Service Manual 7BWS10-13

Front Cover
Master Service Manual
7BWS10/13
Electric Walkie Low-Lift Pallet Truck
Effective Serial Number 40500 - UP
Warning Read and observe all warnings on this unit

before operating it.
Warning DO NOT operate this equipment unless all
factory installed guards and covers are
properly secured in place.
Part no: 00700-CL3WS-06 Date: June 12, 2006

© Copyright 2006 by Toyota Industrial Equipment
All rights reserved. No portion of this manual may be reproduced mechanically, electronically
or by any other means, including photocopying, electronic retrieval or transfer, or recording
without the written permission of the publisher.
Toyota Industrial Equipment believes the information in this manual is accurate and current as of
the publication date; such information is subject to change without notice. Toyota Industrial
Equipment is not responsible for any errors that may appear in the manual.
F-code Section C-code
Ordering Spare Parts

Version no T-code
000 7BWS10/13

Supply the following information will assure prompt, efficient
handling of the order:
1. Identify truck model and serial number.
2. Refer to Parts Book and locate page with the
exploded diagram.
3. Find item number for the part required. Select the
column for the actual truck model and serial
number.
4. The following is an explanation of a serial number:
7BWS10 40500
Truck number
Capacity 10-2000 lbs

13-2500 lbs
Model (7BWS)
CAUTION Although some trucks appear to be similar,

component parts may not be
interchangeable. If an incorrect part is
used, the truck may malfunction.
5. Note part number.

6. Call your local Toyota Dealer and state part
number.
7. If the truck model, serial number, or article number
cannot be found on the truck, call your local
Toyota Dealer for assistance.
Master Service Manual 2006-06-12 1


Version no T-code
000 7BWS10/13
This page is intentionally left blank.
2 Master Service Manual 2006-06-12

Table Of Contents
Table of Contents
Ordering Spare Parts .................................................................................... 1
Standard Codes ............................................................................................ 11
Warning Symbols ......................................................................................... 13

Warning Levels ..................................................................................................... 13
Prohibitory Symbols .................................................................................... 14

Ordinance Symbols .............................................................................................. 14
Safety ............................................................................................................. 15
General Safety ..................................................................................................... 15
Battery Safety ............................................................................................... 20
Static Discharge Precautions ...................................................................... 25
Welding Safety .............................................................................................. 27
Introduction, Service Manual ...................................................................... 29
Contents, Section M ..................................................................................... 31

Machine Information ............................................................................................. 31
General Product Information ....................................................................... 33

Truck Presentation ............................................................................................... 33
Truck Side Views .......................................................................................................... 33
Intended Truck Application ........................................................................................... 33
Prohibited Truck Application ......................................................................................... 34
Truck Data .................................................................................................................... 34
Dimensions ................................................................................................................... 35
Data Plate ..................................................................................................................... 36
Main Components ................................................................................................ 37
Inch (SAE) and Metric Fasteners ................................................................ 39

Introduction .......................................................................................................... 39
Nomenclature, Threads ........................................................................................ 40
Strength Identification ........................................................................................... 41
Truck Torque Specifications ................................................................................. 47
Conversion of Metric and English Units ............................................................... 48
Technical Service Data ................................................................................ 51
Contents, Section P ...................................................................................... 55

Planned Maintenance ........................................................................................... 55
Introduction, Maintenance ........................................................................... 57

Jacking Truck Off The Floor ................................................................................. 58

Table of Contents
Elevate Rear of Truck ................................................................................................... 58

Elevate Either Side of Truck ......................................................................................... 59
Lubricants ............................................................................................................ 59
Standard ....................................................................................................................... 59
Service Schedule ......................................................................................... 61

Planned Maintenance Schedule .......................................................................... 61
Planned Maintenance Procedures ....................................................................... 65
General ......................................................................................................................... 65
Hardware ................................................................................................................. 65
Noise ....................................................................................................................... 65
Leaks ....................................................................................................................... 65
Cables and Connections ......................................................................................... 66
Grease Location Points ........................................................................................... 66
Services Performed Daily or Every 8 Operating Hours ................................................ 66
Chassis ................................................................................................................... 66
Brakes ..................................................................................................................... 66
Wheels/Tires ........................................................................................................... 66
Tiller Arm ................................................................................................................. 66
Functions/Operations .............................................................................................. 67
Battery ..................................................................................................................... 67
Battery Connector ................................................................................................... 67
Services Performed Every Six Months or 500 Operating Hours Under Moderate
Usage or Three Months or 250 Hours Under Severe Usage ....................................... 68
Chassis ................................................................................................................... 68
Motors ..................................................................................................................... 68
Drive Unit ................................................................................................................ 68
Brake ....................................................................................................................... 68
Electrical Control System ........................................................................................ 69
Battery ..................................................................................................................... 69
Electrical Panel ....................................................................................................... 69
Hydraulic System .................................................................................................... 69
Mast ........................................................................................................................ 69
Lifting Devices ......................................................................................................... 69
Services Performed 12 Months or Every 1000 Operating Hours Under
Moderate Usage and Six Months or Every 500 Operating Hours Under Severe Usage 70
Drive Unit ................................................................................................................ 70
Hydraulic System .................................................................................................... 70
Lubrication Chart ......................................................................................... 71
Oil and Grease Specifications .................................................................... 72

Lubricants ............................................................................................................ 72
Grease Location Points ........................................................................................ 72
Contents, Section S ..................................................................................... 73

Service Instructions .............................................................................................. 73
Stabilizer Support Arms .............................................................................. 75

Theory of Operation ............................................................................................. 76
Maintenance ........................................................................................................ 76

Table of Contents
Support Arm Width Adjustment .................................................................................... 76
Inspection, Covers ....................................................................................... 81

Maintenance ......................................................................................................... 82
Troubleshooting .................................................................................................... 82
Repair and Rebuild ............................................................................................... 82
Decals ............................................................................................................ 83
Decal with Protective Sheet ................................................................................. 83
Decal without Protective Sheet ............................................................................ 83
Electric Motors .............................................................................................. 85

Maintenance ......................................................................................................... 85
Troubleshooting .................................................................................................... 86
Repair and Rebuild ............................................................................................... 87
Pump Motor .................................................................................................................. 87
Removal .................................................................................................................. 88
Installation ............................................................................................................... 89
Drive Motor ................................................................................................................... 90
Brush Inspection and Replacement ........................................................................ 90
Brush Inspection ..................................................................................................... 90
Brush Replacement ................................................................................................. 92
Motor Disassembly .................................................................................................. 93
Motor Assembly ...................................................................................................... 94
Transmission ................................................................................................ 99
Theory of Operation ............................................................................................ 101
Maintenance ........................................................................................................ 101
Fluid Changing ............................................................................................................ 101
Troubleshooting ................................................................................................... 102
Repair and Rebuild .............................................................................................. 104
Parking Brake System ................................................................................. 111

Maintenance ........................................................................................................ 114
Mechanical Brake Release .......................................................................................... 114
Brake Adjustment ........................................................................................................ 114
Drive Wheel .................................................................................................. 117

Maintenance ........................................................................................................ 118
Drive Wheel Nut Inspection ......................................................................................... 118
Load Wheels ................................................................................................ 125

Table of Contents

Maintenance ....................................................................................................... 126
Troubleshooting .................................................................................................. 126
Repair and Rebuild ............................................................................................. 126
Tiller Arm Handle ........................................................................................ 129

Maintenance ....................................................................................................... 131
Inspection .................................................................................................................... 131
Tiller Arm Head ............................................................................................ 135

Maintenance ....................................................................................................... 137
Steering Bearing ......................................................................................... 139

Maintenance ....................................................................................................... 140
Electrical Functions .................................................................................... 141

Battery Plugged In With Keypad ................................................................................. 142
Battery Plugged In With Key Switch ............................................................................ 144
Main ON/OFF Switch/Keypad ON ............................................................................... 146
Travel, Low Speed ...................................................................................................... 148
Travel, High Speed ...................................................................................................... 150
Reverser ...................................................................................................................... 152
Lift ................................................................................................................................ 154
Lower ........................................................................................................................... 156
Maintenance ....................................................................................................... 159
Wiring .......................................................................................................................... 159
Definitions .............................................................................................................. 159
Shorts to Frame Test ............................................................................................. 160
Troubleshooting Flowchart .......................................................................................... 163
Main Harness Replacement ........................................................................................ 166
Operator Display and Programming ............................................................................ 170
Special Modes ........................................................................................................ 170
Service Display ...................................................................................................... 171
Digital Inputs/Outputs from Transistor Controller ................................................... 172
Transistor Controller System Mode ........................................................................ 173
Changing Driver Accessible Parameters (P) ............................................................... 174
Changing Service Parameters .................................................................................... 176
Parameter Description ........................................................................................... 179
Operating Parameter Programming ....................................................................... 183

Table of Contents
Display Part Numbers (Pn) .................................................................................... 183

Error Codes (E) ........................................................................................................... 183
Error Code History ................................................................................................. 183
Truck Fault Codes .................................................................................................. 184
Troubleshooting Chart Index ....................................................................................... 194
Travel (Tractor-first / Forks-first) System ............................................................... 194
Wiring System ........................................................................................................ 194
Other Possible Troubleshooting Issues ................................................................. 194
Troubleshooting Charts ............................................................................................... 195
Battery .......................................................................................................... 199

Maintenance ........................................................................................................ 199
Inspection and Care .................................................................................................... 199
Exterior Cleaning ......................................................................................................... 200
Charging ...................................................................................................................... 200
Storage ........................................................................................................................ 201
History Record ............................................................................................................. 202
Swing Out Battery Pack .............................................................................. 205

Maintenance ........................................................................................................ 210
Electrical Testing ......................................................................................................... 210
Required Equipment .............................................................................................. 210
Instructions ............................................................................................................. 210
Battery Connector ....................................................................................... 217

Maintenance ........................................................................................................ 217
Inspection .................................................................................................................... 217
Switches ....................................................................................................... 221

Maintenance ........................................................................................................ 223
Main ON/OFF Switch ................................................................................................... 225
Arm Angle Switches .................................................................................................... 225
Key Switch (Optional) .................................................................................................. 227
Horn Switch ................................................................................................................. 227
Converting Keypad to Key Switch ............................................................................... 227
Fuses ............................................................................................................ 229

Maintenance ........................................................................................................ 229

Table of Contents
Wiring Harness ............................................................................................................ 230

Power Cables .............................................................................................................. 231
Master Control Relay ................................................................................................... 232
Contactor Panel ........................................................................................... 235

Maintenance ....................................................................................................... 237
Resistance Testing ...................................................................................................... 237
Transistor Controller .................................................................................. 239

Basics Of Circuit Operation ......................................................................................... 239
Interface ...................................................................................................................... 240
Control Features .......................................................................................................... 241
Motor Circuit ................................................................................................................ 241
Control Circuit .............................................................................................................. 242
Definitions .................................................................................................................... 243
Maintenance ....................................................................................................... 244
Safety .......................................................................................................................... 244
Cleaning ...................................................................................................................... 244
Diagnostics and Troubleshooting ................................................................................ 245
Fault Codes ................................................................................................................. 245
Electronic Tiller Arm Card (ETAC) ............................................................. 249

Lift Cutout. ................................................................................................................... 251
Maintenance ....................................................................................................... 251
Hydraulic System ........................................................................................ 253

Lift ................................................................................................................................ 254
Lower ........................................................................................................................... 255
Relief Pressure ............................................................................................................ 256
Maintenance ....................................................................................................... 257
Changing Hydraulic System Fluid ............................................................................... 257
Hydraulic Pump Pressure Relief Valve ....................................................................... 259
Troubleshooting Chart Index ....................................................................................... 260
Troubleshooting Charts ............................................................................................... 260
Hydraulic Unit .............................................................................................................. 265
Reservoir ..................................................................................................................... 266

Table of Contents
Filter Screen and Inlet Tube ........................................................................................ 267

Lift Pump ..................................................................................................................... 268
Lift Cylinder .................................................................................................. 269

Maintenance ........................................................................................................ 270
Inspection .................................................................................................................... 270
Mast .............................................................................................................. 275

Maintenance ........................................................................................................ 275
Visual Inspection ......................................................................................................... 275
Lift Chain Inspection .................................................................................................... 275
Lift Chain Lubrication ................................................................................................... 280
Lift Chain Adjustment .................................................................................................. 281
Mast Guides/Dampers Adjustment .............................................................................. 281
Forks ............................................................................................................. 297

Maintenance ........................................................................................................ 298
Inspection .................................................................................................................... 298
Appendix ...................................................................................................... 301

Table of Contents

Standard Codes
Version no T-code
000 7BWS10/13
Standard Codes
B-Code = Business area
F-Code = Product family
T-Code = Product type
C-Code = Component function
Worksheet standard
W-Code = Working code

R-Code = Reason code
SO-Code = Assortment
F-Code List
T-Code List
No. Model
7BWS10/13
C-Code List
No Function Group C-Code
0 Chassis / Frame 0000
1 Motors 1000
2 Drive Gear / Transmission 2000
3 Brake / Wheel System 3000
4 Steering System 4000
5 Electrical System 5000
6 Hydraulic / Pneumatic System 6000
7 Operating Function-lifting Mast / Cylinders 7000
8 Peripheral / Installation Equipment 8000
9 Optionals / Attachments 9000
10 Tools 10000

Standard Codes
Version no T-code
000 7BWS10/13

Warning Symbols
Version no T-code
001
Warning Symbols
Always follow the warnings given in this Service Manual
and on the truck to avoid accidents from occurring.
1. Warning Levels
Warning levels
Warning text is given in four levels and provide information on
the risks, describe the consequences, and instruct how to
avoid accidents.
DANGER
Warns that an accident will occur if the instructions are not
followed.
The consequences are serious personal injury or possibly
death, and/or extremely large material damage.
WARNING
Warns that an accident can occur if the instructions are not
followed.
The consequences are serious personal injury or possibly
death, and/or large material damage.
CAUTION
Warns that an accident can occur if the instructions are not
followed.
The consequences are personal injury and/or material
damage.
NOTE!
Marks the risk of a accident or breakdown if the
instructions are not followed.

Prohibitory Symbols
Version no T-code
001
Prohibitory Symbols
NO SMOKING
If smoking occurs in situations where a restriction against
smoking is stated, a serious accident can occur.
OPEN FLAMES PROHIBITED

If open flames are used in situations where open flames are
prohibited, a serious accident can occur.
GENERAL PROHIBITION
If the prohibition is ignored, a serious accident can occur.
1. Ordinance Symbols
SAFETY SHOES
When the directive for safety shoes is given, safety shoes
shall always be worn to avoid personal injury.
PROTECTIVE GLASSES
When the directive for protective glasses is given,
protective glasses shall always be worn to avoid personal
injury.

Safety
Version no T-code
001
Safety
1. General Safety
Do NOT operate or work on this truck unless trained,
qualified, and authorized to do so and have read the
Operator’s Manual.
Know the truck controls and what they do.
Do NOT operate truck if it needs repair or if it is in any way

unsafe.

Safety
Version no T-code
001
Operate truck only from the position of the operator.
Before working on this truck always press the red OFF (O)
key on the keypad and disconnect truck battery connector
(unless this manual states otherwise).
Do NOT wear watches, rings, or jewelry when working on this

truck.

Safety
Version no T-code
001
Follow the scheduled lubrication, maintenance, and

inspection steps.
Follow exactly the safety and repair instructions in this

manual. Do NOT take “shortcuts”.
Do NOT Use an open flame near the truck.
Do NOT use gasoline or other flammable liquids for cleaning

parts.

Safety
Version no T-code
001
Clean up any hydraulic fluid, oil, or grease that has leaked or

spilled on the floor.
Always operate and park truck indoors.
Do not park truck in a cold storage area overnight.
Do NOT wash truck with a hose.

Safety
Version no T-code
001
Do NOT add to or modify truck without written approval from

Toyota

Battery Safety
Version no T-code
001
Battery Safety
WARNING As a battery is being charged, an explosive

gas mixture forms within and around each
cell. If the area is not properly ventilated,
this explosive gas can remain in or around
the battery for several hours after charging.
Be sure there are no open flames or sparks
in the charging area. An open flame or
spark can ignite this gas, resulting in
serious damage or injury.
WARNING Battery electrolyte is a solution of sulfuric

acid and water. Battery acid causes burns.
Should any electrolyte come in contact with
clothing or skin, flush the area immediately
with cold water. Should the solution get on
your face or in the eyes, flush the area with
cold water and receive medical attention
immediately.
Read, understand and follow procedures, recommendations

and specifications available by the battery and battery
charger supplier.

Battery Safety
Version no T-code
001
Wear personal protective equipment to protect eyes, face,

and skin when checking, handling, or filling batteries. This
equipment includes goggles or face shield, rubber gloves
(with or without arm shields) and a rubber apron.
Make sure a shower and eyewash station are nearby in case

there is an accident.
A battery gives off explosive gases. Never smoke, use an

open flame, or use anything that gives off sparks near a
battery.

Battery Safety
Version no T-code
001
Keep the charger area well-ventilated to avoid hydrogen gas

concentration.
Press the red OFF (O) key on the keypad before

disconnecting the battery from the truck at the battery
connector. Do NOT break live circuits at the battery terminals.
A spark often occurs at the point where a live circuit is
broken.
Do NOT lay tools or metal objects on top of battery. A short

circuit or explosion could result.
Keep batteries clean. Corrosion causes shorts and possibly

sparks to the frame.

Battery Safety
Version no T-code
001
Keep plugs, terminals, cables, and receptacles in good

condition to avoid shorts and sparks.
Cable
Filler
Plugs
Keep filler plugs firmly in place at all times 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 gas to
escape from the cells.
Filler Plug Vent Hole
Do NOT allow cleaning solution, dirt, or any foreign matter to

enter the cell.

Battery Safety
Version no T-code
001
Make sure to install the correct size and weight battery. A

smaller or lighter weight battery could seriously affect truck
stability. See the truck specification (data) plate for more
information.
Never plug a battery charger into the truck battery connector.

Plug battery charger ONLY into battery connector from
battery.
Follow the charging procedures available by the supplier on

the “Battery” and “Battery Charger”.

Static Discharge Precautions

Version no T-code
001

Electronic circuit board and devices used on the truck can be
damaged by the discharge of static electricity, called
electrostatic discharge.
Static charges can accumulate from normal operation of the
truck as well as movement or contact between non-
conductive materials such as plastic bags, synthetic clothing,
synthetic soles on shoes, styrofoam coffee cups, etc.
Accumulated static can be discharged through human skin to
a circuit board or component by touching the parts. Static
discharge is also possible through the air when a charged
object is placed close to another surface at a different
electrical potential. Static discharge can occur without
seeing or feeling it.
Whenever working on or near static-sensitive electronics,
always use static discharge precautions.
1. Static-sensitive items are to remain in their
protective containers except when actually in use
at the static-free station.
2. Before removing the item(s) from their protective
container, the operator should place the container
on the conductive grounded bench top. Make sure
the wrist strap fits snugly around the wrist and is
properly plugged in/attached to ground receptacle
or the truck. The operator should then touch hands
to the conductive bench top, workstation, or truck.
3. All operations should be performed with the items
in contact with the truck or grounded bench top.
4. Do not allow conductive magazine (static-sensitive
items) to touch hard-grounded test gear or bench
top.
5. Ordinary plastic solder-suckers and other plastic
assembly aids should not be used.
6. In cases where it is impossible or impractical to
ground the operator with a wrist strap, a conductive
shoe strap can be used along with conductive tile/
mats.


Version no T-code
001
7. When the operator moves from any other place to

the static-free station, the start-up procedure
should be the same as the preparation for working
at a static-free workstation.
8. “Plastic snow” polystyrene foam, peanuts, or other
high-dielectric materials should never come in
contact with or be used around electrostatic
sensitive items, unless they have been treated with
an antistatic compound. Such treatment is often
indicated by a pink color on the foam material.
9. Static-sensitive items should not be transported or
stored in trays, tote boxes, vials, or similar
containers made of untreated plastic material
unless items are protectively packaged in
conductive material.

Welding Safety
Version no T-code
001
Welding Safety
WARNING Flame cutting or welding on painted

surfaces may produce potentially harmful
fumes, smoke and vapors. Prior to
performing flame cutting or welding
operations, it is recommended that the
coating be removed in the vicinity where the
operation(s) will be performed.
WARNING Coating removal may be by mechanical

methods, chemical methods or a
combination of methods. Flame cutting and/
or welding operations should be carried out
in well ventilated areas using local exhaust
if necessary.
Before working on the truck, make sure of the following:

• Fire protection equipment is nearby.
• Know where the nearest eyewash station is located.

Welding Safety
Version no T-code
001
CAUTION Disconnect battery before attempting to

inspect, service or repair truck. Discharge
residual charge in the transistor controller
by connecting a load across the transistor
controllers B+ and B- terminals (such as a
contactor coil or by pressing the horn
button).
• Check for shorts to frame. If any shorts are detected,

remove before proceeding with the welding operation.
• 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.
• Disconnect all electrical cards before any type of electric
resistance welding is done.
• Only trained, qualified, and authorized personnel should
weld on the truck.
• Do not perform any welding operations near the electrical
components.
• If welding must be done, disconnect and remove the
battery from the truck.
• When welding is completed, perform all ground tests and
electrical inspections before the truck is operated.

M
Introduction, Service Manual
Version no T-code
000 7BWS10/13

The information in this service manual covers model
7BWS10/13.
Federal and State laws require that operators be completely
trained in the safe operation of lift trucks in accordance with
OHSA regulation 1910.178.
An operator’s manual is sent with every Toyota truck when it
is manufactured. If the operator’s manual is missing from the
truck, a new manual may be obtained by contacting:
Toyota Industrial Equipment
www.toyotaforklift.com
The information contained in this service manual is intended
as a guide to help trained, qualified, and authorized
technicians safely service the truck.
The service manual is divided into four separate sections
which cover needed information for servicing the truck types.
The main subject for each of these sections is described
below.
SECTION SUBJECT
M MACHINE INFORMATION
P PLANNED MAINTENANCE
S SERVICE INSTRUCTIONS
O OPTIONS

M
Version no T-code
000 7BWS10/13

M
Contents, Section M
Version no T-code
000
Contents, Section M
1. Machine Information
M1.0 GENERAL PRODUCT INFORMATION
M2.0 TECHNICAL SERVICE DATA

M
Contents, Section M
Version no T-code
000

M1.0
General Product Information
Version no T-code
000 7BWS10/13

1. Truck Presentation
The 7BWS10/13 are battery powered adjustable baseleg
stacker trucks. These trucks are intended solely to be
operated indoors carrying pallets or similar load carriers. The
trucks are equipped with a tiller arm with all the controls for
operating within easy access. The trucks lifting capacities can
be found on the truck’s data plate.
The 7BWS10/13 trucks are equipped with a 24 volt electrical
system. Speed is regulated by means of a transistor
controller to provide infinite control of acceleration and speed
while driving.
The forks are raised by means of a hydraulic unit. The control
of the lift/lower is activated by rotating the control on the tiller
arm handle head.
1.1. Truck Side Views

The terms right-hand and left-hand used indicate the right
and left side of the truck as viewed from the operator’s line of
sight for proper operation of the truck. Use this view when
ordering parts to assure proper selection of parts.
Left Side
Tractor-first Forks-first
Right Side
1.2. Intended Truck Application

The trucks are solely designed and manufactured to handle
goods. The trucks should be fitted with the appropriate
accessories relevant to the application.

M1.0
Version no T-code
000 7BWS10/13
1.3. Prohibited Truck Application

The trucks are designed for handling goods indoors. It is not
permitted to use the trucks for other purposes including the
following:
• As a towing tractor for trailers.
• To tow other trucks.
• To transport/lift passengers.
• To drive on gravel or grass.
1.4. Truck Data

The following table provides information regarding technical
data which is of value with daily use of the trucks. Lifting
capacity and weight can be found on the truck’s data plate
(see page 36).
Metric dimensions and capacities are shown in parenthesis
and have been rounded for convenience.
Truck Data 7BWS10/13

0 - 3.6 mph
Without Load
(0 - 5.7)
Traveling speed mph (kph)
0 - 3.4 mph
Loaded
(0 - 5.4)
1610 - 1875
Without battery
(730 - 850)
Service weight, lb (kg)
1910 - 2425
With battery
(866 - 1100)

M1.0
Version no T-code
000 7BWS10/13
1.5. Dimensions
The following diagram shows external dimensions for the
7BWS10/13 truck in its standard design.
FF
P
P
GG
MM Q R
R
T
T
Q
E
E
41°
87° 6°
35°
W
W
38°
JJ
X
X
H
H
8°
U
U
K
K
N
N
CC VV L
L
SS
D
D B
B
AA
A = 58.9 inch (1496 mm) J = 48.6 inch (1234 mm) S = 3.9 inch (99 mm)
B = 47.0 inch (1194 mm) K = 24.2 inch (615 mm) T = 10/31.5 inch (254/800 mm)
C = 21.0 inch (553 mm) L = 10.0 inch (254 mm) U = 6 inch (152 mm) [Fork Free Lift Height]
D = 7.2 inch (183 mm) M = 27.3 X 7.8 inch (693 X 198 mm) U = 128 inch (3251 mm) [Max Fork Height]
E = 33.2 inch (843 mm) N = 1.6 inch (41 mm) V = 2.0 inch (51 mm)
F = 54.2 inch (1377 mm) P = 4 inch (100 mm) W = 84 inch (2134 mm)
G = 28.0 inch (711 mm) Q = 32 to 51 inch (813 to 1295 mm) X = 168 inch (4267 mm)
H = 32.8 inch (833 mm) R = 40 to 59 inch (1016 to 1499 mm)

M1.0
Version no T-code
000 7BWS10/13
Battery packs available from the factory.
Battery Pack Dimension Specifications

24 Volt Battery Pack Amp Hour Length Width Height Weight
Swing-out Upper Trays 26.5 inch 7.5 inch 26.45 inch
152 330 lbs (150 kg)
with 15 amp charger (675 mm) (192 mm) (672 mm)
GNB PalletPro™ 26.5 inch 7.5 inch 26.25 inch
195 375 lbs (171 kg)
with 25 amp charger (675 mm) (192 mm) (665 mm)
1.6. Data Plate

The illustration shows the data plate used on this truck.
1 2
3 4 5
7 8
9 10 11 12
C
B
A
Legend
1 Truck model number 7 Minimum battery weight
2 Truck serial number 8 Maximum battery weight
3 Truck type 9 Battery maximum AMP hours
4 Truck weight (less battery) 10 Hour Rate
5 Attachment 11 Truck voltage DC
6 Truck lifting capacity 12 Battery type UL class

M1.0
Version no T-code
000 7BWS10/13
2. Main Components
1. Tiller Arm:
The truck is to be controlled by the operator with 180 degree
steering angle. The brake is applied in the upper and lower
position of the tiller arm head.
2. Hydraulic unit:
Pump motor, pump, electric valve and oil tank reservoir
integrated in a compact unit.
3. Hydraulic lowering valve:
For controlling lifting and lowering functions with hydraulic
lowering valve.
4. Battery:
24 volt with different capacities and weights.
5. Drive unit with brake:
Drive unit with a spring-loaded electromagnetic brake, drive
motor, drive wheel, and transmission assembly. The steering
bearing is located at the top of the drive unit.
6. Steering pivot point.
7. Data plate:
See data plate on page 36.
8. Operator Display:
Display includes hourmeter, error codes, parameters, hardware
and software part numbers.
9. Electrical panel:
24 volt electrical system. Truck speed is regulated by means of
a transistor controller.
10. Fuse:
10A, Fuse Keypad and ETAC (supplied with main harness)
10A, Fuse Main ON/OFF (supplied with main harness)
130A, Fuse (one for drive motor and one for pump motor)
11. Load wheel:
The load wheels have seals on the outside of the bearings to
protect them in wet environments.
12. Keypad:
Enter PIN-key code in the keypad and press green ON (I) key
on the keypad starts truck. Press red OFF (O) on the keypad to
shut off electrical power to the control system. Up to 10 drivers
can be assigned their own individual PIN-key code for access
to the truck.
13. Main ON/OFF Switch:
The main ON/OFF switch will cut off all electrical power to the
control functions on the truck when pressed.

M1.0
Version no T-code
000 7BWS10/13
14. Travel speed / direction selection:

To select direction, rotate thumb controls in the direction of
travel. The further you rotate in that direction the faster the
travel.
15. Fork lower switch:
Forks will lower when switch is pressed or until mast reaches
the top. Then, if dead headed, the relief valve relieves the
pressure.
16. Fork raise switch:
Forks raise when switch is pressed or until mast reaches the
top. Then, if dead headed, the relief valve relieves the
pressure.
17. Horn switch:
Activates horn to warn others of your position. Horn button is
also used to cycle through special truck mode displays (see
page 170).
18. Battery Connector:
Disconnects off all electrical power to the truck.
19. Mast Guard.
20. Baselegs:
Adjustable in width from 32 to 51 inch (813 to 1300 mm).
17
15
19
16 14
18
1 8
9, 10
12
3
2
1 6
5
4 9
8
I
2, 3
7
0
O
13
7
4
6
5
11
20

M1.1
Inch (SAE) and Metric Fasteners
Version no T-code
000 7BWS10/13
5 9 10
5 9 10
1. Introduction
Threaded fasteners such as bolts, nuts, cap screws, and
studs are made to specifications that describe mechanical
strength and hardness of fastener. A fastener used in a
design application is selected in accordance with its
specifications. Parts used on this truck are purchased from
many countries. Many fasteners are similar but cannot be
used as direct replacements.
Service technicians must use replacement fasteners that
have the same specifications. Fasteners made to each
specification have identification marks for that specification.
This specification is commonly called “grade” for SAE
standards and “property” for metric standards. This section
describes identification of some common fasteners.
The metric system used is described as SI (International
System of Units, also called SI in all languages). The SI
system of measurement is described in ISO Standard 1000,
1973.

M1.1
Version no T-code
000 7BWS10/13
2. Nomenclature, Threads
The thread design is specified by a series of numbers and
letters for inch and metric fasteners (see figure below). The
diameter of shank of fastener is shown first in the series, e.g.
M12=12 mm, M20=20 mm (1/2=1/2 inch, 3/4=3/4 inch).
The number of threads per inch is normally not shown for inch
nomenclature and only UNC (Unified National Coarse) or
UNF (Unified National Fine) is shown. This number of threads
per inch is not shown because a UNC or UNF fastener has a
standard number of threads per inch for a specific diameter.
The length of a shank is often indicated as part of the
description of a fastener. This length is shown in inches for
inch fasteners and in millimeters for metric fasteners.
A cap screw will have the following description:
Inch Metric
1/2 x 13 UNC x 1-1/2 M12 x 1.75 x 50
A B C D A B C
A =Shank diameter
A =Thread size
B =Number of threads per unit of length
B =Pitch
C =Type of thread
C =Length
D =Shank length

M1.1
Version no T-code
000 7BWS10/13
3. Strength Identification
The most common property classes for metric fasteners are
8.8 and 10.9. The property class is marked with a number on
the head of the cap screw or on a nut. Property classes less
then 8.8 are often not marked. Grades for inch bolts go from 2
to 8. Grade 2 fasteners normally do not have marks. The
following tables show marks that identify grades and property
classes for different fasteners.
WARNING When fasteners must be replaced new

fasteners must be of same strength or
greater than original fasteners. The new
fasteners must also be the correct size.
NOTE! Identification marks are according to bolt

strength. The higher the number, or
increase in number of marks, indicates
increased bolt strength.

