts2-10
Static Safety 2-11
Welding Safety 2-12
Systems Overview3-1
Introduction 3-2
Truck Model Identification3-3
Lift Truck Specifications 3-4
Special Tools 3-5
Service Key 3-5
Jumper Harness 3-5
Operator Display and Programming 3-6
Special Truck Mode 3-6
Hour Meter (H)3-6
Error Codes (E)3-6
Changing Truck Parameters (P) 3-7
Service Input/Output Displays 3-17
Digital Inputs/Outputs from Traction Amplifier and VM 3-17
Automated Truck3-20
Overview 3-20
Components 3-20
Graphical Operator Interface (GOI) 3-22
Guidance System Overview 3-23
Operating the Automated Lift Truck 3-23
Using the GOI3-23
Startup 3-23
Opening Screen in Manual Mode3-23
“Choose Route” Screen 3-24
“Training and Service” Menu 3-25
Operating Procedures3-35
Table of Contents Raymond® Model 3010/3020 Maintenance Manual
ii Publication: 1134255, Issued: 25 Feb 2015
Backing Up and Restoring Routes3-36
Changing Log Level 3-36
FlashWare3-38
Overview 3-38
Requirements 3-38
Installing FlashWare on PC 3-38
Connecting PC to Truck 3-38
Starting FlashWare 3-38
Scheduled Maintenance 4-1
Maintenance Guidelines 4-2
Initial 90 Day/250 Deadman Hours (HD) Maintenance4-3
Every 180 Days or 500 Deadman Hours4-4
Every 360 Days or 2000 Deadman Hours (HD) 4-7
Contactor Tip Inspection 4-8
Grease Fittings (All Models)4-9
Grease Fittings (Trucks without Steel Bushings Only)4-10
Undercarriage Pin and Bushing Inspection Points4-11
Troubleshooting 5-1
How to Use This Section 5-2
Electrical Troubleshooting Guidelines 5-3
General5-3
Troubleshooting the CAN Bus 5-3
Shorts to Frame5-6
Fuses 5-9
Test/Inspection5-9
DC Electric Motors5-10
DC Motor Types 5-10
Inspection5-10
Service5-10
Open Circuit Motor Test 5-12
Grounded Motor Test 5-13
Short-Circuited Armature 5-13
Short-Circuited Winding 5-13
AC Electric Motors5-14
AC Motor Type5-14
Open Winding5-14
Shorted Winding 5-14
Hydraulic Troubleshooting Guidelines5-15
Symptom Tables: Lift/Lower System 5-16
No Lift, Lift Motor Does Not Run, Travel is OK5-16
No Lift or Slow Lift, Lift Motor Does Run 5-17
No Lower, Lift and Travel OK 5-17
Unable to Pick Up a Load 5-18
Slow Lower5-18
Load Drifting/Settling5-19
Symptom Tables: Travel (Forward/Reverse) System 5-20
No Travel, Lift/Lower OK Main Contactor Does Not Close
TA Amber LED is Flashing Once Every 2 Seconds 5-20
No Travel, No Lift/Lower TA Flash Code 3,1 Operator
Display May Indicate Error Code E106 5-20
Raymond® Model 3010/3020 Maintenance Manual Table of Contents
Publication: 1134255, Issued: 25 Feb 2015 iii
No Travel, No Lift/Lower TA Flash Code 1,3 Operator
Display Indicates Error Code E2025-21
No Travel, No Lift/Lower TA Flash Code 1,2 Operator
Display Indicates Error Code E2015-21
No Travel, Main Contactor Does Not Close TA Flash Code 3,9
Operator Display Indicates Error Code E107 5-21
Slow Travel, Lift/Lower OK No Fault Codes 5-22
No Emergency Reverse, Travel/Lift/Lower OK
No TA Flash Codes5-22
No Rabbit Speed, Travel/Lift/Lower OK No Fault Codes 5-22
