Raymond 8210 - Page 151

Model 8210/8250 Maintenance Manual Section 7. Component Procedures
List of Component Procedures by Component System
Publication: 1146945/001, Revised: 25 Sep 2018 7-3
Cell Module Assembly, Battery
Monitoring Unit, and Cell
Module Assembly Fuse
Installation . . . . . . . . . . . . . 7-52
Battery Management Controller. . . 7-54
BMC Removal . . . . . . . . . . . . . 7-54
BMC Installation . . . . . . . . . . . 7-55
BMC Fuse . . . . . . . . . . . . . . . . . . . 7-56
BMC Fuse Removal . . . . . . . . . 7-56
BMC Fuse Installation . . . . . . . 7-56
Charger . . . . . . . . . . . . . . . . . . . . 7-56
Charger Removal . . . . . . . . . . . 7-56
Charger Installation . . . . . . . . 7-57
Charger Cord . . . . . . . . . . . . . . . . 7-57
Charge Cord Removal . . . . . . . 7-57
Charge Cord Installation . . . . . 7-57
Lithium-ion Battery User
Interface (HUD) . . . . . . . . . . . . . 7-58
Lithium-ion Battery Display
Removal. . . . . . . . . . . . . . . . 7-58
Lithium-ion Battery Display
Installation . . . . . . . . . . . . . 7-58
Wire Harness . . . . . . . . . . . . . . . . 7-58
Wire Harness Removal. . . . . . . 7-58
Wire Harness Installation . . . . 7-59
Counterweight . . . . . . . . . . . . . . . 7-60
Counterweight Removal. . . . . . 7-60
Counterweight Installation . . . 7-60
Cooling Fan . . . . . . . . . . . . . . . . . 7-61
Cooling Fan Removal . . . . . . . . 7-61
Cooling Fan Installation . . . . . 7-61
SBX Cable Assembly . . . . . . . . . . . 7-61
SBX Cable Assembly
Removal. . . . . . . . . . . . . . . . 7-61
SBX Cable Assembly
Installation . . . . . . . . . . . . . 7-62
Specification and Warning
Labels . . . . . . . . . . . . . . . . . . . . 7-63
Label Removal . . . . . . . . . . . . . 7-63
Label Installation. . . . . . . . . . . 7-63
Battery Connector (Lead Acid
Battery) . . . . . . . . . . . . . . . . . . . 7-64
Inspection. . . . . . . . . . . . . . . . . . . 7-64
Battery Connector Access
and Removal . . . . . . . . . . . . . . . 7-64
Cable Removal, Replacement,
and Installation . . . . . . . . . . . . . 7-65
Power Cables . . . . . . . . . . . . . . . . . . . 7-66
Power Cable Repair . . . . . . . . . . . . 7-66
Wiring Harness . . . . . . . . . . . . . . . . . 7-68
Wiring Harness Terminology . . . . . 7-68
Wiring Harness Inspection . . . . . . 7-68
Wiring Harness Repair . . . . . . . . . 7-69
Wiring Harness Soldering
Procedures . . . . . . . . . . . . . . . . 7-69
Main Harness Bracket Removal . . 7-70
Main Harness Installation . . . . . . 7-70
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
Fuse Test/Inspection . . . . . . . . . . 7-72
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
Horn Removal . . . . . . . . . . . . . . . 7-73
Horn Installation . . . . . . . . . . . . . 7-73
Traction Amplifier . . . . . . . . . . . . . . . . 7-74
To Clean the Traction Amplifier . . 7-74
Traction Amplifier Removal. . . . . . 7-74
Traction Amplifier Installation . . . 7-74
Contactors . . . . . . . . . . . . . . . . . . . . . 7-76
Resistance Testing . . . . . . . . . . . . 7-76
Contactor Removal . . . . . . . . . . . . 7-76
Contactor Installation. . . . . . . . . . 7-76
Lift Motor Solenoid . . . . . . . . . . . . . . . 7-78
Switches (General) . . . . . . . . . . . . . . . 7-79
Testing/Inspecting Switches. . . . . 7-79
Main ON/OFF Switch. . . . . . . . . . 7-79
Main ON/OFF Switch
Inspection . . . . . . . . . . . . . . 7-79
Main ON/OFF Switch
Removal . . . . . . . . . . . . . . . 7-79
Main ON/OFF Switch
Installation . . . . . . . . . . . . . 7-79
2-Position Keyed Switch
(Optional) . . . . . . . . . . . . . . . . . 7-80
Replacement. . . . . . . . . . . . . . 7-80
Arm Angle Proximity Switch . . . . . 7-80
Replacement. . . . . . . . . . . . . . 7-80
Arm Angle Proximity Switch
Adjustment . . . . . . . . . . . . . 7-81
Lift Cutout Proximity Switch . . . . 7-82
Replacement. . . . . . . . . . . . . . 7-82
DC Motors, General . . . . . . . . . . . . . . 7-83
Motor Brush Inspection . . . . . . . . 7-83
Motor Brush Replacement . . . . . . 7-83
Motor Brush Spring Tension . . . . 7-84
Brush Spring Tension
Inspection . . . . . . . . . . . . . . 7-84
Terminal Nuts . . . . . . . . . . . . . . . 7-85
Polishing the Commutator . . . . . . 7-85
Traction Motor . . . . . . . . . . . . . . . . . . 7-86
Traction Motor Disassembly . . . . . 7-88
Traction Motor Assembly . . . . . . . 7-88
Speed Sensor (Encoder)
Replacement . . . . . . . . . . . . 7-89
Terminal Block Replacement . 7-90
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