M1.1
Version no T-code
000 7BWS10/13
Table 1. Bolt and Screw Designations
Types of Inch Fasteners Metric Fasteners

Strength Levels: SAE Grades Strength Levels: Property Classes
Fasteners
* Markings Not Required
4.6* 4.8* 5.8* 8.8
2 5 5.2 7 8 4.6 4.8 5.8 8.8
9.8 10.9 12.9 Markings

Hex Head Bolts for size
& Cap Screws 9.8 10.9 12.9 M5 and
Larger
5 8
Hex Head Same As Above

Flange Screws
5 8
12 Point
Flange Screws
Markings Not Required

8.8 12.9
8.8 12.9
Hex Socket Head
Cap Screws
5.1
4.8* 9.8
4.8 9.8
Sems

M1.1
Version no T-code
000 7BWS10/13
Table 2. Stud and Nut Designations

Fasteners
4.6* 4.8* 5.8* 8.8
4.6 4.8 5.8 8.8
5* 5.2*
9.8 10.9 12.9
Markings
9.8 10.9 12.9
for size
M5 and
8* 8.1 Larger
or
Studs Optional Geometric Symbols for
Size M5 through M11.
5 8 9
5 8 9
2 5 8
5 8 9
or or 10 12
Hex Nuts
10 12
10 12
5 8 9 10 12
5 8 9 10 12
Hex Slotted Nuts
5 8 9 10 12

Hex Flange Nuts 5 8 9 10 12

M1.1
Version no T-code
000 7BWS10/13
Table 3. Torque Nut Designations

Fasteners
A B C 5 9 10
B C 5 9 10
or
All Metal Prevailing
Torque Nuts
F G
9 10
or
All Metal Prevailing 9 10
Torque Flange Nuts
or

M1.1
Version no T-code
000 7BWS10/13
Table 4. Torque Nut with Nylon Insert Designations

Fasteners Strength Levels: SAE Grades Strength Levels: Property Classes
5 9 10
or
Markings Not Required or

Nylon Insert Pre-
vailing Torque
Nuts 5 9 10
or
9 10
Markings Not Required or
Nylon Insert Pre-

vailing Torque
Flange Nuts
9 10

M1.1
Version no T-code
000 7BWS10/13
Table 5. Fastener Torque Values
Property, Class Property, Class Property, Class

Size and 8.8* 10.9** 12.9***
Pitch N•m in-lbs N•m in-lbs N•m in-lbs
M5 x 0.8 5-6 44-53 7-8 62-71 8-10 71-88
M6 x 1 8-10 71-88 12-14 106-124 14-16 124-142
M8 x 1.25 20-25 177-221 30-35 265-309 ------------ ------------
Size and
N•m ft-lbs N•m ft-lbs N•m ft-lbs
Pitch
M8 x 1.25 ------------ ------------ 29-35 22-26 34-40 26-30
M10 x 1.5 40-45 30-33 60-65 44-48 70-75 52-55
M12 x 1.75 70-80 30-33 100-110 74-81 115-130 85-96
M14 x 2 110-125 52-59 155-180 114-133 180-210 133-155
M16 x 2 170-190 125-140 240-270 177-199 280-320 207-236
M20 x 2.5 340-380 251-280 450-500 332-369 550-600 406-443
M24 x 3 580-650 428-479 800-900 590-664 900-1050 664-774
M30 x 3.5 1150-1300 848-959 1600-1800 1180-1328 1850-2100 1364-1549
M36 x 4 2000-2250 1479-1660 2800-3150 2065-2323 3250-3700 2397-2729
* Property class 8.8, Protective Treatment CMHC

Specification “H” (zinc phosphate), applies also to
internally threaded fasteners made of property
class 8 material.
** Property class 10.9, Protective Treatment CMHC

internally threaded fasteners made of property
class 10 material.
*** Property class 12.9, Protective Treatment CMHC

internally threaded fasteners of property class 12
material.

M1.1
Version no T-code
000 7BWS10/13
4. Truck Torque Specifications

Description Torque Specification
Drive motor end cover bolts 50 in-lbs (5.6 N•m)
Gear case cover mounting bolts 200 in-lbs (22.6 N•m) (sealant, see page 107)
Drive wheel lug nuts 55 ft-lbs (74.6 N•m)
Drive wheel studs 23 - 28 ft-lbs (32-38 N•m) Loctite 290®
Drive unit assembly 30 - 33 ft-lbs (40-45 N•m)
Steering bearing 336 - 384 in-lbs (38.0-43.4 N•m)
Stem mount nut 79 in-lbs (8.9 N•m)
Friction disc mounting bolts 50 in-lbs (5.6 N•m)
Electrical panel screws 48 - 60 in-lbs (5-7 N•m)
Hydraulic motor contactor coil nut 30 - 40 in-lbs (3.4-4.5 N•m)
Hydraulic reservoir clamp 48 - 60 in-lbs (5.5-7 N•m)
Hydraulic unit mounting bolts 20.5 - 24 ft-lbs (28-33 N•m) Loctite 243®
Hydraulic motor to adapter body 96 - 120 in-lbs (10.8-13.6 N•m)
Pump to adapter body nut 100 - 134 in-lbs (11.3-15.0 N•m)
Baseleg bolts 180 - 200 ft-lbs (244-271 N•m)
Support arm bolts 40 ft-lbs (54.2 N•m)
Truck bumper bolts 246 - 283 in-lbs (27.8-32.0 N•m)
Mast mounting bolts 140 - 150 ft-lbs (190-203 N•m)

M1.1
Version no T-code
000 7BWS10/13
5. Conversion of Metric and English

Units
AREA
Multiply By To Get Multiply By To Get
inches² 6.451 centimeters² (cm²) centimeters² 0.155 inches² (in²)
feet² 0.093 meters² (m²) meters² 10.764 feet² (ft²)
LINEAR
inches 25.4 millimeters(mm) millimeter 0.03937 inches (in)
feet 0.305 meters (m) meter 3.280 feet (ft)
yards 0.914 meters (m) meter 1.094 yards (yd)
miles 1.609 kilometers (km) kilometer 0.621 miles (mi)
MASS
ounces (oz) 28.49 grams (g) grams 0.035 ounces (oz)
pounds (lb) 0.454 kilograms (kg) kilograms 2.205 pounds (lb)
tons (2000 lb) 907.18 kilograms (kg) kilograms 0.001 tons (2000 lb)
tons (2000 lb) 0.907 metric ton (t) metric ton 1.102 tons (2000 lb)
POWER
horsepower 0.746 kilowatts (kW) kilowatts 1.34 horsepower (hp)
PRESSURE
pounds/in² 6.895 kilopascal (kPa) kilopascals 0.145 pounds/in² (psi)
pounds/in² 0.007 megapascal (MPa) megapascals 145.04 pounds/in² (psi)

M1.1
Version no T-code
000 7BWS10/13
TEMPERATURE
(Fahrenheit
0.56 Celsius (C) (Celsius x 1.8) +32 Fahrenheit (F)
-32)
TORQUE
inch pounds
inch pound 0.113 Newton meter (N•m) Newton meter 8.851
in-lbs
foot pounds
feet pound 1.356 Newton meter (N•m) Newton meter 0.738
ft-lbs
VELOCITY
kilometer/hour miles/hour
miles/hour 1.609 kilometer/hour 0.621
(km/h) (mph)
VOLUME
inches³ 16.387 centimeters³ (cm³) centimeters³ 0.061 inches³ (in³)
inches³ 0.016 liters liters 61.024 inches³ (in³)
quarts, U.S. 0.946 liters liters 1.057 quarts, U.S. (qt)
quarts, U.S. 0.83 quarts, Imp. (qt) quarts, Imp. 1.205 quarts, U.S. (qt)
gallons, U.S.
gallons, U.S. 3.785 liters liters 0.264
(gal)
gallons, U.S.
gallons, U.S. 0.83 gallons, Imp. (gal) gallons, Imp. 1.205
(gal)
ounces 29.57 milliliters (ml) milliliters 0.034 ounces (oz)

M1.1
Version no T-code
000 7BWS10/13

M2.0
Technical Service Data
Version no T-code
000 7BWS10/13

NOTE! When the battery is fully charged,
performance may vary due to motor and
system efficiency tolerance. Technical
service data represents nominal values
obtained under typical operating conditions.
Specifications are subject to change
without notice.
DRIVE UNIT
Type Shunt wound

Power - horsepower [hp] (kilowatts [kW]) 1.2 (0.90)
Duty factor 1 hour
Min carbon brush length - inch (mm) 0.59 (15)
Min commutator diameter - inch (mm) 1.85 (47)
Min brush - ounce-force (N•) 44.8 (12.4)
Gear ratio 22:1
Oil volume, oz (liter) 13.5 (0.4)
Standard operation (see page 59) Mobil-1 Synthetic Gear Lube 75W-90
temperature down to 32° F (0° C) or Texaco Synstar GL 75W-90
WHEELS
Drive wheel - inch (mm) 10.0 x 5.0 (255 x 125)

Drive wheel % load distribution without load 7BWS13
(7.8” battery compartment 128” LFL Mast 62%
(7.8” battery compartment 143” LFL Mast 64.3%
(7.8” battery compartment 128” FFL Mast 64.4%
Drive wheel % load distribution with maximum load 7BWS13
(7.8” battery compartment 128” LFL Mast 29%
(7.8” battery compartment 143” LFL Mast 30.2%
(7.8” battery compartment 128” FFL Mast 27.6%
Torque drive lug nut, ft-lbs (N•m) 55 (74.6)
Load wheel - inch (mm) 4.0 x 3.0 (101 x 76)

M2.0
Version no T-code
000 7BWS10/13
LOAD WHEELS
7BWS13 (EACH WHEEL)
Percent load distribution without load
19%
(7.8” battery compartment 128” LFL Mast
17.8%
17.8%
(7.8” battery compartment 128” FFL Mast
LOAD WHEELS
7BWS13 (EACH WHEEL)
Percent load distribution with maximum load
35.5%
34.9%
36.2%
(7.8” battery compartment 128” FFL Mast
HYDRAULIC UNIT
Power - horsepower [hp] (kilowatts [kW]) 4 (3)

Duty factor 20% on 5 min. cycles
Minimum brush length - inch (mm) 0.59 (15)
Minimum commutator diameter - inch (mm) 1.89 (48)
Minimum brush spring tension - ounce-force (N•) 36 (10)
Relief pressure - psi (bar) 3100 (213)
Pump flow 2.0 cc
Tank volume - gallons (liters) 1.3 (5)
Standard operation (see page 59)
Union 76 TH
temperature down to 32° F (0° C)
FUSES
Keypad and ETAC Fuse 10 Amp

Control Circuit Fuse 10 Amp
Drive Motor Fuse 130 Amp
Pump Motor Fuse 130 Amp
BATTERIES
27.3 x 6.8 (693 x 172) Optional
Compartment Dimension L x W - inch (mm) 27.3 x 7.8 (693 x 198) Standard
27.3 x 9.0 (693 x 228) Optional
Capacity (recommended Max. Amp-hrs.) 255

M2.0
Version no T-code
000 7BWS10/13
Weight (Minimum) - lbs (kg) 330 (150)

Weight (Maximum) - lbs (kg) 375 (171)
Lead length - inch (mm) 18 (457)
Lead position B
DRIVING SPEEDS (FORKS DIRECTION)
Without load - mph (kph) 3.6 (5.7)

With rated load - mph (kph) 3.4 (5.4)
LIFTING/LOWERING TIME (128 inch LFL [3251 mm] mast)
Lift without load (fpm) 41

Lift with rated load (fpm) 22
Lower without rated load (fpm) 44
Lower with rated load (fpm) 48
AVERAGE CURRENT READINGS
Driving without load (with truck on level floor) 17 Amps

Driving with rated load (with truck on level floor) 30 Amps
Lifting without load 61 Amps
Lifting with rated load 130 Amps

M2.0
Version no T-code
000 7BWS10/13

P
Contents, Section P
Version no T-code
000
Contents, Section P
1. Planned Maintenance
P1.0 INTRODUCTION, MAINTENANCE
P2.0 SERVICE SCHEDULE
P3.0 LUBRICATION CHART
P4.0 OIL AND GREASE SPECIFICATIONS

P
Contents, Section P
Version no T-code
000

P1.0
Introduction, Maintenance
Version no T-code
000 7BWS10/13
The schedule of maintenance and lubrication given in this
section of the service manual cover up to one year’s
operation of the truck. These schedules are based on hourly
usage and can be adapted to suit most schedules. The
following hourly usage figures have been used when
calculating the schedule:
Single shift, 30 hours per week usage
Double shift, 60 hours per week usage
Triple shift, 90 hours per week usage
The “Planned Maintenance Schedule” on page 61 is
based on the single shift schedule. The schedules are
intended only as a guide, not as a rigid structure. Owners of
the trucks may wish to adapt to local requirements; but it is
emphasized that the schedules represent minimum
manufacturer requirements, and all items should be included
in a service program to ensure minimum downtime and a high
status of the equipment.
• Use spare parts approved by Toyota.
• Always clean the equipment and carry out a full
check after service.

P1.0
Version no T-code
000 7BWS10/13
1. Jacking Truck Off The Floor

To perform maintenance that requires the truck to be lifted
from the floor, observe the proper precautions as follows:
1. Lower the forks completely. Remove any load.
2. Press the red OFF (O) key on the keypad.
Disconnect battery connector from the truck.
3. If possible, stabilize the top of the mast with an
overhead chain hoist.
WARNING Use extreme care whenever the truck is

jacked up for any reason. Never block the
truck between the mast column and the
floor. Use a suitable hoist to stabilize the
mast. Keep hands and feet clear from
beneath the truck while jacking. After the
truck is jacked, position solid blocks
beneath it to support it. DO NOT rely on the
jack alone to support the truck.
4. Position the jack under the designated jacking
points.
1.1. Elevate Rear of Truck

1. Place jack in the designated jacking position.
2. Jack the truck so that the drive tire is off the floor
no more than 3.0 inch (76 mm).
3. Block the truck in place.

P1.0
Version no T-code
000 7BWS10/13
Jack only in these areas
Jack under frame

only. “DO NOT Jack
directly on mast.
Figure 0-1: Jacking Truck Off the Floor
1.2. Elevate Either Side of Truck

1. Place jack in the designated jacking position.
2. Jack the side of the truck so that the load wheel is
off the floor no more than 0.50 inch (12.7 mm).
3. Block the truck in place.
2. Lubricants
2.1. Standard
The standard conditioning truck is designed for operation in
temperatures down to 32 degrees F (0 degrees C).

P1.0
Version no T-code
000 7BWS10/13

P2.0
Service Schedule
Version no T-code
000 7BWS10/13
Service Schedule
1. Planned Maintenance Schedule
WORK REQUIRED Time Interval
1 Day 6 Months 12 months
Moderate Usage
ITEM 8 Hrs. or 500 Hrs. or 1000 Hrs.
Check Severe Usage
8 Hrs. or 250 Hrs. or 500 Hrs.
General
1 Check for loose hardware. Tighten as necessary. X
2 Note any unusual noise during operation. X
3 Check for leaks around drive unit and hydraulic X
system.
4 Visually inspect all cables for damage. X
5 Check grease location points (See Section P4.0 for X
locations and specific Section S.0 for information.)
0300 Chassis
0300.1 Check truck data plate and decals for legibility. X
0300.2 Check for crack formation and damage. X
1700 Motors
1700.1 Check connections for proper contact. X
1700.2 Clean motor of dirt and dust. X
1700.3 Check condition of brushes, springs, and holders. X
1700.4 Check brush length. Replace brushes if necessary X
(see page 90.)
2550 Drive Unit
2550.1 Check oil in drive housing. Check for contamination X
in the oil (see page 102.)
2550.2 Change transmission oil (see page 101.) X
3300 Brake
3300.1 Check brake operation. X
3300.2 Clean dust and debris. X
3300.3 Check brake disc for wear. X
3500 Wheels
3500.1 Remove all string, wrapping, and debris. X
3500.2 Check all wheels for wear. X
4100 Tiller Arm
4100.1 Check return of tiller arm to upper rest position. X
5000 Electrical Control System
5000.1 Check operation of horn button. X
5000.2 Check speed and thumb controls. X
5000.3 Check tiller arm/angle switches for adjustment. X

P2.0
Service Schedule
Version no T-code
000 7BWS10/13

Moderate Usage
Check Severe Usage
5000.4 Check steering operation. X
5000.5 Check lift/lower functions. X
5000.6 Check operation of main ON/OFF switch. X
5000.7 Check for electrical shorts in chassis. X
5000.8 Check operation of reverse button. X
5110 Battery
5110.1 Check cleanliness and exterior conditions. X
5110.2 Check the battery charge. X
5110.3 Check the battery weight. X
5110.4 Check all connections; battery, battery and charger X
plugs.
5110.5 Check battery mounting bolt or freeplay. X
5111 Battery Connector
5111.1 Check battery connector. Make sure all powered X
functions shut down when disconnected.
5400 Electrical Panel
5400.1 Clean and check mounting to chassis. X
5400.2 Check contactors for welded conditions. X
5400.3 Check contactor tips for free movement. X
6000 Hydraulic System
6000.1 Check hoses for wear and damage. X
6000.2 Check reservoir for cracks, leaks, and mounting. X
6000.3 Check for correct oil level. X
6000.4 Check hydraulic connections and mounting. X
6000.5 Change hydraulic oil. Clean filters. X
7100 Mast
7100.1 Check for damage and cracks. X
7100.2 Check clearance of rollers. Check rollers for unusual X
wear patterns.
7100.3 Check lateral play of inner section. X
7100.4 Check for wear on lift chains and chain rollers. X
7100.5 Check adjustment of lift chains. X
7100.6 Clean and lube lift chains. X
7100.7 Clean and lube mast columns. X
7100.8 Lube chain sheaves. X

P2.0
Service Schedule
Version no T-code
000 7BWS10/13

Moderate Usage
Check Severe Usage
7400 Lift Device
7400.1 Check clearance of fork carriage/yoke rollers. X
7400.2 Check fork carriage/yoke for damage and crack X
formation.
7400.3 Check forks for wear and cracks. X

P2.0
Service Schedule
Version no T-code
000 7BWS10/13
5110
5400
5110
5000
1700
4100
5700 6000
3300
3500
1700
2550

P2.0
Service Schedule
Version no T-code
000 7BWS10/13
2. Planned Maintenance Procedures

This section describes how to perform the services listed in
the Schedule of Planned Maintenance Operations. As with
the “Schedule”, this section is subdivided into service
intervals.
2.1. General
The following general inspections are to be made by the
operator. The frequency of these inspections are based on
the usage of the truck (see page 61). It is the operator's
responsibility to report any problems with the truck to the
appropriate personnel. The truck should not be operated until
it has been inspected and repaired by a trained, qualified, and
authorized technician. The operator is ultimately responsible
for the safe operation of the truck.
2.1.1. Hardware
Inspect the truck for loose, damaged, or missing parts. All
shields and covers must in place and functional. Inspect truck
for missing data plate or decals and make sure they are
legible. Report any problems to the appropriate personnel.
DO NOT operate the truck until it has been inspected and
repaired by a trained, qualified, and authorized technician.
Check all fasteners and connections, torque as required (see
page 47). Check the drive wheel studs. Ensure that the lug
nuts and studs are tightened to the proper torque
specification (see page 47). Check torque on motor end cap
bolts. Check that support arm adjustment bolts are torqued to
180 - 200 ft-lbs (244 - 271 N•m) [see page 76].
2.1.2. Noise
Check for an abnormal noise coming from the truck.
2.1.3. Leaks
Inspect the entire truck for leaks, especially around the
hydraulic pump assembly and the lift cylinders. Any sign of oil
on the floor under the truck is an indication that the truck may
be leaking hydraulic oil or transmission fluid. Report any
problems to the proper authorities. DO NOT operate the truck
until it has been inspected and repaired by a trained,
qualified, and authorized technician.

P2.0
Service Schedule
Version no T-code
000 7BWS10/13
Check for proper fluid level in drive unit. When truck is level,
oil must be up to the bottom of the plug opening. If fluid is low,
check for leaks (see page 101).
2.1.4. Cables and Connections

Tighten connections. Check all cable insulation for damage.
Check that all electrical connections are clean and tight. Plug-
in connectors should be unplugged and plugged back in to
clean terminals.
2.1.5. Grease Location Points

Lubricate load wheel bearings. For location of the grease
points see page 72. Clean and lube lift chains. Clean and
lube mast columns (for proper lube, see page 71.)
2.2. Services Performed Daily or Every 8

Operating Hours
Daily inspection is to be made by the operator prior to each
operating shift. It is the operator's responsibility to report any
problems with the truck to the appropriate personnel. The
truck should not be operated until it has been inspected and
The operator is ultimately responsible for the safe operation
of the truck.
2.2.1. Chassis
Check truck data plate and decals to see that data is legible.
2.2.2. Brakes
Check operation of brakes.
2.2.3. Wheels/Tires
Inspect wheels and tires for wear and damage. Remove any
steel chips and foreign material to prevent damage to the
wheels. Check for gouging and chunking of the surface.
Trash that is wrapped around wheels and axles will cause
premature tire wear and bearing damage. The floors should
be kept clear of trash to prevent damage to the wheels and
tires.
2.2.4. Tiller Arm
Check return of tiller arm to upper rest position.

P2.0
Service Schedule
Version no T-code
000 7BWS10/13
2.2.5. Functions/Operations
Test truck for the proper operation of all functions including
the speed and thumb controls (arm angle switches), lift and
lower functions, brakes, steering, reverser button, horn button
and the main ON/OFF switch. Devices must be operational.
Report any problems to the proper authorities. DO NOT
operate the truck until it has been inspected and repaired by a
trained, qualified, and authorized technician.
2.2.6. Battery
Contact your battery supplier for specific instructions on
care and maintenance of the battery. Determine if the
battery needs to be washed down. This can only be done by
a trained, qualified, and authorized technician.
An average battery will have a specific gravity of 1.170 at the
80 percent discharged level. However, there are many
different batteries on the market. The battery supplier can
accurately determine the fully charged and 80 percent
charged levels. Contact an authorized battery supplier to
determine the overall condition of the battery.
Check status of the Battery Discharge Indicator (BDI) on the
truck. If the BDI displays a flashing “O”, then lift-cutout is
enabled and travel only is allowed. Drive unit safely to battery
charging location and replace battery or charge existing
battery in unit. The BDI should decrement from “100” (Fully
Charged Battery) to “O” (Completely Discharged Battery)
during truck operation.
2.2.7. Battery Connector
On the battery connector inspect the negative and positive
cables for breaks and wear. Check connectors for damage
and to ensure proper connections of cables.

P2.0
Service Schedule
Version no T-code
000 7BWS10/13
2.3. Services Performed Every Six Months

or 500 Operating Hours Under Moderate
Usage or Three Months or 250 Hours
Under Severe Usage
The following inspections are to be made by the operator.
The frequency of these inspections are based on the usage
of the truck. It is the operator's responsibility to report any
problems with the truck to the appropriate personnel. The
truck should not be operated until it has been inspected and
The operator is ultimately responsible for the safe operation
of the truck.
2.3.1. Chassis
Check chassis for crack formation and damage.
2.3.2. Motors
WARNING When using compressed air, wear effective

chip-guarding and personal protective
equipment. Compressed air used for
cleaning MUST be reduced to less than 30
psi (207 kPa).
Check motors for improper connections due to poor
connections. Check tightness on all connections. Blow
carbon, copper, and plastic particle accumulations out from
the drive motor fan and vents using compressed air. Check
for signs of oil on the drive motor air vents. Check for any
damage to the air vents. For minimum brush lengths see
page 51 or page 52.
2.3.3. Drive Unit

Check oil in drive housing. Check for contamination in the oil
(see page 102).
2.3.4. Brake
Clean brake of dust and debris. Check brake disc for wear.
1. Remove brake coil, and inspect brake disc for
wear. If the brake disc is damaged or worn, replace
with a new disc (see page 116).

P2.0
Service Schedule
Version no T-code
000 7BWS10/13
2. Before replacing the brake disc see page 115.

2.3.5. Electrical Control System
Check tiller arm angle switches for adjustment (see
page 223).
Check for electrical shorts to chassis (see page 160.)
2.3.6. Battery
Check battery mounting bolt. Check freeplay in battery
mounting area.
2.3.7. Electrical Panel
Clean and check electrical panel mounting to chassis. Check
for connections in harness connectors. Check contactors for
welded conditions. Check contactor tips for free movement.
Clean operation of contactors for proper operation (see
page 237.)
2.3.8. Hydraulic System

Check the fluid level in the hydraulic reservoir (see
page 258). Check hoses and connections on the hydraulic
system for leaks. Repair or replace hoses if worn or
damaged. Check oil reservoir for cracks, leaks and mounting.
2.3.9. Mast
Check mast (see page 275) for damage and cracks. Check
clearance of rollers. Check lateral play of inner section.
Check for wear and adjustment of lift chains. Check chain
anchors and sheaves.
2.3.10. Lifting Devices

Inspect the fork carriage and forks for damage and cracks.

P2.0
Service Schedule
Version no T-code
000 7BWS10/13
2.4. Services Performed 12 Months or

Every 1000 Operating Hours Under
Moderate Usage and Six Months or Every
500 Operating Hours Under Severe Usage
2.4.1. Drive Unit
Fluid from the transmission should be drained and new fluid
added (see page 101).
2.4.2. Hydraulic System
The hydraulic system should be drained, flushed, and refilled.
Clean hydraulic filters when hydraulic fluid is changed. The
pressure relief valve setting should be checked.
WARNING Before siphoning oil from reservoir, make
certain siphon is clean.
To drain reservoir, disconnect and remove the hydraulic

pump assembly (see page 257).

P3.0
Lubrication Chart
Version no T-code
000 7BWS10/13
Lubrication Chart
Interval/Running Lubricant
Pos. No Service Point Hours (See “Lubricants”
500 h 1000 h on page 72)
1 Wheel bearings L A
2 Mast columns L E
3 Lifting chains L D
4 Hydraulic system C O B
5 Transmission C O C
L= Lubrication C = Check O = Oil change
2 3

P4.0
Oil and Grease Specifications
Version no T-code
000 7BWS10/13
Oil and Grease Specifications

1. Lubricants
Lubricant Specifications
Location
Standard Operation Down

Lubricant Application area
To 32° F (0° C)
A Grease Mystik JT-6 Bearings and bushings

B Hydraulic oil Union 76 TH Hydraulic system
Mobil-1 Synthetic Gear Lube 75W-90
C Transmission oil Gears
or Texaco Synstar GL 75W-90
D Lifting chains #10W40 Lifting chains
E Grease Gleitmo 805 or equivalent Mast beams
2. Grease Location Points
Optional B

S
Contents, Section S
Version no T-code
000
Contents, Section S
1. Service Instructions
NO FUNCTION GROUP C-CODE
0 CHASSIS 0000
1 MOTORS 1000
2 DRIVE GEAR / TRANSMISSION 2000
3 BRAKE / WHEEL SYSTEM 3000
4 STEERING SYSTEM 4000
5 ELECTRICAL / PNEUMATIC SYSTEM 5000
6 HYDRAULIC SYSTEM / CYLINDERS 6000
10 TOOLS 10000

S
Contents, Section S
Version no T-code
000

S0.1 0300
Stabilizer Support Arms
Version no T-code
000 7BWS10/13
Plate
Bolt

S0.1 0300
Version no T-code
000 7BWS10/13
1. Theory of Operation
The truck is designed with the stabilizer support arms
(baselegs), with separate mounting points from the mast and
lift cylinder, bolted to the drive unit chassis. The support arms
of the straddle chassis are adjustable in width from 32 to 51
inch (813 to 1300 mm) to suit different pallet sizes. Normally,
the support arms are adjusted to the customers specifications
prior to delivery.
2. Maintenance
The fastening of the support arms (baselegs) need to be
checked at the regular planned maintenance service (see
page 61).
2.1. Support Arm Width Adjustment
NOTE! Think Safety First!

1. Make sure truck is unloaded and parked on a level
surface.
2. Lift forks high enough to place a toe jack under the
frame as shown in the Figure 0-2. Shut truck off,
unplug the battery and remove the battery.
Remove both side plates by lifting up and out as
shown in Figure 0-5.
Figure 0-2: Lift Forks for Toe Jack

S0.1 0300
Version no T-code
000 7BWS10/13
3. Jack truck up one side just high enough to raise

load wheels off the floor. No more than 1/4 inch (6
mm) should be allowed between the floor and the
load wheel. Place a wood or metal block under the
frame as shown in Figure 0-3.
Block
Figure 0-3: Blocking Truck to Raise Load Wheels
4. Slowly lower the jack until the frame rests on the

block.
5. Repeat step 3 for the other side. When blocking
the other side place a carpenter’s level on the side
of the mast and make sure it remains level from
side to side as shown in Figure 0-4.

S0.1 0300
Version no T-code
000 7BWS10/13
Figure 0-4: Blocking Opposite Load Wheel
Figure 0-5: Side Plate Removal
6. Loosen the four adjustment bolts on each support

arm.
7. To determine the correct amount of adjustment for
the desired I.D., use the following calculation. This
measurement will be a starting point and further
adjustments may be necessary.

S0.1 0300
Version no T-code
000 7BWS10/13
(Desired I.D.) Divided by (2) minus 12 = Distance

between Surface “A” and Surface “B”. (See
Figure 0-6.)
B A
Distance to Adjust
Figure 0-6: Support Arm Adjustment
8. Move one support arm outward until the width

calculated in step 7 is reached. Repeat this step for
the other support arm. Tighten bolts to 40 ft-lbs
(54.2 N•m) in a cross pattern for both arms.
9. Measure the distance between points “C” and “D”
as shown in Figure 0-7. If the measurement is less
than desired ID, adjust each support arm equally
until the desired ID is reached. Make sure
adjustments made to each arm are in equal
amount and are torqued to 40 ft-lbs (54.2 N•m)
before remeasuring. Make sure the distance
between points “A” and “B” on both support arms
are equal once desired ID is achieved.
10. Snug the adjustment bolts in a cross pattern in 40
ft-lbs (54.2 N•m) increments and continue in a
cross pattern until all bolts reach 180-200 ft-lbs
(244-271 N•m) It is very important that a cross
pattern is maintained in 40 ft-lbs (54.2 N•m)
increments and each bolt is torqued between 180-
200 ft-lbs (244-271 N•m) when finished.
11. Using a toe jack remove the blocks that were
installed under the frame one side at a time
returning the unit to the ground.
12. Using a carpenters level, check the mast again
ensuring it is plumb and level. See Figure 0-4.

S0.1 0300
Version no T-code
000 7BWS10/13
13. Install battery. Replace the side panels, plug in the

battery, turn truck on, and check truck for correct
operation.
Measure between these points
Figure 0-7: Support Arm Measuring Distances

S0.2 0340
Inspection, Covers
Version no T-code
000 7BWS10/13
Inspection, Covers
2
3
6 7
8
No function on this truck
Item No. Description Item No. Description

1 Cover, upper 6 Nut
2 Screw 7 Bumper
3 Cover, lower 8 Plate, left
4 Plate, right 9 Clip
5 Screw

S0.2 0340
Inspection, Covers
Version no T-code
000 7BWS10/13
Windshield
The truck covers are easily removed for access to the
components. The windshield is standard on the truck. During
operation of the truck, the covers must be secured to the
truck.
2. Maintenance
See “Planned Maintenance Schedule” on page 61.
3. Troubleshooting
Inspect covers and windshield for damage. Damaged covers
and windshield should be replaced.
4. Repair and Rebuild

When the covers and windshield become damaged and do
not fit properly, replace with new as necessary.

S0.3 0851
Decals
Version no T-code
000 7BWS10/13
Decals
Remove and replace any decals that are damaged or
missing. Remove a damaged decal by using a sharp edge to
peel the decal from the surface. Use caution not to scratch or
damage the paint on the truck when removing the decal. New
warning decals are free from Toyota. Refer to truck parts book
for location and quantities of the decal.
Using a cleaning solution, thoroughly clean the surface of the
truck before applying a new decal. Allow the surface to dry
completely, be sure that there is no residue. Before applying
decal, touch up the paint in area of the decal, as required.
1. Decal with Protective Sheet

To install this style, peel off the backing, place the decal into
position, and press the decal into place. Do not wrinkle the
decal. Rub over the protective over-sheet with a firm, straight,
plastic edge to remove air bubbles and any wrinkles. Peel off
the over-sheet.
2. Decal without Protective Sheet

To install this style, peel off the backing, place the decal into
position, and press the decal into place. Do not wrinkle the
decal. Smooth the decal into place using clean fingers. Be
sure all the edges are secured to the surface.

