Service Manual - 4100-4200 Stand-Up Counterbalanced

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Maintenance Manual
Models 4100 and 4200
Stand-Up Counterbalanced Lift Trucks
With The ACR System ™
Models Serial Numbers

4100 00001 and Up
4200 00001 and Up
1060345A Issued: 8/27/07

This publication, 1060345A, applies to the Stand-Up Counterbalanced Lift Truck Model 4100 and 4200,
serial number 00001 and up, and to all subsequent releases of this product until otherwise indicated in
new editions or bulletins. Changes occur periodically to the information in this publication.
If you need assistance with your lift truck, or need to order additional copies of this manual, contact your
local authorized Raymond dealer. To locate your local authorized Raymond dealer, go to
www.raymondcorp.com.
©2007 The Raymond Corporation.

The following terms are trademarks of The Raymond Corporation: The ACR System, Maintenance Minder,
Raymond. All other brand and product names are trademarks or registered trademarks of their respective
companies.
Models 4100/4200 Maintenance Manual Table of Contents
Table of Contents
How to Use This Manual . . . . . . ........... . ........... . . . . 1-1
Map of the Manual . . . . . . . . ............ . ............ . . . . . 1-2
Manual Design . . . . . . . . . . . ............ . ............ . . . . . 1-4
Abbreviations and Symbols . . ............ . ............ . . . . . 1-5
Safety. . . . . . . . . . . . . . . . . . . . ........... . ........... . . . . 2-1

Safety Definitions . . . . . . . . . ............ . ............ . . . . . 2-2
General Safety . . . . . . . . . . . . ............ . ............ . . . . . 2-3
Battery Safety . . . . . . . . . . . . ............ . ............ . . . . . 2-5
Static Precautions . . . . . . . . . ............ . ............ . . . . . 2-8
Jacking Safety . . . . . . . . . . . . ............ . ............ . . . . 2-10
Towing Safety . . . . . . . . . . . . ............ . ............ . . . . 2-11
Welding Safety . . . . . . . . . . . . ............ . ............ . . . . 2-12
Systems Overview . . . . . . . . . . . ........... . ........... . . . . 3-1

General . . . . . . . . . . . . . . . . . ............ . ............ . . . . . 3-2
Lift Truck Specifications . . . . ............ . ............ . . . . . 3-3
Modes of Operation . . . . . . . . ............ . ............ . . . . . 3-4
Passwords . . . . . . . . . . . . . . . ............ . ............ . . . . 3-10
Attachment Control . . . . . . . . ............ . ............ . . . . 3-12
FlashWare Program . . . . . . . . ............ . ............ . . . . 3-15
Cold Storage . . . . . . . . . . . . . ............ . ............ . . . . 3-23
Storage . . . . . . . . . . . . . . . . . ............ . ............ . . . . 3-24
Scheduled Maintenance . . . . . . . . . . . . . . . . . . ........... . . . . 4-1

Scheduled Maintenance Guidelines . . . . . . . . . ............ . . . . . 4-2
Maintenance Minder™ Tool . . . . . . . . . . . . . . . ............ . . . . . 4-3
Initial 90 Day/250 HD Maintenance . . . . . . . . ............ . . . . . 4-5
Every 180 Days or 500 Deadman Hours (HD) . ............ . . . . . 4-6
Every 360 Days or 1500 Deadman Hours (HD) ............ . . . . . 4-9
Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ . . . . 4-10
Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . ............ . . . . 4-11
Troubleshooting . . . . . . . . . . . . ........... . ........... . . . . 5-1

Electrical Troubleshooting . . . ............ . ............ . . . . . 5-2
Contactors . . . . . . . . . . . . . . . ............ . ............ . . . . 5-17
Hydraulic Troubleshooting . . . ............ . ............ . . . . 5-18
Messages, Codes, and Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Operator Display Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Messages and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Component Procedures . . . . . . . . . . . . . . . . . . . ........... . . . . 7-1

List of Component Procedures . . . . . . . . . . . . . ............ . . . . . 7-2
Component Locator . . . . . . . . . . . . . . . . . . . . . . ........... . . . . 7-5
Steering and Controls . . . . . . . . . . . . . . . . . . . . ........... . . . . 7-9
Steerable Wheel Assembly . . . . . . . . . . . . . . . . ............ . . . 7-10
Control Handle - Standard . . . . . . . . . . . . . . . . ............ . . . 7-15
Control Handle - Optional. . . . . . . . . . . . . . . . . ............ . . . 7-18
Publication: 1060345A, Issued: 8/27/07 i

Table of Contents Models 4100/4200 Maintenance Manual
Drive and Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... 7-23

Drive Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ . 7-24
Drive Axle Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ . 7-26
Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . ............ . 7-30
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ . 7-31
Electrical Components . . . . . . . . . . . . . . . . . . . . . . ........... 7-33
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ . 7-34
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ . 7-41
Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ . 7-43
Battery Procedures. . . . . . . . . . . . . . . . . . . . . . . . . ............ . 7-44
Power Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . ............ . 7-45
Wiring and Harness Connectors . . . . . . . . . . . . . . . ............ . 7-46
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . ........... 7-55
Manifold Solenoids, Fittings, and Attachments . . . . ............ . 7-56
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ . 7-62
Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . ............ . 7-64
Cylinder Service . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ . 7-65
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... 7-67
Mast Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ . 7-68
Carriage - Model 4200 . . . . . . . . . . . . . . . . . . . . . . ............ . 7-78
Cylinder Removal/Installation . . . . . . . . . . . . . . . . ............ . 7-80
Free Lift Cylinder Supply Hose - Model 4200 . . . . . ............ . 7-83
Hose Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ . 7-84
Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ . 7-92
Mast Tilt Adjustment . . . . . . . . . . . . . . . . . . . . . . . ............ . 7-94
Theory of Operation . . . . . . . . . . . . ........... . ........... . 8-1

System Architecture . . . . . . . . . . ............ . ............ . . 8-2
Systems Overview . . . . . . . . . . . . ............ . ............ . . 8-3
Traction System Theory . . . . . . . . ............ . ............ . . 8-6
Steering System Theory . . . . . . . . ............ . ............ . . 8-8
Lift/Lower System Theory . . . . . . ............ . ............ . . 8-9
Pinout Matrix . . . . . . . . . . . . . . . ............ . ............ . 8-13
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Lubrication Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Thread Adhesives, Sealants, and Lubricants . . . . . . . . . . . . . . . . . . . A-3
Component Specific Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Torque Chart - Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Torque Chart - Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Torque Chart - Standard (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
ii Publication: 1060345A, Issued: 8/27/07

Models 4100/4200 Maintenance Manual Page Revision Record
Page Revision Record

This section is a record of original or revised
pages of this manual.
Whenever a page is revised, this section is

updated and included in the revision package.
Custodians of this manual need to ascertain

that the date of the page matches the date
shown in this section.
Pages are revised due to technical and

non-technical changes described as follows:
• Technical changes – These changes are
identified by a vertical line (change bar) in
the left margin next to the change. Pages
affected by technical changes are
identified with the revision date in the
footer. These pages are also available on
the Raymond iNet.
• Non-technical changes – These changes
consist of typographical and grammatical
corrections, paragraph renumbering,
repagination, and so forth. Non-technical
changes are not identified with a change
bar; however, affected pages are identified
with the revision date in the footer.
Original Issue Date: 8/27/07
Publication: 1060345A, Issued: 8/27/07 iii

Page Revision Record Models 4100/4200 Maintenance Manual
iv Publication: 1060345A, Issued: 8/27/07

Models 4100/4200 Maintenance Manual Section 1. How to Use This Manual
Section 1. How to Use This Manual
Publication: 1060345A, Issued: 8/27/07 1-1

Section 1. How to Use This Manual Models 4100/4200 Maintenance Manual
Map of the Manual
Map of the Manual
Table of
Contents Page Revision Record
How To Use This

Manual Map of the Manual
Manual Design
Safety
Abbreviations and
Systems Symbols
Overview Vehicle Specifications
Scheduled
Maintenance
Troubleshooting
Messages, Codes
And Tests
Go to Chart
MAP2
1-2 Publication: 1060345A, Issued: 8/27/07

Map of the Manual
MAP2: Map of the Manual (Continued)
Component
Procedures List of Component
Procedures
Component Location
Theory of Photos
Operation
Appendix Lubrication
Equivalency Chart
Torque Charts
Index
Decimal Equivalent
Chart
Standard/Metric
Conversions
Electrical and
Hydraulic
Schematics

Manual Design
Manual Design • Component Procedures gives

step-by-step procedures for testing,
removing, replacing, and servicing
This manual is designed with the following individual lift truck components.
objectives in mind: Components are grouped by lift truck
• provide technical coverage for expected system. To find a component procedure,
levels of user expertise you may use one of three methods:
• anticipate your needs and reduce your • Look up the component name in the
decisions regarding maintenance List of Component Procedures.
• reduce page flipping through a “one-stop • Find the component in the Component
shopping” approach Locator Photos.
• Look up the component name in the
The two-line running page header at the top of maintenance manual Index.
each page tells you:
• Theory of Operation explains signal flow
• Name of the manual within the electrical and hydraulic
(Model 4100 and 4200 Maintenance systems for various conditions of lift truck
Manual) operation. This section also contains a
• Current Section Title detailed connection point table (Pinout
(for example, this page; Section 1. How to Matrix) designed to assist in testing and
Use This Manual) troubleshooting the truck.
• Current topic • Appendix contains reference information
(for example, this page; Manual Design) such as torque values, lubricants,
standard/metric conversions, and system
This manual consists of the following sections: schematics.
• How to Use This Manual explains the • Index lists subjects alphabetically.
manual format and design as well as
abbreviations and symbols used.
• Safety explains warning and caution notes
and general safety rules, as well as safety
rules for batteries, static, jacking, and
welding.
• Systems Overview includes general lift
truck specifications, programming
instructions, and configuration menu.
• Scheduled Maintenance outlines the
recommended schedule of preventive
services to keep the lift truck working
most efficiently.
• Troubleshooting guides the user from
fault symptoms to a specific sequence of
tests in order to isolate a failing
component.
• Messages, Codes and Tests lists the
electrical fault codes and procedures for
running firmware-based electrical tests.

Abbreviations and Symbols
Abbreviations and
Symbols
The following abbreviations, acronyms, and symbols are used in this manual.
Term/Symbol Definition Term/Symbol Definition

A Ampere gal. gallon or gallons
Agnd analog ground Gnd ground
amp Ampere or amplifier
approx/Approx. approximately HD hours on deadman
Assy assembly Ht height
Aux auxiliary Hgt/Wgt Height/Weight
AWG American Wire Gauge
in. inch or inches
BSOC Battery State-of-Charge
kg kilogram(s)
CAN Controller Area Network kHz kilohertz
CCW counterclockwise km/h kilometers per hour
cm centimeter kPa kilo Pascal
COP Computer Operating
Program lb. pound or pounds
CW clockwise L/H Load Holding
CS cold storage L/L Lift/Lower
LPA Lift Power Amplifier
Dgnd/D-GND digital ground LPC Lift Power Contactor
DMLL Deadman Lift/Lower LTPA Left Traction Power Amp
DMM Digital Multi Meter
DVM Digital Voltmeter mA milliampere
max maximum
EE UL Electric Truck Type min minute or minimum
Certification Rating where mm millimeter
electrical equipment is
MM Maintenance Minder™
completely enclosed
mph miles per hour
EMF ElectroMotive Force
mS millisecond or milliseconds
EPO Emergency Power Off
mV millivolt or millivolts
ESD Electrostatic Discharge
mVAC millivolts - alternating
ESDS Electrostatic Discharge
current
Sensitive
FF Forks-first
fpm feet per minute
FRC Fuse/Relay Card
ft. foot or feet

Abbreviations and Symbols
Term/Symbol Definition Term/Symbol Definition

No. number V Volt or Volts
NV non-volatile VDC Volts Direct Current
NVM Non-Volatile Memory VM Vehicle Manager
Nm newton meter wrt with respect to
Wt Weight
OACH Overall Collapsed Height w/ with
OD Operator Display w/o without
OI Operator Interface
OSHA Occupational Safety and @ at
Health Association ™ trademark
oz. ounce © copyright
+ plus or positive
prox proximity – minus or negative
pot potentiometer ± plus or minus
psi pounds per square inch ° degrees
PTC Positive Temperature °F degrees Fahrenheit
Coefficient (Thermistors) °C degrees Celsius/Centigrade
PWM Pulse Width Modulation < less than
P/N Part Number > greater than
% percent
rpm Revolutions per Minute = equals
R/R repair/replace
RTPA Right Traction Power Amp
SAE Society of Automotive

Engineers
sec. second
SG specific gravity
SOL Solenoid
spec specification
SW Switch
temp Temperature
TF Tractor-first
TML Traction Motor Left
TMR Traction Motor Right
TPA Traction Power Amplifier
TPC Traction Power Contactor
TS Traction Speed
T/S troubleshoot
UL Underwriters Laboratories,
Inc.

Models 4100/4200 Maintenance Manual Section 2. Safety
Section 2. Safety

Section 2. Safety Models 4100/4200 Maintenance Manual
Safety Definitions
Safety Definitions
Throughout this manual, you will see two kinds
of safety reminders:
Indicates a potentially hazardous

situation which, if not avoided, could
result in death or serious injury.
Indicates a potentially hazardous

situation which, if not avoided, may
result in minor or moderate injury. It can
also be used to alert against unsafe
practices.

General Safety
General Safety Operate this lift truck only from the operator
position.
Do not operate or work on this lift truck unless

you are trained, qualified, and authorized to do
so, and you have read both the Owner Manual
and the Operator Manual.
27j27011s.eps
Before working on this truck, turn the key

switch OFF and disconnect the battery
connector (unless this manual tells you
21864_002.eps otherwise).
Do not operate or work on this lift truck unless

you know the truck’s controls and what they
do.
?
27j27012s.eps
Always use and park this lift truck indoors.
27j27009s.eps
Do not operate this lift truck if it needs repair or

if it is in any way unsafe.
27j27014s.eps
Do not park in a cold storage area overnight

unless the lift truck is conditioned for cold
storage.
27j27010s.eps

General Safety
Do not wear watches, rings, or jewelry when Do not use gasoline or other flammable liquids
working on this truck. for cleaning parts.
21864_067.eps 23369_002.eps
Perform exactly the scheduled lubrication, Properly clean up any hydraulic fluid, oil, or
maintenance, and inspection steps. grease that has leaked or spilled on the floor.
2schedmnt.eps 2spills.eps
Follow exactly the safety and repair instructions Do not wash this lift truck with a hose. Do not
in this manual. Do not take shortcuts. steam clean inside compartments.
21864_003.eps 23369_001.eps
Do not use an open flame near the truck. Do not add to or modify this lift truck until you
contact your local authorized Raymond dealer
to receive written manufacturer approval.
27j27013s.eps
27j27015s.eps

Battery Safety
Battery Safety goggles or face shield, rubber gloves (with or

without arm shields), and a rubber apron.
As a battery is being charged, an

explosive gas mixture forms within and
around each cell. If the area is not
correctly ventilated, this explosive gas
can remain in or around the battery for
several hours after charging. Make sure 225l6s016.eps
there are no open flames or sparks in

the charging area. An open flame or Make sure a shower and eyewash station are
spark can ignite this gas, resulting in nearby in case there is an accident.
serious damage or injury.
Battery electrolyte is a solution of

sulfuric acid and water. Battery acid
causes burns. Should any electrolyte
come in contact with your clothing or
skin, flush the area immediately with
cold water. Should the solution get on
your face or in your eyes, flush the area
with cold water and get medical help 204g6s059.eps
immediately.
A battery gives off explosive gases. Never smoke,
Read, understand, and follow procedures, use an open flame, or use anything that gives
recommendations, and specifications in the off sparks near a battery.
battery and battery charger manufacturer’s
manuals.
223l6s012.eps
225l6s014.eps
Keep the charging area well-ventilated to avoid
hydrogen gas concentration.
Wear personal protective equipment to protect
eyes, face, and skin when checking, handling,
or filling batteries. This equipment includes
204g6s058.eps

Battery Safety
Turn the key switch OFF before disconnecting Keep plugs, terminals, cables, and receptacles
the battery from the lift truck at the battery in good condition to avoid shorts and sparks.
connector. Do not break live circuits at the
battery terminals. A spark often occurs at the
point where a live circuit is broken.
27j27012s.eps
Do not lay tools or metal objects on top of the 227ys7s013.tif
battery. A short circuit or explosion could

Keep filler plugs firmly in place at all times
result.
except when the electrolyte level is checked,
when water is added to the cells, or when the
specific gravity is checked.
Make sure vent holes in filler plugs are open to

allow the gas to escape from the cells.
Vent Hole
204g6s057.eps
Keep batteries clean. Corrosion causes shorts

to the frame and possibly sparks.
209g6s047.tif
Do not allow cleaning solution, dirt, or any

foreign matter to enter the cells.

Battery Safety
Make sure you install the correct size battery. A

smaller or lighter weight battery could seriously
affect lift truck stability. See the lift truck’s
specification plate for more information.
22823_010.eps
Never plug a battery charger into the truck’s

battery connector. Plug the battery charger only
into the battery connector from the battery.
27j27017s.eps

Static Precautions
Static Precautions 2
Ground Jack
Electronic circuit boards can contain
Electrostatic Discharge Sensitive (ESDS)
devices.
Static charges can accumulate from standard

operation of the lift truck as well as movement
or contact between non-conductive materials
such as plastic bags, synthetic clothing,
synthetic soles on shoes, and styrofoam coffee
cups.
Accumulated static electricity can be

discharged to a circuit board or component by
touching the parts. Electrostatic Discharge
(ESD) is also possible through the air when a
charged object is placed close to another
surface at a different electrical potential. Static Figure 2-1. Ground Jack Location
discharge can occur without seeing or feeling it.
• Handle circuit boards by the edges only.
Avoid touching the edge connectors.
Whenever working on or near ESDS devices,
follow these precautions: • If you are removing or installing
static-sensitive components, place them
• Wear an ESD wrist strap. The wrist strap
on a correctly grounded antistatic mat.
should be equipped with a 1 megohm
resistor to protect against shock hazard. If • To transport static sensitive components,
the resistor is open, replace the strap. including failed components being
returned, place the components in an
• Connect the wrist strap plug to the ground
antistatic bag or box (available from your
jack on the lift truck. See Figure 2-1. If
local authorized Raymond dealer).
you cannot use the ground jack, connect
the ground clip to an unpainted, grounded
Test the wrist strap and related accessories
surface on the lift truck frame.
before each use to make sure they are working
correctly.
Figure 2-2 shows the components of the

Raymond antistatic field service kit as
P/N 1-187-059.

Static Precautions
2MAT2.TIF
Figure 2-2. Anti-Static Kit with Wrist Strap and Mat
The kit includes a wrist strap, ground cord, and

static-dissipative work surface (mat). Follow the
instructions packaged with the kit.
Wrist straps (P/N 1-187-058/001) are available

in quantities of 25.
A wrist strap tester (P/N 1-187-060) is also

available.
Contact your local authorized Raymond dealer

for information.

Jacking Safety
Jacking Safety
Some maintenance procedures require the lift
truck to be jacked up. Observe the safety
precautions that follow when jacking the truck.
1. Lower the forks completely to the floor.
Remove any load.
2. Place all controls in neutral.
3. Block the wheels to prevent movement of
the vehicle.
4. Turn the key switch OFF and disconnect
the battery connector.
28D14047S.TIF
Figure 2-4. Jacking Tractor
6. To jack the drive wheel: Place the jack in

Use extreme care whenever the truck is the designated jacking position. See
jacked up. Never block the truck Figure 2-3. Jack the truck up just high
between the telescopic and the floor. enough to raise the drive wheel off the floor.
Use a suitable hoist to stabilize the mast. Place a block under the frame as shown.
Keep hands and feet clear from vehicle 7. To jack the tractor: Place the jack in the
while jacking the truck. After the truck is designated jacking position near the
jacked, place solid blocks beneath it to steerable wheel. See Figure 2-4. Jack the
support it. Do not rely on the jack alone truck so that the steerable wheel is off the
to support the truck. floor no more than 1 in. (25 mm). Block
under the frame as shown.
5. Place the jack under the designated
jacking points. See Figures 2-3 and 2-4. NOTE: After working on a vehicle, test all
controls and functions to ensure correct
operation.
28D14044S.TIF
Figure 2-3. Jacking Drive Wheel

Towing Safety
Towing Safety
To safely tow this truck:
1. Lower the carriage and remove any load
from the forks.
3. Install the brake release bolts.
4. Using a suitable towing vehicle, lift the
truck until the steer tire is no more than
1 in. (25 mm) off the floor.
5. Tow the truck slowly in the tractor-first
direction.
When towing is complete, remove the

brake release bolts. Failure to do so can
cause serious injury.

Welding Safety
Welding Safety
Disconnect the battery before you
attempt to inspect, service, or repair the
lift truck.
Flame cutting or welding on painted
surfaces may produce potentially
harmful fumes, smoke, and vapors.
Prior to performing flame cutting or
welding operations, remove the coating Before removing a power amplifier,
in the vicinity where the operation(s) discharge the amplifier’s internal
will be performed. capacitor by jumpering the + and –
terminals with a 100 ohm 25W resistor.
Coating removal may be by mechanical
methods, chemical methods, or a • Check for any shorts to the frame. See
combination of methods. Perform flame Shorts to Frame Test on page 5-10. If any
cutting and/or welding operations only shorts are detected, remove them before
in well ventilated areas. Use local you proceed with the welding operation.
exhaust if necessary. • Clean the area to be welded.
• Protect all truck components from heat,
weld spatter, and debris.
• Attach the ground cable as close to the
weld area as possible.
• Do not perform any welding operation
near electrical components.
• If welding must be done near the battery

compartment, remove the battery.
• When finished welding, perform all ground
tests and electrical inspections before the
2
vehicle is operated.
Before working on this truck, make sure that:
• Fire protection equipment is nearby.
• You know where the nearest eyewash
station is.

Models 4100/4200 Maintenance Manual Section 3. Systems Overview
Section 3. Systems Overview

Section 3. Systems Overview Models 4100/4200 Maintenance Manual
General
General
Model 4100 and 4200 stand-up
counterbalanced lift trucks operate with a 36V
battery system. Operator input/command
signals are communicated to various electronic
components via a CAN Bus.
Two AC motor/drive unit assemblies provide

traction via dedicated AC power amplifiers
(TPA). An electrically activated brake is located
on each traction motor.
Steering is accomplished via a closed loop

hydraulic system that uses a dedicated steering
pump and DC motor.
Model 4100 Trucks - Pressure for lift, tilt,

sideshift, and attachments is provided by a
hydraulic pump driven by a DC motor.
Model 4200 Trucks - Pressure for lift, tilt,

sideshift, and attachments is provided by a
hydraulic pump driven by an AC motor. The
pump motor is controlled by an AC power
amplifier (LPA).

Lift Truck Specifications
Lift Truck Specifications

Specification Plate
This lift truck is rated for performance by load
center and load weight. Review the specification
plate for detailed load capacity and load center
information. See Figure 3-1.
Due to continuous product improvement,

specifications are subject to change without
notice or obligation.
Raymond Model # Serial number Nominal battery voltage
*Max battery
weight for this lift
Approximate weight
truck
of lift truck with Raymond Corporation
P.O. Box 130
Greene, New York 13778
battery installed, Battery Volts/Nominal Width
Model Serial Number (in./mm)
minus load and Max Battery
operator Truck Weight (lb./kg) Battery Weight (lb./kg) Battery Max. Rated Capacity
Rated Capacity
With Maximum Battery Maximum (A.H.)
Without Battery Minimum z Attachment
Approximate weight HORIZONTAL MOTION OF BATTERY MUST NOT EXCEED 0.5 INCHES/ 12.7MM.
ATTACH RESTRAINT TO BATTERY COMPARTMENT AS REQUIRED.
of lift truck minus

battery, load, and *Min battery
HORIZONTAL LOAD CTR.
operator
A 23.6 IN. 600 mm
weight for this
VERTICAL LOAD CTR.
B 23.6 IN. 600 mm
lift truck
SIDESHIFT
C 4 IN. 101 mm CAPACITY CAPACITY
Max load capacity of ELEV STANDARD WITH ELEV STANDARD WITH
HT 'D' SIDESHIFT HT 'D' SIDESHIFT
this lift truck
in. lb. lb. mm kg kg
196 4000 4000 1814 1814 1814
C
C
203 4000 3700 1814 1814 1678
B
220 3800 3000 1724 1724 1360

D
227 3450 2750 1565 1565 1247
A OR
FLO
251 2750 2200 1247 1247 997
CENTER ALL LOADS ON MAST CENTERLINE
MANUFACTURED TO COMPLY WITH MANDATORY REQUIREMENTS OF ASME B56.1 PART III EFFECTIVE ON THE DATE
OF MANUFACTURE FOR TYPE E INDUSTRIAL TRUCKS WHEN EQUIPPED WITH TYPE EO BATTERY.
GIVE MODEL AND SERIAL NUMBER IN ALL CORRESPONDENCE.
412-858
*Battery weight must be between the min and max weight.
3412-645.wmf
Figure 3-1. Lift Truck Specification Plate

Modes of Operation
Modes of Operation 2. R e s t o r e F a c t o r y D e f a u l t s - Restores

all initial truck values established at the
factory. Configuration settings should be
There are three modes of operation for this documented for that truck before a reset is
truck: performed.
• RUN MODE - the standard working mode 3. S e t F o r w a r d M a x S p e e d - Use to set
for the truck. maximum forward speed. Default is 6.8
• CONFIGURE MODE - use to enter the mph for Model 4100 and 7.2 mph for
truck’s software and change parameters. Model 4200. Can be set as low as 1 mph,
in increments of 0.1 mph.
• MAINTENANCE MODE - use to access
Learn Mode, perform various tests needed 4. S e t R e v e r s e M a x S p e e d - Same as
for troubleshooting, enable Active item 3, for reverse travel.
Maintenance, view logged errors, and 5. S e t Tr a v e l A c c e l - Software control of
adjust sideshift (tilt) speed. how quickly the truck is permitted to
change speeds; useful when the truck
operates in high or very low traffic
Run Mode environments. Options are S o f t ,
M e d i u m , and H a r d . Default is M e d i u m .
When the truck is powered ON and Selftest is
completed, the truck automatically enters Run 6. S e t C o a s t D i s t a n c e - Software control
Mode, the default mode of operation. Run Mode that establishes the distance the truck
is also entered when the truck exits Configure travels once the control handle is released
Mode. and returns to the neutral position.
Options are L o n g , M e d i u m , and S h o r t .
Default is S h o r t .
Configure Mode
7. S e t L i f t A c c e l - Software control of how
Configure Mode is used to change individual quickly the truck is permitted to lift and
truck performance parameters for specific lower loads; useful for limiting new
customer requirements. Refer to Table 3-1. operators, or when large loads are
expected. Options are S l o w , M e d i u m ,
When Configure Mode is entered, the current and H a r d . Default is H a r d .
value selected is displayed first, followed by a 8. S e t L i f t C u t o u t P o i n t - Use to set the
description of the setting being modified. lowest state-of-charge the battery can have
and still lift. It is adjusted to keep from
For example, item 3 will be displayed on the OD over-discharging the battery. Optional
initially as 7 . 0 M P H , then will change to S e t value is from 0 % to 5 0 % in increments of
Forward Maximum Speed. 5%. Default is 2 0 % .
9. E n t e r N e w C o n f i g u r a t i o n P a s s w o r d -
The following is a list of each configurable Allows the password used to enter Config
parameter’s displayed description and a Mode to be changed. Default password is
detailed explanation. Refer to Table 3-1, 1 _ _ _ _ _ _ _. See Passwords on page 3-10.
Configure Mode Menu on page 3-6.
10. S e t U n i t s f o r M e s s a g e s - Used to
1. E x i t C o n f i g u r a t i o n M o d e - Allows exit specify the unit of measure displayed on
of Config Mode, either because the the OD: E n g l i s h (lbs, inch) or M e t r i c (kg,
operator entered Config accidently, or mm). Default is E n g l i s h .
because all necessary truck configuration
values have been entered and accepted. 11. S e t u p M a i n t e n a n c e M i n d e r - Use to
Select Ye s to save changes. Select N o to turn off, quit, or setup Maintenance
abandon changes before leaving Configure Minder (MM). Options are Q u i t M M ,
Mode. E n a b l e , R e s e t , D i s a b l e , or S e t u p . See
Table 3-2, Maintenance Minder Menu

Configure Mode
(after Enable is Activated). Note that 24. S e l e c t O p t i o n a l H y d r a u l i c

D i s a b l e , R e s e t , or E n a b l e are not A t t a c h m e n t - See Attachment Control on
displayed if their value is already true. page 3-12.
12. E n t e r t h e A u t o P o w e r - O f f T i m e - Use 25. S e t t h e S p e e d L i m i t S w i t c h S p e e d -
to turn on/off sleep mode, that is designed Use to set speed when speed limit switch
to disable the truck’s power after a preset is activated.
time of inactivity. Values are D i s a b l e d , 1 26. S e t t h e L i f t L i m i t W / B y p a s s - Use to
Min, 2 Min, 3 Min, 4 Min, 5 Min, 10 turn on/off lift limit with bypass.
M i n . Default is D i s a b l e d .
27. S e t t h e B a t t e r y G a t e A c t i o n - Use to
13. S e t T i m e a n d D a t e - Use to set truck’s assign what happens if the battery gate
internal clock. Options are; Q u i t ; 2 4 switch is activated. Options are
H o u r ? Y / N (Select 12 or 24-Hour Clock); S h u t d o w n or O f f .
D a y L t S ? Y / N (Daylight Savings Time);
S e t T i m e (10:41PM=10:41 PM or 28. S e l e c t t h e W e i g h t S e n s o r - Use to
2241=10:41 PM); S e t D a t e ( mm/dd/yy). turn on/off the weight sensor. When On,
weight on forks is displayed on the OD.
14. Ve h i c l e M a n a g e r S o f t w a r e Ve r s i o n -
Displays version number. Format is 29. L i f t / L o w e r w h e n O f f D e a d m a n - Use
VM_XX.X to turn off the lift function when the
Deadman pedal is released (O f f ). When
15. V M B o o t S o f t w a r e Ve r s i o n - Displays enabled (O n ), allows approx. five feet of
boot version number internal to VM. lift. Return control to neutral to repeat.
Format is V M B _ X . X .
30. E n a b l e S i d e s h i f t - Use to turn on/off
16. L e f t Tr a c t i o n A m p S o f t w a r e Ve r s i o n standard sideshift function.
- Displays version number. Format is
LT PA X X . X
17. L e f t Tr a c t i o n A m p B o o t Ve r s i o n -
Displays boot version number internal to
power amp. Format is LTA B X . X X
18. R i g h t Tr a c t i o n A m p S o f t w a r e
Ve r s i o n - Displays version number.
Format is R T PA X X . X
19. R i g h t Tr a c t i o n A m p B o o t Ve r s i o n -
Displays boot version number internal to
power amp. Format is R TA B X . X X
20. L i f t A m p S o f t w a r e Ve r s i o n - Indicates
version number loaded into the truck.
Format is L PA _ X X . X
21. L i f t A m p B o o t Ve r s i o n - Displays boot
version number internal to power amp.
Format is L PA B X . X X
22. E n t e r N e w E l e c t r o n i c K e y P a s s w o r d
- Option that permits password protection
before a truck is put in service. Format is
3 _ _ _ _ _ _ _.
23. S e t Tr a v e l A l a r m - Use to assign when
the alarm sounds. Options are F o r k s ,
Tr a c t o r, B o t h , N o n e . Default is B o t h .

Configure Mode
Table 3-1. Configure Mode Menu
Initial or Text Displayed (V02.2 shown)

Item Selections/Parameters
Default Value (Shaded Rows are Options)
1 Quit Exit Configuration Mode Save? Yes; Save? No

2 Default Restore Factory Defaults Yes; No
3 6.8 mph (4100) Set Forward Max Speed 4100: 1.0 to 6.8 mph (2.0 to
or 10.9 Km/h)
7.2 mph (4200) 4200: 1.0 to 7.2 mph (2.0 to
11.5 Km/h)
4 6.8 mph (4100) Set Reverse Max Speed 4100: 1.0 to 6.8 mph (2.0 to
or 10.9 Km/h)
7.2 mph (4200) 4200: 1.0 to 7.2 mph (2.0 to
11.5 Km/h)
5 Medium Set Travel Accel Soft; Medium; Hard
6 Long Set Coast Distance Long; Medium; Short
7 Hard Set Lift Accel Soft; Medium; Hard
8 20 Set Lift Cutout Point 0% - 50% in 5% increments
9 1_______ Enter New Configuration Password See Passwords on page 3-10.
10 English Set Units for Messages English; Metric
11 Mnt Mind Setup Maintenance Minder Quit MM; Enable; Reset;
Disable; Setup (See Table 3-2)
12 APOFF Enter the Auto Power-Off Time Disabled; 1 Min; 2 Min; 3 Min;
4 Min; 5 Min; 10 Min
13 Clock Set Time and Date Quit; 24 Hour? Y;
24 Hour? N; DayLtS? Y;
DayLtS? N; Set Time;
mm/dd/yy
14 VM XX.X Vehicle Manager Software Version Read Only
15 VMB X.X VM Boot Software Version Read Only
16 LTPAXX.X Left Traction Amp Software Version Read Only
17 LTABX.XX Left Traction Amp Boot Version Read Only
18 RTPAXX.X Right Traction Amp Software Version Read Only
19 RTABX.XX Right Traction Amp Boot Version Read Only
20 LPA_XX.X Lift Amp Software Version Read Only
21 LPABX.XX Lift Amp Boot Version Read Only

Configure Mode
Table 3-1. Configure Mode Menu
Initial or Text Displayed (V02.2 shown)

Item Selections/Parameters
Default Value (Shaded Rows are Options)
22 3_______ Enter New Electronic Key Password See Passwords on page 3-10.
23 Both Set Travel Alarm Forks; Tractor; Both; None
24 HydOpt Select Optional Hydraulic Attachment See Attachment Control on
page 3-12.
25 6.0MPH Set the Speed Limit Switch Speed 1.0 to 6.0 mph (1.6 to
9.6 Km/h)
26 LftLimit Set the Lift Limit W/ Bypass (Off is Default) On; Off
27 Bat Gate Set the Battery Gate Action (Off is Default) Shutdown; Off
28 Weight Select the Weight Sensor (Off is Default) On; Off
29 DMLL On Lift/Lower when Off Deadman (Default is On) On; Off
30 Sideshft Enable Sideshift (Default is ON) ON; Off
Table 3-2. Maintenance Minder Menu (after Enable is Activated)
Item Values Description
Setup See MNT MIND in Table 3-1, Configure Mode Menu

50 to 500 Hours of use (Deadman Pedal) (Factory Set at 500)
(in 50 Hr. increments)
Msg. Only Message Only

L Cutout Cutout Lift Function and Message

Maintenance Mode
Maintenance Mode
Maintenance Mode is used to test, cycle, and
troubleshoot functions on the truck. Refer to
Table 3-3.
To enter Maintenance Mode, you must enter the

maintenance password. See Entering a
Password on page 3-10.
L e a r n - required after replacing the VM,

control handle, control handle pots, or optional
weight transducer.
_ 2 _ _ _ _ _ _ - Maintenance Mode
password. See Entering a Password on
page 3-10.
D I n p u t s - brings up Input Test sub-menu.

Allows individual input test to be run.
A I n p u t s - brings up Analog Test sub-menu.

Allows individual analog test to be run.
Before performing an Output Test:
• Jack the lift truck so that the drive

tires are off the floor.
• Make sure the controls are in
neutral.
• Make sure the lift truck is blocked to
keep it from moving.
• Lower the forks all the way to the
floor.
O u t p u t s - brings up Output Test sub-menu.

Allows individual output test to be run.
A c t i v e M a i n t e n a n c e - allows the menu to

appear on the display to toggle between Analog
and Input tests while the truck is in Run Mode.
# o f E r r o r s L o g g e d - error code log capable

of storing up to 20 errors.
S / S - used to adjust sideshift speed between 3

and 4.5 seconds.

Maintenance Mode
Table 3-3. Maintenance Mode Menu
Initial or Selections/
Text Displayed/Description
Default Value Parameters
Quit Exit Maintenance Mode
Learn Enter the Learn Mode Enter (See Table 3-4)

Quit
_2 ______ Enter New Maintenance Password. (Default is _ 2 _ _ _ _ _ _ ) _2 ______
D Inputs See Digital Input Tests beginning on page 6-27.
A Inputs See Analog Tests beginning on page 6-45.
Outputs See Output Tests beginning on page 6-79.
Active Select Active Maintenance

Maintenance Display Active Maintenance On
Do Not Display Active Maintenance Off
# of Errors Error Codes Logged

Logged System Will Store Up To 20 Error Codes 0-20
Exit Error Log Menu Quit
If not zero, Press to Scroll Through Logged Error Codes Enter
Press ENTER key to Clear all errors from log Clear
S/S Select sideshift speed. This is used to adjust sideshift speed 60% to 90%
between 3 and 4.5 seconds (the higher the percentage, the
faster the sideshift speed). It is also used to set the proper speed
of an attachment that has a second AUX function. Changing this
setting will affect tilt speed as well.
Table 3-4. Learn Mode Menu
Item Values Text Displayed/Action
Enter See Learn in Table 3-3, Maintenance Mode Menu

Quit Exit Learn Mode
Weight Learn the Weight Sensor (Optional)
Travel Return Control to Neutral, then Press Enter

Lift Return Control to Neutral, then Press Enter
Tilt Return Control to Neutral, then Press Enter (Optional handle only)
Sideshft Return Control to Neutral, then Press Enter (Optional handle only)

Passwords
Passwords character position. To move the active

character position to the right, press the
ENTER key.
Two levels of passwords are used on this truck;
To move the active character position to
Configuration and Maintenance.
the left, hold down the ENTER key and
press the DOWN button.When the
Configuration Mode Password character position you want to change is
active, stop pressing the button.
The Configuration Password allows you to enter
3. Press the UP button. You will scroll up
Configure Mode. This is intended for customer
through the numbers (0 , 1 , 2 , 3 — 7 , 8 , 9 )
use in setting performance parameters within
and letters (a , b , c — x , y, z ).
those features purchased with the truck.
If you press the DOWN button, you will
scroll down through the letters
Maintenance Mode Password (z , y, x — c , b , a ) and numbers
(9 , 8 , 7 — 2 , 1 , 0 ).
The Maintenance Password allows you enter
Maintenance Mode. This is intended to be used NOTE: If you push and hold the button, you
by qualified service technicians only. will scroll very quickly.
Stop pressing the button when the letter
It is strongly recommended that the or number you want appears in the
Maintenance Password be changed during character position.
installation from the factory. This is to ensure
that access to Maintenance Mode is restricted 4. Move to the next character position you
to qualified personnel only. If the password is want to change by:
lost, changed, or forgotten, FlashWare is • Pressing the ENTER key to move the
required to reset it to the original factory active character position to the right.
password. • Holding down the ENTER key and
pressing the DOWN button to move the
In doing so, all settings are reset to the original active character position to the left.
factory default parameters. Consequently, all
variable settings will need to be reconfigured. 5. Repeat step 3 to change the letter or
Configuration settings should be documented number in this character position. Repeat
for that truck before a reset is performed. steps 3 and 4 to enter the remaining
characters of the password.
6. When the OD shows the correct password,
Entering a Password press the ENTER key. If the password was
NOTE: Press the ENTER key to access correct, you are now in Maintenance
Maintenance or Configure Mode after an Mode.
error code is displayed. 7. If you make a mistake while entering a
1. Press the ENTER key. The OD will show an character, repeat steps 3 thru 6.
eight character field of underscores.
2. Enter the password as follows: Electronic Key
NOTE: The default Maintenance Password is
Electronic Key is a configurable software
_ 2 _ _ _ _ _ _. The default Configuration
feature that permits the customer to establish
Password is 1 _ _ _ _ _ _ _.
an operator password.
To illustrate this procedure, assume you
are entering the default Maintenance When the key switch is turned ON, the operator
Password (_ 2 _ _ _ _ _ _). Look at the OD. is prompted to enter the electronic key
The flashing underscore is the active (password).

Changing a Password
The truck will not enter Run Mode unless the

correct password (electronic key) is entered.
If the user makes the password and the

electronic key the same, the lift truck will
recognize only the password.
Changing a Password
NOTE: When entering the default value
Configuration password, you must enter
the password in the beginning space.
For the Maintenance password, you
leave the beginning space blank.
1. After entering either the Configuration or
Maintenance password, the screen will
scroll and ask if you want to change the
password.
Example: E n t e r N e w M a i n t P a s s w o r d
Press the ENTER key. The screen will stop
scrolling. Enter a new password.
2. Press the ENTER key to cursor all the way
to the right until you are asked to enter a
new password again.
3. Scroll up or down, selecting Q u i t until you
get to a S a v e prompt. Select Ye s .

Attachment Control
Attachment Control
Several types of hydraulic attachments can be
installed on Model 4100/4200 lift trucks.
Attachment 1
If an attachment is added to the truck that
requires only one set of hoses to operate, the
hydraulic lines are connected to ports AC and
AR on the hydraulic manifold. The flow rates
associated with this connection are
configurable under Attach 1 in the HydOpt
menu. See Table 3-5, Hydraulic Attachment
Sub-Menu.
Attachment 2
If the attachment requires two sets of hoses, the
second set of hoses are connected to SSR and
SSL on the manifold. The flow rates associated
with this connection are configurable under
Attach 2 in the HydOpt menu. See Table 3-5,
Hydraulic Attachment Sub-Menu on page 3-12.
Vehicles with this configuration cannot be
equipped with integral sideshift.
Table 3-5. Hydraulic Attachment Sub-Menu
Item Values Description
HydOpt Set Optional Hydraulic Attachment
Attach 1 Attachment 1 (Setup)

Enter Flow: None (Default)
2-7 GPM - Clamp? (Model 4100) N (Default)
2-11 GPM - Clamp? Model 4200) Y - Set pressure for Low
Med
High
Max
Attach 2 Attachment 2 (Setup)

Enter Flow: None (Default)
2-7 GPM - Clamp? (Model 4100) N (Default)
2-11 GPM - Clamp? Model 4200) Y - Set pressure for Low
Med
High
Max
QuitAtt Exit Attachment Selection

Setup and Operation
Setup and Operation

Refer to Table 3-6 for specific attachment setup
information.
Refer to Table 3-7, “Attachment Operation,” on

page 3-14 for specific attachment operation
information.
Table 3-6. Attachment Setup
Operator Display: Adjustment

FlashWare Hydraulic Hose
Function Config or Maintenance Mode Range for Flow
Action Ports
Menu Action Rate
Sideshift Enable Sideshift speed configurable SSR (Sideshift Set SS Speed -

Sideshift via Maintenance Mode menu Right) 60% to 90%
checkbox item S S . SSL (Sideshift
Left)
Push/Pull Enable Config Menu: Navigate to AC (Aux Cap) Begin with

Attachments H y d O p t and press Enter. AR (Aux Rod) 7 GPM and
checkbox _Select A t t a c h 1 adjust as needed
___Select flow rate or specified by
_____Set clamp=N manufacturer*.
Fork Positioner Enable Config Menu: Navigate to AC (Aux Cap) Begin with
___Select flow rate or specified by
_____Set clamp=N manufacturer*.
Clamp Enable Config Menu: Navigate to AC (Aux Cap) Begin with

__Select flow rate or specified by
___Set clamp=Y (see Note 1) manufacturer*.
____Set PSI (see Note 2)
Clamp with roll Enable Config Menu: Navigate to SSR (Sideshift Begin with
(see Note 3) Attachments H y d O p t and press Enter. Right) 3 GPM and
checkbox and _Select A t t a c h 2 SSL (Sideshift adjust as needed
disable the __Select flow rate Left) or specified by
Sideshift manufacturer*.
checkbox
*Flow rate can be adjusted in Configure Mode in 1 GPM increments; 2 to 7 (4100), 2 to 11 (4200)
Note 1: Any clamp function, carton clamp or barrel clamp, must be connected to AC and AR, never to SSR
and SSL.
Note 2: MAX PSI is fixed at 2300. Default values are High=1250, Med=1000, Low=750. Overall Range is 250
to 2250 PSI, but values cannot overlap. Example, the highest setting for Low depends on what medium is set
to. The highest value for medium depends on what High is set to.
Note 3: Use SSR and SSL for the roll function on the clamp with roll attachment.

Adjusting Attachment Pressure
Table 3-7. Attachment Operation
Function Input Device Description
Tilt Tilt Down and Tilt Up On higher Quad masts, tilt rate
depends on status of mast proximity
switch.
Sideshift Sideshift Left and Sideshift Sideshift flow rate (function speed)
Right depends on the S e t S S S p e e d
value in Maintenance Mode menu.
Attachment added Function 1 and Function 2 If Clamp is used, momentary tilt

(Push/Pull, Clamp) activation is required to unclamp
load.
Attachment Function Function 1 and Function 2 The input for the second function of
added to the truck that Sideshift Left and Sideshift the attachment requires the use of
requires 2 functions Right the sideshift input.
(Barrel Clamp with
Roll, Fork Positioner
with Sideshift)
Adjusting Attachment Pressure 3
1. Press the top attachment button

momentarily to activate the clamp. See
Figure 3-2.
3
Figure 3-3. UP/DOWN Keys on Operator Display
NOTE: Several pressure settings are available:

Low, Med, High, and Max (Max is the
auxiliary relief pressure setting).
Figure 3-2. Top Attachment Button
2. The clamp pressure is shown on the OD.

3. To select another pressure, use the
UP/DOWN keys on the OD. See
Figure 3-3. The clamp pressure you select
remains active until another is selected;
even if the lift truck is turned OFF.

FlashWare Program
FlashWare Program “Readme” file in the software package for the

latest detailed installation instructions.
Overview PC Connection to Truck

The FlashWare program allows you to update 1. Turn the truck key switch OFF.
software, view, and configure options on Model 2. Connect a surge protector to the COM1 or
4100 and 4200 trucks through the following COM 2 port on the back of your PC.
features: 3. Connect a standard 9-pin serial cable to
• Vehicle Manager software the surge protector, and connect the other
• Clear primary memory end to JPT-9 on the Vehicle Manager
• Reset factory default settings 4. Turn the truck key switch ON.
• Download Software
Starting FlashWare
NOTE: For more detailed information about
FlashWare, click on Help, and select 1. Make sure the truck key switch is ON.
Help Topics from the menu bar. 2. Double-click the FlashWare icon on the
main desktop screen, or navigate via Start
Requirements > Programs > FlashWare.
3. The truck opening screen appears. See
FlashWare can be installed on an Figure 3-4.
IBM-compatible PC. The PC communicates with
the truck software through a 9-pin serial cable.
NOTE: A USB to 9-pin serial adapter
(P/N 610-809/USB) is available for
computers that do not have a serial
port.
To protect your PC from possible

electrostatic discharge or voltage surge,
we recommend using the surge
protector (P/N 154-010-801).
Install FlashWare on PC
3
Figure 3-4. Flashware Truck Opening Screen
If you are a customer service technician, obtain NOTE: When entering or using FlashWare, it is
FlashWare from your Raymond dealer. usual for the vehicle to display a
Code 50.
If you are a Raymond dealer technician, obtain 4. From the menu bar, click Connect To
FlashWare from the iNet software download Truck. A pull down menu will appear.
site. If you do not have access to the download
page on iNet, contact the Parts Distribution 5. Select “All Other Trucks”.
Center.
To install FlashWare on the PC, double-click the

installation file and follow the instructions on
the screen. The software package is a
self-extracting executable file. Read the

Truck Setup Screen
Truck Setup Screen • Date of Manufacture: displays date truck

was manufactured
The Truck Setup screen feature allows the user • Serial Number: displays serial number of
to monitor configuration data and input or the truck
tailor other parameters within FlashWare for
this truck. See Figure 3-5. Current Meter readings are displayed for
Deadman Hours, Travel Distance, Lift Hours,
Software and model information displayed: and Key Hours.
• VM Software Version: displays current
version installed
• Software Model Number: displays truck
software model number.
1036 = 4100/4200)
• Model: displays truck model number and
mast capacity
3gofer3.eps
Figure 3-5. Typical Truck Setup Screen

Truck Setup Screen
Change A Truck Option NOTE: *These options may not be enabled

without a passkey. To obtain a passkey,
Truck Options currently configured on this a Form S-207, Field Modification
truck are displayed with color-coded titles and Request Form, must be submitted.
check boxes in the large center window. Items
in red require an authorization code from As the information in the Truck Setup screen is
Raymond. tailored or recorded as needed, command
buttons at the bottom permit the user to
Turn options on by placing a check mark in the RECONNECT (refresh), SAVE the current
required option box. To disable an option, settings, and SEND (overwrite) the changes
remove the check mark. See Figure 3-5. made to the FlashWare operating parameters.
• RECONNECT (Re-read Truck) is used to
These options include: re-establish communication with the
• Electronic Key* - requires operator to enter vehicle.
a code prior to operating the vehicle • SAVE Settings to File is used to store
• Weight - enables weight of load to be vehicle current configuration for future
displayed on Operator Display reference.
• High Speed Limit - reduces top travel • SEND Changes to Truck is used to
speed based on mast mounted switch transmit desired option and height related
placement changes to vehicle. When the options are
correctly configured, click SEND Changes
• Travel Alarm - enables alarm to sound
to Truck button.
when truck is moving
• Aux Attachments - configuration Other functions can be initiated and screens
dependant requested using the command buttons on the
• Lift Limit w/Bypass - limits lift height right side of the screen.
based on mast mounted switch placement
These functions (screens) include:
• Bottlers Tilt* - enables reduced speed
and/or forward tilt based on mast • Vehicle Manager Software. See Vehicle
mounted switch(es) Manager Software on page 3-18.
• 2 Speed Tilt* - enables reduced tilt speed • Clear Primary Memory. See Clear Primary
on trucks equipped with a Quad mast, Memory on page 3-19.
based on placement of mast switch • Configuration. See Configuration Screen
• Operator Compartment Sensor - enables on page 3-20.
option that requires the operator • Display Manager/Power Amplifier. See
compartment threshold to remain Display Manager/Power Amp Software on
unblocked page 3-22.
• Ambient Temp Sensor - sensor used to
determine if heater assembly in handle The EXIT button in the lower right allows the
should remain on even with key switch off user to leave this screen.
• Battery Gates* - enables option requiring
both battery gates to be installed to allow
travel
• Breakaway QD* - enables breakaway
quick disconnect option
• 4200 Handle Type* - used to identify type
of handle installed on truck (standard,
optional, lever controls)

Truck Setup Screen
Vehicle Manager Software
The Vehicle Manager Software screen is used to

load/upload Vehicle Manager software. See
Figure 3-6.
From the VM Software screen, users can

perform the following functions:
• Check the current Vehicle Manager
software version
• Select Software Version, if multiple
versions are loaded (selected version is
displayed in window in upper right of
screen)
• Load VM with Selected Software Version
(Update Existing)
• Install VM Software Version into Directory
• Delete Selected Software Version from
Directory
• Upload (Extract) Software from VM to a file
on the PC
When VM software management tasks are

complete, click EXIT to return to the main
Truck Setup screen.
3Flash.tif
Figure 3-6. VM Software Screen

Truck Setup Screen
Clear Primary Memory
The Clear Primary Memory feature allows the Do not cycle the key switch. Primary
user to clear a the trucks identity in the memory will be restored to the current
Operator Display. truck configuration if the key switch is
NOTE: If the Clear Primary Memory and Clear cycled.
Vehicle Manager are performed at the
same time, the primary vehicle identity 4. Remove the VM.
and back-up identity will be removed. A
programmed Operator Display will be
required to remedy this.
The Clear Primary Memory function is selected

by clicking the Clear Primary Memory button on
the right of the Truck Setup window. See
Figure 3-5.
1. On the Truck Setup Screen, Click on the
Clear Primary Memory button.
2. The Clear Primary Memory dialog box
appears to confirm the user really wants to
clear primary memory. See Figure 3-7.
3clearcau.tif
Figure 3-7. Clear Primary Memory Screen
3. If the user selects No, the action is

cancelled. If the user selects Yes, a new
dialog box appears, prompting the user to
remove the cleared memory prior to
restarting the truck. See Figure 3-8. Click
OK.
3clear2.tif
Figure 3-8. Remove Cleared Memory Screen

Truck Setup Screen
Configuration Screen
1. Activate the Configuration control function
by selecting the Configuration button on
the right of the Truck Setup window. See
Figure 3-5.
2. The Configuration screen will appear. See
Figure 3-9.
3gofer3.eps
Figure 3-9. Configuration Screen
Reset Factory Defaults
Use this feature to reset vehicle configuration.

1. Record customer-specific configurations
from the Truck Config screens before
resetting defaults.
2. Select the Reset Factory Defaults button
on right side of the Configuration screen.
3. A warning dialog box appears to confirm
the user really wants to reset factory
defaults.

Truck Setup Screen
BSOC Calibration (Adjusts Time to 0%)
Occasionally, additional adjustment is required

outside of Configure Mode to obtain correct
Battery State-of-Charge readings.
Battery State-of-Charge (BSOC) Calibration in

FlashWare specifies the average voltage
required in order to be considered at 0% (5 is
the factory default):
• setting this number smaller (down to 1),
will lower the average voltage that will be
zero resulting in increasing the time to 0%
and using more of the battery
• setting this number higher (up to 9) will
increase the average voltage that will be
zero resulting in decreasing the time to 0%
and using less battery.
If the user states that he is not using all of his

battery, the technician can lower the number.
If the user states he is draining the battery to

much, the technician can increase the number.
Clear Vehicle Manager
The Clear Vehicle Manager feature allows the

user to remove existing memory and software
from a Vehicle Manager so that it may be used
in a different model truck with a compatible
Vehicle Manager.
1. The Clear Vehicle Manager feature is
activated by clicking the Clear Vehicle
Manager button on the right of the Truck
Setup window. See Figure 3-5.
2. The Erase Vehicle Manager Software
screen appears.
3. The user can view the Software Model
Number Table, which is a cross reference
that permits verification that the correct
software is loaded for this truck.
4. Do not select ERASE unless the software
model number is incorrect.
5. Select Erase. VM memory is cleared, and
the correct software model number can
now be selected and loaded.

Truck Setup Screen
Display Manager/Power Amp

Software
This feature is used to view and/or change

power amplifier software.
1. Click Display Manager/Power Amp
Software button in the Truck Setup
screen.
NOTE: Models 4100/4200 do not have a
Display Manager.
2. When the Display manager/Power
amplifiers screen appears, follow prompts
on the screen to Load/Upload software.
See Figure 3-10.
3diagnost.tif
Figure 3-10. Display Manager/Power Amp Screen

Cold Storage
Cold Storage • all terminals on the hydraulic solenoids

• all terminals on the horn
Cold Storage (CS) is an option that enables • terminals of the key switch and EPO
truck operation in temperatures of –20°F switch
(–28.86°C) to 40°F (4°C). • terminals on lift motor
• terminals of the steer motor
On cold storage trucks, the electrical panel on
the tractor is completely enclosed to contain • terminals on both traction motors
heat. 4. Install the recommended hydraulic fluid
and gear case oil.
Cold Storage Conditioning
Perform Cold Storage conditioning with the
items listed below:
Description Part Number
Silicone Grease 990-564
Sealing Compound 990-542
LPS3 Spray 990-644
NOTE: Optional Handle is Cold Storage Ready.

1. Spray LPS3 on the steering plate.
2. Fill the two small holes in the body and
shank of the key switch with sealing
compound.
3. Apply silicone grease to the following
electrical connections:
• terminals of the switch mounted on the
underside of the deadman pedal
• all terminals and connectors on power
amplifiers
• both connectors on the operator display
• the back side of the VM connectors
(including unused connectors)
• the back side of the communications
jacks (JPC3, JPC4, and JPC9) on the
VM
• the free hanging connectors in the
harnesses
• the contactor coil terminals
• fuse bodies, cable terminals, and
terminal studs on the contactor panel
• connectors, fuses, terminal strips, and
relays where they plug into the sockets

Storage
Storage Before returning the truck to service, drain the

reservoir and change the filter. Fill the reservoir
with new hydraulic fluid.
When storing the truck for any length of time,
cover the truck with canvas or plastic. Operate the hydraulic systems slowly at first to
allow lubrication of internal components.
If storing the truck for more than 30 days, jack
and block the truck up off the floor. NOTE: If the truck is going to be stored for more
than six months, spray hydraulic
components with a silicone protectant.
Do not let silicone protectant spray get
on circuit cards.
Use extreme care whenever the truck is
jacked up for any reason. Never block
the truck between the telescopic and the Hydraulic Cylinders
floor. Use a suitable hoist to stabilize the
mast. Keep hands and feet clear from Store the truck with the cylinder pistons
beneath vehicle while jacking. Use jack retracted. Coat all exposed chrome surfaces of
stands or solid blocks to support truck. the piston with hydraulic fluid.
Do Not rely on the jack alone. See
Jacking Safety on page 2-10. Lift Chains
Warranty Liberally coat all chains with oil to prevent rust
and corrosion.
The Raymond Corporation must be contacted
by an authorized Raymond dealer for the Electronics
correct warranty procedures.
Make sure all electronics stay dry.
DC Motors
The brushes in DC motors must be lifted away
from the commutator surface. When preparing
the truck for service, the surface must be
inspected and polished, if necessary, using a
rubber abrasive polish. Polishers are
specifically made for polishing commutators. Do
Not use a stone.
While in storage, periodically rotate the DC

motor shafts to coat the bearings with
lubricant, reducing the possibility of oxidation
and corrosion.
Hydraulic System
The hydraulic system will absorb moisture
when left standing for a long time.
Make sure the reservoir is full before storing.

Models 4100/4200 Maintenance Manual Section 4. Scheduled Maintenance
Section 4. Scheduled Maintenance

Section 4. Scheduled Maintenance Models 4100/4200 Maintenance Manual
Scheduled Maintenance Guidelines
Scheduled Maintenance
Guidelines
A successful 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 under standard operating
conditions.
When operating under severe or extreme
conditions, perform these services more often
as indicated in the chart below.
Operating
Working Environment Service Frequency
Conditions
Light to 180 days or 500 hours,
An eight hour shift of basic material handling
Moderate whichever comes first
• Extended heavy duty operation
• Freezer operation
Severe 250 hours
• Sudden temperature changes such as going from freezer to
room temperature
• All UL Type EE rated lift trucks
• Dusty or sandy conditions such as in cement plants, lumber or
flour mills, coal dust, or stone-crushing areas
Extreme • High temperature areas such as in steel mills, foundries, 100 hours
enclosed (Type EE) applications
• Corrosive atmosphere such as in chlorine or salt-sea air
environments

Maintenance Minder™ Tool
Maintenance Minder™ Setting Time Interval and Action

Option
Tool
The first time you enter the time interval menu,
Maintenance Minder Tool is a feature that the Factory Suggested setting, followed by the
allows a customer to be prompted when the letters FS is displayed. Subsequently, when you
truck is due for scheduled maintenance. enter the time interval menu, the last used
setting is displayed. Values from 50 to 500
Maintenance Minder, when configured and
hours, in increments of 50, are available. Use
enabled, monitors the Hours on Deadman (HD)
the Up/Down (▲▼) button to scroll to the
meter. When the time interval for scheduled
desired time interval. With the desired value
maintenance is exceeded, the operator is
displayed, press the Enter (↵) button.
informed in the following ways:
1. One of two messages scrolls on the Use the Up/Down (▲▼) button to select the
Operator Display for at least 30 seconds desired action option. Then press the Enter (↵)
following the DAILY CHECKLIST message. button.
• SCHEDULED MAINTENANCE DUE • MSG ONLY causes the Operator Display to
• LIFT CUTOUT, SCHEDULED MAINTENANCE DUE show SCHEDULED MAINTENANCE DUE when the
2. A wrench icon flashes. scheduled maintenance time interval is
exceeded.
3. The audible alarm sounds the high-low
tone for approx. five seconds. • L CUTOUT causes the Operator Display to
show LIFT CUT OUT, SCHEDULED MAINTENANCE
Lift Cutout, when active, will not disable the lift DUE when the scheduled maintenance time
function until power to the control circuits is interval is exceeded. Lift is disabled the
cycled (key switch OFF or battery next time the power circuits are cycled.
disconnected).
When the control circuit power is cycled, lift is Use the Up/Down (▲▼) button to select QUIT MM
disabled until Maintenance Minder is reset or from the submenu. If the status has changed,
disabled, or the lift cutout option is turned OFF. you are prompted to save changes. Press the
Enter (↵) button.
Enabling From the Config Menu, exit by selecting QUIT

CFG.You will not be prompted again to save
Once installed in the configuration options, changes, but any changes saved when you QUIT
MAINTENANCE MINDER appears in the Configure MM are retained.
Mode menu. The initial factory setting is
DISABLE. To enable the feature, enter Configure Changing Time Interval or Action
Mode. Option
NOTE: For instructions on selecting Modes of
Operation, see Modes of Operation on When Maintenance Minder is active, and you
page 3-4. want to change the time interval or action
option, enter Configure Mode.
With Configuration Mode selected, use the
Up/Down button to scroll to display With Configuration Mode selected, use the
MAINTENANCE MINDER. Press the Enter (↵) button. Up/Down (▲▼) button to display the MNT MIND
When entered from a disabled state, item. Press the Enter (↵) button. When entered
Maintenance Minder offers a submenu with the from an enabled state, Maintenance Minder
options QUIT MM and ENABLE. Use the Up/Down offers a submenu with the options QUIT MM,
button to select ENABLE. Press the Enter (↵) RESET, DISABLE, and SETUP. Use the Up/Down
button. (▲▼) button to select SETUP, then press the
Enter (↵) button. The current time interval is

Disabling
displayed (hours). Proceed as described under

Setting Time Interval and Action Option.
Resetting Maintenance Minder
When Maintenance Minder is active, and, after

you have performed scheduled maintenance,
you want to reset the reminder prompt, enter
Configure Mode.

