Raymond forklift pump motor brush set
Part: Raymond brush pack
Price after confirming pump motor heat, brush length, and hydraulic load.
$25-$40
Check price
Raymond Forklift Error Codes - ACR Fault Families
Raymond forklifts (7000, 8000, 9000 series reach trucks, order pickers, and counterbalanced models) use the ACR (Advanced Control Resolution) system. Codes are displayed as two-digit format (X-X) on the operator display.
Raymond Traction System Codes (1-X)
| Code | Fault | Common Cause | Action |
|---|---|---|---|
| 1-1 | Traction controller internal | ACR board failure | Cycle key, replace ACR if persists |
| 1-2 | Traction motor overtemp | Drive motor too hot | Let cool 30 min, check fan |
| 1-3 | Traction motor current limit | Excessive drive current | Check motor, wiring, wheel bearings |
| 1-4 | Traction motor field fault | Field winding short/open | Check field wiring, motor |
| 1-5 | Accelerator pedal fault | Accelerator sensor out of range | Check pedal sensor 0.5-4.5V signal |
| 1-6 | Brake fault | Parking brake not releasing | Check brake solenoid, linkage |
| 1-7 | Contactor fault | Main contactor failed open | Check contactor coil, tips |
| 1-8 | Controller overtemp | ACR heatsink too hot | Check cooling fan, clean fins |
Raymond Hydraulic and Steer Codes (2-X)
| Code | Fault | Common Cause | Action |
|---|---|---|---|
| 2-1 | Pump motor overtemp | Continuous lift operation | Let cool, reduce cycle rate |
| 2-2 | Pump motor current limit | Hydraulic pump binding | Check pump, hydraulic oil level |
| 2-3 | Lift position sensor | Height sensor signal lost | Check sensor connector, replace |
| 2-4 | Tilt position sensor | Tilt sensor out of spec | Check sensor, linkage |
| 2-5 | Steer motor overtemp | Continuous maneuvering | Let cool, reduce tight turns |
| 2-6 | Steer encoder fault | Steer feedback signal lost | Check encoder harness, replace |
Raymond Battery and System Codes (3-X)
| Code | Fault | Common Cause | Action |
|---|---|---|---|
| 3-1 | Battery voltage low | Battery discharged | Charge to 100% |
| 3-2 | Battery voltage high | Overcharge or wrong battery | Check charger setting, battery voltage |
| 3-3 | Battery temperature high | Battery overheated | Let cool, check charger profile |
| 3-4 | Battery charger comm | Charger not communicating | Check CAN wiring between charger/ACR |
| 3-5 | System voltage fault | Internal power supply | Replace ACR controller |
| 4-1 | CAN bus communication | Wiring or terminator failure | Check CAN harness, 120 ohm terminator |
| 4-2 | Display comm lost | Display module not responding | Check display connector, replace |
| 4-3 | System configuration lost | ACR memory/power lost | Reload config via Raymond Service Tool |
Most Common Raymond Forklift Faults
Code 2-1 — Pump Motor Overtemp
The most common code on Raymond reach trucks, especially in high-throughput warehouses running double-shift operations. The pump motor drives the hydraulic system for lift, tilt, and attachments. When operated at high cycle rates, the motor temperature exceeds the sensor threshold and the controller limits lift speed to creep mode.
The fix is usually time - let the truck cool with the key off for 20-30 minutes. But if it happens daily, the pump motor brushes may be worn, causing increased resistance and heat. Check brush length and compare it with the service manual before ordering a brush set.
Code 1-1 — ACR Controller Fault
When the ACR controller itself fails, the truck is dead. Cycle the key off and wait 60 seconds for the capacitors to discharge. If the code clears on restart, it was a transient fault. If it persists, the ACR board needs replacement. Raymond Generation III ACR controllers run about $1,200-2,000. Before ordering, check all harness connectors to the ACR; a corroded connector can look like an expensive failed controller.
Code 3-1 — Battery Low
Raymond 36V and 48V electrics cut lift and drive functions when battery voltage drops below the controller threshold. On reach trucks, this threshold is typically 31.5V for 36V systems. If a fully-charged battery triggers 3-1 within a short time, the battery has lost capacity. For lead-acid: check water levels and perform an equalization charge. For lithium-ion: check the BMS for cell group faults. Raymond has a battery profile setting in the ACR — make sure the correct battery type (lead-acid vs Li-Ion) is selected.
Parts Reference
| Part | Notes | Cost |
|---|---|---|
| Pump motor brush set | Raymond brush packs per model | $25-$40 |
| Accelerator pedal sensor | Raymond 930860-xxx | $80-$150 |
| ACR controller (Gen III) | Raymond 953385-xxx | $1,200-$2,000 |
| Display module | Raymond 959500-xxx | $400-$700 |
| Contactor (main) | Raymond 937200-xxx | $100-$200 |
| Hydraulic pump motor | Raymond model-specific | $400-$800 |
Focused Parts Searches
Before ordering, match the replacement part to the truck model, battery voltage, connector style, controller family, and failure symptom.