S0.3 0851
Decals
Version no T-code
000 7BWS10/13

S1.0 1700
Electric Motors
Version no T-code
000 7BWS10/13
Electric Motors
Electric motors provide power to the transmission and
hydraulic systems. Motor speed and direction are controlled
by the transistor controller or contactor with inputs from the
operator controls.
The lift pump motor assembly consists of the pump motor,
pump assembly and lift valve assembly. The pump motor and
pump are an integrated unit. The drive unit assembly consists
of the electromagnetic brake assembly, drive motor,
transmission assembly, and drive wheel. The drive motor is
integral part of the drive unit. The steering bearing is mounted
on top of the drive unit assembly.
2. Maintenance
A routine maintenance schedule with recorded findings is the
best way to reduce costly shut-downs and repair of
equipment during operating hours. The goal of any
maintenance program, long-life and trouble-free operation, is
related to time spent making inspections and correcting minor
problems as they occur.
Inspect the motor more frequently when working in an
abnormally severe environment or if in a rigorous duty cycle.
Set up and maintain a strict inspection schedule to obtain the
maximum efficiency from the electrical equipment.
Operating environments of truck motors varies widely.
The following recommendations should be applied as actual
conditions dictate:
Normal Service: Basically an eight hour shift of indoor
material handling.
Severe Service: Extended operating hours, or constant
usage.
Extreme Service: Chemical processing
Processing plants (poultry, meat)

S1.0 1700
Electric Motors
Version no T-code
000 7BWS10/13
Each partial inspection of the motor must include:

1. Inspect the brushes for wear and for correct
contact with the commutator. Record the level of
wear on the brushes. This history will indicate
whether a brush must be changed or if it can wait
until the next inspection. For acceptable brush
length see page 51 or page 52.
NOTE! Overloading a unit is ultimately reflected in

the motor and brush wear. Therefore, take
this into account when considering brush
replacement.
2. Check the brush spring tension. For acceptable
brush spring tension see page 51 or page 52.
3. Clean the brushes and holders. Wipe the
commutator with a dry, lint-free cloth. Do not use
lubricants of any kind on or around the
commutator.
4. Check the brush holders for solid connection to the
mounting support. Tighten the mounting screws as
necessary.
5. Check the cap screws holding the brush cross
connectors to the brush holder body.
6. Make sure the motor terminals are secured tightly
to the motor frame. Do not strip the threads or
crush the insulating parts.
7. Check all the cap screws around the frame for
tightness.
8. Keep the outside frame of the motor clean and free
from dirt. Maintain a free air passage around the
motor to permit heat radiation.
3. Troubleshooting

S1.0 1700
Electric Motors
Version no T-code
000 7BWS10/13

4.1. Pump Motor
Pump Motor Mounting
Pump / Motor Assembly
To Mast
1 Item
Description
No.
1 Pump Motor Assembly
2 Kit, brush and spring
3 Cover, “EE”

S1.0 1700
Electric Motors
Version no T-code
000 7BWS10/13
4.1.1. Removal
1. Park truck on a level surface and make sure
parking brake is applied and load wheels are
blocked to prevent accidental movement.
2. Release pressure in hydraulic system by pressing
the lowering button on tiller arm until lift cylinders
are completely collapsed.
3. Press red OFF button (O) on the keypad. Depress
main ON/OFF switch to the OFF position.
4. Disconnect battery connector from the truck.
Remove battery from the truck (see page 203).
5. Remove truck cover(s) [see page 81].
6. Remove hydraulic line from hydraulic pump
assembly and cap end to prevent contaminants
from entering the hydraulic system.
7. Disconnect hydraulic motor power cables and mark
their positions. Disconnect coil wiring, noting their
positions.
8. Remove bolts securing hydraulic pump and motor
assembly to frame. Remove pump/motor assembly
from truck.
9. Repair pump/motor as necessary.

S1.0 1700
Electric Motors
Version no T-code
000 7BWS10/13
4.1.2. Installation

psi (207 kPa).
1. Thoroughly clean all parts with non-corrosive
cleaning fluid and air dry all parts.
2. Install pump/motor assembly in truck and secure
with bolts to truck frame. (For torque values see
page 47.)
3. Properly connect electrical power cables and coil
wiring, noting their positions recorded earlier. For
torque values see page 47.
4. Uncap and connect hydraulic hose to hydraulic
pump assembly.
5. Fill hydraulic reservoir with new clean oil (see
“Lubricants” on page 72).
6. Install battery and secure with mounting bolt, if
applicable (see page 203.)
7. Install truck cover(s) [see page 81].
8. Reconnect battery connector to the truck.
9. Remove wheel blocks.
10. Turn the main ON/OFF switch to the ON position.
Enter key code and press the press green ON
button (I) on the keypad.
11. Check the reservoir fluid level. Operate the truck’s
hydraulic system and check operation of system as
a whole. Inspect for leaks.

S1.0 1700
Electric Motors
Version no T-code
000 7BWS10/13
4.2. Drive Motor

4.2.1. Brush Inspection and Replacement
1. Press red OFF (O) key on the keypad. Depress
main on/off switch to the OFF position. Disconnect
battery connector from the truck.
2. Remove the truck cover.
3. Remove any shields around the motor end cover to
expose the bushes. See Figure 1-1.
Brush
Shield
Figure
Figure 1-1: Drive Motor Brush Shield
4. Lift the spring off the brush, pull the brush out of
the holder.
5. Follow the brush inspection and replacement
instructions below.
6. Replace the shields that were removed in step 3.
4.2.2. Brush Inspection

Brushes should be inspected for uneven wear and signs of
overheating such as discolored brush shunts and brush
springs. Check the brush holders for physical damage and
make sure they are secure on the brush holder plate and
motor end head. Check the brush springs for correct
alignment on the brush. A brush spring that does not apply
equal pressure on the center of the brush will cause the brush
to wear unevenly. Check for correct clearance and freedom of
brush movement in the holder. If the brushes are worn to the
point that replacement is necessary, the complete brush set
should be replaced (see page 92).

S1.0 1700
Electric Motors
Version no T-code
000 7BWS10/13
1. Inspect the brushes for wear and for correct

contact with the commutator. Record the level of
wear on the brushes. This history will indicate
whether a brush must be changed or if it can wait
until the next inspection. Acceptable brush length
is 0.59 in. (15 mm).
NOTE! Overloading a unit is ultimately reflected in

the motor and brush wear. Therefore, take
this into account when considering brush
replacement.
2. Check the brush spring tension. Minimum brush
spring tension is 44.8 oz. force (12.4 N•).
3. Clean the brushes and holders. Wipe the
commutator with a dry, lint-free cloth. Do not use
lubricants of any kind on or around the
commutator.
4. Check the brush holders for solid connection to the
mounting support. Tighten the mounting screws as
necessary.
5. Check the cap screws holding the brush cross
connectors to the brush holder body.
6. Make sure the motor terminals are secured tightly
to the motor frame. Do not strip the threads or
crush the insulating parts.
7. Check all the pole shoe cap screws around the
frame for tightness.
8. Keep the outside frame of the motor clean and free
from dirt. Maintain a free air passage around the
motor to permit heat radiation.

S1.0 1700
Electric Motors
Version no T-code
000 7BWS10/13
4.2.3. Brush Replacement

Do not replace just one or two brushes. When brush service
is required on the motor, lift brush spring over holding bracket
before removing brush (See Figure 1-2.)
Figure 1-2: Motor Brush Removal

psi (207 kPa).
CAUTION Do not substitute brushes. The brushes are

matched to the motor type and application
to provide the best service. Substituting
brushes of the wrong grade can cause
commutator damage or excessive brush
wear.
NOTE! Blow stone dust out with dry compressed

air.
After the installation of new brushes, the motor should be

operated at half speed (12 Volts), no load and brushes
seated to the commutator with a dressing stone. Remove
stone dust.

S1.0 1700
Electric Motors
Version no T-code
000 7BWS10/13
4.2.4. Motor Disassembly

2. Remove the truck cover.
3. Disconnect the power cables from the terminal
block on the drive motor, noting their correct
position. (See Figure 1-3.)
Cable-A1 Cable-F1 Brake Wire

Wire-3 Wire-5 Wire-26
W2 U2 V2
U1 V1 W1

Figure 1-3: Terminal Block Connections
4. Follow steps 1 through 2 on page 106 to remove

the top (pinion) gear attached to the motor
armature shaft.
5. Remove the electromagnetic brake assembly by
removing the three mounting bolts that secure the
assembly to the motor end head. See
“Mechanical Brake Release” on page 114.
6. Remove the brake disc from the brake hub.
7. Remove the retaining ring that secures the brake
hub then remove the hub and woodruff key.
8. Punch or mark the motor end head and motor
housing to help alignment during reinstallation.
9. Remove the four screws and lock washers holding
the motor end head and brush holder to housing
motor end head.

S1.0 1700
Electric Motors
Version no T-code
000 7BWS10/13
10. Separate the motor end head from the motor

housing. The armature will come out with the end
head.
11. To remove the motor end head from the armature,
remove the snap ring that holds the bearing in the
motor end head. If needed, press off the bearing
end replace.
4.2.5. Motor Assembly

1. Thoroughly clean all parts with solvent or other
non-corrosive cleaning fluid. Air dry all parts.
NOTE! Assemble the drive motor in a dirt-free

area.
2. If previously removed, install the drive motor
bearing, bearing shim, and seal in the gear case.
NOTE! The seal must be installed correctly with its

open side and seal ring positioned towards
the bearing.
3. Reinstall the motor end head, with the brush plate
attached, on the motor armature shaft.
4. Carefully slide the drive motor armature in the
motor housing.
5. Realign punch marks on motor and head housing.
6. Attach the motor end head to the motor housing
with the four cap screws. Torque screws to 50 in-
lbs (5.6 N•m).
7. Install brushes. See “Brush Inspection and
Replacement” on page 90.
8. Install the pinion gear, woodruff key, and the
retaining ring on the armature shaft.
9. Use gasket eliminator on the mating surface. Install
the gear case cover. Secure cover with bolts and
torque to 200 in-lbs (22.6 N•m).
10. Make sure the drive unit is filled to the correct level
with gear oil. Install the fill/level plug. See
“Lubricants” on page 72.

S1.0 1700
Electric Motors
Version no T-code
000 7BWS10/13
11. Install the brake hub and woodruff key then secure
with the retaining ring.
12. Install the brake disc on the hub.
13. Install the brake coil assembly and attach with
three hex head cap screws.
14. Reattach the power cables and electromagnetic
brake wiring connections to the terminal block.
Torque electrical panel screws to 48-60 in-lbs (5-7
N•m).
15. Before testing operation, move the handle from the
extreme left to right and down into the operating
position and back several times. Check for any
wire and cable interference. Repair or adjust as
necessary.
16. Install the battery, reconnect the battery connector
to the truck, and turn the main ON/OFF switch ON.
Enter your PIN-key code then press the ON (I) key
on the keypad.
17. Test the operation of the truck.

S1.0 1700
Electric Motors
Version no T-code
000 7BWS10/13
Drive Motor
31 10 15
29 14
8 30
7
12 13
6 11
9
5
4
1 2 3
18
22 17 16
23 20 19
24 21
28
26
25 27
33
32
33
“EE”

S1.0 1700
Electric Motors
Version no T-code
000 7BWS10/13
Item No. Description Item No. Description Item No. Description

1 Ring, retainer 12 Shim 23 Brush
2 Gear 13 Seal 24 Nut
3 Key 14 Armature 25 Ring, retainer
4 Case 15 Key 26 Bearing
5 Terminal 16 Ring, retainer 27 Lockwasher
6 Screw 17 Hub 28 Screw
7 Nut 18 Band, cover “E” 29 Shoe, pole
8 Washer 19 Screw 30 Washer
9 Field 20 Cover 31 Screw
10 Isolator 21 Plate, brush 32 Band, cover “EE”
11 Bearing 22 Spring 33 Screw “EE”
Drive Motor Mounting
Steering
Bearing
Steering
Drive Control Head
Motor
Drive Wheel
Frame
mbly
ke Asse
Bra
Transmission
Assembly

S1.0 1700
Electric Motors
Version no T-code
000 7BWS10/13

S2.0 2550
Transmission
Version no T-code
000 7BWS10/13
Transmission
Transmission
TransmissionMounting
Mounting
3 5
2 4 7
1 6 9
23
8
10
11
22 12
13
25 14
10 11
24
15
16
17
18
20 21
19

S2.0 2550
Transmission
Version no T-code
000 7BWS10/13

1 Screw 14 Washer, plastic
2 Grommet 15 Screw
3 Screw 16 Drive unit
4 Cushion, up-stop 17 Drive motor
5 Screw 18 Brake assembly
6 Retainer 19 Transmission assembly
7 Stem, handle 20 Steering bearing
8 Screw, set 21 Drive wheel
9 Tiller arm head 22 Pin
10 Washer 23 Mount, stem
11 Bushing 24 Clamp
12 Spring 25 Screw
13 Sleeve

S2.0 2550
Transmission
Version no T-code
000 7BWS10/13
This transmission is of the double reduction gear type. The
gears are a combination of helical and straight cut gears for
strength and low noise. The final drive gear is mounted on
opposing tapered roller bearings. The intermediate gear is
mounted on ball bearings. Gears and bearings are enclosed
in an oil filled case. The drive motor frame is an integral part
of the transmission case with the drive motor pinion gear
mounted on the armature shaft. The brake is mounted on the
drive motor end head.
2. Maintenance
2.1. Fluid Changing

1. Lower Forks.
3. Remove drain plug to drain transmission oil.
4. Flush transmission case with a safe cleaning
solution and allow it to drain.
5. Clean and install drain plug.
Fill Level Plug
Drain Plug
Figure 2-1: Fill and Drain Locations

S2.0 2550
Transmission
Version no T-code
000 7BWS10/13
NOTE! When the truck is level, the oil must be up

to the bottom of the fill/level opening.
6. Fill transmission case with oil (see “Lubricants”
on page 72) through plug opening in transmission
cover.
3. Troubleshooting
Because of the uncomplicated nature of the transmission,
troubleshooting is limited to identifying problems if they are
mechanical or electrical in nature. Fluid leaks are obviously
mechanical in nature and can be found by visual inspection.
Unusual noise and/or slow running could be mechanical or
electrical in nature. Generally, if the problem is caused
internally in the transmission, then metal contamination will
be evident in the oil. If there is a mechanical problem outside
of the transmission, then it will become evident by inspecting
the drive motor and brakes. See page 114 for instructions to
release the brake, if necessary.

S2.0 2550
Transmission
Version no T-code
000 7BWS10/13
22
1
21
20
19
14 15
18
17
16
2
3
5 4
13
4 6
7
10 Transmission
12 8
Assembly
11 9
Item Item Item

Description Description Description
No. No. No.
1 Stud 9 Ring, retainer 16 Bearing
2 Axle 10 Gear 17 Gear
3 Seal 11 Cover 18 Bearing
4 Bearing 12 Plug, fill 19 Retainer ring
5 Spacer 13 Vent 20 Gear
6 O ring 14 Screw 21 Key
7 Plug, drain 15 Lockwasher 22 Case
8 Gear

S2.0 2550
Transmission
Version no T-code
000 7BWS10/13

Visually inspect outside of gear case for damage, wear, or
cracks. Excessive damage, wear, or cracks in the gear case
indicate that the transmission needs to be replaced rather
than repaired or rebuilt.
Removal
WARNING There is no brake on the truck when the

drive motor is removed from the
transmission assembly. Block all wheels to
reduce the risk of truck movement.
NOTE! Call-outs in the following procedure refer to

illustration on page 99.
1. Lower forks.
4. Remove truck covers (1,3, 4, 7, 8, see page 81).
5. Remove battery from the truck.
6. Jack truck and block the frame (see page 58).
7. Remove up-stop cushion by removing two screws,
see Figure 2-2 on page 104.
Screws Screws
Up-Stop
Cushion
Figure 2-2: Up-stop Cushion Location

S2.0 2550
Transmission
Version no T-code
000 7BWS10/13
8. Disconnect handle stem harness, see Figure 2-3

on page 105.
Remove Bolts
Disconnect Harness
Figure 2-3: Handle Harness
9. Disconnect arm angle switches. See Figure 2-3’ on

page 105.
10. Disconnect cable/wires from the terminal block on
the transmission. See page 141 for connections on
drive motor terminal block.
11. Slide main harness to stem harness connector off
metal support tab. Carefully pull main harness up
and out of stem mount (23).
12. Remove three screws securing stem mount with
handle assembly to the drive unit assembly. See
Figure 2-3’ on page 105.
WARNING Transmission assembly may fall free from

mounting after bolts are removed causing
damage to assembly or injury to personnel.
13. Remove bolts (15) securing transmission assembly

and bearing assembly to frame.
14. Remove transmission and steering bearing
assembly by lowering it through the pivot-frame
mounting.
15. Drain gear case lubricant. Thoroughly clean the
outside with cleaning solution. Dry all parts.
16. Remove drive wheel (see page 121).

S2.0 2550
Transmission
Version no T-code
000 7BWS10/13
Disassembly
NOTE! Call-outs in the following procedures refer

to illustration on page 103.
After draining gear case, thoroughly lubricate and clean with
a non-corrosive cleaning fluid. Dry all parts and proceed as
follows.
1. Remove screws (14) and lockwashers (15)
securing gear case cover (11). Remove gear case
cover (11).
2. Remove retaining ring (19) securing the top pinion
gear (20). Remove top pinion gear (20) and key
(21) attached to drive motor armature shaft.
NOTE! If bearing (16) does not remove with cover

(11), then remove bearing (16) with a
bearing puller.
3. Remove the second stage gear set (10) and (17)
from the gear case (22).
4. Remove retaining ring (9) from the drive axle (2).
Remove output gear (8).
5. Press drive axle (2) through the inner and outer
gear case bearings.
6. Remove old bearings (4), spacer (5), and seal (3)
from the gear case (22).
Reassembly

1. Thoroughly clean gear case (22).
2. Install new bearings (4), spacer (5), and seal (3) in
the gear case (22) for the drive axle (2).
3. Place the gear case (22) in a fabricated assembly
base and carefully press the drive axle (2) in the
gear case (22).

S2.0 2550
Transmission
Version no T-code
000 7BWS10/13
4. Position transmission on a work bench with gear

cover (11) side up. Install output gear (8) on axle
(2) and secure with retaining ring (9).
5. Install second stage gear set (10) and (17).
NOTE! The seal must be installed correctly with its

open side and seal ring positioned towards
the bearing.
6. Install woodruff key (21), pinion gear (20), and
retaining ring (19) on the armature shaft.
7. Apply sealant (GE Weicon Silmate) on the mating
surface and install gear case cover (11). Install
lockwashers (15) and screws (14). Torque cover
screws (14) to 30 ft-lbs (42 N•m).
Installation
CAUTION Make sure the main ON/OFF switch is OFF

and the battery connector is removed from
truck before proceeding.

1. If removed earlier, install steering bearing
assembly (20). Torque to 336-384 in-lbs (38.0-43.4
N•m).
2. Reinstall drive unit assembly and secure with
mounting bolts (15). Torque to 30-33 ft-lbs (40-45
N•m).
3. Apply Loctite 243® to three mounting bolts. Attach
stem mount onto drive unit with handle assembly
using the three mounting bolts.
4. Feed the wire harness and power cables through
the stem mount to the drive motor terminal block.
See page 141 for connections. For proper routing
of stem harness see Figure 2-4 on page 108.
5. Reconnect cables/wire to terminal block on the
transmission.
6. Connect arm angle switches.

S2.0 2550
Transmission
Version no T-code
000 7BWS10/13
Spring Sleeve
Tiller
Assembly
Handle
Return Spring
Plastic
Washer
Stem Harness
Figure 2-4: Stem Harness Routing
7. Connect stem harness to main harness and slide

the connector back onto the metal support tab.
NOTE! Replace any wire ties that were removed

during disassembly.
8. Reinstall up-stop cushion.
9. Ensure drive unit contains the correct gear oil level
(see page 72). Install fill/level plug.
10. With truck still blocked and drive unit off the
ground, connect the truck to a battery. (Do not
install the battery on the truck at this time.)
11. Test ease of steering. Test to make sure truck
powers ON and all functions on the handle head
are functional. Move handle up and down to test
arm angle switches.
12. Disconnect battery.
13. Install drive wheel (see page 121).
14. Install truck covers (7, 3,1) in this order as shown
on page 81.
15. Unblock and lower truck.
16. Install battery on the truck.

S2.0 2550
Transmission
Version no T-code
000 7BWS10/13
17. Install truck covers (4, 8) as shown on page 81.


S2.0 2550
Transmission
Version no T-code
000 7BWS10/13

S3.0 3300
Parking Brake System
Version no T-code
000 7BWS10/13
7
6
5
3 4
Item Item
Description Description
No. No.
1 Transmission assembly 5 Disc
2 Brake assembly 6 Coil
3 Flange, friction 7 Screw

4 Hub 8 Retaining ring

PT S3.0 3300
Version no T-code
000 7BWS10/13
The parking brake is an electrically released disc brake
mounted on the drive motor armature for increased braking
force through the transmission. The parking brake is applied
when the tiller arm handle is returned to the upper rest
position or in the bottom 8 degrees of the operating range.
The brake may be released when the handle is moved as
little as 6 degrees and travel request is made to allow for
reduced speed operation with the handle in near-vertical
position for greater maneuverability. Normal stopping during
truck operation is accomplished by reversing the travel
controls (plugging) and activating the inductive, regenerative
braking through the motor.
Electromagnetic
Brake
Figure 3-1: Electromagnetic Brake

S3.0 3300
Version no T-code
000 7BWS10/13
When the tiller arm handle is in the upper rest position, the
parking brake is engaged. When the handle is within 8 to 41
degrees of the upper rest position and travel request is made,
the brake disengages, allowing the truck to operate in slow
speed. When the handle is placed beyond 41 degrees from
the upper rest position, the truck can operate in fast speed.
When the handle is placed in the bottom 8 degrees of the
operating range, the parking brake is engaged.
41°
87° 35° 6°
38°
8°
Figure 3-2: Handle Positions

PT S3.0 3300
Version no T-code
000 7BWS10/13
2. Maintenance
2.1. Mechanical Brake Release

If the brake can not be mechanically released, perform the
following procedures:
1. Park truck on a level surface and load wheels are

Mounting Bolts 2. Press red OFF button (O) on the keypad. Depress
main ON/OFF switch to the OFF position, or turn
key switch OFF and turn main ON/OFF switch
OFF.
4. Loosen the mounting bolts four turns each to allow
the truck to roll.
5. Move truck to desired location.
WARNING Before truck is put back into service, the

mounting bolts will need to be tighten. DO
NOT OPERATE TRUCK WITHOUT THE
BRAKE.
6. Reinstall truck cover(s).
2.2. Brake Adjustment
WARNING Before adjustments are made, disconnect

battery from truck to prevent accidental
operation.
Adjusting 2. Press red OFF button (O) on the keypad. Depress

Screws main ON/OFF switch to the OFF position.
4. Jack the truck and block the frame (see page 58).

S3.0 3300
Version no T-code
000 7BWS10/13

6. Loosen assembly mounting bolts on brake.
7. Turn the adjusting screws while checking the air
gap at several points with a 0.008 to 0.010 inch
(0.20 to 0.25 mm) feeler gauge.
8. Tighten the mounting bolts to 50 in-lbs (5.6 N•m).
Recheck the gap with feeler gauge.
Air Gap
Adjusting 0.008 - 0.010 inch
Screw (0.20 - 0.25 mm) Mounting Bolt
Coil
Friction Disc Pressure Plate
3. Troubleshooting
Check brake disc for wear. Replace friction disc if worn
unevenly or when its total thickness is reduced to 0.20 inch
(5.5 mm).

PT S3.0 3300
Version no T-code
000 7BWS10/13

Removal
5. Loosen and remove mounting bolts (7). Remove
brake coil (6) assembly.
6. Remove friction disc (5) from hub (4).
7. Remove retaining ring (8) from hub (4).
8. Remove friction flange (3).
Installation
1. Inspect friction flange (3) for wear, replace if the
surface is worn unevenly. Install friction disc (5) on
hub (4). Place friction flange (3) on motor.
2. Install brake coil (6) assembly on the motor end.
Adjust gap (see page 115). Torque mounting bolts
(7) to 50 in-lbs (5.6 N•m).
3. Install truck cover(s).
5. Remove blocks. Turn the main ON/OFF switch to
the ON position. Enter key code and press the
press green ON button (I) on the keypad.
6. Test truck for proper operation before returning to
service.

S3.1 3530
Drive Wheel
Version no T-code
000 7BWS10/13
Drive Wheel
4
2 3
Item No. Description

1 Wheel assembly
2 Tire
3 Hub
4 Nut
The drive wheel is mounted on the transmission drive axle.
The drive wheel is part of the drive unit assembly.
Drive Wheel Specifications
10 inch X 5 inch X 6.5 inch

(250 mm X 127 mm X 165 mm)
Service Manual 2006-06-12 117

PT S3.1 3530
Drive Wheel
Version no T-code
000 7BWS10/13
2. Maintenance
2.1. Drive Wheel Nut Inspection

4. Remove truck cover(s) and bumper (see page 81).
5. Without jacking, insert block that fits snug under
support arm adjustment bracket as shown in
Figure 3-3.
Figure 3-3: Block Support Arm Adjustment Bracket
6. Using a toe jack positioned on the other side, lift

the unit until drive tire clears the ground and insert
a block under the Support Arm Bracket as shown
in Figure 3-4. Release jack to lower onto the block.
118 Service Manual 2006-06-12

S3.1 3530
Drive Wheel
Version no T-code
000 7BWS10/13
Figure 3-4: Support Arm Toe Jack Positioning
7. Visually inspect lug nuts for signs of being loose.

Inspect studs to see if one or more studs protrude
through the lug nut farther than the others. If either
condition exists, proceed as follows.
8. Loosen lug nuts to finger tight. If one or more studs
turn while loosening the lug nuts, proceed as
follows.
9. If any of the studs appear damaged, replace studs.
NOTE! The installation procedure of the studs,

wheel and lug nuts must be completed in
less than 0.50 hour to ensure the thread
locking compound does not start to set up
before the installation is complete.
10. Remove and clean studs.

11. Install two lug nuts, jammed together, to the end of
the stud. This will allow the tightening of the studs
using a torque wrench.
12. Apply Loctite 290® thread-locking compound to
studs.

PT S3.1 3530
Drive Wheel
Version no T-code
000 7BWS10/13
13. Install studs and torque to 23 - 28 ft-lbs (32 - 38

N•m).
NOTE! Do not overtighten studs. If studs are

tightened to more to 30 ft-lbs (41 N•m) of
torque, the studs will start to cut new
threads and go too far hitting the lip seal. If
the lip seal is damaged due to studs being
installed too far, the axle will have to be
replaced.
14. Remove the two lug nuts on studs, making sure
studs do not rotate.
15. Install drive wheel and lug nuts. Torque lug nuts,
starting with a low torque (possibly 5 ft-lbs [6.8
N•m]), using a star pattern. This is to make sure
the lugs are centered in the mounting holes. On the
final pass, apply 55 ft-lbs (74.6 N•m) of torque to
nuts.
16. Remove blocking.
17. Install truck covers and bumper.
20. Check operation of drive wheel.
3. Troubleshooting
Inspect wheel and tire for wear and damage. Trash that is
wrapped around the wheel and axle will cause premature tire
wear and bearing damage. The floors should be kept clean of
trash to reduce risk of damage to wheel and tire.

S3.1 3530
Drive Wheel
Version no T-code
000 7BWS10/13

Removal
1. Park truck on level surface.
main on/off s on the keypad. Depress main on/off
switch to the OFF position. Disconnect battery
connector from the truck.
3. Remove dash cover and drive motor cover.
4. Without jacking, insert block that fits snug under
Support Arm Adjustment Bracket as shown in
Figure 3-3 on page 118.
5. Using a toe jack positioned on the other side, lift

the unit until drive tire clears the ground and insert
a block under the Support Arm Bracket as shown
in Figure 3-4 on page 119. Release jack to lower
onto the block.
6. Remove truck bumper by removing six bolts, three
on each side as shown in Figure 3-5.
Figure 3-5: Removal of Bumper
7. Remove truck bumper by removing six bolts, three

on each side as shown in Figure 3-5.

PT S3.1 3530
Drive Wheel
Version no T-code
000 7BWS10/13
8. Remove five existing drive wheel lug nuts and

remove wheel.
Installation
1. Install new tire and all five wheel lug nuts. In a
crossing pattern torque wheel bolts 55 ft. lb. (74.6
N•m).
2. Attach bumper with six bolts, apply Loctite 243®,
and tighten.
3. Using the toe jack, lift the unit as shown in
Figure 3-4 on page 119 and remove the block.
Lower toe jack and remove from unit.
4. Remove block from the other side in Figure 3-3 on
page 118.
5. Reconnect battery connector, turn on, and check
for correct operation.

S3.1 3530
Drive Wheel
Version no T-code
000 7BWS10/13
Tire Pressing Procedure

1. Check the inside surface of metal insert on the new
tire. Remove any scaling or rust with sandpaper.
Clean the inside of metal insert and lubricate with a
soap solution.
Outside of Hub 2. Place a circular ram on press table. The length of
and Tire Assembly ram must be longer than the width of the old tire to
allow complete removal of old tire. The outside
New diameter of ram must be small enough to fit loosely
Tire
in the insert of tire, but large enough to rest
squarely on the level surface on the outer edge of
Worn
Tire
hub.
Circular
Ram
3. If the outside edge of the hub is not flush with the
edge of the metal insert in old tire, measure how far
hub is recessed inside tire. The new tire must be
Press placed in the same position the old tire was
Table
installed on the hub. A spacer (slightly smaller in
diameter than the inside diameter of tire insert and
the same thickness as the depth of the recess) can
be used to obtain proper amount of recession.
4. Position hub assembly with the old tire on the top
of circular ram so the outside of the wheel is
positioned upward. The outside edge of hub has a
chamfer to help guide the new tire onto the wheel.
The chamfered edge must always be the leading
edge when a tire is pressed onto hub.
5. Center hub assembly on the top of the ram and
make sure they mate squarely.
6. Position new tire with its chamfered insert facing
hub. Align new tire and hub so they are concentric.

PT S3.1 3530
Drive Wheel
Version no T-code
000 7BWS10/13
CAUTION Any misalignment of tire and hub while tire

is being pressed onto hub can cause
damage to hub. For this reason, chamfers
have been provided on the outside edge of
hub and on the end of the inside diameter
of tire’s metal insert. The chamfers help to
center hub and tire during the pressing
operation and reduce the possibility of
misalignment. To prevent damage, hub
must be installed on circular ram with its
chamfered side up.
NOTE! If new tire does not press on with a

minimum of 5 tons (68,947 kPa) force,
replace hub.
7. Begin pressing new tire onto hub and old tire off
wheel. Run press slowly for the first few inches of
travel, because this is the critical stage of the
operation. If tire begins to cock to one side, stop
press and realign tire. A sharp jar with a soft-
headed mallet will usually realign tire on hub.
8. Release press. Remove wheel, tire assembly, and
old tire from press table. Inspect wheel and tire
assembly.
9. Install wheel assembly following the procedure for
the specific type of wheel.

S3.2 3550
Load Wheels
Version no T-code
000 7BWS10/13
Load Wheels
Inside Of Truck
1
2
3
4
5
Item
Description
No.
1 Fitting, grease
2 Axle
3 Screw, set
4 Washer
5 Bearing
6 Wheel, load
Load Wheel Specifications
4 inch X 3 inch (1020 mm X 176 mm)

S3.2 3550
Load Wheels
Version no T-code
000 7BWS10/13
The load wheels are mounted on the load arms to support the
rated load. Load wheels contain sealed bearings on both
sides.
2. Maintenance
Inspect the wheels for wear and debris wrapped around the
wheels. Check load wheel bearings for binding or excessive
play.
3. Troubleshooting
Inspect load wheel bearings for chunking, bond failure, and
excessive or uneven wear. Make sure wheels are functioning
smoothly and sufficient grease is applied to load wheel
bearings.