Up/Down (▲▼) button to display the MNT MIND
item. Press the Enter (↵) button. Use the
Up/Down (▲▼) button to select Reset, then
press the Enter (↵) button. Select QUIT MM and
press the Enter (↵) button again. Save changes,
as prompted.
Disabling
When Maintenance Minder is active and you
want to disable it, enter Configure Mode.

Up/Down (▲▼) button to display the MNT MIND
item. Press the Enter (↵) button. Use the
Up/Down (▲▼) button to select DISABLE, then
press the Enter (↵) button. Select QUIT MM and
press the Enter (↵) button again. Save changes,
as prompted.

Initial 90 Day/250 HD Maintenance
Initial 90 Day/250 HD
Maintenance
Perform the following maintenance tasks 90 days after the lift truck was put into service or at
250 HD, whichever comes first.
Component What To Do
Drive Unit Change fluid.
Hydraulic Reservoir Change fluid and filter.
Power Amplifiers Torque power amplifier terminal bolts to 100 in. lb. (11.3 Nm).

Every 180 Days or 500 Deadman Hours (HD)
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. Check for voltage leaks to frame. Refer to Shorts to Frame Test
on page 5-10. If cleaning does not remove voltage to frame, install a new battery.
Inspect all battery connectors and leads for damage and cuts in protective
coatings. Make sure the battery has no more than 0.5 inch (13 mm) free play in
any direction.
Battery Gates Make sure the battery gates are in place and not damaged.
Brakes In an open area, measure stopping distance. Traveling 2 to 3 mph (3.2 to

4.8 Km/hr) empty, push the EPO switch; the empty lift truck should stop within
2 to 4 feet (0.6 to 1.2 m). During normal operation, with a rated load and
traveling at top speed, the lift truck should stop within approximately one and
one-half truck lengths. Stopping distance depends on the load, floor, and tire
condition.
Visually inspect the friction disc and plates with the brakes released. The air gap
between the armature disc and the brake coil must be between 0.004 and
0.020 in (0.1 and 0.5 mm). Replace worn parts. Refer to Brakes on page 7-31.
Cables Inspect all cables for nicks or cuts. Replace any cable that is damaged or shows
signs of excessive heat.
Make sure over-the-mast pulley’s spin freely and show no signs of wear.
Contactors Inspect contactor tips for burnt or pitted surfaces. See Contactor Tip Inspection
on page 5-17. 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.
For EE trucks, remove cover to inspect tips.
Control Handle Operate the lift/lower function. Verify the response is smooth and controllable.
Functions Operate the travel function. Verify that the full range of acceleration is smooth
and responsive. Make sure that plugging is functioning correctly.
Look for any play in the center position of the lift or travel.
Operate the Tilt, Sideshift and Optional attachment switches. Verify they operate
correctly and function smoothly and do not stick. Make sure nylon plug is in the
lift/lower knob set screw hole.
Cylinders Inspect for leaking seals, scored pistons, and secure mounting.
Deadman Pedal Check the Deadman Pedal for smooth operation with no binding.
Check for correct activation and deactivation of the deadman switch.
Drain Holes (beneath Make sure the drain holes are not blocked by any debris.
deadman pedal and in
battery compartment)

Component Task
Drive Unit Check for correct fluid level in the drive unit. If the fluid level is low, investigate
for leaks and determine causes.
Forks Inspect forks for modifications, bends, cracks, or wear. Check for welding arcs
and signs of excessive heat. Tool P/N 922-369 is available for measuring the
thickness of the fork heels.
If any of the above are found, replace the fork immediately.
Hardware Check the tightness of wire and cable connections. This is done by physically
(bolts, nuts, and trying to move the connection with your hand.
screws)
Horn Make sure the horn sounds loudly when activated.

Make sure the horn is insulated from the frame.
Hoses Inspect all hydraulic hoses for leaks, nicks, cuts, chafing, and bulges. Replace
damaged hoses as soon as possible.
Inspect all fittings for leaks. Repair any leaks immediately.
Make sure over-the-mast pulleys spin freely and show no signs of wear
Hydraulic Reservoir Check for proper fluid level.
Lift Chains Check for correct adjustment of the chains. Lubricate as required.
Inspect the chains for excessive stretch or wear. Tool (P/N 950-350/CG) is
available to determine when lift chains must be replaced. Refer to Lift Chains on
page 4-10.
On Quad masts, adjust the lift chains on each section of the mast so that the top
of any section is within 1/4 in. (6.35 mm) of the top of the adjacent mast section
when fully lowered.
Make sure there is adequate clearance between the crossties and the “thru mast”
hoses.
Lights Check all lights are functional and securely mounted.
Mast Inspect the mast bearings and rollers for damage or wear.
Inspect the outside of the main frame for wear, especially if the truck is used in
drive-in racks.
Inspect the grease for contamination, then remove and re-apply as required.
Model 4200 masts: Each pair of load rollers on the uprights and carriage should
be shimmed so that a total side to side clearance no greater than 1/16 in.
(1.5 mm) occurs at the tightest point throughout the travel of the member. See
Mast Inspection - Model 4200 on page 7-69.
Motors, AC Re-torque terminal stud nuts. Refer to Terminal Hardware on page 7-36.
Check the cable lugs. Make sure they are tight to the terminal studs. Both the
inside and outside nut must be torqued to spec.
Replace any cable that shows signs of excessive heat. Check sensor wires for
sound connection and condition.

Component Task
Motors, DC Visually inspect brushes for excessive heat (discolored pigtails). If excessive heat
is evident, inspect the armature circuit for loose connections.
Check brush length and evenness of wear. Refer to DC Motor Brushes on
page 7-34.
Check brush spring tension. Refer to DC Motor Brush Spring Tension on
page 7-34.
Inspect brush rigging for damage or loose brush holders.
Re-torque terminal stud nuts. Make sure the connections on the brush leads are
tight. Refer to Terminal Hardware on page 7-36.
Use compressed air to clean the inside of the motor. Blow out impeller and
cooling fins.
Inspect and clean commutator. Check condition per photos in this manual. Refer
to Inspection on page 5-5.
Find the shortest brush in the holder. Remove the brush and check overall
dimension. Refer to Table 7-1, Brush Length and Spring Tension on page 7-35.
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.
Check the cable lugs. Make sure they are tight to the terminal studs. Both the
inside and outside nut must be torqued to spec.
Replace any cable that shows signs of excessive heat.
Check sensor wires for sound connection and condition.
Overhead Guard Look for any physical damage to the guard. If the overhead guard is structurally
damaged, replace the guard.
Shorts to Frame Check for electrical shorts to frame. Refer to Shorts to Frame Test on page 5-10.
Sideshift Carriage Make sure the capscrews securing the lower mounting hooks to the carriage bar
are tight.
Check lower hook nut torque. Grease lower bearing surface.
Steerable Wheel Lubricate the steer axle assembly and chain.

Assembly Inspect the steer chain for correct adjustment. Chain should flex approx. 1/8 in.
(3.175 mm).
Inspect the caster wheel axle and bearings for excessive wear.
Check caster wheel bearing for binding or excessive play. Inspect drive axle for
excessive play.
Switches Check mast and optional switches for correct operation.
Wheel and Tires Inspect all wheels and tires for chunking, bond failure, and excessive or uneven
wear. Replace any tire exhibiting any of these symptoms.
Warning Decals Replace any warning decals that have become unreadable or are damaged.

Every 360 Days or 1500

Deadman Hours (HD)
Component What To Do
Hydraulic Reservoir Change the fluid in the hydraulic reservoir and install a new fluid filter.
Drive Unit Change the fluid.
Pump Couplings Remove, clean, inspect, and repack. On lift pump, apply Molybdenum Anti-Seize
Compound (P/N 990-638) to the splines.

Lift Chains
Lift Chains
Inspection and Maintenance
Make sure chains are not damaged. Check the
chain for wear using a Chain Gauge
(P/N 950-350/CG). See Figure 4-1. Replace
chains with genuine Raymond spare parts.
4
A
A
Chain
Wear
Scale
A
A
MA0634.
Chain Replace
OK Chain
Figure 4-1. Chain Wear Scale
Condition Cause Maintenance Procedure
Use a chain gauge or lay the chain on a flat

surface and push it together. Measure and mark
a 12 in. (305 mm) length that has operated over
Chain Elongation Wear
the pulley sheave. Stretch the chain; if more
than 1/3 in. (8.5 mm) play is detected, replace
the chain.
Steam cleaning or degreasing new

Rust and corrosion Oil chain frequently.
truck chains.
Infrequent Oiling, Rust, Corrosion,

Cracked Plates
Chain Fatigue
Bent pins or plates Replace the chain.

Tight Joints
Rusty joints or peened plate edges
Chain side wear Chain misalignment

Fork Inspection
Fork Inspection Measuring Fork Wear

Using Fork Wear Caliper P/N 922-369 (see
Visually inspect all fork surfaces for signs of Figure 4-3), perform the following steps.
damage, including, but not limited to: excessive
wear, bends, cracks, excessive heat, or 4
unauthorized modifications.
Remove any fork from service when

bends, cracks, or wear are revealed
during inspection.
Thoroughly examine the fork visually for

cracks. Give special attention to the heel, top
and bottom hooks. See figure. If necessary,
subject the forks to a non-destructive crack
detection process.
4
Figure 4-3. Fork Wear Caliper
1. Open the caliper to approximately 90° and

place the caliper in the top inside heel area
of the fork (on top of the blade). See
Figure 4-4.
2. Make sure the two lower pieces on the
horizontal leg are both touching the top of
the blade.
Figure 4-2. Fork Inspection 3. Move the caliper toward the upright. Make
sure the caliper arms are both parallel to
Check the difference in height between the the blade and upright.
blade tips on each pair of forks. This must not 4. Open/close the caliper so that the two
measure more than 1/4 in. (6.4 mm) with the similar extruding pieces on the vertical leg
forks installed on the fork carriage. of the calipers both touch the
upright/shank of the fork.
Check that the forks positioning locks are in
good working order. 5. When you are sure that all four points are
simultaneously in contact with the fork,
gently remove the calipers and look at the
indicator lines found at the top of the
hinge pin.
If the lines on the horizontal leg (that
points vertically) is found to lie beyond
either the 93° or 87° indicator line, the
forks should be marked to be checked for
either permanent deformation, possible

Measuring Fork Wear
stress cracks, or any other defect that

could impede the safe use of the fork.
Figure 4-4. Fork Wear Inspection

Models 4100/4200 Maintenance Manual Section 5. Troubleshooting
Section 5. Troubleshooting

Section 5. Troubleshooting Models 4100/4200 Maintenance Manual
Electrical Troubleshooting
Electrical • Whenever measuring resistance, turn the

key switch OFF and disconnect the battery
Troubleshooting connector. Battery current can damage an
ohmmeter. Isolate the component from the
circuit.
General
Block the lift truck so that the drive tire

is off the floor whenever a
troubleshooting procedure requires
turning the key switch ON. This will
prevent accidents caused by unexpected
lift truck travel.
Unless otherwise directed, disconnect

the battery connector when you check
electrical circuits or components with an
ohmmeter. Electrical current can damage
an ohmmeter.
• Many problems are caused by a faulty or

dirty battery. Make sure the battery is
clean.
• Save time and trouble by looking for
simple causes first.
• For information on electrical connector
location and function, see Electrical
Connector Locations on page 5-14.
• Use a Digital Multi Meter (DMM) such as a
Fluke meter for all measurements. Analog
meters can give inaccurate readings and
load down sensitive electronic circuits
enough to cause failure. Make sure meter
cables are connected to the correct meter
jacks and that the correct function and
scale are selected.
• Printed circuit boards are conformal
coated. Clean test points in order to obtain
accurate readings.
• When measuring voltage, connect the
positive meter lead to the connector or
probe point marked (+) in the test.
Connect the negative meter lead to the
connector or probe point marked (–).

Battery State-of-Charge
Battery State-of-Charge (BSOC), as displayed
on the Operator Display, shows the amount of
usable energy that remains in the battery. The
value displayed is the percentage of energy in
the battery available for use. BSOC uses battery
voltage under load for this calculation.
When 0% is displayed, lift is prevented until the

battery is recharged or replaced with a fully
charged battery.
The battery should not be changed or charged

until the Operator Display reads 0 to 5%.
Recharging a battery that is not fully discharged
drastically shortens the life of the battery. If a
battery is changed before the Operator Display
reads 0 to 5%, the display may not reset, but
will continue to show the percentage of the
battery removed. This percentage will be
displayed until the battery installed reaches the
percentage on the display. The display will then
start to count down as the battery discharges.
NOTE: As a battery ages or is improperly
maintained, it will not accept a full
(100%) charge. Therefore, the Operator
Display will show less than 100% even
after a full recharging session.
After a battery is charged, allow it to cool down.

Failure to allow sufficient cooling time may also
destroy the battery prematurely due to
overheating.

Lift Cutout Adjustment

1. Run lift truck until lift cutout is activated.
2. Allow battery to set unused for two hours.
Check Specific Gravity (SG) and compare
to manufacturer’s recommendations.
3. Adjust cutout in Config until correct
discharge is obtained.
NOTE: Additional BSOC adjustment is available
using FlashWare. See BSOC Calibration
(Adjusts Time to 0%) on page 3-21.
Fuses
Table 5-1 lists the fuses for a lift truck with all
available options. Not all trucks will have all of
the fuses listed.
Table 5-1. Fuses

Fuse Function Location Amps
FU1 Power Fuse for Steer Motor 150
FU2 Power Fuse for Traction Power Amplifier Contactor Panel 750
FU3 Power Fuse for Lift Pump Motor 500
FU5 Control Fuse for Vehicle Manager B+ 15
FU6 Control Fuse for Vehicle Manager B– Fuse/Relay Card 15

(See Figure 5-5 on
FU7 Control Fuse for Aux Power B+ page 5-16.) 15/5
FU8 Control Fuse for Aux Power B– 15/5
FU11 Control Fuse for Strobe and Warning Light (Optional) In-line Wiring 1.5
FU12 Control Fuse for Operator’s Cooling Fan (Optional) In-line Wiring 1.5

DC Motors If the commutator appears rough, pitted, or has

signs of burning or heavy arcing between the
commutator bars, remove the motor for
Types of DC Motors servicing.
There are two primary types of DC Motors (refer
to Figure 5-1): Servicing
• A series-wound motor has only two
If the commutator requires service, you will
external connections because the
need to remove the armature from the motor.
armature and field windings are connected
internally.
Do not use a stone to even out high and low
• A permanent magnet motor has two spots on the commutator.
external connections. The field is produced
by an internal magnet. Servicing a motor for an abnormal commutator
NOTE: Field connections may be labeled A or S. surface condition and high mica or mica
undercutting requires special equipment at a
Series wound motor field connections
motor rebuilding facility.
may be labeled D.
Series-Wound Motor Permanent Magnet

S/D Motor
MS+
A2
MS
MS–
A1
MP
A
5MOTOR_SERIES.EPS
MOTOR_COMPOUND.EPS
Figure 5-1. Motor Circuits
Inspection
The commutator must be inspected for surface

condition and high mica. Most armatures have
the mica undercut. If the armature on your
motor does not, do not attempt to cut it.
The commutator must be smooth and clean to

provide maximum brush wear. When
commutators are not correctly maintained,
carbon dust can collect in the grooves between
the segments. This can lead to a short circuit in
the armature.
Good commutation is indicated by a dark

brown polished commutator and an evenly
polished brush wearing surface. See Table 5-2,
“Commutator Surfaces.”

Table 5-2. Commutator Surfaces

Condition Probable Cause Commutator Surface
Uniform coloring indicates satisfactory operation

of machine and brushes. Film color is largely an
Good Condition-Light Film
effect of thickness, therefore provided the film is
uniform it is perfectly acceptable.
This is not a good condition but in our experience

it is known that machines having this
commutator pattern have operated with
Satisfactory satisfactory results for long periods of time. This
Condition-Light and Dark condition can appear in alternating bars as
Pattern shown or every 3rd or 4th bar. This is related to
the winding design of the armature or difficulty
caused from split windings crossing in the same
slot.
Frequently due to under-loaded operation,

Unsatisfactory machine grossly over-brushed or brush grade
Condition-Streaky Film incorrect for particular machine application.
With No Commutator Wear Atmosphere and environmental conditions can
contribute.
Patchy colors of varying densities and shape. Due

Unsatisfactory
to unclean operating conditions or incorrect
Condition-Uneven Film
physical condition of commutator.
These areas can be isolated or regular.

Commutator out of round. This can be caused by
Unsatisfactory Condition-
vibration or mechanical deficiencies in
Film With Dark Areas
equipment operation, bearings, couplings, and so
forth.
Unsatisfactory Bars are low on entry and leaving edges giving

Condition-Example of Poor rise to the brushes riding on the middle of the
Commutator Machining bars.
Bars are low in the middle giving rise to the

Unsatisfactory
brushes riding on entry and leaving bar edges.
Condition-Example of Poor
This and the previous illustration indicate the
Commutator machining
need for better maintenance.
This is a further development of the third

Unsatisfactory
example. Brush grade, machine applications,
Condition-Streaky Film
and working environment are all suspect. Earlier
With commutator Wear
corrective action should have been taken.

Table 5-2. Commutator Surfaces
Condition Probable Cause Commutator Surface
Unsatisfactory Darkening of commutator in sequences two pole

Condition-Double Pole pitches apart is due to armature fault, bad coil,
Pitch riser bars, or equalizer connections.
Storage of machines, for lengthy periods, with

Unsatisfactory
brushes in position. This can also result from
Condition-Brush Contact
operation of machine in prolonged stall
Mark
conditions.
Unsatisfactory Illustration shows high mica in every slot. Same

Condition-Bar Edge effect can occur on one bar only. Similar
Burning-Cause High Mica conditions can be caused by a high or low bar.
Related to overloaded machines and low brush

Unsatisfactory
pressure. Due to sparking under brush, that
Condition-Small Bright
gives rise to spots being of a random distribution.
Spots
If not corrected, will result in scored commutator.
Open Circuit Motor Test 3. Observe the following measurements:
An open circuit is an electrical circuit within the DC Motor Probe Points Resistance
motor that is broken. This can be caused by: A to S Less than 1 ohm
Lift
• bad brushes or brush springs A to Frame
Greater than
• a broken wire in the field or armature Steer MS+ or MS– to 100,000 ohms
winding Frame
• loose or bad connections
4. If the meter indicates high resistance in
Refer to Figure 5-1 on page 5-5 while the armature, check the condition of the
performing the following procedure: brushes before replacing the motor.
1. Isolate the motor from the lift truck circuit 5. If you find an open circuit in a
by removing the power cables. Use two series-wound motor, the motor must be
wrenches to avoid twisting the terminal disassembled by a motor rebuilding facility
stud. to isolate the problem to the field or
2. With the motor at room temperature, armature circuit.
connect the leads of a digital ohmmeter
between the individual circuits in the
motor.

Grounded Motor Test • Severe burning or discoloration on one or

two commutator segments every 90° of
In a grounded motor, an electrical circuit exists rotation.
between the current-carrying conductors and
the motor housing. This can be caused either by These symptoms can be caused by problems
direct contact or through conductive foreign other than the motor itself, such as binding in a
material. related pump, hose, or solenoid valve.
The ground may be caused by: Testing a motor for short circuited windings
requires special equipment at a motor
• insulation breakdown
rebuilding facility.
• brush leads touching the motor housing
• build-up of carbon dust or other materials
Isolate the motor from the lift truck circuit by

removing the power cables. Use two wrenches
to avoid twisting the terminal studs.
Attach one lead of a megohm meter or a digital

ohmmeter to a motor terminal and the other
lead to an unpainted surface of the motor
housing. Set the ohmmeter to the highest scale.
If the ohmmeter reads resistance of less than

100,000 ohms, the motor is grounded. Clean,
repair, or replace the motor as necessary.
Short Circuited Armature or Field

Winding
A short circuited winding is one that the

insulation on the field or armature has broken
down at two or more points. The breakdown
creates a low resistance path, allowing current
to flow from one turn of the coil to another
adjacent coil turn, without actually flowing
through the coil wire. The result is a decrease in
total resistance of the motor winding and an
increase in the current flow. The severity of the
short circuit depends on its location.
A shorted motor may be indicated by:

• Slow or sluggish operation
• Running faster than usual (suggests a
short in the field)
• Overheating
• Blowing a power fuse
• Burning of brush wires
• Severe burning or discoloration on
armature coil

AC Motors Shorted Winding
AC motors used on this lift truck are brushless, If the AC motor fails with a shorted winding, the
3-phase, internally delta-connected, variable motor will move erratically, as if hunting, and
speed motors. there is a high-pitched sound.
The AC motor has a rotor (in place of the DC Using a clamping ammeter, measure current in
armature) and a stator (in place of the DC field). each of the motor power cables. The shorted
There is no electrical connection to the rotor; phase will read significantly higher than the
current is induced in the rotor. The stator has other two phases.
three windings staggered 120° apart, and three
external connections labeled U, V, and W. See
Figure 5-2.
AC
3φ
V W
U
AC
V
3φ
W
5MOTOR_AC3PHASEA.EPS
MOTOR_AC3PHASEB.EPS
Figure 5-2. Drive Motor Circuits
Open Winding
If the AC motor fails with an open winding, the

motor will move erratically, as if hunting, and
there is a ticking sound. Rotation is much
slower than usual.
Using a clamping ammeter, measure current in

each of the motor power cables. The open phase
will read significantly lower than the other two
phases.

Shorts to Frame Test To test for shorts to frame:

“Shorts to frame” is an industry term for the battery connector.
unintentional current leakage paths between 2. To test the battery for shorts to case,
normally isolated electrical circuits and their connect a 12V test light to the battery case
metal enclosures. from battery B+, and then to the battery
case from battery B–. If the light
Shorts to frame may be metallic connections, illuminates at all, even momentarily, there
such as a wire conductor contacting metal is a serious problem with the battery,
through worn insulation. More often, shorts to either external contamination or internal
frame are resistive “leakage” paths caused by damage. Do not continue until this condition
contamination and/or moisture. is corrected. The meter may be damaged if
you proceed before correcting this
These leakage paths can result in unwanted condition.
electrical noise on the metallic lift truck
structure and can cause incorrect operation. Install another battery in the lift truck and
repeat this procedure from step 1.
Shorts to frame are caused by: If the test light does not light, continue to
• Accumulation of dirt the next step.
• Battery electrolyte leakage 3. Use a DMM set on the ampere function to
measure the current leakage from the
• Motor brush dust battery case to battery B+ and from the
• Motor brush leads touching the housing battery case to battery B–. Begin
• Breakdown in insulation measuring at the highest ampere scale
and work toward the lowest. A reading of
• Bare wires more than 0.001A (1mA) indicates a
• Pinched wiring harness serious short. Do not continue until this
• Incorrect mounting of circuit cards condition is corrected. The meter may be
damaged if you proceed before correcting
Shorts to frame can occur at numerous this condition.
locations on a lift truck, including: Install another battery in the lift truck and
• Batteries repeat this procedure from step 1.
• Motors If the current is less than 0.0002A
(0.2mA), go to step 4. If the current is
• Cables, wiring, and harnesses greater than 0.0002A (0.2mA) and less
• Heatsinks than 0.001A (1mA), remove the battery
• Bus bars from the truck, then continue with step 4.
Make sure the battery case does not touch
• Solenoids the lift truck frame during the remaining
• Contactors tests.
• Terminal strips 4. With the battery disconnected (or removed
• Switches and disconnected) from the truck, use a
DMM to measure the resistance from lift
• Power panel insulation
truck frame to lift truck B+, to lift truck B–
• Circuit card mounts (not battery B+ and B–), and to all fuses
and motors. A reading of less than 1000
ohms indicates a serious short. Do not
continue until this condition is corrected.
The meter may be damaged if you proceed
before correcting this condition.

a. To identify the cause of the short to a. To identify the cause of the short to
frame, disconnect circuit components frame, disconnect circuit components
until the low resistance condition until the leakage current reads less
disappears. Do not reconnect than 0.001A (1mA). Do not reconnect
components one at a time, but leave components one at a time, but leave
them disconnected until the low them disconnected until the leakage
resistance reading disappears. Prevent current reads less than 0.001A (1mA).
disconnected terminals or connectors Prevent disconnected terminals or
from touching the lift truck frame or connectors from touching the lift truck
other conductive surfaces. frame or other conductive surfaces.
b. The most likely areas to check are: b. The most likely areas to check are:
• Motors • Motors
• Heatsinks • Heatsinks
• Power cables • Power cables
• Power circuit components • Power circuit components
• Control circuit components • Control circuit components
c. Repair or replace the component c. Repair or replace the component(s)
causing the low resistance condition. causing the leakage current.
Repeat step 4. Repeat step 6.
d. Reconnect all other components d. Reconnect all other components
previously disconnected, one at a time, previously disconnected, measuring
measuring resistance between steps. If current between steps. If a reading is
a reading is less than 1000 ohms when more than 0.001A (1mA) when
reconnecting a component, that reconnecting a component, that
component or its wiring is faulty; repair component or its wiring is bad. Repair
or replace as appropriate. or replace as appropriate.
e. When, after all components are 7. When, after all components are
reconnected, you get readings greater reconnected, you get a reading less than
than 1000 ohms, continue with the 0.001A (1mA) there is no short to frame
next step. condition with the lift truck or the battery.
If you previously removed the battery from
5. Reconnect the battery connector and turn
the truck, re-install the battery.
the key switch ON. If the battery was
previously removed, make sure the battery
case does not touch the lift truck frame.
NOTE: The functions being checked must be
energized. Example: to check for shorts
to frame in the travel circuit, travel must
be requested.
6. Use a DVM set to the current function to
measure current leakage to the lift truck
frame from B+, B–, and all fuses and
motor terminals. Begin measuring at the
highest ampere scale and work toward the
lowest. If the current is less than 0.001A
(1mA), go to step 7. If the current is more
than 0.001A (1mA), continue with the
following steps.

Communication Error Code

Troubleshooting
Intermittent Communication Codes
If possible, determine what the operator was

doing when the codes were generated; driving,
plugging, lifting, sounding horn, and so on.
Focus on these circuits for shorts to frame and

external noise being generated that can
interfere with the communication circuits.
Determine where in the SelfTest Cycle the code
is generated (for instance, when the drive motor
is energized or when the horn was sounded).
Intermittent Codes During SelfTest
Make sure the key switch is turned OFF for at

least five seconds before turning it back to the
ON position. Test the key switch for high
resistance. If nothing is found in the following
steps, replace the key switch.
Test for shorts to frame. See Shorts to Frame

Test on page 5-10.
During Travel and/or Plugging
If lift truck is equipped with optional travel

alarm, disconnect wires to the relay. If code
goes away, troubleshoot travel alarm circuitry.
NOTE: The condition of the travel alarm
suppressor module cannot be checked
with a DMM. If the suppressor module is
suspected to be bad, replace it.
Test and clean static straps.
Test for shorts to frame. See Shorts to Frame

Test on page 5-10.
Communication Code Every Time Key

Is Turned ON
Troubleshoot per code on display using Test I23

- CAN Communication Test (Page 6-36).

Wiring
Visually inspect all wiring and electrical Table 5-3. Wiring Codes
components for:
Sleeve Ident Wire is Associated with
• Loose connections or connectors
FU Fuse
• Loose or broken terminals
• Damaged terminals, blocks, or strips H Horn
• Exposed wire at terminations, excessive H2 Travel Alarm Horn
strip gap
JP Jack and Pin Connector
• Abrasions, scrapes, nicks in the wire,
damage from overheating or burns, or K Relay
other general insulation damage
M Motor
• Broken wire strands and shorted
conditions (especially those that are close MP Pump Motor
to metal edges or surfaces) PC Power Cut-Off (Contactor)
During troubleshooting and repairs, it may be S Switch

necessary to unplug a connector, move a
SOL Solenoid
harness, cut a cable tie, or remove the wire
from a bracket. Note the location of the wire and SPL Splice
all protective or securing attachments before
moving the harness. SUP Suppressor
TP Tie Point
After repair, return or replace all protective
and/or securing hardware to its original VM Vehicle Manager
condition. Protective materials are necessary to
provide reliable performance of the interconnect
system.
Examine and maintain any added materials

used to dress and protect the wire. This
includes spiral wrap, brackets, cable ties,
fasteners, and flexible conduit.
Do not attach cable ties so tight that they pinch

cable harnesses. Avoid attaching cables to
hydraulic hoses that expand with pressure,
pinching the attached electrical cables. Use a
DMM to check for wiring continuity.
A printed letter or number at a wire termination

indicates the specific component where the wire
is attached. Refer to Table 5-3.

Electrical Connector Locations

Pin Identifier Lines
Terminology
The term “connector JPx” means a mated
connector consisting of two connector (jack and
pin) halves. One half contains male connectors,
or pins (P); the other half contains female
connectors, or jacks (J). For a list of connectors,
See Pinout Matrix on page 8-13.
Pins
When a technician disconnects a mated JP Jacks
connector, it becomes two connector halves.
The individual connector halves are designated 58C04013S.TIF
by “Jx” and “Px.” If you cannot locate a Figure 5-3. Molex Jack and Pin Connector
connector designated “Jx” or “Px,” look for
“JPx,” and vice versa.
Molex-type connectors have ridges on the sides
to help locate pin number 1. Molex female
sockets have a single ridge on the short side at
pin number 1. Male plugs have 1, 2, and 3
raised ridges on the long side at pin numbers 1,
2, and 3. See Figure 5-3. Refer to Table 5-4 for
electrical connector locations on the lift truck.
Table 5-4. Electrical Connector Locations and Functions

Connector Function or Routing Location
H2 Travel Alarm Forward of Battery Connector
JPA Ambient Temperature Sensor Forward of Fuse/Relay Card
JPB3 Left Side Brake Near Left Traction Motor
JPB4 Right Side Brake Near Right Traction Motor
JPC3 USB
JPC4 Optional Lever #1 Connector
JPC6 Display Inputs and Outputs
JPC9 FlashWare
JPC10 CAN Digital Inputs/Outputs

Vehicle Manager
JPC12 Handle
JPC12A Lever Option Harness
JPC12B Lever Option Harness
JPC14 Bus+ and Bus– CAN Communications
JPC18 Some Coils, Horn and Travel Alarm

JPC20 Proportional Coils
JPC22 Digital Inputs Vehicle Manager
JPC24 Inputs from Display, and Battery and Temp Sensor
JPD1 Display
Operator Display
JPD2 Display
JPF1 B– Aux Power, B+ Power Amp
JPF2 B+ Connector (B+K1, B+K2, B+K4)

Fuse/Relay Card
JPF3 B– Connector on Fuse Relay Card
JPF4 Key Switch, EPO, Battery Sense
JPH1 Control Handle Control Handle
JPL1 Lift Power Amp Lift Power Amp
JPL2 Lift Encoder

Near Lift Motor
JPL3 Lift Motor Temperature Sensor
JPL4AC Lift Power Contactor Configuration (Model 4200)

Near Fuse/Relay Card
JPL4DC Lift Power Contactor Configuration (Model 4100)
JPS1 Contactor Panel Interface Near Contactor Panel
JPS2 Steering Position Sensor Near Steering Hub
JPS5 High Speed Limit Option
JPS6 Lift Limit Switch Option

Forward of Fuse/Relay Card
JPS13 Right Battery Gate Switch
JPS14 Left Battery Gate Switch
JPT1 Mast Tilt Sensing Option Near Lift Motor
JPTL1 Left Traction Amp Left Traction Amp
JPTL2 Left Traction Motor Encoder

Near Left Traction Motor
JPTL3 Left Traction Motor Temperature Sensor
JPTR1 Right Traction Amp Right Traction Amp
JPTR2 Right Traction Motor Encoder

Near Right Traction Motor
JPTR3 Right Traction Motor Temperature Sensor
JPW1 OCSS - Upper Left Emitter Near Steering Hub
JPW2 OCSS - Upper Right Detector Right side of Operator

JPW3 OCSS - Lower Right Emitter Compartment

JPW4 OCSS - Lower Left Detector Near Steering Hub
JPY1 Weight Pressure Sensor Option Near Hydraulic Manifold
TS1 Terminal Strip for Optional Equipment To Right of Control Handle
Vehicle Manager Connectors
MOTOR_AC3PHASEB.EPS
Figure 5-4. Vehicle Manager Connectors
Fuse/Relay Card Connectors
15A 15A
PF1
PF1
1 4
1 4
FU7
FU8
FU5
FU6
3 6
FU8 FU7 FU5 FU6
K3 K2 K4 K1
K3 K2 K4 K1
15 3 9 3 12 3
13 1 7 1 10 1
13 1 7 1 10 1
PF4 PF2 PF3

PF4 PF2 PF3
MOTOR_AC3PHASEB.EPS
Figure 5-5. Fuse/Relay Card Connectors

Contactors
Contactors
Contactor Tip Inspection
When inspecting contactor tips, follow these
guidelines:
• Darkened points do not indicate burning.
• Burning indicates a loss of contact point
material.
• Replace the contact points if there is not
enough contact point material to last until
the next regular inspection or severe
pitting is evident. See Figure 5-6.
• The silver alloy part of the point is usable
contact material; the copper backing is
not.
• Do not file contact points to remove
discoloration or minor irregularities. This
practice produces a surface more
susceptible to sticking.
• If a cone and crater appear, replace the
tips.
58a21032s.tif
Figure 5-6. Severely Pitted Contactor

Hydraulic Troubleshooting
Hydraulic
Troubleshooting
Auxiliary Hydraulic Pressure
The auxiliary hydraulic system pressure is not
adjustable, however correct function of the
sideshift and tilt capabilities is dependent on
adequate pressure.
Pressure Measurement
A calibrated pressure gauge capable of
measuring 3000 psi (20684 kPa) at mid-range
is required to measure the system pressure.
2. Remove the front covers.
3. Connect the pressure gauge to the
auxiliary pressure test port (G2) on the
main hydraulic manifold.
the key switch ON.
5. Tilt the mast back against the stops.
6. Continue to tilt the mast backward. The
correct pressure is nominally 2000 psi
(13789 kpa), unless there is an
attachment. If pressure is too high, replace
SOL5. If pressure is too low, check pump,
SOL4, and/or SOL5.
8. Remove the pressure gauge.
9. Reinstall the front covers.

Symptom Tables: Hydraulic Functions

Section 5. Troubleshooting
Symptom Tables: Hydraulic

Functions
NOTE: If it is determined that a component
failed as a result of hydraulic fluid
contamination, replace the failed
component and flush, fill, and bleed the
hydraulic system.
NOTE: Reference Schematics on page A-11.
Intermittent Lift/Lower
Possible Cause Action

Bad wiring Check wiring harnesses between valves and VM.
Hydraulic contamination (can Replace damaged component and flush, fill, and bleed the
cause binding proportional hydraulic system.
valve or load holding solenoid)
Lift Function
No Lift - Lift motor does not run

Bad battery Adjust lift cutout as necessary. Replace battery with fully-charged
battery. Test battery for bad cells. See Battery Procedures on
page 7-44.
Bad optional lift limit switch Run Test I05 - Lift Limit (S12) (Page 6-30).

Slow Lift - Lift motor runs

Bad battery Adjust lift cutout as necessary. See Lift Cutout Adjustment on
page 5-4. Replace battery with fully-charged battery. Test battery
for bad cells.
Bad proportional lift/lower Inspect for binding. Run Test O12 - Lift/Lower Solenoid (SOL2)
valve (Page 6-88).
Relief valve SOL3 stuck open Test system pressure. Check for contamination. If contamination is
present, replace valve, flush, fill, and bleed the hydraulic system.
Run Test O09 - Lift Relief Solenoid (SOL3) (Page 6-86).
Plugged or malfunctioning Check for contamination in hydraulic fluid. If contamination is
flow control valve in lift present, replace the flow control valves, flush, fill, and bleed the
cylinder hydraulic system.
Bad lift pump Test system pressure.
Binding in the mast Inspect the mast and bearings for signs of binding.
Bad lift motor 4100 DC Lift Trucks: Test lift motor. See DC Motors on page 5-5.
Check amp draw.
4200 AC Lift Trucks: Run Test O28 - Ramp Lift Motor (AC Lift)
(Page 6-92) and/or Test I20 - Lift RPM (AC Lift only) (Page 6-35).
Bad lift motor encoder Run Test I20 - Lift RPM (AC Lift only) (Page 6-35).
Unable to Pick Up a Load

Battery problems Adjust lift cutout as necessary.
Replace battery with fully-charged battery.
Test battery for bad cells. See Battery Procedures on page 7-44.
Incorrect lift pressure Check and adjust lift pressure setting.
adjustment
Bad lift pump Test system pressure.
Bad lift motor 4100 DC Lift Trucks: Test lift motor. See DC Motors on page 5-5.
Check amp draw.
4200 AC Lift Trucks: Run Test O28 - Ramp Lift Motor (AC Lift)
(Page 6-92) and/or Test I20 - Lift RPM (AC Lift only) (Page 6-35).
Binding in the mast Inspect mast and bearings for signs of binding.

Lower Function
Slow Lower

Binding proportional valve Check valve operation. Run Test O12 - Lift/Lower Solenoid (SOL2)
(Page 6-88).
Binding in the mast Inspect the mast and bearings for signs of binding
Plugged or malfunctioning Check for contamination in hydraulic fluid. If contamination is
flow control valve present, flush, fill, and bleed the hydraulic system. If no
contamination is found, replace the flow control valves in the main
lift cylinders.
Intermittent Lower

Bad load hold solenoid Run Test O11 - Load Hold Solenoid (SOL1) (Page 6-87).
Binding proportional valve Check valve operation. Run Test O12 - Lift/Lower Solenoid (SOL2)
(Page 6-88).
Plugged or malfunctioning If still slow, remove and inspect. Check for contamination in
flow control valve hydraulic fluid. If contamination is present, flush, fill, and bleed
the hydraulic system. If no contamination is found, replace the flow
control valves in the main lift cylinders.
Load Drifting/Settling

Load holding solenoid Run Test O11 - Load Hold Solenoid (SOL1) (Page 6-87). Check for
contamination in hydraulic fluid. If contamination is present,
inspect and clean the relief valve, flush, fill, and bleed the
hydraulic system.

Auxiliary Functions
No Aux Functions

SOL4 not functioning Perform Test O36 - Priority Bypass Solenoid (SOL4) (Page 6-96).
correctly
Aux Functions in One Direction Only

SOL6 not functioning Perform Test O04 - Aux. Direction Solenoid (SOL6) (Page 6-83).
correctly
No Sideshift

No input Perform Test A73 - Sideshift Right (S9) (Page 6-68) and Test A74 -
Sideshift Left (S8) (Page 6-69) or Test A74 - Sideshift Left/Right
(SW4) (Optional Handle) (Page 6-70).
SOL9L/9R not functioning Perform Test O08 - Sideshift Solenoid (SOL9L, SOL9R) (Page 6-85).
correctly
Configuration Make sure Sideshift is enabled in FlashWare. Refer to FlashWare
Program on page 3-15. Check the selected percentage for Sideshift
speed. Refer to Maintenance Mode on page 3-8.
No Tilt

No input Perform Test A71 - Tilt Down (S7) (Page 6-65) and Test A72 - Tilt
Up (S6) (Page 6-66), or Test A72 - Tilt Up/Down (SW4) (Optional
Handle) (Page 6-67).
SOL10 not functioning Perform Test O07 - Tilt Solenoid (SOL10) (Page 6-84).
correctly
Unrequested Tilt

SOL10 stuck on Perform Test O07 - Tilt Solenoid (SOL10) (Page 6-84).

Symptom Tables: Drive Units
Symptom Tables: Drive Units

See “Drive Units” on page 7-24 for standard
drive unit repair procedures.
Oil Leaks

Damaged sealing rings Replace sealing rings, bearing shims, and drive
shaft bearings, if needed.
Worn or damaged drive shaft Replace sealing rings, bearing shims, drive shaft
bearings, and drive shaft.
Housing/cover joint Reseal.
Worn or damaged housing Replace drive unit.
Drive Wheel Wobbles

Worn or damaged drive shaft bearings Replace sealing rings, bearing shims, and drive
shaft bearings.
Worn or damaged drive shaft Replace sealing rings, bearing shims, drive shaft
bearings, and drive shaft.
Loose wheel mounting hardware Inspect housing and drive shaft for damage;
re-torque mounting hardware.
Noise

Worn or damaged drive shaft bearing Replace sealing rings, bearing shims, and drive
shaft bearings.
Worn or damaged pinion bearings Replace pinion bearing and pinion shaft nut.
Worn or damaged gear set (drive shaft is in Replace sealing rings, bearing shims, drive shaft
good condition) bearings, pinion bearings, pinion shaft nut, and
gear set.
Worn or damaged gear set (drive shaft is worn Replace sealing rings, bearing shims, drive shaft
or damaged) bearings, pinion bearings, pinion shaft nut, gear
set, and drive shaft.
Worn or damaged helical gear and pinion Replace helical gear and pinion.
Incorrect oil level Add oil.

Symptom Tables: Travel Functions
Symptom Tables: Travel

Functions
Slow or Sluggish Acceleration

Dragging brake Replace brake or worn parts (see note).
Worn wheel bearings Replace wheel bearings (see note).
Debris in wheel axle Remove debris (see note).
Binding drive unit Remove motor and check movement (see note).
Note: Perform Test A11 - Left Traction Current (Page 6-51) and Test A67 - Right Traction Current
(Page 6-63) with the traction tires off the floor and the truck correctly blocked. At full travel speed,
readings should be approx. 30A to 50A. If one test is significantly higher than the other, focus on the
corresponding drive unit.
Slow Travel

Note: Determine if problem is mechanical or electrical.
Mechanical:
Dragging brake Replace brake or worn brake parts (see note).
Debris in wheel axle Remove debris (see note).
Binding drive unit Remove motor and check movement (see note).
Binding in control handle Run Test A22 - Traction Request (Page 6-57) to determine if the
controller is still seeing a 100% request.
Electrical:
Bad mast speed limit switch Run Test I02 - High Speed Limit SW (S11) (Page 6-29) or Test I89 -
(S10 or S11) or associated Steer Position Sensor (Page 6-44).
wiring
Incorrect reading from steer Run Test I89 - Steer Position Sensor (Page 6-44).
position sensor
Speed limited due to drive Run Test A08 - Left Traction Motor Temp (Page 6-48), Test A10 -
motor or power amplifier Left Traction Power Amp Temp (Page 6-50), Test A65 - Right
temperature (temperature Traction Power Amp Temp (Page 6-62), and Test A68 - Right
icon illuminated) Traction Motor Temp (Page 6-64).
Bad encoder pulses from Run Test I19 - Left Traction RPM (Page 6-34) and/or Test I82 -
drive motor encoder Right Traction RPM (Page 6-41).

Symptom Tables: Travel Functions
Sluggish or No Steering

Pump Check pressures (may have to obtain fittings to access and test
pressures). Approx. 1800 psi at bypass; working pressure - approx.
900 psi
Motor Check amperage, inspect brushes and holders, motor cables.
Mechanical Check steer chain, pump coupling, and steerable wheel bearings.

Symptom Tables: Electrical Symptoms
Symptom Tables: Electrical

Symptoms
NOTE: Reference Schematics on page A-11.
Electrical Motors
Motor Arcing

Worn brushes or incorrect Replace brushes and brush springs.
brush tension
Partially shorted motor Replace motor.
armature or field
Rough or pitted motor Replace motor.
commutator
Motor Overheating

Dragging brake Replace brake or worn brake parts (see note). See Drive Units on
page 7-24.
Application exceeds designed Check with Dealer Service Manager to verify application.
workload -- short runs with
plugging/acceleration or
heavy-duty lifting cycles
Bad battery Check voltage, both open circuit and under load. Replace if
necessary with fully-charged good battery.
Incorrect BSOC Cutout value Check battery specific gravity at cutout, after battery has
stabilized. Compare to battery manufacturer specifications for
discharged battery. Adjust BSOC Cutout as needed.
Cable, terminal, or wiring Replace wiring or cables as necessary.
problems. Look for discolored Check cable connection torque.
terminals, loose or damaged
crimps
Worn, damaged, or bad Inspect motor brushes.
brushes or springs Check brush spring tension.
Binding gearbox or pump Check gearbox or pump for binding (see note for traction motors;
check amp draw for lift motor). Clean, repair, or replace as
necessary.
Hydraulic fluid viscosity too Replace hydraulic fluid with correct fluid. See Lubrication
high or too low Specification Chart on page A-2.
Pressure relief too high Adjust SOL3.

Operator Display
Scrambled or Intermittent Display

Loose harness or display Reseat harness connections. Check schematic for display-related
connectors connectors.
Intermittent wires or Test for continuity while flexing harness. If discontinuity is found,
connectors in harness replace individual wire or entire wiring harness.
Electrical noise in motors Check tightness of motor power cable connections. Check motor
brushes for arcing. Replace if necessary.
Worn or missing static straps Replace as necessary.
Dead Lift Truck

Display is Dark - No functions operate

No LED illuminated on circuit Refer to Pinout Matrix on page 8-13 and Schematics on page A-11.
cards Check for B+ at the following locations with respect to TP4:
• FU5
• JPF4-10
• JPC14-12
Check for B– at the following locations with respect to TP1:
• FU6
• JPF3-3, 4, 5, 6, 7
• JPC14-1, 2, 8, 9 and 10
If all of the above locations have the correct voltages, refer to the
Diagnosis and Repair table in Test A14 - Ext. Supply Sense
(12VDC) (Page 6-53).


Models 4100/4200 Maintenance Manual Section 6. Messages, Codes, and Tests
Section 6. Messages, Codes, and Tests

Section 6. Messages, Codes, and Tests Models 4100/4200 Maintenance Manual
Operator Display Messages
Operator Display
Messages
The Operator Display (OD) displays
alphanumeric data received from the Vehicle
Manager.
The displayed data includes:

• Time or calendar
• BSOC (Battery State-of-Charge)
• Hour meters (hours on deadman [HD],
hours spent lifting [HL], total miles [TM])
• Status/Fault messages
• Weight of load (option)
• Fork Height (option)
• Maintenance required indicator
• Over-temperature indicator
• Lift-limit indicator (optional)

Models 4100/4200 Maintenance Manual Section 6. Messages and Codes Summary List
Summary List Messages
Summary List
Section 6. Messages and Codes Summary List
Messages
Step Off the Deadman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Release Control Handle to Resume Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Lift Cut-out Pending... Low Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
EPO Depressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Scheduled Maintenance Due . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Lift Cutout, Scheduled Maintenance Due. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Battery Low, No Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Speed Limited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Press Bypass Switch To Continue Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Stalled, Release Control Handle to Resume Operation . . . . . . . . . . . . . . . . . . . . 6-8
Release Handle Button to Resume Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Release Lift to Resume Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Release Lift and Step on Deadman to Resume Operation . . . . . . . . . . . . . . . . . . 6-9
Release Tilt to Resume Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Release Side Shift to Resume Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Release Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Press TILT BACK to Unclamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Lower Mast or Tilt Back to Resume Travel and Lift . . . . . . . . . . . . . . . . . . . . . 6-10
Release Bypass Switch To Continue Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Lift Stalled, Re-key to Resume Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Check Battery Gates/Travel Cutout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Entrance Beam Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Codes
Code 1H: Overheated, Allow Time to Cool . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-10
Code 2A: Left Traction Motor Approaching Overtemp . . . . . . . . . . . . . . . . . . .. 6-11
Code 2E: Left Traction Motor Temp Sensor Out-of-Range. . . . . . . . . . . . . . . .. 6-11
Code 2G: Phase Open on Left Traction Motor. . . . . . . . . . . . . . . . . . . . . . . . .. 6-11
Code 2H: Failure Detected in Left Traction Motor Speed Feedback Encoder . .. 6-11
Code 2M: Left TPA Pre-Charge Failed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-11
Code 2T: Left TPA Current Calibration Error . . . . . . . . . . . . . . . . . . . . . . . . .. 6-12
Code 2U: Left TPA Overcurrent or Short Circuit . . . . . . . . . . . . . . . . . . . . . . .. 6-12
Code 2V: Left TPA High DC Bus Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-12
Code 2W: Left TPA Internal Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-12
Code 2X: Left TPA Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-12
Code 2Y: Incorrect TPA Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-12
Code 42: LPC Detected Closed When Commanded Open . . . . . . . . . . . . . . . .. 6-13
Code 43: LPC Detected Open When Commanded Closed . . . . . . . . . . . . . . . .. 6-13
Code 4B: Steer Contactor Detected Closed When Commanded Open . . . . . . .. 6-13
Code 4C: Steer Contactor Detected Open When Commanded Closed . . . . . . .. 6-13
Code 4F: TPC Detected Closed When Commanded Open . . . . . . . . . . . . . . . .. 6-13
Code 4G: TPC Detected Open When Commanded Closed . . . . . . . . . . . . . . . .. 6-13
Code 4J: TPC Contactor Coil Open or Shorted TPC . . . . . . . . . . . . . . . . . . . .. 6-14
Code 4K: LPC Contactor Coil Open or Shorted . . . . . . . . . . . . . . . . . . . . . . . .. 6-14
Code 59: CAN Transmission Buffer Error. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-14
Code 5A: CAN-Bus Error Overflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-14

Section 6. Messages and Codes Summary List Models 4100/4200 Maintenance Manual
Codes Summary List
Code 5B: CAN Transmission Buffer Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Code 5F: No Communications Received by VM from Right TPA . . . . . . . . . . . . . 6-14
Code 5G: No Communications Received by VM from Left TPA . . . . . . . . . . . . . . 6-15
Code 5J: No Communications Received by VM from LPA . . . . . . . . . . . . . . . . . . 6-15
Code 5M: Left TPA NMT Start Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Code 5P: LPA NMT Start Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Code 5U: Right TPA NMT Start Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Code 5Y: Left TPA Incorrect Ampacity for Application . . . . . . . . . . . . . . . . . . . . 6-15
Code 61: Mast Switch Not Sensed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 6D: Pressure Sensor Output Voltage Out-of-Range . . . . . . . . . . . . . . . . . . 6-16
Code 7A: Lift Motor Overtemp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 7E: Lift Motor Temperature Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . 6-16
Code 7F: LPA Overtemp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 7G: LPA Motor Phase Open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 7H: Lift Motor Feedback Encoder Failure Detected . . . . . . . . . . . . . . . . . . 6-17
Code 7M: LPA Failed to Precharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 7T: LPA Current Sensor Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 7U: LPA Overcurrent or Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 7V: LPA High Voltage on DC Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 7W: LPA Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 7X: LPA Power Supply Out-of-Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 7Y: Incorrect LPA Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 80: Throttle Potentiometer (VR1) Voltage Out-of-Range . . . . . . . . . . . . . . . 6-18
Code 81: Lift/Lower Potentiometer (VR2) Voltage Out-of-Range . . . . . . . . . . . . . 6-18
Code 83: Throttle Potentiometer (VR1) Out-of-Neutral . . . . . . . . . . . . . . . . . . . . 6-18
Code 84: Brakes Inoperable - Not Applied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 88: 5V Power Supply Out-of-Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 8A: OCSS Photo Sensor Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 8F: Lift/Lower Potentiometer Out-of-Neutral. . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 8J: Ambient Temperature Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . . 6-19
Code 8P: Tilt Potentiometer Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 8R: Tilt Out-of-Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 8S: Sideshift Potentiometer Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 8T: Sideshift Out-of-Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 8U: Attachment Function 1 Out-of-Range. . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 8V: Attachment Function 1 Out-of-Neutral . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 8W: Attachment Function 2 Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 8X: Attachment Function 2 Out-of-Neutral . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code A0: Incorrect Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code A2: Software Compatibility Issue with VM and Left TPA . . . . . . . . . . . . . . 6-21
Code A3: Software Compatibility Issue with VM and Right TPA . . . . . . . . . . . . . 6-21
Code A4: Software Compatibility Issue with VM and LPA. . . . . . . . . . . . . . . . . . 6-21
Code AG: Communications To/From Operator Display Failed . . . . . . . . . . . . . . 6-21
Code AH: Bad Operator Display Checksum . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code AL: VM Battery Backed Up RAM Failed. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code AP: Left TPA Software Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code AT: LPA Software Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code EC: COP Not Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code FE: Internal VM Circuit for BSOC Not Calibrated . . . . . . . . . . . . . . . . . . . 6-22
Code FG: +5V Reference Voltage and +12V Power Supply Failure . . . . . . . . . . . 6-22
Code FH: Battery Voltage Out-of-Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code FN: Relays Did Not Open at Power Off . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

Models 4100/4200 Maintenance Manual Section 6. Messages and Codes Summary List
Summary List Input Tests
Code FT: VM Internal Software Error . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 6-23

Code G2: Bad Steer Position Reference Input. . . . . . . . . . . . . . . . . . .. . . . . . . 6-23
Code HA: Right Traction Motor Overtemp . . . . . . . . . . . . . . . . . . . . .. . . . . . . 6-23
Code HE: Right Traction Motor Temperature Sensor Out-of-Range . .. . . . . . . 6-23
Code HF: Right TPA Overtemp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 6-23
Code HG: Right Traction Motor Phase Open. . . . . . . . . . . . . . . . . . . .. . . . . . . 6-24
Code HH: Right Traction Motor Feedback Encoder Failure. . . . . . . . .. . . . . . . 6-24
Code HM: Right TPA Pre-Charge Failed . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 6-24
Code HT: Right TPA Current Sensor Fault . . . . . . . . . . . . . . . . . . . . .. . . . . . . 6-24
Code HU: Right TPA Overcurrent or Short Circuit . . . . . . . . . . . . . . .. . . . . . . 6-24
Code HV: Right TPA High DC Bus Voltage . . . . . . . . . . . . . . . . . . . . .. . . . . . . 6-24
Code HW: Right TPA Software Error . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 6-25
Code HX: Right TPA Power Supply Out-of-Range . . . . . . . . . . . . . . . .. . . . . . . 6-25
Code T0: Aux Relief SOL5 Open Circuit or Constant Low . . . . . . . . . .. . . . . . . 6-25
Code T3: Proportional Lower SOL2 Open Circuit or Constant Low . . .. . . . . . . 6-25
Code T4: Priority Bypass SOL4 Open Circuit or Constant Low . . . . . .. . . . . . . 6-25
Code VC: Internal Error in VM Communications . . . . . . . . . . . . . . . .. . . . . . . 6-25
Input Tests
Test I00 - Deadman (S2) . . . . . . . . . . .. . .. ........................ .. . 6-28
Test I02 - High Speed Limit SW (S11) .. . .. ........................ .. . 6-29
Test I05 - Lift Limit (S12) . . . . . . . . . .. . .. ........................ .. . 6-30
Test I13 - Lift Contactor (DC Lift) . . . .. . .. ........................ .. . 6-31
Test I14 - Steer Contactor . . . . . . . . . .. . .. ........................ .. . 6-32
Test I15 - Horn (S3, SW1) . . . . . . . . . .. . .. ........................ .. . 6-33
Test I19 - Left Traction RPM . . . . . . . .. . .. ........................ .. . 6-34
Test I20 - Lift RPM (AC Lift only) . . . . .. . .. ........................ .. . 6-35
Test I23 - CAN Communication Test . .. . .. ........................ .. . 6-36
Test I65 - Tilt Position SW (S18) . . . . .. . .. ........................ .. . 6-38
Test I80 - OCSS - Low . . . . . . . . . . . .. . .. ........................ .. . 6-39
Test I81 - OCSS - High . . . . . . . . . . . .. . .. ........................ .. . 6-40
Test I82 - Right Traction RPM . . . . . . .. . .. ........................ .. . 6-41
Test I87 - Battery Gate . . . . . . . . . . . .. . .. ........................ .. . 6-42
Test I88 - Battery Gate 2 . . . . . . . . . .. . .. ........................ .. . 6-43
Test I89 - Steer Position Sensor . . . . .. . .. ........................ .. . 6-44
Analog Tests
Test A04 - Travel Pot (VR1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-46
Test A05 - Lift/Lower Pot (VR2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-47
Test A08 - Left Traction Motor Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-48
Test A09 - Lift Motor Temp (AC Lift only) . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-49
Test A10 - Left Traction Power Amp Temp . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-50
Test A11 - Left Traction Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-51
Test A13 - Weight Sensor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-52
Test A14 - Ext. Supply Sense (12VDC) . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-53
Test A15 - Battery Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-54
Test A19 - Lift Power Amp Temp (AC Lift only) . . . . . . . . . . . . . . . . . . . .. . .. . 6-55
Test A20 - Lift Current (AC Lift only) . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-56
Test A22 - Traction Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-57
Test A23 - Lift Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-58

Section 6. Messages and Codes Summary List Models 4100/4200 Maintenance Manual
Output Tests Summary List
Test A26 - Pot Supply (5VDC) . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . 6-59

Test A34 - Lift/Lower Current (SOL2) . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . 6-60
Test A36 - Ambient Temperature . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . 6-61
Test A65 - Right Traction Power Amp Temp . . . . . . . . . . . .. . .. . . . . . . . . . . . 6-62
Test A67 - Right Traction Current . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . 6-63
Test A68 - Right Traction Motor Temp . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . 6-64
Test A71 - Tilt Down (S7) . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . 6-65
Test A72 - Tilt Up (S6) . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . 6-66
Test A72 - Tilt Up/Down (SW4) (Optional Handle) . . . . . . .. . .. . . . . . . . . . . . 6-67
Test A73 - Sideshift Right (S9) . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . 6-68
Test A74 - Sideshift Left (S8) . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . 6-69
Test A74 - Sideshift Left/Right (SW4) (Optional Handle) . . .. . .. . . . . . . . . . . . 6-70
Test A75 - Attach Fcn 1 (S4) . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . 6-71
Test A75 - Attach Fcn 1 (SW3) (Optional Handle) . . . . . . . .. . .. . . . . . . . . . . . 6-72
Test A76 - Attach Fcn 2 (S5) . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . 6-73
Test A76 - Attach Fcn 2 (SW2) (Optional Handle) . . . . . . . .. . .. . . . . . . . . . . . 6-74
Test A77 - EPO (S21) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . 6-75
Test A80 - Lift Relief Current (SOL3) . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . 6-76
Test A81 - Priority Bypass Current (SOL4) . . . . . . . . . . . . .. . .. . . . . . . . . . . . 6-77
Test A82 - Aux. Relief Current (SOL5) . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . 6-78
Output Tests
Test O00 - TPC Contactor . . . . . . . . . . . . . . . . . . . .. .. . .. . .. .. . . . . . . . . . 6-80
Test O01 - Steer Contactor (STR) . . . . . . . . . . . . . . .. .. . .. . .. .. . . . . . . . . . 6-81
Test O02 - Lift Contactor (LPC) . . . . . . . . . . . . . . . . .. .. . .. . .. .. . . . . . . . . . 6-82
Test O04 - Aux. Direction Solenoid (SOL6) . . . . . . . .. .. . .. . .. .. . . . . . . . . . 6-83
Test O07 - Tilt Solenoid (SOL10) . . . . . . . . . . . . . . .. .. . .. . .. .. . . . . . . . . . 6-84
Test O08 - Sideshift Solenoid (SOL9L, SOL9R) . . . . .. .. . .. . .. .. . . . . . . . . . 6-85
Test O09 - Lift Relief Solenoid (SOL3) . . . . . . . . . . . .. .. . .. . .. .. . . . . . . . . . 6-86
Test O11 - Load Hold Solenoid (SOL1) . . . . . . . . . . .. .. . .. . .. .. . . . . . . . . . 6-87
Test O12 - Lift/Lower Solenoid (SOL2) . . . . . . . . . . .. .. . .. . .. .. . . . . . . . . . 6-88
Test O18 - Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. .. . . . . . . . . . 6-89
Test O19 - Ramp Sounder . . . . . . . . . . . . . . . . . . . .. .. . .. . .. .. . . . . . . . . . 6-90
Test O20 - Travel Alarm . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. .. . . . . . . . . . 6-91
Test O28 - Ramp Lift Motor (AC Lift) . . . . . . . . . . . . .. .. . .. . .. .. . . . . . . . . . 6-92
Test O29 - Ramp Traction Motors . . . . . . . . . . . . . . .. .. . .. . .. .. . . . . . . . . . 6-93
Test O30 - Electric Brakes . . . . . . . . . . . . . . . . . . . .. .. . .. . .. .. . . . . . . . . . 6-94
Test O32 - Toggle Relay Enable . . . . . . . . . . . . . . . .. .. . .. . .. .. . . . . . . . . . 6-95
Test O36 - Priority Bypass Solenoid (SOL4) . . . . . . .. .. . .. . .. .. . . . . . . . . . 6-96
Test O37 - Aux. Relief Solenoid (SOL5) . . . . . . . . . . .. .. . .. . .. .. . . . . . . . . . 6-97
Test O45 - HSA 1 Solenoid (SOL7C, SOL7R) . . . . . . .. .. . .. . .. .. . . . . . . . . . 6-98

Models 4100/4200 Maintenance Manual Section 6. Messages, Codes and Tests
Messages and Codes
Messages and Codes

Section 6. Messages, Codes and Tests
Icon Code Title/Reason Tests to Run Notes/Corrective Action
Message Displayed: S t e p O f f t h e D e a d m a n
Step Off the Deadman Test I00 - Deadman (S2) Release deadman.
Deadman (S2) is activated while lift (Page 6-28)
truck is trying to perform SelfTest.
Message Displayed: R e l e a s e C o n t r o l H a n d l e t o R e s u m e O p e r a t i o n
Release Control Handle to Resume Test A04 - Travel Pot (VR1) Release throttle, step on
Operation (Page 6-46) deadman, resume travel.
Control handle moved before deadman
pressed.
Message Displayed: L i f t C u t O u t P e n d i n g . . . L o w b a t t e r y
Lift Cut-out Pending... Low Battery None Message is displayed for five
Battery low. minutes, then lift is
disabled. Change Battery.
Message Displayed: E P O D e p r e s s e d
EPO Depressed Test A77 - EPO (S21) Lift EPO Button and cycle
VM senses the EPO switch is open (IN). (Page 6-75) key switch to clear.
Message Displayed: S c h e d u l e d M a i n t e n a n c e D u e
Scheduled Maintenance Due None Reset Maintenance Minder in
This message occurs when Configure Configure Mode.
Mode Maintenance Minder has been
set to request it be activated.
Message Displayed: L i f t C u t o u t , S c h e d u l e d M a i n t e n a n c e D u e
Lift Cutout, Scheduled Maintenance None Lift is disabled.
Due Reset Maintenance Minder in
This message occurs when Configure Configure Mode.
Mode Maintenance Minder has been
set to request it be activated.