No Truck Functions Active TA Flash Code 1,8, (Excessive
Battery Voltage) Operator Display May Indicate E2225-22
No Truck Functions Active TA Flash Code 1,7, (Low
Battery Voltage) Operator Display May Indicate E2215-23
No Travel or Slow Travel TA Flash Code 2,2,
(Thermal Cutback) Heatsink Temperature Exceeded
185°F (85°C) Operator Display May Indicate Hot2 (C45) 5-23
No Travel Static Return to OFF (SRO) Fault
Display may indicate ‘Sro’ and Error and Parameter
Control Indicators Blinking 5-23
No Travel High Pedal Disable Fault
Display may indicate ‘HPd’ and Error and Parameter
Control Indicators Blinking 5-24
Truck Does Not Accelerate Correctly 5-24
Symptom Tables: Wiring System5-25
Symptom Tables: Guidance System 5-26
Jumper Harness Installation5-26
Unit Deviates from Trained Path 5-27
Erratic Behavior 5-27
Unit Accelerates Unexpectedly 5-27
Frequent Stoppages During Path Follow 5-28
Frequent Localization Failures 5-29
Light Curtain Module Intermittently Showing Obstruction 5-29
Low Battery Warning5-29
Obstruction Sensor Displays an Error Code (E1, and so forth) 5-30
Automated Truck Will Not Move 5-30
No GOI display 5-30
Automated Truck Boots with Camera Error 5-31
Steering Does Not Complete Alignment 5-31
VIM Lights Not On 5-31
GOI Screen Hangs Up During Start UP 5-31
Green “GO” Button Does Not Illuminate 5-32
VGU Indicator Lights Do Not Illuminate 5-32
GOI Displays “No Media Device Detected”5-32
GOI Displays “Not Enough Space on USB Disk” 5-32
GOI Does Not Acknowledge Key Presses 5-33
SICK “Windshield” LED Illuminated on Obstruction
Sensor or Light Curtain Module 5-33
Pallet Does Not Disengage5-33
Table of Contents Raymond® Model 3010/3020 Maintenance Manual
iv Publication: 1134255, Issued: 25 Feb 2015
Messages and Codes 6-1
List of Messages and Codes6-2
Traction Amplifier LED Diagnostics6-6
Traction Amplifier Flash Codes6-7
Caution and Error Codes 6-9
Message and Caution Codes 6-10
Code ‘tESt’6-10
Code ‘GaTE’ 6-10
Code ‘SLO’6-10
Code ‘Sro’ (C14) 6-11
Code ‘LoGn’ (C15) (iWAREHOUSE Only) 6-11
Code C19 6-11
Code ‘HPd’ (C20) 6-12
Code C21 6-12
Code C22 6-12
Code C24 6-13
Code C25 6-13
Code C26 6-13
Code C27 6-14
Code C30 6-14
Code C31 6-14
Code C32 6-15
Code C33 6-15
Code C34 6-15
Code C35 6-16
Code C36 6-16
Code C38 6-16
Code C39 (Models 3010 with Orderpicking Option)6-17
Code C40 6-17
Code Lo (C41) 6-17
Code Hi (C42) 6-18
Code Hot1 (C44) 6-18
Code Hot2 (C45) 6-19
Code C46 (iWAREHOUSE Only) 6-19
Code C47 (iWAREHOUSE Only) 6-19
Code C50 6-20
Code C51 6-20
Code C52 6-20
Code C57 6-21
Code C60 6-21
Code C61 6-21
Code C62 6-22
Code C63 6-22
Code C64 6-22
Code C65 6-23
Code C66 6-23
Code C67 6-24
Code C68 6-24
Code C70 6-24
Code C71 6-25
Code C72 6-25
Code C74 6-25
Raymond® Model 3010/3020 Maintenance Manual Table of Contents
Publication: 1134255, Issued: 25 Feb 2015 v
Code C756-26
Code C766-26
Code C776-26
Code C786-27
Code C796-27
Code C806-27
Code C816-28
Code C826-28