Removal
WARNING Block all wheels to prevent the truck from

rolling.
1. Park the truck on a level surface and block the

truck from moving.
3. Jack truck as shown in Figure 3-6 on page 127,
sufficient enough to remove set screw (3). Block
truck with wood or steel block.
4. Remove the axle set screw (3), see Figure 3-7 on
page 127.

S3.2 3550
Load Wheels
Version no T-code
000 7BWS10/13
Figure
Figure 3-6: Jacking Load Wheels
Axle Setscrew Underneath
Figure
Figure 3-7: Load Wheel Setscrew
5. Drive the axle out of the load arm casing with a

hammer and drift pin.
6. Push the wheel out.
7. If the bearings (5) are to be reused, insert a brass
drift pin into each end of the load wheel and knock
out the bearings.
Installation
1. Install the bearings in the new load wheel with seal
side out.
2. Place the new load wheel upright on a level
surface. Position the bearing over the load wheel.
Place a flat metal plate over the bearing and tap
the bearing in place with a plastic mallet. Make
sure the bearing is fully seated in the load wheel.
3. Align the load wheel assembly (see page 125) into
the load arm.

S3.2 3550
Load Wheels
Version no T-code
000 7BWS10/13
4. Install the axle through the load arm hole and

wheel. Align the “dimple” in the axle with the set
screw hole.
5. Install and tighten the set screw.
6. Lower truck and remove blocks.
7. Reconnect the battery connector to the truck. Turn
the main ON/OFF switch ON. Enter your PIN-key
code then press the ON (I) key on the keypad.
8. Test the operation of the truck.

S4.0 4100
Tiller Arm Handle
Version no T-code
000 7BWS10/13
Tiller Arm Handle
3 5
2 4 7
1 6 9
23
8
10
11
22 12
13
25 14
10 11
24
15
16
17
18
20 21
19

S4.0 4100
Tiller Arm Handle
Version no T-code
000 7BWS10/13

1 Screw 14 Washer
2 Grommet 15 Screw
3 Screw 16 Drive unit
4 Cushion, up-stop 17 Drive motor
5 Screw 18 Brake assembly
6 Retainer 19 Transmission assembly
7 Stem, handle 20 Steering bearing
8 Screw, set 21 Drive wheel
9 Tiller arm head 22 Pin
10 Washer 23 Mount, stem
11 Bushing 24 Clamp
12 Spring 25 Screw
13 Sleeve

S4.0 4100
Tiller Arm Handle
Version no T-code
000 7BWS10/13
The tiller arm head fastens to the handle stem and mounts on
the frame.
2. Maintenance
2.1. Inspection

equipment. Compressed air is used for
psi (207 kPa).
NOTE! CLEANLINESS! Perform procedures in a

clean environment. Make sure all parts are
cleaned before disassembly and kept clean
during assembly.
1. Thoroughly clean all parts and remove all nicks
and burrs with emery cloth.
2. Inspect all parts for excessive wear or scoring. If
heavy scoring is found replace part(s).
3. Inspect handle stem for nicks or rust; clean with
emery cloth or replace handle stem.
4. Inspect head harness for wear or broken wiring(s).
3. Troubleshooting
Check fasteners and the ease of steering.

S4.0 4100
Tiller Arm Handle
Version no T-code
000 7BWS10/13

Removal
the lowering button on tiller arm.
5. Remove two screws (3) securing up-stop cushion.
6. Lift up-stop cushion (4) off assembly and set to one
side.
Wiring Harness
Figure 4-1: Wiring Harness
NOTE! Make note locations of cable ties on handle

harness before disconnecting wiring.
7. Disconnect wiring harness connector (see
Figure 4-1).
CAUTION The tiller arm stem will be free to fall

forward when cap screws are removed.

S4.0 4100
Tiller Arm Handle
Version no T-code
000 7BWS10/13
8. Loosen set screw (8) and carefully drive out pin

(22) using a hammer and a brass drift pin.
Inspect stem harness and washer (10), bushing

(11), spring (12), sleeve (13), and washer (14) for
excessive wear. Replace if necessary.
9. Carefully remove tiller arm stem (7).
Installation
NOTE! For proper routing of stem harness see

Figure 2-4 on page 108.
1. Position tiller arm stem (7) on the pivot assembly
with stem harness routed underneath the pin (22).
2. Insert pin (22) through stem mount (23) and into
handle stem (7), making sure set screw hole on pin
(22) is properly aligned to the set screw (8). Using
a hammer and a brass drift pin, carefully drive pin
(22) into hole and use caution not to cause
damage to bushings.
3. Apply Loctite 243® to set screw (8). Install set
screw (8) and tighten.
4. Reconnect handle stem harness connector. Install
cable ties in their original locations on the handle
harness.
5. Install up-stop cushion (4) securing with two
screws (3).
Washer Harness Sleeve Spring
Figure 4-2: Tiller Arm

S4.0 4100
Tiller Arm Handle
Version no T-code
000 7BWS10/13
A Switch B Switch
Position Function
(S24) (S25)
Top 6° Open Open Top Brake
6° to 41° Open Closed Slow
41° plus Closed Closed Fast
Bottom 8° Closed Open Bottom Brake
6. Remove blocks.
Enter key code and press the press green ON (I)
key on the keypad.
9. Test operation of all tiller arm functions before
returning to service.

S4.1 4100
Tiller Arm Head
Version no T-code
000 7BWS10/13
Tiller Arm Head

12
13
45 14
15
44 16
43 17
20
42 25 19
21
41
22
17 18
29 28 26
27
24
23
30
32 31
34 33
35
36
38 37
39
38
34
31 32 40
1
2 3
4
5
6
11
8
10 9 7

S4.1 4100
Tiller Arm Head
Version no T-code
000 7BWS10/13
Item Item
Description Description
No. No.
1 Screw 24 Spring
2 Plate 25 Display
3 Handle 26 Screw
4 Screw 27 Tie, cable
5 Cover (option) 28 Screw
6 Pad, key 29 Tie, cable
7 Screw 30 Thumb wheel assembly
8 Screw 31 Screw
9 Relief, strain 32 Washer
10 Plate 33 Rocker, right
11 Handle assembly, control 34 Bearing
12 Cover, lift/lower 35 Stop lug
13 Rocker 36 Arm
14 Button, reverser 37 Axle
15 Button, horn (right) 38 Support
16 Housing 39 Spring
17 Switch, horn 40 Rocker, left
18 Screw 41 Button, horn (left)
19 Electronic Tiller Arm Card (ETAC) 42 Seal
20 Spring 43 Cap, transparent plastic
21 Housing 44 Button / cover
22 Screw 45 Blank
23 Gasket

S4.1 4100
Tiller Arm Head
Version no T-code
000 7BWS10/13
The tiller arm head is mounted to the tiller arm. For functions
of the tiller arm handle assembly see “Changing Driver
Accessible Parameters (P)” on page 174 or “Changing
Service Parameters” on page 176.
2. Maintenance
3. Troubleshooting
Check fasteners and ease of steering.

Removal

the lowering button on tiller arm head.
5. Remove screw (7) from key pad (6). Unplug and
remove key pad (6) from handle (3).
6. Holding the top cover (11) firmly, remove four
screws (4) and (8).
7. Disconnect stem harness connected to ETAC (19).
8. Remove three screws (22) from housing (21) to
gain access to ETAC (19).
NOTE! Place finger between housing (21) and

reverser button (14) to hold right rocker (33)
in place while removing housing (21).

S4.1 4100
Tiller Arm Head
Version no T-code
000 7BWS10/13
9. Carefully lift off housing (21).

10. Remove horn button (15) and (41).
11. Disconnect connection for the switch on the ETAC
(19).
12. Press switch out from its mounting in the top cover
assembly.
Horn Button Removal
13. Remove thumb wheel assembly (30).
14. Remove lift/lower cover (12) assembly screws.
Installation
NOTE! Place finger between housing (21) and
reverser button (14) to hold right rocker (33)
in place while installing housing (21).
1. Install thumb wheel assembly (30).
2. Install lift/lower cover (12) and secure with screws.
3. Install horn button (15) and (41).
NOTE! Do not force housing (21). Install carefully.

Lift/Lower Switch 4. Install housing (21) and secure with screws (22).
5. Connect stem harness to ETAC (19).
NOTE! Make sure stem harness is properly routed

before installing top cover (see Figure 2-4
on page 108.)
6. Install top cover (16) and hold firmly in place while
securing with screws (4) and (8).
7. Plug in key pad (6) in handle (3). Secure with
screws (7).
8. Remove blocks.
Lift/Lower Switch Screws
9. Reconnect battery connector to the truck
service.

S4.2 4180
Steering Bearing
Version no T-code
000 7BWS10/13
Steering Bearing
1
2
3
4
5
1 Screw
2 Lockwasher
3 Bearing
4 Stop, steering
5 Transmission assembly

S4.2 4180
Steering Bearing
Version no T-code
000 7BWS10/13
The steering bearing is part of the drive unit assembly. The
vertical and horizontal loads are carried by the steering
bearing.
2. Maintenance
Inspect for wear or damage.
3. Troubleshooting
Probable Cause Required Action
Worn or damaged Replace steering
steering bearing bearings

The steering bearing can not be repaired or rebuilt. Replace
steering bearing with new as necessary.

1. Remove the drive unit see page 104.
2. Remove steer bearing screws (1) and lift off steer
bearing.
3. Replace steer bearing if necessary.
4. Install the drive unit see page 107.

S5.0 5000
Electrical Functions
Version no T-code
000 7BWS10/13
Main Harness Assembly
Contactor
Panel
Assembly
Contactors
3
Power
Cable
2
1 6
5
4 9
8
7 I
0
O
Transistor
Controller
Relay 10 Amp
Fuse
Hydraulic
System
130 Amp
Fuse
Stem Harness
Power
Cables Transmission
Assembly
Power
Cables

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The travel control system on the truck is electrically controlled and monitored. The lift/lower systems are electrically
controlled and hydraulically operated. All circuits are protected against overload with fuses. Refer to the following detailed
electrical circuit schematics as they apply. The complete electrical circuit schematics can be found in the Appendix on
page 302. When starting the truck, the transistor controller checks the closing sequence of the arm angle switches in the
circuit. For information on the transistor controller see page 239.
Normal Operation
1. When the truck is first powered on, it displays an hourmeter (see parameter 20 on page 181) for the first five
seconds. Then, it normally displays the battery state-of-charge throughout the operation.
2. While a Caution error code is tripped, it is displayed 3.4 seconds out of every 5.1 seconds. The other 1.7
seconds shows normal display.
3. When battery state-of-charge is zero percent, lift is not allowed. When the battery state-of-charge is 10 percent
or lower, the battery light blinks.
1.1. Battery Plugged In With Keypad

With the battery connected to the truck, wire number 1 connects battery voltage to the positive side of the main contactor
(K10), control fuse (F50), and positive side of resistor (PTC R1). From resistor (PTC R1), a voltage of 1.0 to 1.5 volts less
than battery voltage is provided to fuse (F51) and positive side of the main ON/OFF switch (S21). A positive on wire
number 1 to the key switch jumper then becomes wire number 22 to the electronic tiller arm card (ETAC) [A2]
Symbol Designation Symbol Designation Symbol Designation

A1 Transistor Controller K10 Main Contactor S18-1 Horn Switch
A2 Electronic Tiller Arm Card Transistor Controller K30 Pump Motor Solenoid S18-2 Horn Switch
F50 Keypad/Tiller Arm Circuit Fuse L2 Flashing Light S21 Main ON/OFF Switch
F51 Main Control Fuse M1 Drive Motor S24 Arm Angle (A) Switch
H1 Horn M3 Pump Motor S25 Arm Angle (B) Switch
H3 Travel Alarm R1 PreCharge Resistor Y1 Brake Coil
J11 Handle Stem Base Wire Connection R2 Noise Filter Resistor Y10 Prop. Lower Valve Coil
J41 Service Key (CAN) Wire Connection R3 Travel Alarm Resistor Y11 Load-hold Valve Coil
K4 Main Contactor Relay S17 Key Switch

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B+ Circuit B- Circuit Signal Pre-Charge Voltage
NOTE: Electrical schematics are found in Appendix A starting on page 302.

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1.2. Battery Plugged In With Key Switch

With the battery connected to the truck, wire number 1 connects battery voltage to the positive side of the main contactor
(K10), control fuse (F50), positive side of the key switch and positive side of resistor (PTC R1). From the resistor (PTC R1),
a voltage of 1.0 to 1.5 volts less than the battery voltage is provided to fuse F51 and positive side of the main ON/OFF
switch (S21).


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Battery Plugged In With Key Switch Version no T-code
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1.3. Main ON/OFF Switch/Keypad ON

Battery voltage supplied from wire number 22 connects to the ETAC (A2) pin J11-1. Battery voltage from wire number 24
inputs to the transistor controller at J5-16, that powers up the ETAC (A2) and transistor controller (A1) for start of
communication between them. A voltage from the resistor (PTC R1) 1.0 to 1.5 volts less than battery voltage is provided to
the positive side of arm angle A switch (S24), and arm angle B switch (S25).


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1.4. Travel, Low Speed

When the tiller arm is between 6 to 41 degrees of the upper rest position and the thumb controls are rotated from neutral,
the travel signal is detected via hall effect sensors. This converts into a travel instruction in the ETAC (A2) and transmitted
via the CAN to the transistor controller (A1). The ETAC (A2) verifies that the reverser button is not activated before
supplying the travel command to the transistor controller. The ETAC (A2) verifies that arm angle B switch (S25) is engaged
for slow speed travel mode. The transistor controller provides a negative pin J5-4 to the main contactor coil (K10) closing
the main contactor (K10) and to the main contactor relay (K4). The main contactor relay (K4) provides battery voltage to the
positive side of pump contactor coil (K30), brake coil (Y1), proportional lower valve coil (Y10), load-hold valve (Y11), and
horn (H1). The transistor controller provides a negative pin J5-5 to the brake coil (Y1) releasing the brake. The voltage at
M- of the drive motor will vary from 24V-stopped to approximately 20V at low speed. The voltage is proportional to the
position of the thumb controls. The drive wheel starts to rotate in the selected direction at a speed proportional to the thumb
controls.


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000 7BWS10/13

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1.5. Travel, High Speed

When the tiller arm is between 41 to 79 degrees of the upper rest position and the thumb controls are rotated from neutral,
the travel signal is detected via hall effect sensors. This converts into a travel instruction in the ETAC (A2) and transmitted
via the CAN to the transistor controller (A1). The ETAC (A2) verifies that the reverser button is not activated before
supplying the travel command to the transistor controller. The ETAC (A2) verifies that arm angle B switch (S25) and arm
angle A switch (S24) is engaged for fast speed travel mode. The transistor controller provides a negative pin J5-4 to the
main contactor coil (K10) closing the main contactor (K10) and to the main contactor relay (K4). The main contactor relay
(K4) provides battery voltage to the positive side of pump contactor coil (K30), brake coil (Y1), proportional lower valve coil
(Y10), load-hold valve (Y11), and horn (H1). The transistor controller provides a negative pin J5-5 to the brake coil (Y1)
releasing the brake. The voltage at M- of the drive motor will vary from 24V to less than 1V at high speed. The voltage is
proportional to the position of the thumb controls. The drive wheel starts to rotate in the selected direction at a speed
proportional to the thumb controls.


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Travel, High Speed Version no T-code
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1.6. Reverser
When the reverser button is activated with the tiller arm lowered in the travel mode, the control system provides an
immediate forks-first direction travel instruction. Reverse signal is converted into a forks-first travel instruction transmitted
via the CAN to the transistor controller. Travel and speed inputs are ignored. The transistor controller provides maximum
torque immediately after the reverser button is pressed. Maximum forks-first travel continues until the reverser button is
released.


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1.7. Lift
When the lift button is pressed, the transistor controller provides a negative at pin J5-4 to the main contactor coil (K10),
closing the main contactor (K10) to the main contactor relay (K4). The main contactor relay (K4) provides battery voltage to
the positive side of pump contactor coil (K30). The transistor controller provides a negative in J5-6 to the pump contactor
coil (K30) closing the pump contactor.
NOTE! The proportional lowering valve plus load-hold valve are not energized during lifting. A check
ball in the load-hold valve allows fluid to flow through it, then to the cylinder. See “Lift” on
page 254.


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1.8. Lower
When the lower button is pressed, the transistor controller provides a negative at pin J5-4 to the main contactor coil (K10),
closing the main contactor (K10) to the main contactor relay (K4). The main contactor relay (K4) provides battery voltage to
the positive side of the proportional lowering valve coil (Y10) and the load-hold valve (Y11). The transistor controller
provides a negative at pin J5-9 to the proportional lowering valve coil (Y10) using (PWM) Pulse Width Modulation and a
continuous negative to pin J5-2, the load-hold valve coil (Y11), opening both valves. See “Lower” on page 255.


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2. Maintenance
Connections must be kept clean and tight. The electrical
components should be protected from moisture.
2.1. Wiring
Many electrical problems are caused by a bad or dirty battery.
Make sure battery is clean. Check the electrolyte level and
battery level.
CAUTION Unless otherwise directed, disconnect

battery connector when checking electrical
circuits or components with an ohmmeter.
Electrical current can damage the
ohmmeter.
Visually inspect all wiring and electrical components for the
following:
• Loose connections or connectors
• Loose or broken terminals
• Damaged terminals, blocks, or strips
• Broken wiring and shorted conditions
(especially those that are close to metal
edges or surfaces)
Use an ohmmeter to check for wiring continuity.
2.1.1. Definitions
Continuity. A continuous and uninterrupted path between
two or more locations in an electrical circuit, typically having a
resistance of less than 1 ohm.
Open Circuit. A lack of a continuous path between two or
more electrical connections. Generally, when such a circuit is
tested, it will have a resistance greater than one megohms.
Pulse Width Modulation. Pulse Width Modulation (PWM),
also called “chopping,” controls the speed of the motor by
switching the battery voltage to the motor on and off very
quickly.
Overtemperature. Overtemperature of the transistor
controller is from 185 degrees F (85 degrees C) and above.
At overtemperature, the drive current limit is linearly
decreased from full set current down to zero. Plug current is

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not reduced to provide full truck braking under all thermal

conditions.
Undertemperature. When the transistor controller is
operating at less than -13 degrees F (-25 degrees C), the
current limit is cut back resulting in reduced travel speed.
Short Circuit or “Short”. A short circuit is an unspecified
path in a circuit that provides unwanted full or partial
continuity between two or more locations in an electrical
circuit.
Example: Two insulated wires are physically next
to each other and the insulation has been worn off
each of the wires. Because the conductors inside
each wire are now touching each other, there is a
short circuit.
Example: A power cable from the battery to a
junction post in the truck has had the insulation
worn away. Because the wire conductors are
touching the frame, there is a short circuit of the
battery cable.
2.1.2. Shorts to Frame Test

“Shorts to frame” is an industry term for unintentional current
leakage paths between normally isolated electrical circuits
and their metal enclosures. Shorts to frame may be metallic
connections, such as a wire conductor contacting metal
through worn insulation. More often, shorts to frame are
resistive “leakage” paths caused by contamination and/or
moisture. These leakage paths can result in unwanted
electrical noise on the metallic truck structure and may result
in improper operation.
Shorts to frame can be caused by the following:
• Accumulation of dirt
• Battery electrolyte leakage
• Motor brush dust
• Motor brush leads touching housing
• Insulation breakdown
• Bare wires
• Pinched wiring harness
• Circuit cards improperly mounted

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Shorts to frame can occur at numerous locations on truck

including the following:
• Batteries
• Motors
• Cables, wiring, and harnesses
• Heat sinks
• Bus bars
• Solenoids
• Contactors
• Terminal strips
• Switches
• Power panel insulation
• Circuit card mounts
To test for shorts from battery to frame:
2. Using a voltmeter set on a 50Vdc scale, attach the
leads as follows:
• Negative (-) lead to an unpainted, grounder
surface on the truck frame
• Positive (+) lead to the positive battery
terminal.
The voltmeter must shown no more than 3V.
3. Attach the leads as follows:
• Negative (-) lead to the negative battery
terminal
• Positive (+) lead to an unpainted, grounded
surface on the truck frame.
The voltmeter must show no more than 3V.
4. If a reading of 3V or more is received in the
previous steps 2 or 3, proceed as follows:

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a. If applicable, remove bolts from battery box

frame on the truck. Remove battery from the
truck (see page 203).
b. Thoroughly clean battery (see page 200).
c. Reinstall battery. If applicable, securely refasten
bolts to battery box frame on the truck.
d. Repeat steps 2 and 3 to see if the problem has
been eliminated.
e. If excessive voltage is still found, check the
battery for internal leakage.
To test for shorts from components to frame:
3. Using an ohmmeter and measure the resistance to
an unpainted, grounded surface on the frame at
B+, B-, and all fuses:
A resistance reading of less than 100,000 ohms
indicates a short to the frame. If this condition
exists, find the source of low resistance or short to
frame using the following step 6.
4. If applicable, remove bolts from battery box frame
on the truck. Remove battery from the truck (see
page 203).
The voltmeter must show no more than 3V.
5. Connect battery lead to the truck.
6. Using an ammeter to measure the leakage current
to the unpainted, grounded surface on the frame at
B+, B-, all fuses and all motors. If the current is less
than 0.001 ampere (1 mA), the truck system
passes. If the current exceeds 1 mA, go to step 6.
7. To find the cause of the low resistance, disconnect
the power cables from each motor or major
subassembly one at a time, to determine if that
item is causing the low resistance.

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000 7BWS10/13
3. Troubleshooting
3.1. Troubleshooting Flowchart
Troubleshooting
Truck Fault
Yes
Code
Find Code
(see page 184)
No
Transistor
Controller Yes
Error
Code
Find Code
(see page 246)
No
Yes, Traction/Overall
Check
Troubleshooting Go to charts
Chart (see page 195)
No
Yes, Hydraulic
Go to charts
General Troubleshooting (see page 260)
(see Service Display page 171)

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Troubleshooting can be broken down into two sections: (1)

mechanical and (2) electrical circuits. Electrical circuits can
be further broken down into control circuit and power circuit.
Many hours of troubleshooting time can be saved by knowing
the exact operational symptoms. Check the control switches;
if they test as operating properly, the problem most likely will
be in the power circuit of that function.
The travel functions are controlled by the transistor controller.
Lift, lower, and horn functions operate separately. To use this
troubleshooting guide locate the failure symptom in the index
(see Troubleshooting Chart Index” on page 194.) Then go
to the expanded outline, and follow the testing procedures
described.
Voltage tests are made with the negative lead of the volt
meter connected to battery negative. If the negative lead is
connected to a negative terminal on the electrical panel, first
verify the negative connection to the battery by touching the
positive meter lead to the positive battery post. The battery
voltage must be at least 25.2 volts for a 24 volt system. If the
battery voltage is below 22 volts (no load), then the transistor
controller may not operate properly. Charge the battery
before starting the troubleshooting procedures.
When testing voltage, the “POSITIVE SIDE” of any
component refers to the terminal on that component that is
closest electrically to the battery positive terminal. The
“NEGATIVE SIDE” of any component refers to the terminal
on that component that is farthest electrically from the battery
positive terminal. It is possible and in many cases desirable to
measure battery voltage on the negative side of a
component.
Tractor-first direction refers to travel in the direction of the
tiller arm handle with the forks-trailing. Reverse direction
refers to travel with the forks-first.
The parking brake will automatically engage when the truck
has come to a stop while the tiller arm handle is in the
operating range and no travel speed is requested. Normal
stopping during travel operation is obtained by reversing the
travel direction controls (plugging) or moving tiller arm to
either braking positions shown on page 165. The tiller arm
handle and the direction control operate together to release
the brake.

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41°
87° 35° 6°
38°
8°
Figure 5-1: Operating Range of Tiller Arm
After the final troubleshooting test is completed, the truck

should be repaired and operating properly. If it is not, then
verify test results and possibly re-evaluate the failure
symptoms. If the truck still has not been repaired, then call
your local Toyota Dealer for assistance. When placing a call,
the following information is required: truck model and serial
number, information on hourmeter and error code, actual
battery voltage at open circuit and at hydraulic operation
under full load, the precise operating symptoms, and the
exact results of the testing you have done. Authorized Toyota
Dealers may call the factory directly if necessary.
The first steps of any troubleshooting procedure include:
1. Inspect truck for physical damage or mechanical
malfunction.
2. Check for ground faults from the electrical system
to the frame with an ohmmeter. A minimum of
100,000 ohms resistance from the frame to any
and all wiring is acceptable.
3. Check that the battery is fully charged and
connected.
4. Operate the truck in all modes to determine the
exact symptoms. DO NOT forget that systems are

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equipped with circuits that reduce operation in the

event of improper operating procedures.
3.2. Main Harness Replacement
Before removal of harness, document wire
NOTE!
to terminal connections for main harness.
Control Wires/
Wire Guard
5 26
6 57
Power Cables
on Left Side
Figure 5-2: Terminal Block

W2 U2 V2
U1 V1 W1

Figure 5-3: Terminal Block Connections
1. Park the truck on a smooth, level surface and

make sure the parking brake is applied and load
wheels are blocked to prevent accidental
movement

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2. Press red OFF button (O) on keypad or if truck has

a key switch turn the key to the OFF position.
Depress main ON/OFF switch to the OFF position.
3. Disconnect the battery connector.
4. Remove the truck covers and tiller up-stop (see
Figure 5-4) to gain access to the wiring and cables.
Reference the electrical schematic on page

NOTE! 302 for location on connectors and
switches.
5. Disconnect connector J11 and switches S24 and
S25 inside the stem mount and all ring terminals
from the drive motor terminal block (see page
166).
6. Remove the stem mount and stem handle as an
assembly from the transmission (see Figure 5-4).
Remove the old harness from the truck (see page
141).
Up-stop
Stem
Mount
Stem Handle
Transmission
Assembly
Figure 5-4: Stem Mounting

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7. Lay the new harness into the truck.

8. Connect the truck end of the harness. For the
proper harness connections, see Figure 5-4 on
page 167. For schematics see page 302.
9. Install the harness down through the transmission
opening and connect cables and wires to the drive
motor terminal block (Figure 5-3 on page 166).
10. Check to make sure the power wires are vertically
stacked one on top of the other on the LEFT side of
the transmission opening above the power
terminals and the wire guard with ring terminals
match on Figure 5-3 on page 166.
11. Position cables and wires as shown in see Figure
5-3 on page 166.
12. Correctly orient the wire guards and power wires
through the transmission as shown in Figure 5-5.
13. Make sure the short wire guard and wire tie are
running down through the transmission as shown
in Figure 5-5.
Wire Ties
Power Cables
Figure 5-5: Transmission with Harness Wiring
14. Install the stem mount and stem handle assembly.

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Wire 24
Wire 50
Switch S24
Wire 51
Switch S25
Wire 24
Figure 5-6: Stem Mount Switch Wiring
15. Refer to Figure 5-3 on page 166 when installing

ring terminals. Install ring terminal and secure
middle nut and torque to 79 in-lbs (8.9 N•m). Install
ring terminal and secure outer nut, making sure
wire is out of the way, before torquing outer nut to
79 in-lbs (8.9 N•m).
16. Install the up-stop (see Figure 5-4 on page 167)
and truck covers.
Enter the key code and press the green ON button
(I) on the keypad or turn the key switch ON.
19. Check all operating functions on the tiller arm
handle.

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3.3. Operator Display and Programming

The display is located on the top of the tiller arm and displays
the operator and machine-specific register.
A
A - Numerical Field
B - Hour Meter Indicator
C - Parameter Control
D - Battery Indicator
E D C B E - Error Indicator
Operator Display
3.3.1. Special Modes

To enter a special truck mode proceed as follows:
1. Hold down horn button.
2. Enter PIN code on keypad and push green ON
button (l) or turn key switch ON.
3. Release horn button at desired display mode.
Options for the display mode are follows:
• (H)ourmeters; use thumb control to choose,
see parameter 20 on page 181 for
Hourmeter options (hours shown are
rounded down, i.e., 3 hours 50 minutes will
display as 3).
• (E)rror codes log; the most recent error code
will be displayed followed by the hour meter
(activity time) it occurred. Use thumb control
to scroll through the last 50 error codes (if no
error code is logged, dashes will be
displayed).
• (P)arameters: use thumb control to choose
and the horn button to access a parameter,
the parameter light blinks (a service key is
required to change some parameters (see
page 176). When the service key is used
to change driver parameters and
parameter 10, the driver number appears
to the right of the normal parameter

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number display. All driver parameters and

drivers are cycled through before Service
Parameters, 1 - 9, 0 (0 = 10th driver).
• (P)art (n)umbers: use thumb control to scroll
through the following:
• (S)oftware (P)art (n)umber
• (H)ardware (P)art (n)umber
• (H)ardware (S)erial (n)umber
3.3.2. Service Display

Connect the service key (see page 176) in connection point
J41 (see page 302). Push the green ON button (l) on the
keypad. The battery status is displayed and the armature
current symbol is lit continually. Use the horn button (S18) to
toggle between display modes.
No. FLASHING SYMBOL DISPLAYED DATA

Speed reference value sent to transistor controller:
1
-127 (FL) to +127 (FT) x parameter 2 for Fast
Digital inputs/outputs from transistor controller –
2
see page 172
3 Battery voltage (V) at ETAC
4 Armature current (A)
5 Field current (A)
6 Armature PWM (%)
7 Transistor Controller System Mode – see page 173
8 Field resistance (Ohms), used for thermal cutback
9 Proportional valve raw data valve.

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NOTE! The first driver’s Driver Parameters are

used while in Service Display.
3.3.3. Digital Inputs/Outputs from Transistor Controller
I II III IV DIGIT SEGMENT FUNCTION

I 1 Not defined
A I 2 Input (J5-14): Arm angle B – see below
I 3 Not defined
I 4 Input (J5-12): Arm angle A – see below
Input (J5-9): Proportional lowering valve (lit if
E D C B I 5
valve present and not powered)
I 6 Not defined
1A Input (J5-5): Brake (lit if brake is present and
I 7
6F 2 not released)
B
G
7 I DP Not defined
5 3
E C
DP
DP II 1 Not defined
4
D
II 2 Output (J5-2): Load-hold valve
II 3 Output (J5-9): Proportional lowering valve
Output (J5-3): Configurable output valve (see
II 4
parameter 16 on page 177.)
II 5 Output (J5-4): Main contactor interlock
II 6 Output (J5-7): Horn
II 7 Output (J5-5): Brake
II DP Output (J5-6): Pump contactor
III 1 Not defined

III 2 Not defined
III 3 Not defined
III 4 ETAC analog (pot) input: lift forks
III 5 ETAC analog (pot) input: lower forks
III 6 Not defined
III 7 Not defined
III DP ETAC input: horn

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3.3.4. Transistor Controller System Mode

The transistor controller system mode is used only in special
cases.These can be seen on the ETAC (see No. 7,
page 197.)
Status Comment
1 Motor drive, plug or active neutral braking
4 Field reversal (transitional)
6 Disable (major fault, such as severe overvoltage)
10 Regen
11 Regen taper (transitional)
No activity: main contactor open because no output
13
requested for 30 seconds or an error occurred
16 Passive restraint
17 Active restraint while drive (overspeed)
24 Passive restraint (transitional)
65 Reverser (drive)
74 Reverser (regen)
129 Emergency shutdown while in drive
144 Emergency shutdown while in passive restraint
1. The system mode shows details of transistor controller activity, including
during normal operation. It is different than, and does not correspond to,
the code from the transistor controller Status LED.
2. Throttle requests are not allowed for any status of 32 and over.
3. Truck is in an emergency shutdown for any status of 128 and over.
A Switch B Switch
Position Function
(S24) (S25)

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3.4. Changing Driver Accessible

Parameters (P)
WARNING Modify specific truck parameters will

change the driving characteristics of the
truck.
I II III IV 1. Enter special truck mode until “P” is displayed The
parameter control indicator is illuminated (see
A page 170).
2. Use the thumb control to scroll to the driver
parameter to locate the one to change or view the
following truck parameter table. Scrolling in forks
E D C B direction will show parameters 1-40. Scrolling in
A B C D tractor first direction will show parameters 40-1.
3. Press horn button once to access the parameter
shown on the display. The parameter symbol (D)
on the display starts flashing.
4. Change parameter value by using the thumb
control to scroll up or down.
Parameter 1-7 can only be modified, see

NOTE! page 175. Parameters 10-40 can only be
viewed.
5. Press the horn button again to confirm the change.
The parameter symbol (O) on the display stops
flashing and remains illuminated.
6. End programming by pressing the red OFF (O) key
on the keypad.
Moving the thumb control 1/4 - 3/8 inch

(6.35 - 9.25 mm) will show the parameter
display in Digit I. Releasing the thumb
NOTE! control to neutral position will then display
the parameter value in digit III and IV,
depending on if it is a single or double digit
number.