Section 6. Messages, Codes and Tests Models 4100/4200 Maintenance Manual
Messages and Codes
Message Displayed: B a t t e r y L o w, N o L i f t
Battery Low, No Lift If charging or changing the Lift is disabled.
Lift interrupt has occurred due to the battery does not clear the Charge/change battery.
battery state-of-charge message, run Test A15 -
Battery Volts (Page 6-54)
Message Displayed: S p e e d L i m i t e d
Speed Limited Test A08 - Left Traction Traction or lift speed is
An overtemperature condition has Motor Temp (Page 6-48) reduced when a traction
been detected. Test A09 - Lift Motor Temp motor or the lift motor
(AC Lift only) (Page 6-49) becomes overheated. Allow
Test A10 - Left Traction time for lift truck to cool.
Power Amp Temp
(Page 6-50)
Test A19 - Lift Power Amp
Temp (AC Lift only)
(Page 6-55)
Test A65 - Right Traction
Power Amp Temp
(Page 6-62)
Motor Temp (Page 6-64)
Message Displayed: P r e s s B y p a s s S w i t c h To C o n t i n u e L i f t i n g
Press Bypass Switch To Continue Test I05 - Lift Limit (S12) Lift is disabled unless
Lifting (Page 6-30) bypass switch (UP button) is
Lift Inhibit Switch (S24) has been activated. Lower carriage
crossed. below lift inhibit switch.
Message Displayed: S t a l l e d , R e l e a s e C o n t r o l H a n d l e t o R e s u m e O p e r a t i o n
Stalled, Release Control Handle to Test I19 - Left Traction Travel or lift speed is limited
Resume Operation RPM (Page 6-34) when the corresponding
No encoder pulses are received by Test I82 - Right Traction power amp is not receiving
Power Amplifiers. RPM (Page 6-41) encoder pulses. Cycle key
Test I20 - Lift RPM (AC Lift switch to clear.
only) (Page 6-35)
Message Displayed: R e l e a s e H a n d l e B u t t o n t o R e s u m e O p e r a t i o n
Release Handle Button to Resume None This code will appear prior to
Operation an out-of-range code being
Digital input from handle activated at displayed.
startup.

Messages and Codes
Message Displayed: R e l e a s e L i f t t o R e s u m e O p e r a t i o n
Release Lift to Resume Operation Test A05 - Lift/Lower Pot Release lift, step on
Lift pot out of learned neutral position (VR2) (Page 6-47) deadman pedal.
at startup.
Message Displayed: R e l e a s e L i f t a n d S t e p o n D e a d m a n t o R e s u m e O p e r a t i o n
Release Lift and Step on Deadman Test I00 - Deadman (S2) Release lift or lower request
to Resume Operation (Page 6-28) and step on deadman.
Applies to trucks with "Lift/Lower
without deadman" enabled. Occurs
after the deadman switch has not been
activated for 30 seconds.
Message Displayed: R e l e a s e T i l t t o R e s u m e O p e r a t i o n
Release Tilt to Resume Operation Test A72 - Tilt Up/Down Release tilt control.
Applies to trucks equipped with (SW4) (Optional Handle)
optional handle. Tilt control out of (Page 6-67)
Learned neutral at startup.
Message Displayed: R e l e a s e S i d e S h i f t t o R e s u m e O p e r a t i o n
Release Side Shift to Resume Opera- Test A74 - Sideshift Release sideshift control.
tion Left/Right (SW4)
Applies to trucks equipped with (Optional Handle)
optional handle. Sideshift control out (Page 6-70)
of Learned neutral at startup.
Message Displayed: R e l e a s e H o r n B u t t o n
Release Horn Button Test I15 - Horn (S3, SW1) Release horn button.
Digital input from handle activated (Page 6-33)
longer than ten seconds.
Message Displayed: P r e s s T I LT B A C K t o U n c l a m p
Press TILT BACK to Unclamp Test A72 - Tilt Up/Down N/A
Informational message to advise (SW4) (Optional Handle)
operator to activate Tilt Back button (Page 6-67)
when the lift truck is equipped with a
clamp.

Messages and Codes
Message Displayed: L o w e r M a s t o r T i l t B a c k t o R e s u m e Tr a v e l a n d L i f t
Lower Mast or Tilt Back to Resume Test I02 - High Speed Follow instructions on
Travel and Lift Limit SW (S11) display. If message still
Informational message for trucks (Page 6-29) scrolls, perform tests.
equipped with bottler’s tilt. Test I65 - Tilt Position SW
(S18) (Page 6-38)
Message Displayed: R e l e a s e B y p a s s S w i t c h To C o n t i n u e L i f t i n g
Release Bypass Switch To Continue None Release UP button.
Lifting
Message Displayed: L i f t S t a l l e d , R e - k e y t o R e s u m e O p e r a t i o n
Lift Stalled, Re-key to Resume Oper- Test I20 - Lift RPM (AC Lift Lift speed is limited. Cycle
ation only) (Page 6-35) key switch to clear.
LPA is not receiving encoder pulses.
Message Displayed: C h e c k B a t t e r y G a t e s / Tr a v e l C u t o u t
Check Battery Gates/Travel Cutout Test I87 - Battery Gate Clear Condition.
Battery Gate Switch open or Travel (Page 6-42)
Cutout circuit activated. Test I88 - Battery Gate 2
(Page 6-43)
Message Displayed: E n t r a n c e B e a m B l o c k e d
Entrance Beam Blocked Test I80 - OCSS - Low Clear Condition. Clean photo
Optional OCSS entrance beam (Page 6-39) eyes.
blocked. Test I81 - OCSS - High
(Page 6-40)
Message Displayed: C O D E 1 H O v e r h e a t e d , A l l o w T i m e t o C o o l
Code 1H: Overheated, Allow Time to Test A10 - Left Traction Cycle key switch to clear
Cool Power Amp Temp after TPA has achieved
The left TPA has reported its internal (Page 6-50) acceptable temperature
temperature is less than –40°F (–40°C) Test I89 - Steer Position levels.
or greater than +203°F (+95°C). Sensor (Page 6-44)

Messages and Codes
Message Displayed: C O D E 2 A O v e r h e a t e d , A l l o w T i m e t o C o o l
Code 2A: Left Traction Motor Test A08 - Left Traction Travel speed is linearly
Approaching Overtemp Motor Temp (Page 6-48). derated starting at 266°F
The TPA senses that the Traction Test I89 - Steer Position (130°C). Travel speed is
Motor is approaching Sensor (Page 6-44) limited to 1 mph at 300°F
overtemperature. Traction (149°C). Cycle key switch to
performance is limited. clear after Traction Motor
has cooled.
Message Displayed: C O D E 2 E I n f o r m s e r v i c e
Code 2E: Left Traction Motor Temp Test A08 - Left Traction Travel is limited to 6.5 mph.
Sensor Out-of-Range Motor Temp (Page 6-48) Clears when reason for fault
The Traction Motor temperature is corrected.
sensor is open or shorted.
Message Displayed: C O D E 2 G I n f o r m s e r v i c e
Code 2G: Phase Open on Left Trac- Test O29 - Ramp Traction Travel is disabled. Cycle key
tion Motor Motors (Page 6-93) switch to clear.
The TPA has detected no current draw
in one of the three phases of the
motor.
Message Displayed: C O D E 2 H I n f o r m s e r v i c e
Code 2H: Failure Detected in Left Test I19 - Left Traction Travel is limited to 1 mph. If
Traction Motor Speed Feedback RPM (Page 6-34) a single channel is bad, this
Encoder code is displayed during
Run. If one or both channels
are bad at SelfTest,
STALLED is displayed. Cycle
key switch to clear.
Message Displayed: C O D E 2 M I n f o r m s e r v i c e
Code 2M: Left TPA Pre-Charge None Travel is disabled. Check for
Failed B+ at the left TPA+ terminal.
Left TPA failed to precharge correctly. Cycle key switch to clear. If
code will not clear, replace
TPA. The VM cannot cause
this code.

Messages and Codes
Message Displayed: C O D E 2 T I n f o r m s e r v i c e
Code 2T: Left TPA Current Calibra- None Travel is limited to 2.5 mph.
tion Error Cycle key switch to clear. If
The TPA has sensed a current code will not clear, replace
calibration error. TPA. The VM cannot cause
this code.
Message Displayed: C O D E 2 U I n f o r m s e r v i c e
Code 2U: Left TPA Overcurrent or None Travel is disabled. Cycle key
Short Circuit switch to clear. Check for
The TPA has sensed current in excess shorted traction motor power
of 400A. cables. If code will not clear,
replace TPA. The VM cannot
cause this code.
Message Displayed: C O D E 2 V I n f o r m s e r v i c e
Code 2V: Left TPA High DC Bus Volt- Test A15 - Battery Volts If voltage is OK, replace TPA.
age (Page 6-54) Cycle key switch to clear.
The left TPA has detected an The VM cannot cause this
overvoltage condition at the code.
+ terminal.
Message Displayed: C O D E 2 W I n f o r m s e r v i c e
Code 2W: Left TPA Internal Fault None Cycle key switch to clear. If
TPA internal circuitry has code will not clear, replace
malfunctioned. TPA.
Message Displayed: C O D E 2 X I n f o r m s e r v i c e
Code 2X: Left TPA Out-of-Range None Travel restricted to 1 mph.
The power supply output in the left Cycle key switch to clear.
TPA is less than 4.5V, greater than Disconnect (+) wire to temp
5.5V, or too much current is being and speed sensors. If code
drawn by an external component. changes, troubleshoot wires
and sensors. If not OK,
cause this code.
Message Displayed: C O D E 2 Y I n f o r m s e r v i c e
Code 2Y: Incorrect TPA Installed None Replace with correct TPA.
Incorrect PA Installed. Should be Travel is limited to 2.5 mph.
500A, 400A was installed.

Messages and Codes
Message Displayed: C O D E 4 2 I n f o r m s e r v i c e
Code 42: LPC Detected Closed When Test O02 - Lift Contactor Lift is disabled. Cycle key
Commanded Open (LPC) (Page 6-82) switch to clear.
AC Lift - the LPA has detected an
incorrect voltage at the B+ terminal on
the amplifier.
DC Lift - the VM has detected an
incorrect voltage at JPC22-20.
Code 43: LPC Detected Open When Test O02 - Lift Contactor Cycle key switch to clear.
Commanded Closed (LPC) (Page 6-82)
AC Lift - the LPA has detected an
the amplifier.
DC Lift - the VM has detected an
incorrect voltage at JPC22-20.
Message Displayed: C O D E 4 B I n f o r m s e r v i c e
Code 4B: Steer Contactor Detected Test I14 - Steer Contactor Check for incorrect voltage
Closed When Commanded Open (Page 6-32) at JPC22-19. Reference
The VM measured greater than Test O01 - Steer Contactor “Pinout Matrix” on
+10VDC at JPC22-19 when the STR (STR) (Page 6-81) page 8-13. Cycle key switch
coil was de-energized. to clear.
Message Displayed: C O D E 4 C I n f o r m s e r v i c e
Code 4C: Steer Contactor Detected Test I14 - Steer Contactor Cycle key switch to clear.
Open When Commanded Closed (Page 6-32)
The VM measured less than +10VDC Test O01 - Steer Contactor
at JPC22-19 when the STR coil was (STR) (Page 6-81)
commanded closed.
Message Displayed: C O D E 4 F I n f o r m s e r v i c e
Code 4F: TPC Detected Closed When Test O00 - TPC Contactor Travel is disabled.
Commanded Open (Page 6-80) Cycle key switch to clear.
The right TPA has detected an
the amplifier.
Message Displayed: C O D E 4 G I n f o r m s e r v i c e
Code 4G: TPC Detected Open When Test O00 - TPC Contactor Travel is disabled.
Commanded Closed (Page 6-80) Cycle key switch to clear.
The TPA has detected the TPC open
after power-up.

Messages and Codes
Message Displayed: C O D E 4 J I n f o r m s e r v i c e
Code 4J: TPC Contactor Coil Open Test O00 - TPC Contactor Travel is disabled.
or Shorted TPC (Page 6-80) Cycle key switch to clear.
TPC contactor coil is open or shorted.
Message Displayed: C O D E 4 K I n f o r m S e r v i c e
Code 4K: LPC Contactor Coil Open Test O02 - Lift Contactor Lift is disabled. Cycle key
or Shorted (LPC) (Page 6-82) switch to clear.
The LPC contactor coil is open or
shorted.
Message Displayed: C O D E 5 9 I n f o r m S e r v i c e
Code 59: CAN Transmission Buffer Test I23 - CAN All functions disabled. See
Error Communication Test Communication Error Code
The VM has detected a CAN (Page 6-36) Troubleshooting in Test I23 -
transmission buffer error. CAN Communication Test
(Page 6-36). Cycle key switch
to clear.
Message Displayed: C O D E 5 A I n f o r m S e r v i c e
Code 5A: CAN-Bus Error Overflow Test I23 - CAN All functions disabled. See
CAN-Bus error overflow detected by Communication Test Communication Error Code
VM. (Page 6-36) Troubleshooting in Test I23 -
CAN Communication Test
(Page 6-36). Cycle key switch
to clear.
Message Displayed: C O D E 5 B I n f o r m S e r v i c e
Code 5B: CAN Transmission Buffer Test I23 - CAN Lift truck will plug to a stop
Error Communication Test if traveling. Cycle key switch
CAN transmission buffer error. (Page 6-36) to clear.
Message Displayed: C O D E 5 F I n f o r m S e r v i c e
Code 5F: No Communications Test I23 - CAN Travel is disabled, lift truck
Received by VM from Right TPA Communication Test will plug to a stop. Cycle key
The VM has not received CAN (Page 6-36) switch to clear.
communications from the right TPA.

Messages and Codes
Message Displayed: C O D E 5 G I n f o r m S e r v i c e
Code 5G: No Communications Test I23 - CAN Travel is disabled, lift truck
Received by VM from Left TPA Communication Test will plug to a stop. Cycle key
The VM has not received CAN (Page 6-36) switch to clear.
communications from the left TPA.
Message Displayed: C O D E 5 J I n f o r m S e r v i c e
Code 5J: No Communications Test I23 - CAN Lift is disabled. Cycle key
Received by VM from LPA Communication Test switch to clear.
AC lift only. The VM has not received (Page 6-36)
CAN communications from the LPA.
Message Displayed: C O D E 5 M I n f o r m S e r v i c e
Code 5M: Left TPA NMT Start Time- None Check B+ and B– to left TPA.
out Check CAN-Bus wiring. If
No communications received from left code will not clear, replace
TPA within one minute. left TPA.
Message Displayed: C O D E 5 P I n f o r m S e r v i c e
Code 5P: LPA NMT Start Timeout None Check B+ and B– to LPA.
AC Lift only. No communications Check CAN-Bus wiring. If
received from LPA within one minute. code will not clear, replace
LPA.
Message Displayed: C O D E 5 U I n f o r m S e r v i c e
Code 5U: Right TPA NMT Start Tim- None Check B+ and B– to right
eout TPA. Check CAN-Bus wiring.
No communications received from If code will not clear, replace
right TPA within one minute. the right TPA.
Message Displayed: C O D E 5 Y I n f o r m S e r v i c e
Code 5Y: Left TPA Incorrect Ampac- None Replace with correct power
ity for Application amp.
Left TPA Incorrect ampacity for
application.

Messages and Codes
Code 61: Mast Switch Not Sensed Test I02 - High Speed Travel is limited to 2.5 mph.
Mast Switch change of state not Limit SW (S11) Clears when switch change
detected within allotted lift request (Page 6-29) of state is detected.
time. Test O12 - Lift/Lower
Solenoid (SOL2)
(Page 6-88)
Message Displayed: C O D E 6 D I n f o r m S e r v i c e
Code 6D: Pressure Sensor Output Test A13 - Weight Sensor A high number is displayed
Voltage Out-of-Range Voltage (Page 6-52) for weight.
The VM has determined that the
pressure sensor voltage has exceeded
the programmed limits.
Message Displayed: C O D E 7 A O v e r h e a t e d , A l l o w T i m e t o C o o l
Code 7A: Lift Motor Overtemp Test A09 - Lift Motor Temp Lift is disabled. Allow time to
AC Lift only. Lift motor temperature (AC Lift only) (Page 6-49) cool. Cycle key switch to
has exceeded 300°F (149°C). clear.
Message Displayed: C O D E 7 E I n f o r m S e r v i c e
Code 7E: Lift Motor Temperature Test A09 - Lift Motor Temp Lift performance is disabled
Sensor Out-of-Range (AC Lift only) (Page 6-49) by LPA. Cycle key switch to
AC Lift only. Lift motor temperature clear.
sensor voltage is out-of-range.
Message Displayed: C O D E 7 F O v e r h e a t e d , A l l o w T i m e t o C o o l
Code 7F: LPA Overtemp Test A19 - Lift Power Amp Lift is disabled. Cycle key
AC Lift only. The LPA has reported its Temp (AC Lift only) switch to clear.
internal temperature is less than (Page 6-55)
–40°F (–40°C) or greater than +203°F
(+95°C).
Message Displayed: C O D E 7 G I n f o r m S e r v i c e
Code 7G: LPA Motor Phase Open Test O28 - Ramp Lift Lift is disabled. Cycle key
AC Lift only. The LPA has detected no Motor (AC Lift) switch to clear.
current draw in one of the three (Page 6-92)
phases of the motor.

Messages and Codes
Message Displayed: C O D E 7 H I n f o r m S e r v i c e
Code 7H: Lift Motor Feedback Test I20 - Lift RPM (AC Lift Lift is limited to approx. ten
Encoder Failure Detected only) (Page 6-35) feet per minute. Cycle key
AC Lift only. The LPA has detected switch to clear.
incorrect pulses from the lift motor
encoder.
Message Displayed: C O D E 7 M I n f o r m S e r v i c e
Code 7M: LPA Failed to Precharge None Lift is disabled. If cycling the
AC Lift only. The LPA failed to key switch does not clear
precharge. this code, replace the LPA.
The VM cannot cause this
code.
Message Displayed: C O D E 7 T I n f o r m S e r v i c e
Code 7T: LPA Current Sensor Fault None Lift is limited to 60% of
AC Lift only. Internal LPA circuitry that maximum request. If cycling
measures current has detected a fault. the key switch does not clear
this code, replace the LPA.
The VM cannot cause this
code.
Code 7U: LPA Overcurrent or Short None Lift is disabled. Cycle key
Circuit switch to clear. Check for
AC Lift only. The LPA has sensed shorted lift motor cables. If
current in excess of 500A. code will not clear, replace
LPA. The VM cannot cause
this code.
Message Displayed: C O D E 7 V I n f o r m S e r v i c e
Code 7V: LPA High Voltage on DC Test A15 - Battery Volts Lift is disabled. Test voltage
Bus (Page 6-54) at LPA+. If OK, replace LPA.
AC Lift only. The LPA has detected that Cycle key switch to clear.
the voltage at the + terminal is The VM cannot cause this
overvoltage. code.
Message Displayed: C O D E 7 W I n f o r m S e r v i c e
Code 7W: LPA Internal Fault None Cycle key switch to clear. If
AC Lift only. Internal circuitry has code will not clear, replace
malfunctioned. LPA. The VM cannot cause
this code.

Section 6. M essa g es, C odes a nd Tests Models 4100/4200 Maintenance Manual
Messages and Codes
Message Displayed: C O D E 7 X I n f o r m S e r v i c e
Code 7X: LPA Power Supply None Cycle key switch to clear.
Out-of-Range Disconnect (+) wire to temp
AC Lift only. The power supply output and speed sensors. If OK,
in the LPA is less than 4.5V, greater troubleshoot wires and
than 5.5V or too much current is sensors. If code will not
being drawn by an external clear, replace LPA. The VM
component. cannot cause this code.
Message Displayed: C O D E 7 Y I n f o r m S e r v i c e
Code 7Y: Incorrect LPA Installed None Replace with correct LPA.
AC Lift only. Incorrect LPA installed,
Incorrect ampacity for application.
Code 80: Throttle Potentiometer Test A04 - Travel Pot (VR1) Travel is disabled. Cycle key
(VR1) Voltage Out-of-Range (Page 6-46) switch to clear.
Code 81: Lift/Lower Potentiometer Test A05 - Lift/Lower Pot Lift is disabled. Cycle key
(VR2) Voltage Out-of-Range (VR2) (Page 6-47) switch to clear.
Code 83: Throttle Potentiometer Test A04 - Travel Pot (VR1) Travel is disabled. Return
(VR1) Out-of-Neutral (Page 6-46) control handle to neutral.
Throttle potentiometer (VR1) out of Cycle key switch to clear.
learned neutral value.
Code 84: Brakes Inoperable - Not Test O30 - Electric Brakes Travel disabled at startup.
Applied (Page 6-94) Make sure brake release
The drive motor bearing encoder bolts are removed from
indicated movement during SelfTest. brake assembly. Cycle key
switch to clear.

Messages and Codes
Code 88: 5V Power Supply Test A04 - Travel Pot (VR1) Cycle key switch to clear.
Out-of-Range (Page 6-46)
Control handle 5V power supply Test A05 - Lift/Lower Pot
located in VM out-of-range. (VR2) (Page 6-47)
Message Displayed: C O D E 8 A I n f o r m S e r v i c e
Code 8A: OCSS Photo Sensor Fault Test I80 - OCSS - Low Clear obstruction. Clean
The VM senses the beams are ON with (Page 6-39) photoeyes. Cycle key switch
the deadman pedal up. Test I81 - OCSS - High to clear.
(Page 6-40)
Message Displayed: C O D E 8 F I n f o r m s e r v i c e
Code 8F: Lift/Lower Potentiometer Test A05 - Lift/Lower Pot Lift and lower disabled.
Out-of-Neutral (VR2) (Page 6-47) Return control handle to
Lift/Lower potentiometer (VR2) out of neutral. Cycle key switch to
learned neutral value. clear.
Message Displayed: C O D E 8 J I n f o r m S e r v i c e
Code 8J: Ambient Temperature Sen- Test A36 - Ambient Cycle key switch to clear.
sor Out-of-Range Temperature (Page 6-61)
Message Displayed: C O D E 8 P I n f o r m S e r v i c e
Code 8P: Tilt Potentiometer Test A72 - Tilt Up/Down Cycle key switch. Check for
Out-of-Range (SW4) (Optional Handle) correct handle configuration
(Page 6-67) in FlashWare.
Message Displayed: C O D E 8 R I n f o r m S e r v i c e
Code 8R: Tilt Out-of-Neutral Test A72 - Tilt Up (S6) Return switch to neutral and
Tilt potentiometer out-of-neutral or (Page 6-66) cycle key switch.
switch detected closed at startup. Test A72 - Tilt Up/Down
(SW4) (Optional Handle)
(Page 6-67)

Messages and Codes
Message Displayed: C O D E 8 S I n f o r m S e r v i c e
Code 8S: Sideshift Potentiometer Test A74 - Sideshift Cycle key switch. Check for
Out-of-Range Left/Right (SW4) correct handle configuration
(Optional Handle) in FlashWare.
(Page 6-70)
Message Displayed: C O D E 8 T I n f o r m S e r v i c e
Code 8T: Sideshift Out-of-Neutral Test A74 - Sideshift Left Return switch to neutral and
Sideshift potentiometer out-of-neutral (S8) (Page 6-69) cycle key switch.
or switch detected closed at startup. Test A74 - Sideshift
Left/Right (SW4)
(Optional Handle)
(Page 6-70)
Code 8U: Attachment Function 1 Test A75 - Attach Fcn 1 Cycle key switch. Check for
Out-of-Range (SW3) (Optional Handle) correct handle configuration
(Page 6-72) in FlashWare.
Message Displayed: C O D E 8 V I n f o r m S e r v i c e
Code 8V: Attachment Function 1 Test A75 - Attach Fcn 1 Return switch to neutral
Out-of-Neutral (S4) (Page 6-71) position. Cycle key switch.
Function 1 potentiometer Test A75 - Attach Fcn 1
out-of-neutral or switch detected (SW3) (Optional Handle)
closed at startup. (Page 6-72)
Message Displayed: C O D E 8 W I n f o r m S e r v i c e
Code 8W: Attachment Function 2 Test A76 - Attach Fcn 2 Cycle key switch. Cycle key
Out-of-Range (SW2) (Optional Handle) switch. Check for correct
(Page 6-74) handle configuration in
FlashWare.
Message Displayed: C O D E 8 X I n f o r m S e r v i c e
Code 8X: Attachment Function 2 Test A76 - Attach Fcn 2 Return switch to neutral
Out-of-Neutral (S5) (Page 6-73) position. Cycle key switch.
Function 2 potentiometer Test A76 - Attach Fcn 2
out-of-neutral or switch detected (SW2) (Optional Handle)
closed at startup. (Page 6-74)

Messages and Codes
Message Displayed: C O D E A 0 I n f o r m s e r v i c e
Code A0: Incorrect Software None Cycle key switch to clear. If
Incorrect VM installed in lift truck or this code appears, upgrade
Flashed with incorrect software. the software in the lift truck
using FlashWare.
Code A2: Software Compatibility None Travel disabled. Cycle key
Issue with VM and Left TPA switch to clear. If this code
appears, upgrade the
software in the lift truck
using FlashWare.
Message Displayed: C O D E A 3 I n f o r m S e r v i c e
Code A3: Software Compatibility None Travel disabled. Cycle key
Issue with VM and Right TPA switch to clear. If this code
appears, upgrade the
using FlashWare.
Code A4: Software Compatibility None Lift disabled. Cycle key
Issue with VM and LPA switch to clear. If this code
AC lift only. appears, upgrade the
using FlashWare.
Message Displayed: C O D E A G I n f o r m S e r v i c e
Code AG: Communications To/From None Cycle key switch. Check
Operator Display Failed cable to display. If code will
Operator Display communications not clear, replace OD.
failure detected by VM.
Message Displayed: C O D E A H I n f o r m S e r v i c e
Code AH: Bad Operator Display None Cycle key switch. If code will
Checksum not clear, replace OD.

Messages and Codes
Message Displayed: C O D E A L I n f o r m s e r v i c e
Code AL: VM Battery Backed Up None Cycle key switch to clear. If
RAM Failed code will not clear, replace
VM.
Message Displayed: C O D E A P I n f o r m s e r v i c e
Code AP: Left TPA Software Fault None Travel disabled. Cycle key
switch to clear. If code will
not clear, Flash TPA with
latest software.
Message Displayed: C O D E AT I n f o r m s e r v i c e
Code AT: LPA Software Fault None Lift disabled. Cycle key
AC lift only. switch to clear. If code will
not clear, Flash LPA with
latest software.
Message Displayed: C O D E F 8 I n f o r m S e r v i c e
Code EC: COP Not Enabled None Cycle key switch to clear. If
code will not clear, replace
VM.
Message Displayed: C O D E F E I n f o r m s e r v i c e
Code FE: Internal VM Circuit for None Code is displayed for 30
BSOC Not Calibrated seconds. Cycle key switch to
clear. If code will not clear,
replace VM.
Message Displayed: C O D E F G I n f o r m s e r v i c e
Code FG: +5V Reference Voltage and Test A14 - Ext. Supply Travel, lift, and lower
+12V Power Supply Failure Sense (12VDC) disabled. Brake will engage.
(Page 6-53) Cycle key switch to clear.
Message Displayed: C O D E F H I n f o r m s e r v i c e
Code FH: Battery Voltage Test A15 - Battery Volts Brake will remain engaged.
Out-of-Range (Page 6-54) Cycle key switch to clear.
Wrong voltage battery or voltage
out-of-range.

Messages and Codes
Message Displayed: C O D E F N I n f o r m s e r v i c e
Code FN: Relays Did Not Open at Test O32 - Toggle Relay Brake will engage. Cycle key
Power Off Enable (Page 6-95) switch to clear.
Message Displayed: C O D E F T I n f o r m s e r v i c e
Code FT: VM Internal Software Error None Travel, lift, and lower
disabled. Brake will remain
engaged. Cycle key switch to
Flash VM with latest
software.
Message Displayed: C O D E G 2 I n f o r m S e r v i c e
Code G2: Bad Steer Position Refer- Test I89 - Steer Position Cycle key switch to clear.
ence Input Sensor (Page 6-44)
Message Displayed: C O D E H A O v e r h e a t e d , A l l o w T i m e t o C o o l
Code HA: Right Traction Motor Test A68 - Right Traction Travel speed is linearly
Overtemp Motor Temp (Page 6-64) derated starting at 266°F
Test I89 - Steer Position (130°C). Travel speed is
Sensor (Page 6-44) limited to 1 mph at 300°F
(149°C). Cycle key switch to
clear after traction motor
has cooled.
Message Displayed: C O D E H E I n f o r m S e r v i c e
Code HE: Right Traction Motor Test A68 - Right Traction Travel is limited to 6.5 mph.
Temperature Sensor Out-of-Range Motor Temp (Page 6-64) Clears when reason for fault
is corrected.
Message Displayed: C O D E H F O v e r h e a t e d , A l l o w T i m e t o C o o l
Code HF: Right TPA Overtemp Test A65 - Right Traction Cycle key switch to clear
The right TPA has reported its internal Power Amp Temp after TPA has cooled.
temperature is less than –40°F (–40°C) (Page 6-62)
or greater than +203°F (+95°C). Test I89 - Steer Position
Sensor (Page 6-44)

Messages and Codes
Message Displayed: C O D E H G I n f o r m S e r v i c e
Code HG: Right Traction Motor Test A67 - Right Traction Travel is disabled. Cycle key
Phase Open Current (Page 6-63) switch to clear.
Message Displayed: C O D E H H I n f o r m S e r v i c e
Code HH: Right Traction Motor Test I82 - Right Traction Travel is limited to 1 mph. If
Feedback Encoder Failure RPM (Page 6-41) a single channel is bad, this
Failure detected in traction motor code is displayed during
speed feedback encoder. operation. If one or both
channels are bad at SelfTest,
S TA L L E D is displayed.
Cycle key switch to clear.
Message Displayed: C O D E H M I n f o r m S e r v i c e
Code HM: Right TPA Pre-Charge Test O32 - Toggle Relay Travel is disabled. Check for
Failed Enable (Page 6-95) B+ at the right TPA+
TPA failed to precharge correctly. terminal. Cycle key switch to
cause this code.
Message Displayed: C O D E H T I n f o r m S e r v i c e
Code HT: Right TPA Current Sensor Test A67 - Right Traction Travel is limited to 2.5 mph.
Fault Current (Page 6-63) Cycle key switch to clear. If
The right TPA has sensed a current code will not clear, replace
sensor fault. TPA. The VM cannot cause
this code.
Message Displayed: C O D E H U I n f o r m S e r v i c e
Code HU: Right TPA Overcurrent or None Travel is disabled. Cycle key
Short Circuit switch to clear. Check for
The right TPA has sensed current in shorted traction motor power
excess of 400A. cables. If code will not clear,
cause this code.
Message Displayed: C O D E H V I n f o r m S e r v i c e
Code HV: Right TPA High DC Bus None If voltage is OK, replace TPA.
Voltage Cycle key switch to clear.
The right TPA has detected an The VM cannot cause this
overvoltage condition at the + code.
terminal.

Messages and Codes
Message Displayed: C O D E H W I n f o r m S e r v i c e
Code HW: Right TPA Software Error None Cycle key switch to clear. If
TPA internal software error (not code will not clear, replace
required for lift truck operation) has TPA.
malfunctioned.
Message Displayed: C O D E H X I n f o r m S e r v i c e
Code HX: Right TPA Power Supply None Travel restricted to 1 mph.
Out-of-Range Cycle key switch to clear.
The power supply output in the right Disconnect (+) wire to temp
TPA is less than 4.5V, greater than and speed sensors. If code
5.5V, or too much current is being changes, troubleshoot wires
drawn by an external component. and sensors. If not OK,
cause this code.
Message Displayed: C O D E T 0 I n f o r m S e r v i c e
Code T0: Aux Relief SOL5 Open Cir- Test A82 - Aux. Relief Cycle key switch to clear.
cuit or Constant Low Current (SOL5)
(Page 6-78)
Code T3: Proportional Lower SOL2 Test A34 - Lift/Lower Cycle key switch to clear.
Open Circuit or Constant Low Current (SOL2)
(Page 6-60)
Code T4: Priority Bypass SOL4 Open Test A81 - Priority Bypass Cycle key switch to clear.
Circuit or Constant Low Current (SOL4)
(Page 6-77)
Message Displayed: C O D E V C I n f o r m S e r v i c e
Code VC: Internal Error in VM Com- None Cycle key switch to clear. If
munications code will not clear, replace
VM.

Messages and Codes

Digital Input Tests
Digital Input Tests

A Diagnosis and Repair table is provided for

most tests. If a test fails, refer to the Diagnosis
and Repair table.
Through the process of elimination, these tables

provide the technician with a step-by-step
approach to diagnosing a problem and the
necessary corrective action. See the sample
table below.
Example Diagnosis and Repair Table

Action/
Step Meter Setting
(+) Lead (–) Lead Expected Results Step Passed Step Failed
This column
identifies the
action(s) required
(if any) before
testing the
circuit. If no
instructions are
given, all circuits
must be
connected. The next
The next
This is the Connection Connection action to be
action to be
order that Note: If point for point for The reading performed if
performed if
the testing something was the Positive the required to consider the
the Expected
must be disconnected in (+) meter Negative (–) the step a success. Expected
Results are
performed. the prior step, lead. meter lead. Results are
met.
reconnect it not met.
before
performing the
next step.
This column also

identifies the
required setting
on the meter for
this step.

Test I00 - Deadman (S2) Digital Input Tests
Test I00 - Deadman (S2)

This test shows what the VM is reading from
Deadman S2.
Run test:
The state of Deadman S2 is displayed:
Deadman Pedal Value Displayed
Up Off
Down On
If these results are not observed, the test has

failed.
Diagnosis and Repair

Action/
Step Meter (+) Lead (–)Lead Expected Results Step Passed Step Failed
Setting
Deadman UP; approx. 5V T/S switch, wiring

1 DCV JPC22-8 TP4 Replace VM
Deadman DOWN: 0V and connections

Digital Input Tests Test I02 - High Speed Limit SW (S11)
Test I02 - High Speed

Limit SW (S11)
This test monitors the state of the optional
Hi-Speed Limit switch (S11) and displays what
the VM is reading from the switch.
NOTE: Correct gap for switch is 0.11 ±0.04 in.
(2.79 ±1 mm).
Run test:
When the test is run, observe the following

results:
Hi-Speed Limit Switch

Value Displayed
Sensor
Near Metal Belw
Away From Metal Abve

failed.

Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting
1 JPC20-8 JPC24-8 Perform step 2 Replace VM

Approx. 12V T/S wiring &
2 JPS5-4 JPS5-2 Perform step 3
connections
DCV
3 JPC22-22 JPC24-8 Switch Not Activated: Replace VM Perform step 4
approx. 5V T/S wiring & Adjust/replace
4 JPS5-1 JPS5-2 Activated: approx. 0V connections switch

Test I05 - Lift Limit (S12) Digital Input Tests
Test I05 - Lift Limit (S12)

This test monitors the state of the optional Lift
Limit switch (S12) and displays what the VM is
reading from the switch.
NOTE: This test will only work on trucks
equipped with the lift limit option.
Run test:

results:
Mast Value Displayed
Below Switch (closed) Belw
Above Switch (open) Abve

failed.
(2.79 ±1 mm).

Action/
Setting
T/S wiring &

1 JPS6-4 JPS6-3 Approx. 12V Perform step 2 connections. If OK,
Perform step 3
DCV
Switch Not Activated:
2 JPS6-1 TP4 approx. 5V Perform step 4 Replace switch
Activated: approx. 0V
JPC20 &
JPC24
3 PC20-6 PC24-6 Approx. 12V Perform step 4 Replace VM
disconnected
/DCV
Switch Not Activated:

T/S wiring &
4 DCV JPC22-6 TP4 approx. 5V Replace VM
connections
Activated: approx. 0V

Digital Input Tests Test I13 - Lift Contactor (DC Lift)
Test I13 - Lift Contactor

(DC Lift)
This test reports the absence or presence of B+
on the load side of the LPC contactor.
It is necessary to manually activate the

contactor in order to see the transition or
perform test in active maintenance.
Energizing the Lift Contactor will cause

the Lift Motor to run.
Run test:

results:
LPC Contactor Value Displayed
Open Out
Closed In

failed. Check fuse FU3 and the LPC Contactor
tips.
.
Action/
Step Meter Setting
(+) Lead (–)Lead Expected Results Step Passed Step Failed
Remove FU3/
1 FU1+ FU1– 0 Ohms Perform step 2 Replace fuse
Ohms
T/S wiring &

Tips open: less than connections.
2 DCV JPC22-20 TP4 0.5V; Replace VM Check contactor
closed: B+ tips. Check for
shorts to frame.

Test I14 - Steer Contactor Digital Input Tests
Test I14 - Steer Contactor

This test reports the absence or presence of
voltage to the load side of the STR contactor.
Run test:
NOTE: Must be in Active Maintenance Mode to
perform this test.
For more information on how to use
Maintenance Mode, refer to page 3-8.

results:
STR Contactor Value Displayed
Open Out
Closed In

failed.
Check fuse FU1 and the STR Contactor tips.

Action/
Step Meter Setting
Remove FU1/
1 FU1+ FU1– 0 Ohms Perform step 2 Replace fuse
Ohms
Check wiring &

Tips open: B+
2 STR-1 STR-2 Perform step 3 connections.
closed: approx. 0V
DCV Replace tips
Tips open: 0V T/S wiring from

3 JPC22-19 TP4 Replace VM
closed: B+ contactor to VM

Digital Input Tests Test I15 - Horn (S3, SW1)
Test I15 - Horn (S3, SW1)

This test checks the input from the horn switch
(S3 on standard handle, SW1 on optional
control handle) to the VM.
Run test:

results:
Horn Switch Position Value Displayed
Out Off
Depressed On

failed.

Action/
Step Meter Setting
Standard Handle
Button depressed:
JPC12 T/S connector &
0 ohms
1 disconnected/ JC12-10 JC12-12 Replace VM cable or replace
released: greater than
Ohms horn switch
1 megohm
Optional Handle
Unplug cable R/R cable or

1 JC12-10 PH1-10 0 ohms Perform step 2
/Ohms connectors
NOTE: A breakout cable or box is required to measure control handle voltages.

Button depressed: less T/S control
2 DCV JPC12-10 JPC12-12 than 1V Replace VM handle wiring &
released: approx. 5V switch

Test I19 - Left Traction RPM Digital Input Tests
Test I19 - Left Traction

RPM
This test displays the output from the speed
encoder on the left Traction Motor as seen by
the left Traction Power Amplifier.
Do this test in an area free of

obstructions with ample room for
maneuvering.
NOTE: For best results, run this test in Active

Maintenance Mode.
Run Test:
The Operator Display should show a linear

increase to maximum RPM.

Action
/
Setting
1 JPTL1-26 JPTL1-7 Perform step 2 Replace TPA

4.5 - 5.5V T/S or replace
2 JPTL2-1 JPTL2-4 Perform step 3
harness
3 DCV JPTL1-31 Perform step 4 Perform step 5

JPTL1-7
4 JPTL1-32 after Stationary: greater than 3.5V Replace TPA Perform step 6
JPTL1-7 is or less than 0.5V
5 JPTL2-3 tested for Running: approx. 2V Replace speed
B–, use TP4 R/R Harness
6 JPTL2-2 encoder

Digital Input Tests Test I20 - Lift RPM (AC Lift only)
Test I20 - Lift RPM (AC

Lift only)
This test displays the input from the speed
encoder on the Lift Motor as seen by the Lift
Power Amplifier.

obstructions with ample room for lifting.

Maintenance Mode.
Run test:


Action/
Setting
1 JPL1-26 JPL1-7 Perform step 2 Replace LPA

4.5 - 5.5V T/S or replace
2 JPL2-1 JPL2-4 Perform step 3
harness
JPTL1-7;
after JPTL1-7
3 DCV JPL1-31 is tested for Perform step 4 Perform step 5
B–, use TP4 for
Stationary: greater than
easier access
3.5V or less than 0.5V
4 JPL1-32 JPL1-7 Running: approx. 2V Replace LPA Perform step 6
5 JPL2-3 Replace speed

JPL1-7 R/R harness
6 JPL2-2 encoder

Test I23 - CAN Communication Test Digital Input Tests
Test I23 - CAN

Communication Test
This test verifies the VM is communicating with
the Left Traction Power Amplifier, Right
Traction Power Amplifier, and (4200 Only) Lift
Power Amplifier.
If the fault code is intermittent, the cause could

be a bad cable or connection. It could also be
caused by a static discharge. Check the static
straps, the terminating resistor, or wiring on
the Left Traction Amp JTL1-21 and JTL1-34.
Additionally, it can be caused by an optional
device or bad DC motor brushes.
Run test:
The Operator Display (OD) shows:

• V if Vehicle Manager is communicating
with any amplifier
• L if the left side Traction Power Amplifier is
communicating with the VM
• R if the right side Traction Power Amplifier
is communicating with the VM
• P (4200 Only) if the Lift Power Amplifier is
communicating with the VM
If V, L, R, or P (4200 Only) are not displayed,

the test has failed.

Digital Input Tests Test I23 - CAN Communication Test

Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Setting Results
If all letters are missing (not displayed):
1 DCV JPTL1-1 B– B+ Perform step 2 T/S B+ from K3 Relay
2 JPTL1 & JPC14 JPTL1-23 JPC14-11 Perform step 3

disconnected/ 0 Ohms R/R harness
3 Ohms JPTL1-35 JPC14-35 Replace VM
If letter P is missing (4200 Only):
1 JPTL1-1 Perform step 2

DCV B– (On Amp) B+
R/R harness
disconnected/ 0 Ohms
4 Ohms JPTL1-35 JPC14-4 Replace LPA
If letter L is missing:

DCV B– (On Amp) B+
R/R harness
If letter R is missing:
2 DCV JPTL1-11 B– (On Amp) B+ Perform step 3
3 JPTL1-12 Perform step 4 R/R harness

4 JPTR1 & JPC14 JPTL1-23 JPC14-11 Perform step 5

Test I65 - Tilt Position SW (S18) Digital Input Tests
Test I65 - Tilt Position SW

(S18)
NOTE: This test applies to trucks equipped with
optional bottler’s tilt.
Using this test, the state of the mast tilt switch

(S18) can be verified.
Run test:

results:
Tilt Position Switch

Value Displayed
(S18)
Depressed In
Released Out

failed.
Check that the tilt position switch has the

proper clearance; the switch should be adjusted
so that it deactivates when the mast is tilted
past 3° forward. See “Mast Tilt Position Switch
Adjustment” on page 7-94

Action/Meter
Step Setting
T/S wiring &

1 JPT1-1 JPT1-3 Approx. 12V Perform step 2 connections. If OK,
perform step 3
DCV If voltage stays high
Switch not activated:
(5V), replace switch.
2 JPT1-2 TP4 approx 5V Perform step 4
If voltage stays low
activated: approx. 0V
(B–), replace VM
JPC20 & 24
PC20-5 PC24-5
3 disconnected Approx. 12V Perform step 4 Replace VM
(on VM) (on VM)
/DCV
Switch not activated:

T/S wiring &
4 DCV JPC22-5 TP4 approx 5V Replace VM
connections
activated: approx. 0V

Digital Input Tests Test I80 - OCSS - Low
Test I80 - OCSS - Low Run test:
Make sure the beam is not blocked. The

This test displays the output from the optional Operator Display shows the state of the beam:
OCSS - Lower Beam.
NOTE: This test shows best results in Active
Maintenance, and the operator must be Down On
on the Deadman for the test to work.
Up Off
Maintenance Mode, refer to page 3-8. If the results do not match the preceding table,
the test has failed. Perform Diagnosis and
Repair.

Deadman Pedal
LED Status
Position
Up or Down Green ON +12V Present at Detector

Receiver (3 Wires) Receiver is Receiving Light Beam
Down Yellow ON
(Properly Aligned)
Emitter (2 Wires) Down Green ON +12V Present at Emitter
If an LED does not illuminate as described above, troubleshoot according to the following table:
Action/
Setting
1 JPW3-1 JPW3-2 Perform step 3 Perform step 2
Check wiring &

2 PC20-9 PC10-3 Replace VM
connections
Approx. 12V
Check wiring &

4 DCV PC20-2 PC18-5 Replace VM
connections
If 5V is missing, check
wiring and connections. If
Beam blocked:
okay, replace VM. If 5V does
5 JPC22-13 TP4 approx. 5V Replace VM
not change state when beam
unobstructed: 0V
is blocked, replace Emitter
or Detector.

Test I81 - OCSS - High Digital Input Tests
Test I81 - OCSS - High Run test:
Make sure the beam is not blocked. The

This test displays the output from the optional Operator Display shows the state of the beam:
OCSS - Upper Beam.
NOTE: This test shows best results in Active
Maintenance, and the operator must be Down On
on the Deadman for the test to work.
Up Off
Maintenance Mode, refer to page 3-8. If the results do not match the preceding table,
the test has failed. Perform Diagnosis and
Repair.

Deadman Pedal
LED Status
Position
Up or Down Green ON +12V Present at Detector

Receiver (3 Wires) Receiver is Receiving Light Beam
Down Yellow ON
(Correctly Aligned)
Emitter (2 Wires) Down Green ON +12V Present at Emitter
If an LED does not illuminate as described above, troubleshoot according to the following table:
Action/
Setting
Check wiring
2 PC20-1 PC10-3 Replace VM
& connections
Approx. 12V
Check wiring
4 DCV PC20-10 PC18-6 Replace VM
& connections
If 5V is missing, check wiring

and connections. If OK,
Beam blocked:
replace VM. If 5V does not
5 JPC22-14 TP4 approx. 5V Replace VM
change state when beam is
unobstructed: 0V
blocked, replace Emitter or
Detector.

Digital Input Tests Test I82 - Right Traction RPM
Test I82 - Right Traction

RPM
This test displays the output from the speed
encoder on the right Traction Motor as seen by
the right Traction Power Amplifier.

maneuvering.

Maintenance Mode.
Run Test:


Action/
Setting
1 JPTR1-26 JPTR1-7 Perform step 2 Replace TPA

4.5 - 5.5V
2 JPTR2-1 JPTR2-4 Perform step 3 R/R harness
3 JPTR1-31 Perform step 4 Perform step 5

DCV JPTR1-7; after
4 JPTR1-32 Stationary: greater than Replace TPA Perform step 6
JPTR1-7 is tested
3.5V or less than 0.5V
5 JPTR2-3 for B–, use TP4
Running: approx. 2V Replace Motor
for easier access R/R harness
6 JPTR2-2 Encoder

Test I87 - Battery Gate Digital Input Tests
Test I87 - Battery Gate

This test checks the input from the left Battery
Gate switch (S22A) to the VM.
Run test:

failed.
Battery Gate Value Displayed
Removed Out
Installed In

(2.79 ±1.00 mm).

Action/
Setting

connections
DCV
3 JPC22-3 JPC24-3 Gate installed: approx. Replace VM Perform step 4
5V
removed: less than T/S wiring & Adjust/replace
4 JPS14-1 JPS14-2
0.5V connections switch

Digital Input Tests Test I88 - Battery Gate 2
Test I88 - Battery Gate 2

This test checks the input from the right
Battery Gate switch (S22B) to the VM.
Run test:

failed.
Battery Gate Value Displayed
Removed Out
Installed In

(2.79 ±1.00 mm).

Action/
Setting

connections
DCV
3 JPC22-4 JPC24-4 Gate installed: approx. Replace VM Perform step 4
5V
removed: less than T/S wiring & Adjust/replace
4 JPS13-1 JPS13-2
0.5V connections switch

Test I89 - Steer Position Sensor Digital Input Tests
Test I89 - Steer Position

Sensor
This test observes feedback from the Steer
Position Sensor.

maneuvering.
NOTE: Steer tire rotation is opposite that of the

steer tiller.
Run test:
As the steer tire rotates, the numbers listed in

the table appear on the display. If they do not
change or are erratic, the test has failed.
Make sure the steer position proximity switch is

not damaged. Replace components as
necessary.
NOTE: Adjust the prox. switch position if the
results are erratic. The gap between the
bottom face of the sensor and the upper
surface of the steer plate should
measure 0.080 ±0.020 in. (2 ±0.005
mm).
Steer
Value
Steer Tire Position Tiller
Displayed
Position
90° (full clockwise) to 67° 101
67° to 41° Left 100
41° to 18º 000
18° to –18° (wheels centered) Centered 001
–18° to –41° 011
–41° to –67° Right 010
–90° (full clockwise) to –67° 110
Error Condition 111

Analog Tests
Analog Tests

and Repair table.

table below.
Action/
Step Meter Setting
This column
identifies the
action(s) required
(if any) before
testing the
circuit. If no
instructions are
given, all circuits
must be
connected. The next
The next
action to be
performed if
the Expected
Results are
met.
before
performing the
next step.
This column also

identifies the
required setting
on the meter for
this step.

Test A04 - Travel Pot (VR1) Analog Tests
Test A04 - Travel Pot Run test:
(VR1) The test is a success if the voltage displayed is

within these limits:
This test displays the voltage the VM produces Throttle Position Value Displayed
based on input from the control handle travel
potentiometer VR1. Full Tractor-First 0.16 to 0.90V
NOTE: Learn must be run whenever the throttle Neutral Position 0.91 to 1.24V
(travel) assembly is replaced, repaired, Full Forks-First 1.25 to 2.00V
or adjusted. See Maintenance Mode on
page 3-8.
If the voltage reading is outside these limits or
NOTE: If vehicle is displaying code 83 (See Code does not change in a smooth (linear) fashion the
83: Throttle Potentiometer (VR1) test has failed. Any voltage fluctuation indicates
Out-of-Neutral on page 6-18), check the a bad cable or potentiometer VR1.
handle spring for excessive movement.
The voltage reading should decrease when the
throttle is moved from the Forks-First to the
Tractor-First position. If these results are not
observed, the test has failed.

Action/
Setting
Approx. 5V. If
JPC12
missing, no other
1 disconnected PC12-1 PC12-12 Perform step 2 Replace VM
control handle
/DCV
functions will work.
T/S the control

Neutral: approx. 1V
handle cable and
2 DCV JPC12-3 JPC12-12 Full TF: approx. 0.52V Replace VM
connector(s). If OK,
Full FF: approx. 1.6V
replace the pot.

Analog Tests Test A05 - Lift/Lower Pot (VR2)
Test A05 - Lift/Lower Pot Run test:
(VR2) The test is a success if the voltage displayed is

This test displays the voltage the VM produces Lift/Lower

Value Displayed
based on input from the control handle Control Position
lift/lower pot VR2.
Full Lift Position 0.21 to 0.95V
NOTE: Learn must be run when the lift/lower
pot is replaced, repaired, or adjusted. Neutral Position 0.94 to 1.34V
See Maintenance Mode on page 3-8. Full Lower Position 1.35 to 2.19V
NOTE: If vehicle is displaying code 8F (See Code
8F: Lift/Lower Potentiometer If the voltage reading is outside these limits or
Out-of-Neutral on page 6-19), check the does not change in a smooth, linear fashion, the
handle spring for excessive movement. test has failed. Any voltage fluctuation indicates
a bad cable or potentiometer VR2.
The voltage reading should decrease when the

lift/lower knob is moved from lower to lift. If
these results are not observed, the test has
failed.

Action/
Setting
Approx. 5V. If
JPC12 T/S control handle
missing, no other
1 disconnected PC12-1 PC12-12 cable. If OK, Replace VM
control handle
/DCV replace pot.
functions will work.
T/S control handle

Neutral: 1.17V
cable and
2 DCV JPC12-2 JPC12-12 Full Lift: 0.62V Replace VM
connector(s). If OK,
Full Lower: 1.68V
replace pot.

Test A08 - Left Traction Motor Temp Analog Tests
Test A08 - Left Traction NOTE: For more information on how to use
Motor Temp NOTE: Also check Test I89 - Steer Position
Sensor on page 6-44.
This test displays the temperature of the left
Traction Motor. Run test:
1. With the lift truck at rest and at ambient
Limits temperature, compare the temperatures
• Normal operation: ambient to 258°F obtained from Maintenance Mode to the
(125°C) ambient temperature.
• Between 266°F (130°C) and 300°F (149°C), 2. If the temperatures are not within several
speed is linearly reduced to 1.0 mph. degrees, the test has failed.
• Temperature icon blinks at 266°F (130°C) 3. If the reading on the display is not at
ambient temperature, refer to Diagnosis
• Fault Code 2A is displayed and travel is
and Repair to isolate the cause.
disabled at 300°F (149°C)
While operating, the VM continually monitors

the temperature of the drive motor. If the
temperature gets too high, performance is
reduced until the motor cools down.
Use Active Maintenance to see the actual

temperature from the temperature sensor. Heat
the lift truck up by driving it hard for
approximately 30 minutes. As the motor heats,
the temperature will increase.

Action/
Step Meter Setting
JPTL3
1 disconnected JTL1-8 JTL1-7 Less than 1200 ohms if Replace left TPA Perform step 2
/Ohms traction motor is cool;
JPTL1 greater than 1200 ohms T/S traction Replace
2 disconnected JTL3-2 JTL3-1 if hot motor temp traction motor
/Ohms sensor wires temp sensor

Analog Tests Test A09 - Lift Motor Temp (AC Lift only)
Test A09 - Lift Motor

Temp (AC Lift only)
This test displays the temperature of the AC lift
motor.
Limits
• Normal operation: ambient to 294°F
(145°C)
• Temperature icon lights at 295°F (146°C)
• Fault Code 6F is displayed and lift is
Run test:
From ambient temperature, as lift is operated,

the readings should increase evenly over time. If
not, the test has failed.

Action/
Step Meter Setting
JPL1
1 disconnected JL1-8 JL1-7 Less than 1200 Replace LPA Perform step 2
/Ohms ohms if traction
motor is cool;
JPL3 greater than 1200 T/S lift motor
Replace lift motor
2 disconnected JL3-2 JL3-1 ohms if hot temp sensor
temp sensor
/Ohms wires

Test A10 - Left Traction Power Amp Temp Analog Tests
Test A10 - Left Traction

Power Amp Temp
This test displays the temperature of the left
Traction Power Amplifier.
Limits
• Normal operation: ambient to 175°F (79°C)
• Starting at 176°F (80°C), speed is linearly
reduced by the TPA to 0.0 mph at 239°F
(115°C), when traction is disabled
• Temperature icon lights at 185°F (85°C)
• Fault Code 1H is displayed at 203°F (95°C)
NOTE: Also check Test I89 - Steer Position
Run test:
The Operator Display shows the heatsink

temperature that the Traction Power Amplifier
reads.
From ambient temperature, as drive is

operated, the readings should increase evenly
over time. If not, the test has failed.

Action/
Step Meter Setting
Is TPA heatsink If not hot, replace

1 N/A N/A Hot to touch Perform step 2
hot to touch? TPA
Allow time to Not hot to touch, no Return to

2 N/A N/A Replace TPA
cool. code service

Analog Tests Test A11 - Left Traction Current
Test A11 - Left Traction continuity. Replace cables as necessary.

