5400-5500-5600 00100-Up MM 1031794

Models 5400/5500/5600 Maintenance Manual Visual Table of Contents
Maintenance Manual
Serial Numbers:
00100 and up
Scheduled Maintenance
Messages and Codes
Symptom Tables
Publication: 1031794C, Revised: 13 Jul 2015

Visual Table of Contents Models 5400/5500/5600 Maintenance Manual
Maintenance Manual
Serial Numbers:
00100 and up
Publication: 1031794C, Revised: 13 Jul 2015

Maintenance Manual
High-Level Orderpicker Lift Truck

with The ACR System ™
Models Serial Numbers

5400, 5500, 5600 00100 and Up
1031794C Revised: 13 Jul 2015

This publication, 1031794C, applies to High-Level Orderpicker Models 5400, 5500, 5600, S/N 00100 and
up, and to all subsequent releases of this product until otherwise indicated in new editions or bulletins.
Changes occur periodically to the information in this publication.
If you need assistance with your lift truck, or to order additional copies of this manual, contact your local
authorized Raymond Sales and Service Center.
To locate your local authorized Raymond Sales and Service Center, go to www.raymondcorp.com.
©2015 The Raymond Corporation.

The following terms are trademarks of The Raymond Corporation: The ACR System, intellidrive, Raymond.
All other brand and product names are trademarks or registered trademarks of their respective companies.
Table of Contents Models 5400/5500/5600 Maintenance Manual
Table of Contents
Document Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Service Information List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Manual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Interactive Electronic Technical Manuals . . . . . . . . . . . . . . . . . . . . . 1-3
Abbreviations and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Static Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Emergency Lower Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Tie-Down for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Lift Truck Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
FlashWare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Wire Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Cold Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
UL Label “EE” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Maintenance Minder™ Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Initial 90 Day/250 Deadman Hours (HD) Maintenance . . . . . . . . . . . 4-5
Every 180 Days or 500 Deadman Hours (HD) . . . . . . . . . . . . . . . . . . 4-6
Every 360 Days or 2000 Deadman Hours (HD) . . . . . . . . . . . . . . . . 4-10
Chain Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Drive Unit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Troubleshooting Aisle Exit Error Code J2 . . . . . . . . . . . . . . . . . . . . 5-26
Symptom Tables: Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . 5-27
Symptom Tables: Travel Functions . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Symptom Tables: Electrical Symptoms . . . . . . . . . . . . . . . . . . . . . . 5-31
Messages, Codes, and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Summary List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Messages and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Analog Input Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Input Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
Output Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-107
Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
i Publication: 1031794C, Revised: 13 Jul 2015

List of Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Component Locator Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Special Tools and Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Decals and Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Steering and Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Steer Motor/Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Home Proximity Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Control Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Deadman Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Drive and Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Drive Unit - Standard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Drive Unit - Heavy Duty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50
Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62
Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69
Battery Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
AC Motor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77
Power Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81
Carriage Control Card Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 7-82
EPROM/Microprocessor Removal/Replacement . . . . . . . . . . . . . . . . 7-83
Wiring and Harness Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-93
Flow Sensor Service Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-94
High Pressure Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . 7-97
Lift/Lower and Load Holding Valves . . . . . . . . . . . . . . . . . . . . . . . . . 7-98
Bleeding Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99
Lift Pump and Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-100
Pressure Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-101
Side Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-102
Center Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-106
Mast Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-109
Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-110
Mast Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-113
Upper Mast Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 7-115
Lift Chains, Three-Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-120
Center Cylinder Ride Spring Chain Anchors . . . . . . . . . . . . . . . . . . 7-122
Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-123
Pallet Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-124
Load Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-125
Skid Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-126
Lift Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-127
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
System Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Traction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Lift/Lower System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Wire Guidance System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
ii Publication: 1031794C, Revised: 13 Jul 2015

Models 5400/5500/5600 Maintenance Manual Table of Contents
Pin-Out Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Lubrication Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Thread Adhesives, Sealants, and Lubricants . . . . . . . . . . . . . . . . . . . A-3
Component Specific Service/Torque Chart . . . . . . . . . . . . . . . . . . . . . A-4
Torque Chart - Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Torque Chart - Straight Thread Face Seal O-Rings . . . . . . . . . . . . . . . A-7
Torque Chart - Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Torque Chart - Metric (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Torque Chart - Standard (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Torque Chart - Metric (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11
Torque Chart - Thread Forming Screws . . . . . . . . . . . . . . . . . . . . . . A-12
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13
Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-15
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
Publication: 1031794C, Revised: 13 Jul 2015 i-iii

i-iv Publication: 1031794C, Revised: 13 Jul 2015

Models 5400/5500/5600 Maintenance Manual
Document Revision History
Document Revision History

Revision Date Description of Changes
1013794A 27 Jan 2006 Inital Release
1013794B 14 July 2006 General Update
1013794C 13 July 2015 Update Format. Incorporated all outstanding RSI’s, RPIN’s, and RSB’s
Service Information List

The following Raymond Service Information (RSI) documents have been incorporated into this
manual (use the blank rows below to log Service Information documents when they are added to
this manual).
Revision
Document Number Subject
Incorporated
RPIN OPR-06-R004 Adjustment procedure rail guidance A.S.C.
RPIN OPR-06-R005 Incandescent Light Wiring Changes
RPIN OPR-06-R007 Error codes 5M & 5P
RPIN OPR-06-R008 Terminal stud movement
RPIN OPR-06-R009 Schematic Revision
RPIN OPR-06-R011 Addition to scheduled maintenance
RPIN GEN-06-R004 Servicing of Power Cables Used on AC Motors
RPIN OPR-07-R002 Center lift cylinder end-cap design change
RPIN OPR-07-R003 Steer motor on gear box replacement
RPIN OPR-07-R006 Wire guidance