Code C836-29
Code C846-29
Code C856-29
Code C866-30
Code C876-30
Code C886-30
Code C896-31
Code C906-31
Code C916-31
Code C926-32
Code C936-32
Code C946-33
Error Codes 6-34
Code E101 6-34
Code E106 6-34
Code E107 6-35
Code E108 6-35
Code E140 6-35
Code E141 6-36
Code E150 6-36
Code E157 6-36
Code E159 6-37
Code E160 6-37
Code E201 6-37
Code E202 6-38
Code E203 6-38
Code E220 6-38
Code E221 6-39
Code E222 6-39
Code E223 6-39
Code E224 6-40
Code E225 6-40
Code E228 6-40
Code E230 6-41
Code E232 6-41
Code E233 6-41
Code E235 6-42
Code E252 6-42
Code E253 6-42
GOI Message Reference 6-43
Code 15 6-64
Component Procedures 7-1
List of Component Procedures by Truck System 7-2
Component Locator Photos7-5
Table of Contents Raymond® Model 3010/3020 Maintenance Manual
vi Publication: 1134255, Issued: 25 Feb 2015
Steering and Controls 7-9
Electric Power Steering 7-10
Replacing the Pinion Gear7-10
Replacing the Power Steer Unit 7-11
Learn Steer 7-11
Checking the Steer Position 7-12
Steer Home Proximity Sensor (SW23) 7-13
Sensor Replacement 7-13
Sensor Flag Adjustment 7-13
Power Steer Handle and Post Assembly 7-14
Removing Handle and Post7-14
Installing Handle and Post7-14
Handle Height Adjustment7-14
Control Head Removal7-15
Control Head Installation 7-15
Steering Potentiometer Replacement 7-16
Control Handle 7-21
Control Handle Disassembly 7-22
Drive and Brake7-25
Drive Unit7-26
Removing the Drive Unit 7-26
Removing the Steering Bearing7-28
Installing the Steering Bearing7-28
Disassembling the Drive Unit 7-29
Assembling the Drive Unit7-30
Checking the Gears 7-32
Adjusting the Tooth Pattern 7-32
Installing the Drive Unit 7-33
Drive Housing Lubrication7-35
Drive Wheel 7-36
Removing the Drive Wheel7-36
Cushion Tire Replacement7-36
Shim Caster Adjustment 7-38
Casters (Spring-Loaded) 7-39
Spring-Loaded Caster Removal7-39
Wheel Removal7-39
Caster Disassembly 7-40
Caster Assembly 7-41
Wheel Installation7-41
Spring-Loaded Caster Installation7-42
Brake7-43
Brake Removal7-43
Brake Installation7-44
Checking the Gap 7-44
Replacing the Rotor 7-44
Electrical Components 7-45
Battery 7-46
Trucks With Battery Gates and Rollers (Optional) 7-46
Battery Removal 7-46
Battery Installation 7-46
Battery Gates (Optional) 7-46
Battery Gate Inspection 7-46
Raymond® Model 3010/3020 Maintenance Manual Table of Contents
Publication: 1134255, Issued: 25 Feb 2015 vii
Battery Rollers (Optional)7-46
Battery Roller Inspection7-46
Battery Roller Replacement 7-46
Trucks Without Battery Gates and Rollers 7-46
Battery Removal 7-46
Battery Installation 7-46
Battery Exterior Cleaning7-47
Testing, Charging, and Maintenance 7-48
Maintenance-Free Batteries 7-48
Battery Storage 7-48
Power Cables7-49
Power Cable Repair 7-49
Wiring Harness 7-51
Wiring Harness Terminology 7-51
Inspecting a Wiring Harness 7-51
Repairing a Wiring Harness 7-51
AMP Water-Resistant Connectors7-53
AMP Connector Pin Extraction 7-53
AMP Connector Pin Insertion7-54