See Terminal Hardware on page 7-36.
Current • If power cable continuity is OK, T/S the
drive motor. See AC Motors on page 5-9.
This test displays the current in the left • If all phases give high readings, the drive
Traction Motor power circuit. unit may be binding. Check drive unit.
2. The power amplifier may be bad. Run Test
Limits: O29 - Ramp Traction Motors on page 6-93.
• Above 266°F (130°C) current is reduced
linearly
• Maximum current up to 540A when
deadman pedal is released, unaffected and
unreduced by temperature
Maintenance Mode.
Run test:
The Operator Display shows the current that

the traction power amplifier reads from the
drive motor.
System Condition Value Displayed
Static at Rest less than 20A
Travel at Full Speed less than 150A
NOTE: Because Test A11 measures only one

phase, the test may not always reveal a
current problem.

NOTE: Check all motor and power amplifier
connections for tightness and corrosion.
Check individual phase currents with a

clamping ammeter. The current should ramp
evenly as the lift truck accelerates and
decelerates. Phase currents must be
approximately equal. Gross differences indicate
a problem.
If readings are not within reference limits, the

test has failed.
1. If any one phase differs significantly from
the other two, check power cable

Test A13 - Weight Sensor Voltage Analog Tests
Test A13 - Weight Sensor

Voltage
This test displays the voltage from the optional
pressure sensor used for load weight sensing.
Limits
The operator display shows the voltage present

with various load weights.
Load Weight Value Displayed
0 lbs. (no load) Approx. 1V
3000 lbs. Approx. 3V
If the weight sensor is disconnected at the VM,

the Operator Display shows 0V.
Run test:
The voltage shown on the operator display

should increase and decrease linearly as the
load weight is either increased or decreased.
If it does not, the test has failed. If the weight

display is inaccurate, the test has failed.

Action/
Step Meter Setting

DCV 10.5-13V
2 JPY1-1 JPY1-3 Perform step 3 T/S harness
Replace
3 JPY1-2 JPY1-3 Approx. 1V at 0 psi; Perform step 4 Pressure
Attach pressure
increases approx. 1V Transducer
gauge to G1/DCV
per 1000 psi
4 JPC24-18 JPC24-10 Replace VM T/S harness

Analog Tests Test A14 - Ext. Supply Sense (12VDC)
Test A14 - Ext. Supply

Sense (12VDC)
This test displays the output of the internal
+12VDC power supply of the Vehicle Manager.
Run test:
The display should read 10.8-13V. If the voltage

fluctuates more than 0.8V in 10 seconds, the
test has failed.

Action/
Step Meter Setting
1 DCV Replace the VM Perform step 2
JPC6-6 Re-connect wires

Disconnect all TP4 10.5 to 13V
(VM side) one at a time and
2 12V supply wires Replace the VM
T/S the circuit that
at the VM/DCV
pulls down the 12V

Test A15 - Battery Volts Analog Tests
Test A15 - Battery Volts

This test displays the voltage the VM is reading
from the battery sense line.
A successful test proves the VM is correctly

reading BATTERY_SENSE_IN at JPC24-24.
NOTE: This voltage is used by the VM to
calculate the battery state-of-charge.
Run test:
The test is a success if the voltage displayed is

Nominal Battery
Value Displayed
Voltage
36V 33.0 to 39.0V
If the reading fluctuates by more than 0.8V in

10 seconds with the lift truck not moving or
lifting, the test has failed.

Action/
Setting
Check battery water level

and specific gravity.
1 TP1 Perform step 2 Replace battery.
T/S/replace battery
cables.
2 DCV JPF4-1 TP4 B+ Perform step 3 T/S harness TP1 to TP4.
Replace Fuse/Relay
3 JPF4-7 Perform step 4
Card
T/S harness from

4 JPC24-24 Replace VM
Fuse/Relay Card to VM

Analog Tests Test A19 - Lift Power Amp Temp (AC Lift only)
Test A19 - Lift Power

Amp Temp (AC Lift only)
This test displays the temperature of the Lift
Power Amplifier heatsink.
Limits
reduced to 0 fpm at 239°F (115°C), when
lift is disabled
• Temperature icon illuminates at 185°F
(85°C)
• Fault Code 7F is displayed at 203°F (95°C)
Run test:

temperature that the lift power amplifier reads.
As the lift is operated, the readings should

increase evenly over time. If not, the test has
failed.

Action/
Step Meter Setting
Is LPA heatsink
Not hot, replace
1 hot to the N/A N/A Hot to touch step 2
LPA
touch?
Allow time to
Cool to touch/no Return to Replace LPA if
2 cool. Does code N/A N/A
code service code does not clear
clear?

Test A20 - Lift Current (AC Lift only) Analog Tests
Test A20 - Lift Current 1. If any one phase differs significantly from
(AC Lift only) continuity. Replace cables as necessary.
• If power cable continuity is OK,
This test displays Lift Motor current through troubleshoot the drive motor. See AC
the Lift Power Amplifier. Motors on page 5-9.
• If all phases give high readings, the lift
pump may be binding.
Maintenance Mode.
2. The power amplifier may be bad. Run Test
For more information on how to use O28 - Ramp Lift Motor (AC Lift) on
Maintenance Mode, refer to page 3-8. page 6-92.
The lift carriage and forks will move

during this test.
The area around the forks must be clear.

The ceiling clearance should allow for
the highest lift.
Limits
• 0 to 500A lifting
• Maximum current 675A
Run test:

the lift power amplifier reads from one phase of
the lift motor.
NOTE: Because only one phase is measured, a
current problem may not be revealed.


evenly as the lift accelerates and decelerates.
Phase currents must be approximately equal.
Gross differences indicate a problem.

test has failed.

Analog Tests Test A22 - Traction Request
Test A22 - Traction

Request
This test displays the percentage of traction
throttle request from control handle travel pot
VR1 being read by the VM.
Run test:
NOTE: Run Learn after you replace, repair, or
adjust the throttle assembly. See
Maintenance Mode on page 3-8.
The Operator Display shows the percentage of

throttle request that the VM reads from the
control handle throttle potentiometer (VR1) and
sends to the TPA.
Acceptable values are:
Throttle Position Value Displayed
Full Tractor-First 0 to +100
Neutral 0
Full Forks-First 0 to –100
The values must change smoothly and evenly

as the handle moves from full tractor-first to
full forks-first.
If percentages are not within reference limits,

NOTE: Any lift limiting conditions will result in
less than 100% shown on display.

Action/
Step Meter Setting
Test should pass. Check traction

Compare Test A04 system for speed
Run Test A04 -
results with the limits due to motor
1 Travel Pot (VR1) N/A N/A Replace TPA
results from A22. temperature, limit
on page 6-46
Max throw should switches, or
show max values. configured speed

Test A23 - Lift Request Analog Tests
Test A23 - Lift Request

This test displays the percentage of lift throttle
request from control handle lift/lower pot VR2
being read by the VM.
Run test:
NOTE: Run Learn after you replace, repair, or
adjust the lift/lower potentiometer VR2.
See Maintenance Mode on page 3-8.
The Operator Display shows the percentage of

lift request that the VM reads from the
lift/lower pot VR2.
Throttle Position Value Displayed
Full Lower 0 to –100
Neutral 0
Full Lift 0 to +100
The values must change smoothly and evenly

as the handle moves from full lower to full lift.
If percentages are not within reference limits,

NOTE: Any lift limiting conditions will result in
less than 100% shown on display.

Action/
Step Meter Setting
Compare Test A05

Run Test A05 - Check lift system
results with the
Lift/Lower Pot for limits due to
1 N/A N/A results from A23. Replace the LPA
(VR2) on motor temperature
Max throw should
page 6-47 or switches
show max values

Analog Tests Test A26 - Pot Supply (5VDC)
Test A26 - Pot Supply

(5VDC)
This test displays the output of the VM internal
+5VDC power supply.
This test measures the +5VDC power supply

voltage for power to control handle switches
and potentiometers.
Run test:
If the Operator Display does not read 5VDC

±0.25V, the test has failed.

Action/
Step Meter Setting
T/S the control

handle cable. If
JPC12
OK, T/S control
1 disconnected/ PC12-1 PC12-12 Approx. 5V Replace VM
handle and
DCV
adjoining
cables.

Test A34 - Lift/Lower Current (SOL2) Analog Tests
Test A34 - Lift/Lower

Current (SOL2)
This test displays the current the proportional
lift/lower solenoid coil (SOL2) is drawing.
Maintenance Mode.
Run test:
State Value Displayed
Neutral Approx. 0.0A
Full Lower Approx. 1.15A
If results do not match the preceding table, the

test has failed.

Action/
Step Meter Setting
JPC20
1 disconnected/ PC20-15 PC20-16 Approx. 15 ohms Perform step 2 T/S wires & coil
Ohms
2 DCV JPC20-15 TP4 B+ Perform step 3
Check valve for

Ramp from B+ when Replace VM
Test activated mechanical
3 JPC20-16 B– off, to approx. 20V
/DCV binding or
at full lower
contamination

Analog Tests Test A36 - Ambient Temperature
Test A36 - Ambient

Temperature
This test displays the ambient temperature of
the area around the lift truck.
Run test:
The Operator Display should display the room

temperature where the lift truck is located.
If not, the test has failed.

Action/
Step Meter Setting
JPA
1 disconnected/ JPC24-23 JPC24-11 Approx. 5V step 2 Replace VM
DCV
2 JPC24-23 JPA-1 Replace temp T/S wires as

Ohms 0 ohms
3 JPC24-11 JPA-2 sensor indicated by test

Test A65 - Right Traction Power Amp Temp Analog Tests

Power Amp Temp
This test displays the temperature of the right
Traction Power Amplifier.
Limits
reduced by the TPA to 0.0 mph at 239°F
(115°C), when traction is disabled
(85°C)
• Fault Code 1H is displayed at 203°F (95°C)
NOTE: Also check Test I89 - Steer Position
Run test:

temperature that the traction power amplifier
reads.
For ambient temperature, as drive is operated,

the readings should increase evenly over time. If
not, the test has failed.

Action/
Step Meter Setting
Is TPA heatsink If not hot, replace

1 Hot to touch Perform step 2
hot to touch? TPA
N/A N/A
Allow time to Not hot to touch, no Return to
2 Replace TPA
cool. code service

Analog Tests Test A67 - Right Traction Current
Test A67 - Right Traction • If any one phase differs significantly from
Current continuity. Replace cables as necessary.
See Terminal Hardware on page 7-36.
This test displays the current in the right • If power cable continuity is OK, T/S the
Traction Motor power circuits. drive motor. See AC Motors on page 5-9.
• If all phases give high readings, the drive
Limits: unit may be binding. Check drive unit.
• Above 266°F (130°C) current is reduced NOTE: The power amplifier may be bad. Run
linearly Test O29 - Ramp Traction Motors on
• Maximum current up to 540A when page 6-93.
deadman pedal is released, unaffected and
unreduced by temperature
Maintenance Mode.
Run test:

the TPA reads from the traction motor.
System Condition Value Displayed
Static at Rest less than 20A
Travel at Full Speed less than 150A
NOTE: Because this test measures only one

phase, the test may not always reveal a
current problem.


evenly as the lift truck accelerates and
decelerates. Phase currents must be
approximately equal. Gross differences indicate
a problem.

test has failed.

Test A68 - Right Traction Motor Temp Analog Tests
Test A68 - Right Traction Run test:

1. With the lift truck at rest and at ambient
Motor Temp temperature, compare the temperatures
obtained using Maintenance Mode to the
This test displays the temperature of the right ambient temperature.
Traction Motor. 2. If the temperatures are not within several
degrees, the test has failed.
Limits 3. If the lift truck is not at ambient
• Normal operation: ambient to 258°F temperature, use the diagnosis and repair
(125°C) chart to isolate the cause.
• Between 266°F (130°C) and 300°F (149°C),
speed is linearly reduced to 1.0 mph
(130°C)
• Fault Code 2A is displayed and travel is
While operating, the VM continually monitors

the temperature of the drive motor. If the
temperature gets too high, performance is
reduced until the motor cools down.
Use Active Maintenance to see the actual

temperature from the temperature sensor. Heat
the lift truck up by driving it hard for approx.
30 minutes. As the motor heats, the
temperature will increase.
NOTE: Also run Test I89 - Steer Position Sensor
on page 6-44.
Action/
Step Meter Setting
Replace right
1 JTR1-8 JTR1-7 Less than 1200 ohms if Perform step 2
JPTR1 TPA
traction motor is cool;
disconnected/ T/S Traction Replace
greater than 1200 ohms
2 Ohms JTR3-2 JTR3-1 Motor temp Traction Motor
if hot
sensor wires temp sensor

Analog Tests Test A71 - Tilt Down (S7)
Test A71 - Tilt Down (S7)

This test displays the voltage at the Tilt Down
switch (S7) on a standard control handle.
Run test:
Neutral Approx. 5V
Switch
Approx. 0.0V
Activated

test has failed.

Action/
Step Meter Setting

S7 open: greater Repair or replace
than 4V control handle,
1 DCV JPC12-6 JPC12-12 Replace VM
S7 closed: less than cable, or S7 (in
1V handle)

Test A72 - Tilt Up (S6) Analog Tests
Test A72 - Tilt Up (S6)

This test displays the voltage at the Tilt Up
switch (S6) on a standard control handle.
Run test:
Neutral Approx. 5V
Switch Activated Approx. 0.0V

test has failed.

Action/
Step Meter Setting

1V handle)

Analog Tests Test A72 - Tilt Up/Down (SW4) (Optional Handle)
Test A72 - Tilt Up/Down

This test displays the voltages at the Tilt
Up/Down switch (SW4) on a optional control
handle.
Run test:
Full Tilt Up 2.80 to 4.69V
Neutral 2.11 to 2.79V
Full Tilt Down 0.21 to 2.10V
If the voltage reading is outside these limits or

does not change linearly, the test has failed.
Any voltage fluctuation indicates a bad cable or
switch.
The voltage reading should decrease when tilt

down is requested and increase when tilt up is
requested. If these results are not observed, the
test has failed.

Action/
Step Meter Setting

Neutral: approx.
2.44V Repair or replace
Full Tilt Down: control handle,
approx. 0.6V cable, or SW4 (in
Full Tilt Up: approx. handle)
4.36V

Test A73 - Sideshift Right (S9) Analog Tests
Test A73 - Sideshift Right

(S9)
This test displays the voltage at the Sideshift
Right switch (S9) on a standard control handle.
Run test:
Neutral Approx. 5V
Sideshift Right Switch

Approx. 0.0V
Activated
If the voltage is outside these limits or does not

change, the test has failed.

Action/
Step Meter Setting

1V handle)

Analog Tests Test A74 - Sideshift Left (S8)
Test A74 - Sideshift Left

(S8)
This test displays the voltage at the Sideshift
Left switch (S8) on a standard control handle.
Run test:
Neutral 5V
Sideshift Right Switch

Approx. 0.0V
Activated


Action/
Step Meter Setting (+) Lead (–) Lead Expected Results Step Passed Step Failed

S8 open: greater than
Repair or replace
4V
1 DCV JPC12-8 JPC12-12 Replace VM control handle, cable,
S8 closed: less than
or S8 (in handle)
1V

Test A74 - Sideshift Left/Right (SW4) (Optional Handle) Analog Tests
Test A74 - Sideshift

Left/Right (SW4)
(Optional Handle)
This test displays the voltages at the Sideshift
switch (SW4) on a optional control handle.
Run test:
Sideshift Left Activated 2.80 to 4.69V
Neutral 2.11 to 2.79V
Sideshift Right
0.21 to 2.10V
Activated
If the reading is outside these limits or does not

change linearly, the test has failed.

Action/

Repair or replace
Neutral: approx. 2.44V
control handle,
1 DCV JPC12-5 JPC12-12 Full Right: approx. 0.6V Replace VM
cable, or SW4 (in
Full Left: approx. 4.36V
handle)

Analog Tests Test A75 - Attach Fcn 1 (S4)
Test A75 - Attach Fcn 1

(S4)
This test displays the voltage at the Attachment
Function 1 switch (S4) on a standard control
handle.
Run test:
Neutral Approx. 5V
Function Activated Approx. 0.0V


Action/

Repair or replace
De-activated: approx. 5V control handle,
Activated: less than 1V cable, or S4 (in
handle)

Test A75 - Attach Fcn 1 (SW3) (Optional Handle) Analog Tests

Function 1 switch (SW3) on a optional control
handle.
Run test:
Not Activated Approx. 4.36V
Fully Activated Approx. 0.57V


Action/

Repair or replace
De-activated: approx. 4.3V
control handle,
1 DCV JPC12-4 TP4 Fully activated: variable Replace VM
cable, or SW3 (in
down to approx. 0.6V
handle)

Analog Tests Test A76 - Attach Fcn 2 (S5)

(S5)
Function 2 switch (S5) on a standard control
handle.
Run test:
Neutral Approx. 5V
Function Activated Approx. 0.0V


Action/

Repair or replace
De-activated: approx. 5V control handle,
Activated: less than 1V cable, or S5 (in
handle)

Test A76 - Attach Fcn 2 (SW2) (Optional Handle) Analog Tests

Function 2 switch (SW2) on a optional control
handle.
Run test:
Not Activated Approx. 4.36V
Fully Activated Approx. 0.57V


Action/

Repair or replace
De-activated: approx. 4.3V
control handle,
1 DCV JPC12-11 TP4 Fully activated: variable Replace VM
cable, or SW2 (in
down to approx. 0.6V
handle)

Analog Tests Test A77 - EPO (S21)
Test A77 - EPO (S21)

This test displays the voltage at the Emergency
Power Off Switch (S21).
Run test:
EPO Button Raised Approx. B+
EPO Button Depressed 0V
If the voltage is outside these limits, the test has

failed.

Action/
Closed: approx. B+ T/S switch, wiring,

Open: less than 0.5V and connections

Test A80 - Lift Relief Current (SOL3) Analog Tests
Test A80 - Lift Relief

Current (SOL3)
This test displays the current at the Lift Relief
Solenoid (SOL3).
Run test:
Neutral Approx. 0A
Lift Request Approx. 0.80A
If results do not match the preceding table. the

test has failed.

Action/
Setting
JPC20 T/S wiring,

1 disconnected JC20-12 JPF2-8 Approx. 30 ohms Perform step 2 connections, &
/Ohms solenoid coil
T/S K2, wiring,

2 SOL3-1 B+ Perform step 3 connections &
Fuse/Relay Card
DCV TP4
Check solenoid for
Off: B+
3 JC20-12 mechanical binding. Replace VM
Lifting: approx. 9V
Replace solenoid

Analog Tests Test A81 - Priority Bypass Current (SOL4)
Test A81 - Priority

Bypass Current (SOL4)
This test displays the current at the Priority
Bypass Solenoid (SOL4).
Run test:
Neutral Approx. 0A
Lifting, No Aux Approx. 1.15A
*Sideshift (speed set to 70%) Approx. 0.70A
*Tilt Approx. 0.55A
*Values listed will vary depending on the

configured Sideshift percentage.

test has failed.
Action/
Setting
JPC20
T/S wires &
1 Disconnected PC20-17 PC20-18 Approx. 20 ohms Perform step 2
coil
/Ohms
B+ when off; ramps to approx. Check valve for

Test Replace VM
26V tilting forward; approx. mechanical
3 activated/ JPC20-18 B–
1V less tilting back; approx. binding/
DCV
25V sideshifting contamination

Test A82 - Aux. Relief Current (SOL5) Analog Tests
Test A82 - Aux. Relief

Current (SOL5)
This test displays the current at the Aux Relief
Solenoid (SOL5).
Run test:
Neutral Approx. 0A
Aux Requests with No Approx. 0.45A

Attachments

test has failed.

Action/
Setting
JPC20
T/S wires &
1 disconnected PC20-19 PC20-20 Approx. 30 ohms Perform step 2
coil
/Ohms
B+ when off; approx. 24V

Check valve for Replace VM
when on (normal mast
3 Test on/DCV JPC20-20 B– mechanical binding
configuration, no
/contamination
attachment)

Output Tests
Output Tests

and Repair table.

table below.

Action/
Step Meter Setting
This column
identifies the
action(s) required
(if any) before
testing the
circuit. If no
instructions are
given, all circuits
must be
connected. The next
The next
action to be
performed if
the Expected
Results are
met.
before
performing the
next step.
This column also

identifies the
required setting
on the meter for
this step.

Test O00 - TPC Contactor Output Tests
Test O00 - TPC Contactor

This test toggles the Traction Power Contactor
(TPC) ON and OFF.
Run test:
PC Contactor Value Displayed
Closed On
Open Off
The test is a success if the TPC contactor tracks

On/Off shown on the display. If these results
are not observed, the test has failed.

Action/
Setting
T/S wires,
JPTR1
connections, and
1 disconnected JTR1-6 Approx. 38 ohms Perform step 2
JTR1-13 contactor coil for
/Ohms
opens or shorts
2 TP4 B+ Perform step 3

Replace right Traction
DCV Test ON: approx. 22V Check for
3 B+ JPTR1-6 Power Amplifier
Test OFF: 0V binding

Output Tests Test O01 - Steer Contactor (STR)
Test O01 - Steer

Contactor (STR)
This test toggles the Steer Power Contactor
(STR) ON and OFF.
Run test:
PC Contactor Value Displayed
Closed On
Open Off
The test is a success if the STR Contactor

tracks the On/Off shown on the display. If
these results are not observed, the test has
failed.

Action/
Step Meter Setting
T/S wires,
JPC18 & JPF2
connections, &
1 disconnected/ JPC18-11 JPF2-1 Approx. 38 ohms Perform step 2
contactor coil for
Ohms
opens or shorts
T/S wire &

connections
2 STR-X TP4 B+ Perform step 3
(including SPL9 &
DCV JPF2-1)
TP1 or Test ON: approx. 23V Check for

3 STR-Y Replace VM
STR-X Test OFF: 0V binding

Test O02 - Lift Contactor (LPC) Output Tests
Test O02 - Lift Contactor

(LPC)
This test toggles the Lift Power Contactor (LPC)
ON and OFF.
Run test:
LPC Contactor Value Displayed
Closed On
Open Off
The test is a success if the LPC contactor tracks

the On/Off shown on the display. If these
results are not observed, the test has failed.

Action/
Setting
Model 4100
JPF2 &
T/S wires,
JPC18
1 JF2-1 JPC18-9 Approx. 18 ohms Perform step 2 connections, and
disconnected
contactor coil
/Ohms
Replace
2 JPF2-1 TP4 B+ Perform step 3
Fuse/Relay Card
DCV Check
TP1 (B+) JPC18-9 Test ON: approx 23V
3 contactor for Replace VM
or LPC-X or LPC-Y Test OFF: 0V
binding
Model 4200
T/S wires
JPL1 connections
1 disconnected JL1-13 JL1-6 Approx. 37 ohms Perform step 2 (including JPL4)
/Ohms and the
contactor coil
2 JPL1-13 TP4 B+ Perform step 3
DCV Check Replace LPA

TP1 (B+) JPL1-6 or Test ON: approx 20V
3 contactor for
or LPC-X LPC-Y Test OFF: 0V
binding

Output Tests Test O04 - Aux. Direction Solenoid (SOL6)
Test O04 - Aux. Direction

Solenoid (SOL6)
This test ramps the Auxiliary Direction Solenoid
(SOL6) from 0% to 90% in 15% increments.
A successful test proves the wiring and the

related circuitry in the VM are all functioning
correctly.
It does not prove that the Auxiliary Direction

solenoid itself is mechanically functional.
Run test:
2. Disconnect wire from Aux Select SOL6-1.
3. Connect an ammeter in series with the
Aux Select solenoid as follows:
• (–) lead to terminal of SOL6-1
• (+) lead to wire removed from SOL6-1
the key switch ON. Start test.
The percentage shown on the display will start

at 0%. Use the UP button to increase the
percentage up to 90% in 15% increments.
Ammeter Reading Value Displayed
0 to 1.3A Ramp (15% Increments)
0.000A 0%

failed.

Action/
Setting
JPC18 &
JPC20
1 JC20-13 JC18-1 Approx. 18 ohms Replace VM T/S wiring & coils
disconnected
/Ohms

Test O07 - Tilt Solenoid (SOL10) Output Tests
Test O07 - Tilt Solenoid

(SOL10)
This test toggles the Tilt Solenoid (SOL10) ON
and OFF.
NOTE: This test does not prove that the
solenoid valve itself is mechanically
functional.
Run test:
2. Disconnect wire from the Tilt Solenoid at
SOL10-1.
3. Connect an ammeter in series with the Tilt
Solenoid as follows:
0.500 to 1.000A On
0.000 to 0.020A Off

failed. Reconnect wire to the Tilt Solenoid at
SOL10-1.

Action/
Setting
JPF2 T/S wiring,

1 disconnected JPC18-15 JF2-8 Approx. 28 ohms Perform step 2 connections, &
/Ohms solenoid coil
TP1 (B+) De-energized: 0V

Check for binding. T/S B+K2. If OK,
2 DCV or SOL10-2 energized: approx.
Replace solenoid replace VM
SOL10-1 23V

Output Tests Test O08 - Sideshift Solenoid (SOL9L, SOL9R)
Test O08 - Sideshift 4. Disconnect wire from the right Sideshift

Solenoid at SOL9R-1.
Solenoid (SOL9L, SOL9R) 5. Connect an ammeter in series with the
right Sideshift Solenoid as follows:
This test toggles the sideshift solenoids (SOL9L, • (–) lead to terminal of SOL9R-1
SOL9R) ON and OFF.
• (+) lead to wire removed from SOL9R-1
Run test: 6. Reconnect the battery connector and turn
the battery connector. Ammeter Reading Value Displayed
2. Disconnect wire from the left Sideshift
0.500 to 1.000A On
Solenoid at SOL9L-1.
3. Connect an ammeter in series with the left 0.000 to 0.020A Off
Sideshift Solenoid as follows:
• (–) lead to terminal of SOL9L-1 If these results are not observed, the test has
failed. Reconnect wire to SOL9R-1.
• (+) lead to wire removed from SOL9L-1
NOTE: Individual coils are approx. 29 ohms.
0.500 to 1.000A On
0.000 to 0.020A Off

failed. Reconnect wire to SOL9L-1 and proceed
to the Diagnosis and Repair section. If the test
passes, proceed to step 4 for a similar
procedure for SOL9R.
Action/
Setting
JPC18 Check wiring,

1 disconnected JPC18-14 JF2-8 Approx. 14 ohms Perform step 2 coils &
/Ohms connections
Check wiring/
2 SOL9L-2 connections.
Check for binding. Perform step 3
DCV JPC18-14 Approx. 22V
Replace solenoid Check wiring/
3 SOL9R-2 connections.
Replace VM

Test O09 - Lift Relief Solenoid (SOL3) Output Tests
Test O09 - Lift Relief 3. Connect an ammeter in series with the Lift
Relief Solenoid as follows:
Solenoid (SOL3) • (–) lead to terminal of SOL3-1
This test ramps the proportional Lift Relief 4. Reconnect the battery connector and turn
(SOL3) Solenoid from 0% to 90% in 15% the key switch ON. Run test.
increments.
related circuitry in the VM are all functioning 0.000 to 1.000A Ramp (15% increments)
correctly. 0.000A 0%
It does not prove that the Lift Relief Solenoid

The percentage shown on the display will start
itself is mechanically functional.
at 0%. Use the UP button to increase the
percentage up to 90% in 15% increments.
Run test:
1. Turn the key switch OFF and disconnect If these results are not observed, the test has
the battery connector. failed. Reconnect wire to SOL3-1.
2. Disconnect wire from SOL3-1.
Action/
Setting
JPC20 &
JPF2
1 JC20-12 JPF2-8 Approx. 32 ohms Perform step 2 T/S wiring & coil
disconnected
/Ohms
T/S wiring,
2 DCV SOL3-1 TP4 B+ Perform step 3 connections &
Fuse/Relay Card
Ramp from B+
Test Check valve for
when OFF to T/S B+K2. If OK,
3 activated JC20-12 TP4 binding/
approx. 9V when replace VM
/DCV contamination
full lower

Output Tests Test O11 - Load Hold Solenoid (SOL1)
Test O11 - Load Hold 4. Connect an ammeter in series with the

L/H Solenoid as follows:
Solenoid (SOL1) • (–) lead to terminal of SOL1-1
This test toggles the Load Holding (L/H) 5. Reconnect the battery connector and turn
Solenoid ON and OFF. the key switch ON. Start test.
Make sure the carriage is fully lowered 0.500 to 1.000A On

before performing this test.
0.000 to 0.020A Off
NOTE: If there is a fault in the proportional
Lift/Lower circuit or in the proportional If these results are not observed, the test has
Lift/Lower valve itself, the carriage may failed. Reconnect wire to SOL1-1.
lower. To guard against unexpected
motion of the carriage, fully lower the
carriage before entering this test.
Run test:
1. Lower the forks to the floor.
3. Disconnect wire from Load Holding
solenoid at SOL1-1.
Action/
Step Meter Setting
JPC18 & JPF2 T/S wiring,

1 disconnected/ JC18-10 JPF2-8 Approx. 29 ohms Perform step 2 connections, &
Ohms solenoid coil
T/S wiring,
2 SOL 1-1 B+ Perform step 3 connections &
Fuse/Relay Card
DCV TP4 Check for
Solenoid OFF: B+ binding.
3 JC18-10 Replace VM
ON: approx. 13V Replace
solenoid

Test O12 - Lift/Lower Solenoid (SOL2) Output Tests
Test O12 - Lift/Lower 2. Disconnect wire from SOL2-1.

Solenoid (SOL2) Lift/Lower Solenoid as follows:
• (–) lead to terminal SOL2-1
This test ramps the proportional Lift/Lower • (+) lead to wire removed from SOL2-1
(SOL2) Solenoid from 0% to 90% in 15%
increments. 4. Reconnect the battery connector and turn
Ammeter
related circuitry in the VM are all functioning Value Displayed
Reading
correctly. It does not prove the Lift/Lower
Solenoid itself is mechanically functional. 0 to 1.300A Ramp (15% increments)
NOTE: Ramping the proportional Lift/Lower 0 0%

Solenoid should not allow the carriage to
lower, since the Load Hold (SOL1) valve The percentage shown on the display will start
should be closed. If there is a fault in the at 0%. Use the UP button to increase the
Load Hold circuit or a fault in Load Hold percentage up to 90% in 15% increments.
Solenoid itself, the carriage may lower.
If these results are not observed, the test failed.
Reconnect wire to SOL2-1.
To guard against unexpected motion of
the carriage, fully lower the carriage
before entering this test.
Run test:
Action/
Step Meter (+) Lead (–) Lead ExpectedResults Step Passed Step Failed
Setting
JPC20
1 disconnected JPC20-16 JPC20-15 Approx. 16 ohms Perform step 2 T/S wires & coil
/Ohms
2 DCV JPC20-15 B+ Perform step 3
Ramp from B+
Test TP4 Replace VM
when OFF to Check for binding/
3 activated JPC20-16
approx. 21V when contamination
/DCV
full lower

Output Tests Test O18 - Horn
Test O18 - Horn

This test toggles the horn ON and OFF.
Run test:
The horn should sound when test is activated.

failed.

Action/
Setting
Test
1 activated/ HRN– Replace horn Perform step 2
DCV HRN+ B+
Check wiring to
2 DCV TP4 Perform step 3
SPL9
Check all wiring &

Test Test OFF: less than
connections for Check wiring. If
3 activated/ TP1 or B+ HRN– 1V
opens, shorts, or OK, replace VM
DCV On: B+
high resistance

Test O19 - Ramp Sounder Output Tests
Test O19 - Ramp

Sounder
Using this test, the operation of the Sounder in
the Operator Display Card can be verified. A
successful test proves the Sounder is
functioning.
Run test:
This test will generate a sound on the Sounder

in the Operator Display Card.
Press Enter. The sounder should emit a short,

warning tone. If this sound is not heard, the
test has failed.
Action/
Step Meter (+)Lead (–) Lead Expected Results Step Passed Step Failed
Setting
Voltage ramps up to 24V and

back down to less than 0.5V. If
the circuit is not open, the voltage
1 TP1 B+ JPC24-2 Perform step 2 Replace VM
starts out at approx. 24V and
Test goes up approx. 4V when ENTER
activated/ is pressed.
DCV Before pressing enter to activate
the test: approx. 12V. Press enter T/S wiring &
Replace
2 JPD1-5 TP4 on the display, the voltage drops connections
Display Card
approx. 4V then comes back to to display
12V.

Output Tests Test O20 - Travel Alarm
Test O20 - Travel Alarm

This test verifies the operation of the optional
Travel Alarm.
A successful test proves the wiring and related

circuitry in the VM are functioning correctly.
NOTE: In order to test the output portion of the
Vehicle Manager, a device is needed that
will load down the circuit. The Load
Holding Coil on the hydraulic manifold
can be used for that purpose. Remove
the Load Holding Coil and carefully
connect its wires into the circuit.
Use extreme caution to prevent its wires

from shorting to any components.
Run test:
Connect a voltmeter between JPF2-2 and

JPC18-18.
Voltage Output Value Display
0.0 to 1.0V Off
22.0V On
When the display shows ON, the travel alarm

must be activated. If these results are not
observed, the test has failed.

Action/
Step Meter Setting
1 H-2 Replace alarm Perform step 2
H-1 B+ T/S wiring

Test activated/
2 Perform step 3 back to horn
DCV TP4 and SPL9
3 JPC18-18 Less than 1V R/R wire to H-2 Perform step 4
Connect load
4 holding coil & TP1 JPC18-18 B+ Replace alarm Replace VM
activate test/DCV

Test O28 - Ramp Lift Motor (AC Lift) Output Tests
Test O28 - Ramp Lift

Motor (AC Lift)
This test ramps the lift motor by gradually
increasing the command to the Lift Power
Amplifier via the CAN Bus.
This test verifies that the Lift Power Amplifier

can drive the lift motor.
Running this test for an extended period

of time can cause damage to the Lift
Motor, Lift Power Amplifier, or wiring.
Run test:
The requested percent of on time is displayed.

Use the UP (▲) button to increase RPM in
increments of 15%, from 0-90%.
Press DOWN (▼) button to decrease the request

to 0 and exit the test.

Action/
Setting
If current does not ramp

to one or two phases, test
cables to Lift Motor. If
OK, replace Lift Motor.
Current
Current must be If phases are low or
probe (amp
even on all phases unequal, replace the Lift
1 clamp) on N/A N/A Replace LPA
and ramp up as the Amplifier.
phases U, V,
percentage increases If phases are equal and
&W
high but Lift Motor runs
slowly, check for binding.
If not binding, replace
Lift Motor.

Output Tests Test O29 - Ramp Traction Motors
Test O29 - Ramp Traction Run test:

1. Step on the deadman pedal and run test.
Motors 2. Press ENTER once to run motors in
reverse. Press a second time to run motors
This test ramps the Traction Motors by in forward. The requested percent of on
gradually increasing the command to the time is displayed.
Traction Power Amplifiers via the CAN Bus. 3. Use the UP (▲) button to increase RPM in
This test verifies that the TPAs can generate increments of 15%, from 0-90%.
current and drive the Traction Motors.
4. Press DOWN (▼) button to decrease the
request to 0, and exit the test.
5. Observe both drive motors; they both
Running this test for an extended period should be moving close to the same rate of
of time can cause damage to the speed.
Traction Motors, Traction Power
Amplifiers, or wiring. If one motor is faster than the other, refer to
Diagnosis and Repair below. Also, see “Test I89
- Steer Position Sensor” on page 6-44.
The Traction Motors will rotate during

this test. Jack the drive wheels off the
floor. Use extreme care whenever the lift
truck is jacked up for any reason. Never
block the lift truck between the
telescopic and the floor. Use a suitable
hoist to stabilize the mast. Keep hands
and feet clear from beneath vehicle
while jacking. Use jack stands or solid
blocks to support truck. DO NOT rely on
the jack alone. See Jacking Safety on
page 2-10.

Action/
Setting
If current does not ramp on

one or two phases, test
cables to Traction Motor. If
Current OK, replace Traction Motor.
Replace
probe Current must be If phases are low or unequal,
associated
(amp even on all phases replace the Traction
1 N/A N/A Traction
clamp) on and ramp up as the Amplifier.
Power
phases U, percentage increases If phases are equal and high
Amplifier
V, & W but Traction Motor runs
slowly, check for binding. If
not binding, replace
Traction Motor.

Test O30 - Electric Brakes Output Tests
Test O30 - Electric Brakes

This test checks for correct brake coil operation
in both brakes.
NOTE: In order for the test to perform correctly,
the Deadman pedal must be depressed.
Run test:
Observe the following results:
Brake Value Displayed
Applied Off
Released On
NOTE: Use UP or DOWN button to cycle the

test.

failed.

Action/
Setting
JPF2 & Right Side:

T/S wires,
JPC20 JF2-3
1 JC20-14 Approx. 17 ohms Perform step 2 Fuse/Relay
disconnected Left Side:
Card & coil
/Ohms JF2-5
If no B+, T/S
wiring &
Inspect brake Fuse/Relay
Brake De-energized: B+
2 DCV JPC20-14 TP4 assembly for Card. If voltage
Energized: approx. 12V
binding does not drop
when energized,
replace VM

Output Tests Test O32 - Toggle Relay Enable
Test O32 - Toggle Relay

Enable
This test toggles Fuse/Relay Card relays K1,
K2, K3, and K4 ON and OFF.
Run test:
NOTE: 50-Series error codes will be logged
while running this test.
NOTE: Must be off deadman when performing
this test.
Run test and observe the following results
Relays Value Displayed
Tips Closed ON
Tips Open OFF

failed.
Action/
Step Meter Setting
Check K1, K2, K3

relay coils. If OK,
1 JF4-5 Approx. 180 K ohm Perform step 2
JPF4 replace Fuse/Relay
disconnected/ Card
Ohms Check K4 relay
JF4-13
2 JF4-10 Approx. 1.66 K ohm Perform step 3 coil. If OK, replace
Fuse/Relay Card
Check FU5. If OK,

3 Perform step 4 replace Fuse/Relay
DCV TP4 B+ Card
T/S wiring from

4 JPC14-6 Replace VM
Fuse/Relay Card

Test O36 - Priority Bypass Solenoid (SOL4) Output Tests
Test O36 - Priority 4. Reconnect the battery connector and turn

Bypass Solenoid (SOL4) Ammeter Reading Value Displayed
This test ramps the Priority Bypass Solenoid 0.000 to 1.000A Ramp (15% increments)
(SOL4) from 0% to 90%. 0.00A 0%

Use the UP (▲) button to increase RPM
failed. Reconnect wire to SOL4-1.
percentage in increments of 15%, from 0-90%.


circuitry in the VM are all functioning correctly.
NOTE: This test does not prove the Priority
Bypass Solenoid (SOL4) valve itself is
mechanically functional.
Run test:
2. Disconnect wire from Priority Bypass
Solenoid (SOL4) at SOL4-1.
Priority Bypass Solenoid (SOL4) as follows:

Action/
Step Meter Setting
JPC20
1 disconnected/ PC20-17 PC20-18 Approx. 20 ohms Perform step 2 T/S wires & coil
Ohms
Ramp from B+ when Check valve for Replace VM

Test activated/
3 JPC20-18 B– OFF, then B+ minus binding/
DCV
9V when 90% ON contamination

Output Tests Test O37 - Aux. Relief Solenoid (SOL5)
Test O37 - Aux. Relief 4. Reconnect the battery connector and turn
Solenoid (SOL5) Ammeter Reading Value Displayed
This test ramps the Proportional Auxiliary Relief 0.000 to 0.700A Ramp (15% increments)
(SOL5) Solenoid (PROP RELIEF) from 0% to 0.00A 0%
90%.
failed. Reconnect wire to SOL5-1.
Use the UP (▲) button to increase RPM
percentage in increments of 15%, from 0-90%.


circuitry in the VM are all functioning correctly.
NOTE: This test does not prove the Proportional
Auxiliary Relief (SOL5) solenoid valve
itself is mechanically functional.
Run test:
2. Disconnect wire from Proportional
Auxiliary Relief (SOL5) at SOL5-1.
Proportional Auxiliary Relief (SOL5) as
follows:

Action/
Step Meter Setting
JPC20
1 disconnected/ PC20-20 Approx. 29 ohms Perform step 2 T/S wires & coil
Ohms PC20-19
2 DCV TP4 B+ Perform step 3
Check for
Ramp from B+ when Replace VM
Test activated/ binding.
3 JPC20-20 B– OFF to B+ minus 9V
DCV Replace
when 90% ON
solenoid

Test O45 - HSA 1 Solenoid (SOL7C, SOL7R) Output Tests
Test O45 - HSA 1 4. Reconnect the battery connector and turn

Solenoid (SOL7C, SOL7R) High Speed
Ammeter Operator
Auxiliary 1
Reading Display
This test turns the optional High Speed Solenoid
Auxiliary (HSA1) Solenoids (SOL7C, SOL7R) ON
Open 0.50 to 1.00A On
and OFF.
Closed 0.00 to 0.02A Off
NOTE: This test is checking the VM; this
particular circuit is used to activate two
coils. If these results are not observed, the test has
failed. Reconnect wire at SOL7C-1.
Run test:
If test results are observed, the test has passed.
Reconnect the wire at SOL7C-1, and perform
the same test on SOL7R.
2. Disconnect wire from HSA1 solenoid at
SOL7C-1. NOTE: Individual coils measure approx.
28 ohms.
solenoid as follows:
• (–) lead to terminal of SOL7C-1
• (+) lead to wire removed from SOL7C-1

Action/
Step Meter Setting
JPT18 & JPF2

1 disconnected/ JPT18-10 JPF2-8 Approx. 14 ohms Perform step 2 T/S wires & coil
Ohms
T/S relays &

2 JPF2-5 TP4 B+ Perform step 3 Fuse/Relay
Card
DCV JP2-8 or
Check for
related
binding.
3 wiring JPC18-12 Approx. 22V Replace VM
Replace
(refer to
solenoid
schematic)

Models 4100/4200 Maintenance Manual Section 7. Component Procedures
Section 7. Component Procedures

Section 7. Component Procedures Models 4100/4200 Maintenance Manual
List of Component Procedures
List of Component Electrical Components . . . . . . . . . . . . . 7-33

Motors . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Procedures DC Motor Brushes . . . . . . . . . . . . . . 7-34
Inspection . . . . . . . . . . . . . . . . . . . 7-34
Installation . . . . . . . . . . . . . . . . . . 7-34
Component Locator . . . . . . . . . . . . . . . 7-5 DC Motor Brush Spring Tension. . . . 7-34
Inspection . . . . . . . . . . . . . . . . . . . 7-34
Steering and Controls. . . . . . . . . . . . . . 7-9 DC Motor Commutator . . . . . . . . . . . 7-36
Steerable Wheel Assembly . . . . . . . . . . 7-10 Inspection . . . . . . . . . . . . . . . . . . . 7-36
Removal . . . . . . . . . . . . . . . . . . . . . . 7-10 Terminal Hardware. . . . . . . . . . . . . . 7-36
Installation . . . . . . . . . . . . . . . . . . . . 7-12 AC Motor Service . . . . . . . . . . . . . . . 7-38
Steer Wheel Disassembly . . . . . . . . . 7-13 AC Motor Temperature Sensor . . . . 7-38
Service . . . . . . . . . . . . . . . . . . . . . . . 7-14 Drive Motor Temp Sensor . . . . . . . . . . . .
Wheel Reassembly. . . . . . . . . . . . . . . 7-14 Replacement . . . . . . . . . . . . . . . . . 7-38
Control Handle - Standard . . . . . . . . . . 7-15 Lift Motor Temp Sensor . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . 7-15 Replacement . . . . . . . . . . . . . . . . . 7-38
Handle Disassembly . . . . . . . . . . . . . 7-15 AC Motor Bearing Encoder . . . . . . . 7-39
Handle Assembly . . . . . . . . . . . . . . . 7-15 Drive Motor Encoder Replacement . 7-39
Lift Knob Values . . . . . . . . . . . . . . . 7-15 Lift Motor Encoder Replacement. . . 7-40
Installation . . . . . . . . . . . . . . . . . . . . 7-16 Drive Motor . . . . . . . . . . . . . . . . . . . . . 7-41
Inspection . . . . . . . . . . . . . . . . . . . . . 7-16 Removal . . . . . . . . . . . . . . . . . . . . . . 7-41
Hand Soldering Procedures . . . . . . . . 7-16 Installation. . . . . . . . . . . . . . . . . . . . 7-41
Control Handle - Optional. . . . . . . . . . . 7-18 Lift Motor. . . . . . . . . . . . . . . . . . . . . . . 7-43
Return Spring Replacement. . . . . . . . 7-18 Removal . . . . . . . . . . . . . . . . . . . . . . 7-43
Handle Removal . . . . . . . . . . . . . . . . 7-18 Installation. . . . . . . . . . . . . . . . . . . . 7-43
Disassembly . . . . . . . . . . . . . . . . . . . 7-18 Battery Procedures . . . . . . . . . . . . . . . 7-44
Lift/Lower Potentiometer (VR2) . . . ...... Battery Exterior Cleaning . . . . . . . . . 7-44
Replacement. . . . . . . . . . . . . . . . . 7-18 Testing, Charging, and Maintenance. 7-44
Travel Potentiometer (VR1) . . . . . . ...... Power Amplifiers . . . . . . . . . . . . . . . . . 7-45
Replacement. . . . . . . . . . . . . . . . . 7-20 Removal . . . . . . . . . . . . . . . . . . . . . . 7-45
Sideshift/Tilt Switch Rubber Boot . ...... Installation. . . . . . . . . . . . . . . . . . . . 7-45
Replacement. . . . . . . . . . . . . . . . . 7-20 Wiring and Harness Connectors. . . . . . 7-46
Assembly . . . . . . . . . . . . . . . . . . . . . 7-20 General Connector Repair Procedures 7-46
Installation . . . . . . . . . . . . . . . . . . . . 7-21 Inspection . . . . . . . . . . . . . . . . . . . 7-46
Repair . . . . . . . . . . . . . . . . . . . . . . . 7-46
Drive and Brake . . . . . . . . . . . . . . . . .. 7-23 Molex Connectors. . . . . . . . . . . . . . . 7-46
Drive Units . . . . . . . . . . . . . . . . . . . . .. 7-24 Pin Extraction . . . . . . . . . . . . . . . . 7-47
Removal . . . . . . . . . . . . . . . . . . . . .. 7-24 Pin Insertion . . . . . . . . . . . . . . . . . 7-47
Installation . . . . . . . . . . . . . . . . . . .. 7-25 AMP Water-Resistant Connectors . . . 7-48
Service - Add Oil to Reservoir . . . . .. 7-25 Pin Extraction . . . . . . . . . . . . . . . . 7-48
Drive Axle Seal . . . . . . . . . . . . . . . . . .. 7-26 Pin Insertion . . . . . . . . . . . . . . . . . 7-49
Removal . . . . . . . . . . . . . . . . . . . . .. 7-26 Seals . . . . . . . . . . . . . . . . . . . . . . . 7-49
Installation . . . . . . . . . . . . . . . . . . .. 7-28 AMP Harness/Traction Power . . . . . . . . . .
Tire Replacement . . . . . . . . . . . . . . . .. 7-30 Amplifier Connector . . . . . . . . . . . 7-51
Brakes . . . . . . . . . . . . . . . . . . . . . . . .. 7-31 Connector Components . . . . . . . . . 7-51
Inspection . . . . . . . . . . . . . . . . . . . .. 7-31 Disassembly (Contact Removal) . . . 7-51
Removal . . . . . . . . . . . . . . . . . . . . .. 7-31 Contact Insertion . . . . . . . . . . . . . . 7-51
Disassembly . . . . . . . . . . . . . . . . . .. 7-31 Assembly . . . . . . . . . . . . . . . . . . . . 7-51
Assembly . . . . . . . . . . . . . . . . . . . .. 7-31 Testing. . . . . . . . . . . . . . . . . . . . . . 7-53
Installation . . . . . . . . . . . . . . . . . . .. 7-31

Hydraulic Components . . . . . . . . . . . . 7-55 Free Lift Cylinder Installation . . . . . ....

Manifold Solenoids, Fittings, . . . . ......... - Mast on Truck . . . . . . . . . . . . . . 7-81
and Attachments . . . . . . . . . . . . . . . . 7-56 Quad Mast . . . . . . . . . . . . . . . . . . . . 7-81
Hydraulic Fluid. . . . . . . . . . . . . . . . . . . 7-62 Main Lift Cylinder Removal. . . . . . . ....
Fluid Level. . . . . . . . . . . . . . . . . . . . . 7-62 - Mast on Floor. . . . . . . . . . . . . . . 7-81
Selecting Hydraulic Fluid Type . . . . . 7-62 Main Lift Cylinder Installation . . . . ....
Bleeding the Hydraulic System . . . . . 7-62 - Mast on Floor. . . . . . . . . . . . . . . 7-81
Model 4100 . . . . . . . . . . . . . . . . . . . 7-62 Free Lift Cylinder Removal . . . . . . . ....
Model 4200 . . . . . . . . . . . . . . . . . . . 7-63 - Mast on Floor. . . . . . . . . . . . . . . 7-81
Pressure Relief Valve. . . . . . . . . . . . . . . 7-64 Free Lift Cylinder Installation . . . . . ....
Measuring System Pressure. . . . . . . . 7-64 - Mast on Floor. . . . . . . . . . . . . . . 7-82
Pressure Adjustment . . . . . . . . . . . . . 7-64 Free Lift Cylinder Supply Hose . . . . . . . ....
Cylinder Service . . . . . . . . . . . . . . . . . . 7-65 - Model 4200 . . . . . . . . . . . . . . . . . . 7-83
Main or Free Lift Cylinders . . . ......... Tracking and Tension Adjustment . 7-83
- Model 4200. . . . . . . . . . . . . . . . . 7-65 Hose Reeving . . . . . . . . . . . . . . . . . . . . 7-84
Piston Removal . . . . . . . . . . . . . . . . . 7-65 Internal Reeving - . . . . . . . . . . . . . . . ....
Model 4200 TF Mast. . . . . . . . . . . 7-84
Mast. . . . . . . . . . . . . . . . . . . . . . . . . . 7-67 Internal Reeving - . . . . . . . . . . . . . . . ....
Mast Service . . . . . . . . . . . . . . . . . . . . . 7-68 Model 4200 TT Mast. . . . . . . . . . . 7-86
Mast Removal . . . . . . . . . . . . . . . . . . 7-68 Bracket Installation . . . . . . . . . . . . 7-86
Mast Installation . . . . . . . . . . . . . . . . 7-69 Hose Tension . . . . . . . . . . . . . . . . . 7-87
Mast Inspection - Model 4200 . . . . . . 7-69 Rear Termination . . . . . . . . . . . . . . 7-87
Model 4200 TF Mast . . . . . . . . . . . . . 7-70 Carriage Termination . . . . . . . . . . . 7-87
Disassembly . . . . . . . . . . . . . . . . . . 7-70 Quad Mast Internal Reeving . . . . . . . 7-88
Reassembly . . . . . . . . . . . . . . . . . . . 7-70 Lift Chains . . . . . . . . . . . . . . . . . . . . . . 7-92
Model 4200 TT Mast . . . . . . . . . . . . . 7-70 Lift Chain Adjustment - Model 4100 . 7-92
Disassembly . . . . . . . . . . . . . . . . . . 7-70 Lift Chain Adjustment - Model 4200 . 7-92
Reassembly . . . . . . . . . . . . . . . . . . . 7-71 Main Lift Chains. . . . . . . . . . . . . . . 7-92
Quad Mast . . . . . . . . . . . . . . . . . . . . 7-72 Free Lift Chains - TF Mast . . . . . . . 7-92
Disassembly . . . . . . . . . . . . . . . . . . 7-72 Mast Tilt Adjustment . . . . . . . . . . . . . . 7-94
Reassembly . . . . . . . . . . . . . . . . . . . 7-73 Mast Tilt Position Switch Adjustment 7-94
Upright Inspection - Model 4200 . . . . 7-76
Mast Skewing - Model 4200 . . . . . . . . 7-76
Carriage - Model 4200. . . . . . . . . . . . . . 7-78
Carriage Removal - Mast on Floor . . . 7-78
TF Mast. . . . . . . . . . . . . . . . . . . . . . 7-78
TT Mast. . . . . . . . . . . . . . . . . . . . . . 7-78
Quad Mast . . . . . . . . . . . . . . . . . . . 7-78
Carriage Installation - Mast on Floor . 7-78
Cylinder Removal/Installation. . . . . . . . 7-80
TF Mast - Model 4200 . . . . . . . . . . . . 7-80
Main Lift Cylinder Removal . . . . . . . ....
- Mast on Floor . . . . . . . . . . . . . . . 7-80
Main Lift Cylinder Installation . . . . . ....
- Mast on Floor . . . . . . . . . . . . . . . 7-80
TT Mast - Model 4200 . . . . . . . . . . . . 7-80
Main Lift Cylinder Removal . . . . . . . ....
- Mast on Floor . . . . . . . . . . . . . . . 7-80
Main Lift Cylinder Installation . . . . . ....
- Mast on Floor . . . . . . . . . . . . . . . 7-80
Free Lift Cylinder Removal. . . . . . . . ....
- Mast on Truck . . . . . . . . . . . . . . 7-80


Component Locator
Overhead Guard
Operator
Mast Compartment
Steer Tiller
Carriage
Tilt Cylinder
Forks
Battery
Compartment
Drive Unit (Behind Panel)
Drive Wheel
Figure 7-1: Models 4100/4200 Major Components

Steering Tiller Left

and Orbitrol Traction
Power
Fuse/Relay Panel Amplifier
Lift Power
Amplifier
Contactor Panel (4200 Only)
Right
Traction
Power
Amplifier
Operator
Display
Horn
Battery Tilt Cylinder

Connector
Brake
Hydraulic
Manifold
Left
Traction
Motor
Steering Motor
and Pump
Battery Rollers
Left Traction
Motor
Right Drive Wheel Lift Motor and Pump Left Drive Unit
Figure 7-2: Major Components - Front View

Hydraulic
Reservoir Steer Motor and Pump
Lift Motor and Pump
Hydraulic
Horn Manifold
Vehicle Operator
Manager Display
Contactor
Panel
Right
Traction
Power
Amplifier
Lift Fuse/Relay
Power Panel
Amplifier
(4200 Only)
Left
Traction Control
Power Handle
Amplifier
Operator
Compartment
Steering
Tiller
Deadman
Pedal
Figure 7-3: Major Components - Top View


Steering and Controls


Steerable Wheel 5. Remove the two screws that hold the steer
position proximity sensor bracket in place,
Assembly then remove the bracket. See Figure 7-5.
Removal Sensor Proximity

Ring Sensor
2. Remove the Steer Compartment Cover.
3. Take the steer chain off the steer plate by
removing the outer nut on the threaded
end of the chain anchor. See Figure 7-4.
Steering
Motor
Steer
Chain Plate
Figure 7-5: Removing Steering Position Sensor
6. Remove the three flat head screws that

hold the steer sensing ring to the top of the
steer plate, then remove the ring. See
Figure 7-6.
Steering
Plate
Chain
Anchor Nut Flat Head Screws
Figure 7-4: Removing Steering Plate Chain Nut
4. Disengage the steer chain from the

steering motor assembly. Leave chain
attached to the other side of the steering
plate.
Figure 7-6: Removing Steering Sensor Ring
7. Scribe a mark from the top of the steer

hub onto the steer plate. (These marks will
be realigned later to help make sure the
steer plate is installed in its correct
position). See Figure 7-7.

9. Remove the six mounting bolts holding the

Scribed Mark On Plate steerable wheel assembly to the lift truck
frame. See Figure 7-9.
Scribed Mark On Hub

Mounting Bolts
Figure 7-7: Scribing a Mark from Hub to Steer Plate
8. Remove the four bolts that hold the steer

plate in place, then remove the steer plate.
See Figure 7-8.
Figure 7-9: Steering Wheel Mounting Bolts
10. Place chocks in front of the drive wheels.

11. Reinstall one of the steer plate bolts. Wrap
a piece of heavy wire around this screw to
use as a temporary support. You will use
this temporary support to lower the steer
assembly to the floor when the lift truck is
jacked up. See Figure 7-10.
Heavy Wire and

Steer Plate Bolt
Figure 7-8: Removing Steering Plate Bolts
Jack
Block
Figure 7-10: Temporary Support for Steerable Wheel

12. Remove the wheel from the steer assembly 17. Move the steerable wheel assembly down
to reduce jacking height and for ease of and out from beneath the truck. See
removal. Figure 7-12.
13. Jack the rear of the truck. As the lift truck
is jacked, the steerable wheel assembly
separates from the tractor frame.
14. Continue to jack the lift truck until the
upper hub on the steerable wheel is flush
with the tractor frame. Block the lift truck
in this position. See Figure 7-11.
Figure 7-12: Steerable Wheel Removed
Wire and Bolt

Installation
1. Position the steerable wheel assembly
within the tractor frame.
2. While holding the steer wheel assembly
Figure 7-11: Wheel Hub Shown Flush with Lift Truck Frame upright, lower the tractor until it is near
the mounting flange.
3. Remove the wire and bolt from the steer
plate. Position the stop correctly.
The steerable wheel assembly is heavy. 4. Apply thread-locking compound
Use a suitable lifting device if necessary. (P/N 990-536) to the six mounting bolts,
install the mounting bolts, then torque to
15. While holding the wire, slowly move the 55 ft. lb. (77 Nm).
steerable wheel assembly out from under
5. Install the steer plate. Align the scribe
the truck.
marks, made during disassembly, between
16. As the wheels come out, lower the casting the hub and the steer plate.
to the floor.
6. Install the four mounting bolts and
tighten.
7. Install the steer sensing ring on top of the
steer plate.
8. Install the steer position proximity sensor
bracket. The gap between the bottom face
of the sensor and the upper surface of the
steer plate should measure 0.080 ±0.02
in. (2 ±0.005 mm).
9. Reinstall and adjust the steer chain.

10. Reconnect the battery connector and turn Steer Wheel Disassembly
the key switch ON.
1. Remove the nut that holds the upper steer
11. Run Test I89 - Steer Position Sensor
hub to the steer pivot. See Figure 7-13.
(Page 6-44). This will verify that the steer
position proximity sensor is adjusted
correctly. Lock Upper
Nut Steer
Hub
13. Remove any blocks supporting the truck.
14. Lower the lift truck to the floor. Key
15. Install the utility cover. Pivot

Hub
16. Reconnect the battery connector and turn Bearings
the key switch ON.
17. Test the steering function. If OK, return lift
truck to service. Steer
Pivot
Figure 7-13: Steerable Wheel Components
2. Use a three-arm puller to remove the

upper steer hub.

3. Pull the steer pivot out of the pivot hub.

See Figure 7-14.
Pivot Hub
Steer Hub
Steer Pivot and Lock Nut
and Wheel
Figure 7-14: Steerable Wheel Shown Unassembled
Service
1. Clean the inside of the pivot hub.
2. Clean and inspect the bearings. Replace
any worn components.
3. Remove, clean, and inspect the keys.
Clean and inspect the keyways.
4. Pack the bearings with grease, see
Appendix for lubrication specifications.
Add additional grease to the pivot spindle
and hub so that when the unit is
assembled, it is 50-75% full of grease.
5. Slide the steer pivot into the pivot hub.
6. Coat the keys and keyways with
thread-locking compound (P/N 990-536).
Wheel Reassembly
1. Install the upper steer hub.
2. Install the nut.
3. Tighten the nut while rotating the pivot
hub that mounts to the tractor frame.
4. Continue to tighten the nut until the pivot
hub just starts to resist rotation.