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The parameter change is complete. The next time the truck is

started, the new parameter will be in effect.
NOTE! All parameters can be viewed, however, not

all parameters can be changed. Truck
parameters may or may not be accessed,
depending on the value of parameter 39
(see page 182).
Truck Parameters
Parameters 1-7 are Driver Parameters (7 parameters for each Drive PIN code entered)
Parameter Name Unit Range Step Default Description

1 Max speed, slow % 10 to 40 2 20 Maximum speed value sent to
mode transistor controller while in Slow,
except during Turtle Torque (gives
torque boost if high load
encountered).
2 Max speed, fast % 10 to 100 2 100 Reduces speed value sent to
mode transistor controller while in Fast
(all throttle positions).
3 Acceleration % 30 to 90 5 65 Defines truck’s acceleration
characteristic, lower number gives
less aggressive acceleration.
4 Deceleration % 40 to 90 5 65 Defines truck’s automatic plug-
braking characteristic when throttle
is reduced (including to neutral);
lower number gives less aggressive
acceleration.
5 Truck off delay min 0 to 20 1 0 Sets truck off delay (energy saving
(keypad only) feature); if truck is not used for this
amount of time, the ETAC powers
the truck OFF. When this
parameter is set to 0, the truck
never powers off. If parameter 39
is 1 or 2 (truck has key switch
option), the truck never powers
OFF.
6 Not defined 0 0 0 Not used (always 0)

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3.5. Changing Service Parameters

NOTE! A service key is required to change service
parameters.
1. Connect the service key at J41.
NOTE! With service key connected, the truck does

not power ON using the keypad or key
switch.
2. Press and hold horn button until “P” is displayed.
The parameter control indicator is illuminated (see
page 171).
Service Key View Parameters with Service Key
When parameters 1-7 and 10 are viewed with the service
key, both the parameter (on the left side of the display, as
normal) and the driver number (on the right) are shown.
When the thumb control is rotated toward the forks, the
parameter number increases, progresses through
parameters 1 - 10, and then rolls over to the next driver (the
driver number increases). There are ten drivers 1-9, 0 (0 =
10th driver). If a parameter is changed, it is valid only for the
driver shown. Parameter 1 for the sixth driver is shown as an
example below:
Service Key
Connection 01 6
After scrolling through all drivers and driver parameters,

service parameters 11-40 will be displayed. Since these
parameters are valid for all drivers, no driver is shown.
Parameter 39 is shown as an example below:
39

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If display/access for a service parameter is required, it is

faster to initially rotate the thumb control away from the forks
(go backwards through parameters/drivers). The parameter
number displays briefly, then if the thumb control is not
rotated further the parameter value is displayed.
Service Parameters
Parameters 1-7 (driver number) are Driver Parameters, 10-40 are Service Parameters

10 Pin code 0 to 9999 1 1 Can set up to 10 PIN codes (need
(keypad Service Key to access this).
only) Note: 0 disables a driver (the 2nd
through 10th driver’s default PIN is 0), if
all drivers are disabled the truck cannot
be driven without the service key, and if
two drivers have the same PIN, the
higher number driver’s parameters will
be used.
14 Creep -10 to 10 1 -5 Defines speed at low throttle positions; a
speed negative number enhances low speed
maneuverability, a positive number
makes the truck more responsive
15 Click to 0 to 1 1 0 Enables creep travel with the tiller in the
Creep fully raised or lowered position “0”
disables, “I” enables. Activate click to
creep by quickly clicking the thumb
control twice with tiller in the brake
position. “SLO” blinks on the display.
Deactivated by clicking the thumb
control twice more. Also deactivates
after 10 seconds or if the reverser is
pushed.
16 Configurabl 0 to 15 1 0 “0” N/A - OFF
e Output “1” Travel FL
“2” Travel FT
“3” Travel FL or FT
“4” Lift
“5” Lift or Travel FL
“6” Lift or Travel FT
“7” Lift or Travel FI or FT
“8” Lower
“9” Lower or Travel FL
“10” Lower or Travel FT
“11” Lower or Travel FL or FT
“12” Lift or Lower
“13” Lift or Lower or Travel FL
“14” Lift or Lower or Travel FT
“15” Lift or Lower or Travel FL or FT.

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Service Parameters

20 Hourmeter 1 to 5 1 2 1 (A.) = key time
selection 2 (b.) = activity time (drive, lift or lower)
3 (c.) = drive
4 (d.) = lift
5 (s.) = time to service
(if parameter 25 = 0, the power-on 5
second hour meter display is skipped
and 5(s) is not shown during Hourmeters
special truck mode). Time to service
counts backward from value of
parameter 25 to zero and decrements
the same as 2(b.) increments.
21 Battery size 1 to 20 1 8 Defines battery capacity; higher number
(The lower represents larger capacity battery (the
the number, truck will allow the battery to become
the deeper more discharged given the same
the displayed battery state-of-charge). In
discharge to other words, if the battery state-of-
the battery.) charge reaches 0% too soon (the battery
still contains adequate charge to
continue operation), this parameter
should be increased. The battery state-
of-charge is reset when the battery
voltage is above 25.2V.
22 Proportional 65 to 255 5 105 Sets the maximum proportional valve
Valve End raw data value. The larger the number
Point the higher the maximum allowed PWM
to the proportional valve.
23 Proportional 1 to 20 1 7 Sets the ramp rate for closing the
Valve Stop proportional valve. The larger the
Ramp number the slower the valve closes.
25 Service hours 0 to 2000 50 0 Sets service timer. C29 will display when
interval time is up. To reset service timer, access
this parameter without changing the
value. To disable the service timer, set
this parameter to 0. See parameter 20
on page 181.

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Service Parameters

39 Access 1 to 4 1 3 Defines whether truck has key switch or
code keypad and what access level personnel
will have to parameters
1=key switch/operator parameters open
2=key switch and closed
3=keypad and open
4=keypad and closed (when closed,
service key is required to access driver
parameters)
All other Not defined 0 0 0 Not used (always 0)
parameter
numbers not
listed above
3.5.1. Parameter Description

Parameter 1
Maximum speed value sent to transistor controller while in
Slow mode except during turtle torque (gives torque boost if
high load is encountered).
Parameter 2
Reduces speed value sent from the Electronic Tiller Arm
Card (ETAC) to the transistor controller while in Fast mode
(all throttle positions).
Parameter 3
Defines truck’s acceleration characteristic when truck starts
from a stop. A high number gives maximum acceleration, a
lower number gives less aggressive acceleration.
Parameter 4
Defines truck’s automatic plug-braking characteristic when
throttle is reduced (including to neutral). A lower number
gives less aggressive acceleration.
Parameter 5
Time until the truck is switched OFF (energy saving feature)
when truck is idle and the brake is applied. Time is counted
from the latest power output is requested. If truck has the
key switch option, the truck never powers OFF.

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Parameter 10
Defines the PIN code for the driver shown. The default
operator PIN-key code is “1”. Programming new key codes
must be done using a service key (see page 176). Each of
the 10 key codes may be programed individually for operating
parameters.
If two drivers have the same PIN, the higher number driver’s
parameters will be used. (EXAMPLE: If both the first and
second driver’s PIN codes are 1111 and the first driver’s
maximum speed is 80 percent and the second driver’s
maximum speed is 90 percent, when someone logs in with
1111 the maximum speed will be 90 percent.) Setting a
driver’s PIN code to 0 will disable that driver. By default, the
first driver’s PIN code is 1 and all other driver’s PIN codes are
0. To enable additional drivers, change these PIN codes to
numbers other than 0. To program operating parameters
proceed as follows:
• With battery connected to the truck, service key
connected, main ON/OFF switch turned to the ON
position, press and hold down the horn button.
• Enter key code and press “I” or turn on key switch.
• The display will now show: H - Hour meter, E - Error
Codes, P - Parameters, and Pn - Software number.
These symbols will cycle continuously until the horn
button is released.
• Release the horn button when the display shows “P”
(if the horn button is released at the wrong time, turn
off the truck and start over).
• The parameter symbol below the display lights up;.
• The value of parameter # 1 is shown on the display
(although parameter # 1 is not functional at this time).
• Use the thumb controls to scroll to the desired
parameter.
When the thumb control is rotated slightly, the display

changes to show the parameter number currently
active. Rotating the thumb control further increments
the parameter up or down according to which
direction the control is rotated.

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• Release the thumb control to neutral when the desired

parameter number is shown. (The current
programmed value of that parameter is now shown on
the display.)
• Press the horn button once to make the parameter
value displayed start to flash.
• Rotate the thumb control to increment the parameter
value up or down, depending upon the direction the
control is rotated.
• Release the thumb control to neutral when the desired
parameter value is displayed.
• Press the horn button once to lock in the new
parameter value and verify this parameter has quit
flashing.
• Turn off truck when programming is completed.
Parameter 14
Defines speed at low throttle positions. A negative number
enhances low speed maneuverability. A positive number
makes the truck more responsive.
Parameter 15
Enables creep travel with the tiller arm in the fully raised or
lowered position: “O” disables, “I” enables. Activate click to
creep by quickly clicking the thumb control twice with tiller in
the brake position. “SLO” blinks on the display. Deactivate by
clicking the thumb control twice more. Also deactivates after
10 seconds or if the reverser is pushed.
Parameter 16
See parameter 16 on page 177.
Parameter 20
Choose the hourmeter to display.
• 1 = A. (key time)
• 2 = b. (activity time
• 3 = c. (drive motor time)
• 4 = d. (pump motor time)
• 5 = s. (time to service)

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Parameter 21
Data must be provided on the battery installed on the truck.
To adjust the disconnection point of the battery discharge
indicator, measure the following:
WARNING Damage may result to the battery if the

parameter settings are not correct.
NOTE! Acid concentration varies with different

battery brands.
• The acid concentration of a fully-charged battery. To
check quality of battery (must be between 1.27 - 1.29
specific gravity (SG).
• At lift cutout, acid concentration should be
approximately 1.14 SG.
• Reset voltage is 25.2V. Lift cutout occurs when the
display shows zero percent state-of-charge.
See “Troubleshooting Chart Index” on page 194.
Parameter 22
Sets the maximum proportional valve raw data value. The
larger the number the higher the maximum allowed PWM to
the proportional valve.
Parameter 23
Sets the ramp rate for closing the proportional valve. The
larger the number the slower the valve closes.
Parameter 25
Used to set a time limit to the next service from 0 to 2000
hours in steps of 50 hours. When it is time for service, caution
29 will display, see page 186. To disable the service timer,
set this parameter to 0. To reset service timer, access this
parameter without changing the value.
Parameter 39
Determines whether the truck has a key switch or keypad and
what access level service personnel will have to the driver
parameters. This parameter is adjustable as follows:
• 1 = Key switch connected, driver parameters open

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• 2 = Key switch connected, driver parameters must be

opened with service key
• 3 = Keypad connected, driver parameters open
• 4 = Keypad connected, driver parameters must be
opened with a service key.
3.5.2. Operating Parameter Programming

The following operating parameters may be programmed by
the operator:
• Parameter 1 - Slow speed range 10 - 40
• Parameter 2 - Fast speed range 10 - 100
• Parameter 3 - Acceleration range 30 - 90
• Parameter 4 - Deceleration range 40 - 90
• Parameter 5 - Automatic time off interval (with keypad
only) - from 0 minute to 20 minutes (a setting of “0”
disables automatic time off).
Additional truck parameters may be viewed but cannot be
changed by the operator.
3.5.3. Display Part Numbers (Pn)

1. Enter special truck mode until “Pn” is displayed
(see page 170).
2. Use the thumb control to scroll and display the
following information:
• HPn - Hardware part number
• HSN - Hardware serial number
• SPn - Software part number
3. End displaying the part number by pressing the red
“OFF” (O) key on the keypad.
3.6. Error Codes (E)
When an error occurs on the truck, a code is displayed (see
page 184).
3.6.1. Error Code History

To access the error code history, proceed as follows:
1. Enter special truck mode (see page 170).

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2. Press and hold the horn button until “E” is

displayed. The error indicator (wrench icon) is
illuminated (see page 171).
Use the thumb control to scroll through the last 50
error codes. The latest fault is shown first. The
display first shows the error code and then the hour
meter reading the fault occurred.
The error codes are divided into two groups; C -
Caution and E - Error.
The C error codes are not stored. It is only a
caution and is highlighted on the display as long as
the fault exists.
For example, if only one fault is registered in the
memory, the second empty place is shown as
follows: Fault E - - - and time: - - -.hour meter
reading.
3. End displaying the error code history by pressing
the red OFF “O” key on the keypad.
3.6.2. Truck Fault Codes

C-codes 0-49 are not logged. C-codes 50-99 are logged.
Code C14 - Arm Angle Reference Warning

Reason Tiller arm was not in up position at power ON or after the truck has not been used for a
time.
Performance Limits Travel is not allowed until code is cleared.
How to Clear Code Code is cleared as soon as tiller arm is put in the Top Brake position.
Possible Causes 1. Tiller arm stuck in down position.
with corrective a. Check up-stop.
actions/checks 2. Arm angle input may be stuck ON.
a. Check switch.
b. Check input to transistor controller.
Code C19 - Default Parameter Warning

Reason Parameter(s) out-of-range (see page 177) or incompatible with software version.
Performance Limits Truck functions are not allowed until after this code has been cleared.
How to Clear Code Parameter area is automatically fixed and then code is cleared.
Possible Causes 1. ETAC parameter area is corrupt.
with corrective a. If code does not clear after 10 seconds, try restarting the truck.
actions/checks

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Code C20 - Thumbwheel Warning

Reason Thumbwheel was not in neutral position at power ON, or a throttle position sensor failure
was detected. Also see code E160 on page 192.
Performance Limits Truck functions are not allowed until code is cleared.
How to Clear Code Code is cleared after problem is corrected.
Possible Causes 1. Thumbwheel stuck in drive position.
with corrective 2. Bad ETAC.
actions/checks
Code C21 - Lift Pot Zero Warning

Reason Lift/lower pot was not in neutral position at power ON.
Performance Limits Lift/lower functions are not to be allowed until after this code is cleared.
How to Clear Code Code is cleared after problem is corrected.
Possible Causes 1. Lift/lower pot is out of neutral position.
actions/checks
Code C28 - Main ON/OFF Switch Warning

Reason Transistor controller could not be reset via the CAN-bus at power ON or transistor
controller reports main ON/OFF switch is open.
Performance Limits Truck functions are not allowed after code has been set.
How to Clear Code This code can only be cleared after the problem is resolved and truck is turned OFF and
back ON.
Possible Causes 1. Main ON/OFF switch activated.
with corrective 2. Low voltage to transistor controller (especially while lifting or driving) due to
actions/checks overcurrent or short circuit.
a. Try driving using a known-good battery.
3. PTC R1 missing, bad, or tripped (very high resistance, due to excessive current
while main contactor is open; should automatically recover).
a. Carefully check to see if R1 is hot (tripped); if so unplug battery and allow it to
cool. Locate low impedance path that tripped R1 and correct.
4. Wire #24 at OV.
a. Check that J5 is connected, fuse and wiring.
b. Check for 24V at J5-16.
5. Short or open circuit in CAN wiring or electrical noise in CAN wiring due to bad
connection or outside interference, both at power ON.
a. Check CAN wiring.
b. Try operating truck in different environment.
6. Bad transistor controller.
a. Check transistor controller for error code.
b. Check power wiring.

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Code C29 - Time to Service Warning

Reason See service parameter 25 on page 182.
Performance Limits None.
How to Clear Code See service parameter 25 on page 182.
Possible Causes 1. Time for service.
with corrective 2. Service interval not reset after last service.
actions/checks
Code C41 - Battery Undervoltage Warning

Reason Voltage at transistor controller B+ connection less than 17V (when main contactor is
closed). Low voltage can also cause problems such as electrical components not
powering up / staying activated and CAN errors.
Performance Limits Truck functions are allowed unless the voltage was below 13V, in which case the truck
must be restarted (Code C28, see page 185) may be displayed).
How to Clear Code Code is cleared when voltage recovers.
Possible Causes 1. Low battery voltage.
with corrective a. Check for proper voltage; charge battery if necessary.
actions/checks 2. Battery parameter not adjusted correctly.
3. Circuit breaker has opened due to overloading or short circuit.
a. Check brake adjustment (see page 114).
4. Open circuit to transistor controller B+ connection.
a. Check cabling.
Code C42 - Battery Overvoltage Warning

Reason Voltage at transistor controller B+ connection over 30V.
Performance Limits Truck functions are allowed unless the voltage was above 34V, in which case the truck
must be restarted (error 142, see page 191, may be displayed).
How to Clear Code Code is cleared when voltage recovers.
Possible Causes 1. High battery voltage.
with corrective a. Check for proper voltage; charge battery may be overcharged.
actions/checks 2. Extreme regenerative motor braking.
3. Battery charger plugged into truck.

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Code C43 - Transistor Controller Thermal Cutback

Reason High or low temperature (such as above 185 degrees F [85 degrees C] or below -13
degrees [25 degrees C] at transistor controller heat sink.
Performance Limits Truck functions may be allowed.
How to Clear Code Code is cleared when transistor controller heat sink temperature recovers (see step 7 on
page 197).
Possible Causes 1. Operating in extreme environment.
with corrective 2. Excessive load on truck.
actions/checks a. Check brake adjustment (see page 114).
b. Reduce value of parameters 2, 3 and/or 4 to help decrease motor temperature.
3. Improper transistor controller mounting.
Code C44 - (“Hot” is displayed) - Traction (Drive) Motor Thermal Cutback

Reason High traction motor temperature detected.
Performance Limits Truck functions are allowed, but maximum speed value sent to transistor controller is
reduced.
How to Clear Code Code is cleared when temperature recovers.
Possible Causes 1. Operating in extreme environment.
with corrective 2. Excessive load on truck.
b. Reduce value of parameters 2, 3 and/or 4 to help decrease motor temperature.
3. Air flow to motor restricted.
4. Problem with motor wiring.
5. Bad traction motor.
Code C46 - Severe Traction Motor Thermal Cutback

Reason Very high traction motor temperature or extreme operation detected.
Performance Limits Same as error code 44.
Corrective Action Same as error code 44.
Possible Causes Same as error code 44.
with corrective
actions/checks

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NOTE! Fault codes 50-99 are logged. The log can

contain multiple faults with the same
number code. Code is cleared when
problem is resolved and truck is turned OFF
and back ON (unless otherwise noted.
Code C77 - Lift Pot Warning

Reason Lift pot short circuit or disconnected.
Performance Limits Lift/lower functions may not be allowed until after this code is cleared.
Possible Causes 1. Lift/lower throttle is out of neutral position.
actions/checks
Code C78 - Pump Contactor Warning

Reason Pump contactor short circuit or open circuit.
Performance Limits Lift function not allowed until after this code is cleared. Lowering will no longer be
proportional.
Possible Causes 1. Pump contactor coil wires open.
with corrective 2. Bad Transistor controller.
actions/checks 3. Pump contactor tips welded.
4. F3 open.
NOTE! Fault codes 100 and over are logged. The

log can contain multiple faults with the
same number code. Throttle is not allowed,
outputs are off (brake is mechanically
applied), and main contactor is dropped.
Code is cleared when problem is resolved
and truck is turned OFF and back ON
(unless otherwise noted).
Code E101 - Transistor Controller Does Not Correspond With The Type Of Truck
Reason Transistor controller is not compatible with ETAC software.
Possible Causes 1. Incorrect transistor controller installed in truck.
with corrective
actions/checks

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Code E104 - Brake Power Error

Reason Transistor controller could not detect presence of brake coil.
Possible Causes 1. Open circuit in brake circuit.
with corrective a. Check brake and wiring.
actions/checks 2. Master control relay missing or stuck open.
3. Main contactor open circuit (especially after it has closed).
4. Communication error due to transistor controller handset.
a. Unplug handset from transistor controller, allow handset to completely boot
before turning truck ON.
Code E106 - Digital Output or Field Overcurrent

Reason Transistor controller attempted to deliver more current than allowed to main contactor
coil; traction motor field winding, or digital output.
Possible Causes 1. Short circuit in transistor controller output circuit.
with corrective a. Check main contactor coil, traction motor field winding, digital output and
actions/checks associated wiring.
b. Replace transistor controller.
Code E110 - Braking System Fault

Reason Transistor controller detected problem with braking functions.
Possible Causes 1. Short circuit in brake circuit.
with corrective a. Check brake and wiring.
actions/checks 2. Bad transistor controller.
Code E112 - Arm Angle Sequence Fault

Reason Improper sequence of arm angle inputs.
Possible Causes 1. Arm angle input stuck on or off.
with corrective 2. Problem with tiller arm angle input wiring.
actions/checks 3. Problem with tiler arm.
a. Check for proper sequence of arm angle switches (see step 2 above).
Code E114 - Traction (Drive) Motor Speed Fault

Reason Transistor controller detected stalled traction motor.
Possible Causes 1. Traction motor stalled.
with corrective 2. Excessive traction motor load at low speed.

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Code E115 - Contactor Off, Welded or Missing, or Bad Transistor Controller

Reason Controller could not close contactor (contactor off), contactor welded or contactor
missing.
Possible Causes Contactor did not close (contactor off)
with corrective 1. Problem with main contactor tips.
actions/checks a. If contactor clicks prior to getting this code, try polishing contactor tips with a
clean pencil eraser. If this doesn’t work or there is permanent contactor
damage, replace contactor.
2. Low voltage.
a. Try closing contactor with a known-good battery.
3. Short in contactor coil.
a. Replace contactor.
Contactor welded
4. Main contactor tips welded.
5. Short circuit in contactor circuit.
a. Check contactor, wiring (coil), and cabling.
Contactor missing
6. Open circuit in contactor circuit.
a. Check contactor, wiring (coil), and cabling.
7. Bad transistor controller
Code E118 - K4 MCR Welded

Reason MCR detected welded at startup.
Possible Causes 1. MCR tips welded.
with corrective 2. Short circuit in MCR circuit.
actions/checks a. Check MCR wiring (coil and tips).
Code E140 - Checksum Error

Reason ETAC software detected that checksum was invalid.
Possible Causes 1. Bad software.
with corrective a. If applicable, try downloading new software.
actions/checks 2. Bad ETAC.
Code E141 - Software Problem

Reason ETAC found problem with software.
Possible Causes 1. Missing or Bad software.
with corrective a. If applicable, try downloading new software.
actions/checks 2. Bad ETAC.

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Code E142 - Transistor Controller Disable Error

Reason Transistor controller detected a major fault.
Possible Causes 1. Severe overvoltage (especially at main contactor close).
with corrective a. Check for proper voltage.
actions/checks 2. High current through a digital output.
a. Check transistor controller outputs and wiring.
3. Open circuit in traction motor field circuit.
a. Check transistor motor field wiring and field windings in motor.
Code E150 - Drive Communication Rx Error

Reason ETAC did not receive CAN data from transistor controller.
Possible Causes 1. Short or open circuit in CAN wiring.
with corrective 2. Electrical noise in CAN wiring due to bad connection, outside interference or low
actions/checks voltage.
b. Try driving using a known-good battery.
c. Try driving in a different environment.
4. Bad ETAC.
Code E151 - Drive Communication Tx Error

Reason ETAC could not send CAN data to transistor controller.
actions/checks voltage (especially while lifting or driving) possibly due to overcurrent or short circuit.
3. Bad ETAC.
Code E157 - CAN-bus Off Error

Reason ETAC detected problem with CAN-bus.
4. Bad ETAC.

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Code E159 - Over Run Error

Reason ETAC detected problem with the CAN-bus.
4. Bad ETAC.
Code E160 - Error In Reversing Circuit

Reason ETAC detected problem with the throttle position sensors, including the sensor used to
initiate reversing. Also see code 20 on page 185.
Possible Causes 1. Bad ETAC.
with corrective
actions/checks
Code E161 - Lower Valve Error

Reason Transistor controller could not detect presence of lower valve coil.
Possible Causes 1. Lower hold-valve missing.
with corrective 2. Open or short circuit in lower valve or wiring.
actions/checks 3. Master control relay missing or stuck open.
4. Main contactor open circuit (especially after it has closed).
Code E200 - Field Open

Reason Transistor controller detected open field.
Possible Causes 1. Open circuit in traction motor field circuit.
with corrective a. Check traction motor field wiring and field windings in motor.
actions/checks b. Replace transistor controller.
Code E201 - M-Error

Reason Transistor controller detected an armature circuit fault.
Possible Causes 1. Incorrect traction motor cabling.
with corrective 2. Bad transistor controller.
actions/checks a. Check transistor controller for error code.

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Code E202 - Transistor Controller Sensor Error

Reason Transistor controller reported an armature current sensor fault.
Possible Causes 1. Abnormal truck operation.
with corrective 2. Low battery voltage or undersized battery.
actions/checks 3. Bad transistor controller.
Code E214 - Transistor Controller CAN Timeout

Reason Transistor controller did not receive CAN data from ETAC or transistor controller selftest
failed.
4. Bad ETAC.

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3.7. Troubleshooting Chart Index

3.7.1. Travel (Tractor-first / Forks-first) System
1. No travel in either direction, lift/lower okay (Code
E106, Digital output or field overcurrent, see
page 189).
E201 M-error, see page 192).
E214, transistor controller CAN timeout, see
page 193).
4. Slow travel, lift/lower okay. No fault codes.
5. No travel (Code C42, Battery overvoltage warning,
see page 186).
6. Slow or no travel (Code C41, Battery undervoltage
warning, see page 186).
7. Slow or no travel (Code C43, transistor controller
thermal cutback, see page 187).
8. Truck does not accelerate correctly.
3.7.2. Wiring System

1. Truck functions partially, some functions do work
when commanded.
3.7.3. Other Possible Troubleshooting Issues

1. Green and red LEDs on keypad do not light when a
button on the keypad is pushed (keypad option
only).
2. No fast travel mode.
3. No travel.
4. Horn does not sound when horn button is pushed.

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3.8. Troubleshooting Charts

The following troubleshooting charts describe a course of
testing and repair for each problem listed. If the given test is
NOT successful, perform the repair listed with the test. If the
given test IS successful, go to the next test or follow the
special instructions given. For electrical legend see
page 304. For the electrical schematics see page 302 or
page 303.
Travel (Tractor-first / Forks-first) System
1. No travel in either direction, lift/lower okay (Code E106,
Digital output or field overcurrent, see page 189).
Possible Cause Remedy

Bad wiring between transistor With main ON/OFF switch OFF and battery disconnected, check wiring
controller and main contactor between transistor controller and main contactor (K10).
Bad transistor controller With main ON/OFF switch OFF and battery connector disconnected, measure
resistance between J5-16 and J5-4. If resistance is approximately 50 ohms,
check wires for shorts to frame, B+, B-, or other conductors. If none found
replace transistor controller.
Bad main contactor coil Disconnect and measure resistance of main contactor (K10) coil. If resistance
is not approximately 50 ohms, replace coil.
2. No travel in either direction, lift/lower okay (Code E201

M-error, see page 192).

Bad wiring between transistor With main ON/OFF switch OFF and battery disconnected, disconnect wires 5
controller and motor and 6 from the transistor controller. Check wiring between motor and transistor
controller.
Bad transistor controller With main ON/OFF switch OFF and battery connector disconnected,
disconnect drive motor cable at transistor controller terminal M-. Reconnect
battery connector, turn key switch ON. If Code 1,3 (see page 246) is still
displayed, replace transistor controller. If Code 1,3 is not displayed, disconnect
battery, remove wires 5 and 6 at transistor controller and measure resistance
in wiring harness between wires 5 and 6. If less than 1.0 ohm, replace
transistor controller.
Bad motor With main ON/OFF switch OFF and battery disconnected, remove wires F1
and F2 at motor. If greater than 2.0 ohm, replace motor.
3. No travel in either direction, lift/lower okay (Code E214,

transistor controller CAN timeout, see page 193).

Bad transistor controller Replace transistor controller.

S5.0 5000
Version no T-code
000 7BWS10/13
4. Slow travel, lift/lower okay. No fault codes.

Battery problems Replace battery with fully-charged good battery.
Transistor controller or ETAC Verify programming. If changed, reset programming.
programming changed
Binding drive wheel assembly/ Jack and block truck (see page 58). Disable brake (see page 114). Check that
drive motor drive wheel spins freely. If not, repair or replace (see page 121).
Binding brake disc Check air gap adjustment (see page 114).
Bad drive motor (may test ok Repair or replace motor brushes (see page 92).
with no load, but fall under load)
or worn brushes
5. No travel (Code C42, see page 186), Battery overvoltage

warning).

Battery problem Verify the correct, fully-charged good battery is installed in truck.
Verify battery charger is not Disconnect battery charger immediately.
plugged into truck
Bad transistor controller Verify correct battery is installed. Replace transistor controller.
6. Slow or no travel (Code C41, see page 186), Battery

undervoltage warning).

Battery problems Verify a correct, fully-charged good battery (24V) is installed in truck.
Bad battery terminals or quick Repair or replace battery terminals.
disconnect plug
Bad transistor controller Verify battery voltage at key switch input. Turn main ON/OFF switch OFF and
disconnect battery connector. Check for continuity and wiring shorts between
B- battery to transistor controller B- and key switch circuit wiring and fuses.
Repair or replace. Measure voltage at transistor controller B+. If 24V, replace
transistor controller.
Bad wiring or connector Jack and block truck (see page 58). With main ON/OFF switch OFF and
battery connected, while attempting travel, measure voltage between A2,
transistor controller B+, B-, and F1, F2, M1, and M3. If not 24V, repair or
replace wiring.

S5.0 5000
Version no T-code
000 7BWS10/13
7. Slow or no travel (Code C43 (see page 187), Transistor

controller thermal cutback).

Binding load wheel(s) Make sure load wheels rotate freely, If not repair or replace (see page 126).
Bad drive wheel assembly Jack and block truck (see page 58). Turn main ON/OFF switch ON. Pull tiller
arm handle down to release brake. Check drive wheel to see if it spins freely. If
not, repair or replace (see page 121).
Binding brake disc Jack and block truck (see page 58). Turn main ON/OFF switch ON. Pull tiller
arm handle down to release brake. Check brake disc to see if it spins freely. If
not, adjust, repair or replace (see page 114 or page 116).
Binding drive motor Jack and block truck (see page 58). Turn main ON/OFF switch ON. Pull tiller
arm down to release brake. Check the brake disc to see if it spins freely. Turn
main ON/OFF switch OFF. Remove brake disc and check armature shaft.
Remove motor and repair or replace drive unit or drive motor (see page 104 or
page 94).
Worn brushes Inspect brushes (see page 90).
Bad drive motor (may test ok Repair or replace drive motor (see page 94).
with no load, but fail under load)
Truck overloaded or operating in Operate and load truck within specifications (see page 51).
extreme conditions
Bad transistor controller Check mounting of transistor controller. Check to make sure transistor
controller is secure and in contact with truck frame (acts as a heatsink). If
transistor controller is mounted correctly, replace transistor controller.
Bad wire or connector Jack and block truck (see page 58). With main ON/OFF switch ON and battery
connected, while attempting travel, measure voltage between B- and transistor
controller B+, B- and J5-16. If not 24V, repair or replace wiring.
8. Truck does not accelerate correctly.

Transistor controller or ETAC Verify programming.
programming not correct
Bad motor brushes or motor With main ON/OFF switch OFF and battery connector disconnect, check drive
motor brushes (see page 90) and motor (see page 94).
Bad transistor controller If all possible causes check out, replace transistor controller.

S5.0 5000
Version no T-code
000 7BWS10/13
Wiring System
1. Truck functions partially, some functions do work when
commanded.