AMP Connector Seals7-54
AMP Harness/Traction Amplifier Connector 7-56
AMP Harness Connector Components7-56
AMP Harness Connector Disassembly (Contact Removal)7-56
AMP Harness Connector Assembly 7-57
Testing AMP Harness Connectors7-58
Lift-Limit Switch (SW8) 7-59
Adjusting the Limit Switch 7-59
Lower Limit Switch 7-60
Hydraulic Solenoids 7-61
Traction Amplifier 7-62
Removing the Traction Amplifier 7-62
Installing the Traction Amplifier 7-63
Programming the Traction Amplifier 7-63
Motors, General 7-64
Terminal Nuts 7-64
Traction Motor 7-65
Removing the Traction Motor7-65
Installing the Traction Motor7-67
Temperature Sensor Replacement7-68
Terminal Board Removal and Replacement 7-69
Speed Sensor Replacement 7-70
Motor Disassembly 7-71
Motor Assembly 7-73
Lift Motor7-76
General Data7-76
Removing the Lift Motor 7-76
Installing the Lift Motor 7-76
Guidance System Components 7-79
Automated Truck Guidance Components7-79
Powering Down 7-80
Powering ON 7-80
Arch 7-81
Table of Contents Raymond® Model 3010/3020 Maintenance Manual
viii Publication: 1134255, Issued: 25 Feb 2015
Floor Mat 7-81
Load Sensor 7-81
Component Removal and Replacement7-81
Cables7-82
Graphical Operator Interface (GOI)7-83
Removing the GOI7-83
Installing the GOI 7-83
Vision Guidance Unit (VGU) 7-84
Cleaning the Camera Lenses 7-84
Removing the VGU7-84
Installing the VGU7-84
Light Curtain Module (LCM) 7-86
Light Curtain Module Removal7-86
Light Curtain Module Installation 7-86
Light Curtain Module Calibration 7-86
Light Curtain Field Verification 7-86
Vehicle Interface Module (VIM)7-88
Removing the VIM7-88
Installing the VIM 7-88
Power Distribution Module (PDM)7-89
Removing the PDM7-89
Installing the PDM7-89
Obstruction (SICK) Sensor (OS) 7-90
Obstruction Sensor Removal 7-90
Obstruction Sensor Installation 7-90
Cleaning the SICK Shields7-90
Leveling the Obstruction Sensor 7-90
Steer Encoder7-92
Straight-Line Test7-92
Hydraulic Components 7-93
Hydraulic Components 7-94
General Guidelines7-94
Hydraulic Fluid 7-95
Checking Hydraulic Fluid Level 7-95
Hydraulic Unit7-96
Removing the Hydraulic Unit 7-96
Installing the Hydraulic Unit 7-96
Hydraulic Reservoir 7-97
Removing the Hydraulic Reservoir7-97
Installing the Hydraulic Reservoir 7-97
Filter Screen and Suction Tube 7-98
Removing Filter Screen and Suction Tube7-98
Installing Filter Screen and Suction Tube 7-98
Hydraulic Pump 7-99
Removing the Pump 7-99
Installing the Pump 7-99
Adjusting Hydraulic Pump Relief Valve Pressure7-100
Checking Relief Valve Setting7-100
Alternate Method Using Rated Load on Pallets 7-101
Raymond® Model 3010/3020 Maintenance Manual Table of Contents
Publication: 1134255, Issued: 25 Feb 2015 ix
Hydraulic Ram 7-102
Inspecting Hydraulic Ram 7-102
Removing Hydraulic Ram 7-102
Installing Hydraulic Ram 7-104
Hydraulic Cylinder Seals 7-106
Disassembling the Cylinder7-106
Assembling the Cylinder7-107
Cast Hydraulic Cylinder Repair7-108
Disassembly7-108