Control Handle - Handle Assembly

Standard 1. Making sure all internal assemblies are
positioned correctly, piece the two halves
of the control handle back together.
Removal 2. Replace the seven screws on the control
handle, making sure that they are located
1. Turn the key switch OFF and disconnect correctly.
3. Position the thumb control return spring
2. Remove the console cover. onto the control handle. Make sure that
the ears of the spring are positioned
correctly. See Figure 7-15.
Use correct electrostatic discharge 7
precautions. See Static Precautions on

page 2-8.
3. Unplug the control handle wiring harness

from the VM at JPC12. Remove any cable
ties that secure the wiring harness.
4. Loosen the socket head screw that secures
the control handle assembly to its support
bracket.
5. Slide the control handle assembly to the
left, out of its support bracket.
Figure 7-15: Correct Positioning of Spring Ears
Handle Disassembly
NOTE: To avoid premature handle failure, do
1. Turn the key switch OFF and disconnect not bend the ears on the spring.
4. Align the lift knob with the potentiometer
2. Remove the control handle.
shaft. Slide the lift knob onto the shaft
3. Using a hex key, loosen the two set screws. until fully seated.
Remove the lift knob.
5. Move the lift knob to verify that it works
4. Remove the return spring that goes over freely and returns to neutral.
the potentiometer shaft.
6. Using a hex key, replace and tighten the
5. Remove the seven socket head screws two set screws attaching the knob to the
located on the handle. Note the locations control handle.
of the three different size screws for
reassembly.
Lift Knob Values
6. Gently separate the two halves of the
control handle, being careful not to lose 1. The lift knob on solid state handles should
any springs or small parts. not require any adjustment.
7. Note the orientation of the parts to ensure 2. The lift potentiometer neutral for handles
correct reassembly. can range between 2 and 3V.
3. The lift potentiometer voltage at fully
Clockwise (CW) should not exceed 4.6V.
4. The lift potentiometer voltage at fully
counterclockwise (CCW) should not
measure below 0.45V.

5. If the lift potentiometer voltages are out of 3. Hold the control handle in place, aligning
range, replace the pot or wiring. the hole in the shaft with the securing
screw hole. Torque the securing screw to
Lift Knob Assembly 30 ft. lb. (42 Nm).
1. Rotate the lift potentiometer shaft fully 4. Route the control handle wiring harness
CCW. and plug into the VM at JPC12.
2. Install the lift knob on the potentiometer 5. Make sure cable extends out of the handle
shaft. Do not tighten the set screws yet. as straight as possible to avoid kinking.
3. Rotate the lift knob fully CCW and tighten 6. Reconnect the battery connector and turn
the set screws. the key switch ON.
4. Verify the lift potentiometer voltages. 7. Enter Maintenance Mode and perform
Learn. See Maintenance Mode on
5. Install the nylon plugs over the set screws. page 3-8.
8. Reinstall the console cover.
The solid state potentiometers used in Inspection

this handle are ESD sensitive.
Whenever the control handle is disassembled,
6. When installing the wire harness, a service perform the checks defined in the following
loop is required. table.
7. Install the handle and route the harness
last, after all the other wires are routed Part Check for:
through this area. Routing should occur
toward the left side of the truck, then Horn button Cracks or deformation
forward and around the front of the VM. assembly
Connect the handle from the right side of Lift/lower pot Cracks, deformation, loose dowel
the VM. bracket pin, over-round or oversized
shaft hole
Travel pot Cracks, loose spirol pin, stripped

Make sure that all other wires are tied enclosure threads, deformation or indents
back and away from the handle harness on external stops
service loop. Do not route through any Handle halves Cracks, damage or
components. deformation/indents on external
stops
8. Test the motion of the service loop by
cycling the handle. The entire length of the Lift/lower Cracks, deformation, stripped
loop should absorb the twist. Make sure knob threads, loose dowel pin
that the loop does not hang up on adjacent Other Stripped threads. All screw
wires, cable ties, or structures. hardware threads must be cleaned.
Installation
Hand Soldering Procedures
1. Insert the shaft of the control handle
assembly into the support bracket. When hand soldering is performed on solid
2. Apply thread-locking compound state potentiometers, the following is
(P/N 990-536) to threads of socket head recommended:
securing screw. • Flux - rosin base
• Solder - 60/40 rosin core or equivalent

• Solder Iron - 55 watt max.

• Tip Size - 0.118 in. (3 mm) dia. x 1.182 in.
(30 mm) long screwdriver
• Tip Temperature - 500°F (260°C) max.
• Terminal Contact Time - 6 seconds max.
NOTE: Apply light soldering iron pressure on
the terminal. Make sure the tip is clean.
A dirty tip does not transfer heat well,
therefore requiring longer dwell time
and greater tip pressure.
Contact contamination can occur if

cleaning solvent is allowed to enter
switches or potentiometers.
After soldering, clean terminals with a brush

dampened with an alcohol-based cleaner
(P/N 990-600/FOF). Make sure cleaner does
not seep into the electrical component.
Components damaged due to solvent saturation

will not be covered under warranty.

Control Handle - 3. Install double-sided tape to back of new

pot.
Optional 4. Slide the lift/lower potentiometer bracket
over the potentiometer shaft, engaging the
metal tab of potentiometer in the slot in
Return Spring Replacement the side of the bracket. See Figure 7-16.
The lift/lower knob return spring can be

replaced without removing and disassembling
Metal Tab
the control handle.
When replacing a return spring, coat the inside

of the spring lightly with lithium grease Bracket
(P/N 990-635).
Handle Removal
2. Remove the console cover.
3. Disconnect cable from the control handle. Figure 7-16: Lift/Lower Pot Bracket Installation
4. Loosen control handle set screw and
remove handle from pivot. 5. Insert the lift/lower pot assembly into the
right control handle shell.
Disassembly 6. Connect PCH2.

7. Adhere heater pad section of flexible
NOTE: A fixture (P/N 828-009-213) is available circuit to back of pot.
to hold the handle in position while
disassembled. Note the orientation of 8. Reassemble and reinstall the control
switches, potentiometers, routing of handle. See Assembly and Installation on
cables and wires for reassembly. page 7-21.
1. Remove nylon plug from the lift/lower
the key switch ON.
knob to expose set screw underneath.
Loosen set screw and remove lift/lower 10. Enter Maintenance Mode and perform
knob. Learn. See Maintenance Mode on
page 3-8.
2. Remove six socket head screws securing
the handle shell halves together. 11. In Run Mode, test the lift/lower function
for correct operation.
3. Carefully remove the left half of the handle
shell.
Lift/Lower Potentiometer (VR2)

Replacement
1. Remove the lift/lower potentiometer
bracket and potentiometer from the
handle shell. Slide the bracket off the
potentiometer. See Figure 7-17 on
page 7-19.
2. Disconnect PCH2.

Sideshift/Tilt Switch Rubber Boot
Lift/Lower Pot Bracket

PCH2
Lift/Lower Pot (VR2)
Flexible Circuit
Travel Pot Return Spring PCH1
Travel Pot (VR1) Positioner Pin Composite Bushings Pivot Shaft Assembly
Figure 7-17: Optional Control Handle

Travel Potentiometer (VR1) 4. For ease of assembly, turn the

replacement boot inside out, install the
Replacement replacement boot and verify that the tabs
1. Lift up gently on the pivot shaft to free the are aligned and that the boot is seated
travel pot assembly from the handle. See properly. Stretch the boot over the joystick
Figure 7-17 on page 7-19. housing. See Figure 7-18.
.
2. Slide the travel pot out of the pivot shaft

assembly.
3. Disconnect PCH1.
4. Install double-sided tape to back of new
pot.
5. Install pot in the pivot shaft assembly,
aligning the flat on the pot shaft with the
flat inside the positioner.
6. Install the travel pot assembly in the
handle shell. The tab of the throttle pot
must engage the slot in the handle shell Boot (turned inside out)
(straight down). Align the composite
bushings with the molded holders in the
handle. Figure 7-18: Boot Installation
7. Connect PCH1.
5. Reassemble and re-install the control
8. Adhere heater pad section of flexible handle.
circuit to back of pot.
9. Reassemble and reinstall the control Assembly
handle. See Assembly and Installation.
1. Check flexible circuit and wires for correct
routing.
the key switch ON.
2. Orient the VR1 return spring ears straight
11. Enter Maintenance Mode and perform
up in the right half of the handle.
Learn. See Maintenance Mode on
page 3-8. 3. Install the left half of the handle shell. The
pin in the left side handle shell must fit
12. In Run Mode, test the travel function for
between the ears of the VR1 throttle
proper operation.
potentiometer return spring. The wires
from the VR2 lift/lower potentiometer
Sideshift/Tilt Switch Rubber must fit between the tabs in the handle
Boot Replacement shell. Make sure the tabs do not crush any
of these wires.
1. Move the lift lower potentiometer and
4. If using a fixture, loosen the thumb screw
bracket out of the way in order to access
and remove the handle from the fixture.
the tilt and sideshift joystick boot.
5. Install the two socket head screws to hold
2. While activating the switch in the tilt
the handle halves together.
position, tilt back and rotate the assembly
out of the handle half. 6. Insert a screwdriver in the handle shaft
mounting hole to hold the shaft in place.
3. Remove the boot assembly.
7. Rotate the control handle from neutral to
NOTE: The joystick assembly has locating maximum forward, then maximum
indentations and the replacement boot backward, then to neutral. The handle
has corresponding tabs. should move freely with no binding.

Correct any binding before proceeding

further.
8. Install the five remaining socket head
screws in the handle. Torque all socket
head screws to 15 to 20 in. lb. (1.7 to
2.25 Nm).
9. Rotate the lift/lower potentiometer shaft
so the flat on the shaft is parallel to the
return spring pin on the potentiometer
bracket. If the potentiometer shaft has no
flat, rotate the shaft to the center of its
travel.
10. Install the lift/lower knob. The pin on the
knob must fit between the ears of the
potentiometer return spring.
11. Install and tighten set screw and nylon
plug in the knob. Check the potentiometer
for correct rotation and spring return to
neutral. Correct any binding.
Installation
1. Install the control handle on to the pivot.
2. Apply thread-locking compound
(P/N 990-536) to the control handle set
screw.
3. Install the set screw and tighten.
4. Form a loop in the control handle cable
harness as it leaves the handle. Do not
route through or under any components.
Route the cable to the VM and connect
JPC12.
5. Make sure that all other wires are tied
back and away from the handle harness
service loop.
6. Test the motion of the service loop by
rotating the handle. The entire length of
the loop should absorb the twist. Make
sure the loop does not hang up on nearby
wires, cable ties, or structures.
7. Install the top cover and right side cover.


Drive and Brake
Drive and Brake

1060345A, Issued: 8/27/07 7-23

Drive and Brake
Drive Units
Lifting Eye hook
Locating Pins
Removal
Drive unit weighs approximately 175 lb.

(79 kg). Use a suitable lifting device if
necessary. Have additional help
available when removing or installing
the drive unit.

the battery connector. 7du-pins.wmf
Figure 7-20. Lifting the Drive Unit

2. Remove the mast from the lift truck. See
Mast Service on page 7-68. 7. Loosen, but do not remove, the eight bolts
3. Drain all the lubricant out of the drive that secure the wheel and tire assembly to
unit. Use a drain pan that is the drive unit.
approximately 1.5 gallons (5.7 liters). See
Figure 7-19.
Use extreme caution whenever the lift

truck is jacked up. Never block the lift
truck between the telescopic and the
mast. Keep hands and feet clear from
beneath vehicle while jacking the lift
truck. After the lift truck is jacked up,
place solid blocks or jack stands
beneath it to support it. DO NOT rely on
the jack alone to support the lift truck.
See “Jacking Safety” on page 2-10.
8. Jack the side of the lift truck to remove the

drive unit. Place blocks beneath the lift
truck to support it. See Figure 7-21.
78D14066S.TIF
Figure 7-19. Drive Unit, Draining
4. Remove the brake assembly.

5. Remove the drive motor.
6. Install a lifting eye hook into one of the
drive motor mounting holes. See
Figure 7-20.
7-24 1060345A, Issued: 8/27/07

Drive and Brake
4. Install the six bolts that hold the drive unit

to the tractor frame. Torque bolts to
120 ft. lb. (168 Nm).
5. Install the drive wheel and tire assembly.
Install the wheel mounting bolts.
6. Lower the lift truck to the floor. Torque
wheel mounting bolts to 110 ft. lb.
(151 Nm).
7. Reinstall the drive motor.
8. Reinstall the brake assembly. Make sure
to remove the brake release bolts from the
brakes.
78D14044S.TIF
9. Refill the drive unit with gear oil until the
Figure 7-21. Drive Wheel Removal fluid is even with the bottom of the fluid
check hole located on the side of the drive
9. Remove the eight bolts that secure the unit.
wheel and tire assembly to the drive unit. 10. Install the mast.
10. Remove the six bolts securing the drive
unit to the lift truck frame. See
Figure 7-22.
Service - Add Oil to Reservoir
NOTE: The drive unit must be installed before
filling the drive unit with oil.
1. Remove the oil level check screw.
2. Remove the fill screw.
3. Refer to “Lubrication Specification Chart”
on page A-2 to determine the correct type
of gear lubricant (or oil for cold storage lift
trucks).
4. Slowly pour the lubricant in the fill hole.
Watch the oil level check screw hole. When
the lubricant is level with the bottom of the
screw hole, stop pouring. Allow all excess
oil to drain out.
78D14072.TIF
5. Reinstall the oil level check screw and fill
Figure 7-22. Drive Unit Mounting Bolts (6)
screw.
Installation
1. Make sure the drain plug is installed in
the drive unit.
(P/N 990-536) to the two locating pins.
Install the locating pins into the drive unit
casting. See Figure 7-20.
3. Position the drive unit in place. Align the
bolt holes in the mounting flange with the
bolt holes in the tractor frame.
1060345A, Issued: 8/27/07 7-25

Drive and Brake
Drive Axle Seal

Drive Unit component replacement is limited to
the axle oil seal.
Any major rework/service that the drive unit

may need requires the drive unit to be sent
back to the factory.
If the axle is removed for any reason, replace

the axle oil seal.
Removal
1. Remove the mast from the lift truck. See
7dso1.tif
Mast Service on page 7-68.
Figure 7-23. Draining Fluid from Drive Unit
the battery connector. 6. Remove the drive tire.
3. Loosen, but do not remove, the eight bolts 7. Remove the drive unit cover by removing
holding the drive tire to the axle shaft. the screws that secure it. Break the
adhesive bond and remove the cover plate.
See Figure 7-24.
Use extreme caution whenever the lift

truck is jacked up. Never block the lift
truck between the telescopic and the
mast. Keep hands and feet clear from
beneath vehicle while jacking the lift
truck. After the lift truck is jacked up,
place solid blocks or jack stands
beneath it to support it. DO NOT rely on
the jack alone to support the lift truck.
See “Jacking Safety” on page 2-10.
4. Jack the drive tire off the floor.

7dso4.tif
5. Place a suitable container under the drive Figure 7-24. Cover Plate Removal
unit. Remove the drain plug. Allow the
fluid to drain from the drive unit. See 8. Loosen the clamp nut locking screw. See
Figure 7-23. Figure 7-25.
7-26 1060345A, Issued: 8/27/07

Drive and Brake
7ds08.tif 7ds19.tif
Figure 7-25. Loosen Clamp Nut Locking Screw Figure 7-27. Spiral Bevel Gear Removal
9. Use a spanner tool to remove the clamp 12. Use a bearing puller to carefully remove
nut from the axle. See Figure 7-26. the bearing cone from the axle. See
Figure 7-28.
Spanner Tool
Bearing Puller
7ds12.tif
Figure 7-26. Remove Clamp Nut

7ds21.tif
10. Support the spiral bevel gear and drive the Figure 7-28. Bearing Cone Removal
axle out of the drive unit housing enough
to allow you to remove the spiral bevel NOTE: Observe the orientation of the axle seal
gear. See Figure 7-27. on the axle shaft before removing it.
11. Remove the axle from the drive unit 13. Remove the axle seal from the axle shaft.
housing using a rubber mallet if
necessary. Do not damage the gear
surfaces.
1060345A, Issued: 8/27/07 7-27

Drive and Brake
14. Clean and inspect all components. See 4. Install the clamp nut on the axle shaft and
Figure 7-29. hand tighten. See Figure 7-31.
5. Place a seal pressing tool between the axle
seal and tire mounting flange on the axle
Axle Shaft shaft.
Bearing Cone Clamp Nut
Axle Seal
7ds23.tif
7ds15.tif
Figure 7-29. Axle Shaft, Bearing Cone, and Axle Seal
Figure 7-31. Install Clamp Nut
Installation 6. Tighten the clamp nut; this will draw the

axle shaft inward. The axle seal will press
1. Lubricate (by hand) the lip of the new seal into the housing. Make sure the seal is
and place new axle seal onto the axle flush with the drive unit housing.
shaft. Make sure that the seal is oriented
correctly. 7. Loosen the clamp nut.
2. Carefully place bearing cone onto axle. 8. Drive the axle shaft out of the drive unit
Press the bearing onto the axle shaft. housing just enough to allow removal of
Press the bearing cone until it is correctly the pressing tool. Remove the pressing
seated. tool. See Figure 7-32.
3. Place axle assembly into housing. Mate
axle with the spiral bevel gear. See
Figure 7-30.
7ds29.tif
Figure 7-32. Install Seal Pressing Tool Halves
9. Tighten the clamp nut to draw the unit

7ds19.tif
until the bearing cone and bearing cup
Figure 7-30. Spiral Bevel Gear make contact.
10. Remove the clamp nut.
7-28 1060345A, Issued: 8/27/07

Drive and Brake
11. Apply thread-locking compound 22. The drive unit must be installed before
(P/N 990-536) to the clamp nut threads filling the drive unit with oil.
and the threads of the screw in the clamp 23. Install the brake. See “Brakes” on
nut. page 7-31.
12. Install the clamp nut on the axle shaft and 24. Install the drive tire. Torque the wheel
hand tighten. mounting screws to 110 ft. lb. (151.2 Nm).
13. Turn the axle several revolutions by hand 25. Lower the lift truck to the floor.
(in both directions). This seats the
bearings in the bearing cones. 26. Install the mast.
14. Torque the clamp nut to 125 ft. lb.

(170 Nm). This process establishes the
proper preload on the bearings.
(P/N 990-536) to the clamp nut screw.
Torque to 140 in. lb. (8 Nm). See
Figure 7-33.
7ds10.tif
Figure 7-33. Torque Clamp Nut Screw
16. There should be no axle end play. The axle

shaft should rotate smoothly.
17. Clean the cover plate and mating surface
on the drive unit. Apply gasket eliminator
(P/N 990-411) to sealing surface.
18. Install the cover. Torque all screws equally
to 6 ft. lb. (8.6 Nm).
19. Install the drain plug.
20. Install the drive motor.
21. Refer to “Lubrication Specification Chart”
on page A-2 to determine the correct type
of gear lubricant (or oil for cold storage lift
trucks) and fill drive unit.
1060345A, Issued: 8/27/07 7-29

Drive and Brake
Tire Replacement 3. If outside edge of hub is not flush with

edge of metal insert in the old tire,
measure how far hub is recessed inside
tire. The new tire must be placed in the
same position the old tire was installed on
Any misalignment of the tire and hub hub. You can use a spacer (slightly smaller
while the tire is being pressed onto the in diameter than inside diameter of tire
hub can damage the hub. For this insert and same thickness as depth of
reason, chamfers are provided on the recess) to obtain correct amount of
outside edge of the hub and on the end recession.
of the inside diameter of the tire’s metal 4. Position hub assembly with old tire on top
insert. The chamfers help to center the of circular ram so outside of wheel is
hub and tire during the pressing positioned upward. The outside edge of
operations and reduce the possibility of hub has a chamfer to help guide new tire
misalignment. To prevent damage, the onto wheel. The chamfered edge must
hub must be installed on the circular always be leading edge when a tire is
ram with its chamfered side up. pressed onto hub.
1. Check inside surface of metal insert on 5. Center hub assembly on top of ram and
new tire. Use sandpaper to remove any make sure that they mate squarely.
scaling or rust. Clean inside of metal 6. Position new tire with its chamfered insert
insert and lubricate it with a soap facing hub. Align new tire and hub so that
solution. they are concentric.
2. Place circular ram on the press table. See 7. Begin pressing new tire onto hub and old
Figure 7-34. The length of the ram must tire off wheel. Run press slowly for the first
be longer than width of the old tire to allow few inches of travel, because this is the
complete removal of old tire. The outside critical stage of the operation. If tire begins
diameter of ram must be small enough to to cock to one side, stop press and realign
fit loosely in the insert of tire but must be tire. A sharp jar with soft-headed mallet
large enough to rest squarely on flat usually realigns tire on hub.
surface on outer edge of hub.
NOTE: If new tire does not press on with a
minimum of 5 tons (68,947 kPa)
pressure, replace hub.
Outside of Hub
and Tire Assembly 8. Release press. Remove wheel, tire
assembly, and old tire from press table.
Inspect wheel and tire assembly.
New Tire
Worn Tire
Circular Ram
Press Table
7
Figure 7-34. Drive Tire Installation
7-30 1060345A, Issued: 8/27/07

Drive and Brake
Brakes 5. Check the thickness of the friction disk. If

the thickness is less than 0.235 in.
(6 mm), replace the friction disk.
Inspection 6. Check the top and bottom friction plates.
Replace them if worn more than 0.003 in.
Check the gap between the brake coil and (0.08 mm).
upper friction plate. The gap should measure
0.004 to 0.020 in. (0.1 to 0.5 mm). If gap
exceeds 0.020 in. (0.5 mm), remove and
Assembly
disassemble the brake assembly to check 1. Place the springs evenly in the holes in the
components. brake coil. (There may be fewer springs
used than there are holes.)
Removal 2. Place the top friction plate over springs.
1. Lower the forks all the way and tilt 3. Carefully clamp assembly together.
forward. 4. Install the two brake release bolts and
2. Turn the key switch OFF and disconnect tighten.
the battery connector. 5. Center the friction disc on the upper
3. Remove the front covers. friction plate.
4. Cut the cable ties joining the brake coil 6. Apply thread-locking compound
harness and the speed feedback sensor (P/N 990-536) to the three bolts previously
harness and temperature sensors. removed and place them through the
Disconnect the brake coil assembly brake coil assembly.
electrical connector JPB4 or JPB3 from 7. Secure the brake coil assembly to the
the lift truck’s harness. lower friction plate assembly. Torque to
5. Install the brake release bolts. Tighten to 9 ft. lb. (12 Nm).
release the brake.
6. Remove nut and washer from motor shaft. Installation
7. Remove the three bolts that hold the brake 1. Install the brake assembly onto the drive
assembly to the motor. Lift the brake motor. Make sure the friction disc fits over
assembly off the drive motor. the splined hub.
2. Tighten the three mounting bolts to
Disassembly 13 ft. lb. (18 Nm).
1. Remove the three bolts that hold the lower 3. Install nut and washer on motor shaft.
friction plate to the brake coil. Torque to 120 ft. lb. (163 Nm).
2. Remove and inspect the brake friction 4. Remove the brake release bolts and store
disc. for future use.
3. Clamp brake assembly in vise or use “C”

clamps.
4. Remove the brake release bolts and top
Make sure that all the brake release
friction plate from the brake coil.
bolts are removed before using the lift
NOTE: When removing the top friction plate truck. The brake will not work if the
from the brake coil, hold the coil brake release bolts are not removed.
inverted so the brake springs will
remain in the coil assembly. 5. Plug the wiring harness connector from
the brake coil into the connector from the
1060345A, Issued: 8/27/07 7-31

Drive and Brake
VM (JPB4 for the right brake coil; JPB3 for

the left brake coil).
6. Re-install the front covers.
the key switch ON.
8. Check the operation of the brake. Travel
with a rated load traveling forks-first at
full speed, depress the EPO button. The
lift truck should stop within one and one
half truck lengths. This distance will vary
depending on floor and tire conditions.
7-32 1060345A, Issued: 8/27/07

Electrical Components

Motors Installation
If one brush needs replacement, always replace

DC Motor Brushes the entire set of brushes.
Use only genuine Raymond replacement

Inspection
brushes. Using another type of brush could
1. Inspect the brushes for wear and for damage the commutator or cause excessive
correct contact with the commutator. brush wear.
Record the level of wear on the brushes.
This history will give you an indication of Do not use emery cloth or sandpaper to seat
whether a brush must be changed or if it brushes. Grit may enter the motor, causing
can wait until the next inspection. See the premature wear and failure. Blowing out the
table on the next page for correct brush motor with compressed air will not guarantee all
length. the debris is removed.
NOTE: Overloading a motor is ultimately
reflected in motor commutator and DC Motor Brush Spring Tension
brush wear: therefore, you must take
this into account when considering Insufficient brush spring tension can result in
brush replacement. excessive arcing and reduced motor
performance. Excessive spring tension results
2. Check the brushes for signs of
in premature commutator wear. A brush spring
overheating: discolored shunts or springs
that does not apply tension evenly on the center
or cracked contact area.
of the brush causes uneven brush wear.
3. Check the brush spring tension. See “DC
Motor Brush Spring Tension”. Inspection
4. Clean the brushes and holders. Wipe the
commutator with a dry, lint-free cloth. Do 1. Turn the key switch OFF and disconnect
not use lubricants of any kind on or the battery connector.
around the commutator. 2. Remove covers as required for access to
5. Check the brush holders for solid motor.
connection to the mounting support. 3. Remove any brush bands.
Tighten any mounting screws as 4. Slide the brush up slightly in its holder.
necessary.
5. Insert a paper strip between the brush
6. Check the screws holding the brush cross face and the commutator.
connectors to the brush holder body.
6. Place a small leather loop around the coil
7. Make sure the motor terminals are spring for the brush. If the brush spring
secured tightly to the motor frame. Use has a loop at the brush, hook the spring
care not to strip the threads or crush the scale directly to the spring.
insulating parts.
7. Attach a 5 lb. (2.27 kilogram) spring scale
8. Check all the screws and bolts around the to the leather loop.
end bell and frame for tightness.
8. While gently pulling the scale outward,
9. Keep the outside frame of the motor clean slowly pull the paper strip in the direction
and free from dirt. Maintain a free air that the commutator normally rotates.
passage around the motor to permit heat
radiation. 9. When the paper strip begins to move
freely, the spring scale will read the spring
brush tension.
10. See Figure 7-35 and Table 7-1 for correct
spring tension.

11. Repeat steps 4 thru 9 for the remaining

brushes.
Paper
Rotation
78B16032.EPS
Figure 7-35. Motor Brush Spring Tension Inspection
Table 7-1. Brush Length and Spring Tension

Brush Length Brush Spring Tension
Raymond
Motor Minimum Maximum New Worn
P/N
in. mm in. mm oz. gr oz. gr
Lift 570-317/500 0.62 16 1.30 35 65 1820 40 1120

579-317
Steer 114-008-594/01 0.50 12.7 N/A

DC Motor Commutator Terminal Hardware

Inspection
Inspect the commutator for surface condition Do not attempt to repair power cable
and high mica. See Figure 7-36. terminal lugs. If a power cable has worn
or damaged lugs, replace the cable. Do
Segment
not substitute other kinds of nuts for the
Mica flanged nuts. Failure to use correct
cables, flanged nuts, and torque values
can result in overheating and damage to
components.
Whenever you disconnect and reconnect any

NORMAL High Mica power cables to a motor or power amplifier,
UNDERCUT always tighten the cable securing hardware
with a torque wrench to prevent over-tightening
them and damaging the motor or amplifier. On
motors with stud terminal securing nuts, use a
second wrench on the securing nut to avoid
twisting the stud. See Figure 7-37. Check these
HIGH MICA
torques each time you check the motor.
71881_003.tif
Figure 7-36. Mica Undercutting

Stud Motor Cable Stud Terminal
Size Securing Nut Securing Nut
The commutator must be smooth and clean to
provide maximum brush wear. When Traction Motors
commutators are not correctly maintained,
M10 12.5 to 18.4 ft. lb. 10.7 to 11.0 ft. lb.
carbon dust can collect in the grooves between
(23.0 to 25.0 Nm) (14.5 to 15.0 Nm)
the segments. This can lead to a short circuit in
the armature. Lift Motor
Good commutation is indicated by a dark M10 12.5 to 18.4 ft. lb. 10.7 to 11.0 ft. lb.
(23.0 to 25.0 Nm) (14.5 to 15.0 Nm)
brown polished commutator and an evenly
polished brush wearing surface (refer to Lift Motor (brass nuts)
Table 5-2 on page 5-6).
M10 8.3 to 10.0 ft. lb. 11.7 to 13.3 ft. lb.
If the commutator appears rough, pitted, or has (11.2 to 13.6 Nm) (15.8 to 18.1 Nm)
high mica, signs of burning, or heavy arcing Steer Motor (brass nuts)
between the commutator bars, remove the
motor for servicing. 7.5 to 9.2 ft. lb. 9.2 to 11.7 ft. lb.
M8
(10.2 to 12.5 Nm) (12.5 to 15.9 Nm)
High ridges between the brush travel paths Traction Power Amplifier (bolt)
indicate the commutator requires turning. High
ridges could chip or damage the brushes. N/A 100 in. lb. N/A
(11.3 Nm)

Terminal Motor Cable

Stud Securing Nut
Conical Washer
Fullness of
cable to bottom
Stud Terminal
Motor
Securing Nut
Housing
(Flanged)
Traction Motor
Terminal
Stud
Motor Cable
Flat
Securing
Washer
Nut
Fiber
Stud Washer
Terminal
Securing Motor
Nut Housing
Lift/Steer Motor
74548_003.EPS CABLENUT.WMF
Figure 7-37. Terminal Nuts

AC Motor Service tie to one of the power leads for stress

relief.
AC traction and lift motor Encoder Bearing 8. Install the top end bell in the position that
Assembly and Temperature Sensor was previously marked. Verify correct
stator installation and install snap ring.
AC Motor Temperature Sensor 9. Secure the top end bell to the bottom end
bell using the four bolts previously
Temperature sensors in the AC drive and lift removed.
motors are integral to the motor. When a motor 10. Install the brake mounting motor flange
temperature sensor fails, it can be replaced with new mounting bolts.
using the procedures below.
11. Re-install the brake assembly including
Drive Motor Temp Sensor Replacement the rotor hub mount and rotor hub.
1. Turn the key switch OFF and disconnect 12. Install the terminal board, reconnect
the battery connector. JPTA3 and power cables. Torque motor
cable securing nuts to 18 ft. lb. (24 Nm).
2. Remove the brake assembly including the
rotor hub nut and rotor hub. Note the 13. Reconnect the battery connector and turn
number of spacers used. the key switch ON.
a. Disconnect the temperature sensor Lift Motor Temp Sensor Replacement
connector JPTA3.
b. Disconnect power cables making sure the battery connector.
that you note locations for reassembly
later. 2. Disconnect the temperature sensor
connector JPLA3.
c. Remove the terminal board.
3. Disconnect cables and motor harness
connections, making sure that you note
locations for reassembly later.
Use correct electrostatic discharge 4. Separate the pump assembly from the lift
precautions. See “Static Precautions” on pump motor and remove lift pump motor.
page 2-8. 5. Remove the four bolts that secure the top
end bell to the bottom end bell.
3. Mark the position of the top end bell and
bottom end bell relative to the stator, then 6. Remove the top end bell. Use care that the
remove the snap ring. bearing remains in the bottom end bell to
reduce the chance of damaging the
4. Remove the brake mounting motor flange. bearing.
NOTE: Use new flange mounting bolts when 7. Install a new temperature sensor using the
reassembling. high temperature silicone (neutral curing)
5. Remove the four bolts that secure the top supplied with the temperature sensor.
end bell to the bottom end bell. Mount the sensor close to the location of
the original. Secure the cable with a cable
6. Remove the top end bell using a puller. tie to one of the power leads for stress
Use care that the encoder bearing remains relief.
in the bottom end bell to reduce the
chance of damaging the bearing. 8. Carefully press the top end bell to the
stator. Do not pinch the cables or allow
7. Install a new temperature sensor using the contact with the rotor. Verify correct stator
high temperature silicone (neutral curing) installation.
supplied with the temperature sensor.
Mount the sensor close to the location of
the original. Secure the cable with a cable

9. Secure the top end bell to the bottom end 8. Remove the four bolts that secure the top
bell using the four bolts previously end bell to the bottom end bell.
removed. 9. Remove the top end bell and bottom end
10. Reinstall lift motor to the lift pump bell using a puller.
assembly. 10. Remove the clamps that secure the
11. Reconnect JPLA3 and power cables. encoder bearing cable.
12. Reconnect the battery connector and turn 11. Remove the encoder bearing from the rotor
the key switch ON. using a suitable puller, pulling on the
outer race only.
AC Motor Bearing Encoder 12. Remove the oil seal to allow pressing of the
bottom end bell to the stator for later
Drive Motor Encoder Replacement reassembly.
1. Turn the key switch OFF and disconnect 13. Make sure that the O-ring and wave
the battery connector. washer are correctly positioned in the
2. Remove the brake assembly including the bottom bell bearing pocket.
rotor hub nut and rotor hub. Note the 14. Position the new encoder bearing in the
number of spacers used. bottom end bell with the cable oriented in
a. Disconnect the temperature sensor the middle of the notch in the side of the
connector JPTA3. bearing pocket.
15. Use an assembly bushing on the outer
b. Disconnect the bearing encoder
race and press the bearing into place. Do
connector JPTA2.
not press on the encoder part of the
c. Disconnect power cables making sure bearing.
that you note locations for reassembly
16. Re-install encoder bearing cable clamps.
later.
17. Install the top end bell in the position that
d. Remove the terminal board. was previously marked. Verify correct
stator installation and install snap ring.
18. Carefully press the bottom end bell to the
Use correct electrostatic discharge stator.
precautions. See “Static Precautions” on 19. Secure the top end bell to the bottom end
page 2-8. bell using the four bolts previously
removed. Re-install oil seal.
3. Remove the steering position reference
20. Install key, pinion gear, and nut to the
bracket.
bottom of the drive motor. Re-install drive
4. Remove the drive motor. See “Drive Motor” motor. See “Drive Motor” on page 7-41.
on page 7-41.
21. Install the brake mounting motor flange
5. Remove the nut that secures the pinion with new mounting bolts.
gear. Remove the gear and key using a
22. Re-install the brake assembly including
suitable puller.
the rotor hub mount and rotor hub. See
6. Mark the position of the top end bell and “Brakes” on page 7-31.
bottom end bell relative to the stator, then
23. Install the terminal board, reconnect
remove the snap ring.
JPTA2, JPTA3, and power cables. Torque
7. Remove the brake mounting motor flange. motor cable securing nuts to 18 ft. lb.
NOTE: Use new flange mounting bolts when (24 Nm).
reassembling. 24. Re-install steering position reference
bracket and filler tube if previously
removed.


the key switch ON.
Lift Motor Encoder Replacement

Use correct electrostatic discharge

precautions. See “Static Precautions” on
page 2-8.
2. Disconnect the bearing encoder sensor

connector JPLA2.
3. Disconnect connectors JPLA2, JPLA3,
cables, and motor harness connections,
making sure that you note locations for
reassembly later.
4. Separate the pump assembly from the lift
pump motor and remove lift pump motor.
5. Remove the four bolts that secure the top
end bell to the bottom end bell.
6. Remove the top end bell using a suitable
puller.
7. Remove the encoder bearing from the
rotor, pulling on the outer race only.
8. Install the new encoder bearing by
applying steady pressure to the inner ring.
9. Carefully press the top end bell to the
stator. Do not pinch the cables or allow
contact with the rotor. Verify correct stator
installation.
10. Secure the top end bell to the bottom end
bell using the four bolts previously
removed.
11. Install lift motor and reconnect lift pump
assembly. See “Lift Motor” on page 7-43.
12. Reconnect JPLA2, JPLA3, and power
cables.
the key switch ON.

Drive Motor c. As you turn the bolts, the drive motor

pushes upward, breaking its seal to the
drive unit. See Figure 7-39.
Removal
1. Turn the key switch OFF and disconnect Drive Motor
2. Remove the three front covers.
3. Remove the mast.
4. Remove the brake assembly.
5. Remove the friction plate retaining nut.
6. Remove the friction plate.
7. Disconnect the three power cables from Bolt In “Blind” Hole
the terminals on the drive motor and label Drive Unit
for later installation. Use two wrenches to 78D14068S.TIF
avoid twisting the terminal studs. Figure 7-39. Drive Motor Removal, Breaking Seal
8. Disconnect JPTL2 (left) or JPTR2 (right)
and JPTL3 (left) or JPTR3 (right).
9. Place a drain pan beneath the drive unit.
The drive motor is heavy. Use a suitable
Remove the drain plug and drain
lifting device to move it if necessary.
approximately two pints (one liter) of drive
unit oil. This prevents oil from spilling
12. Lift the drive motor off the drive unit.
when the drive motor is removed. See
Figure 7-38. 13. If you won’t be reinstalling a drive motor,
use plastic film and masking tape to seal
the opening for the traction motor so that
no debris can fall into the drive unit.
14. Remove the pinion gear from the drive
motor shaft.
Installation
1. Thoroughly clean the mating areas on the
drive motor shaft and pinion gear.
1. Install the pinion gear on the drive motor
shaft and torque to 45 ft. lb. (63 Nm).
2. Thoroughly clean the mating areas on the
top of the drive unit and the bottom of the
Figure 7-38. Drive Unit Drain Plug drive motor mounting flange.
10. Remove the four bolts that attach the drive 3. Apply a coat of gasket cement
motor to the top of the drive unit. (P/N 990 556) to the mating surface on
the top of the drive unit. A gasket
11. To break the drive-motor-to-drive-unit
(P/N 828 013-978) may be used instead of
seal:
the gasket cement.
a. Install two of the bolts you removed in
4. Position the drive motor on top of the drive
step 10 into the two “blind” holes on the
unit and align the mounting holes.
drive motor mounting flange.
b. Evenly turn each bolt clockwise.
(P/N 990-536) to the four motor mounting

bolts and install the bolts. Torque to

13 ft. lb. (18.2 Nm).
6. Install the brake assembly.
7. Reconnect the cables to the terminals on
the drive motor. Use two wrenches to avoid
twisting the terminal studs. Torque cable
securing nuts to 205 to 220 in. lb. (23 to
25 Nm).
8. Reconnect the harnesses to the drive
speed feedback sensors and temperature
sensors.
9. Add gear oil to the drive unit through the
filler plug hole.
10. Install the mast.
the key switch ON.

Lift Motor Installation

(P/N 990-536) to the lift motor mounting
studs.
Discharge the power amplifiers energy 2. Carefully place the lift motor on the
storage capacitors before removing any mounting bolts on the frame. Support the
large fuse or motor cable for service. To motor on the wood blocks used during
discharge, turn the key switch OFF, removal.
disconnect the battery, and manually
3. Install washers and mounting nuts and
push in the plungers on all three
tighten.
contactors.
4. Apply a thin coat of anti-seize compound
(P/N 990-638) to the spline on the end of
Removal the lift/aux pump.
1. Remove the mast. 5. Mate the lift/aux pump to the lift motor.
2. Turn the key switch OFF and disconnect Apply thread-locking compound
the battery connector. (P/N 990-536) to the mounting bolts and
install. Reconnect hoses.
3. Remove the three front covers.
6. Reconnect the power cables to the motor.
4. Remove the power cables, labeling if Use two wrenches to avoid twisting the
necessary for reinstallation. Use two terminal studs. For Model 4100, torque to
wrenches to avoid twisting the terminal 100 to 120 in. lb. (11.2 to 13.6 Nm); Model
studs. 4200, torque to 205 to 220 in. lb. (23 to
5. Model 4200 only: Disconnect speed sensor 25 Nm).
(JPL2) and temperature sensor (JPL3). 7. Model 4200 only: Reconnect speed sensor
6. Remove the two bolts securing the front (JPL2) and temperature sensor (JPL3).
cover mounting bracket to the reservoir. 8. Remove the wood block from beneath the
7. Using caution not to get oil in motor, motor.
remove the lift pump from the lift motor. It 9. Reinstall the front cover mounting
may be necessary to disconnect the lift bracket.
pump hoses.
10. Install the mast.
8. Place wood blocks beneath the lift motor to
help support it during removal. Leave no 11. Reconnect the battery connector and turn
more than a 1/2 in. (13 mm) gap between the key switch ON.
the top of the wood blocks and the bottom 12. Test lift/lower functions. Check for
bell of the lift motor. hydraulic leaks where mast hoses were
removed.
13. Install the front covers.
The lift motor is heavy. Use a suitable
lifting device if necessary.
9. Remove the mounting nuts that hold the

lift motor to the frame.
10. Carefully slide the lift motor off the
mounting studs.

Battery Procedures
Do not clean the top of the battery with
Battery Exterior Cleaning the soda solution while it is installed in
the truck. Water can seep into the
1. Read, understand, and follow procedures,
electrical compartments and cause
recommendations, and specifications in
serious damage.
service manuals provided by the battery
and battery charger manufacturer.
6. Wash dirty batteries (or any that have had
2. Wear personal protective equipment. See electrolyte spilled on them) with a solution
Battery Safety on page 2-5. of 1 lb. (0.45 kg) of baking soda added to
3. Turn the key switch OFF and disconnect 0.5 gal. (1.9 liters) of hot water.
the battery connector. Remove the battery 7. Use a brush with flexible bristles to clean
from the lift truck. the entire top of the battery with the soda
4. Inspect the battery cables to make sure solution. Wait until all foaming stops,
they are not frayed or loose. Inspect the indicating that the battery exterior is
battery connector to make sure there is no neutralized.
foreign material inside the connector. 8. Rinse the battery with clean water.
Make sure the filler plugs are tight and the
9. Dry the battery completely before
vent holes in the filler plugs are open. See
reinstalling it.
Figure 7-40.
10. Reinstall the battery in the lift truck, using
a suitable battery-moving device.
Cable
Reconnect the battery connector.
Vent Hole
Testing, Charging, and
Maintenance
For information on testing, charging, and
maintaining your lift truck battery, consult the
battery manufacturer’s specifications and
instruction manual.
Filler Plug
709g6s047
Figure 7-40. Battery Filler Plugs and Vent Holes
5. Keep the top of the battery clean and dry.

Corrosion, dust, and moisture provide a
conducting path to short-circuit cells or
create shorts to ground.
725l6s014.eps

Power Amplifiers
Removal
2. Disconnect JT1 from the power amplifier.
3. Disconnect the power cables and the B–
bus bar from the power amplifier.
4. Remove the four mounting screws.
5. Lift the power amplifier off the mounting
plate.
Installation
1. Install new thermal conductive material
(provided with new power amplifier)
between the base of the power amplifier
and the heatsink.
2. Position the power amplifier and install the
four mounting screws.
3. Tighten the mounting screws to 7.4 ft. lb.
(10 Nm).
Do not attempt to repair power cable

terminal lugs. If a power cable has worn
or damaged lugs, replace the cable.
Failure to use correct cables, bolts, and
torque values can result in overheating
and damage to components.
4. Reinstall the bus bar and reconnect the

power cables to the correct terminals.
Torque to 100 in. lb. (11.3 Nm).
5. Reconnect JT1.
the key switch ON.

Wiring and Harness The failed wire can be left in the bundle, or can
be pulled by one end to remove it from the
Connectors bundle.
When replacing wires, follow these guidelines:

General Connector Repair • Use the appropriate tools to remove and
Procedures insert terminations at each connector.
• Remove damaged terminations and
Inspection discard. Never reuse a termination from a
wire.
Whenever working on the lift truck, use care • Do not cut away a terminal lug and reuse
around wiring harnesses. the wire strands that were crimped into
• Carefully connect and disconnect all the original lug.
connections. • When stripping wire, use new wire strands
• Do not pry connectors apart with for new terminations. Make sure to use a
unspecified tools. new wire with extra length to allow for
cutting and stripping of the ends to install
There should be a wire marker at each new terminations.
termination. If the marker is missing or • Use a new wire that is the same gauge
unreadable, remark the wire to allow easier (typically gauge 18 AWG), size, type, and
identification. color as the wire it is replacing.
NOTE: It is normal to find unused connectors • Use a hand stripper capable of stripping
for uninstalled options that have had by wire gage number. Use care not to nick
heat shrink applied over them and have or cut any of the wire strands. Discard and
been strapped to the harness. replace a wire with damaged strands.
Insert the wire strands the correct length
Repair into termination before crimping.
Molex Connectors
Use correct electrostatic discharge Molex connectors have pins with locking ears
precautions. See Static Precautions on that engage ridges in the plastic connector
page 2-8. body. See Figure 7-41.
When pulling a wire out through a bundle, cut

off the pin or socket so it will not snag. When
replacing wires, in some cases you will be able Pin
to tape or solder one end of a new wire to one
end of the failed wire. Then you can pull the old
wire out of the bundle and pull the new wire
Socket
into the bundle, all at the same time.
Make sure to disconnect the old wire from the

new wire. In other cases, it will be easier to
secure a new wire to the outside of the existing
wire bundle with cable ties of an appropriate Locking Ears
size.
Figure 7-41. Molex Connectors - End View

To remove a pin from a Molex connector, these 2. The locking ears have now engaged the
locking ears must be depressed far enough to connector.
clear the ridge in the connector.
Pin Extraction
To remove a pin from a Molex connector, use

pin extraction tool P/N 950-026. See
Figure 7-42.
1. Insert the extraction tool over the pin and
push all the way into the connector. This
releases the locking ears on the pin.
2. Pull the wire and pin from the connector.
Pin Insertion
1. To insert a pin into a Molex connector,
insert the pin into the back side of the
connector and push the wire all the way in
until it clicks.
Tool Inserted Over Pin

Top View
Locking Ears
Extraction Tool
Side View
Figure 7-42. Pin Extraction Tool

AMP Water-Resistant
Connectors
AMP connectors provide water-resistant
connection by the use of seals between wires
and connectors and between the mating
connector halves.
To maintain the integrity of water-resistant

seals, use the following procedures when
working with AMP connectors. See Figure 7-43.
Wire Seal
Interface Seal
Contact Cavity
Wire Seal
Jack Housing
Pin Contact
Pin Housing
Sealing Plug
Figure 7-43. AMP Water Resistive Connectors
Pin Extraction pulling it through the wire seal. See

Figure 7-44. This prevents damage to the
To aid in separating AMP connectors, use seal.
unlatching tool P/N 950-042. To remove a pin
from an AMP connector, use pin extraction tool
P/N 950-009.
1. While holding the wire seal, push the
selected wire forward, then insert the
extraction tool into the contact socket.
2. Pull the wire gently until you feel the
contact locking lances disengage.
3. Holding the wire seal and connector
housing together, rotate the wire while

Extraction Tool
Figure 7-46. Wire Insertion

Locking Lance 3. Grasp the wire close behind the contact
Figure 7-44. AMP Pin Extraction Tool insulation barrel and push the wire
straight through the wire seal into the
Pin Insertion socket until it clicks. Pull back gently to
make sure the contact is locked in place.
1. Make sure the connector has a wire seal
attached to the connector back. See
Figure 7-45.
Seals
1. Use a wire seal at the back (wire end) of
each connector half. See Figure 7-47.
2. Plug unused pin positions with sealing
plugs.
Figure 7-45. Wire Seal
2. If re-inserting a wire previously removed,

check the pin contact locking lances to
make sure they are extended to their
original position. See Figure 7-46. Figure 7-47. Sealing Plug
3. Align the split tapered end of the sealing

plug with the unused opening in the wire
seal. Push the plug through the wire seal
into the connector until it snaps into
position.

4. Sealing plugs can be removed by pulling

with needle-nose pliers while grasping the
wire seal and connector.
5. Use an interface seal between pin and jack
halves of the connector. To prevent
damage to the seal, use the matching
connector cap to slide the interface seal
over the contact silos on the pin housing.
See Figure 7-48.
Figure 7-48. Interface Seal
6. When mating connectors, make sure

polarized silos are correctly oriented. Push
pin and jack halves of the connector
together until locking latches engage. See
Figure 7-49.
Figure 7-49. Latching Amp Connector

AMP Harness/Traction Power

Amplifier Connector
Connector Components
(PT-1 on Traction Power

Amplifier)
(JT-1)
74570_001.TIF
Figure 7-50. Power Amp Connector Components
Disassembly (Contact Removal) Contact Insertion

1. Insert a 4.8 mm screwdriver blade between The axial concentricity of the crimped contact
the mating seal and one of the red wedge must fall into an area defined by a 2 mm
lock tabs. See Figure 7-50. diameter cylinder whose center is the centerline
2. Pry the wedge lock to the open position. of the contact front end. See Figure 7-52.
3. While rotating the wire back and forth over
a half turn (1/4 turn in each direction), Assembly
gently pull the wire until the contact is
removed. See Figure 7-51. Make sure the wedge lock is open.
1. To insert a contact, push it straight into
the appropriate circuit cavity as far as it
will go. See Figure 7-52. (a) and (b).
2. Pull back on the contact wire with a force
of 1 or 2 lbs. to make sure the retention
fingers are holding the contact. See
Figure 7-52. (c).
74570_001.TIF
Figure 7-51. AMP JPT1 Connector

74570_001.TIF
Figure 7-52. Contact Insertion
3. After all contacts have been inserted, the

wedge lock must be closed to its locked
position. Release the locking latches by
squeezing them inward. See Figure 7-53.
74570_001.TIF
Figure 7-53. Wedge Lock Latches

Be very careful when putting the wedge

lock in the locked position. Forcing the
wedge lock can cause damage to the
connector. Make sure the wedge lock is
aligned correctly. If resistance is felt,
slightly adjust the wedge lock until it
slides in freely.
4. Slide the wedge lock into the housing until

it is flush with the housing. See
Figure 7-54.
74570_001.TIF
Figure 7-54. Wedge Lock Flush With Housing
Testing
Do not pierce wire insulation with a sharp point

while troubleshooting.
The wedge lock has slotted openings in the

forward (mating) end. These slots accommodate
circuit test tabs that are approximately 3.3 by
0.6 mm and prevent damage to the receptacle.
For circuit testing in the field, use a flat probe
such as a pocket knife blade. Do NOT use a
probe with a sharp point.


Hydraulic Components

Manifold Solenoids,
Fittings, and
Attachments
Table 7-2. provides torque specifications to be
followed when performing maintenance on
manifold components.
Table 7-2. Main Manifold Torque Specifications
Valve/Fitting Torque Coil Nut Torque

Component Function
ft. lb. (Nm) ft. lb. (Nm)
SOL1 Load Hold 60 (80) 5 (6.8)
SOL2 Lift/Lower 100 (135) Finger Tight
SOL3 Lift Relief 37 (50) Finger Tight
SOL4 Priority Bypass 37 (50) 12 (16)
SOL5 Aux Proportional Relief 25 (35) 5 (6.8)
SOL6 Aux Select 60 (80) 10 (14)
SOL7C/7R HSA (4200 Only) 27 (35) 7 (9.0)
SOL9L/9R L/R Sideshift 27 (35) 7 (9.0)
SOL10 Tilt 25 (35) 5 (6.8)
CV-1 Check Valve 35 (47) N/A
N/A Filter Plug 30 (40) N/A
CB1, CB2 Counterbalanced Check Valve 35 (47) N/A

SSR
Hydraulic Filter and Plug
SOL7R SOL9L SOL9R
SOL6
G2
AC
SOL10 SOL7C
CB2 SOL2
CB1
Figure 7-55: Hydraulic Manifold (1 of 5)

Expansion
Plugs
CV-1
Figure 7-56: Hydraulic Manifold - Bottom View (2 of 5)

SOL9L SOL9R
SOL7R SOL10 SOL7C

SSR
P1 SSL
AA
G1
CYL
TC TR
AUX-P AR

SOL5
SOL4
SOL1
SOL3
TANK CYL-P

Hydraulic Fluid Model 4100

the key switch ON. Step on the deadman
Fluid Level pedal and lift the forks 6 to 12 in. (150 to
300 mm) off the ground.
To check the level of the hydraulic fluid in the
system: 2. Loosen (do not remove) the bleed screw on
the lift cylinder to let any air escape. See
1. Tilt the mast all the way back.
Figure 7-61. Hold a shop rag close to and
2. Unscrew the fill cap from the hydraulic beneath the bleed screw to keep any
reservoir. hydraulic fluid from spraying out.
3. The hydraulic fluid should be 1/2 to 1 in. 3. When all of the air has escaped and
(12.6 to 25.4 mm) above filler screen. See hydraulic fluid starts coming out of the
Figure 7-60. Reservoir capacity is approx. bleed screw hole, securely tighten the
5.0 gal (22 liters). bleed screw.
4. Lower the forks all the way to the floor.
NOTE: When bleeding the hydraulic system,
bleed all cylinders.
5. Bleed the auxiliary system:
a. Tilt the mast all the way forward and
backward several times.
b. If the lift truck has sideshift, shift the
carriage all the way to the left and right
several times.
6. Check the hydraulic fluid level.
7. Add hydraulic fluid as needed.
78D14083S.TIF
Figure 7-60: Hydraulic Fluid Filler Screen
Selecting Hydraulic Fluid Type

See Lubrication Specification Chart on
page A-2.
Bleeding the Hydraulic System

You must bleed the hydraulic system whenever
you: Bleed Screw
• Change the hydraulic fluid and filter
• Change a hydraulic hose
• Disconnect a hydraulic fitting
• Notice that the load is bouncing
• Remove a hydraulic cylinder
• Remove a hydraulic pump 78D14012S.TIF
Figure 7-61: Cylinder Bleed Screw

• Remove the hydraulic reservoir

Model 4200
1. Without a load extend the free lift cylinder
and continue to extend the main lift
cylinders to 90% of full stroke. Retract all
cylinders completely. Repeat three times.
2. Extend the cylinders without a load at 50%
lift speed, then build full system pressure
at the end the main lift cylinder stroke.
Retract cylinders. Repeat four times.
3. Cycle the mast with a half load (50% mast
rated capacity) through full cylinder
extension several times. The cylinders
should extend smoothly. Repeat the steps
if cylinder extension is not smooth.

Pressure Relief Valve 7
Measuring System Pressure

NOTE: To measure the system pressure, you
will need a calibrated pressure gauge
capable of measuring 3000 psi (20684
kPa) at mid-range and the coupler to
attach to the manifold.
2. Remove the front covers.
3. Connect the pressure gauge to the test
port (G1) on the main hydraulic manifold.
the key switch ON. Figure 7-62: Uninstalled Circlip
5. Place a maximum rated load (or heaviest 2. Elevate the forks until the upper limit is
load available) on the forks. reached.
6. Elevate the forks. Record the pressure 3. Continue to try and elevate. Using a 5/64
required to lift the load. Make sure the hex key, push in and turn the lift pressure
load is elevated near the maximum rated adjusting screw to obtain a pressure
height for that load when taking the reading 10% greater than that previously
pressure reading. recorded, ±50 psi.
7. Lower the forks and remove the load.
NOTE: A 5K lift truck may need +50 psi over
the 10% value.
Pressure Adjustment
NOTE: Make sure to push the adjuster in when
turning.
Be very careful not to lose the retaining NOTE: The adjuster is very sensitive, and
circlip on SOL3. changes pressure very quickly with very
little movement.
1. Use a jeweler’s screwdriver or other small 4. Turn the adjusting screw clockwise to
tool to remove the retaining circlip on increase pressure; counterclockwise to
SOL3. See Figure 7-62. Save the clip to decrease pressure.
reinstall after pressure is set. 5. Reinstall the circlip.
6. Check the pressure again. If the value has
changed, repeat this procedure until the
correct pressure reading is obtained.
8. Remove the pressure gauge.
9. Reinstall the front covers.

Cylinder Service Free Lift Cylinder - Install the plunger

retainer on the plunger. Install the
plunger/piston assembly into the cylinder
Main or Free Lift Cylinders - shell.
Model 4200 • TF/TT Masts - Pour 25 to 30 cc
hydraulic oil into the cylinder cavity
1. Remove the cylinder from the mast. See between the shell and rod. Tighten the
Cylinder Removal/Installation on retainer to 280 to 300 ft. lb. (380 to
page 7-80. 407 Nm) using the claw spanner
2. Use a spanner wrench to remove the wrench and a strap wrench.
retainer. • Quad Masts - Pour 120 cc hydraulic oil
3. Remove the plunger/piston assembly from into the cylinder cavity between the
the shell. To remove the piston, refer to shell and rod. Tighten the retainer to 95
Piston Removal. to 125 ft. lb. (129 to 169 Nm) using the
claw spanner wrench and a strap
4. Remove the Hydraulic Fuse or fitting as
wrench.
equipped.
5. Inspect all components for nicks or burrs.
Minor nicks or burrs can be removed with Piston Removal
400-grit emery cloth. 1. Remove the plunger/piston assembly from
NOTE: Minor nicks are those that will not the cylinder shell.
bypass oil when under pressure. If they 2. Use a strap wrench and 400-grit emery
cannot be removed with emery cloth, cloth to secure the plunger while turning
replace the part. the piston with a pin type spanner wrench.
See Figure 7-63.
6. Replace the retainer and piston seals,
back-up rings, O-rings and bearing. 7
Lubricate the new seals with petroleum

jelly prior to installation.
NOTE: Observe correct seal direction. The
cylinder will not operate correctly if the
seals are installed backwards.
When replacing the piston check valve
O-ring, make sure the check valve is
reinstalled with the arrow pointed in the
correct direction. MA0677 eps
Figure 7-63: Piston Removal
7. Main Lift Cylinder - Install the plunger
3. Turn the piston until the snap wire end is
retainer on the plunger. Install the
visible through the hole. Use a screwdriver
plunger/piston assembly into the cylinder
to start the wire end out the hole. Turn the
shell. Using the claw spanner wrench and
piston to feed the wire out.
a strap wrench, tighten the retainer to:
4. Pull the piston from the plunger.
• TF Mast - 225 to 250 ft. lb. (305 to
339 Nm) 5. For reassembly, reverse the removal
procedure. Install a new snap wire when
• TT Mast - 180 to 200 ft. lb. (244 to
installing the piston.
271 Nm)
• Quad Mast - 95 to 125 ft. lb. (129 to
169 Nm)


Mast
Mast

Mast
Mast Service 10. Turn the key switch OFF and disconnect
11. Wrap a chain or lifting strap around the
Mast Removal top of the mast. Attach the chains or
straps to a hoist.
12. Lift the hoist just enough to take the slack
out the chain or strap.
A hoist or lift truck of suitable capacity is
required for this procedure. 13. Count the number of threads visible in
back of the tilt cylinder jam nut for
1. Turn the key switch OFF and disconnect reference in re-assembly. Loosen tilt
the battery connector. cylinder jam nuts. Remove the piston from
the tilt cylinder pivot block.
2. Remove the console, front covers, and
forks. 14. Reconnect the battery connector and turn
the key switch ON. Actuate the tilt control
3. Reconnect the battery connector and turn and retract the tilt rams.
the key switch ON.
4. Elevate the fork carriage approx. 18 in. the battery connector.
(450 mm). Place blocks under the fork
carriage. Lower the fork carriage onto the 16. Carefully lay the tilt cylinder down on the
blocks. brake assembly. Remove cable ties.
Disconnect the main feed hose.
5. Turn the key switch OFF and disconnect Disconnect both auxiliary function hoses.
the battery connector. Cap all hoses.
6. Remove the lower mounting bolt only from 17. Remove the upper mounting bolt securing
each mast bearing cap. Do not remove the the mast pivot bearing cap on each drive
upper bolt. See Figure 7-64. unit. Remove the mast pivot bearing cap.
18. Use the hoist or other lift truck to lift the
mast just enough to allow it to be moved
away from the tractor.
19. Have wood blocks positioned to support
the mast off the floor.
20. Carefully lower the mast onto the support
blocks with the fork carriage facing down.
21. Note the number of shims between the
Oilite bearings and mast. See Figure 7-65.
Drive Unit
Lower Mounting Bolts Shims
78D14030S.TIF
Figure 7-64: Mast Pivot Bearing Caps Drive Wheel

Mast
the key switch ON.
8. Elevate the fork carriage, remove the
blocking, and lower the fork carriage all
the way to the floor. Verify that the mast is Pivot
in a vertical position. Bearing Cap
Oilite Bearing
9. Position the lift truck beneath the hoist. 78D14035S.TIF
Figure 7-65: Mast Pivot Bearing Parts

Mast
Mast Installation 16. Reconnect the battery connector and turn

the key switch ON.
17. Elevate the fork carriage and remove any
blocking.
A hoist or lift truck of suitable capacity is 18. Install the forks.
required for this procedure.
19. Bleed the hydraulic system. See Bleeding
1. Make sure the pivot bearings are shimmed the Hydraulic System on page 7-62.
as they were when the mast was removed. 20. Install the covers.
2. Wrap a chain or lifting strap around the
top of the mast. Attach the chains or Mast Inspection - Model 4200
straps to the lifting device.
3. Slowly lift the mast up and off the wooden During normal Scheduled maintenance checks,
blocks. pry between the upright and load roller so the
opposite load roller is tight against the upright.
4. Slowly move the mast towards the truck.
Measure the clearance for the pair of rollers at
5. Position the lower pivot bearings on the XXX shown in Figure 7-66.
mast at the same height as the pivot yokes
on the drive units. Pry Here
Load Roller
6. Carefully engage the mast pivot bearings
with the yokes on the drive unit.
7. Place the mast pivot bearing caps over
both mast pivot bearings. Apply
thread-locking compound (P/N 990-536) X
X
to the mast mounting bolts and install. X
8. Reconnect the hydraulic hoses and cable

tie the auxiliary hoses.
the key switch ON.
10. Slowly extend the tilt rams until you are .06 in.
(1.5 mm)
able to thread the piston into the tilt Max.
cylinder pivot block. Screw the jam nut

snug against the pivot block. Adjust so the
number of threads showing behind the
jam nut is the same as before removal.
11. Remove the lifting device and any
chains/straps used to lift the mast.
12. Slowly elevate and tilt the mast. Check for
any hydraulic leaks.
MA1174.eps
13. Elevate the fork carriage approx. 18 in. 7MA1174.EPS
(450 mm). Place blocks under the fork Figure 7-66: Load Roller Clearances (TT Mast shown)
carriage. Lower the fork carriage onto the
blocks. Each pair of load rollers on the uprights and
carriage should be shimmed so that a total side
14. Turn the key switch OFF and disconnect to side clearance no greater than 0.06 in.
the battery connector. (1.5 mm) occurs at the tightest point
15. Torque pivot bearing cap bolts to 43 ft. lb. throughout the travel of the member.
(60 Nm).