Bad wiring in tiller arm With main ON/OFF switch OFF and battery connector disconnect, visually
inspect wiring in the handle where the wiring leaves the handle and over the
brake. Repair or replace.
Bad wiring in hydraulic control With main ON/OFF switch OFF and battery connector disconnect, visually
area inspect wiring. Repair or replace.
Other Possible Troubleshooting Issues

1. Green and red LEDs on keypad do not light when a button
on the keypad is pushed (keypad option only).

Open circuit of wires that power Check control wires, especially wires 1, 20, and 22 (red in tiller arm cable) and
ETAC 40 (black in tiller arm cable).
Bad connectors Repair and replace bad connectors (check connector J11 at tiller arm base,
connector into ETAC and connector J5 to transistor controller).
F50 Open Ensure control fuse has not tripped.
Keyswitch jumper not connected Connect keyswitch jumper.
2. No fast travel mode.

Arm angle switch “A” always off Check for proper operation of arm angle switch “A” and correct if necessary.
Check wiring, transistor controller and switch adjustment.
3. No travel.

Arm angle switch failure Check arm angle switch adjustment (see page 223), wiring and transistor
controller.
4. Horn does not sound when horn button is pushed.This

Bad horn switch/wiring in handle Repair/replace as necessary (see page 227).
head
Bad transistor controller Check and replace if necessary.
Bad horn Replace horn.

S5.1 5110
Battery
Version no T-code
000 7BWS10/13
Battery
Check the truck’s data plate for the weight of battery required
for the truck. Contact your local battery supplier for the
purchase of a proper voltage battery. A 24 volt battery may
not be supplied with the truck.
2. Maintenance
Information in this section does not supercede or replace
information available by the battery and battery charger
supplier. Read, understand, and follow the procedures
available by the battery and battery charger supplier. Notify
your supervisor if there are any concerns or questions
regarding the battery or procedures.
2.1. Inspection and Care

immediately.
CAUTION Before working on the battery, review

Battery Safety beginning on page 20.
Batteries may weigh more than 375 pounds
(125 kg). Use extreme care during
replacement. Use a suitable replacement
device or hoist for lifting.
NOTE! Read, understand, and follow procedures,

recommendations and specifications
available by the battery and battery charger
supplier.

S5.1 5110
Battery
Version no T-code
000 7BWS10/13
Batteries in industrial trucks pick up various kinds of dirt and

dust depending on their surroundings and the types of
material handled. If cells are overfilled and electrolyte collects
on the covers, the following occurs:
1. The top of the battery becomes wet and stays wet,
since the acid in the electrolyte does not
evaporate.
2. This moist surface, in combination with certain
kinds of dirt, becomes electrically conductive and
permits stray currents to flow externally over the
top of the battery. This degrades battery
performance and truck operation.
3. The acid also causes corrosion of cell posts, nuts,
connectors and the steel battery case.
When inspecting batteries, check the following:
1. Wet covers can indicate overfilling, leaky seals at
posts, or excessive gassing during charge. If
covers are wet, determine the cause and correct
the problem.
2. Make sure batteries cannot move more than 0.5
inch (13 mm) in any horizontal direction. Shim or
block the batteries to restrain them.
2.2. Exterior Cleaning

Refer to recommended battery supplier’s guidelines for
details.
2.3. Charging
OSHA regulations require that battery charging installations
be located in areas designated for that specific purpose. Such
areas must provide for flushing and neutralizing spilled
electrolyte, fire protection, protecting charging equipment
from damage by trucks and adequate ventilation of fumes
from gassing batteries.
To charge a battery, direct current is passed through the
battery cells in the direction opposite that of discharge.
Charging time is 5 to 20 percent longer than discharge time.

S5.1 5110
Battery
Version no T-code
000 7BWS10/13
Read, understand, and follow procedures, recommendations

and specifications available by the battery and battery
charger supplier.
CAUTION NEVER plug the battery charger into the

truck. This will severely damage the truck’s
electrical system. Plug the charger into the
connector from the battery.
2.4. Storage
Before storing the battery, make sure the electrolyte is at the
proper level in all the cells, the filler plugs are tight, and the
battery is fully charged. Store battery in a clean, cool, dry
location away from radiators and other sources of heat.
Check electrolyte level and specific gravity every 30 days
during storage. Whenever specific gravity is less than 1.230,
charge the battery.

S5.1 5110
Battery
Version no T-code
000 7BWS10/13
2.5. History Record

A battery record system is essential because battery failure
can cause production slowdowns and increased battery
operating costs. A properly supervised record system can
detect and call attention to such operating irregularities as:
• Overcharging
• Undercharging
• Over-discharging
• Excessive water consumption
• Excessive dirt and corrosion
• Worn-out batteries
• Excessive current consumption of trucks
Records should be kept for each battery. Your battery
supplier should be able to provide maintenance record
sheets. Each report should contain:
• Battery number, type, serial number, and service
data
• Specific gravity and voltage readings for each cell
• Electrolyte
• Amperes
• Condition of connectors, covers, sealing
compound and tray
• General cleanliness
• Number of total cycles
• Average specific gravity drop
• Watering frequency
3. Troubleshooting
Many electrical problems are caused by a bad or dirty battery.
Make sure the battery is clean. Check the electrolyte level
and battery level. Look for simple causes of problems. A
trained, qualified, and authorized technician should perform
testing and troubleshooting on batteries.

S5.1 5110
Battery
Version no T-code
000 7BWS10/13

Contact your local battery supplier for replacements or
repairs of industrial batteries.
Removal
parking brake is applied.
3. Position battery replacement device in accordance
with the supplier’s recommendations.
4. If applicable, remove bolts from battery box frame
on the truck. Remove battery from truck onto
suitable battery table or with battery lifting device.
Installation
1. With a fully charged and tested battery on the
battery handling device, position the handling
device at truck in accordance with the supplier’s
recommendations.
2. Move the battery into the compartment. Be sure
the battery has no more than 0.50 inch (13 mm) of
“free play” movement in the battery compartment.
If applicable, securely refasten bolts to battery box
frame on the truck.
3. Move handling device from the area.
service.

S5.1 5110
Battery
Version no T-code
000 7BWS10/13

S5.2 5110
Swing Out Battery Pack
Version no T-code
000 7BWS10/13
Battery Specifications
2
Exide type GC-3 6 volt
75-91 AMPS
3 Trojan type T-90 or T-1900

6 volts 75-91 AMPS
4
1
7 22
6
5
8 11
17 9 10
16
21 18
15
14
23
20 14
13
19
12
17 16

S5.2 5110
Version no T-code
000 7BWS10/13

1 Battery pack assembly 13 Tray, left
2 Bracket 14 Screw
3 Screw 15 Grommet
4 Battery Pack 16 Screw
5 Decal 17 Support, battery
6 Charger, battery 18 Nut, clip
7 Decal, warning 19 Screw, frame mounting
8 Screw 20 Nut, clip
9 Cable assembly 21 Tray, right
10 Cover 22 Decal
11 Screw 23 Tray, cord
12 Decal, warning

S5.2 5110
Version no T-code
000 7BWS10/13
Battery Cable Routing Diagram

2
3 4
1 11
5
2
11 1
9
7 1
2
2 2
11 11
11 10 8
1
11
1 2
9 9
Item
Description
No.
2 1 1 Boot
11 2 Nut
2 3 Tie, cable
1
11
4 Cable
9 5 Cable
6 Battery connector
7 Cable
8 Cable
Battery Specifications 9 Battery
10 Cable
Exide type GC-3 6 volt 11 Washer, flat
75-91 AMPS
Trojan type T-90 or T-

1900

S5.2 5110
Version no T-code
000 7BWS10/13
Battery Pack (GNB Pallet Pro™ Start/Stop

Charger)
18
1
19
20
21
18
6
14
15 7
16 5
12
17
10
11 9
8 13

S5.2 5110
Version no T-code
000 7BWS10/13

1 Battery pack assembly 12 Decal, serial number
2 Pallet pro™ battery pack, 24 Volt 13 Bracket
3 Charger assembly (does not 14 Tray
include item 17)
4 Battery, 6 Volt 15 Cable, SB175 plug
5 Grommet 16 Battery connector
6 Decal, Champion 17 Cable, AC power
7 Decal, DANGER 18 Screw
8 Cable assembly 19 Bracket
9 Bolt, M6x20 20 Screw
10 Lockwasher 21 Clip, nut
11 Washer, flat

S5.2 5110
Version no T-code
000 7BWS10/13
The truck may be equipped with a multiple battery pack, or a
maintenance-free battery and charger.
2. Maintenance
immediately.
CAUTION Before working on the battery, review

Battery Safety beginning on page 20.
Batteries may weigh more than 375 pounds
(125 kg). Use extreme care during
replacement. Use a suitable replacement
device or hoist for lifting.
2.1. Electrical Testing

2.1.1. Required Equipment
1. Common hand tools.
2. AC/DC volt/ohm meter.
3. Battery connector with + to - loop (use on charger
only).
4. Battery hydrometer.
2.1.2. Instructions
1. Check condition of batteries (check each cell).
a. Specific gravity, before and after charging.
Acceptable values:
Dead battery - 1.180
Fully charged battery - 1.280
Any cell that is different by more then 20 points
indicates a suspect battery.

S5.2 5110
Version no T-code
000 7BWS10/13
b. Volts per cell, open circuit, before and after

charging.
Acceptable values:
Dead battery - 1.9 v/cell
Fully charged - 2.2 v/cell
c. Charging rate DC amps, at start and finish of
charge cycle.
Acceptable values Start Finish at 2.5 VPC

24 volt system 15 amps 0.5 amps or less
d. Charging rate at battery DC volts, at start and
finish.
Acceptable values Start Finish

24 volt system 25.6 volts 30.0 volts
2. Visually inspect charger with all power
disconnected.
a. Inspect AC power supply circuit breaker, wall,
outlet, plug, cord.
b. Inspect charger for physical damage.
c. Inspect internally for loose or discolored
connections and wires damaged due to
overheating.
d. Inspect transformer coils for obvious
discrepancies.
e. Inspect the charger’s internal AC power fuse. It
should be 10 amp rated.
NOTE! If the AC power fuse is blown, it could

indicate a shorted diode on the DC output
circuit.
3. Testing the DC output circuit.
NOTE! If the AC power fuse blows or the DC 1 x

circuit breaker trips, check for reverse
polarity of the battery connection.

S5.2 5110
Version no T-code
000 7BWS10/13
a. Open circuit voltage test.

With batteries disconnected and the charger
turned on, the DC output voltage should be
1-1/2 times the rated DC voltage.
System voltage
24 volts
b. Short circuit amperage test.

With charger output battery connector short
circuited (positive to negative jumper connector
plugged into charger output connector), and the
charger turned on, the DC output amps should
be 80 percent of the normal DC amps.
System voltage Short circuit output voltage

24 volts approximate 12 amps
(1) With charger in the OFF position, connect

AC power cord to appropriate AC power
supply, connect with the + to - loop to the
charger.
(2) Turn battery charger on and note the amp
gauge reading. It should be as stated on the
chart above. Leave charger on for five
minutes while watching the amp gauge.
The amp gauge should remain steady. This
verifies the condition of the circuit breaker
and any loose connections.
(3) Turn charger off before disconnecting the
jumper connector.
4. Testing components
WARNING Before checking components disconnect

AC power supply, unplug batteries, and
discharge capacitor with an insulated
screwdriver. All tests should be made with
the charger disconnected unless otherwise
stated. Use extreme caution when a test
calls for the power to be “on” at the charger.

S5.2 5110
Version no T-code
000 7BWS10/13
a. Diodes
(1) A quick test for shorted diodes may be
made by connecting the leads of the
ohmmeter to the charger battery connector
terminals and testing for continuity in each
direction. If the test shows open, the DC
circuit breaker, may be open. To bypass an
open DC circuit breaker, connect the test
leads to the positive and negative lugs
behind the circuit breaker and reverse the
ohmmeter probes. A shorted diode will
show continuity in both directions. Retest
the diodes individually to determine which
diode is bad.
(2) Disconnect diode flexible leads to isolate
the diodes from the circuit.
(3) Use an ohmmeter to test the continuity of
each diode in both directions. A shorted
diode will show continuity in both directions
and an open diode will show no continuity in
either direction. A good diode will show
continuity in only one direction.
(4) Reconnect diode leads in charger.
b. Capacitor
(1) Discharge capacitor.
(2) Disconnect capacitor leads.
(3) Set ohmmeter R x 10,000 scale and
connect ohmmeter leads to terminals on
capacitor. When needle (or display) quits
moving, reverse leads.
On a good capacitor, the needle will deflect
to the right (low resistance) and then deflect
back to the left (high resistance) each time
the meter leads are reversed. On a shorted
capacitor, the needle will deflect to the right
(low resistance) and remain there. On an
open capacitor, the needle will not deflect
(stationary display).
(4) Reconnect capacitor leads in the charger.

S5.2 5110
Version no T-code
000 7BWS10/13
(5) Set AC voltmeter on a scale to read at least

500 volts AC. Connect meter leads to the
capacitor terminals.
A shorted capacitor will indicate 0 volts AC.
An open capacitor will indicate about 300
volts +/-20 volts AC. This is the same as the
capacitor transformer winding voltage
without a capacitor connected in circuit.
(6) Turn on charger power.
WARNING Before checking components, disconnect

AC power supply, unplug batteries and
discharge capacitor with insulated
the charger disconnected unless otherwise
stated. Use extreme caution when a test
calls for the power to be “on” at the charger.
5. Overcharging problems
Most complaints about charging problems can be
remedied by following the previous procedures.
Overcharging problems may not be the fault of the
charger. Often, overcharging is caused by bad
batteries or poor connections. The following items
should be checked to resolve problems of
overcharging or failure of charging amps to taper
down.
a. Charger and battery not properly matched.
Check specifications on both batteries and
charger. Battery pack (GNB) has been
designed for a specific size and type of battery.
If another battery has been installed, be certain
that it is comparable to the original batteries.
Automotive type batteries will not function
properly in this application.
b. Excessive battery temperatures causing
suppressed battery voltage.
Allow batteries to cool.
c. Bad battery or poor DC connection.

S5.2 5110
Version no T-code
000 7BWS10/13
Check battery voltage while charger rate is

controlled by the battery state of charge. This
will adjust the output to the proper level if the
battery is in good condition. If the voltage does
not come up to finish rate, this may indicate a
bad cell within a battery or a marginal DC
connection between the battery and the
charger. Carefully inspect connections for
excessive heat. Test battery cell voltages and
specific gravity.
3. Troubleshooting
The charger incorporates a very simple and reliable design
which makes troubleshooting relatively easy. The repair
procedure involves testing the output of the charger and then
testing individual components. The test procedures follow a
logical sequence of electrical flow through the circuit. Only
standard hand tools and an AC/DC volt/ohm meter are
required. A battery hydrometer is recommended.
WARNING Before checking charger, disconnect AC

power supply, unplug batteries, and
discharge capacitor with an insulated
extreme caution when a test calls for power
to be “on” at the charger.

Contact your local battery supplier for replacements or
rebuilds.

S5.2 5110
Version no T-code
000 7BWS10/13

S5.3 5190
Battery Connector
Version no T-code
000 7BWS10/13
Battery Connector
The truck battery connector is located at the top of the truck
cover. The battery and charger have similar battery
connectors. It is necessary to connect the battery to the truck
before powering ON.
Figure 5-7: Battery Connector
2. Maintenance
Visually inspect cables and connectors. Negative and positive
cables should be visually inspected for breaks and wear.
Check connectors for damage and to ensure proper
connections of cables.
2.1. Inspection
3. Check battery connectors for damaged cables.
4. Check to see if cables are pulling out of the
connectors.
5. Check cables at battery terminals. Connections
should be tight, with no corrosion.

S5.3 5190
Battery Connector
Version no T-code
000 7BWS10/13
6. Check inside connectors at internal contacts for

damage, dirt, or corrosion. DO NOT use a metal
object to clean connectors.
7. Connector housings must not be cracked or
broken.
3. Troubleshooting
Make sure cable wires are in good condition and connector
has proper connections to cables.

S5.3 5190
Battery Connector
Version no T-code
000 7BWS10/13
To Battery
2
3 Item
Description
No.
1 Puller
2 Cable, negative
1 3 Cable, positive
4
4 Nut
5 Connector, SB-175
9 6 Cable, positive
7 Cable, negative
5
8 Screw, cap
9 Screw, cap
7
6
To Truck

S5.3 5190
Battery Connector
Version no T-code
000 7BWS10/13

Do not attempt to repair or rebuild the battery connector or
power cables. Replace damaged parts with new.
Removal, Repair, and Installation
The cables to the battery connectors have a lip on the forward
end. This lip snaps over a spring-loaded retainer which is part
of the connector. To remove a cable from the connector, push
retainer down while pushing cable towards the rear and out of
the connector.

S5.4 5310
Switches
Version no T-code
000 7BWS10/13
Switches
2
1
3 12
4
11
9
10 5
6
10
5
7
7 8
Item Item Item

No. No. No.
1 Switch, main ON / OFF 5 Screw 9 Screw
2 Switch, key (option) 6 Nut 10 Lockwasher
3 Screw 7 Switch, arm angle 11 Switch, horn

4 Bracket 8 Bracket 12 Button, horn

S5.4 5310
Switches
Version no T-code
000 7BWS10/13
The main ON/OFF switch (S21) is provided on the truck. In
the OFF position, battery power to all control functions is
interrupted. In the ON position, battery potential is provided to
all control functions via the transistor controller.
The arm angle switches are located at the base of the tiller
arm stem. The arm angles switches (S24) and (S25)
determine brake activation and truck travel speed. Each
switch is activated by the tiller arm position. The tiller arm
must be positioned between 6 degrees of the upper rest
position and in the bottom 8 degrees of the operating range in
order for switches to close, permitting travel. When the tiller
arm is within 6 degrees of the upper rest position, the parking
brake is activated. When the tiller arm is between 6 to 41
degrees of the upper rest position, arm angle B switch (S25)
closes and enables slow speed operation. When the tiller arm
is placed beyond 41 degrees from the upper rest position,
arm angle A switch (S24) also closes enabling fast speed
operation. When the tiller arm is placed in the bottom 8
degrees of the operating range, arm angle switch B (S25)
opens, activating the parking brake.
A Switch B Switch
Position Function
(S24) (S25)
A two-position (ON/OFF) optional key switch (S17) is located

on the main console, which energizes all truck control
functions when in the ON position, provided the main ON/
OFF switch is in the ON position.

S5.4 5310
Switches
Version no T-code
000 7BWS10/13
2. Maintenance
General
Examine switch for signs of arcing, overheating,
discoloration, cracking, or other physical damage. Replace
switch if such damage is noticed.
Use an ohmmeter set to a low resistance scale to measure
resistance across the switch. In a closed position, the switch
should be less than 1 ohm. In an open position, the switch
should show a resistance greater than 10 megohms.
With the battery connected, use a voltmeter to check for
voltage on both the positive and negative side of the switch
while in the closed position. The voltage must be the same on
both sides of the switch. If not, the switch is worn or bad.
Main ON/OFF Switch Main ON/OFF Switch Inspection
To inspect switch proceed as follows:
1. With the battery plugged in and main ON/OFF
switch (S21) in the ON position, battery voltage B+
must be present on the two terminals of the switch.
2. Test main ON/OFF switch with an ohmmeter after
disconnecting battery and removing wires from the
switch terminals.
3. In the OFF position, the ohmmeter must read
greater than 1 megohm. In the ON position, the
ohmmeter must read less than 1 ohm. If not,
replace switch.
Adjustment of Arm Angle Switches
To adjust switches, proceed as follows:
Arm Angle Switches
3. Remove up-stop cushion (see page 224).
Screws 4. Loosen screws holding the switch on the bracket.
Slide the switch out as far as possible and
retighten screws.

S5.4 5310
Switches
Version no T-code
000 7BWS10/13
NOTE! Make sure the cam arm makes solid

contact with switch lever. Switch S25 must
operate within 6 degrees of the upper rest
position or in the bottom 8 degrees of the
operating range. Make sure switch does not
bottom out when fully compressed.
5. Install up-stop cushion.
Up-Stop Cushion
service.
Key Switch (Optional) Inspection
To inspect optional key switch, proceed as follows:
2. With the battery plugged in and the key switch ON,
battery voltage B+ must be present on the two
terminals of the switch.
3. Turn key switch to OFF. Depress main ON/OFF
switch to the OFF position.
4. Disconnect the battery connector from the truck.
5. Remove wires from switch terminals.
6. Test key switch for continuity with an ohmmeter. In
the OFF position, the ohmmeter must read greater
than 1 ohm. If not, replace switch.
3. Troubleshooting
To troubleshoot the main ON/OFF switch see page 147, and
arm angle switches see page 149 and/or page 151.

S5.4 5310
Switches
Version no T-code
000 7BWS10/13

The switches can not be repaired or rebuilt. Replace a bad
switch with new as necessary.

4.1. Main ON/OFF Switch

Removal
4. Disconnect wires from switch
5. Remove main ON/OFF switch.
Installation
1. Install new main ON/OFF switch and connect wires
to the switch terminal.
Enter key code and press the green ON button (I)
on the keypad.
service.
4.2. Arm Angle Switches

Removal
1. Lower the forks completely.
3. Remove up-stop cushion (see page 224).
4. Disconnect wires from switch (7).

S5.4 5310
Switches
Version no T-code
000 7BWS10/13
5. Remove screws (9) and carefully remove bracket

(8) and switches (7).
6. Remove the screws (5) holding the switch (7) on
the mounting bracket (8). Remove switch.
Installation
1. Mount the switch to the mounting bracket.
Arm Angle Switches 2. Install bracket with switches into the truck.
3. Connect the wires to the switch.
5. Turn main ON/OFF switch to the ON position.
on the keypad. Test drive the truck.
6. Adjust switch if necessary (see page 223).
8. Install up-stop cushion.

S5.4 5310
Switches
Version no T-code
000 7BWS10/13
4.3. Key Switch (Optional)

Removal
1. Turn key switch OFF. Disconnect battery
connector from the truck.
3. Remove wires from switch terminals.
4. Remove key switch.
Installation
1. Install new key switch.
2. Reconnect wires to terminal.
5. Turn main ON/OFF switch to the ON position. Turn
key switch ON.
service.
4.4. Horn Switch

See tiller arm head repair section on page 137.
4.5. Converting Keypad to Key Switch

Removal
2. Using the service key (see page 176), change
parameter 39 to 1 or 2 (see page 176).
New Switch Location
5. Disconnect wires from the main ON/OFF switch.
Remove main ON/OFF switch.
6. Remove main ON/OFF switch mounting bracket
(see page 221).

S5.4 5310
Switches
Version no T-code
000 7BWS10/13
Installation
1. Install new main ON/OFF switch and key switch
mounting bracket.
2. Install original main ON/OFF switch into new
Keypad mounting bracket. Connect wires that were
Cover removed earlier to the main ON/OFF switch.
3. Install key switch in mounting bracket.
4. Remove jumper wire between wire 20 and 22 (see
page 302). Connect wires 20 and 22 to new key
switch.
Keypad
5. Remove screw from keypad. Remove keypad.
6. Install new keypad cover.
7. Remove service key.
10. Turn main ON/OFF switch to the ON position. Turn
key switch ON.
service.

S5.5 5390
Fuses
Version no T-code
000 7BWS10/13
Fuses
Fuse F50 Fuse F51
The keypad and electronic tiller arm card (ETAC) circuit FU50
fuse is 10 Amps. The main ON/OFF switch circuit fuse FU51
is 10 Amps. The fuses located on the contactor panel are as
follows:
• 10A, Fuse Keypad and ETAC, part number 00590-
42566-71 (supplied with main harness)
• 10A, Fuse Main ON/OFF, part number 00590-
42566-71 (supplied with main harness)
• 130A, Fuse (one for drive motor and one for pump
motor,) part number 00590-46786-71
2. Maintenance
Examine the fuse for signs of overheating, discoloration,
cracking, or other physical damage. Check for blown fuse
through the fuse window. If the fuse is damaged replace it. To
test a fuse, remove or isolate it from the electrical circuit. Do
this by removing the fuse from the truck or by removing all the
connections from one side of the fuse. Use an ohmmeter set
to Rx1 scale and measure the resistance across the fuse.
The resistance should be less than 1 ohm.

S5.5 5390
Fuses
Version no T-code
000 7BWS10/13
2.1. Wiring Harness
When working on the truck, use care around the wiring

harnesses.
• Do not pull on wires.
• Carefully mate and unmate all connectors.
• Do not pry apart connectors with unspecified tools.
• Examine and maintain any added materials used
to dress or protect wire. This includes spiral wrap,
brackets, cable ties, fasteners, flexible conduit, etc.
• Check harness wires for abrasions, scrapes, nicks
in wire, damage from overheating or burns, or
other general insulation damage.
• Replace terminations with exposed wire visible at
connectors. Damaged terminations, exposed
wires, or damaged connectors can cause
operational failure of truck.
There should be a wire marker at each termination. If marker
is missing or unreadable, remark wire to allow easier
identification.
NOTE! It is normal to find unused connectors for

uninstalled options that have had heat
shrink applied over them and have been
strapped to harness.

S5.5 5390
Fuses
Version no T-code
000 7BWS10/13
2.2. Power Cables
Power cables should be checked for damage including:

• Evidence of overheating
• Burned spots in cable
• Nicks in insulation
• Damaged or overheated terminal lugs
• Damaged mounting hardware or brackets

S5.5 5390
Fuses
Version no T-code
000 7BWS10/13
2.3. Master Control Relay
Wire #24 Wire #26
The master control relay should be tested regularly for proper

operation. To inspect/test master control relay proceed as
follows:
2. With battery connector connected, press green ON
3. Use a voltmeter to check the voltage between wire
#26 (terminal 2) and wire #24 (terminal 4). The
voltmeter should read approximately 24V.
4. Move tiller arm down into the operate position. The
voltmeter should now read near 0V. If not, replace
master control relay.

S5.5 5390
Fuses
Version no T-code
000 7BWS10/13
3. Troubleshooting
During troubleshooting and repairs, it is sometimes
necessary to unmate a connector, move a harness, cut a
cable tie, or remove wire from a bracket. Note carefully the
location of wire and all protective or securing attachments
before moving harness. When replacing fuses, make sure
fuses are installed in the proper position.

Repair or replace damaged cables or mounting hardware as
necessary. Power cables are marked on terminal lug with
location where they belong. If marking is missing or is not
readable, remark cable with correct information. The terminal
lugs should be crimped tightly and securely on the wire.
Replace cable if necessary. After repair, return or replace all
protective and/or securing hardware to its original condition.
Protective materials are necessary to provide reliable
performance of interconnect system. The fuses can not be
repaired or rebuilt. Replace fuses with new as necessary.

S5.5 5390
Fuses
Version no T-code
000 7BWS10/13

S5.6 5436
Contactor Panel
Version no T-code
000 7BWS10/13
Contactor Panel
1
4 24
23
4
15
2
21 22
18
19 17
20
3
15
19 16 4
25
14 15
13
12
5
11
10 8
9
7

S5.6 5436
Contactor Panel
Version no T-code
000 7BWS10/13

1 Battery connector 14 Transistor controller
2 Nut 15 Washer, flat
3 Panel 16 Solenoid, pump
4 Nut 17 Screw
5 Not Used 18 Solenoid, drive
6 Decal, 10A 19 Fuse, 130A
7 Main harness 20 Cable
8 Tie, wire 21 Screw
9 Horn 22 Lockwasher
10 Screw 23 Standoff, isolator
11 Screw 24 Stud
12 Relay 25 Screw, cap
13 Screw

S5.6 5436
Contactor Panel
Version no T-code
000 7BWS10/13
The main contactor (K10) controls battery power to the drive
motor. The lift pump contactor (K30) controls the hydraulics.
2. Maintenance
Visually inspect the contactors for any signs of burning or
physical damage.
3. Troubleshooting
3.1. Resistance Testing
2. Remove truck cover (see page 81).
3. Disconnect wires from the coil contactor.
4. Connect one coil lead of ohmmeter to the coil lead
from contactor. Connect the other lead to the lead
from the contactor.
5. The reading should be approximately 50 ohms. If
resistance is outside that range, replace contactor.

S5.6 5436
Contactor Panel
Version no T-code
000 7BWS10/13

Removal
1. Disconnect wires from the terminals on the
contactor coils.
2. Remove nuts securing the cables to the contactor,
noting the location for assembly later.
3. Remove screws holding the contactor assembly to
the electrical panel.
Main Contactor
Pump Contactor
Figure 5-8: Main Contactor K10 & Pump Contactor K30
Installation
1. Secure contactor to the electrical panel with
screws. Torque screws to 48-60 in-lbs (5 - 7 N•m).
2. Secure cable to the contactor with nuts.
3. Connect wires to the terminals.
4. Install truck cover.
6. Turn main on/off switch to the ON position. Enter
key code and press the green ON button (I) on the
keypad. Test truck for correct operation before
returning to service.

S5.7 5460
Transistor Controller
Version no T-code
000 7BWS10/13
WARNING Interchanging the transistor controller

with different truck model could cause
internal failure to the transistor
controller. The warranty will be void if
the transistor controller is interchanged
from one truck to another!
The transistor controller is programmed specifically for this

truck. It is microprocessor based and programmable
designed for separately excited motors. The transistor
controller provides smooth control of the traction (drive) motor
utilizing four distinct operating modes. An LED is built into the
transistor controller that indicates controller status.
1.1. Basics Of Circuit Operation

The transistor controller provides both armature and field
outputs. Through these outputs, it regulates the voltage and
current applied to the motor according to it’s programmed
motor control algorithm. The polarity and magnitude of the
field is controlled to provide solid state, contactor-less
direction control and plug braking.
As the transistor controller is powered up, it performs an
internal self test.
• A short between M- and Ground.
(Insures the M- output or power MOSFETs are not
shorted.)
• Continuity in the field coil.
(Occurs each time tractor-first or forks-first travel is
selected.)
Selecting either tractor-first or forks-first travel selects the
direction of current flow in the field. The voltage and current in
the armature circuit raises when the throttle increases. The
field current will then follow a predetermined current map to
match the armature current. In this manner, the motor is kept
in its optimal commutation range and arcing on the
commutator is minimized. As the throttle is increased and the

S5.7 5460
Version no T-code
000 7BWS10/13
motor speeds up, the armature voltage will approach the

battery.
Plug braking involves reversing the travel control to the
opposite direction causing the truck to decelerate smoothly.
The operator may choose to continue holding the travel
controls in the opposite direction. This will start the truck
moving in that direction or the operator may release the
handle and allow the truck to come to a complete halt. The
parking brake is automatically applied when handle is
released.
When using plug braking the operator may regulate (within
the programmed capabilities) the degree of the plugging
force and distance travelled during plugging. For the lightest
plugging force, and the longest distance, the travel control
should be operated to slow speed in the opposite direction.
For the strongest plugging power, and the shortest distance,
the travel control should be operated to full speed in the
opposite direction.
1.2. Interface
The direction control section of the transistor controller
controls the drive motor direction by manipulating the drive
motor field polarity according to the directional signal inputs
from the Electronic Tiller Arm Card (ETAC).
The thumb control section of the transistor controller controls
the drive motor speed and torque by monitoring the position
change of the arm angle A and arm angle B switches.
Variable motor speed is accomplished by separate control of
field and armature currents.
The reverser circuitry in the ETAC provides the reverse travel
control command to the transistor controller.
The control circuit section of the transistor controller controls
all truck inputs and outputs (excluding tiller arm head inputs).
The ETAC controls the transistor controller.

S5.7 5460
Version no T-code
000 7BWS10/13
1.3. Control Features

• Reversing without the use of direction contactors permitted
with full bridge control of motor field.
• Controlled and limited truck speed at top end through
separate field and armature control.
• Fully protected inputs and outputs.
• Active power on self test and continuous diagnostics during
operation.
• Internal watchdog circuits ensure proper software
operation.
1.4. Motor Circuit
Control
wire plug
16-pins
B- B+ M-
S1
S2

S5.7 5460
Version no T-code
000 7BWS10/13
The transistor controller has three terminals for the high

current circuits B-, M-, and B+. Two quick connect terminals
are provided for the field winding connections S1 and S2.
Terminal Connecting
B- Negative connection to battery
B+ Overcurrent protected and K10 switched
positive connection to the battery and motor
armature
M- Motor armature
S1 Motor field F1
S2 Motor field F2
1.5. Control Circuit

The transistor controller has an integrated 16-pin connector
to provide the low power logic control connections. The
designation of the pins are according to the following table.

