Raymond Pallet Truck 8510

Turn the truck OFF and disconnect the battery connector

Caution: Note the position of cable ties holding harnesses and cables. When reassembling, attach new cable ties in the same locations.

Remove the cable ties securing the cables and harness above the brake drum

Attach the two brake release bolts and tighten only until snug. Do not overtighten.

Remove the three 6 mm screws that hold the brake to the mounting plate

Lift the brake off the motor. The rotor remains on the motor shaft.

Lift the rotor off the motor shaft.

Reconnect all harness connections unplugged in previous procedures

Check if the traction amplifier has a flash code active

Is the red LED on the TA solid RED?

Cycle the key switch. Did the solid RED light turn off?

Hold down the horn button and turn the key switch ON. Did 'E' display?

Scroll through the stored codes with the throttle. Are there additional codes other than E150?

Using a service key, connect to the truck and enter service mode. Are all service mode functions normal?

Using FlashWare, connect to the truck. Does FlashWare communicate with the VM?

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

Check bolt torque of major components (motors, brake, drive unit, and hydraulic unit)

Replace any broken or missing hardware

Upload a photo of the replaced hardware

Sign off on the hardware maintenance

Set the brake, turn the key switch OFF, remove the key (if equipped), and disconnect the battery connector.

Upload a photo of the installed caster assembly

Check if the caster wheel hits the frame and does not rotate the full 360 degrees.

Adjust the coarse adjustment to place the caster wheel against the floor. Use shims only if needed.

Use the caster fine adjustment screw to make sure the caster just contacts the floor (after taking out any existing play). Loosen the jam nut. Turn the bolt OUT to lower the caster, turn the bolt IN to raise the caster. Tighten the jam nut when adjustment is complete.

Reconnect the battery connector and turn the key switch ON.

Warning: This maintenance check requires trained personnel with PPE!

Inspect commutator for surface condition and high mica

If the armature on your motor does not have the mica undercut, do not attempt to cut it

Check if the commutator is smooth and clean to provide maximum brush wear

When commutators are not correctly maintained, carbon dust can collect in the grooves between the segments leading to a short circuit in the armature

Check for good commutation indicated by a dark brown polished commutator and an evenly polished brush wearing surface

If the commutator appears rough, pitted, or has signs of burning or heavy arcing between the commutator bars, remove the motor for service

Check if the commutator requires service and if so, remove the armature from the motor

Do not use a stone to even out high and low spots on the commutator. Servicing a motor for an abnormal commutator surface condition and high mica or mica undercutting requires special equipment at a motor rebuilding facility