Mast
Model 4200 TF Mast 4. Install the free lift chains to the inner
upright crossmember chain anchors.
Disassembly 5. Install the free lift cylinder.
6. Install the carriage. Refer to Carriage
1. Remove the mast assembly from the truck.
Installation - Mast on Floor on page 7-78.
Refer to Mast Removal on page 7-68.
7. Turn the mast over.
2. Remove the main lift cylinders from the
mast. Refer to Main Lift Cylinder Removal 8. Install the main lift cylinders. Refer to
- Mast on Floor on page 7-80. Main Lift Cylinder Installation - Mast on
Floor on page 7-80.
3. Turn the mast over.
9. Install the mast to the truck. Refer to Mast
4. Remove internal reeving hoses.
Installation on page 7-69.
5. Remove the free lift cylinders from the
10. Install the internal hose reeving hoses (if
mast.
equipped). Refer to Internal Reeving -
6. Remove the carriage from the mast. Refer Model 4200 TF Mast on page 7-84.
to Carriage Removal - Mast on Floor on
11. Adjust the free lift chains.Refer to Lift
page 7-78.
Chain Adjustment - Model 4200 on page
7. Remove the cotter pins and pins fastening 7-92.
the free lift chains to the inner upright
12. Check for mast skewing. Refer to Mast
chain anchors
Skewing - Model 4200 on page 7-76.
8. Attach an overhead hoist to the inner
upright crossmember.
Model 4200 TT Mast
9. Roll the inner upright downward to expose
the upper and lower load rollers. Remove
the load rollers. Note the number of shims
Disassembly
behind each load roller. 1. Remove the internal hose reeving sheaves
10. Slide the inner upright out of the top of the and hoses from the mast.
outer upright. 2. Remove the mast assembly from the truck.
11. Inspect upright. Refer to Upright Inspection Refer to Mast Removal on page 7-68.
- Model 4200 on page 7-76. 3. Remove the main lift cylinders from the
mast. Refer to Main Lift Cylinder Removal
Reassembly - Mast on Floor on page 7-80.
4. Remove the free lift cylinders from the
1. Lubricate the outer upright rails. See mast.
Lubrication Specification Chart on
page A-2. 5. Remove the carriage from the mast. Refer
page 7-78.
upright. Install the inner upright through
the top of the outer upright. 6. Remove the pins fastening the main lift
chains to the inner upright chain anchors.
3. Assemble the load rollers on the stub Pull the main lift chains back through the
shafts using the correct number of shims. chain sheaves.
The shims should be installed to provide a
total side to side clearance no looser than
0.06 in. (1.5 mm) at the tightest point
throughout the travel in the upright. Use
an equal amount of shims on each side.
NOTE: Roll the inner upright past the thrust
plugs before checking roller clearances.

Mast
in the upright. Use an equal amount of

shims on each side.
The chain anchor nuts should be used NOTE: Roll the upright past the thrust plugs
one time only and be replaced after before checking roller clearances.
removal.
5. Lubricate the intermediate upright rails.
See Lubrication Specification Chart on
7. Remove the main lift chain anchors (long
page A-2.
anchors) from the inner upright lower back
side. Tag the anchors for reassembly. 6. Attach an overhead hoist to the inner
upright. Install the inner upright through
8. Remove the free lift cylinder supply hose
the top of the intermediate upright. Adjust
and sheave. Remove the main lift chain
thrust plugs with shims as required.
sheaves.
7. Assemble shims and load rollers to the
9. Roll the inner upright downward to expose intermediate upright top and inner upright
the inner and intermediate upright load lower stub shafts. The shims should be
rollers. Remove the load rollers. Note the installed to provide a total side clearance
number of shims behind each load roller. no looser than 0.06 in. (1.5 mm) at the
10. Attach an overhead hoist to the inner tightest point throughout the travel in the
upright. Remove the inner upright through upright. Use an equal amount of shims on
the top of the intermediate upright. each side.
11. Remove the main lift chain anchors (long NOTE: Roll the upright past the thrust plugs
anchors) and chains from the outer upright before checking roller clearances.
crossmember. Tag the anchors for
8. Install the chain sheaves and free lift hose
reassembly.
sheave to the intermediate upright. Torque
12. Roll the inner upright downward to expose the capscrew to 26 to 30 ft. lb. (35 to
the intermediate and outer upright load 40 Nm).
rollers. Remove the load rollers. Note the
9. Install the main lift chain anchors (long
number of shims behind each load roller.
anchors) and chains to the outer upright
13. Attach an overhead hoist to the crossmember using new nuts.
intermediate upright. Remove the 10. Install the chain anchors (long anchors) to
intermediate upright through the top of the the back side of the inner upright lower
outer upright. crossmember using new nuts.
11. Pull the main lift chains over the chain
Reassembly sheaves and attach to the lower inner
1. Lubricate the outer upright rails. See upright chain anchors.
Lubrication Specification Chart on 12. Install the free lift cylinder supply hose
page A-2. clamp on the outer upright and route hose
2. Attach an overhead hoist to the over the sheave on the intermediate top
intermediate upright. Install the upright.
intermediate upright through the top of 13. Install the carriage. Refer to Carriage
the outer upright. Installation - Mast on Floor on page 7-78.
3. Install the thrust plugs. 14. Install the free lift cylinders.
4. Assemble shims and load rollers to the 15. Install the main lift cylinders. Refer to
outer upright and lower intermediate Main Lift Cylinder Installation - Mast on
upright stub shafts. The shims should be Floor on page 7-80.
installed to provide a total side to side
16. Install the mast to the truck. Refer to Mast
clearance no looser than 0.06 in. (1.5 mm)
Installation on page 7-69.
at the tightest point throughout the travel

Mast
17. Adjust the main lift and free lift chains. 2. Remove the mast assembly from the truck.
See Lift Chain Adjustment - Model 4200 Refer to Mast Removal on page 7-68.
on page 7-92. 3. Remove the main lift cylinders from the
18. Check for mast skewing. Refer to Mast mast. Refer to Main Lift Cylinder Removal
Skewing - Model 4200 on page 7-76. - Mast on Floor on page 7-81.
19. Install the internal reeving sheave and 4. Using an overhead chain hoist, turn the
hoses (if equipped). Refer to Internal mast over (face up).
Reeving - Model 4200 TT Mast on page 5. Remove the free lift cylinder from the
7-86. mast. Refer to Free Lift Cylinder Removal -
Mast on Floor on page 7-81.
Quad Mast 6. Remove the carriage from the mast. Refer
Disassembly page 7-78.
7. Remove the free lift chain anchors and
NOTE: Quad Mast uprights require complete chains from the inner upright center
disassembly in order to service load crossmember and tag for reassembly.
rollers, thrust plugs/blocks, and
chain/hose sheaves. 8. Disconnect the free lift cylinder hose from
the tube and remove the stop/hose
Refer to Figure 7-67. bracket/tube assembly.
1. Remove the internal hose reeving from the

mast while it is on the truck.
8 Inner 12 12
Intermediate
Upright
9
10 Thrust
Plug
7 10 Thrust
Plug
Shim
Inner
Main Lift
Chains
11
10
10
MA0244.eps
12 9
7 12
Free Lift
Chains
MA0078.eps
Figure 7-67: Quad Mast Disassembly

Mast
9. Disconnect the inner main chain anchors Remove the upper rollers and thrust
from the lower end of the inner upright blocks from the outer upright. Note the
and the upper end of the outer number of shims behind each roller and
intermediate upright. thrust block for reassembly.
10. Move the inner upright downward. Remove 20. Attach an overhead hoist to the outer
the free lift hose sheave, hose, and main intermediate upright and remove it
chain sheaves at the top of the inner through the top end of the outer upright.
intermediate upright.
NOTE: The lower end of the inner upright must Reassembly
be raised slightly to clear the inner
1. Lubricate the full length of the outer
intermediate upright lower
upright rails. See Lubrication Specification
crossmember.
Chart on page A-2.
11. Remove the inner main lift chains and tag 2. Attach an overhead hoist to the outer
for reassembly. intermediate upright and install it through
12. Remove the load rollers from the lower end the top of the outer upright. Position it out
of the inner upright. Remove the load the lower end of the outer upright approx.
rollers and thrust plugs from the upper 6 in. (15 cm).
end of the inner intermediate upright. Note 3. Assemble shims, load rollers and thrust
the number of shims behind each for blocks to the upper end of the outer
reassembly. upright. Assemble shims and load rollers
13. Attach an overhead hoist to the inner to the lower end of the outer intermediate
upright and remove it through the top end upright.
of the inner intermediate upright. Roller Shimming - Install shims to provide
NOTE: The stub shafts on the lower end of the a total side-to-side clearance of 0.06 in.
inner upright come out of the inner (1.5 mm) max. at the tightest point
intermediate upright between the rail throughout the travel of the upright. See
cutout and the stub shaft. Figure 7-68. Pry between the upright and
the load roller so that the opposite load
14. Remove the outer main lift chain anchors roller is tight against the upright. Measure
from the lower end of the inner the clearance for the pair of rollers at the
intermediate upright and the top end of XXX shown. Use an equal number of
the outer upright. Set the chains aside and shims on each side.
tag for reassembly.
NOTE: Roll the uprights past installed thrust
15. Remove the lower stop from the outer plugs/blocks before checking load roller
intermediate upright. clearance.
16. Remove the chain sheaves from the outer
Thrust Plug/Block Replacement - Install
thrust plugs/blocks to provide a clearance
17. Roll the inner intermediate upright of 0.06 in. (1.5 mm) max. between an
downward and remove the lower rollers. upright and its corresponding thrust
Remove the upper rollers and thrust plugs plug/block. See Figure 7-69. Pry between
from the outer intermediate upright. Note the upright upper crossmembers. Measure
the number of shims behind each roller for the clearance at the XXX shown to
reassembly. determine which thickness thrust
18. Attach an overhead hoist to the inner plug/block to use. Thrust plugs/blocks
intermediate upright and remove it may be shimmed as required.
through the top end of the outer
19. Roll the outer intermediate upright
downward and remove the lower rollers.

Mast
7
4. Lubricate the full length of the outer
intermediate upright rails. See Lubrication
1 4 Lube
Specification Chart on page A-2 and
Figure 7-68.
Upright 5. Attach an overhead hoist to the inner
Rails
intermediate upright and install it through
the top end of the outer intermediate
upright. Position it out the lower end of the
outer intermediate upright approx. 6 in.
(15 cm).
6. Install shims and load rollers to the lower
end of the inner intermediate upright.
Install shims, load rollers and thrust plugs
Upright to the upper end of the outer intermediate
Rail upright. Refer to step 3 for roller shimming
Shim and thrust plug clearance measurement.
7. Install the chain sheaves to the upper end
Load
Rollers of the outer intermediate upright. Install
the outer main lift chain anchors and
chains over the outer intermediate upright
chain sheaves.
3
.06 in.
(1.5 mm)
Max. MA0259.eps
Figure 7-68: Load Roller Clearance and Channel Lubrication
3
Thrust Thrust
Plugs Block
2
.06 in.
(1.5 mm)
Max.
2 Thrust
Block
Inside
of Rail
Outer
3 Upright
MA0246.eps
Outer
Intermediate
Upright
Figure 7-69: Outer Intermediate Upright Installation

Mast
8. Install the outer main lift chain anchors inner intermediate upright. Position it out
(long anchors) to the lower end of the inner the lower end of the inner intermediate
intermediate upright. upright approx. 6 in. (25 cm).
9. Install the lower stop on the outer 14. Assemble shims and load roller to the
intermediate upright. Torque the capscrew lower end of the inner upright. Assemble
to 81-88 ft. lb. (110-120 Nm). shims, load rollers, and thrust plugs to the
10. Install the main chain sheaves, free lift upper end of the inner intermediate
sheaves, and hose in the inner upright. Refer to step 3 for roller shimming
intermediate upright. Torque the retainer and thrust plug clearance measurement.
capscrews to 26-30 ft. lb. (35-40 Nm). 15. Install the inner main lift chain anchors
11. Install the upper inner main chain (long anchors) on the back side, lower end
anchors to the outer intermediate upright. of the inner upright and connect the inner
Install the free lift hose bracket and tube. main lift chains.
12. Lubricate the inner intermediate upright 16. Install the stop/hose bracket/tube
rails. See Lubrication Specification Chart assembly on the lower end of the inner
on page A-2. upright. Torque the capscrews to
81-88 ft. lb. (110-120 Nm).
upright and install through the top of the
14
13 Thrust
Plug
15 Thrust
13 Plug
Shim
MA0269.eps
14
14
Inner
Upright
16
MA0251.eps
Figure 7-70: Inner Upright Installation

Mast
17. Install the free lift chain anchors (short Upright Inspection - Model
anchors) and chains to the inner upright
center crossmember.
4200
18. Install the free lift cylinder supply hose to Inspect the thrust plugs. See Figure 7-72.
the free lift cylinder tube. Leave the tubing
7
clamp loose.
19. Install the carriage. See Carriage 4
Installation - Mast on Floor on page 7-78.
20. Install the free lift cylinder. See Free Lift Thrust Plug
Cylinder Installation - Mast on Floor on
page 7-82. Connect the tube to the
cylinder fitting and tighten the tubing
clamp.
21. Place a 2x4 in. (5x10 cm) wood block
between the outer and outer intermediate 1
lower crossmembers to prevent upright MA1192.eps
movement.
22. Turn the mast over (face down), rotating it
on its lower end. Make sure the mast is
re-blocked in a level position. See
Figure 7-71.
Figure 7-72: Upright Inspection
If the wear surface is worn to less than 0.06 in.

22 21 (1.5 mm), they should be replaced.
Inspect the lift chains. See Lift Chains on

page 4-10.
MA0254.eps
Mast Skewing - Model 4200
Figure 7-71: Blocking Uprights Before Turning Mast Over
1. Extend the mast to the full lift height.
23. Install main lift cylinders. See Main Lift a. If the mast kicks to the right at full
Cylinder Installation - Mast on Floor on extension, a shim must be installed to
page 7-81. the right hand main lift cylinder rod.
24. Install the Mast. Refer to Mast Installation b. If the mast kicks to the left at full
on page 7-69. extension, a shim must be installed to
25. Install the internal hose reeving. See Quad the left hand main lift cylinder rod.
Mast Internal Reeving on page 7-88.
2. Place a 4x4x20 in. (10x10x50 cm) wood
26. Adjust the main and free lift chains. See block between the upper intermediate and
Lift Chain Adjustment - Model 4200 on the upper outer crossmember. Lower the
page 7-92. mast onto the block.
27. Check the mast for skewing. See Mast
Skewing - Model 4200.

Mast
3. Remove the bolt from the cylinder to be

adjusted. Activate the lower control to allow
the center (free lift) cylinders to fully
retract. Tap the main lift cylinder rod down
past the cylinder mount to install the shim.
See Figure 7-73.
Bolt
Shim
Main Lift Cylinder
Figure 7-73: Shim Installation
4. Carefully activate lift to raise the main lift

cylinder back into the cylinder mount.
Reinstall the bolt.
5. Repeat steps 3 and 4 until skewing is
removed.

Mast
Carriage - Model 4200 3. Disconnect the internal reeving hoses from

the carriage fittings (if equipped). Plug the
hose ends.
Carriage Removal - Mast on 4. Remove the socket head stops on the inner
Floor upright lower crossmember. For
reassembly, tighten to 80 ft. lb. (110 Nm).
TF Mast 5. Roll the carriage to the bottom end of the
mast.
1. Remove the mast from the truck. See Mast
6. Attach an overhead hoist to the carriage
Service on page 7-68.
side bars and remove the carriage through
2. Remove the cotter pins and pins fastening the bottom end of the mast.
the chains to the chain anchors.
7. Remove the load rollers, noting the
3. Disconnect the internal reeving hoses from number of shims behind each roller for
the carriage fittings (if equipped). Plug all reassembly.
hose ends.
4. Roll the carriage to the bottom of the mast. Carriage Installation - Mast on
5. Attach an overhead hoist to the carriage Floor
fork bars. Remove the carriage through
the bottom of the mast. Reverse the removal procedure and do the
6. Note the number of shims located behind following:
each load roller for reassembly. • Inspect the carriage.
• Lubricate the inner upright rails. Refer to
TT Mast Lubrication Specification Chart on page
1. Remove mast from truck. See Mast Service A-2.
on page 7-68. • Assemble shims and load rollers on the
2. Remove chain anchor nuts. carriage stub shafts. The shims should be
installed to provide a total side to side
NOTE: Install new self-locking chain anchor clearance no looser than 0.06 in. (1.5 mm)
nuts during reassembly. at the tightest point throughout the travel
3. Remove the chain anchors. of the carriage. Use an equal amount of
shims on each side.
4. Disconnect the internal reeving hoses for
the carriage fittings. Plug the hose ends. • TT and Quad Masts - Adjust the carriage
side thrust rollers for unrestricted
5. Roll the carriage to the bottom of the mast. clearance along the travel of the carriage.
6. Attach an overhead hoist to the carriage Turn the eccentric mount base of each
fork bars. Remove the carriage through roller toward the upright rail to decrease
the bottom of the mast. clearance. See Figure 7-74. Torque the
7. Note the number of shims located behind capscrews to: TT Mast 63-70 ft. lb.
each load roller for reassembly. (85-95 Nm); Quad Mast 79-80 ft. lb.
(95-110 Nm).
Quad Mast • Check and adjust the free lift chains. See
Lift Chains on page 7-92.
1. Remove mast from truck. See Mast Service
NOTE: On TT Mast carriages, make sure the
on page 7-68.
retainer bolts are torqued to at least 84
2. Remove the pins fastening the free lift in. lb. (9.5 Nm). If retainer bolts or plate
chains to the carriage chain anchors. are damaged, replace them.

Mast
7MA0927.EPS
Left Right
Roller Roller
Carriage Side
Thrust Rollers
Important:
Adjust roller
toward rail in
Direction shown.
Figure 7-74: Carriage Side Thrust Rollers - TF Mast

Mast
Cylinder TT Mast - Model 4200

Removal/Installation Main Lift Cylinder Removal - Mast on
Floor
TF Mast - Model 4200 1. Remove the mast from the truck. See Mast
Main Lift Cylinder Removal - Mast on 2. Lay the mast down on wooden blocks.
Floor Extend inner and intermediate rails to
expose the lower fittings on the main lift
1. Remove the mast from the truck. See Mast cylinders.
3. Disconnect the cylinder supply hoses from
2. Lay the mast down on wooden blocks as the cylinder inlet ports. Remove the
shown. Block under the outer upright so fittings from the cylinder ports and install
the inner upright will be free to move. The plug fittings.
carriage must be positioned between the
blocks and free to move. 4. Remove bolts fastening the cylinder rods
to the intermediate upright. Remove the
3. Disconnect the cylinder supply hoses from
bolts at the base of the cylinders that
the cylinder inlet ports. Remove the special
attach the cylinders to the lower outer
long fittings from the cylinder ports and
cross member.
install plugs
5. Remove nuts from chain mounts. Remove
4. Disconnect the hose and tube from the mount from cylinder and lay over carriage.
cylinder plungers.
6. Pull the inner and intermediate upright
5. Remove the snap rings fastening the outward as required to allow the main lift
cylinder rods to the inner upright. cylinders to be removed.
6. Pull the inner upright outward 2 ft. (50
7. Lift the cylinder from the base mount and
cm).
angle inward to remove.
7. Lift the cylinder from the base mount and 8. Note the number of shims on each cylinder
angle inward to remove through the gap at rod.
the top of the uprights.
8. Note the number of shims (if equipped) on Main Lift Cylinder Installation - Mast
each cylinder rod.
on Floor
9. For reassembly, reverse the above
procedures except as follows: For installation, reverse the Removal procedure.
Bleed the system. See Bleeding the Hydraulic
Main Lift Cylinder Installation - Mast System on page 7-62.
on Floor
Free Lift Cylinder Removal - Mast on
For installation, reverse the Removal procedure. Truck
System on page 7-62. 1. Lower the carriage completely. Remove
forks or attachment if equipped. Make
sure the free lift cylinder is completely
retracted. Attach an overhead hoist to the
top carriage bar.

Mast
2. Insert a 2 x 4 in. (5 x10 cm) wood block

between the lower cross members of the
outer upright and outer intermediate
The carriage must be supported by a upright to prevent uprights from moving
block while removing the cylinder to out the bottom of the mast.
avoid possible injury. 3. Lay the mast face-down on wood blocks.
Block under each end of the outer upright
2. Raise the carriage to the center of the so the mast is level and the inner uprights
cylinder to slacken the chains and internal and carriage are free to move.
reeving hoses (if equipped). Block the 4. Using a 1 in. wrench, disconnect the
carriage in place using a 4 x 4 x 24 in. (10 x cylinder supply hoses from the cylinder
10 x 60 cm) wood block between the lower inlet ports. Using a 1 in. socket, remove
carriage bar and the floor. the special long fittings from the cylinder
3. Remove the chain guards from the ports and install plugs.
crosshead. 5. Remove the snap ring from the top of the
4. Remove the snap ring fastening the left hand cylinder rod, the tube, and fitting
crosshead to the cylinder rod. from the top of the right hand cylinder rod.
Plug the cylinder port.
5. Pull the crosshead with chains and hoses (if
equipped) off the cylinder rod and lay over 6. Roll the uprights through the top of the
the upper carriage bar. mast 1 to 2 ft. (30 to 60 cm) and disengage
the cylinder rods from the outer
6. Remove cylinder mounting bolts, keeping intermediate upright.
the shims for reassembly.
7. Lift the cylinder from its base mounting
7. Pry the cylinder up out of the support boss in the outer upright and angle
casting to gain access to the cylinder hose inward. Remove the cylinders through the
fitting. Remove the hose from the 45° sides of the uprights.
fitting. Cap the fitting and plug the hose.
8. Note the number of shims (if equipped) on
8. Remove the cylinder from the mast from the each cylinder rod.
top.
Main Lift Cylinder Installation - Mast
Free Lift Cylinder Installation - Mast on Floor
on Truck
For installation, reverse the Removal procedure.
For installation, reverse the Removal procedure. Bleed the system. See Bleeding the Hydraulic
System on page 7-62.
Torque the chain guard capscrews to 48 to
52 ft. lb. (65 to 70 Nm). Free Lift Cylinder Removal - Mast on
Floor
System on page 7-62. 1. Remove the mast from the truck. See Mast
Quad Mast 2. Lay the Mast face-up, blocking under the
lower mounts so the mast is level.
Main Lift Cylinder Removal - Mast on 3. Roll the carriage upward to allow slack in
Floor the free lift chains and internal reeving.
4. Remove the snap ring fastening the
1. Remove the mast from the truck. See Mast
crosshead to the cylinder rod
5. Pull the crosshead with chains and hoses
of the cylinder rod.

Mast
6. Roll the carriage above the free lift

cylinder.
7. Using a 1 in. wrench, disconnect the tube
from the cylinder fitting. Cap the cylinder
fitting and plug the tube.
8. Using a 5 mm Allen wrench, remove the
cylinder strap.
9. Remove the cylinder from the mast.
Free Lift Cylinder Installation - Mast

on Floor
For installation, reverse the Removal procedure.

System on page 7-62.

Mast
Free Lift Cylinder Supply

Hose - Model 4200
Tracking and Tension Adjustment
1. Make sure the cylinder supply hose is not
twisted, and that it travels evenly in the
hose sheave.
2. Check the hose to make sure it is not
scuffing.
3. Adjust the hose by loosening the hose
clamp on the outer upright as shown in
Figure 7-75 and twisting the hose.
Free Lift
Hose Clamp
MA1157.eps
Figure 7-75: Free Lift Cylinder Supply Hose Adjustment
4. Tighten the clamp while holding the hose

in place.
5. Tension on the hose can be adjusted by
sliding the hose through the loosened
clamp as required.
NOTE: The hose and the clamp must be dry of
oil and water before inserting the hose
into the clamp.
6. After inserting the hose through the loose
clamp and tensioning the hose, snugly
tighten the two clamp bolts, then tighten
to 5.9 ft. lb. (8 Nm) with a torque wrench.

Mast
Hose Reeving capscrews to 25-30 ft. lb. (35-40 Nm).

Check and adjust hose clearances.
10. Install the bulkhead fittings to the bracket
Internal Reeving - Model 4200 with the securing nuts located on the top
TF Mast side. Install the hose ends to the fittings.
11. Move the lowering control valve and
NOTE: For double function or left hand internal
bracket to the back side of the center
reeving, a spacer is added on the left
crossmember. Torque the capscrews to
hand rear guide.
25-30 ft. lb. (35-40 Nm). Check and adjust
hose clearances.
Refer to Figure 7-76.
12. Raise and lower the mast several times to
1. Install the fittings on the carriage bracket.
make sure the hoses are tracking correctly
2. Install the front hose guide bracket to the in the guide brackets. Use the white line
back side of the inner upright cross on the hoses to detect twisting. Adjusting
member. Torque the capscrews to the hose ends with a slight amount of twist
48-52 ft. lb. (65-70 Nm). may improve hose tracking in the guides.
3. Install the rear hose bracket to the outer
upright by inserting the round bar at the
end of the bracket into the hole in the
upper outer.
4. Attach the lower end of the bracket to the
inside of the outer upright chain anchor
mounting leaving a gap between the top of
the bracket and the chain anchor mount.
The bracket should be parallel with the
upright. Torque the capscrew to
48-52 ft. lb. (65-70 Nm).
5. Remove the existing capscrew and guard
from one side of the cylinder crosshead.
Install the hose sheave and guard with the
hardware supplied. Tighten the capscrew
to a torque of 48-52 ft. lb. (65-70 Nm).
6. Install the hoses to the carriage fittings
with the white line facing outward.
7. Feed the hoses between the crosshead
guard and sheave. Raise the carriage just
above free lift. Route the hoses under the
front hose guide bracket. Install the hose
clamp. Pull on the hoses to remove slack.
Torque the capscrew to 25-30 ft. lb.
(35-40 Nm). Completely lower the carriage.
8. Route the hoses to the rear guide bracket.
The loop in the hoses should be 4 ±1 in.
(101 ±25 mm) below the bottom of the rear
bracket.
9. Install the hose clamps at the top of the
rear guide bracket. Make sure the loop is
the same for both hoses. Torque the

Mast
7
4
Hoses must not
contact bottom of
chain anchor mount.
Rear Hose
Guide Bracket
7
10
4
5 2 8 11
1 6
MA2146.eps
11
Left Hand
DETAIL A Guide Spacer
DETAIL C
Figure 7-76: Internal Reeving - TF Mast (Model 4200)

Mast
Internal Reeving - Model 4200

TT Mast
Bracket Installation
NOTE: For single function internal reeving,
perform the following procedure for the
left side only.
Refer to Figure 7-77.

1. Install fittings and caps to the carriage
termination bracket and install brackets
on carriage.
2. Install two tube assemblies on lower inner
cross member.
3. Install guard and sheave onto existing left
hand upper intermediate chain guard.
4. Install bracket (with sheave) to tapped
block located on upper intermediate cross
member. .
5. Install bracket and one clamp piece on

outer tab (on both sides of mast, left and
right).
Step 3
Step 5 Step 4
MA2971.eps
Step 2
Step 1
Figure 7-77: Bracket Installation - TT Mast (Model 4200)

Mast
Hose Tension 7
Rear Termination
1. Route hoses over upper intermediate
sheave and down to clamp mounted on
outer weldment. See Figure 7-78.
Between
2.0 and 3.1 in.
(50 and 80 mm)
movement
Clamp
Figure 7-79: Hose Tension - Rear Termination
Carriage Termination
1. Make sure carriage is correctly adjusted
for desired fork settings.
2. Mount carriage termination bracket (with
fittings installed) to carriage in the desired
hole (based on fork height setting). See
Figure 7-78: Rear Hose Termination Figure .
2. Loosely clamp hoses so that tension is 7
held when hoses are pulled through the

clamp.
3” Fork Height
3. Pull hoses tight so that when 4 to 6 lbs.
(1.8 to 2.7 kg) of horizontal force is applied 2” Fork Height
to the hoses at 24 in. (0.6 m) above the
clamp, the hoses move between 2.0 and
3.1 in. (50 and 80 mm). See Figure 7-79.
MA
Termination
Bracket
Figure 7-80: Bracket Installation
3. Route hoses over free lift crosshead sheave

and attach to fittings on carriage bracket.

Mast
4. After hoses are fully installed with 7 to Quad Mast Internal Reeving
10 lbs. (3.2 to 4.5 kg) of horizontal force at
a point midway between the upper integral 1. Install the shaft, sheave, and hose guards
sideshift cylinder block and crosshead to to the crosshead center plate. See
determine movement of the hoses (refer to Figure 7-82. Leave the capscrew and nut
Figure 7-81): finger tight to allow for hose installation.
• If movement is more than 2.3 in. 7
(60 mm), remove hoses from bracket

and move down one hole to increase
tension. 1
• If the movement is less than 1.2 in.
(30mm), remove the hoses from the
bracket and move up one hole to
decrease tension.
• If correct tension cannot be obtained,
hoses are incorrect length and must be
replaced.
MA0222.eps
Figure 7-82: Crosshead Center Plate Assembly
2. Install the carriage hose bracket to the

center tab on the lower carriage bar. See
Figure 7-83.
Hose
Hose movement
movement as
described in Step 4.
as described in
Section 4a or 4b
MA2972.eps
Figure 7-81: Hose Tension - Carriage Termination

3
Figure 7-83: Carriage Hose Bracket Installation

Mast
3. Install the fittings on the bracket. See 4. Make up two hose assemblies by
Figure 7-84. connecting the two hoses to the two long
• Single Function - Install the fittings to hoses. See Figure 7-86.
the left or right side location. Tighten 5. Install the shaft, sheave(s), shim and
the fittings finger tight. hardware to the inner intermediate
• Double Function - Install the fittings to upright chain sheave shaft. See
the left and right side location. Tighten Figure 7-85. Torque the capscrew to 37 ft.
the fittings finger tight. lb. (50 Nm).
6. Route the hose ends over the inner
7
intermediate upright sheave(s) down to the
OR inner upright bracket.
3
NOTE: The short hose routes over the cylinder
crosshead.
7. Position the hoses with the tabs on the
SINGLE DOUBLE inner upright bracket as shown in
FUNCTION FUNCTION Figure 7-86.
Figure 7-84: Fitting Installation
13
Outer
Outer 14
Upright
Intermediate
Upright
Inner
Intermediate
Upright
Upper
Hose
14 Guide
5 Double
Function 14
Single
Function
11
10
Lower
Hose
Guide
MA0225.eps
Figure 7-85: Hose Reeving Hardware Installation on Uprights

Mast
8. Loosen the crosshead cover plate carriage bracket fittings. Connect the hose
capscrew. Route the hoses up over the ends to the fittings leaving the hose ends
crosshead rollers. finger tight.
9. Completely lower the carriage. Route the
hoses down behind the carriage bar to the
16
6
8
Inner
Intermediate
Upright Sheave
SINGLE DOUBLE
FUNCTION FUNCTION
Long
Hose
Upper
8 12 Hose
Short Guide
Hose
15
17
7 Lower
Hose
Guide
Connect
4 hoses
SINGLE DOUBLE
FUNCTION FUNCTION
FRONT VIEW
Inner
Upright
Bracket
7 MA0257.eps
9
Carriage
Bracket
Fittings
SINGLE DOUBLE
FUNCTION FUNCTION
SINGLE DOUBLE
FUNCTION FUNCTION BACK VIEW
Figure 7-86: Hose Reeving Installation

Mast
10. Install the lower hose guide and spacer to 7
the outer intermediate upright. Tighten

the capscrews to a torque of 37 ft. lb. 4
21
(50 Nm).
11. Install the hose clamps to the lower hose
guide. Leave the capscrews finger tight.
12. Route hoses down to the lower hose guide. 4
21
Place hoses under the hose clamp at the
top of the lower hose guide. Pull downward
on the hoses with 20 lbs. force. Tighten
clamp capscrews enough to stop hose
movement.
13. Install the upper hose guide to the outer
upright. Tighten the capscrew to 37 ft. lb. Upper
(50 Nm). Hose
Guide
14. Install the hose clamps to the upper hose
guide. Leave the capscrews finger tight.
15. Route the hoses up into the upper hose
18
1
guide.
16. Route the hoses under the hose clamps at 20
3 4
21
the top of the upper hose guide. Tighten
Crosshead
the capscrews finger tight.
17. Route the hoses under the hose clamps at
the bottom of the upper hose guide. Do not
tighten the clamp capscrews.
18. Tighten the crosshead cover plate
capscrew to 30-33 ft. lb. (40-45 Nm).
19. Align the hoses by twisting the hose ends 20
3
to travel centered in the crosshead on the
natural curve of the hose. The hoses
should travel parallel to each other. Hold
the hoses while tightening the fittings to
keep the hoses from twisting.
20. Loosen the hose clamps at the top of the Lower
lower hose guide. Pull down on the hoses Hose
Guide
with 40 lbs. of force. Tighten the hose
clamp capscrews to 7-11 ft. lb.
(10-15 Nm).
21. Loosen the hose clamps on the upper hose 2
19
guide. Adjust the hoses to the natural
hose bend and align evenly spaced in the
guide rails. Tighten the hose clamp
capscrews to 7-11 ft. lb. (10-15 Nm).
22. Raise and lower the mast slowly through
several cycles and check for proper hose
alignment, clearances and hose tracking Figure 7-87: Hose Reeving Installation - continued
in the guides.

Mast
Lift Chains 1. Adjust one chain to achieve the correct

upright position when fully lowered.
2. Adjust each pair to achieve equal chain
Lift Chain Adjustment - Model tension. Tighten the nuts together to a
4100 torque of 50 to 70 ft. lb. (98 to 96 Nm).
Make sure cotter pins are installed in the
1. Loosen the locking nut on the chain hole at the bottom of each chain anchor.
anchor, See Figure 7-88.
confirm the adjustment is correct.
Main Lift
Chain Anchors
Main Lift
Locking Nut
Adjusting Nuts
Figure 7-89: Main Lift Chains - Model 4200

7
Figure 7-88: Lift Chain Locking Nut

Free Lift Chains - TF Mast
2. Tighten the adjusting nut until the chain
is free of any twist and tension is correct. The free lift chains should be adjusted so that
Lift chain tension is correct if the lift chain when the unloaded mast is fully lowered, the
can be forced sideways approx. 0.5 in. to upright channels and carriage are positioned as
1 in. (12.7 to 25.4 mm) before the lift shown in Figure 7-90.
frame raises slightly.
7
3. Retighten the locking nut on the chain *3 in. *5 in.

anchor and install a cotter pin. Underclearance Underclearance
Lift Chain Adjustment - Model

4200 Outer Upright
and Carriage
Flush Outer
Upright
Main Lift Chains
The main lift chains should be adjusted so that Carriage 2 in.

Below Outer
when the unloaded mast is fully lowered, the Upright
uprights are positioned as shown in Figure 7-90: Upright and Carriage Position
Figure 7-89.

Mast
1. Locate the threaded chain anchors on the

front side of the inner upright
crossmember on each side of the cylinder.
Adjust one chain to achieve the correct
upright position when fully lowered. See
Figure 7-91.
Free Lift
Cylinder
Cylinder
Strap
Free Lift
Adjusting
Nuts
MA0387.ill
Figure 7-91: Free Lift Chains
2. Adjust the other chain to achieve equal

chain tension. Tighten the nuts together to
a torque of 50-70 ft. lb. (68-95 Nm).
confirm the adjustments.

Mast
Mast Tilt Adjustment 2. Tilt the mast forward completely.

3. Place a square on the mast 39.4 in.
(1 meter) below where the plumb line is
Perform the following procedure when adjusting
attached and measure the distance
mast tilt.
between the face of the mast and the
1. Attach a plumb line to the mast. See plumb line.
Figure 7-92.
4. Repeat steps 1 thru 3 using the back of
the mast main frame for backward tilt.
5. Adjust the stroke of the tilt cylinders as
necessary to achieve the correct mast tilt.
Refer to Figure 7-92 and Table 7-3.
Table 7-3. Mast Tilt Parameters

Fwd Tilt BackTilt
Tilt Type
39.4 in. Angle Dim. A Angle Dim. A
(1 meter) 2.05 in. 3.4 in.
Standard 3° 5°
(52 mm) (87 mm)
3.4 in.
Optional 5°
(87 mm) 2.05 in.
3°
6.8 in. (52 mm)
Bottler’s 10°
(173 mm)
Mast Tilt Position Switch

Adjustment
Trucks equipped with the Bottler’s Tilt option
require mast mounted switches (S11 and S18)
for the VM to determine carriage and mast
position.
The Mast Tilt Position Switch (S18) must be

Mast adjusted so that it opens when the mast is tilted
Face beyond 3° forward.
39.4 in. (1 meter) Plumb 1. Attach a plumb line to the mast. See
from plumb line
attach point Line Figure 7-92.
2. Place a square on the mast 39.4 in.
(1 meter) below where the plumb line is
attached and tilt the mast forward 3°
(2.05 in./52 mm at Dim. A in Figure 7-92).
3. Adjust Mast Tilt Position Switch (S18)
bracket so that the switch opens when the
mast is tilted further forward.
Dim. A
Figure 7-92. Measuring Mast Tilt

Models 4100/4200 Maintenance Manual Section 8. Theory of Operation
Section 8. Theory of Operation

Section 8. Theory of Operation Models 4100/4200 Maintenance Manual
System Architecture
System Architecture
Table 8-1 identifies the electronic components
found on Model 4100/4200 lift trucks and their
function. Table 8-2 identifies where memory is
stored.
Table 8-1. Electrical System Components
Component Function Ident

Vehicle Manager Controlling Manager for the truck. VM
Right Traction Power Amp Controls the drive motor on the right-hand side. RTPA
Left Traction Power Amp Controls the drive motor on the left-hand side. LTPA
Lift Power Amplifier Controls the pump motor. Used for 4200 hydraulic systems. LPA
Fuse/Relay Card Distributes B+/– to the truck. Houses the B+/– control fuses, and FRC
the relays.
Contactor/Fuse Panel Contactors and power fuses are located on this panel.
Standard Handle Assembly Contains Solid State potentiometers for Lift/Lower and Travel.
Contains mechanical type switches for Horn, Sideshift, Tilt, and
Aux functions.
Optional Handle Assembly Contains Solid State potentiometers for Lift/Lower, Travel, Sideshift,
Tilt, and Aux functions. Contains Hall Effect switch for Horn.
Operator Display Card Displays information and fault codes to operator. Contains the
vehicle identity (Primary Memory) and stores hour meter
information.
Steer Position Sensor Is used for the VM to determine the steering position for correct
control of the drive motors.
Table 8-2. Stored Value Location
Value Location
Primary Memory Primary Memory is stored in the Operator Display. There is a backup copy in
the VM.
• If the Operator Display is blank or has corrupted memory, the VM will
send a copy to the Display if they can communicate.
• If both cards are valid, but different, the Operator Display will overwrite
the VM.
Configure Mode Settings Configure Mode settings are stored in the VM.
Learn Mode Values Learn Mode values are stored in the VM.
Date and Time Date and Time are calculated and stored in the VM.
Hour Meters Hour Meters (Hours Deadman, Hours Lifting, Key Hours, and Traction Miles)
are stored in the Operator Display.

Systems Overview
Systems Overview operator requests. The VM calculates the

steering position based on the three channels in
the steering position sensor. The VM reduces
The 4100/4200 control system uses up to four the travel speed (or changes the direction of
“intelligent” devices working together to control rotation) of each individual motor if necessary
the lift truck and respond to operator requests. due to the steering position. It also may cause
These devices pass information to each other speed reduction due to drive motor
via the Controller Area Network (CAN) Bus. The temperature. The VM contains a backup copy of
devices are: the primary memory (see Operator Display
• Vehicle Manager (VM) Card). The VM contains a power supply that
provides a regulated +12V and +5V. The VM
• Right Traction Power Amplifier (RTPA)
also determines that the correct battery is
• Left Traction Power Amplifier (LTPA) connected, and determines the Battery
• Lift Power Amplifier (LPA) (4200 only) State-of-Charge (BSOC) from the voltage
measured at Battery Sense In.
The system uses other “non-intelligent” devices.
• Operator Display Card Traction Power Amplifiers
• Fuse/Relay Card
The Traction Power Amplifiers (TPAs)
• Contactors communicate only with the VM, from where
• Steer Position Sensor they receive all requests regarding travel
direction and speed. The TPAs monitor the drive
motor encoders and temperature sensors. They
Intelligent Devices determine, based on the encoder feedback and
the travel request, if the lift truck should be in
BUS+/– Communications travel, plugging, or regenerative braking, and
determine if the performance has achieved the
BUS+/– are the communication lines that the travel request from the VM. If it has not, the
intelligent modules use to communicate with TPA adjusts the motor control voltage or sends
one another. BUS+ is a digital, serial a fault code to the VM, as appropriate. The TPAs
communication line. BUS– is a digital, serial are solely responsible for controlling traction
communication line that is a mirror image of motor current. The TPAs send the traction
BUS+. Using communication lines in this motor temperature status to the VM. The VM
fashion limits noise problems associated with then alters the travel request if necessary
long communication lines operating in a noisy depending on the traction motor temperature.
environment. The TPAs monitor their internal temperature
and limits current or travel speed as required
Vehicle Manager by their internal programming. The TPAs also
check the charging of the amplifiers, and
The Vehicle Manager (VM) controls the system. various internal operating parameters. They
It communicates with all other devices that are also send fault codes to the VM if anything is
on the communications BUS. It receives all operating incorrectly. The right-hand side TPA
requests for travel, auxiliary and lift. The VM monitors and controls the TPC (Traction Power
receives information on the status of all Contactor).
switches such as the Deadman, Horn, Steer
Position Sensor, and EPO. It also receives Lift Power Amplifier (Model 4200)
traction motor speed, direction, and
temperature information from the Traction The Lift Power Amplifier (LPA) is used for all
Power Amplifiers, and lift motor speed and hydraulic functions except steering. The LPA
temperature information from the Lift Power only communicates with the VM, from where it
Amplifier (LPA). The VM determines allowable receives all requests regarding motor rotation
vehicle operation based on those inputs and speed. The LPA monitors both the lift motor

Non-intelligent Devices
encoder and temperature sensor. Motor speed TPC Contactor

may be fixed or vary based on different types of
requests (such as tilt versus sideshift versus The TPC Contactor provides B+ to the power
high speed clamp). It determines from the side of both traction amplifiers. It is controlled
encoder feedback if the motor has achieved the by the right-hand side traction power amplifier.
requested speed request. The LPA is solely
responsible for controlling lift motor current. It
STR Contactor
sends the lift motor temperature status to the
VM. The VM then determines if the motor must
The STR Contactor provides B+ to the power
be shut-down due to motor temperature. The
side of the Steer Motor (SM). It is controlled by
LPA monitors its internal temperature and
the VM.
limits current or lift speed as required by its
internal programming. The LPA also checks the
operation of the LPC, the charging of the Steer Position Sensor
amplifiers, and various internal operating
parameters. It also sends fault codes to the VM Consists of three independent Steer Feedback
if anything is operating incorrectly. Proximity Sensors located in one potted
assembly. The steering hub has a plate
mounted on it that changes the sequence the
Non-intelligent Devices sensors are activated when the steering hub is
rotated. The VM uses this to determine the
Operator Display Card steering position for correct control of the drive
motors.
The Operator Display Card is connected to the
VM. Messages and codes are displayed on it.
The Display contains the Primary Memory,
Hydraulic Devices
which includes Model Number, Serial Number,
The lift system consists of single acting
Date of Manufacture, Hour Meters, and a list of
hydraulic cylinders. During a lift from floor
enabled Options. The keypad that contains the
level, the free lift cylinders elevate the carriage
data entry push buttons connects to the
before the telescopic is extended by the lift
Operator Display.
action of the main cylinders.
Fuse/Relay Card Lift/Aux Pump (P1)

The Fuse/Relay Card is the control power
Pump P1 is a positive displacement gear pump
distribution board. It contains the B+ and B–
that rotates clockwise from the shaft end. P1 is
control fuses and the K1 thru K4 relays. It
used for all lift and aux functions.
provides B+ and B– to the VM, TPC, LPC, and
STR. It also supplies B+ and B– to optional
equipment. Sideshift Cylinders
The sideshift cylinder is a double-acting

LPC Contactor
hydraulic cylinder used to shift the load left and
right with respect to the mast. It is an integral
In the Model 4200, this contactor is used to
part of the sideshift carriage.
supply B+ to the power side of the Lift Power
Amplifier.
Tilt Cylinders
In the Model 4100, this contactor is used to
supply B+ to the DC Lift Motor. The tilt cylinders are double-acting hydraulic
cylinders used to tilt the mast forward and
back.

Hydraulic Devices
Load Hold Valve (SOL1) Attachment Solenoids (SOL7C/R)
The load hold valve is a normally closed SOL7C/R are normally closed solenoid valves
solenoid valve used to hold the carriage in an used to block (de-energized) or allow (energized)
elevated position. fluid flow to and from the attachment cylinders.
Lift/Lower Valve (SOL2) Sideshift Solenoids (SOL9R/L)
The proportional lower valve is a pressure SOL9R/L are normally closed solenoid valves
compensated flow control solenoid valve used to used to block (de-energized) or allow (energized)
lower the carriage. As the voltage to the valve fluid flow to and from the sideshift cylinders.
increases, the flow through the valve increases,
regardless of the pressure. The Model 4100 Tilt Solenoid (SOL10)
uses SOL2 for feathering lift as well.
SOL10 is a normally closed solenoid valve used
Dump Valve (SOL3) to block (de-energized) or allow (energized) fluid
flow to and from the tilt cylinders.
SOL3 is a solenoid used as a lift system relief.
In addition, SOL3 is used to divert oil from P1 Steer Valve
back to the reservoir after a lift is stopped and
the pump is still spinning. It also acts as a valve The steer valve is an orbitrol type rotary flow
to port excess oil back to the reservoir when valve with an auxiliary port. When no steering
performing auxiliary functions. is being done, fluid flows through the auxiliary
port (E). When steering is requested, fluid flows
Priority Bypass (SOL4) first through the steer valve, hydraulic motor,
and the steer return port (T). Any excess flow
SOL4 is a normally open proportional pressure exits out the auxiliary port.
compensated priority flow valve. It will regulate
flow to the auxiliary system by the voltage to the Counterbalance Check Valves (CB1,
coil regardless of the system working pressure.
CB2)
Increasing the voltage will decrease the flow to
the auxiliary system.
Counterbalanced check valves used to hold the
tilt cylinders in place when a tilt request is no
Prop Relief (SOL5) longer present.
SOL5 is a proportional solenoid used as an

Check Valve (CV1)
auxiliary system relief. Voltage is used to adjust
the relief pressure (24V=3000 psi; 0V=100 psi).
Check valve used to make sure the fluid exiting
The voltage to this valve will vary when different
the lift cylinders during a lower command is
pressure settings are chosen on the display for
routed through SOL2.
auxiliary attachments.
Hydraulic Filter
Aux Select (SOL6)
The hydraulic system has a filter in the main
SOL6 is a directional solenoid valve providing
manifold. Its purpose is to filter impurities from
directional control to the tilt, sideshift, or
the hydraulic system. It filters oil on the return
auxiliary functions. When SOL6 is energized
to the reservoir from the lift system. It has no
flow direction is reversed for tilt, sideshift, or
internal bypass.
auxiliary functions.

Traction System Theory
Traction System Theory lift/lower. These values are also stored in

memory in the VM. See Configure Mode on
page 3-4. For Travel or Lift/Lower, the VM
Key ON compares the pot position information to the
values that it stored when it learned the pots.
When the key is turned ON, the Vehicle
Manager will power up and proceed with When the control handle is moved from neutral,
SelfTest. If the Battery_Sense_In (JPC24-24) the VM detects a different voltage at JPC12-3
voltage is between 28 and 45V, a circuit is from VR1. To release the brake, the VM must
turned on in the VM that provides B– to the know the deadman switch is operational and
RELAY_ENABLE (JPC14-6) in order to energize that the control handle has moved. The VM
the relays. After this, the Battery_Sense_In then provides B– to JPC20-14 (Brake) that
voltage is used to determine BSOC. When K1, energizes the brake coils and releases the
K2, K3, and K4 are energized, K3 provides B+ to brakes. The lift truck is equipped with two drive
the control side of the power amplifiers as well motors, each with its own brake. Both brakes
as the precharge circuit internal to the are controlled by the same circuit from the VM.
amplifiers.
When the VM receives a request to travel by
The VM will then establish communication to seeing the VR1 voltage change (control handle
the amplifiers and after successful moved), it compares that voltage to the learned
communications has been established, the VM value for VR1 to determine the direction and
will request the RTPA to activate the TPC magnitude of the travel request. The VM then
contactor and check its status. For the 4200, looks at all speed limiting inputs such as motor
the VM will request the LPA to activate the LPC temperature, height, weight, steering angle, and
contactor and check its status. For the 4100, fault codes to determine if the requested speed
the VM will activate the LPC contactor via pin is allowable. The VM then initiates a request for
LPC_CTRL (JPC18-9) and verify by LPC_SENSE the appropriate direction and speed to the TPAs
(JPC22-20). over the communications BUS. The VM
constantly updates the travel request to the
TPAs.
Deadman Pedal Depressed
When the TPA receives a travel request from the
When the Deadman Pedal is depressed, S2 VM, it produces a control output to the traction
(Deadman Switch) is closed. The switch is an motor. All operational parameters that affect
input at JPC22-8 to the VM. When S2 closes, it traction motor torque and speed are controlled
switches Deadman Switch voltage from a high exclusively by the TPA. It monitors motor
state (greater than 4.5VDC) to a low state (less current, voltage, and RPM, and from them, can
than 0.7VDC). determine motor performance. The TPA will
alter its control output to the traction motor to
When the VM receives that voltage, it will match the motor performance to the travel
activate a circuit in the VM that provides B– to request from the VM. As the travel request from
JPC18-11, energizing the STR contactor coil the control handle changes, so does the travel
and the steer motor is powered up. request from the VM to the TPA. That in turn,
alters motor operation. To track the travel
Travel Theory request from the operator, the TPA monitors the
speed sensor. The TPA also monitors drive
During Learn, the VM learns the neutral motor temperature and the internal
position for the travel (VR1) and lift (VR2) temperature of the amplifier and can alter travel
potentiometers and stores those values in based on the TPA temperature. The TPA sends
memory. See Maintenance Mode on page 3-8. motor temperature to the VM, and the VM
During normal use, the VM learns the extreme alters the travel request based on drive motor
values for full forward/reverse and full temperature.

Travel Theory
When the lift truck is moving and the travel The VM constantly monitors the steering
control handle is moved to request the opposite position sensor for reduction in speed to a
direction, the same sequence of events takes particular drive motor, cut power to a particular
place. drive motor, or cause the motor to reverse the
direction of travel even if the travel control
The VM does not request plugging or direction request did not change.
regeneration; it just requests travel in the
opposite direction. This allows the vehicle to corner correctly with
the dual drive system.
The TPA calculates both direction and speed,
then determines whether the travel request
from the VM must be met with a travel, a plug,
or a regeneration control output to the drive
motor.
Table 8-3. Steering Parameters
Operator
Steer Tiller
Steer Tire Position Effect On System Display
Position
Message
90° (full CW) to 67° Reverse direction in 1 motor Left 101
67° to 41° One motor power cut Left 100
41° to 18° Reduced throttle percentage Left 000
18° to –18° (wheels centered) Full Speed Centered 001
–18° to –41° Reduced throttle percentage Right 011
–41° to –67° One motor power cut Right 010
–90° (full CCW) to –67° Reverse direction in 1 motor Right 110

Steering System Theory
Steering System Theory

With the key switch ON, the deadman pedal
depressed, and the EPO switch closed, Relay K2
is energized, sending B+K2 from the Fuse/Relay
Card at JPF2-1 to SPL9.
From SPL9, the voltage goes to the STR

contactor X terminal. The VM supplies a
negative (JPC18-11) to energize the steering
contactor coil. When the coil is energized, the
steer contactor tips close, supplying battery
voltage to the steer motor.
With the steer motor running, oil is sent

through the steering orbitrol and back to the
hydraulic reservoir. When steering is requested,
oil is sent through the orbitrol to the hydraulic
steer motor to rotate (steer) the drive unit.

Lift/Lower System Theory
Lift/Lower System motor to determine that the lift motor has

stopped spinning. As long as the VM senses
Theory voltage on the P Sense line, it will provide
voltage to the Priority Bypass (SOL4) and
lift/lower proportional (SOL2) coil, keeping the
Model 4100 valve(s) open to allow the fluid from the pump to
return to tank. This ensures the cylinders do
not continue lifting after the request has ended.
Lift System
Once the lift motor has completely stopped
spinning, the VM removes voltage to the Priority
The VM constantly monitors the output voltage
Bypass (SOL4) and lift/lower proportional
of VR2. The VM compares this voltage to the
(SOL2) coil, closing the Priority Bypass (SOL4)
voltages stored during the Learn process. The
and lift/lower proportional valve.
VM checks the battery voltage (for lift cutout),
and all enabled options and switches that could
prevent the activation of the lift system. When Lower System
satisfied that no criteria are present to prevent
lift, it then determines the requested percentage The following description is based on a lower
of full speed lift. It then activates Priority request from a full speed lift situation.
Bypass (SOL4) and the lift/lower proportional
valve (SOL2) fully open and closes the lift pump VR2 passes through neutral to a full speed
contactor (LPC) by taking the coils to B–. lower request. The VM recognizes the change
and realizes full speed lower is required. All
Opening the lift/lower valve fully prevents enabled options and switches that can prohibit
sudden movement when the lift pump is first lower are checked.
activated by allowing the fluid to return to the
tank. As soon as the command to close the P Once the VM is satisfied that lower is allowed, it
contactor is activated, the VM looks at the monitors the LPC_Sense line to determine the
LPC_Sense input, verifying the contactor closed condition of the P contactor (open or closed) and
as commanded. It then slowly reduces the PWM verifies the lift motor is not still spinning by
(Pulse Width Modulation) output to the coil for checking for back ElectroMotive Force (EMF).
the lift/lower proportional valve to match the As long as the VM senses voltage on the
percentage of full speed lift requested. As the LPC_Sense line, it provides voltage to the
lift/lower proportional valve closes, hydraulic Priority Bypass (SOL4) and lift/lower
fluid passes through the CV1 check valve, the proportional coil, keeping the valve(s) open to
normally closed check valve in the load holding allow the fluid from the pump to return to tank.
valve, to the flow limiter on the crosstie, to the This ensures the cylinders do not continue
flow limiters at the bottom of the lift cylinders. lifting after the request has ended.
The flow limiter in the cylinder allows
unrestricted fluid flow to the center lift ram. The Once the lift motor has completely stopped
free lift cylinder elevates first because less spinning, the VM removes voltage to the
pressure is required. Once the carriage hits the lift/lower coil, closing the lift/lower
stops on the inner telescopic, the pressure proportional valve. The Load Holding solenoid
increases enough to start elevating the main (SOL1) is activated by the VM, opening the
cylinder(s). valve. The VM then gradually opens the
lift/lower solenoid (SOL2) to the percentage of
The VM monitors the LPC_Sense line to requested lower. This allows the oil to flow from
determine the condition of the LPC contactor the cylinders, the load holding valve, the
and verify the lift motor is spinning. When a lift lift/lower proportional valve, the filter, and back
request has finished (VR2 has either returned to the reservoir. The telescopics will lower first
to neutral or through neutral to a lower due to the greater weight of the telescopics.
request), the VM monitors the LPC_Sense line Once the telescopics are fully lower, the center
for back ElectroMotive Force (EMF) from the cylinder will begin to lower.