S5.7 5460
Version no T-code
000 7BWS10/13
Pin number 1 is located in the back row right side when

viewing the logic connector.
Pin No Connecting
P1 CAN High
P2 OUT Load-Hold Valve
P3 OUT Alarm
P4 Out Main Contactor
P5 IN/OUT Brake
P6 OUT Pump Contactor
P7 Not Used
P8 CAN Low
P9 OUT Proportional Lowering Valve
P10 OUT Horn
P11 Not Used
P12 IN Arm Angle A
P13 Not Used
P14 IN Arm Angle B
P16 IN +24 VDC
1.6. Definitions
Overtemperature. Overtemperature of the transistor
controller is from 185 degrees F (85 degrees C) and above.
Overheating is unusual, but can occur if the transistor
controller is installed incorrectly or overloaded. At
overtemperature the drive current limit is linearly decreased
from full set current down to zero. Plug current is not reduced
by any thermal conditions to allow full plugging strength at all
times.
Undertemperature. When the transistor controller is
operating at less than −13 degrees F (−25 degrees C), the
current limit is cut back resulting in reduced travel speed and
acceleration.
Pulse Width Modulation. Pulse Width Modulation (PWM),
also called “chopping,” controls the speed of the motor by
switching the battery voltage to the motor on and off very
quickly.

S5.7 5460
Version no T-code
000 7BWS10/13
Thermal Cutback. Thermal cutback of the transistor

controller is below -13 degrees F (-25 degrees C) or above
185 to 203 degrees F (85 to 95 degrees C), the PWM drive
current limit is linearly decreased from full set current down to
zero. At -13 to -40 degrees F (-25 to -40 degrees C), the
current limit is reduced to approximately half the set current,
resulting in reduced travel speed. Below -40 degrees F (-40
degrees C) or above 203 degrees F (95 degrees C), the
allowed PWM is zero percent.
2. Maintenance
There are no serviceable parts inside the transistor controller.
No attempt should be made to open the transistor controller.
OPENING THE TRANSISTOR CONTROLLER WILL VOID
THE WARRANTY!
2.1. Safety
WARNING Because there is a risk of short circuits,

remove all watches and jewelry; always use
insulated tools.
The transistor controller is essentially a high-power device.

When working around any battery powered vehicle, proper
safety precautions should be taken. These include, but are
not limited to the following: proper training, wearing eye
protection, avoiding loose clothing, removing watches and
jewelry, and using insulated tools.
2.2. Cleaning
The supplier recommends that the transistor controller
exterior be cleaned periodically with an approved and
regulated air supply (blower). Although the transistor
controller virtually requires no maintenance if properly
installed, the following is recommended on a regular basis of
500 hours.
1. Remove power by disconnecting the battery at the
battery connector.
2. Discharge capacitors in the transistor controller by
connecting a load (such as a contactor coil or horn)
across the transistor controller’s B+ and B-

S5.7 5460
Version no T-code
000 7BWS10/13
terminals before doing any work on the transistor

controller.
3. Remove dirt or corrosion from the bus bar area.
The transistor controller should be wiped clean
with a moist rag. Allow to dry before reconnecting
the battery.
4. Make sure the connections to the bus bars are
tight. Use two well insulated wrenches for this task
in order to avoid stressing the bus bars.
3. Troubleshooting
3.1. Diagnostics and Troubleshooting
The transistor controller provides diagnostic information to
assist technicians in troubleshooting drive system problems.
The information can also be obtained by looking at the status
LED built in the transistor controller that is visible through the
window label.
3.2. Fault Codes
Transistor
Controller
J5 Connector
An internal microcontroller automatically checks the function

of the transistor controller. When this microcontroller detects
a fault, it signals the appropriate fault code through the
diagnostic LED on the bottom of the transistor controller.
These are not the codes that appear on the tiller arm display.
Under normal operation, the LED flashes a single flash at
approximately one flash per second. A two-digit flash code
signals the transistor controller has detected an electrical
system fault.

S5.7 5460
Version no T-code
000 7BWS10/13
Error Program Fault

Probable Cause Explanation
Code LCD Display Category
0,1 No known faults 0 N/A N/A
1. Abnormal truck operation causing high
Cycle Key Switch Input
current spikes.
1, 1 Current shunt 1 (KSI). If problem persists,
2. Current sensor error.
replace controller.
3. Controller defective
1. Noisy environment.
Hardware Cycle KSI. If problem
1, 2 1 2. Self-test or watchdog fault.
failsafe persists, replace controller.
3. Controller defective.
1. Internal or external short of M- or B-. Check wiring; cycle KSI. If
1, 3 M- shorted 1 2. Incorrect motor wiring. problem persists, replace
3. Controller defective. controller.
1. Improper sequence of KSI, interlock,
and Direction inputs.
Follow proper sequence;
2. Direction switch circuit open.
adjust throttle if necessary;
1, 4 SRO 3 3. Sequencing delay too short.
adjust programmable
4. Wrong SRO type or throttle type
parameters if necessary.
selected.
5. Misadjust throttle pot.
1. Improper sequence of KSI, interlock,
and throttle inputs.
2. Interlock switch open. Follow proper sequence;
2, 3 HPD 3 3. Sequencing delay too short. adjust programmable
4. Wrong HPD type or throttle type parameters if necessary.
selected.
5. Misadjust throttle pot.
1. Main contactor coil shorted.
CONT COIL/ Check contactor coil and
3, 1 1 2. Field winding shorted to B+ or B-.
FLD Short field winding; cycle KSI.
3. Field resistance too low.
Main CONT 1. Main contactor stuck closed. Check contactor condition;
3, 2 1
Welded 2. Main contactor driver shorted. cycle KSI.
1. Field winding connection open.
3, 3 Field Open 1 Check wiring and cycle KSI.
2. Field winding open.
1. Main contactor coil open.
Missing
3, 4 1 2. Main contactor missing. Check wiring and cycle KSI.
contactor
3. Wire to main contactor open.
1. Battery voltage < undervoltage cutback.
Low battery When voltage rises above
4, 1 2 2. Corroded battery terminal.
voltage undervoltage cutoff point.
3. Loose battery or controller terminal.
1. Battery voltage > overvoltage shutdown
When voltage falls below
4, 2 Overvoltage 2 limit.
overvoltage cutoff point.
2. Truck operating with charger attached.
1. Temperature >85°C (185°F)or < -25°C
(-13°F). Clears when heatsink
4, 3 Thermal cutback 2 2. Excessive load on truck. temperature returns within
3. Improper mounting of controller. acceptable range.
4. Operation in extreme environment.

S5.7 5460
Version no T-code
000 7BWS10/13
Error Program Fault

Probable Cause Explanation
Code LCD Display Category
1. Mode switches shorted to B+.
4,4 Anti-Tiedown 3 2. Mode switch “tied down” to select Release Model Select 1.
Model 1 permanently

There are no serviceable parts inside the transistor controller.
No attempt should be made to open the transistor controller.
OPENING THE TRANSISTOR CONTROLLER WILL VOID
THE WARRANTY! Replace transistor controller with new as
necessary.

S5.7 5460
Version no T-code
000 7BWS10/13

S5.8 5700
Electronic Tiller Arm Card (ETAC)
Version no T-code
000 7BWS10/13

Lift/Lower
Button Reverser
Button
Horn Electronic
Button Tiller Arm
Right Card (ETAC)
Button
Cover
Horn Display
Button Housing
Left
Horn Button/
Switch
Speed
Control
Tiller Keypad
Arm Handle

S5.8 5700
Version no T-code
000 7BWS10/13
The programmable motor control functions are performed by
the ETAC housed within the tiller arm. The ETAC controls the
transistor controller. The basic function of the ETAC include
the following:
• Monitor relative positioning of the thumb controls to 18
hall effect sensors for speed and direction control.
• Monitor position of reverser button for reversing of the
truck direction.
• Monitor truck performance and provide input data and
commands to the service display.
• Provide lift/lower input commands to the transistor
controller.
• Monitor horn switches S18-1 and S18-2 for horn
operation.
• Monitor and define truck performance parameters.
• Fully compatible for programming, diagnostic and test
information.
• Armature current controlled at all times, reducing
arcing and brush wear.
• Automatic neutral braking: adjustable plugging force.
• Truck acceleration and response controlled through
programmable parameters.
• Linear temperature cutback on motor current limit. No
sudden loss of power under thermal conditions.
• Interlock features ensure proper start-up sequence.
• Integral fault LED provides a “transistor controller
operating properly” signal and flashes error code
information when a fault occurs.
• Provide battery discharge status to display.

S5.8 5700
Version no T-code
000 7BWS10/13
1.1. Lift Cutout.

This truck is equipped with lift-cutout preventing lifting once
the battery has been discharged 80 percent. The Battery
Discharge Indicator (BDI) is located on the ETAC and is non-
serviceable by itself. It is important that Parameter 21 (see
page 182) be set correctly to insure no greater than 80
percent discharge of the battery.
A battery discharged 80 percent should have an acid
concentration of approximately 1.14 SG. a fully charged
battery should have an acid concentration of approximately
1.27-1.29 SG. The BDI resets at 25.2 volts.
2. Maintenance
3. Troubleshooting
See “Error Codes (E)” on page 183.

A bad ETAC must be replaced with a new card.
CAUTION To avoid risk of static discharge that can

damage the electronics, make sure to take
the necessary precautions before working
with electronics (see page 25).
To replace the ETAC see page 137.

S5.8 5700
Version no T-code
000 7BWS10/13

S6.0 6000
Hydraulic System
Version no T-code
000 7BWS10/13
Hydraulic System
Components of Hydraulic System
The hydraulic system consists of a compact hydraulic unit,
including a lowering proportional valve, load-hold valve,
pressure relief valve and a cylinder for lifting the forks.

S6.0 6000
Hydraulic System
Version no T-code
000 7BWS10/13
1.1. Lift
When the lift button is pushed, the lift pump contactor is
energized starting the pump and motor. Fluid is drawn from
the reservoir, through a pick up screen to the inlet of the gear
pump. As the gear pump rotates, oil is forced out the pressure
port and is blocked from returning to the reservoir by a closed
proportional lowering valve and pressure relief valve. Oil
continues to flow to the top of the lift cylinder and pushes
against the end of the cylinder rod to extend the rod from the
cylinder tube. When the lift pump motor is shut off and the
gear pump is not turning, the cylinder is held extended by a
closed check ball in the load-hold valve.
Pressure
Return
Supply

S6.0 6000
Hydraulic System
Version no T-code
000 7BWS10/13
1.2. Lower
Hydraulic fluid is retained in the hydraulic cylinder by a check
ball in the load-hold valve. When the solenoid on the load-
hold valve and proportional lowering valve is energized, oil
passage from the cylinder to reservoir is opened. Due to the
load on the lift cylinder, fluid is forced out of the lift cylinder
and back to the reservoir while the lift cylinder is lowering.
Lowering speed is regulated by a flow regulator inside the
bottom of the lift cylinder and the proportional lowering valve.
This process allows the truck to lower.
Pressure
Return
Supply

S6.0 6000
Hydraulic System
Version no T-code
000 7BWS10/13
1.3. Relief Pressure

When hydraulic flow pressure exceeds 3100 psi (213 bar),
the relief valve opens allowing fluid to return to the tank.
NOTE! If the pump continues to run with no

request, being given and the relief valve is
open, an error code E118 (see page 190)
will be displayed and the transistor
controller will terminate the negative output
at J5-4 turning off the pump motor.
Pressure
Return
Supply

S6.0 6000
Hydraulic System
Version no T-code
000 7BWS10/13
2. Maintenance
To prolong the life of the truck, keep all fittings and
connections tight to prevent leaks. To avoid damage or
distortion, do not over-tighten brass fittings. Before removing
any component from the hydraulic system, wash the
component and surrounding area with cleaning solution to
prevent foreign matter from entering the system. Cap and
plug all openings immediately. Whenever removing fitting
with a pipe thread, use a sealing compound on the
outside of threads before reinstalling. (Do not use
Teflon® tape.) Make sure all parts are clean. When installing
a hose assembly, make sure that it is not twisted when fittings
are tightened. Always use two wrenches on a swivel-type
fitting, one to hold the fitting and the other to tighten the hose.
2.1. Changing Hydraulic System Fluid

Hydraulic fluid level must be checked periodically (see
“Planned Maintenance Schedule” on page 61). If the
reservoir regularly requires additional oil to maintain proper
level, a leak is indicated and must be repaired. When
scheduled, the reservoir should be removed and drained for
cleaning and replaced with new oil. After refilling, check lift,
lower and other hydraulic functions for proper operation. If the
truck will not lift a full load, the pressure relief setting should
be checked and adjusted. During normal operation, pressure
relief setting will not change. As the lift pump wears with age,
some loss of performance will be experienced. When this loss
becomes severe, the lift pump should be replaced.
WARNING Fluid is under pressure and may spray or

splash. Point hose away from your body
and hold firmly in waste fluid container.
NOTE! Be sure truck is in a clean area, away from

possible contaminating elements that could
enter the hydraulic system during the
changing process.
Contaminated hydraulic fluid is the major cause of
hydraulic system failures. Keep any service equipment,
such as containers, funnels, and hand pumps clean at all
times by covering when not in use.

S6.0 6000
Hydraulic System
Version no T-code
000 7BWS10/13
1. Lower forks.
5. Disconnect lift cylinder hose at the hydraulic
cylinder.
NOTE! Wear protection eye and face gear when

Lift Cylinder Hose draining oil.
6. Insert hose in a waste fluid container.

on the keypad.
9. Run hydraulic pump by pressing the lift button until
all hydraulic fluid is pumped from the system.
12. Reconnect lift cylinder hose.
13. Remove fill plug and fill reservoir to the oil fill line
with recommended fluid (see page 72). The usable
reservoir capacity is 1.3 gallons (5 liters).
17. Raise and lower forks several times to purge air
from the system.
18. Properly dispose of waste fluid.

S6.0 6000
Hydraulic System
Version no T-code
000 7BWS10/13
2.2. Hydraulic Pump Pressure Relief Valve

The hydraulic system is protected by a relief valve installed in
the adapter body. The relief valve is set by the supplier to
open at specific pressure (3100 psi [213 bar]). There is no
need to ever adjust the relief valve on this truck.
3. Troubleshooting
NOTE! Proper care and cleanliness should be
observed in servicing to insure oil does not
become contaminated with dirt or other
foreign material. Contaminants can be
drawn into pump so as to stick or score
pump which will cause failure of pump
assembly.
If the hydraulic pump assembly does not operate properly,

the following preliminary checks should be made:
1. Proper oil level
2. All electrical connections tight
3. Battery fully charged
When checking voltage at contactors, make sure hydraulic
lines and components are fully installed.
When possible, keep the main ON/OFF switch OFF and
battery connector disconnected.
After the preliminary check is accomplished, install a 0-5000
psi (0-34473 kPa) pressure gauge in between the adapter in
the manifold and hydraulic hose. The installation of a
pressure gauge is required to insure proper observation of
what is occurring in the unit during trouble shooting. Start
pump and raise lift cylinder to its upper limit stops to develop
maximum pressure of the unit, which will normally be passing
all flow over a relief valve. Pressure gauge should be reading
the set pressure of the relief valve. Remove pressure on
hydraulic system by actuating the solenoid operated lowering
valve.
Different hydraulic and electrical sources may be causing
improper operation. Refer to the following troubleshooting
chart.

S6.0 6000
Hydraulic System
Version no T-code
000 7BWS10/13
3.1. Troubleshooting Chart Index

1. No lift, lift motor does not run, travel is okay.
2. No lift or slow lift, lift motor does run.
3. No lower, lift and travel okay.
4. Unable to pick up a load.
5. Slow lower.
6. Load drifting/settling.
3.2. Troubleshooting Charts
The following troubleshooting charts describe a course of
testing and repair for each problem listed. If the given test is
NOT successful, perform the repair listed with the test. If the
given test IS successful, go to the next test or follow the
special instructions given. For electrical legend see
page 304.
1. No lift, lift motor does not run, travel is okay.

Bad ETAC (A2) With main ON/OFF switch in the ON position, the pin key code entered
in the keypad, the green ON (I) button pressed on the keypad, and the
lift switch depressed, does main contactor (K10) and pump contactor
(K30) energize (click)? If not, check “Service Display” on page 171. If
no signal is detected, check mechanical problems in the tiller arm head.
Replace electronic tiller arm card ETAC (A2) as a last alternative in
resolving problem.
Bad lift pump contactor With main ON/OFF switch in the ON position, the pin key code entered
lift switch depressed, does main contactor (K10) and pump contactor
(K30) energize (click)? If not, measure voltage between pump contactor
coil terminals. If B+ voltage is present, replace the pump contactor.
Bad wiring continuity or wiring When main ON/OFF switch OFF and battery connector disconnected,
shorts check for continuity and wiring shorts in wiring harness or cables.
Bad lift pump motor brushes With main ON/OFF switch in the ON position, the pin key code entered
lift switch depressed, does pump contactor (K30) energize (click)? If
yes, measure voltage between B- and lift pump motor terminal. If okay,
check lift motor brushes (see page 92).
Bad lift pump motor If lift motor brushes are okay, test pump motor.
Bad pump If motor is okay, remove motor from the pump and rotate pump shaft by
hand. Replace pump if not okay.

S6.0 6000
Hydraulic System
Version no T-code
000 7BWS10/13
2. No lift or slow lift, lift motor does run.

Battery problems Replace battery with fully-charged battery.
Mechanical binding in lift Repair lift mechanism.
mechanism
Low hydraulic pressure Check hydraulic pressure setting and adjust if necessary (see
page 259).
Relief valve contaminated or When main ON/OFF switch OFF, and battery connector disconnected,
bad. (Unable to get the remove pressure relief valve and check for damage or contamination.
correct hydraulic pressure) Replace valve or flush system and replace the hydraulic fluid (see
page 257).
Bad lift pump motor or Check lift motor brushes (see page 92). If brushes are okay, replace lift
brushes pump.
Contamination found in pump Flush system and replace hydraulic fluid (see page 257).
Bad pump If motor is okay, remove motor from the pump and rotate pump shaft by
hand. Replace pump if necessary.
3. No lower, lift and travel okay.

Load-hold or proportional With main ON/OFF switch in the ON position, cycle the lower switch.
lowering valve Does both solenoid valves energize (click)? If yes, disconnect the
battery connector, then slowly loosen, but DO NOT REMOVE the
hydraulic line at the hydraulic pump assembly. Have drain pan and rags
ready and allow the forks to slowly lower.
If forks do not lower, check for Replace lift cylinder or repair lift mechanism.
mechanical binding in lift
cylinder or fork mechanism
If forks lower, remove and Inspect for free movement and signs of contamination. Clean solenoid
inspect load-hold and valve or flush system, clean filter and replace hydraulic fluid. If not
proportional lowering valve contamination is found, repair or replace load-hold and/or proportional
lowering valve or pump assembly.
Check for bad ETAC (A2) With main ON/OFF switch in the ON position, the pin key code entered
lower button depressed, check “Service Display” on page 171. If no
signal is detected, check mechanical problems in the tiller arm head.
Replace ETAC (A2) as a last alternative in resolving problem.

S6.0 6000
Hydraulic System
Version no T-code
000 7BWS10/13
4. Unable to pick up load.

Load too large for lift truck Check load weight. Check lift pressure setting.
capacity
Battery problems Replace battery with fully-charged battery.
Incorrect lift pressure Check and adjust lift pressure setting.
adjustment
Contaminated or bad Check for contamination in hydraulic fluid. If contamination is present,
pressure relief valve flush, fill and bleed the hydraulic system and clean relief valve. If no
contamination is found, replace relief valve.
Bad lift pump Replace lift pump (see page 268).
Bad lift motor Replace lift motor (see page 88).
5. Slow Lower.

Bad proportional lowering Repair or replace valve or wiring.
valve or wiring
Plugged or malfunctioning Check for contamination in hydraulic fluid. If contamination is present,
flow hydraulic proportional flush, fill and bleed hydraulic system and clean valve. If no
lowering valve contamination is found, replace flow control valve.
Contamination in proportional Inspect solenoid for contamination or binding.
lowering solenoid valve
Mechanical binding in lift Adjust or replace mechanism.
mechanism
NOTE: If pump hits relief and lower is attempted, lowering will be slow. Release lower button
momentarily, then continue to lower. Normal lower speed should resume.
6. Load Drifting/Settling.

Incorrect lift pressure adjust Check and adjust lift pressure setting (see page 259).
Contamination or bad check Check for contamination in hydraulic fluid. If contamination is present,
valve flush, fill and bleed hydraulic system and clean check valve. If no
contamination is found, replace check valve.
Leaking or contaminated Check for contamination in hydraulic fluid. If contamination is present,
hydraulic load-hold valve flush, fill and bleed hydraulic system and clean load-hold valve. If no
contamination is found, replace load-hold valve.
Load too large for lift truck Check load weight. Check lift pressure setting.
capacity

S6.0 6000
Hydraulic System
Version no T-code
000 7BWS10/13

The lift motor solenoid, hydraulic reservoir, lowering valve,
adapter body and lift pump can be repaired or rebuilt.
Replace items as necessary.
2
No motor mounting
screw is used in
3 1
this position.
4
5
43
44 12
45 11
10
9
43 8
7
13 6
14
42 15
41
40 16
39 17 21
18
38 22
19
23
37
20
24
25
26
35
29
36 27
34
33 28
32 30
31

S6.0 6000
Hydraulic System
Version no T-code
000 7BWS10/13

1 Pump and motor assembly 25K Stud, M8
2 Pump motor assembly 26K Pump
3 Screw 27K Lockwasher
4 Lockwasher 28K Nut
5 Kit, relief Valve 29K O Ring
6 Seat assembly 30Q Tube, inlet
7 Plunger 31Q Strainer
8 Spring 32 Magnet
9 O Ring 33K Ring, star
10 Screw, adjustment 34 Reservoir
11 Gasket 35 Clamp, hose
12 Cap 36 Plug
13K Coupler 37 Screw
14 Adapter 38 Retainer
15 Breather 39 O Ring
16K O Ring 40 Valve, check
17Q O Ring 41 Plug
18Q Ring, retainer 42 Valve, 2pos/2way
19Q Spacer 43 Coil
20Q Tube, return 44 Fitting
21Q O Ring 45 Valve, proportional flow control
22Q Ring, retainer K Kit, pump (items marked with “K”)
23Q Washer Q Kit, tube (items marked with “Q”)
24Q Tube, return

S6.0 6000
Hydraulic System
Version no T-code
000 7BWS10/13
WARNING DO NOT use your hands to check for

hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing injury. Relieve
pressure before disconnecting hydraulic or
other lines. Tighten all connections before
applying pressure. Keep hands and body
away from pinholes and nozzles which
eject fluids under high pressure.
Pump Motor NOTE! Call-outs in the following procedure refer to

Load-Hold and
4.1. Hydraulic Unit
Proportional Valve
Removal
1. Lower forks to the floor.
Adapter Body
(Pump)
Fill
Plug
Hydraulic
Reservoir 5. Remove battery from the truck.
6. Remove and tag all wires and cables connected to
the pump motor (2).
7. Remove and cap hydraulic line from the hydraulic
unit. Disconnect contactor control wires.
8. Remove bolts attaching hydraulic unit mounting
Y11
bracket to truck.
Load-Hold Valve 9. Remove hydraulic unit from truck.
Y10
Proportional Valve

S6.0 6000
Hydraulic System
Version no T-code
000 7BWS10/13
Installation
1. Install hydraulic unit on the truck.
2. Install hydraulic line on hydraulic unit.
3. Fill reservoir with specified fluid (see page 72). Use
a funnel with a flexible neck. Fill reservoir to oil fill
line. Capacity is 1.3 gallons (5 liters).
4. Install fill plug.
5. Connect wires and cables to pump motor.
6. Install battery.
button (I) on the keypad
9. Raise and lower forks. Check hoses and fittings for
leaks.
10. Check hydraulic fluid level in the reservoir (see
page 257).
4.2. Reservoir
Removal
1. Remove hydraulic unit from truck (see page 265).
2. Remove hose clamp securing hydraulic reservoir to
the adapter (14) housing.
3. Tap reservoir (34) lightly to loosen. Wiggle reservoir
sideways while pulling up on the pump and motor at
the same time to remove.
4. Remove reservoir (34) and properly dispose of old
hydraulic fluid.
5. After fluid has drained, flush the inside of the
reservoir with a suitable cleaning solution.
6. Dry the inside of the reservoir with clean, dry
compressed air.

S6.0 6000
Hydraulic System
Version no T-code
000 7BWS10/13
Inspection
1. Inspect the reservoir O ring and inside leading
edge for defects. Replace if necessary.
Installation
1. Lubricate O ring with hydraulic fluid. Install O ring.
2. Carefully install reservoir on adapter (14) housing
and attach with hose clamp. Torque clamp to 48 -
60 in-lbs (5.5 - 7 N•m).
3. Install hydraulic unit on truck (see page 266).
4.3. Filter Screen and Inlet Tube

Removal
1. Remove reservoir (see page 266).
2. With pump assembly inverted, unthread and
Filter Screen remove inlet tube fitting and sealing washer from
pump housing.
3. Clean filter screen at the bottom of the inlet tube
with a suitable cleaning solution.
Inspection
Inlet Tube
1. Inspect filter screen and inlet tube for defects.
Replace if necessary.
Installation
1. Install inlet tube in the pump housing.
2. Install hydraulic reservoir to the adapter. Torque
clamp to 48-60 in-lbs (5.5-7 N•m).

S6.0 6000
Hydraulic System
Version no T-code
000 7BWS10/13
4.4. Lift Pump

Removal
1. Remove hydraulic unit from truck (see page 265)
and put on a clean bench for disassembly.
2. Remove reservoir to gain access to pump (see
page 266).
3. Remove inlet tube with filter screen from pump
housing (see page 267).
4. Remove pump mounting bolts. Remove pump from
adapter (14) body.
Installation
1. Stand motor assembly on end, with adapter (14)
body facing up.
2. Lubricate O ring and install on adapter (14) body
facing up.
3. Insert pump drive coupling on the end of the motor
armature shaft and fill the cavity with lubricant.
4. Align splines on the motor drive and pump shaft.
Gently push pump pilot on the adapter (14).
5. Secure pump with mounting bolts and torque to 100
- 134 in-lbs (11.3 - 15.0 N•m).
6. Install hydraulic reservoir (see page 267).

S6.1 6420
Lift Cylinder
Version no T-code
000 7BWS10/13
Lift Cylinder

1 Cylinder assembly 3 Bleeder
2 Kit, seal 4 Valve

S6.1 6420
Lift Cylinder
Version no T-code
000 7BWS10/13
The lift cylinders are the piston type, meaning there are seals
at the bottom of the cylinder rod.
2. Maintenance
Inspect cylinder for leakage.
2.1. Inspection

psi (207 kPa).
NOTE! CLEANLINESS! Perform procedures in a

cleaned before disassembly and kept clean
during assembly.

1. Park truck on a level surface and apply the brake.
3. Fully extend the cylinder to inspect for gouges or
pits. If gouges or pits are detected, replace
cylinder.
4. Inspect hydraulic hose and replace if worn.
3. Troubleshooting
Check cylinder for leakage.

S6.1 6420
Lift Cylinder
Version no T-code
000 7BWS10/13

If the cylinder contains gouges or pits it can not be repaired.
DANGER HOT OIL under pressure may be present.

Be certain truck is safely blocked and
pressure is released. Some spillage of
hydraulic oil may occur.

psi (207 kPa).
Outer
Column NOTE! CLEANLINESS! Perform procedures in a
Inner cleaned before disassembly and kept clean
Column during assembly.

Removal
1. Park the truck on a level surface and apply the
brake. Block wheels to prevent truck from moving.
2. Raise the fork carriage sufficient enough to place a
block under the assembly.
Lift 3. Press red OFF button (O) on the keypad. Depress
Cylinders main ON/OFF switch to the OFF position.
5. Lower the fork carriage onto the block using the
manual hydraulic control lever. The assembly will
rest on the block with slack on the lift chain.
6. Remove forks.
7. Remove the lift chain by first removing the cotter
pin then the chain pin and washer.
8. Remove the adjustable guide screws and nuts
Blocked Fork
from the inner mast cross tie.
Carriage

S6.1 6420
Lift Cylinder
Version no T-code
000 7BWS10/13
9. Plug in the battery and power truck ON. Engage

the lowering button to lower the hydraulic cylinder
further. Disconnect the battery from the truck.Slide
the chain mast yoke out of the mast cross tie.
10. Disconnect the hydraulic hose from the base of the
hydraulic cylinder. Place a shallow receptacle
under the cylinder to catch any spillage of hydraulic
Chain Pin
and Washer oil that may occur.
Adjustable
Guide Screw 11. Remove the bolts from the upper cylinder bracket.
12. Remove the hydraulic cylinder from the truck.
Installation
Chain mast 1. Install the hydraulic cylinder into the truck frame.
Yoke
2. Attach the upper cylinder bracket using the bolts
previously removed.
Upper Cylinder 3. Slide the chain yoke into the inner mast cross tie
Bracket
bracket, making sure the rubber washer is in place
inside the bracket.
4. Install the adjustable guide screws and jam nuts.
5. Reattach the hydraulic hose to the base of the
cylinder.
6. Attach the lift chain to the chain pin and secure with
a new cotter pin.
7. Remove blocks from wheels.
9. Remove block from under the fork carriage.
NOTE! DO NOT use your hands to check for

hydraulic leakage. Use a piece of
cardboard or paper to search for leaks.
Escaping fluid under pressure can
penetrate the skin causing an injury.
Relieve pressure before disconnecting
hydraulic or other lines. Tighten all
connections before applying pressure.
Keep hands and body away from pinholes
and nozzles when eject fluids under high
pressure.

S6.1 6420
Lift Cylinder
Version no T-code
000 7BWS10/13

on the keypad.
11. Test operation of cylinder and look for leakage
around fitting and cylinder rod.

S6.1 6420
Lift Cylinder
Version no T-code
000 7BWS10/13

S7.0 7110
Mast
Version no. T-code
000 7BWS10/13
Mast
The mast, and associated components, provide the lifting
function in the trucks. These components consist of the mast
columns, lift cylinders, lift chains, chain rollers, and carriage
assembly. The hydraulic system provides the necessary force
and controls to do the work. When lifting, the lift cylinders
extend as hydraulic pressure and volume is applied.
On a two stage, low-freelift mast, the lift cylinder extends and
starts raising the carriage and forks till the forks are about 5.9
inch (150 mm) from the floor without the inner column raising.
As the forks pass 5.9 inch (150 mm) of lift, the inner column
starts to extend up out of the outer column. The forks
continue to rise up until they reach the design maximum fork
height of the mast.
On a two stage, full-freelift mast, when the freelift cylinder has
fully extended, the staging cylinder will begin to extend. The
staging cylinder, working in parallel, pushing the inner column
up. Lifting stops when no more volume of hydraulic fluid is put
into the lift cylinder, either by stopping the pump or by
extending the lift cylinders to their maximum height. Refer to
the hydraulic section (page 265) for further information.
2. Maintenance
2.1. Visual Inspection
Visually inspect the mast columns for abnormal wear (3/32
inch [2.38 mm] mast column flange wear) in the bearing
contact area. Inspect column assemblies and weldments for
cracks.
2.2. Lift Chain Inspection

Unsatisfactory chain performance can be traced directly to
inadequate maintenance. Highly stressed precision chains
require periodic maintenance to deliver maximum service life.
The chain system on the mast was designed for efficient,
reliable transmission of lifting force from the hydraulic cylinder

S7.0 7110
Mast
Version no. T-code
000 7BWS10/13
to the forks. Safe, uninterrupted use of the truck depends on

proper care and maintenance of lift chains.
Lift chains are very important components of the truck. Lift
chains should be inspected and lubricated (see page 61).
When operating in unfamiliar corrosive environment, inspect
chains every 50 hours.
When performing inspection, observe the following chain
conditions: chain wear; rust and corrosion; cracked plates;
protruding or turned pins; and chain side wear.
Chain Wear
See “Planned Maintenance Schedule” on page 61. As the
chain flexes on and off the sheaves, the joints gradually wear.
The “stretch” a chain develops in service is due to material
Chain
Wear being worn off the pin on the outside diameter and the pitch
Scale hole inside diameter on the inside plates.
Chain wear can be measured by using a wear gauge or a
steel tape. Discard chains when elognated three percent.
(For example, one foot of chain contains 16 pitches (links).
When 16 pitches measures 12-3/8 inches (314 mm), replace
chains.) When checking chain wear, measure a segment of
chain that operates over a sheave.
NOTE! Do not repair chains by cutting out the worn

section and splicing in a new piece.
New Chain Stretched
Chain Rust and Corrosion
Lift chains are highly stressed precision components. It is
very important that maintenance is performed throughout the
chain service life. Corrosion will cause a major reduction in
the load-carrying capacity of the lift chain, because corrosion
causes sideplate cracking. It is extremely important to protect
the lift chain from corrosion, whether in service or in storage.
NOTE! Do not steam clean or degrease new lift

chains.
Lift chain lubricant serves both as a joint lubricant and
corrosion inhibitor. During inspection, carefully examine the
external lift chain surfaces for the presence of an oily film.
Under severe operating conditions, oil lift chains every 250
hours and more frequent under adverse conditions.