Assembly 7-108
Mast 7-109
Top Linkage Subassembly 7-110
Removing the Top Linkage Subassembly7-110
Installing the Top Linkage Subassembly7-111
Pull Rod Subassembly 7-113
Removing the Pull Rod Subassembly 7-113
Installing the Pull Rod Subassembly7-114
Load Wheels7-116
Single Load Wheels – Model 3010 7-116
Tandem Load Wheels – Model 30107-117
Suspension Wheel – Model 30207-118
Pallet Entry Sliders7-120
Slider Replacement 7-120
Pallet Entry Rollers7-121
Roller Replacement 7-121
Fork Height Adjustment7-122
Measurement/Adjustment 7-123
Downstop Installation 7-124
Downstop Adjustment 7-124
Pallet Entry/Exit Enhancements 7-125
Options 7-129
Cold Storage Conditioning 7-130
Battery Spacer Kit Installation 7-131
Part Selection 7-132
Installation 7-133
Battery Gate Interlock Sensors 7-134
Battery Gate Interlock Sensor Replacement7-134
Battery Gate Interlock Sensor Adjustment 7-134
Theory of Operation 8-1
Definitions8-2
Acceleration Rate 8-2
Continuity8-2
Controller Area Network (CAN)8-2
Current Limiting 8-2
Fault Codes 8-2
High Pedal Disable (HPD) 8-2
Neutral Plugging Rate (Deceleration) 8-2
Open Circuit 8-2
Overvoltage Cutoff8-2
PIN-Key Code 8-2
Pulse Width Modulation 8-3
Ramp Shape 8-3
Table of Contents Raymond® Model 3010/3020 Maintenance Manual
x Publication: 1134255, Issued: 25 Feb 2015
Regenerative Braking 8-3
Sequencing Delay 8-3
Short Circuit or “Short”8-3
Speed Limiting 8-3
Static Return To Off (SRO) 8-4
Thermal Cutback (Traction Amplifier) 8-4
Throttle Map 8-4
Truck Off Delay (Keypad only) 8-4
Undervoltage Cutoff8-4
VM (Vehicle Manager) 8-4
Walking Speed 8-4
Traction System8-5
Vehicle Manager (VM) 8-5
Traction Amplifier (TA) 8-5
Battery Plugged In 8-5
Key Switch ON 8-6
Travel Request, Tractor-First (Manual Mode) 8-6
Travel Request, Forks-First8-7
Travel Request, Tractor-First (Automatic Mode)8-7
Floor Mat Switch (SW25) JP37-1 input to the TA 8-7
E-Stop Circuit 8-8
Lift/Lower System 8-9
Lift (Manual Mode) 8-9
Lift (Automatic Mode) 8-9
Lower (Manual Mode) 8-9
Lower (Automatic Mode)8-9
Theory of Operation – Electric Power Steering 8-10
Power Steering Potentiometers8-10
PSU: Power Steering Unit 8-10
Steering (Manual Mode) 8-10
Steering (Automatic Mode)8-11
Travel Speed Reduction (Manual Mode) 8-11
Travel Speed Reduction (Automatic Mode)8-11
Jumper Harness 8-11
Pinout Matrix 8-12
Appendix A-1
Lubrication Equivalency ChartA-2
Thread Adhesives, Sealants, and Lubricants A-3
Component Specific Service/Torque ChartA-4
Torque Chart – Standard (Ferrous)A-7
Torque Chart – Standard (Brass) A-8
Torque Chart – Metric (Ferrous) A-9
Torque Chart – Metric (Brass)A-10
Torque Chart – Thread Forming Screws A-11
Torque Chart – Metric Thread-Forming Screws A-13
Torque Chart – Hydraulic Fittings A-14
Torque Chart – Straight Thread Face Seal O-Rings A-15
Decimal Equivalent Chart A-16
Standard/Metric Conversions A-18
Index I-1
IMAGES PREVIEW OF THE MANUAL:
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V