Model 4200
Model 4200 Lower System
Lift System With the key switch ON and the deadman

depressed, rotating the lift/lower control VR2 to
the lower position will send a change in voltage
All inputs and outputs related to the lift/lower
to the VM on JPC12-2 (the voltage is an
system are controlled by the Vehicle Manager
increasing voltage).
(VM). The VM determines what actions are
required based on inputs from the operator and
The VM senses the request for lower and sends
from system feedback.
the negative to the load holding solenoid (SOL1)
at JPC18-10 to energize its coil.
The VM sends voltage through lift/lower
potentiometer VR2. When VR2 is moved to
After the load holding solenoid opens, the
request lift, a voltage is sent to the VM at
proportional lower solenoid (SOL3) opens to
JPC12-2. The VM sees a voltage different from
allow fluid to flow back to the reservoir by
the “learned” neutral voltage, and sends a
controlling the negative to the coil. This
request to the lift power amplifier via BUS+/–
negative comes from the VM at JPC20-16. SOL3
(JPC14-11 and JPC14-4 on the VM to JPL1-23
opens proportionally to the amount that VR2 is
and JPL1-35 on the Lift Amp). To lift, voltage
moved from neutral during lower.
from VR2 decreases; when it is moved to lower,
the voltage from VR2 increases.
Voltage across the proportional lower solenoid
Lift speed varies directly with lift motor RPM. varies, depending on the position of the
The voltage supplied to the lift motor is lift/lower control (VR2):
proportional to the amount of lift request from • Low voltage = slow lowering
VR2, faster lift = higher motor voltage.
Frequency is also manipulated to perform the • High voltage = fast lowering
operator’s request.
The lift power amplifier internally supplies B+ Auxiliary Function - Sideshift
and B– to the lift contactor coil (LPC coil) at With the key switch ON and the deadman pedal
JPL1-13 and JPL1-6 respectively. B– is depressed, the following occurs to activate the
controlled to close the normally open contactor sideshift function.
tips. When the lift contactor coil is energized,
the contactor tips close, allowing B+ the power Moving the sideshift control to one side varies
side of the lift power amplifier, which supplies the output voltage of the sideshift pot (optional
voltage to the lift motor to make it rotate. handle). This voltage goes to the VM at
JPC12-5. The VM sees a voltage change and
Prior to requesting a lift, all valves are in the sends a request to the lift amplifier via BUS+/–
de-energized state. (JPC14-11 and JPC14-4 to JPL1-23 and
SOL4 receives oil flow at port 1 placing pressure JPL1-35).
on the pilot line of the valve. This pressure The lift power amplifier internally supplies B– to
moves the spool in the valve to allow flow out of the lift contactor coil (LPC) at JPL1-6, closing
port 2 and down to CV-1. Then the oil flows the normally open contactor tips.
through the de-energized load holding solenoid
(SOL1), through the mast mounted flow limiter When the lift contactor coil is energized, the
to the flow limiters in the base of the lift contactor tips close, allowing B+ to be supplied
cylinders, and into the lift cylinders producing to the power side of the lift power amplifier,
lift. which supplies voltage to the lift motor to make
it rotate. The motor turns at a speed
When the lift knob is returned to neutral, the predetermined by software.
lift motor is ramped down. SOL3 is opened to
relieve any pressure spikes in the system. SOL4 receives oil flow at port 1, that flows
through the valve and out port 3 to SOL6, the

Aux Function - Tilt
directional solenoid. When energized, SOL6 will From SOL10, the oil flows through CB-1 or 2,
reverse the direction of the Aux functions. depending on the requested tilt direction. The
oil then flows through the hoses to the Tilt
Oil flow then goes to solenoid 9R or 9L. Solenoid
cylinders.
9R and 9L must be energized for Sideshift to
work in either direction. From SOL9, the oil
During a lift and aux function at the same time,
flows through the over-the-mast hoses to the
SOL4 becomes energized to allow the correct oil
Sideshift cylinders.
flow to the Aux functions.
From the Maintenance Menu, the user can
establish sideshift speed. See Table 3-3, Bottler’s Tilt (Option)
“Maintenance Mode Menu,” on page 3-9.
Bottlers Tilt allows additional forward mast tilt
This is used to adjust sideshift speed between 3 while in free lift, and may limit the lift height
and 4.5 seconds. It is also used to set the depending on the tilt position.
correct speed of an attachment that has a
second AUX function. Changing this setting will To accomplish this, there are modifications to
affect tilt speed as well. The VM varies the the lift truck and the option must be enabled in
voltage to SOL4 in order to create the differing FlashWare. See Table 3-1, “Configure Mode
sideshift speeds. Menu,” on page 3-6.
When the mast is fully lowered and vertical, the

Aux Function - Tilt High Speed Limit Switch (SW11) and Mast Tilt
Switch (SW18) are normally closed.
With the key switch ON and the deadman pedal
depressed, the following occurs to activate the
When tilt is requested, greater than 3° tilt
Tilt function.
forward is possible.
Moving the Tilt control forward or back varies
the output voltage of the Tilt pot (optional When the lift truck is elevated above free lift,
handle). This voltage goes to the VM at SW11 opens, causing a change in state to be
JPC12-8. The VM sees a voltage change and seen at the VM.
sends a request to the lift amplifier via BUS+/–
(JPC14-11 and JPC14-4 to JPL1-23 and The VM will not allow tilt forward to go more
JPL1-35). than 3° as seen by SW18.
The lift power amplifier internally supplies B– to
When the vehicle is tilted more than 3° while in
the lift contactor coil (LPC) at JPL1-6, closing
free lift, and lift is requested, lift will stop when
the normally open contactor tips.
switch SW11 has been de-activated.
When the lift contactor coil is energized, the
contactor tips close, allowing B+ to be supplied
to the power side of the lift power amplifier. This
supplies voltage to the lift motor to make it
rotate. The motor turns at a speed
predetermined by software.
SOL4 receives oil flow at port 1, that flows
through the valve and out port 3 to SOL6, the
directional solenoid. When energized, SOL6
reverses the direction of the Aux functions.
Oil flow then goes to SOL10. SOL10 must be
energized for Tilt to work in either direction.

Bottler’s Tilt (Option)

Pinout Matrix
Pinout Matrix • Theory of Operation A detailed

Section 8. Theory of Operation
description of the signal carried on the

wire. If the signal can be variable, the state
The pinout matrix chart lists functions and of a related component that will cause the
normal voltages of terminals and harness signal to vary is indicated. Identifies
connector pins. The matrix columns have the possible causes for lack of correct signal.
following meanings: • Normal Level: the approximate voltage
• Item: sequential number to aid in that must be seen on that wire for the
reference. state indicated. Unless otherwise
• Connection: the actual wire numbers or indicated, voltages are measured with
component abbreviations on the electrical respect to (wrt) B– at TP4.
schematic. • Signal Source: the device or connection
• Function Description: brief definition of that supplies the signal directly to the
the signal carried on the wire. wire.
• Signal User: the device or connection
where the wire directly delivers the signal.
Functional Signal Signal

Item Connector Theory of Operation Normal Level
Description Source User
1 JPC3-1 VBUS Voltage Supply for USB.
2 JPC3-2 D– Used for USB Communication.
3 JPC3-3 D+ Used for USB Communication.
4 JPC3-4 DGND B– for USB. <0.5V
5 JPC6-2 DATA_OUT No usable data can be obtained.
6 JPC6-4 DGND This is the negative path for the <0.5V VM OD

operator display circuits.
7 JPC6-5 SHIFT_CLOCK No usable data can be obtained.
8 JPC6-6 +12V This is the positive path for the 12V 10.8-13V VM OD
supply to the operator display.
9 JPC9-2 TXD Connector for FlashWare.
10 JPC9-3 RXD Connector for FlashWare.
11 JPC9-5 DGND Connector for FlashWare.
12 JPC10-3 ENABLE Connection for VM to enable Key ON:12V VM OCSS

Emitters for OCSS after the Deadman down: Emitters
Deadman pedal is depressed. <1V
13 JPC12-1 +5VP 5V supply from VM used for VR1 5V VM VR1, VR2

std. handle (Travel) and VR2 (Lift/Lower) pots.
14 JPC12-1 +5VP 5V supply from VM used for switches 5V VM Optional

opt. handle in optional handle. handle
switches
15 JPC12-2 LIFT Input to VM from VR2. Neutral: 1.17V VR2 VM

Full Lift: 0.62V
Full Lwr:1.68V

Pinout Matrix

16 JPC12-3 TRAVEL Input to VM from VR1. Neutral:1.0V VR1 VM

Full TF: 0.52V
Full FF: 1.60V
17 JPC12-4 FUNCTION 1 Input to VM from SW3. 4.32V SW3 VM

opt. handle de-activated;
variable down to
0.597 fully
activated
18 JPC12-4 FUNCTION 1 Input to VM from S4. De-activated: 5V S4 VM

std. handle Activated: <1V
19 JPC12-5 SSHIFT Input to VM from SW4. Neutral: 2.44V SW4 VM

opt. handle Full Tilt Dn: 0.6V
Full Tilt Up 4.36V
20 JPC12-5 TILT_UP Input to VM from S6. De-activated: 5V S6 VM

21 JPC12-6 TILT_Down Input to VM from S7. De-activated: 5V S7 VM

22 JPC12-7 H_HTR 8V to the heater in the optional Linear based on VM HTR6

opt. handle control handle. ambient temp.
0V@97°F,
8V@50°F
23 JPC12-8 TILT Input to VM from SW4. Neutral: 2.44V SW4 VM

opt. handle Full SS Right: 0.6V
Full SS Left: 4.36V
24 JPC12-8 SSHIFT_LEFT Input to VM from S8. De-activated: 5V S8 VM

25 JPC12-9 SSHIFT_RIGHT Input to VM from S9. De-activated: 5V S9 VM

26 JPC12-10 HORN Input to VM from SW1. De-activated: 5V SW1 VM

opt. handle Activated: <1V
27 JPC12-10 HORN Input to VM from S3. De-activated: 5V S3 VM

28 JPC12-11 FUNCTION 2 Input to VM from SW2. De-activated: SW2 VM

opt. handle 4.32V
Variable down to
0.597V fully
activated
29 JPC12-11 FUNCTION 2 Input to VM from S5. De-activated: 5V S5 VM

30 JPC12-12 DGND B– to control handle. <0.5V VM Handle

switches
31 JPC14-1 B–F B–F for the VM. <0.5V TP4 VM
32 JPC14-2 DGND B–F for DGND on the VM. <0.5V TP4 VM

Pinout Matrix

34 JPC14-4 BUS– The wire that carries the negative 2.185V VM VM,
component of the digital Power
communications between the VM Amps
and power amplifiers.
35 JPC14-6 RELAY_ENABLE Control path for K1, K2, K3 & K4 on B+ w/Key Switch VM K1, K2,
the Fuse/Relay Card. After S1 is ON and all relays K3 & K4
closed, all relays are energized de-energized;
simultaneously during SelfTest if the <0.5V w/Key
voltage at Battery_Sense_In is Switch OFF or ON
between 28 and 45V. If the vehicle and any relay
is equipped with optional heaters, energized
the VM may keep this circuit active
at B– even with the Key Switch OFF
(JPC14-7) to allow the heaters to run
based on the ambient temperature
sensor reading.
36 JPC14-7 B+K4 This is used for a circuit in the VM. If B+ w/key ON, B+ VM K4
the lift truck is equipped with the w/key OFF if the
optional heater assembly, the VM vehicle is
will look at the Ambient Temperature equipped with
Sensor (JPC24-23) input to optional Cold
determine if the Relay Enable circuit Storage and the
should remain activated in order to ambient
have power remaining to the VM temperature
power supply. requires that the
heaters remain on.
40 JPC14-11 BUS+ The wire that carries the positive 2.8V VM VM,
component of the digital Power
communications between the VM Amps
and power amplifiers.
41 JPC14-12 B+KEY B+ that is switched by the Key Switch B+ S1 VM

(S1) to power functions on the VM
that are initiated after S1 is closed
and are not affected by the EPO.
This includes the VM power supplies,
the operation of the microprocessor,
and execution of the firmware.
42 JPC14-13 B+K2 B+ provided to the VM when the K2 B+ K2 VM

relay tips are closed. They are
de-energized when the EPO is open.
43 JPC14-14 B+K2 B+ provided to the VM when the K2 B+ K2 VM

relay tips are closed. They are
de-energized when the EPO is open.

Pinout Matrix

44 JPC18-1 AUX SELECT Control path for SOL6. Voltage will Neutral: B+ VM SOL6
vary with different functions and also SS Left: 23.7V
depends on selection of sideshift SS Rt: 23.7V
percentage in Configure Mode. Tilt Up: 9.0V
Tilt Dn: 33.5V
45 JPC18-5 DGND DGND for OCSS lower left detector. <0.5V VM Lower Left
Detector
46 JPC18-6 DGND DGND for OCSS upper right <0.5V VM Upper

detector. Right
Detector
47 JPC18-9 LPC_CTRL Control path for LPC Contactor De-energized: B+ VM LPC Coil
(4100 only). Energized: 12.7V
48 JPC18-10 LOAD HOLD Control path for SOL1. De-energized: B+ VM SOL1

Energized: 13V
49 JPC18-11 STR_CONTACTOR Control path for Steering Contactor. De-energized: B+ VM Steering

Energized: 11.3V Contactor
Coil
50 JPC18-12 HSA1 Control path for SOL7R and SOL7C. De-energized: B+ VM SOL7R,
Energized: 12.7V SOL7C
51 JPC18-14 SIDESHIFT Control path for SOL9R and SOL9L. De-energized: B+ VM SOL9R &
Energized: 11.9V SOL9L
52 JPC18-15 TILT Control path for SOL10. De-energized: B+ VM SOL10

Energized: 10.6V
53 JPC18-16 HORN Control path for Horn. De-energized: B+ VM Horn

Energized: 0.1V
54 JPC18-18 TRAV/LIFT ALARM Control path for Trav/Lift Alarm. De-energized: B+ VM Trav/Lift
Energized: 0.09V Alarm
55 JPC20-1 +12VP 12V supply to optional OCSS Upper 10.8-13V VM Upper Left
Left Emitter. Emitter
56 JPC20-2 +12VP 12V supply to optional OCSS Lower 10.8-13V VM Lower Left
Left Detector. Detector
57 JPC20-3 +12VP 12V supply to optional Left Battery 10.8-13V VM S22A

Gate (S22A).
58 JPC20-4 +12VP 12V supply to optional Right Battery 10.8-13V VM S22B

Gate (S22B).
59 JPC20-5 +12VP 12V supply to optional Mast Tilt 10.8-13V VM S18

(Bottler’s Tilt) Switch (S18).
60 JPC20-6 +12VP 12V supply to optional Lift Limit 10.8-13V VM S12

Switch (S12).
61 JPC20-8 +12VP 12V supply to optional (Bottler’s Tilt) 10.8-13V VM S11

Hi-Speed Limit Switch (S11).

Pinout Matrix

62 JPC20-9 +12VP 12V supply to optional OCSS Lower 10.8-13V VM Lower

Right Emitter. Right
Emitter
63 JPC20-10 +12VP 12V supply to optional OCSS Upper 10.8-13V VM Upper

Right Detector. Right
Detector
64 JPC20-12 DUMP Control path for SOL3. No request: B+ VM SOL3

Feather Lift: 9.0V
Full Lift: 8.1V
Full Lift & Aux
Request: 7.0V
65 JPC20-13 ISENSE5(K2) B+ from the K2 relay to the SOL6 B+ VM SOL6

coil. This is also used to sense the
current drawn by SOL6.
66 JPC20-14 BRAKES Control path for the Brake coils. B+ without request VM Brakes
Brakes are released after a throttle and key ON
command has been initiated, and Initial brake
are applied when travel has stopped release: 0.4V,
or EPO is depressed. then16V
67 JPC20-15 ISENSE2(K2) B+ Supply from the K2 relay to the B+ VM SOL2

SOL2 coil. This is also used to sense
the current drawn by SOL2.
68 JPC20-16 LIFT/LOWER Control path for proportional SOL2. De-energized: B+ VR2 VM

(4100) Voltage should vary depending on Lift: approx. 21 to
the position of Lift pot (VR2). 34V
Lower: approx. 35
to 19V
69 JPC20-16 LIFT/LOWER Control path for proportional SOL2. De-energized: B+ VR2 VM

(4200) Voltage should vary depending on Lower: approx. 35
the position of Lift pot (VR2). to 19V
70 JPC20-17 ISENSE3(K2) B+ from the K2 relay to SOL4 coil. B+ VM SOL4

This is also used to sense the current
drawn by SOL4.
71 JPC20-18 PRIORITY BYPASS Control path for SOL4. (Normal Key ON: B+ VM SOL4
std. handle Model 4100 voltages are approximate Sideshift: 22.75V
depending on sideshift setting in Tilt: 23.9V
Maintenance Mode.)
72 JPC20-18 PRIORITY BYPASS Control path for SOL4. (Normal Key ON:B+ VM SOL4
opt. handle Model 4200 voltages are approximate Feather Lift: 12.4V
depending on sideshift setting in Full Lift: 11.4V
Maintenance Mode.) Tilt: 26V
Tilt & Lift: 20V
73 JPC20-19 ISENSE4(K2) B+ from the K2 relay to the SOL5 B+ VM SOL5

coil. This is also used to sense the
current drawn by SOL5.
74 JPC20-20 PROP RELIEF Control path for SOL5. Lift:9V VM SOL5

std. handle Aux:34V

Pinout Matrix

75 JPC20-20 PROP RELIEF Control path for SOL5. Full Lift: 33V VM SOL5
opt. handle Feather Lift: 12.4V
Full Lift: 11.4V
Tilt: 26V
Tilt & Lift: 20V
76 JPC22-3 GATE_L Input to the VM from the optional left Activated: approx. S22A VM
Battery Gate Switch (S22A). 0V
Not activated: 5V
77 JPC22-4 GATE_R Input to the VM from the optional Activated: approx. S22B VM
right Battery Gate Switch (S22B). 0V
Not activated: 5V
78 JPC22-5 TILT_DN Input to the VM from the optional Activated: approx. S18 VM
Mast Tilt Switch (S18) (Bottler’s Tilt). 0V
Not activated: 5V
79 JPC22-6 LIFT_LIM Input to the VM from the optional Lift Activated: approx. S12 VM
Limit Switch (S12). 0V
Not activated: 5V
80 JPC22-8 ON DEADMAN Input to the VM from the Deadman Approx. 5V open; S2 VM

Switch (S2). 0V closed
81 JPC22-9 POS C POS C input to the VM from the Activated: 1.36V Steer VM
Steer Position Sensor. Not activated: Position
8.12V Sensor
82 JPC22-10 DISP_MISO No usable data can be obtained.
83 JPC22-11 DGND DGND for Deadman Switch (S2). B– VM S2
84 JPC22-13 BEAM_L Input to the VM from the optional Clear: <1V Lower Left VM
Lower Left OCSS Detector (Deadman Blocked: 5V Detector
depressed).
85 JPC22-14 BEAM_R Input to the VM from the optional Clear: <1V Upper VM
Upper Right OCSS Detector Blocked: 5V Right
(Deadman depressed). Detector
86 JPC22-19 STR_SENSE Sense wire used by the VM to Contactor STR VM

determine the state of the Steer de-energized: Contactor
Contactor and FU1. <0.5V
Energized: B+
87 JPC22-20 LPC_SENSE Sense wire used by the VM to Contactor LPC VM

(4100) determine the state of the LPC de-energized: Contactor
Contactor and FU3 (4100 only). <0.5V
Energized: B+
88 JPC22-21 EPO_SENSE Sense wire used by the VM to EPO Closed: B+ S21 VM

determine when the EPO (S21) is Open: <0.5V
open. This is used to initiate braking
and display a message.
89 JPC22-22 HIGH_SPD Input to the VM from the optional Activated: approx. S11 VM
Hi-Speed Limit Switch (S11) (Bottler’s 0V
Tilt). Not activated: 5V

Pinout Matrix

90 JPC24-1 +12VP 12V supply to the Steer Position 10.8-13V VM Steer

Sensor from the VM. Position
Sensor
91 JPC24-3 DGND DGND for left Battery Gate Switch <0.5V VM S22A
(S22A).
92 JPC24-4 DGND DGND for right Battery Gate Switch <0.5V VM S22B
(S22B).
93 JPC24-5 DGND DGND for Mast Tilt Switch (S18). <0.5V VM S18
94 JPC24-6 DGND DGND for Lift Limit Switch (S12). <0.5V VM S12
95 JPC24-6 DGND DGND for Mast Tilt Speed Reduction <0.5V VM S12
Quad Mast Switch (S12).
96 JPC24-7 DGND DGND for Ambient Temperature <0.5V VM Ambient

Sensor. Temp
Sensor
97 JPC24-8 DGND DGND for Hi-Speed Limit Switch <0.5V VM S11

(S11).
98 JPC24-10 DGND DGND for Pressure (Weight) Sensor. <0.5V VM Pressure

Sensor
99 JPC24-12 DATA_LATCH No usable data can be obtained.
100 JPC24-13 +12VP 12V supply to the optional Pressure 10.8-13V VM Pressure
Sensor from the VM. Sensor
101 JPC24-14 ADDR_LATCH No usable data can be obtained.
102 JPC24-17 POS A POS A input to the VM from the Activated: 1.36V Steer VM
Steer Position Sensor. Not activated: Position
8.12V Sensor
103 JPC24-18 PRESSURE_AIN Input to the VM from the optional 0 - 5V Based on Pressure VM
Pressure Sensor. weight on forks Sensor
104 JPC24-20 POS B POS B input to the VM from the Steer Activated: 1.36V Steer VM
Position Sensor. Not activated: Position
8.12V Sensor
105 JPC24-22 TILT_AIN Not Used.
106 JPC24-23 AMBIENT Input to the VM from the optional 0 - 5V Based on Ambient VM
Ambient Temperature Sensor. ambient temp. Temp
Sensor

Pinout Matrix

107 JPC24-24 BATTERY_SENSE_IN B+ present when the battery is B+ (there should TP1 VM
plugged in. It is supplied through a be no voltage
thermistor on the Fuse/Relay Panel. drop)
This is used by the VM to determine
that the correct battery is connected.
It will accept between 28 and 45V. If
the correct battery is sensed, Relay
Enable is energized during start-up.
After start-up, this voltage is used to
determine BSOC.
108 JPF1-1 B– B– for FU8 (15A/5A) Fuse for <0.5V TP4 Accessory
optional Accessory Power. Power
109 JPF1-2 B– B– for FU8 (15A/5A) for optional <0.5V TP4 Accessory
Accessory Power. Power
110 JPF1-3 ID0 Provides either B+F or B–F to B+ID0 K3 de-energized: K3 LPA
on the LPA. At Startup, the K3 coil is B– energized:
energized and this is used to identify energized: B+ FU5
amplifiers. de-
energized:
FU6
111 JPF1-4 B–F B– from FU8 (15A/5A) for optional <0.5V TP4 TS1-1 & 2
Accessory Power.
112 JPF1-5 ID0,ID1 Provides either B+F or B–F to B+ID’s K3 de-energized: K3 TPAs
on the TPAs. At Startup, the K3 coil is B– energized:
energized and this is used to identify energized: B+ FU5
amplifiers. de-
energized:
FU6
113 JPF1-6 B+F or B–F Provides either B+F or B–F to B+K3 K3 de-energized: K3 Power
on the Power Amplifiers. At Startup, B– energized: Amplifiers
the K3 coil is energized, providing energized: B+ FU5
B+ to the pre-charge circuit and logic de-
circuits in the power amplifiers. With energized:
the K3 coil de-energized, JPF1-6 is at FU6
B– to discharge the amplifier
pre-charge circuits.
114 JPF2-1 B+K2 B+ supplied to the Steer Contactor, B+ with K2 K2 tips STR, LPC
LPC Contactor, and optional Power energized CNTR and
Amp Fan. optional
power
amp fan
115 JPF2-2 B+K2 B+K2 to power the Horn and B+ with K2 K2 tips Horn and
Travel/Lift Alarm. energized Travel/Lift
Alarm
116 JPF2-3 B+K2 B+ Supply from the K2 relay to the B+ with K2 K2 tips Right
Right Brake Coil. energized Brake Coil

Pinout Matrix

117 JPF2-4 B+K4 Supply input to the VM that allows B+ with K4 K4 tips VM
the VM to remain powered up with energized
the Key Switch OFF. This is used in
cold storage applications to allow
the handle heater circuit to work
based on input from the ambient
temperature sensor.
118 JPF2-5 B+K2 B+ from the K2 relay to the Left B+ with K2 K2 tips Left Brake
Brake Coil. energized Coil
119 JPF2-6 B+K2 B+ from the K2 relay to VM. B+ with K2 K2 tips VM

energized
120 JPF2-7 B+K2 B+ from the K2 relay to VM. B+ with K2 K2 tips VM

energized
121 JPF2-8 B+K2 B+ Supply from the K2 relay to B+ with K2 K2 tips SOL1, 3,
SOL1, 3, 7R, 7C, 9R, 9L, and energized 7R, 7C,
optional SOL11. 9R, 9L &
SOL11
122 JPF2-9 B+Key B+ from the K1 relay to be used for B+ with K1 K1 tips TS1-5 & 6
accessory power after the Key energized
Switch has been activated.
123 JPF3-1 B– B– for FU6 that provides B– to the <0.5V TP4 VM

VM.
124 JPF3-2 B– B– for FU6 that provides B– to the <0.5V TP4 VM

VM.
125 JPF3-3 DGND B–F for DGND on the VM. <0.5V FU6 VM
126 JPF3-4 DGND B–F for DGND on the VM. <0.5V FU6 VM
127 JPF3-5 B–F B–F for the VM. <0.5V FU6 VM
130 JPF4-1 B+ B+ from TP1 to FU5 to supply K4 coil B+ TP1 VM

and the K2, K4 relay tips. Also
supplies Battery_Sense_In to the VM.
131 JPF4-2 B+ B+ from TP1 to FU5 to supply the K4 B+ TP1 VM

coil and the K2, K4 relay tips. Also
supplies Battery_Sense_In to the VM.
132 JPF4-3 B+ B+ from TP1 to FU7 and K1 tips to B+ TP1 FU7 &
supply Accessory Power option. Accessory
Power
Option
133 JPF4-4 B+ B+ from TP1 to FU7 and K1 tips to B+ TP1 FU7 and
supply Accessory Power option. Accessory
Power
Option

Pinout Matrix

134 JPF4-5 B+EPO B+ supply from EPO to K1, K2 and EPO closed: B+ EPO K1, K2,
K3. All functions associated with open: 0.05V K3
these relays are inoperable when the
EPO is open.
135 JPF4-7 BATTERY_SENSE_IN B+ present when the battery is B+ (there should TP1 VM
plugged in. It is supplied through a be no voltage
thermistor on the Fuse/Relay Panel. drop)
This is used by the VM to determine
that the correct battery is connected.
It will accept between 28 and 45V. If
the correct battery is sensed, Relay
Enable is energized during start-up.
After start-up, this voltage is used to
determine BSOC.
136 JPF4-8 BRAKES Control path for the Brake coils. B+ without request VM Brakes
Brakes are released after a throttle and key ON;
command has been initiated, and Initial brake
are applied when travel is stopped release: 0.4V,
or EPO is depressed. then16V
137 JPF4-10 B+F B+ to the Key Switch. B+ FU5 S1
138 JPF4-11 BRAKES (Left) Control path for the left brake coil. B+ without request VM Brakes
Brake is released after a throttle and key ON;
command has been initiated, and is Initial brake
applied when travel is stopped or release: 0.4V,
EPO is depressed. then16V
139 JPF4-12 BRAKES (Right) Control path for the right brake coil. B+ without request VM Brakes
Brake is released after a throttle and key ON;
command has been initiated, and is Initial brake
applied when travel is stopped or release: 0.4V,
EPO is depressed. then16V
140 JPF4-13 RELAY_ENABLE Control path for K1, K2, K3, and K4 B+ w/Key Switch VM K1, K2,
on the Fuse/Relay Card. After S1 is ON and all relays K3 & K4
closed, all relays are energized de-energized;
simultaneously during SelfTest if the <0.5 w/Key
voltage at BATTERY_SENSE_IN is Switch OFF or ON
between 28 and 45V. If the vehicle and any relay
is equipped with optional heaters, energized
the VM may keep this circuit active
at B– even with the Key Switch OFF
(JPC14-7) to allow the heaters to run
based on the ambient temperature
sensor input.
141 JPL1-1 B+K3 B+ to the LPA. Present when K3 is B+ w/K3 K3 LPA

energized. energized
142 JPL1-6 LPC Control path for the LPC. The Lift LPC de-energized: LPA LPC
Power Amplifier supplies a path for B+
B– for the contactor by the way of energized:14.7V
the B– terminal.

Pinout Matrix

143 JPL1-7 L VEL SENSOR– Return path for the encoder in the Lift <0.5V LPA Lift
Motor. Encoder
144 JPL1-8 T TEMP+ Temp Sensor input to the LPA. Approx. 1V @ Lift Motor LPA
Analog voltage that varies with the 75ºF (24ºC) Temp
Lift Motor temperature. Sensor
145 JPL1-11 ID0 B+ present at the amp with the K3 Approx. B+ w/K3 K3 LPA
tips activated. It is used as an energized
identifier.
146 JPL1-12 ID1 Not Used
147 JPL1-13 B+K3 B+ for the LPC(4200 only). The Lift B+ w/Key ON LPA LPC Coil
Power Amplifier supplies B+ for the
LPC.
148 JPL1-23 BUS+ Positive component of the digital 2.8V VM VM,

communications (CAN Bus) between Power
the VM and Power Amplifiers. Amps
149 JPL1-26 L VEL SENSOR+ 5V to the encoder on the Lift Motor. 4.95V LPA Lift
Encoder
150 JPL1-31 L VEL PHASE A Input to LPA from Lift Motor Encoder. Motor Stationary: Lift LPA
It is a square wave that is either high 4.06 or 0.03V Encoder
(>3V) or low (<1V). The frequency Turning: 2.3V
varies directly with motor speed.
Identical to L VEL Phase B except for
phase. The LPA uses the relationship
between phases to determine lift
speed.
151 JPL1-32 L VEL PHASE B Input to LPA from Lift Motor Encoder. Motor Stationary: Lift LPA
Identical to L VEL Phase A except for
phase. The LPA uses the relationship
between phases to determine lift
speed.
152 JPL1-33 BUS– Negative component of the digital 2.185V VM VM,

153 JPTL1-1 B+K3 B+ to Left TPA. Present when K3 is B+ w/K3 K3 Left TPA
154 JPTL1-7 T VEL SENSOR– Return path for the encoder in the <0.5V Left TPA TML
Left Traction Motor (TML). Encoder
155 JPTL1-8 T TEMP+ TML Temp Sensor input to the left Approx. 1V @ TML Temp Left TPA
TPA. Analog voltage that varies with 75ºF (24ºC) Sensor
motor temperature.
156 JPTL1-11 NOT USED

Pinout Matrix

157 JPTL1-12 ID1 B+ present at the amp with the K3 B+ K3

tips activated. It is used as an –1V w/K3
identifier. energized
158 JPTL1-21 CAN TERM H Connection used to terminate the 2.96V w/K3 Left TPA Left TPA
BUS+, BUS– communication. energized
159 JPTL1-23 BUS+ Positive component of the digital 2.8V VM VM,

160 JPTL1-26 T VEL SENSOR+ 5V supply to the TML Encoder. This 4.95V Left TPA TML
voltage is produced by the left TPA Encoder
from B+K3.
161 JPTL1-31 T VEL PHASE A Input from TML Encoder to left TPA. It Motor Stationary: TML Left TPA
is a square wave that is either high 4.06V or 0.03V Encoder
Identical to T VEL Phase B except for
phase. The left TPA uses the
relationship between phase A and B
to determine travel speed and
direction.
162 JPTL1-32 T VEL PHASE B Input from TML Encoder to left TPA. It Motor Stationary: TML Left TPA
is a square wave that is either high 4.06 or 0.03V Encoder
Identical to T VEL Phase A except for
phase. The TPA uses the relationship
between phase A and B to determine
travel speed and direction.
163 JPTL1-33 BUS– Negative component of the digital 2.185V VM VM,

164 JPTL1-34 CAN TERM L Connection used to terminate the 2.96V w/K3 Left TPA Left TPA
Bus+, Bus– communication. energized
165 JPTR1-1 B+K3 B+ to Right TPA. Present when K3 is B+ w/K3 K3 Right TPA
166 JPTR1-6 TPC Control path for the TPC. The right TPC de-energized: Right TPA TPC
TPA supplies a path for B– for the B+
contactor. energized:14.7V
167 JPTR1-7 T VEL SENSOR– Return path for the encoder in the <0.5V Right TPA TMR
Right Traction Motor (TMR). Encoder
168 JPTR1-8 T TEMP+ TMR Temp Sensor input to the right Approx. 1V@75ºF TMR Temp Right TPA
TPA. Analog voltage that varies with (24ºC) Sensor
motor temperature.
169 JPTR1-11 ID0 B+ present at the amp with the K3 Approx. B+ w/K3 K3 VM
identifier.

Pinout Matrix

170 JPTR1-12 ID1 B+ present at the amp with the K3 Approx. B+ w/K3 K3 VM
identifier.
171 JPTR1-13 B+K3 B+ to the TPC from the right TPA. B+ w/Key ON TPA TPC Coil
172 JPTR1-23 BUS+ Positive component of the digital 2.8V VM VM,

communications between the VM Power
and Power Amps. Amps
173 JPTR1-26 T VEL SENSOR+ 5V supply to the TMR Encoder. This 4.95V Right TPA TMR
voltage is produced by the Right TPA Encoder
from B+K3.
174 JPTR1-31 T VEL PHASE A Input from TMR Encoder to right TPA. Motor Stationary: TMR Right TPA
Identical to T VEL Phase B except for
phase. The right TPA uses the
direction.
175 JPTR1-32 T VEL PHASE B Input from TMR Encoder to right TPA. Motor Stationary: TMR Right TPA
Identical to T VEL Phase A except for
phase. The right TPA uses the
direction.
176 JPTR1-33 BUS– Negative component of the digital 2.185V VM VM,


Pinout Matrix

Models 4100/4200 Maintenance Manual Section A. Appendix
Section A. Appendix
Publication: 1060345A, Issued: 8/27/07 A-1

Section A. Appendix Models 4100/4200 Maintenance Manual
Lubrication Specification Chart
Lubrication Specification
Chart
Approved Raymond Lubricants
Where Used Type Specification Raymond Part Number
75W-90 Synthetic Gear

Drive Unit Gear Case Gear 990-655/001 (1 qt./0.9 liter)
Oil
(all applications) Lubricant 990-655/003 (1 gal/3.8 liters)
API Service GL-5
10W-30 Motor Oil 990-603/04 (1 qt./0.9 liter)

Lift Chains Oil API Service CE, CD, CC, 990-603/03
SG, SF (5 gal/18.9 liters)
Hydraulic Reservoir 990-616/04 (1 qt./0.9 liter)

ISO 46
(Non-CS trucks) Hydraulic 990-616/01 (1 gal/3.8 liters)
Anti-Wear Hydraulic
(+50°F to +120°F) Fluid 990-616/02 (2 gal/7.6 liters)
Fluid
(+10°C to +49°C) 990-616/03 (5 gal/18.9 liters)
Hydraulic Reservoir
(CS trucks)
Hydraulic 990-618/TX1 (1 gal/3.8 liters)
(–20°F to –0°F) MIL-H-5606E
Fluid 990-618/01 (1 gal/3.8 liters)
(–29°C to –18°C)
(confined to freezer)
Hydraulic Reservoir
(CS trucks)
Hydraulic 990-617/01 (1 gal/3.8 liters)
(–20°F to +70°F) ISO 32
Fluid 990-617/03 (5 gal/18.9 liters)
(–29°C to +21°C)
(in and out of freezer)
Hydraulic Reservoir ISO 46

Hydraulic 990-615/01 (1 gal/3.8 liters)
(high performance/ Multi-Viscous Hydraulic
Fluid 990-615/03 (5 gal/18.9 liters)
high temp conditions) Fluid
1012992/01
Mast Uprights, Bearings Grease NLGI Grade 2 (10 cartridges/case)
1012992/02 (5 gal/18.9 liters)
1012992/01
Mast Uprights, Bearings, Grease
NLGI Grade 2 (10 cartridges/case)
(CS trucks) w/Teflon
1012992/02 (5 gal/18.9 liters)
SAE Standard J1705F 990-625/01 (1 gal/3.8 liters)

Hydraulic Brake Brake Fluid Federal Motor Vehicle 990-625/02 (1 qt./0.9 liter)
Standard No. 116, DOT-5 990-625/03 (1 pt./0.47 liter)
A-2 Publication: 1060345A, Issued: 8/27/07

Thread Adhesives, Sealants, and Lubricants
Thread Adhesives,
Sealants, and Lubricants
Loctite*
Application Raymond P/N
Number/Color
Thread-locking 1/4 in. and below 990-403 222/Purple
Thread-locking 1/4 to 3/4 in. contamination tolerant 990-536 243/Blue
Thread-locking 1 in. and under 990-544 271/Red
Thread-locking 1 in. and under, contamination tolerant 990-463 603/Green
Thread-locking 1 in. and over 990-571 277/Red
Thread-locking Cleaner/Primer 990-538 7075
Thread-locking Primer 990-533 T7471
Hydraulic Sealant, fittings up to 2 in. 990-552 569
Molybdenum Anti-Seize Compound (Molykote) 990-638 Silver
Gasket Cement 990-556 Permatex 300
Cover Plate Sealant 990-443 587/UltraBlue
Corrosion Inhibitor Coating 990-456/001
Silicone Sealant (cold storage) 990-445 Dow Corning III
NOTE: * Loctite is a registered trademark of the

Loctite Corporation. Brand endorsement
is not implied here, but listed only as a
commonly identified product.

Component Specific Torque Chart
Component Specific
Torque Chart
Thread-Locking
Component Sub-Component(s) Torque to:
Compound
mounting to drive motor 13 ft. lb. (18.2 Nm)
Brake coil mounting to lower
9 ft. lb. (12 Nm)
friction plate
clamp nut 125 ft. lb. (170 Nm)
Drive Axle
clamp nut screw P/N 990-536 140 in. lb. (8 Nm)
mounting bolts 13 ft. lb. (18.2 Nm)
Drive Motor cable securing nuts 18 ft. lb. (24 Nm)
pinion shaft 45 ft. lb. (63 Nm)
cover screws 6 ft. lb. (8.6 Nm)
Drive Unit tractor frame mounting
120 ft. lb. (168 Nm)
bolts
Drive Wheels mounting bolts 108 ft. lb. (146 Nm)
Hydraulic Steer Motor sprocket set screws P/N 990-536 N/A
Lift Cylinders end caps P/N 990-571 200 ft. lb. (271 Nm)
4100 cable securing nuts 100 - 120 in. lb. (11.3 - 13.6 Nm)
Lift Motor
4200 cable securing nuts 205 - 220 in. lb. (23 - 24.8 Nm)
lower and upper
Mast 43 ft. lb. (60 Nm)
mounting bolts
cover capscrew 63 ft. lb. (18.2 Nm)
Mast, Quad
clamp capscrew 11 ft. lb. (15 Nm)
Power Amplifiers mounting bolts 7.4 ft. lb. (10 Nm)
Power Amplifiers power cables 100 in. lb. (11.3 Nm)
Free lift cylinder supply
5.9 ft. lb. (8 Nm)
hose clamp
Solenoid Coils securing nut 5 ft. lb. (7 Nm)
Solenoid Valves N/A 60 ft. lb. (81 Nm)
Speed Feedback Sensor mounting bolts P/N 990-536 N/A
impeller shroud mounting
P/N 990-536 N/A
screws
power cable securing
Steer Motor 45-55 in. lb. (5.0-6.2 Nm)
nuts
Reference Torque Chart -
mounting bolts (qty. 4) P/N 990-536
Standard (Ferrous) on page A-5.
sensor mounting screws
P/N 990-536 N/A
Steer Reference (Home) (qty. 4)
Proximity Sensor bracket mounting bolts
P/N 990-536 N/A
(qty. 2)
A minimum pressure of 5 tons (4536 kg) is required to press on a new tire. If
Tire Replacement
the minimum pressure is not met, replace the hub.

Torque Chart - Standard (Ferrous)
Torque Chart - Standard

(Ferrous)
Grade
Identification None
Marking
SAE Grade 2 Bolts SAE Grade 5 Bolts SAE Grade 8 Bolts
Tightening Torque Tightening Torque Tightening Torque
Size
Dry Oiled Dry Oiled Dry Oiled
in. lb. in. lb. in. lb. in. lb. in. lb. in. lb.
4-40 5 4 8 6 12 9
4-48 6 5 9 7 13 10
6-32 10 8 16 12 23 17
8-32 19 14 30 22 41 31
8-36 20 15 31 23 43 32
10-24 27 21 43 32 60 45
10-32 31 23 49 36 68 51
1/4-20 66 49 96 75 144 108
1/4-28 78 56 120 86 168 120
ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb.
5/16-18 11 8 17 13 25 18
5/16-24 12 9 19 14 25 20
3/8-16 20 15 30 23 45 35
3/8-24 23 17 35 25 50 35
7/16-14 30 24 50 35 70 55
7/16-20 35 25 55 40 80 60
1/2-13 50 35 75 55 110 80
1/2-20 55 40 90 65 120 90
9/16-12 65 50 110 80 150 110
9/16-18 75 55 120 90 170 130
5/8-11 90 70 150 110 220 170
5/8-18 110 85 180 130 240 180
3/4-10 160 120 260 200 380 280
3/4-16 180 140 300 220 420 320
7/8-9 140 110 400 300 600 460
7/8-14 155 120 440 320 660 500
1-8 220 160 580 440 900 680
1-12 240 170 640 480 1000 740
1 1/8-7 300 220 800 600 1280 960
1 1/8-12 340 260 880 660 1440 1080
1 1/4-7 420 320 1120 840 1820 1360
1 1/4-12 460 360 1240 920 2000 1500
1 3/8-6 560 420 1460 1100 2380 1780
1 3/8-12 640 460 1680 1260 2720 2040
1 1/2-6 740 560 1940 1460 3160 2360
1 1/2-12 840 620 2200 1640 3560 2660
Note: Use “oiled” values for bolts with thread-locking compound.

Torque Chart - Metric
Torque Chart - Metric

Ferrous Metric Bolts, Coarse Thread
(The grade rating is stamped on the head of the bolt)
Grade 8.8 Grade 10.9
Diameter
Torque (with bolts oiled) Torque (with bolts oiled)
(in millimeters)
Nm ft. lb. Nm ft. lb.
6 8.6 6 12 9
8 21 15 29 21
10 42 30 68 43
12 72 55 101 75
16 174 130 245 181
20 340 255 475 350
24 580 435 820 605
Brass MS63 Metric Bolts, Coarse Thread

Diameter Torque (with bolts oiled)
(in millimeters) Nm in. lb.
3 0.5 4.4
3.5 0.79 7.0
4 1.2 10
5 2.2 19
6 3.9 34
8 9 79
10 17 150

Torque Chart - Standard (Brass)
Torque Chart - Standard

(Brass)
Brass MS63 Standard Bolts, Coarse Thread

Torque (with bolts oiled)
Size
Nm in. lb.
4-40 0.37 3.3
4-48 0.40 3.6
6-32 0.69 6.1
6-40 0.77 6.8
8-32 1.24 11
8-36 1.24 11
10-24 1.58 14
10-32 1.92 17
1/4-20 3.96 35
1/4-28 4.52 40
5/16-18 8.25 73
5/16-24 9.15 81
3/8-16 14.69 130
3/8-24 16.61 147

Decimal Equivalent Chart

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
1/64 .016 .02 0.397
1/32 .031 .03 0.794
3/64 .047 .05 1.191
1/16 .062 .06 1.587
5/64 .078 .08 1.984
3/32 .094 .09 2.381
7/64 .109 .11 2.778
1/8 .125 .12 3.175
9/64 .141 .14 3.572
5/32 .156 .16 3.969
11/64 .172 .17 4.366
3/16 .188 .19 4.762
13/64 .203 .20 5.159
7/32 .219 .22 5.556
15/64 .234 .23 5.593
1/4 .250 .25 6.350
17/64 .266 .27 6.747
9/32 .281 .28 7.144
19/64 .297 .30 7.540
5/16 .312 .31 7.937
21/64 .328 .33 8.334
11/32 .344 .34 8.731
23/64 .359 .36 9.128
3/8 .375 .38 9.525
25/64 .391 .39 9.922
13/32 .406 .41 10.319
27/64 .422 .42 10.716
7/16 .438 .44 11.112
29/64 .453 .45 11.509
15/32 .469 .47 11.906
31/64 .484 .48 12.303
1/2 .500 .50 12.700

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
33/64 .516 .52 13.097
17/32 .531 .53 13.494
35/64 .547 .55 13.891
9/16 .562 .56 14.288
37/64 .578 .58 14.684
19/32 .594 .59 15.081
39/64 .609 .61 15.478
5/8 .625 .62 15.875
41/64 .641 .64 16.272
21/32 .665 .66 16.669
43/64 .672 .67 17.065
11/16 .688 .69 17.462
45/64 .703 .70 17.859
23/32 .719 .72 18.256
47/64 .734 .73 18.653
3/4 .750 .75 19.050
49/64 .766 .77 19.447
25/32 .781 .78 19.844
51/64 .797 .80 20.241
13/16 .812 .81 20.637
53/64 .828 .83 21.034
27/32 .844 .84 21.431
55/64 .859 .86 21.828
7/8 .875 .88 22.225
57/64 .891 .89 22.622
29/32 .906 .91 23.019
59/64 .922 .92 23.416
15/16 .938 .94 23.812
61/64 .953 .95 24.209
31/32 .969 .97 24.606
63/64 .984 .98 25.003
1.000 1.00 25.400

Standard/Metric Conversions
Standard/Metric
Conversions
To Convert... Multiply, Add, or Subtract...
Area
Square Inches to Square Centimeters Square Inches x 6.452
Square Centimeters to Square Inches Square Centimeters x 0.155
Square Feet to Square Meters Square Feet x 0.093
Square Meters to Square Feet Square Meters x 10.753
Square Yards to Square Meters Square Yards x 0.836
Square Meters to Square Yards Square Meters x 1.196
Distance
Inches to Millimeters Inches x 25.4
Millimeters to Inches Millimeters x 0.039
Inches to Centimeters Inches x 2.54
Centimeters to Inches Centimeters x 0.394
Feet to Meters Feet x 0.305
Meters to Feet Meters x 3.281
Yards to Meters Yards x 0.914
Meters to Yards Meters x 1.094
Miles to Kilometers Miles x 1.609
Kilometers to Miles Kilometers x 0.621
Mass
Ounces to Grams Ounces x 28.35
Grams to Ounces Ounces x 0.035
Ounces to Kilograms Ounces x 0.028
Kilograms to Ounces Kilograms x 35.27
Pounds to Kilograms Pounds x 0.454
Kilograms to Pounds Kilograms x 2.2
Pressure
Pounds per Square Inch (PSI) to kiloPascals PSI x 6.894
kiloPascals to Pounds per Square Inch (PSI) kiloPascals x 0.145
Speed
Miles per hour to Kilometers per hour Miles per hour x 1.609
Kilometers per hour to Miles per hour Kilometers per hour x 0.6214
Temperature
Fahrenheit to Celsius (°F minus 32) x 0.555
Celsius to Fahrenheit (°C x 1.8) plus 32
Torque
Inch Pounds (in. lbs.) to Newton Meters (Nm) Inch Pounds x 0.113
Newton Meters (Nm) to Inch Pounds (in. lbs.) Newton Meters x 8.85
Foot Pounds (ft. lbs.) to Newton Meters (Nm) Foot Pounds x 1.3568
Newton Meters (Nm) to Foot Pounds (ft. lbs.) Newton Meters x 0.737
Volume
Pints to Liters Pints x 0.473
Liters to Pints Liters x 2.113
Quarts to Liters Quarts x 0.946
Liters to Quarts Liters x 1.057
Gallons to Liters Gallons x 3.785
Liters to Gallons Liters x 0.26

Schematics
Schematics

Schematics

Models 4100/4200 Maintenance Manual
A
A B C D E F G H
MOTOR VELOCITY JPTL2 JPTL1 JPS2 JPC24

RED -1 -26
T VEL SENSOR+
TRACTION -1 BRN -1
+12VP VEHICLE
SPL4
BLACK -4 -7
T VEL SENSOR-
LEFT POWER
JPTL1
STEER
POSITION
-2 WHT -17
POS A MANAGER
TLE WHITE -3 -31 AMPLIFIER SENSOR -3 BLK -20
T VEL PHASE A
2
-21 CAN BUS POS B
BLUE -2 -32 CAN TERM H TERMINATION
T VEL PHASE B -34 -4 BLU JPC22-9
POS C
RED JPTL3 -2 -8 CAN TERM L
T TEMP+
WHT -1 JPC12-1 JPH1-1
TLT -23 +5VP +5VP OPTIONAL
BUS+
SEE NOTE 2 -35 CONTROL HANDLE
BUS- +5VP
MOTOR TEMPERATURE -11 -3 -3
ID0 TRAVEL VR1
-12
ID1
- DGND
+5VP +5VP +
U 0
U -2 -2 SW1
CONTACTOR V
LIFT VR2
PANEL TML V
B+K3
-1
DGND DGND
-
TP1 W
W -10 -10 +5VP
HORN
+
-4 -4
FCN 1
SW3
FU1 FU3 FU2
(750A) MOTOR VELOCITY JPTR2 JPTR1 DGND
(150A) (500A)
RED -1 -26 +5VP
TP2 TP3 TP5 T VEL SENSOR+ TRACTION
-4 SPL6 -7
BLACK -11 -11
JP JPS1-1 T VEL SENSOR- RIGHT POWER FCN 2
B+ TRE WHITE -3 -31 +5VP
-2 1 1 1 T VEL PHASE A AMPLIFIER SW2
BLUE -2 -32 -5 -5
3
-3 STR LPC TPC T VEL PHASE B DGND
2 SSHIFT
-4 2 2 RED JPTR3 -2 -8 JPTR1
T TEMP+
WHT -1 -23
TRT BUS+ JOYSTICK
-35 SW4
SEE NOTE 2 -13 BUS-
B+K3
MOTOR TEMPERATURE -6 -8 -8
TPC -11 TILT
JPS1 ID0
-12
-11 ID1
CONTROL HANDLE
-12 -12
- DGND DGND
X Y -13
-8 U
TPC U HTR6
-7
SPL8
-7
V H_HTR
TMR V -1
B+K3
W
W
SPL1
SPL2
SPL3
+
JPC12-1
+5VP +5VP STANDARD
+5VP
CONTROL HANDLE
X X MOTOR VELOCITY JPL2 JPL1
RED -1 -26 -3
STR L VEL SENSOR+ LIFT POWER TRAVEL VR1
LPC SPL5
BLACK -4 -7 AMPLIFIER
SEE L VEL SENSOR-
Y LME WHITE -3 -31 DGND
Y NOTE L VEL PHASE A
+5VP
4
3 BLUE -2 -32 S3
L VEL PHASE B
JPL1 JPC14 -2
JPS1 -5 -12 -6 -7 -9 -10 RED JPL3 -2 -8 LIFT VR2
L TEMP+
-23 -11 DGND
LMT WHT -1 BUS+ BUS+
-35 -4 DGND
AUX(+) BUS- BUS- -10
-3 HORN
MOTOR TEMPERATURE -11 DGND -4 S4
SM -13 ID0 FCN 1
B+K3
-6 -12 -11
ID1 JPC9-2 DGND
JP JL4-AC (AC LIFT) LPC TXD FCN 2
FLASHWARE
B- AUX(-)
-1 -3 -5
RXD TILT_UP S6
-2 -5
PL4 U DGND -6
SPL7
-1 U TILT_DOWN S7 S5
V -8
-2 JL4-DC (DC LIFT) AC LIFT -1 SSHIFT_LEFT S8
-1 LM V DGND
COMMUNICATIONS
B+K3 -9
ONLY JPC3-1 SSHIFT_RIGHT S9
W VBUS
-2 W -12
+ - -2
D- DGND DGND
USB
-3
D+
TP4 -4 DGND
JPC18-9
LPC_CTRL
JPC22-20
LPC_SENSE JPC20-15
JPC18-11 ISENSE2(K2) SOL2
STR_CONTACTOR 1
JPC22-19 2
STR_SENSE -16
LIFT/LOWER
JPC14-10
-2
-1
DGND
DGND ISENSE5(K2)
-13
SOL6 5
B-F 1 2
-8 JPC18-1
B-F AUX SELECT
-9
B-F JPC20-17
ISENSE3(K2) SOL4
OPERATOR 1 2
JPD2 DISPLAY JPD1 -18
-1 -1 JPC6-6 PRIORITY BYPASS
+12V
UP -6 -2 -19
ADDR_LATCH
SPL9 1 2
-2 -3 JPC24-12 -20
DATA_LATCH PROP RELIEF
DN -5 -4 JPC22-10 JPF2-8 FUSE
DISP_MISO JPC18 ZONE C7
RELAY
-3 -5 JPC24-2 -10 CARD
SOL1
JPF1-3
JPF2-1
JPF2-2
JPF1-6
LOAD HOLD
JPF3-3
ALARM_PWM
ENTER 2 1
-10
-11
-12
JPB1 -4 SOUNDER -6 JPC6-5

-5
-8
-9
-4
-5
-6
-7
-1 SHIFT_CLOCK
POWER AMP - + JPC20-12
FAN OPTION -7 JPC6-2 SOL3
ACCESORY DATA_OUT DUMP
(MODEL 4200 -2
JPF3-1 POWER -8 JPC6-4 2 1
ONLY) DGND
FU6 (15A) TS1
-2 T° T° -1 JPC18-12
HSA1 SOL7R
1 2 JPC18-17
JPF1-4 -2 B- PA_FAN 2 1
JPF1-1
-3 HRN
FU8 (15A/5A) JPB4-1 HRN+ -14
-2 SIDESHIFT SOL9R
-4 BATTERY HRN0 JPC18-16
1 2 JPF4-15 HORN 2 1
-5
HRN-
6
JPF4-3 FU7 (15A/5A) K1 -15
-6 KEY LEFT RIGHT H TILT SOL10
JPF2-9
-4 1 2 BRAKE BRAKE H-1(+) 2 1
-3
TRAVEL
K3 -5 JPB3-1 H-2(-) JPC18-18 SOL7C
ALARM TRAV/LIFT ALARM
T° JPF4-11 -2 2 1 MAST MOUNTED SOLENOIDS
OPTION
JPB4-2
-12
JPC20-14 SOL9L
-8 BRAKES
PCB
MOUNTING FUSE/ 2 1 JPH2 1
STUD
RELAY HSA2
-8 -1 SOL11 SOL12
JPF4-13 JPC14-6
CARD JPC22-21
RELAY_ENABLE MAST 1 2
CONNECTOR 2
EPO_SENSE -2
K4 K3 K2 K1 JPC14-12 1
B+KEY
-5
SOL13
2 1 JPC22-8 -3
S21 ON DEADMAN
EPO NC
S2 2
S2-NO S2-COM JPC22-11
FU5 (15A) S1 DGND -4
-1 -10 1 2
1 2 DEADMAN
KEYSWITCH SWITCH
K2 K4 OR ROTARY SWITCH JPC14
-2 JPF2-4 -7
B+K4
-6 -13
B+K2
-7 -14
B+K2
T° JPF4-7 JPC24-24
BATTERY_SENSE_IN 7
JPF2-8 ZONE G5
TO SOLENOID 1
Model 4200
MODEL - AC
4200 Lift
- AC LIFT
Publication: 1060345A, Issued: 8/27/07 Figure A-1. Electrical Schematic (Sheet 1 of 4) A-13
A
A B C D E F G H
TS1
-5 WHT
JPW5
-2 RED +
WL
- BLK WARNING LIGHT VEHICLE
JPC20 JPS14
2
-2 FU11 OPTION MANAGER -3 -3
BLK -1 +12VP
S22A
JPC22
1.5A -3 -1 LEFT
GATE_L
BATTERY
JPC24 GATE
DGND -3 -2
OPTION
JPC20 JPS13
+12VP -4 -3
S22B
JPC22
-4 -1 RIGHT
GATE_R
BATTERY
JPC24 GATE
DGND -4 -2
OPTION
JPC20 JPS5
MODEL 4200 ONLY
+12VP -8 -4
WORKING LIGHTS S11
JPC22
JPWL3 -22 -1 HI-SPEED
OPTION HIGH_SPD
-1 LIMIT
1 2 JPC24 SWITCH
S10 JPWL5 JPWL1
DGND -8 -2
-1 -1 WORK OPTION
3
TS1 SPL11 JPWL4 JPWL2 LIGHTS
-3 -1 -2 -1 -1 LEFT RIGHT REV BOTTLER'S
ACCESSORY POWER
JPC20 JPT1
(BATTERY) 2 1 1 1 1 MODEL 4200 ONLY TILT OPTION
S15 JPWL4 JPWL2 -5 -1
-1 +12VP S18
ACCESSORY POWER -2 -2 2 2 2 JPC22
-5 -2 MAST
B- JPWL5 JPWL1 TILT_DIN
-2 -2 TILT
JPC24 SWITCH
JPWL3 -5 -3
DGND OPTION
-2
-22 -4
TILT_AIN
JPC20 JPS6
MODEL 4200 ONLY TP1 (B+)
+12VP -6 -4
S12
JPC22 S12
-6 -1 LIFT
LIFT_LIM MAST TILT SPEED
LIMIT OR
JPC24 REDUCTION
SWITCH JPHT1
DGND -6 -3 (QUAD MAST ONLY)
OPTION -1 HTR6
-2
CONTROL HANDLE
THERMOSTAT
VM
+12VP
JPC24
-13
JPY1
-1
PRESSURE
4
-18 -2 (WEIGHT) TP4 (B-)
PRESSURE_AIN PRESS
-10 -3 SENSOR
DGND OPTION
SWITCH BASED HANDLE
INTERNAL HEATER
MODEL 4200 ONLY LEVER OPTION

VEHICLE
MANAGER JPC4
SPL18 RED
-1
+5VP
LEVER
SPL19 YELLOW 1 OPERATOR'S COMPARTMENT
-4
LEVER1_AIN VR3 SENSOR SYSTEM
DGND
-2
SPL20 BLACK
JPH3
VEHICLE
JPC20
(OCSS) OPTION
JPW1
-1
5
FAN MANAGER -1 BRN
-1 RED +12VP UPPER
TS1 -2 S36 -1
ACCESSORY POWER -5 + - LEVER JPC10 SPL10 LEFT
KEY 2 -3 -2 BLU EMITTER
-3 YEL ENABLE
TS1 FU12 JPC20
ACCESSORY POWER -2 -2 BLK -2
+12VP
B- JPW4
1.5A -1 BRN
-4 WHT JPC22
OPERATOR'S COOLING FAN OPTION SW5 -13 -3 BLK LOWER
JPC22 JM1 BEAM_L
LEFT
-2 -2 -5 ORG JPC18
LEVER2_DIN DETECTOR
-5 -4 BLU
JPH4 DGND
-1 RED JPC20 JPW3
-9 -1 BRN
LEVER +12VP LOWER
-3 3
YEL JPC20 RIGHT
-10 -2 BLU
+12VP EMITTER
-2 BLK JPW2
SPL17 JPC22 -1 BRN
-2 -4 WHT -14 -2 BLK UPPER
BEAM_R
-1 SW6 RIGHT
JPC22 JM1 JPC18 DETECTOR
-1 -1 -5 ORG -6 -4 BLU
LEVER3_DIN DGND
6
MODEL 4200 ONLY JPC12A SPL15 JPC12B
VEHICLE
+5VP -1 -1
MANAGER -2 -1 -2 -2
LIFT
TRAVEL -3 -3
FUNCTION 4A -4 -4
JPC24 JPA SSHIFT -5 -5
-23 -1 -6 TO
AMBIENT LEVER2_AIN TRUCK
T H_HTR -7 -7 CONTROL
-7 -2 -8 -8 HANDLE
DGND TILT
LEVER3_AIN -9
HORN -10 -10

FUNCTION 4B -11 -11
DGND -12 -12

AMBIENT TEMPERATURE SENSOR OPTION -1 -2
SPL16
A
A B C D E F G H
NOTES:
1. MAST IN FULLY LOWERED POSITION.