S7.0 7110
Mast
Version no. T-code
000 7BWS10/13
NOTE! In all cases, the external surface of the lift

chains must be protected with a film of oil.
Outside plates are susceptible to stress-corrosion cracking. If
lift chains are heavily rusted or corroded, remove them from
the mast to thoroughly inspect for cracked plates. Replace all
lift chains on the truck if the plates are cracked. Lubricate the
Stress-corrosion Cracking chains when reinstalled on the truck.
Cracked Plates
Fatigue failure is the most common cause of plate cracking.
After many repeated heavy loads (load’s higher than the
truck’s capacity), plates may crack causing the chains to
eventually break. Fatigue cracks are almost always found
through the pitch holes perpendicular to the pitch line. If
cracks are present, replace all lift chains on truck.
Ultimate Strength Failure

This type of failure is caused by overload
in excess of the truck design load.
Broken Plate Caused by Overload
All joints in lift chain should flex freely. Tight joints resist
flexure, increase internal friction. This accelerates wear and
fatigue problems. In lift chains, tight joints are usually caused
by rust. Replace chains if rusty.

S7.0 7110
Mast
Version no. T-code
000 7BWS10/13
Tight joints prevent proper flexing of roller chain
Bent or peened plates on lift chains can

cause tight joints and prevent flexing.
Tight joints in lift chains may also be caused by the following:

• Bent pins or plates
• Rusty joints
• Peened plate edges
• Oily rusty chains with bent or peened components
Peening of plate’s edges may be caused by worn sheaves,
unusually heavy loads or chain sliding past a guide in the
mast.
Protruding or Turned Pins

Heavily loaded chains operating with too little lubrication
causes wear between the pin and plates. In some extreme
cases, the torque in the joint can turn pins in the press-fit
outside plate.
If the chain is allowed to operate in this condition, pins slowly
work out of the chain, causing chain failure. Turned pins can
be quickly spotted because the flats on the “V” head are no
longer in line.

S7.0 7110
Mast
Version no. T-code
000 7BWS10/13
NOTE! Chains with turned or with protruding pins

should be replaced. Do not attempt to
repair chain by driving pins back into chain.
Protruding
Turned Pins
Out-of-line flats on “V” heads indicate that pins have turned in

place.
Chain Side Wear

A wear pattern on pin heads and outside plates indicates
misalignment. This condition damages chain and sheaves as
well as increasing internal wear in the chain system.
Chain Anchors and Sheaves

See “Planned Maintenance Schedule” on page 61. An
inspection of the chain system includes a close look at chain
anchors and sheaves. Check chain anchors for wear,
breakage, and misalignment. Anchors with worn, cracked or
broken fingers should be replaced. Anchors should be
adjusted to eliminate twisting or misalignment in chain. When
chain is misaligned, load is not spread uniformly between
plates. Prolonged operation will result in premature failure.
Worn or seized sheaves should be replaced. Heavy flange
wear indicates chain misalignment.

S7.0 7110
Mast
Version no. T-code
000 7BWS10/13
2.3. Lift Chain Lubrication

Lubrication of lift chain in field maintenance is a very
important duty. Lift chains must be lubricated for acceptable
service life. Specially “chain lubes” are recommended. Heavy
motor oil (40 weight) may also be used. Lubricate the entire
length of all lift chains. For lubricant specification, see
page 72. For service schedule, see page 61.
The oil must penetrate the chain joint. Applying oil to the
external surface will reduce rust, but oil must flow into the live
bearing surface for maximum wear life.
Lubricate
Lubricate
Apply oil to chains with a narrow paint brush. A plastic liquid

detergent bottle makes a handy lube applicator. Flood the
chain with oil over its entire length.

S7.0 7110
Mast
Version no. T-code
000 7BWS10/13
2.4. Lift Chain Adjustment

1. Loosen the locking nut on the chain anchor.
2. Tighten the adjusting nut until the chain is free of
any twist and in proper tension. Lift chain tension is
correct if the lift chain can be forced sideways
approximately 1/2 - 1 inch (12.7 - 25.4 mm) before
the lift frame raises slightly.
Locking Nut 3. Retighten the locking nut on the chain.
2.5. Mast Guides/Dampers Adjustment

NOTE! Rattles may come from some other source,
such as the forks, or fork carriage.
Over time, the mast guides may require adjustment to reduce
Stop Screws rattles that may occur as the truck travels over floor
irregularities.
3. Check the clearance between the inner column
mast and the plug.
4. If plug clearance is excessive, loosen jam nut and
Mast Guide readjust the stop screws, making sure to adjust the
clearance equally on both sides of the mast.

S7.0 7110
Mast
Version no. T-code
000 7BWS10/13
Plug
Jam Nut
Stop Screw
Outer Column
Inner Column
3. Troubleshooting
Troubleshooting of mast and carriage lift problems must be
divided into hydraulic and mechanical functions. Generally,
hydraulic problems will be evident of slow or no lift depending
upon load weight. For problems that appear to be related to
hydraulics, see page 259. Mechanical troubleshooting
consists primarily of inspection. Except in the case of
disastrous mechanical failure, mechanical troubleshooting
consists of physical inspection for the cause of unusual
noises (pops and grindings) and excessive lateral motion
(shimming). To help determine mechanical failures see
“Maintenance” on page 275.

S7.0 7110
Mast
Version no. T-code
000 7BWS10/13

Replace bearings and chains as necessary. The mast
columns can not be rebuilt. DO NOT WELD ON MAST. DO
NOT REPAIR BROKEN MAST COLUMNS. Replace mast as
necessary.
Mast Mounting
Screw
Washer

S7.0 7110
Mast
Version no. T-code
000 7BWS10/13
Chain / Yokes / Rollers (S - mast) Item No. Description

1 Plate
1 2 Screw
2
3 Chain yoke
4 Axle
5 Cotter pin
6 Chain wheel
7 Bushing
3
4
8 Bracket
5 9 Screw
10 Lift cylinder
25
11 Bracket
7
7 6 12 Connection
8
13 Hose
9
14 Cotter pin
10
15 Nut
16 Nut
13 17 Washer
12 18 Chain, complete
11
19 Anchor, chain
18
20 Chain
21 Pin
14
22 Cotter pin
24 23 22 20 19 17 23 Washer
21
24 Anchor, chain
15
25 Column
16

S7.0 7110
Mast
Version no. T-code
000 7BWS10/13
Chain / Yokes / Rollers (V - mast)

5 6
7
3 8
4 9
12
11 13
10 14
1
16
2
16
15
17 18
22
21
19
20
24
25 23
26
28
29
30
27
32 37
35 39 40
31 33 34 36
38

S7.0 7110
Mast
Version no. T-code
000 7BWS10/13
Item Item Item

No. No. No.
1 Column, outer 15 Sheave 28 Seal
2 Nut 16 Bushing 29 Pin
3 Washer 17 Bracket 30 Chain, complete
4 Plate, slide 18 Column, inner 31 Anchor, chain
5 Plug 19 Screw, set 32 Washer
6 Plate 20 Nut 33 Pin, cotter
7 Nut 21 Bumper 34 Pin, chain
8 Screw, stop 22 Lift cylinder 35 Chain
9 Screw 23 Roller 36 Oscher, chain
10 Washer 24 Connector 37 Washer
11 Screw 25 Hose 38 Nut
12 Yoke, chain 26 Ring, retainer 39 Nut
13 Axel 27 Washer 40 Pin, cotter
14 Pin, cotter

S7.0 7110
Mast
Version no. T-code
000 7BWS10/13
Chain / Yokes / Rollers (FV - mast)

4
5
1 6
2 7
3 8
9
13 12
13
11
10
16
14 17
11 18
10 13 12 20
21 19
13 16
14
15
16
36
22
38
35
37
23
39
24
31
23
33
32 27
30 29 28 26
34 25

S7.0 7110
Mast
Version no. T-code
000 7BWS10/13
Item Item Item

No. No. No.
1 Column, outer 14 Yoke, chain 27 Pin, cotter
2 Washer 15 Bracket 28 Pin
3 Plate, slide 16 Screw 29 Chain
4 Plug 17 Washer 30 Anchor, chain
5 Plate 18 Ring, retainer 31 Pin, cotter
6 Nut 19 Sheave, hose 32 Washer
7 Screw, stop 20 Bracket 33 Nut
8 Screw 21 Bracket 34 Nut
9 Column, inner 22 Lift cylinder 35 Roller
10 Pin, cotter 23 Bracket 36 Ring, retainer
11 Pin 24 Chain, complete 37 Washer
12 Sheave, chain 25 Anchor, chain 38 Seal
13 Bushing 26 Washer 39 Pin

S7.0 7110
Mast
Version no. T-code
000 7BWS10/13
Removal
WARNING Block all wheels to prevent truck from

rolling. Park the truck on a level surface and
make sure all wheels are blocked to
prevent accidental movement.
3. Remove battery from the truck.
Adjustable
Guide Screw
CAUTION Replacement of the mast assembly
requires the use of a hoist capable of safely
lifting 10,000 lbs (4536 kg). Failure to use
proper hoisting equipment could cause
personal injury or damage to equipment.
4. Attach a hoist to the top of the inner column
assembly.
5. Remove forks (see page 299).
6. Remove the adjustable guide screws and nuts
from the inner mast cross tie.
WARNING When blocking mast columns to prevent

lowering, always block both sides of
column. If truck is not blocked, it could tip
on its side.
7. Disconnect the lift chain at the fork carriage.
8. Use the hoist attached to the inner column to raise
it sufficiently enough to clear the fork carriage
bearings. If repairs are replace of the fork carriage
Mast Bolts
is required see page 299.
9. Separate inner column from the main mast by
lifting the column until it clears the mast and lift
cylinder.
10. Separate the mast from the straddle chassis.
Remove lift cylinder (see page 271).
11. Place a suitable hoist around the mast cross tie.

S7.0 7110
Mast
Version no. T-code
000 7BWS10/13
12. Remove bolts securing mast to straddle chassis.

13. Using a hoist, lift main frame to clear straddle
chassis.
Installation
1. Attach chain or sling around top tie bars of mast
assembly.
CAUTION Always watch for pinch points when raising

mast assembly. Use caution not to damage
mast cable during installation.
2. Install mast using a hoist.
3. Install mast mounting bolts. Torque bolts to 140-
150 ft-lbs (189-203 N•m).
4. Connect hydraulic hoses to lift cylinders.
5. Hydraulically lift up inner column enough to install
carriage assembly.
6. Adjust lift chains.
Loosen jam nut and tighten chains equally until the
top of the rails are level in the fully lowered
position. Retighten jam nut and torque to 200 ft-lbs
(271 N•m).
Chains should be adjusted in the fully lowered
position. Adjust chains until the top of forks are 2-1/
2 inches (63 mm) off the floor.
7. Grease all chain sheaves.
8. Bleed air from cylinders.
10. Test operations of mast and unit.

S7.0 7110
Mast
Version no. T-code
000 7BWS10/13
Disassembly
1. Lower mast assembly to a horizontal position
before work can begin.
2. Remove lift chain anchors, lift chain, attachment
hydraulic hoses, and electrical cable from the
mast.
3. Remove chain anchor, cotter pins, and cylinder
anchor pins from inner column. Pull straight up to
remove lift cylinder assembly.
NOTE! Only seals can be replaced. Tube and rod

cannot be repaired.
4. Remove chain sheaves and cable sheaves from all
columns.
5. Pull inner column straight forward until it stops (hits
bearings) and then 90 degrees straight up from
outer column.
6. Remove mast bearings and shim washers from all
columns.
7. Thoroughly clean all parts.
Assembly
WARNING Compressed air used for cleaning MUST

be reduced to less than 30 psi (207 kPa),
and then only with effective chip-guarding
and personal protective equipment.
1. Thoroughly clean all parts and air dry.
2. Replace mast roller bearing on outer column as
necessary.
3. Determine amount of shims required. Pry inner
column to one side and slip shims between bearing
and web on mast. Add shims by hand until no more
can be added.
4. Divide shims as equally as possible between the
two bearings. Install shims under the bearings.

S7.0 7110
Mast
Version no. T-code
000 7BWS10/13
5. Extend inner column through the outer column as

far as it will go under normal operation. Check
bearing shimming as column is extended. Remove
shims as required if tight spots are encountered
where an assembler cannot roll the mast by hand.
Check for excessive bearing clearance with
columns in the fully extended position. Pry column
to one side and check with a 1/32 inch (0.76 mm)
shim. Maximum clearance must not exceed 1/32
inch (0.76 mm).
6. Assemble inner column in outer column. Slide
columns together.
7. Determine amount of shims required. Pry inner
column to one side and slip shims between bearing
and web on the mast. Add shims by hand until no
more can be added.
two bearings. Install shims under bearings.
9. Extend inner column through the outer column as
far as it will go under normal operation. Check
bearing shimming as the column is extended.
Remove shims as required if tight spots are
encountered where an assembler cannot roll the
mast by hand.
Check for excessive clearance with columns in the
fully closed position. Pry column to one side and
check with a 1/16 inch (1.5 mm) shim. Maximum
clearance must not exceed 1/16 inch (1.5 mm).
Check for excessive bearing clearance with
columns in the fully extended position. Pry column
inch (0.76 mm).
10. Install lift cylinder assembly in outer column lower
end.
11. Press roller bearings in lift chain sheaves. Grease
roller bearings, then slide inner races in roller
bearings.

S7.0 7110
Mast
Version no. T-code
000 7BWS10/13
12. Install lift chain on chain anchors and secure with

chain pins. After chain pins have been installed,
run lift chain over chain sheaves. Make sure chain
and sheaves are properly aligned and installed on
lift chain anchors through outer column. Thread a
wheel nut on each anchor and secure with a jam
nut.
13. Assemble chain to inner column chain anchor with
pin.
14. Install lift cylinder assembly on inner column.
Secure with cap screws and nuts.
15. Connect hydraulic lines to lift cylinder.
16. Lubricate grease fittings using a standard lube gun
(see page 72).
Shimming Carriage with Mast on Truck
WARNING Block all wheels to prevent truck from

rolling. Park the truck on a level surface and
make sure all wheels are blocked to
prevent accidental movement.
3. Remove battery from truck.
DANGER When blocking the mast columns to prevent

lowering, always block both sides of
column. If truck is not blocked, it could tip
on its side.
4. Attach a hoist to the top of carriage assembly.
Hoist to loosen lift chains. Jack truck up (see
page 58). This will allow removal of lift chain
anchor pins, electrical cable, and hydraulic hoses.
5. Thoroughly clean off all outside dirt around the
mast roller bearings.
6. Determine amount of shims required. Pry carriage
to one side and slip shims between bearings and

S7.0 7110
Mast
Version no. T-code
000 7BWS10/13
web on the column. Add shims by hand until no

more can be added.
Fork Carriage Item No. Description

1 Fork yoke
1
2 Roller assembly
3 Ring, retainer
4 Washer
2
3
5 Seal
7 4
5 6 Pin
8 6 7 Guard, backrest
8 Screw

two bearings. Install under bearings.
8. Hydraulically lift up inner column enough to remove
reach carriage assembly.
9. Lower carriage down through the inner column to
expose bearings. Remove bearings to install shims
behind the bearings.
10. Raise carriage up through the inner column as far
as it will go under normal operation. Check bearing
shimming as carriage is raised. Remove shims as
required if tight spots are encountered where an
assembler cannot move the carriage smoothly.
Check for excessive bearing clearance with the
carriage in fully lowered position. Pry the carriage
inch (0.76 mm). Check for excessive bearing
clearance with carriage in fully raised position. Pry
the carriage to one side and check with a 1/32 inch
(0.76 mm) shim. Maximum clearance must not
exceed 1/32 inch (0.76 mm).
11. Lower carriage to install hydraulic hoses, lift chain
anchor pins, and electrical cable. When installing

S7.0 7110
Mast
Version no. T-code
000 7BWS10/13
lift chains, chains are to be free of twists and

adjusted for equal tension with adjusting nuts
(wheel nuts) and locknuts (jam nuts) torqued to
200 ft-lbs (271 N•m). Chains are to be centered on
the sheave within 5/16 inch (0.8 mm)
12. Remove hoist from carriage. Check operation first
with no load, then with a capacity rated load.

S7.0 7110
Mast
Version no. T-code
000 7BWS10/13

S7.1 7410
Forks
Version no. T-code
000 7BWS10/13
Forks

1 Knob
2 Wedge
3 Washer
4 Spring
5 Pin
6 Fork

S7.1 7410
Forks
Version no. T-code
000 7BWS10/13
The forks are raised by means of an electric powered
hydraulic pump unit. The lift and lower forks thumb control is
on the tiller arm head. Press up on the thumb control to lift the
forks. Press down on the thumb control to lower the forks.
2. Maintenance
2.1. Inspection
Visually inspect all fork surfaces for signs of damage,
including, but not limited to, bending, cracking, and
unauthorized modifications.
Inspect forks for the amount of wear on the bottom surface,
as follows:
Unworn thickness 1. Using “Fork Wear Calipers”, set the outer-most
points of the wear caliper to the thickness of
unworn vertical shank.
Minimum 2. Without changing the setting, move to the
worn thickness untapered portion of fork base. The inner points of
the caliper represent the minimum acceptable
thickness. If inner points pass over any portion of
the untapered fork base, replace fork.
Shank
(unworn portion)
Untapered portion
3. Troubleshooting
Make sure forks are in good condition.

S7.1 7410
Forks
Version no. T-code
000 7BWS10/13

Removal
3. Remove battery from truck.
4. Release fork locking mechanism by lifting up latch
on top of fork.
Cutout
5. Slide fork toward cutout on bottom of carriage.
Once fork is aligned with cutout, pull up on tip of
fork and move fork away from lower cross member.
6. Remove by lifting top of fork up and away from
upper cross member.
Installation
1. Place top of fork onto upper cross member, over
cutout in lower cross member.
2. Carefully lower bend in fork toward cutout until fork
is in position at carriage lower cross member.
3. Slide fork to desired location on carriage and
secure in position by pushing fork latch down to
lock it. Latch will engage if fork is over one of the
Cutout slots on upper carriage cross member.
Ensure lateral fork stops are in place. The

NOTE! load backrest or bolts in the fork bar face
are commonly used methods.
4. Try to slide fork back and forth to be sure it is
locked into position.
service.

S7.1 7410
Forks
Version no. T-code
000 7BWS10/13

Appendix
Appendix
Version no T-code
000 7BWS10/13
Appendix

000
302
F-code
Version no
Appendix
Ledger
Sh. = Sheet or page of Diagram
First number = Previous page was found.
T-code
Section
Second number = Second page wire is found.

7BWS10/13
C-code

Electrical Schematic 1(2)
2006-06-12
Ledger
Sh. = Sheet or page of Diagram
First number = Previous page was found.
Second number = Next page wire is found.
1 2 3
4 5 6
- +
7 8 9
O 0 |

2006-06-12
Electrical Schematic 2(2)
000
F-code
Version no
T-code
Section
7BWS10/13
303
C-code
Appendix
Appendix
Version no T-code
000 7BWS10/13
Electrical Legend
Symbol Description Function Remark
A1 Transistor Controller Drive motor
A2 Transistor Controller Electronic Tiller Arm Card E.T.A.C.
A2-S1 to A2-S9 Speed Ref Value Electronic Tiller Arm Card
A2-S10 to A2-S18 Speed Ref Value Electronic Tiller Arm Card
A2-S17 Reverser Electronic Tiller Arm Card
A2-S19 Lift Electronic Tiller Arm Card
A2-S20 Lower Electronic Tiller Arm Card
A6 Transistor Controller Operator Display
A17 Transistor Controller Keypad
B+ Battery Positive 24 volt
B- Battery Negative 24 volt
F1 Fuse Drive motor circuit 130 amp
F3 Fuse Power motor circuit 130 amp
F50 Fuse Keypad and tiller arm circuit 10 amp
F51 Fuse Main Control 10 amp
H1 Horn
J11 Wire Connection Handle stem base
J41 Wire Connection Service key (CAN)
K4 Contactor Relay Main
K10 Contactor Main
K30 Solenoid Pump motor
M1 Motor Drive
M3 Motor Pump
R1 Resistor Pre-charge PTC
R2 Resistor CAN Buss 120 Ohm
R3 Resistor Travel Alarm 250 Ohm
S17 Switch Key
S18-1 Switch Horn
S18-2 Switch Horn
S21 Switch Main ON/OFF
S24 Switch Arm angle (A)
S25 Switch Arm angle (B)
Y1 Coil Brake
Y10 Coil Proportional Lowering valve
Y11 Coil Load-Hold valve

Appendix
Version no T-code
000 7BWS10/13
Electrical Graphics
Electrical Graphics
Symbol Description Symbol Description
Battery Brake (coil)

+ -
Contactor Diode
Main ON/OFF Fuse

Switch
Inductive sensor
Horn (normally closed)
Inductive sensor
(normally open) Key switch
Magnet switch Magnet switch

(normally closed) (normally open)
A1 A2 Motor Potentiometer
M

Appendix
Version no T-code
000 7BWS10/13
Electrical Graphics
Symbol Description Symbol Description
Push button switch Push button switch

P P
Resistor Switch
Switch Switch
Valve

Index
Index
A Error Codes . . . . .. . . . . . . . . . . . . . . . 183

Graphics . . . . . . .
. . . . . . . . . . . . . . . . 305
Appendix . . . . . . . . . . . . . . . . . . . . . . . .301 Interface . . . . . . .
. . . . . . . . . . . . . . . . 240
Application Legend . . . . . . . .
. . . . . . . . . . . . . . . . 304
Normal Operation . . . . . . . . . . . . . . . . . 142
Intended Truck Application . . . . . . . . . . . .33
Schematic 1(2) . . . . . . . . . . . . . . . . . . . 302
Prohibited Truck . . . . . . . . . . . . . . . . . . .34
Schematic 2(2) . . . . . . . . . . . . . . . . . . . 303
Service Display . . . . . . . . . . . . . . . . . . 171
B Service Parameters . . . . . . . . . . . . . . . 177
Special Modes . . . . . . . . . . . . . . . . . . . 170
Battery . . . . . . . . . . . . . . . . . . . . . . . . . .199 Truck Fault Codes . . . . . . . . . . . . . . . . 184
Safety . . . . . . . . . . . . . . . . . . . . . . . . . .20 Wiring . . . . . . . .
. . . . . . . . . . . . . . . . 159
Battery Connector . . . . . . . . . . . . . . . . . .217 Error Codes . . . . . . . . . . . . . . . . . . . . . . 183
Battery Pack
Swing Out . . . . . . . . . . . . . . . . . . . . . .205 F
Cable Routing Diagram . . . . . . . . . . .207
Charger Diagram . . . . . . . . . . . . . . .208 Fasteners
Brake Designations . . . . . . . . . . . . . . . . . . . . . 42
Adjustment . . . . . . . . . . . . . . . . . . . . .114 Strength Identification . . . . . . . . . . . . . . . 41
Disc . . . . .
. . . . . . . . . . . . . . . . . . . . .115 Torque Values . . . . . . . . . . . . . . . . . . . . 46
Release . . . . . . . . . . . . . . . . . . . . . . .114 Fault Codes
Brush Inspection and Replacement . . . . . .90 Transistor Controller . . . . . . . . . . . . . . . 245
Truck . . . . . . . . . . . . . . . . . . . . . . . . . 184
C Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . .75
Contactor Panel . . . . . . . . . . . . . . . . . . .235 G
Conversion Formulas . . . . . . . . . . . . . . . .48
Cylinder Grease Location Points . . . . . . . . . . . . . . . 72
Lift . . . . . . . . . . . . . . . . . . . . . . . . . . .269
H
D
Hydraulic
Decals . . . . . . . . . . . . . . . . . . . . . . . . . . .83 Filter Screen and Inlet Tube . . . . . . . . . . 267
Definitions Lift Schematic . . . . . . . . . . . . . . . . . . . 254
Electrical . . . . . . . . . . . . . . . . . . . . . . .159 Lower Schematic . . . . . . . . . . . . . 255, 256
Transistor Controller . . . . . . . . . . . . . . .243 Reservoir . . . . . . . . . . . . . . . . . . . . . . 266
Drive Motor Hydraulic System
Assembly . . . . . . . . . . . . . . . . . . . . . . .94 Changing Fluid . . . . . . . . . . . . . . . . . . . 257
Drive Wheel Pump Pressure Relief Valve . . . . . . . . . . 259
. . . . . . . . . . . . . . . . . . . .117
Specifications Troubleshooting Charts . . . . . . . . . . . . . 260
Drive Wheel Nut Inspection . . . . . . . . . . .118
I
E
Inspection Covers . . . . . . . . . . . . . . . . . . . 81
Electric Motors . . . . . . . . . . . . . . . . . . . . .85 Interface
Electrical ETAC and Transistor Controller . . . . . . . . 240
Error Code History . . . . . . . . . . . . . . . .183

Index
J Service Key . . . . . . . . . . . . . . . . . . . . . . 176

Spare Parts, Ordering . . . . . . . . . . . . . . . . . 1
Jacking Truck off the Floor . . . . . . . . . . . . .58 Steering Bearing . . . . . . . . . . . . . . . . . . 139
Switch
Arm Angle . . . . . . . . . . . . . . . . . . . . . . 225
L Converting Keypad to Key Switch . . . . . . 227
Horn . . . . . . . . . . . . . . . . . . . . . . . . . 227
Lift Pump . . . . . . . . . . . . . . . . . . . . . . . .268 Key . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Load Wheels Master Control ON/OFF . . . . . . . . . . . . . 225
Specifications . . . . . . . . . . . . . . . . . . . .125 Symbols
Lubricants . . . . . . . . . . . . . . . . . . . . .59, 72 Caution . . . . . . . . . . . . . . . . . . . . . . . . 13
Standard . . . . . . . . . . . . . . . . . . . . . . . .59 Danger . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lubrication Chart . . . . . . . . . . . . . . . . . . .71 Ordinance . . . . . . . . . . . . . . . . . . . . . . . 14
Prohibitory . . . . . . . . . . . . . . . . . . . . . . 14
Warning . . . . . . . . . . . . . . . . . . . . . . . . 13
M
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . .275 T
Motor
Drive . . . . . . . . . . . . . . . . . . . . . . . . . .90 Technical Service Data . . . . . . . . . . . . . . . 51
Pump . . . . . . . . . . . . . . . . . . . . . . . . . .87 Tiller Arm . . . . . . . . . . . . . . . . . . . . . . . . 129
Transistor Controller . . . . . . . . . . . . . . . . 239
O Control Circuit . . . . . . . . . . . . . . . . . . . 242
Interface . . . . . . . . . . . . . . . . . . . . . . . 240
Motor Circuit . . . . . . . . . . . . . . . . . . . . 241
Oil and Grease . . . . . . . . . . . . . . . . . . . . .72
Transmission
Operator Display and Programming . . . . .170 Fluid Changing . . . . . . . . . . . . . . . . . . . 101
Troubleshooting
P . . . . . . . . . . . . . . . . . 163
Electrical System
. . . . . . . . . . . . . . . . . 260
Hydraulic System
Parameters Truck Torque Specifications . . . . . . . . . . . 47
. . . . . . . . . . . . . . . . .176
Changing Service
Changing Truck .
. . . . . . . . . . . . . . . . .174
Planned Maintenance Schedule . . . . . . . . .61
W
Wheels
S Drive . . . . . . . . . . . . . . . . . . . . . . . . . 117
Load . . . . . . . . . . . . . . . . . . . . . . . . . 125
Safety Wiring
Battery . . . . . . . . . . . . . . . . . . . . . . . . .20 Harness . . . . . . . . . . . . . . . . . . . . . . . 230
Static Discharge Precautions . . . . . . . . . . .25 Master Control Relay . . . . . . . . . . . . . . . 232
Welding . . . . . . . . . . . . . . . . . . . . . . . .27 Power Cables . . . . . . . . . . . . . . . . . . . 231

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Front Cover

Master Service Manual

Warning Read and observe all warnings on this unit

Part no: 00700-CL3WS-06 Date: June 12, 2006

Ordering Spare Parts

Ordering Spare Parts

Capacity 10-2000 lbs

CAUTION Although some trucks appear to be similar,

5. Note part number.

Master Service Manual 2006-06-12 1

Ordering Spare Parts

This page is intentionally left blank.

2 Master Service Manual 2006-06-12

Ordering Spare Parts .................................................................................... 1

Standard Codes ............................................................................................ 11

Warning Symbols ......................................................................................... 13

Prohibitory Symbols .................................................................................... 14

Battery Safety ............................................................................................... 20

Static Discharge Precautions ...................................................................... 25

Welding Safety .............................................................................................. 27

Introduction, Service Manual ...................................................................... 29

Contents, Section M ..................................................................................... 31

General Product Information ....................................................................... 33

Inch (SAE) and Metric Fasteners ................................................................ 39

Technical Service Data ................................................................................ 51

Contents, Section P ...................................................................................... 55

Introduction, Maintenance ........................................................................... 57

Master Service Manual 2006-06-12 3

Elevate Rear of Truck ................................................................................................... 58

Service Schedule ......................................................................................... 61

Lubrication Chart ......................................................................................... 71

Oil and Grease Specifications .................................................................... 72

Contents, Section S ..................................................................................... 73

Stabilizer Support Arms .............................................................................. 75

4 Master Service Manual 2006-06-12

Support Arm Width Adjustment .................................................................................... 76

Inspection, Covers ....................................................................................... 81

Electric Motors .............................................................................................. 85

Parking Brake System ................................................................................. 111

Drive Wheel .................................................................................................. 117

Load Wheels ................................................................................................ 125

Master Service Manual 2006-06-12 5

Theory of Operation ............................................................................................ 126

Tiller Arm Handle ........................................................................................ 129

Tiller Arm Head ............................................................................................ 135

Steering Bearing ......................................................................................... 139

Electrical Functions .................................................................................... 141

6 Master Service Manual 2006-06-12

Display Part Numbers (Pn) .................................................................................... 183

Battery .......................................................................................................... 199

Swing Out Battery Pack .............................................................................. 205

Battery Connector ....................................................................................... 217

Switches ....................................................................................................... 221

Fuses ............................................................................................................ 229

Master Service Manual 2006-06-12 7

Wiring Harness ............................................................................................................ 230

Contactor Panel ........................................................................................... 235

Transistor Controller .................................................................................. 239

Electronic Tiller Arm Card (ETAC) ............................................................. 249

Hydraulic System ........................................................................................ 253

8 Master Service Manual 2006-06-12

Filter Screen and Inlet Tube ........................................................................................ 267

Lift Cylinder .................................................................................................. 269

Mast .............................................................................................................. 275