KEY SWITCH OFF, EPO NOT DEPRESSED, NOT ON DEADMAN. LEGEND LEGEND
2. TEMPERATURE SENSOR COLOR CODES SHOWN ARE FOR 4K TRACTION MOTOR.
FOR 5K TRACTION MOTOR, PIN 1 IS BLACK AND PIN 2 IS BROWN.
3. MOTOR ENCODER COLOR CODES SHOWN ARE FOR 4K LIFT MOTOR.
FOR 5K LIFT MOTOR, PIN 2 IS WHITE AND PIN 3 IS BLUE.
IDENT. ZONE/SHEET DESCRIPTION IDENT. ZONE/SHEET DESCRIPTION
2
AUX(+) A4/1&4 STEER MOTOR POSITIVE TERMINAL
SM A4/1&4 STEER MOTOR
AUX(-) A4/1&4 STEER MOTOR NEGATIVE TERMINAL
SOL1 G6/1&4 LOAD/HOLD SOLENOID
EPO C7/1&4 EMERGENCY POWER OFF (S21) SOL2 G5/1&4 LIFT/LOWER PROPORTIONAL SOLENOID
SOL3 G5/1&4 DUMP SOLENOID
FU1 B3/1&4 POWER FUSE FOR STEER G5/1&4
SOL4 PRIORITY BYPASS SOLENOID
FU2 B3/1&4 POWER FUSE FOR TRAVEL SOL5 G5/1&4 PROPORTIONAL RELIEF SOLENOID
FU3 B3/1&4 POWER FUSE FOR LIFT SOL6 G6/1&4 AUX SELECT SOLENOID
SOL7C G6/1&4 SOLENOID FOR HIGH-SPEED ATTACHMENTS
FU5 B7/1&4 CONTROL FUSE FOR VEHICLE MANAGER B+ G6/1&4 SOLENOID FOR HIGH-SPEED ATTACHMENTS
SOL7R
FU6 B6/1&4 CONTROL FUSE FOR VEHICLE MANAGER B- G6/1&4
SOL9L SIDESHIFT LEFT SOLENOID
FU7 B6/1&4 CONTROL FUSE FOR AUX. POWER B+ G6/1&4
SOL9R SIDESHIFT RIGHT SOLENOID
FU8 B6/1&4 CONTROL FUSE FOR AUX. POWER B- G6/1&4
SOL10 TILT SOLENOID
SOL11 H6/1&4 HIGH SPEED ATTACHMENT 2 SOLENOID
FU11 A2/2 CONTROL FUSE FOR WARNING LIGHT & STROBE
FU12 B5/2 CONTROL FUSE FOR OPERATOR'S FAN E4/1&4
SPL1 SPLICE
SPL2 F4/1&4 SPLICE
HRN E6/1&4 HORN SPL3 F4/1&4 SPLICE
H E6/1&4 TRAVEL ALARM SPL4 D2/1&4 SPLICE
SPL5 D4/1&4 SPLICE
SPL6 D3/1&4 SPLICE
HTR6 G3, G5/1 HEATER FOR CONTROL HANDLE (INTERNAL) E5/1&4
SPL7 SPLICE
JPA
JPB+
B6/2
A3/1&4
CONNECTOR FOR TEMPERATURE SENSOR
BATTERY +
SPL8
SPL9
E3/1&4
C5/1&4
SPLICE
SPLICE 3
SPL10 F4/2 SPLICE
JPB- A4/1&4 BATTERY - SPL11 B3/2 SPLICE
JPB1 E6/1&4 POWER AMP FAN OPTION CONNECTOR
JPB3 D6/1&4 BRAKE CONNECTOR-LEFT
JPB4 D6/1&4 BRAKE CONNECTOR-RIGHT D6/2
SPL15 SPLICE
SPL16 D7/2 SPLICE
JPC3 F5/1&4 USB CONNECTOR ON VM D6/2
SPL17 SPLICE
JPC4 D5/2 OPTIONAL LEVER #1 CONNECTOR SPL18 D5/2 SPLICE
JPC6 F5/1&4 CONNECTOR ON VM SPL19 D5/2 SPLICE
JPC9 F4/1&4 CONNECTOR ON VM FOR FLASHWARE SPL20 D5/2 SPLICE
JPC10 F4/1&4 CAN; DIGITAL INPUTS & OUTPUTS CONNECTOR ON VM
JPC12 G3, G4/1&4 HANDLE CONNECTOR ON VM STR B4/1&4 STEER POWER CONTACTOR
JPC12A D6/2 CONNECTOR FOR LEVER OPTION HARNESS
JPC12B E6/2 CONNECTOR FOR LEVER OPTION HARNESS SW1 H2/1 CONTROL HANDLE HORN SWITCH
OPTIONAL
JPC14 F4/1&4 B+, B-, CAN COMMUNICATIONS CONNECTOR ON VM SW2 H3/1 CONTROL HANDLE ANALOG PUSHBUTTON FOR FCN 2
ANALOG
JPC18 F5/1&4 COIL DRIVERS CONNECTOR ON VM SW3 H3/1 CONTROL HANDLE ANALOG PUSHBUTTON FOR FCN 1
HANDLE
JPC20 G6/1&4 PROPORTIONAL COIL DRIVERS ON VM SW4 G3/1 CONTROL HANDLE TILT/SIDESHIFT JOYSTICK
SW5 E6/2 LEVER #2 INPUT SWITCH
JPC22 F2/1&4 DIGITAL INPUTS CONNECTOR ON VM SW6 E6/2 LEVER #3 INPUT SWITCH
JPC24 F2/1&4 ANALOG INPUTS CONNECTOR ON VM H-1(+) E6/1&4 TRAVEL ALARM POSITIVE TERMINAL
H-2(-) E6/1&4 TRAVEL ALARM NEGATIVE TERMINAL
JPD1 F5/1&4 DISPLAY CONNECTOR C2/1&4
4
TLE TRACTION LEFT MOTOR ENCODER
JPD2 E5/1&4 DISPLAY CONNECTOR FOR OVERLAY C2/1&4
TLT TRACTION LEFT TEMPERATURE SENSOR
JPF1 B6/1&4 B- AUX POWER, B+ POWER AMPS CONNECTOR ON FUSE/RELAY CARD TML D3/1&4 TRACTION MOTOR LEFT
JPF2 C5/1&4 B+ KEY SWITCH RELAYS CONNECTOR ON FUSE/RELAY CARD TMR D4/1&4 TRACTION MOTOR RIGHT
JPF3 B5/1&4 B- CONNECTOR ON FUSE/RELAY CARD
JPF4 B6/1&4 KEY SWITCH, EPO, BATTERY SENSE CONNECTOR ON FUSE/RELAY CARD B3/1&4
TP1 TIE POINT ON B+
JPH1 G2, G4/1 CONTROL HANDLE CONNECTOR TP2 B3/1&4 TIE POINT ON AUXILIARY MOTOR FUSE
JPH2 G6/1&4 CONNECTOR FOR MAST TP3 B3/1&4 TIE POINT ON LIFT MOTOR FUSE
JPH3 D5/2 CONNECTOR FOR LEVER 2 TP4 A5/1&4 TIE POINT ON B-
JPH4 D6/2 CONNECTOR FOR LEVER 3 TP5 B3/1&4 TIE POINT ON TRACTION MOTOR FUSE
JPHT1 F2/2 MODEL 4100 HANDLE HEATER
TRE C3/1&4 TRACTION RIGHT MOTOR ENCODER
TRT C3/1&4 TRACTION RIGHT TEMPERATURE SENSOR
JPL1 D4/1 LIFT POWER AMP CONNECTOR

JPL2 C4/1 LIFT ENCODER CONNECTOR TS1 D6/1&4 TERMINAL STRIP FOR ACCESSORY POWER
JPL3 C4/1 LIFT MOTOR TEMPERATURE SENSOR CONNECTOR
JPL4-AC,-DC C4/1 LIFT POWER CONTACTOR CONFIGURATION CONNECTOR TPC C3/1 TRACTION POWER CONTACTOR
JM1 D6/2 LEVER OPTION CONNECTOR G2, G4/1,G4/4
VR1 CONTROL HANDLE VARIABLE INPUT DEVICE FOR TRAVEL
JPS1 B4/1&4 CONTACTOR PANEL INTERFACE CONNECTOR VR2 G2, G4/1,G4/4 CONTROL HANDLE VARIABLE INPUT DEVICE FOR LIFT/LOWER
JPS2 F2/1&4 STEERING POSITION SENSOR CONNECTOR VR3 E5/2 LEVER #1 VARIABLE INPUT DEVICE
VR4 E6/2 LEVER #2 VARIABLE INPUT DEVICE
JPS5 D3/2 HIGH SPEED LIMIT OPTION CONNECTOR
VR5 E6/2 LEVER #3 VARIABLE INPUT DEVICE
JPS6 D3/2 LIFT LIMIT SWITCH OPTION CONNECTOR
JPS13
JPS14
D3/2
D2/2
RIGHT BATTERY GATE SWITCH CONNECTOR
LEFT BATTERY GATE SWITCH CONNECTOR
WL B2/2 WARNING LIGHT 5
SOUNDER E5/1&4 DISPLAY AUDIBLE ALARM
JPT1 D3/2 MAST TILT SENSING OPTION CONNECTOR
T B7/2 AMBIENT TEMPERATURE SENSOR
JPTL1, JPTR1 D2, D3/1&4 TRACTION AMP CONNECTORS
D2, D3/1&4 FAN B5/2 OPERATOR'S COOLING FAN
JPTL2, JPTR2 TRACTION MOTOR ENCODER CONNECTORS
JPTL3, JPTR3 C2, C3/1&4 TRACTION MOTOR TEMPERATURE SENSOR CONNECTORS
JPWL1 B3/2 CONNECTOR FOR WORKING LIGHT
JPWL3 C3/2 CONNECTOR FOR WORKING LIGHT
JPWL5 B2/2 CONNECTOR FOR WARNING LIGHT
JPW1 F4/2 CONNECTOR FOR OCSS-UPPER LEFT EMITTER

JPW2 F5/2 CONNECTOR FOR OCSS-UPPER RIGHT DETECTOR
JPW3 F4/2 CONNECTOR FOR OCSS-LOWER RIGHT EMITTER
JPW4 F4/2 CONNECTOR FOR OCSS-LOWER LEFT DETECTOR
JPW5 B2/2 CONNECTOR FOR WARNING LIGHT
JPY1 B4/2 CONNECTOR WEIGHT PRESSURE SENSOR OPTION
K1 C6/1&4 KEYSWITCH RELAY-OPTIONS

K2 C7/1&4 KEYSWITCH RELAY-SOLENIODS, ATTACHMENTS, HORN
K3
K4
C6/1&4
C7/1&4
KEYSWITCH
KEYSWITCH
RELAY, POWER AMPS
RELAY 6
LM D5/1 AC LIFT MOTOR
LME C4/1 LIFT MOTOR ENCODER
LMT C4/1 LIFT MOTOR TEMPERATURE SENSOR
LPC B3/1&4 LIFT POWER CONTACTOR
MP B4/4 DC LIFT MOTOR
PRESS B4/2 LIFT PRESSURE SENSOR
S1 D7/1&4 KEY SWITCH

S2 E7/1&4 DEADMAN SWITCH
S3 H4/1&4 CONTROL HANDLE HORN SWITCH
S4 H4/1&4 CONTROL HANDLE FCN 1 SWITCH
S5 H4/1&4 CONTROL HANDLE FCN 2 SWITCH
S6 G4/1&4 CONTROL HANDLE TILT UP SWITCH SWITCHED BASED CONTROL HANDLE
S7 G4/1&4 CONTROL HANDLE TILT DOWN SWITCH
S8 G4/1&4 CONTROL HANDLE SHIFT LEFT SWITCH
S9 G4/1&4 CONTROL HANDLE SHIFT RIGHT SWITCH
S10 B2/2 REVERSE WORKING LIGHT SWITCH
S11 D3/2 HIGH SPEED LIMIT SWITCH
S12 D4/2 LIFT LIMIT SWITCH
S15
S18
B2/2
D3/2
D2, D3/2
WORKING LIGHT SWITCH
MAST TILT SWITCH OPTION 7
S22A, S22B BATTERY GATE SWITCHES
S36 B5/2 SWITCH FOR OPERATOR'S FAN
A
A B C D E F G H
MOTOR VELOCITY JPTL2 JPTL1 JPS2 JPC24

RED -1 -26
T VEL SENSOR+
TRACTION -1 BRN -1
+12VP VEHICLE
SPL4
BLACK -4 -7
T VEL SENSOR-
LEFT POWER
JPTL1
STEER
POSITION
-2 WHT -17
POS A MANAGER
TLE WHITE -3 -31 AMPLIFIER SENSOR -3 BLK -20
T VEL PHASE A CAN BUS
2
-21 POS B
BLUE -2 -32 CAN TERM H TERMINATION
T VEL PHASE B -34 -4 BLU JPC22-9
POS C
RED JPTL3 -2 -8 CAN TERM L
T TEMP+
TLT WHT -1 -23
BUS+
SEE NOTE 2 -35
BUS-
MOTOR TEMPERATURE -11
ID0
-12
ID1
-
U
U
CONTACTOR V
PANEL TML V
B+K3
-1
TP1 W
W
+
FU1 FU3 FU2

(750A) MOTOR VELOCITY JPTR2 JPTR1
(150A) (500A)
RED -1 -26
TP2 TP3 TP5 T VEL SENSOR+ TRACTION
-4 SPL6 -7
JP BLACK
JPS1-1 T VEL SENSOR- RIGHT POWER
B+ TRE WHITE -3 -31
-2 1 1 1 T VEL PHASE A AMPLIFIER
-3 BLUE -2 -32
3
STR LPC TPC T VEL PHASE B
2
-4 2 2 RED JPTR3 -2 -8 JPTR1
T TEMP+
WHT -1 -23
TRT BUS+
-35
SEE NOTE 2 -13 BUS-
B+K3
MOTOR TEMPERATURE -6
TPC -11
JPS1 ID0
-12
-11 ID1
CONTROL HANDLE
-
X Y U
-8
TPC U
SPL8
V
TMR V -1
B+K3
W
W
SPL1
SPL2
SPL3
+
JPC12-1
+5VP +5VP CONTROL HANDLE
X +5VP
X
-3
STR TRAVEL VR1
LPC
Y DGND
Y
+5VP
JPS1 -5
MP-S
-12 -6 -7 -9 -10
JPC14
-11
LIFT
-2
VR2
DGND
S3
4
BUS+
-4 DGND
AUX(+) BUS- -10
-3 HORN
DGND -4 S4
SM DC FCN 1
LIFT -11
JP JPC9-2 FCN 2 DGND
MOTOR TXD
FLASHWARE
B- AUX(-)
-3 -5
MP RXD TILT_UP S6
-5
DGND -6
SPL7
TILT_DOWN S7 S5
-8
SSHIFT_LEFT S8
DGND
COMMUNICATIONS
JPC3-1 -9
MP-A VBUS SSHIFT_RIGHT S9
-12
- -2
D- DGND DGND
USB
-3
D+
TP4 -4 DGND
JPC18-9
LPC_CTRL
JPC22-20
LPC_SENSE JPC20-15
STR_CONTACTOR 1
JPC22-19 2
STR_SENSE -16
LIFT/LOWER
5
JPC14-10
DGND
-2 ISENSE5(K2) -13
DGND SOL6
-1
B-F 1 2
-8 JPC18-1
B-F AUX SELECT
-9
B-F JPC20-17
ISENSE3(K2) SOL4
OPERATOR 1 2
JPD2 DISPLAY JPD1 -18
-1 -1 JPC6-6 PRIORITY BYPASS
+12V
UP -6 -2 ISENSE4(K2) -19
JPC24-14 SOL5
ADDR_LATCH
SPL9 1 2
-2 -3 JPC24-12 -20
DATA_LATCH PROP RELIEF
DN -5 -4 JPC22-10 JPF2-8 FUSE
DISP_MISO JPC18 ZONE C7
RELAY
-3 -5 JPC24-2 -10 CARD
LOAD HOLD SOL1
JPF1-3
JPF2-1
JPF2-2
JPF1-6
JPF3-3
ALARM_PWM
ENTER 2 1
-10
-11
-12
-4 SOUNDER -6 JPC6-5
-5
-8
-9
-4
-5
-6
-7
SHIFT_CLOCK
-7 JPC6-2 JPC20-12
ACCESORY DATA_OUT DUMP SOL3
JPF3-1 POWER -8 JPC6-4 2 1
FU6 (15A) TS1 DGND
-2 T° T° -1 JPC18-12
HSA1 SOL7R
1 2
JPF1-4 -2 B- 2 1
JPF1-1
-3 HRN
FU8 (15A/5A) JPB4-1 HRN+ -14
-2 SIDESHIFT SOL9R
-4 BATTERY HRN0 JPC18-16
1 2 JPF4-15 HORN 2 1
-5
FU7 (15A/5A) K1 HRN-
6
JPF4-3 -6 KEY -15 SOL10
JPF2-9 LEFT RIGHT H TILT
-4 1 2 BRAKE BRAKE H-1(+) 2 1
-3
TRAVEL
K3 -5 JPB3-1 H-2(-) JPC18-18 SOL7C
ALARM TRAV/LIFT ALARM
T° JPF4-11 -2 2 1 MAST MOUNTED SOLENOIDS
OPTION
JPB4-2
-12
JPC20-14 SOL9L
-8 BRAKES
PCB
MOUNTING FUSE/ 2 1 JPH2 1
STUD
RELAY HSA2
-8 -1 SOL11 SOL12
JPF4-13 JPC14-6
CARD JPC22-21
RELAY_ENABLE MAST 1 2
CONNECTOR 2
EPO_SENSE -2
K4 K3 K2 K1 JPC14-12 1
B+KEY
-5
SOL13
2 1 JPC22-8 -3
S21 ON DEADMAN
EPO NC
S2 2
S2-NO S2-COM JPC22-11
FU5 (15A) S1 DGND -4
-1 -10 1 2
1 2 DEADMAN
KEYSWITCH SWITCH
K2 K4 OR ROTARY SWITCH JPC14
-2 JPF2-4 -7
B+K4
-6 -13
B+K2
-7 -14
B+K2
T° JPF4-7 JPC24-24
BATTERY_SENSE_IN
7
JPF2-8 ZONE G5
Model 4100 - 4100

DC - DC Lift
TO SOLENOID 1
MODEL LIFT
A
A B C D E F G H
JPF2
-2
-3
-5
2
-8
TS1-3
JPS1 JPF4 JPF4 -7
-3 -3 FU7 -15 TS1-4
-6
JPF2 FUSE/RELAY
-4 -4 -9 TS1-5 JPB3 JPB4
5A/15A CARD -1
K1 -1 -1
TS1-6
K2
KEY SWITCH LEFT RIGHT
JPS1 JPF4 JPF4 S1 BRAKE BRAKE
-1 -1 FU5 -10 -1 -2
JPB3 JPB4
-2 -2
15A -5 -2 -2
X
K4 JPF4
LPC K4 K3 K2 K1 JPF4 -12 3
-2 -1
Y S21 -11 FUSE/RELAY
CARD HRN+ H-1 (+)
FU3 JPS1 K3 EPO
-9 -10 PTC
500A TP3 JPF4
HORN TRAVEL
RESISTOR
-8
MODULE
PL4 ALARM
LPC -2 -1
POWER AMP
FU2 JL4-AC JL4-DC FAN OPTION
750A TP5 JPB1 JPB1 HRNO HRN- H-2 (-)
-2 -1 -2 -1 -1 -2
JPF1 JPF2 JPF4
-6 -4 -13
TP1 FU1 X JPL1 JPC18 JPC18 JPC18
150A TP2 -6 -13 -17 -16 -18
TPC
JPS1 SPL
Y -6 9
JP
B+
-1 -1 JPS1
-11 -8 X B+ B+ B+
4
STR TPC CD OUT CD OUT CD OUT
STR
JPTR1 B- B- B-
-13 -6 Y
-2 SPL
-2
7 JPS1
JPL1 -7 JPC14
-1 -13 -14
SYSTEM
AC LIFT
AUX+ VEHICLE MANAGER

STEER
AC TRACTION
MOTOR
JPTR1
-1 JPH2-4 2 1
IN IN IN IN SOL13
AUX-
RIGHT
CM CM CM CM
JPH2-3 2 1
OUT OUT OUT OUT
AC TRACTION
SOL14
JPTL1
-1
5
-15 -17 -19 -13
LEFT
MP-S
JPC20 JPC20 JPC20 JPC20 JPH2
DC -1
LIFT
MOTOR
PRIORITY BYPASS
LOAD HOLD
LIFT/LOWER
-1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1
AUX SELECT
PROP RELIEF
MP-A
SIDESHIFT
DUMP
HSA1
JP
HSA2
SOL2 SOL4 SOL5 SOL6 SOL1 SOL3 SOL7R SOL7C SOL9R SOL9L SOL10 SOL11
TILT
B-
-2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2 -2
JPH2
-2
TP4 JPC14 JPC14 JPC18 JPC18 JPC20 JPC20 JPC20 JPC18 JPC18 JPC20 JPC18 JPC20
JPC18 JPC18 JPC18
-7 -12 -6 -9 -11 -16 -18 -20 -1 -10 -12 -12 -14 -15 -8 -14
OUT B+ B+ B+ B+ B+ B+ B+ B+ B+ B+ B+ B+ B+
6
POWER
CD CD OUT CD OUT CD OUT CD OUT CD OUT CD OUT CD OUT CD OUT CD OUT CD OUT CD OUT CD OUT CD OUT
SUPPLY
B- B- B- B- B- B- B- B- B- B- B- B- B- B-
JPF3 JPF3 JPC14 DGND

FU6
-1 -3 -10
-2 15A -4 -2
-5 -1 PGND
FUSE/RELAY -6 -8
CARD
-7 -9
VEHICLE MANAGER
JPF1 JPF1
FU8 TS1-1
-1 -4 LEGEND
-2 5A/15A TS1-2 EPO EMERGENCY POWER OFF LPC LIFT POWER CUTOFF CONTACTOR
JPC CONNECTOR ON VM STR STEER MOTOR CONTACTOR
JPF CONNECTOR ON FUSE/RELAY
JPS CONNECTOR ON CONTACTOR PANEL
SOL HYDRAULIC SOLENOID
SPL SPLICE MODEL 4100 AND 4200 7
PTC POSITIVE TEMPERATURE COEFFICIENT RESISTOR CM CURRENT MEASUREMENT CIRCUIT
CD COIL DRIVER
TPC TRACTION POWER CUTOFF CONTACTOR
Publication: 1060345A, Issued: 8/27/07 Figure A-5. Power Distribution Diagram A-17
A
A B C D E F
SIDE SHIFT 2
SSL
SSR
1 SOL-9L
2
AC
2 2 1
SOL-9R
SOL-7C
G2 AR
2 1
AUX-P
AC MOTOR
TACH
SOL-4
M
SOL-7R CB-1
3
4 3 2 1
SOL-6
TC
4 2 1
3 3 3
P1 TILT
P1 SOL-10
1 3
1 2
2 SOL-5
1 TR
2 1
100
PSI
2 CB-2
SPRING
CV1 G1
1 2 1 2
STEER VALVE
CYL1
REL-1
SOL-1
M
P
S-RET
1
MAIN LIFT 4
P2
T FREE LIFT
SOL-2
SOL-3
1
L R
2
FILTER 2
PRESSURE LINES
RETURN AND PILOT LINES
HYD STEER MOTOR COMPONENT BOUNDARIES
CYL-P
Model 4200 - AC Lift

Publication: 1060345A, Issued: 8/27/07 Figure A-6. Hydraulic Schematic (Sheet 1 of 3) A-18
A
A B C D E F
SIDE SHIFT
2
SSL
SSR
1 SOL-9L
2
AC
2
SOL-9R
G2 AR
AUX-P
DC MOTOR
SOL-4
CB-1
M
4 3 2 1 3
SOL-6
TC
4 2 1
3 3 3
P1 TILT
P1 SOL-10
1 3
1 2
2 SOL-5
1 TR
2 1
100
PSI
2 CB-2
SPRING
CV1 G1
1 2 1 2
STEER VALVE
CYL1
REL-1
SOL-1
M
S-RET MAIN LIFT

P 1 FREE LIFT
P2
T
4
SOL-2
SOL-3
1
L R
2
FILTER
2
PRESSURE LINES
RETURN AND PILOT LINES
CYL-P
HYD STEER MOTOR COMPONENT BOUNDARIES
Model 4100 - DC Lift

A
A B C D E F
PUSH/PULL
SIDE SHIFT CYLINDERS
SOL-11
PB PR
SSL
SSR
GB
1
2
GRIPPER
AC AC 5 6
CYLINDERS
2 1
1 4
2
GR 3
EXT
3
AR AR
CARRIAGE MOUNTED SOLENOID
RET USED FOR SELECTING BETWEEN TWO
HIGH SPEED AUXILIARY FUNCTIONS
4200-INTEGRAL SIDESHIFT SHOWN WITH
PUSH/PULL ATTACHMENT
SHEET RETAINER
CYLINDER PUSH/PULL SIDE SHIFT SSL
SIDE SHIFT CYLINDERS
SSR
SOL-11
4200-
SSR SSL
PB PR
SSL
SSR
2
1
GB
4
AC
OPEN
AC
2
1
GR
AR CLAMP
EXT
GRIPPER
AR CYLINDERS
RET
SIDE SHIFTING PUSH/PULL ATTACHMENT 4200-BOX CLAMP WITH INTEGRAL SIDESHIFT

WITH SHEET RETAINER
(SOL-11 SUPPLIED WITH ATTACHMENT)
Models 4100/4200 Maintenance Manual Section I. Index
Section I. Index
A Charts
Decimal Equivalent . . . . . . . . . . . . . A-8
AC Motors . . . . . . . . . . . . . . . . . . . . . . 5-9 Torque
Adjustment Component Specific . . . . . . . . . . A-4
Attachment Pressure . . . . . . . . . . 3-14 Metric . . . . . . . . . . . . . . . . . . . . A-6
Free Lift Cylinder Supply Hose . . . .... Standard (Brass) . . . . . . . . . . . . A-7
- Model 4200 . . . . . . . . . . . . . 7-83 Standard (Ferrous) . . . . . . . . . . A-5
Lift Chain . . . . . . . . . . . . . . . . . . 7-92 Check Valve
Mast Tilt . . . . . . . . . . . . . . . . . . . 7-94 CV-1 . . . . . . . . . . . . . . . . . . . . . . . 7-56
System Pressure . . . . . . . . . . . . . 7-64 Check Valve (CV1) . . . . . . . . . . . . . . . . 8-5
Attachment Control . . . . . . . . . . . . . . 3-12 Checking Hydraulic Oil Level, see Oil
Attachment Solenoids (SOL7C/R) . . . . 8-5 Codes
Attachments 1H . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Setup and Operation . . . . . . . . . . 3-13 2A . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Aux Prop Valve SOL5 . . . . . . . . . . . . . 7-56 2E . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Aux Select (SOL6) . . . . . . . . . . . . . . . . 8-5 2G . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Axle Seal . . . . . . . . . . . . . . . . . . . . . . 7-26 2H . . . . . . . . . . . . . . . . . . . . . . . . 6-11
2M . . . . . . . . . . . . . . . . . . . . . . . . 6-11
2T . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
B 2U . . . . . . . . . . . . . . . . . . . . . . . . 6-12
2V . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Battery 2W . . . . . . . . . . . . . . . . . . . . . . . . 6-12
BSOC . . . . . . . . . . . . . . . . . . . . . . 5-2 2X . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Charging . . . . . . . . . . . . . . . . . . . 7-44 2Y . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Cleaning . . . . . . . . . . . . . . . . . . . 7-44 42 . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Procedures . . . . . . . . . . . . . . . . . 7-44 43 . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Safety . . . . . . . . . . . . . . . . . . . . . . 2-5 4B . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Bleeding Hydraulic System . . . . . . . . 7-62 4C . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Model 4100 . . . . . . . . . . . . . . . . . 7-62 4F . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Model 4200 . . . . . . . . . . . . . . . . . 7-63 4G . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Brakes . . . . . . . . . . . . . . . . . . . . . . . 7-31 4J . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Disassembly . . . . . . . . . . . . . . . . 7-31 4K . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Installation . . . . . . . . . . . . . . . . . 7-31 59 . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Brushes, DC Motor . . . . . . . . . . . . . . 7-34 5A . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Inspection . . . . . . . . . . . . . . . . . . 7-34 5B . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Spring Tension . . . . . . . . . . . . . . 7-34 5F . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
5G . . . . . . . . . . . . . . . . . . . . . . . . 6-15
C 5J . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
5M . . . . . . . . . . . . . . . . . . . . . . . . 6-15
CAN Bus 5P . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Test . . . . . . . . . . . . . . . . . . . . . . . 6-36 5U . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Theory of Ops . . . . . . . . . . . . . . . . 8-3 5Y . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Carriage 61 . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Installation - Model 4200 . . . . . . . 7-78 6D . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Removal - Quad Mast . . . . . . . . . 7-78 7A . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Removal - TF Mast/Model 4200 . . 7-78 7E . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Removal - TT Mast/Model 4200 . . 7-78 7F . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Chain, Lift . . . . . . . . . . . . . . . . . . . . . 7-92 7G . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Storage Preparation . . . . . . . . . . . 3-24 7H . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Publication: 1060345A, Issued: 8/27/07 I-1

Section I. Index Models 4100/4200 Maintenance Manual
7M . . . . . . . . . . . . . . . . . . . . . . . . 6-17 T4 . . . . . . . . . . . . . . . . . . . . . . . . 6-25
7T . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 VC . . . . . . . . . . . . . . . . . . . . . . . . 6-25
7U . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Codes and Messages . . . . . . . . 6-7 to 6-25
7V . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Cold Storage . . . . . . . . . . . . . . . . . . . 3-23
7W . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Conditioning . . . . . . . . . . . . . . . . . 3-23
7X . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Communication Error Code
7Y . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Troubleshooting . . . . . . . . . . . . . . 5-12
80 . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Configure Mode . . . . . . . . . . . . . . . . . . 3-4
81 . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Configure Mode Menu . . . . . . . . . . . . . 3-6
83 . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Connectors
84 . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 AMP . . . . . . . . . . . . . . . . . . . . . . . 7-46
88 . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 General . . . . . . . . . . . . . . . . . . . . 7-46
8A . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Molex . . . . . . . . . . . . . . . . . . . . . . 7-46
8F . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Power Amp . . . . . . . . . . . . . . . . . . 7-51
8J . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Repair . . . . . . . . . . . . . . . . . . . . . 7-46
8P . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 Contactors . . . . . . . . . . . . . . . . . . . . . 5-17
8R . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 LPC . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8S . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 STR . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8T . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Tests
8U . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 LPC . . . . . . . . . . . . . . . . . . . . 6-82
8V . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Steer . . . . . . . . . . . . . . . . . . . . 6-81
8W . . . . . . . . . . . . . . . . . . . . . . . . 6-20 TPC . . . . . . . . . . . . . . . . . . . . 6-80
8X . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 TPC . . . . . . . . . . . . . . . . . . . . . . . . 8-4
A0 . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Control Handle
A2 . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Optional . . . . . . . . . . . . . . . . . . . . 7-18
A3 . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Soldering Procedures . . . . . . . . . . 7-16
A4 . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Standard . . . . . . . . . . . . . . . . . . . 7-15
AG . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Conversions, Standard/Metric . . . . . . A-10
AH . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Counterbalance Check Valves . . . . . . . . . . .
AL . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 (CB-1, CB-2) . . . . . . . . . . . . . . . . . . 8-5
AP . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 CV-1 Check Valve . . . . . . . . . . . . . . . . 7-56
AT . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Cylinder
F8 . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Piston Removal . . . . . . . . . . . . . . . 7-65
FE . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Service . . . . . . . . . . . . . . . . . . . . . 7-65
FG . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Storage Preparation . . . . . . . . . . . 3-24
FH . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Cylinder, Free Lift
FN . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Installation
FT . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Quad Mast . . . . . . . . . . . . . . . 7-82
G2 . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 TT Mast/Model 4200 . . . . . . . 7-81
HA . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Removal
HE . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Quad Mast . . . . . . . . . . . . . . . 7-81
HF . . . . . . . . . . . . . . . . . . . . . . . . 6-23 TT Mast/Model 4200 . . . . . . . 7-80
HG . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Supply Hose/Model 4200 Tracking . . . .
HH . . . . . . . . . . . . . . . . . . . . . . . . 6-24 and Tension Adjustment . . . . . 7-83
HM . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Cylinder, Main
HT . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Installation
HU . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Quad Mast . . . . . . . . . . . . . . . 7-81
HV . . . . . . . . . . . . . . . . . . . . . . . . 6-24 TF Mast/Model 4200 . . . . . . . 7-80
HW . . . . . . . . . . . . . . . . . . . . . . . . 6-25 TT Mast/Model 4200 . . . . . . . 7-80
HX . . . . . . . . . . . . . . . . . . . . . . . . 6-25
T0 . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
T3 . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
I-2 Publication: 1060345A, Issued: 8/27/07

Removal Hydraulic
Quad Mast . . . . . . . . . . . . . . . 7-81 Cylinder Service . . . . . . . . . . . . . . 7-65
TF Mast/Model 4200 . . . . . . . 7-80 System Storage Preparation . . . . . 3-24
TT Mast/Model 4200 . . . . . . . 7-80 Components . . . . . . . . . . . 7-55 to 7-92
Filter . . . . . . . . . . . . . . . . . . . 7-56, 8-5
D Hydraulic Fluid, see Oil
Hydraulic Oil, Selecting, see Oil
Hydraulic System
DC Motor
Bleeding . . . . . . . . . . . . . . . . . . . . 7-62
Troubleshooting . . . . . . . . . . . . . . 5-5
Bleeding - Model 4100 . . . . . . . . . 7-62
Decimal to Fraction Conversion . . . . . . A-8
Bleeding - Model 4200 . . . . . . . . . 7-63
Default Passwords, see Passwords
Display Messages . . . . . . . . . . . . . . . . 6-2
Drive Motor, see Motors I
Drive Units . . . . . . . . . . . . . . . . . . . . 7-24
Dump Valve (SOL3) . . . . . . . . . . . . . . . 8-5 Input Tests . . . . . . . . . . . . . . . 6-27 to 6-44
E K
Electrostatic Discharge . . . . . . . . . . . . 2-8 Kit, Antistatic . . . . . . . . . . . . . . . . . . . . 2-8

ESD
Antistatic Kit . . . . . . . . . . . . . . . . . 2-8 L
Precautions . . . . . . . . . . . . . . . . . . 2-8
L/L Pot Test . . . . . . . . . . . . . . . . . . . . 6-47
F Learn Mode
Menu . . . . . . . . . . . . . . . . . . . . . . . 3-9
Filter, Hydraulic . . . . . . . . . . . . . . . . 7-56 Lift Chain . . . . . . . . . . . . . . . . . . . . . . 7-92
FlashWare Program . . . . . . . . 3-15 to 3-22 Adjustment . . . . . . . . . . . . . . . . . . 7-92
Fluids, see Oil Inspection and Maintenance . . . . . 4-10
Fork Maintenance . . . . . . . . . . . . . . . . . 4-10
Inspection . . . . . . . . . . . . . . . . . . 4-11 Storage Preparation . . . . . . . . . . . 3-24
Measuring Wear . . . . . . . . . . . . . . 4-11 Lift Cylinder
Fraction to Decimal Conversion . . . . . . A-8 Piston Removal . . . . . . . . . . . . . . . 7-65
Fuse/Relay Card Service . . . . . . . . . . . . . . . . . . . . . 7-65
Theory of Ops . . . . . . . . . . . . . . . . 8-4 Lift Motor, see Motors
Lift Power Amp
G Theory of Ops . . . . . . . . . . . . . . . . . 8-3
Lift Power Amplifier . . . . . . . . . . . . . . 7-45
Lift/Aux Pump (P1) . . . . . . . . . . . . . . . . 8-4
General Information . . . . . . . . . . . . . . 3-2
Lift/Lower
Potentiometer . . . . . . . . . . . . . . . . 7-18
H Theory of Ops . . . . . . . . . . . 8-9 to 8-11
Valve (SOL2) . . . . . . . . . . . . . . . . . . 8-5
Harness Connectors . . . . . . . . . . . . . 7-46 Lights
Hose Reeving Steering Indicator . . . . . . . . . . . . . . 6-2
Quad Mast . . . . . . . . . . . . . . . . . 7-88 Load Holding Valve (SOL1) . . . . . 7-56, 8-5
TF Mast/Model 4200 . . . . . . . . . . 7-84 LPC Contactor . . . . . . . . . . . . . . . . . . . 8-4
TT Mast/Model 4200 . . . . . . . . . . 7-86 Lubricants . . . . . . . . . . . . . . . . . . . . . . A-3
Hose, Supply Lubrication
Free Lift Cylinder/Model 4200 Specification Chart . . . . . . . . . . . . . A-2
Adjustment . . . . . . . . . . . . . . 7-83 Lubrication Equivalency Chart . . . . . . . A-2

M AC . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Bearing Encoder . . . . . . . . . . . 7-39
Maintenance Open Winding . . . . . . . . . . . . . . 5-9
180 Day/500 HD . . . . . . . . . . . . . .4-6 Shorted Winding . . . . . . . . . . . . 5-9
360 Days/1500 HD . . . . . . . . . . . . .4-9 Temperature Sensor . . . . . . . . 7-38
90 Day . . . . . . . . . . . . . . . . . . . . . .4-5 Armature . . . . . . . . . . . . . . . . . . . . 5-8
Maintenance Minder . . . . . . . . . . . . . . .4-3 DC . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Disabling . . . . . . . . . . . . . . . . . . . . .4-4 Brush Spring Tension . . . . . . . 7-34
Enabling . . . . . . . . . . . . . . . . . . . . .4-3 Brushes . . . . . . . . . . . . . . . . . 7-34
Menu . . . . . . . . . . . . . . . . . . . . . . .3-7 Commutator . . . . . . . . . . . . . . 7-36
Maintenance Mode . . . . . . . . . . . . . . . .3-8 Field Winding Test . . . . . . . . . . 5-8
Maintenance Mode Menu . . . . . . . . . . .3-9 Grounded Motor Test . . . . . . . . 5-8
Manual Design . . . . . . . . . . . . . . . . . . .1-3 Open Circuit Test . . . . . . . . . . . 5-7
Map of the Manual . . . . . . . . . . . . . . . .1-2 Short Circuited Armature . . . . . 5-8
Mast Tests . . . . . . . . . . . . . . . . 5-7 to 5-8
Disassembly Drive . . . . . . . . . . . . . . . . . . . . . . 7-41
Quad Mast . . . . . . . . . . . . . . . 7-72 Lift . . . . . . . . . . . . . . . . . . . . . . . . 7-43
TF Mast/Model 4200 . . . . . . . . 7-70 Steer . . . . . . . . . . . . . . . . . . . . . . 7-10
TT Mast/Model 4200 . . . . . . . . 7-70 Storage Preparation . . . . . . . . . . . 3-24
Inspection/Model 4200 . . . . . . . . . 7-69 Terminal Hardware . . . . . . . . . . . . 7-36
Installation . . . . . . . . . . . . . . . . . . 7-69 Troubleshooting
Quad AC . . . . . . . . . . . . . . . . . . . . . . 5-9
Hose Reeving . . . . . . . . . . . . . . 7-88 DC . . . . . . . . . . . . . . . . . . . . . . 5-5
Hose Replacement . . . . . . . . . . 7-88
Reassembly O
Quad Mast . . . . . . . . . . . . . . . 7-73
TF Mast/Model 4200 . . . . . . . . 7-70 Oil
TT Mast/Model 4200 . . . . . . . . 7-71 Checking Hydraulic Oil Level . . . . 7-62
Skewing - Model 4200 . . . . . . . . . . 7-76 Selecting Hydraulic Oil . . . . . . . . . 7-62
TF Hose Reeving/Model 4200 . . . . 7-84 Open Circuit DC Motor Test . . . . . . . . . 5-7
Tilt Adjustment . . . . . . . . . . . . . . . 7-94 Open Winding AC Motor . . . . . . . . . . . . 5-9
TT Hose Reeving/Model 4200 . . . . 7-86 Operator Display . . . . . . . . . . . . . . . . . 6-2
Upright Inspection - Model 4200 . . 7-76 Steering Indicator Lights . . . . . . . . . 6-2
Mast Service . . . . . . . . . . . . . . 7-68 to 7-94 Operator Display Card
Mast, Main Theory of Ops . . . . . . . . . . . . . . . . . 8-4
Lift Chain . . . . . . . . . . . . . . . . . . . 7-92 Output Tests . . . . . . . . . . . . . 6-79 to 6-98
Memory Location . . . . . . . . . . . . . . . . .8-2
Menu
P
Attachment . . . . . . . . . . . . . . . . . . 3-12
Configure Mode . . . . . . . . . . . . . . . .3-6
Learn Mode . . . . . . . . . . . . . . . . . . .3-9 Passwords . . . . . . . . . . . . . . . ...... 3-10
Maintenance Minder . . . . . . . . . . . .3-7 Changing a Password . . . . ...... 3-11
Maintenance Mode . . . . . . . . . . . . .3-9 Config Mode . . . . . . . . . . . ...... 3-10
Messages and Codes . . . . . . . . .6-7 to 6-25 Default . . . . . . . . . . . . . . . ...... 3-10
Modes of Operation Entering a Password . . . . . ...... 3-10
Configure . . . . . . . . . . . . . . . . . . . .3-4 Maintenance Mode . . . . . . ...... 3-10
Maintenance . . . . . . . . . . . . . . . . . .3-8 Pin-Out Matrix . . . . . . . . . . . . 8-13 to 8-25
Run . . . . . . . . . . . . . . . . . . . . . . . . .3-4 Potentiometer
See also Passwords Lift/Lower (VR2) . . . . . . . . . . . . . . 7-18
Motors . . . . . . . . . . . . . . . . . . 7-34 to 7-40 Travel (VR1) . . . . . . . . . . . . . . . . . 7-20
Power Amplifier
Connectors . . . . . . . . . . . . . .7-47, 7-51

Replacement . . . . . . . . . . . . . . . . 7-45 SOL2

Pressure Test . . . . . . . . . . . . . . . . . . . . . . . 6-88
Attachment Adjustment . . . . . . . . 3-14 Theory . . . . . . . . . . . . . . . . . . . . . . 8-5
Relief Valve . . . . . . . . . . . . . . . . . 7-64 Torque Specs . . . . . . . . . . . . . . . . 7-56
System, Adjustment . . . . . . . . . . 7-64 SOL3
System, Measuring . . . . . . . . . . . 7-64 Test . . . . . . . . . . . . . . . . . . . . . . . 6-86
Priority Bypass (SOL4) . . . . . . . . . . . . . 8-5 Theory . . . . . . . . . . . . . . . . . . . . . . 8-5
Prop Relief (SOL5) . . . . . . . . . . . . . . . . 8-5 Torque Specs . . . . . . . . . . . . . . . . 7-56
SOL4
Q Test . . . . . . . . . . . . . . . . . . . . . . . 6-96
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5
Torque Specs . . . . . . . . . . . . . . . . 7-56
Quad Mast
SOL5
Carriage Removal . . . . . . . . . . . . 7-78
Test . . . . . . . . . . . . . . . . . . . . . . . 6-97
Free Lift Cylinder
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5
Installation . . . . . . . . . . . . . . 7-82
Torque Specs . . . . . . . . . . . . . . . . 7-56
Removal . . . . . . . . . . . . . . . . . 7-81
SOL6
Hose Replacement . . . . . . . . . . . . 7-88
Test . . . . . . . . . . . . . . . . . . . . . . . 6-83
Main Cylinder
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5
Installation . . . . . . . . . . . . . . 7-81
Torque Specs . . . . . . . . . . . . . . . . 7-56
Removal . . . . . . . . . . . . . . . . . 7-81
SOL7C/R
Test . . . . . . . . . . . . . . . . . . . . . . . 6-98
R Theory . . . . . . . . . . . . . . . . . . . . . . 8-5
Torque Specs . . . . . . . . . . . . . . . . 7-56
Run Mode . . . . . . . . . . . . . . . . . . . . . . 3-4 SOL9L/R
Test . . . . . . . . . . . . . . . . . . . . . . . 6-85
S Theory . . . . . . . . . . . . . . . . . . . . . . 8-5
Torque Specs . . . . . . . . . . . . . . . . 7-56
Solenoid Tests
Safety
Aux. Direction . . . . . . . . . . . . . . . . 6-83
Battery . . . . . . . . . . . . . . . . . . . . . 2-5
Aux. Relief . . . . . . . . . . . . . . . . . . 6-97
Definitions . . . . . . . . . . . . . . . . . . . 2-2
HSA 1 . . . . . . . . . . . . . . . . . . . . . . 6-98
General . . . . . . . . . . . . . . . . 2-3 to 2-4
Lift Relief . . . . . . . . . . . . . . . . . . . 6-86
Towing . . . . . . . . . . . . . . . . . . . . . 2-11
Lift/Lower . . . . . . . . . . . . . . . . . . . 6-88
Welding . . . . . . . . . . . . . . . . . . . . 2-12
Load Hold . . . . . . . . . . . . . . . . . . . 6-87
Scheduled Maintenance . . . . . . 4-1 to 4-9
Priority Bypass . . . . . . . . . . . . . . . 6-96
180 Day/500 HD . . . . . . . . . . . . . . 4-6
Sideshift . . . . . . . . . . . . . . . . . . . . 6-85
360 Day/1500 HD . . . . . . . . . . . . . 4-9
Tilt . . . . . . . . . . . . . . . . . . . . . . . . 6-84
90 Day . . . . . . . . . . . . . . . . . . . . . 4-5
Specification Plate . . . . . . . . . . . . . . . . 3-3
Guidelines . . . . . . . . . . . . . . . . . . . 4-2
Specifications, Vehicle . . . . . . . . . . . . . 3-3
Sealants . . . . . . . . . . . . . . . . . . . . . . . A-3
Standard/Metric Conversions . . . . . . . A-10
Seals, Axle . . . . . . . . . . . . . . . . . . . . 7-26
Steer Motor . . . . . . . . . . . . . . . . . . . . 7-10
Shorted Winding AC Motor . . . . . . . . . 5-9
Steer Position Sensor Theory . . . . . . . . 8-4
Sideshift Cylinders . . . . . . . . . . . . . . . 8-4
Steer Valve Theory . . . . . . . . . . . . . . . . 8-5
Sideshift Solenoids (SOL9L/R) . . . . . . . 8-5
Steerable Wheel
SOL1
Assembly . . . . . . . . . . . . . . . . . . . 7-10
Test . . . . . . . . . . . . . . . . . . . . . . . 6-87
Disassembly . . . . . . . . . . . . . . . . . 7-13
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5
Steering . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Torque Specs . . . . . . . . . . . . . . . . 7-56
Indicator Lights . . . . . . . . . . . . . . . 6-2
SOL10
Steering System Theory . . . . . . . . . . . . 8-8
Test . . . . . . . . . . . . . . . . . . . . . . . 6-84
Storage
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5
Hydraulic Cylinders . . . . . . . . . . . 3-24
Torque Specs . . . . . . . . . . . . . . . . 7-56

Hydraulic System .. . .. . . . . . . . . 3-24 A74 - Sideshift Left . . . . . . . . . . . . 6-69

Lift Chains . . . . . .. . .. . . . . . . . . 3-24 A74 - Sideshift Switch (SW4) . . . . . . . .
Motors . . . . . . . . .. . .. . . . . . . . . 3-24 (Optional Handle) . . . . . . . . . . 6-70
Warranty Issues . .. . .. . . . . . . . . 3-24 A75 - Attach Func 1 . . . . . . . . . . . 6-71
STR Contactor . . . . . .. . .. . . . . . . . . .8-4 A75 - Attach Func 1 . . . . . . . . . . . . . . .
Switches (Optional Handle) . . . . . . . . . . 6-72
Tests A76 - Attach Fcn 2 (SW2) . . . . . . . . . . .
S11 . . . . . . . . . . . . . . . . . . . . . 6-29 (Optional Handle) . . . . . . . . . . 6-74
S12 . . . . . . . . . . . . . . . . . . . . . 6-30 A76 - Attach Func 2 . . . . . . . . . . . 6-73
S18 . . . . . . . . . . . . . . . . . . . . . 6-38 A76 - Attach Func 2 . . . . . . . . . . . . . . .
S21 . . . . . . . . . . . . . . . . . . . . . 6-75 (Optional Handle) . . . . . . . . . . 6-74
S22A . . . . . . . . . . . . . . . . . . . . 6-42 A77 - EPO (S21) . . . . . . . . . . . . . . 6-75
S22B . . . . . . . . . . . . . . . . . . . . 6-43 A80 - Lift Relief Solenoid . . . . . . . . 6-76
S3 . . . . . . . . . . . . . . . . . . . . . . 6-33 A81 - Priority Bypass Current . . . . . . . .
S6 . . . . . . . . . . . . . . . . . . . . . . 6-66 (SOL4) . . . . . . . . . . . . . . . . . . 6-77
S7 . . . . . . . . . . . . . . . . . . . . . . 6-65 A82 - Aux. Relief Current (SOL5) . 6-78
S9 . . . . . . . . . . . . . . . . . . . . . . 6-68 I02 - High Speed Limit SW (S11) . . 6-29
SW1 . . . . . . . . . . . . . . . . . . . . 6-33 I05 - Lift Limit (S12) . . . . . . . . . . . 6-30
SW2 . . . . . . . . . . . . . . . . . . . . 6-74 I13 - Lift Contactor (DC Lift) . . . . . 6-31
SW3 . . . . . . . . . . . . . . . . . . . . 6-72 I14 - Steer Contactor . . . . . . . . . . 6-32
SW4 . . . . . . . . . . . . . . . 6-67, 6-70 I15 - Horn (S3) . . . . . . . . . . . . . . . 6-33
System Architecture . . . . . . . . . . . . . . .8-2 I15 - Horn (SW1) . . . . . . . . . . . . . 6-33
Systems Overview I19 - Left Traction RPM . . . . . . . . 6-34
General . . . . . . . . . . . . . . . . . . . . . .3-2 I20 - Lift Motor RPM . . . . . . . . . . . 6-35
I23 - CAN Communication Test . . 6-36
T I65 - Tilt Position SW (S18) . . . . . . 6-38
I82 - Right Traction RPM . . . . . . . 6-41
I87 - Battery Gate . . . . . . . . . . . . . 6-42
Tests
I88 - Battery Gate 2 . . . . . . . . . . . 6-43
A04 - Travel Pot . . . . . . . . . . . . . . 6-46
I89 - Steer Position Sensor . . . . . . 6-44
A05 - L/L Pot . . . . . . . . . . . . . . . . 6-47
Input . . . . . . . . . . . . . . . . 6-27 to 6-44
A08 - Left Trac Motor Temp . . . . . . 6-48
O00 - TPC Contactor . . . . . . . . . . 6-80
A09 - Lift Motor Temp . . . . . . . . . . 6-49
O01 - Steer Contactor (STR) . . . . . 6-81
A10 - Left TPA Temp . . . . . . . . . . . 6-50
O02 - Lift Contactor (LPC) . . . . . . . 6-82
A11 - Left Traction Current . . . . . . 6-51
O04 - Aux. Direction Solenoid . . . . . . .
A13 - Press Sensor Voltage . . . . . . 6-52
(SOL6) . . . . . . . . . . . . . . . . . . 6-83
A14 - Ext. Supply Sense (12VDC) . 6-53
O07 - Tilt Solenoid (SOL10) . . . . . 6-84
A15 - Battery Voltage . . . . . . . . . . . 6-54
O08 - Sideshift Solenoid . . . . . . . . . . . .
A19 - LPA Temp . . . . . . . . . . . . . . 6-55
(SOL9L, SOL9R) . . . . . . . . . . . 6-85
A20 - Lift Motor Current . . . . . . . . 6-56
O09 - Lift Relief Solenoid (SOL3) . . 6-86
A22 - Traction Throttle Request . . . 6-57
O11 - Load Hold Solenoid (SOL1) . 6-87
A23 - Lift Request . . . . . . . . . . . . . 6-58
O12 - Lift/Lower Solenoid (SOL2) . 6-88
A26 - Pot Supply (5VDC) . . . . . . . . 6-59
O18 - Horn . . . . . . . . . . . . . . . . . . 6-89
A34 - Lift/Lower Current (SOL2) . . 6-60
O20 - Travel Alarm . . . . . . . . . . . . 6-91
A36 - Ambient Temperature . . . . . 6-61
O28 - Ramp Lift Motor (AC Lift) . . 6-92
A65 - Right TPA Temp . . . . . . . . . . 6-62
O29 - Ramp Traction Motors . . . . 6-93
A67 - Right Trac Motor Current . . . 6-63
O30 - Electric Brakes . . . . . . . . . . 6-94
A68 - Right Trac Motor Temp . . . . 6-64
O32 - Toggle Relay Enable . . . . . . 6-95
A71 - Tilt Down (S7) . . . . . . . . . . . 6-65
O36 - Priority Bypass Solenoid . . . . . . .
A72 - Tilt Up (S6) . . . . . . . . . . . . . 6-66
(SOL4) . . . . . . . . . . . . . . . . . . 6-96
A72 - Tilt Up/Down (SW4) . . . . . . ....
O37 - Aux. Relief Solenoid (SOL5) . 6-97
(Optional Handle) . . . . . . . . . . 6-67
A73 - Sideshift Right (S9) . . . . . . . 6-68

O45 - HSA 1 Solenoid . . . . . . . . . . . . . Pressure Relief . . . . . . . . . . . . . . . 7-64

(SOL7C, SOL7R) . . . . . . . . . . . 6-98 SOL1
Output . . . . . . . . . . . . . . 6-79 to 6-98 Test . . . . . . . . . . . . . . . . . . . . . 6-87
Theory of Operation Torque Spec . . . . . . . . . . . . . . 7-56
Pin-Out Matrix . . . . . . . . 8-13 to 8-25 SOL10
Theory of Ops Test . . . . . . . . . . . . . . . . . . . . . 6-84
CAN Bus . . . . . . . . . . . . . . . . . . . . 8-3 Torque Spec . . . . . . . . . . . . . . 7-56
Fuse/Relay Card . . . . . . . . . . . . . . 8-4 SOL2
Lift Power Amp . . . . . . . . . . . . . . . 8-3 Test . . . . . . . . . . . . . . . . . . . . . 6-88
Lift/Lower . . . . . . . . . . . . . 8-9 to 8-11 Torque Spec . . . . . . . . . . . . . . 7-56
Operator Display Card . . . . . . . . . . 8-4 SOL3
Steer Position Sensor . . . . . . . . . . . 8-4 Test . . . . . . . . . . . . . . . . . . . . . 6-86
Steer Valve . . . . . . . . . . . . . . . . . . . 8-5 Torque Spec . . . . . . . . . . . . . . 7-56
Steering System . . . . . . . . . . . . . . . 8-8 SOL4
Traction Power Amps . . . . . . . . . . . 8-3 Test . . . . . . . . . . . . . . . . . . . . . 6-96
Traction System . . . . . . . . . 8-6 to 8-7 Torque Spec . . . . . . . . . . . . . . 7-56
VM . . . . . . . . . . . . . . . . . . . . . . . . 8-3 SOL5
Thread Adhesives . . . . . . . . . . . . . . . . A-3 Test . . . . . . . . . . . . . . . . . . . . . 6-97
Tilt Solenoid (SOL10) . . . . . . . . . . . . . . 8-5 Torque Spec . . . . . . . . . . . . . . 7-56
Tilt, Mast SOL6
Adjustment . . . . . . . . . . . . . . . . . 7-94 Test . . . . . . . . . . . . . . . . . . . . . 6-83
Tire Replacement . . . . . . . . . . . . . . . 7-30 Torque Spec . . . . . . . . . . . . . . 7-56
Torque Chart SOL7C/R
Component Specific . . . . . . . . . . . . A-4 Test . . . . . . . . . . . . . . . . . . . . . 6-98
Metric . . . . . . . . . . . . . . . . . . . . . . A-6 Torque Spec . . . . . . . . . . . . . . 7-56
Motor Terminals . . . . . . . . . . . . . 7-36 SOL9L/R
Standard (Brass) . . . . . . . . . . . . . . A-7 Test . . . . . . . . . . . . . . . . . . . . . 6-85
Standard (Ferrous) . . . . . . . . . . . . A-5 Torque Spec . . . . . . . . . . . . . . 7-56
Towing Safety . . . . . . . . . . . . . . . . . . 2-11 Valves
TPC Contactor . . . . . . . . . . . . . . . . . . . 8-4 CB1, CB2 . . . . . . . . .. .. . . . . . . . . 8-5
Traction Motor, see Motors, Drive CV1 . . . . . . . . . . . . .. .. . . . . . . . . 8-5
Traction Power Amplifiers . . . . . . . . . 7-45 Vehicle Specifications . . .. .. . . . . . . . . 3-3
Theory of Ops . . . . . . . . . . . . . . . . 8-3 VM, Theory of Ops . . . . .. .. . . . . . . . . 8-3
Traction System VR1 Test . . . . . . . . . . . .. .. . . . . . . . 6-46
Theory of Ops . . . . . . . . . . . 8-6 to 8-7 VR2 Test . . . . . . . . . . . .. .. . . . . . . . 6-47
Travel Potentiometer . . . . . . . . . . . . . 7-20
Troubleshooting W
BSOC . . . . . . . . . . . . . . . . . . . . . . 5-2
Communication Error Codes . . . . 5-12
Warranty
Drive Units . . . . . . . . . . . . . . . . . 5-23
Storage Issues . . . . . . . . . . . . . . . 3-24
Electrical Symptoms . . . . 5-26 to 5-27
Welding Safety . . . . . . . . . . . . . . . . . . 2-12
Hydraulic Functions . . . . 5-19 to 5-22
Wheel
Motors . . . . . . . . . . . . . . . . . 5-5 to 5-9
Steerable . . . . . . . . . . . . . . . . . . . 7-10
AC . . . . . . . . . . . . . . . . . . . . . . 5-9
Disassembly . . . . . . . . . . . . . . 7-13
DC . . . . . . . . . . . . . . . . . . . . . . 5-5
Removal . . . . . . . . . . . . . . . . . 7-10
Pin-Out Matrix . . . . . . . . 8-13 to 8-25
Wiring Connectors . . . . . . . . . . . . . . . 7-46
Travel Functions . . . . . . . . . . . . . 5-24
Valve
CV-1 Check Valve . . . . . . . . . . . . 7-56


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1060345A

Service Manual - 4100-4200 Stand-Up Counterbalanced

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Models Serial Numbers

1060345A Issued: 8/27/07

©2007 The Raymond Corporation.

Safety. . . . . . . . . . . . . . . . . . . . ........... . ........... . . . . 2-1

Systems Overview . . . . . . . . . . . ........... . ........... . . . . 3-1

Scheduled Maintenance . . . . . . . . . . . . . . . . . . ........... . . . . 4-1

Troubleshooting . . . . . . . . . . . . ........... . ........... . . . . 5-1

Messages, Codes, and Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Component Procedures . . . . . . . . . . . . . . . . . . . ........... . . . . 7-1

Publication: 1060345A, Issued: 8/27/07 i

Drive and Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... 7-23

Theory of Operation . . . . . . . . . . . . ........... . ........... . 8-1

ii Publication: 1060345A, Issued: 8/27/07

Page Revision Record

Whenever a page is revised, this section is

Custodians of this manual need to ascertain

Pages are revised due to technical and

Original Issue Date: 8/27/07

Publication: 1060345A, Issued: 8/27/07 iii

iv Publication: 1060345A, Issued: 8/27/07

Section 1. How to Use This Manual

Publication: 1060345A, Issued: 8/27/07 1-1

Map of the Manual

Map of the Manual

How To Use This

1-2 Publication: 1060345A, Issued: 8/27/07

Map of the Manual

MAP2: Map of the Manual (Continued)

Publication: 1060345A, Issued: 8/27/07 1-3

Manual Design • Component Procedures gives

1-4 Publication: 1060345A, Issued: 8/27/07

Abbreviations and Symbols

Term/Symbol Definition Term/Symbol Definition

Publication: 1060345A, Issued: 8/27/07 1-5

Abbreviations and Symbols

Term/Symbol Definition Term/Symbol Definition

SAE Society of Automotive

1-6 Publication: 1060345A, Issued: 8/27/07

Publication: 1060345A, Issued: 8/27/07 2-1

Indicates a potentially hazardous

Indicates a potentially hazardous

2-2 Publication: 1060345A, Issued: 8/27/07

Do not operate or work on this lift truck unless

Before working on this truck, turn the key

Do not operate or work on this lift truck unless

Always use and park this lift truck indoors.

Do not operate this lift truck if it needs repair or

Do not park in a cold storage area overnight

Publication: 1060345A, Issued: 8/27/07 2-3

2-4 Publication: 1060345A, Issued: 8/27/07

Battery Safety goggles or face shield, rubber gloves (with or

As a battery is being charged, an

there are no open flames or sparks in

Battery electrolyte is a solution of

Publication: 1060345A, Issued: 8/27/07 2-5

Do not lay tools or metal objects on top of the 227ys7s013.tif

battery. A short circuit or explosion could

Make sure vent holes in filler plugs are open to

Keep batteries clean. Corrosion causes shorts

Do not allow cleaning solution, dirt, or any

2-6 Publication: 1060345A, Issued: 8/27/07

Make sure you install the correct size battery. A

Never plug a battery charger into the truck’s