Revision C
RPIN OPR-07-R008 Input test correction
RPIN OPR-08-R001 New error codes
RPIN OPR-08-R002 Enabling active maintenance tests
RPIN GEN-08-R003 New Cylinder End Cap Wrenches
RPIN GEN-08-R004 Terminal Torque on Curtis Power Amplifier P/N 1042226/XXX
RPIN OPR-08-R005 Steer motor test, O44
RPIN OPR-08-R008 Steer motor gear orientation
RPIN GEN-09-R002 Intermittent issues on truck with optional alarms
RPIN OPR-09-R004 Error Code AH
RPIN OPR-10-R002 Scheduled Maintenance Task Update
Publication: 1031794C, Revised:13 Jul 2015 iii

Service Information List
Revision
Document Number Subject
Incorporated
RPIN GEN-10-R004 Recommended Chain Lubrication
RSB OPR-06-006 Drive Unit Leaking
RSB OPR-06-007 This bulletin supersedes RPIN OPR-06-R005
RSB OPR-08-002 Drive Motor Pinion Nut
RSB OPR-08-003 Incandescent Light Wiring
RSB OPR-08-004 Software Update 3.5
RSB OPR-09-001 Drive Unit Leakage
RSB OPR-09-003 VM Software Version 4.6
RSI OPR-11-002 Correction to Test A34
RSI OPR-12-001 Motor Terminal Stud Torque
RSI GEN-12-002 Static Strap Resistance
RSI GEN-12-004 Shorts to Frame Test
RSI OPR-13-001 Fuse/Relay Card Troubleshooting
RSI GEN-13-002 Fuse/Relay Card Troubleshooting
RSI OPR-13-002A Carriage Control Card (CCC) Firmware Troubleshooting
RSI OPR-13-003 OPR Wire Guidance Configure Mode Settings Revision C
MM Update. Additional info. needs to be added to the symptom

RSI OPR-13-004
tables
RSI MUL-14-001 Carriage/Mast Shimming and Bearing Inspection
RSI OPR-14-001 Lift Chain and Fork Adjustment
RSI MUL-14-002 Intermittent 2T Codes
RSI OPR-14-003 Drive Unit Radial Ring Inspection
RSI MUL-14-004 Temperature Sensor Replacement
RSI OPR-14-004 Code 2M
RSI OPR-14-005A New Wire Guidance Manager Circuit Card and Code 9F
RSI OPR-14-006 Heavy Duty Drive Unit Updates
RSI OPR-14-008 New Software Release
RSI MUL-15-002 Fuse/Relay Card Troubleshooting
RSI MUL-15-001 Recommended Lift Chain Lubrication
RSI MUL-15-005 New Horn Available
RSI MUL-15-006 Updated Torque Check Procedure
iv Publication: 1031794C, Revised:13 Jul 2015

Models 5400/5500/5600 Maintenance Manual Section 1. How to Use This Manual
Section 1. How to Use This Manual
Publication: 1031794C, Revised:13 Jul 2015 1-1

Section 1. How to Use This Manual Models 5400/5500/5600 Maintenance Manual
Manual Design
Manual Design • “Component Procedures” gives

step-by-step procedures for testing,
removal, installation, and adjustment of
This manual is designed with the following individual lift truck components.
objectives in mind: Components are grouped by lift truck
• provide technical coverage for expected system.
levels of user expertise To find a component procedure, you may
• anticipate your needs and reduce your use one of three methods:
decisions regarding maintenance • Look up the component name in the
• reduce page flipping through a “one-stop “List of Component Procedures” on
shopping” approach page 7-2.
• Find the component in the “Component
The two-line running page header at the top of Locator Photos”
each page tells you:
• Look up the component name in the
• Name of the manual maintenance manual “Index”.
(Model 5400, 5500, and 5600 Maintenance
• “Theory of Operation” explains signal flow
Manual)
within the electrical and hydraulic
• Current Section Title systems for various conditions of lift truck
(for example, this page; Section 1. How to operation. This section also contains a
Use This Manual) detailed connection point table (Pin-Out
• Current topic Matrix) designed to assist in testing and
(for example, this page; Manual Design) troubleshooting the lift truck.
• “Appendix” contains reference information
This manual consists of the following sections: such as torque values, lubricants,
• “How to Use This Manual” explains the standard/metric conversions, and system
manual format and design as well as schematics.
abbreviations and symbols used. • “Index” lists subjects alphabetically.
• “Safety” explains warning and caution
notes, general safety rules, and safety
rules for batteries, static, jacking, and
welding.
• “Systems Overview” includes general lift
truck overview, programming instructions,
and configuration menu.
• “Scheduled Maintenance” outlines the
recommended schedule of preventive
services to keep your lift truck working
most efficiently.
• “Troubleshooting” is designed to take you
from a symptom to a specific sequence of
tests in order to isolate a failing
component.
• “Messages, Codes, and Tests” lists the
electrical fault codes and procedures for
running firmware electrical tests.
1-2 Publication: 1031794C, Revised:13 Jul 2015

Interactive Electronic Technical Manuals
Interactive Electronic
Technical Manuals
The electronic version of this document is an
Interactive Electronic Technical Manual (IETM).
IETMs put service and parts information at
your fingertips and are available on iManuals or
from your local authorized Raymond Sales and
Service Center.
Important:
• IETMs require Adobe Reader 9.0 or higher.
Blue colored text in the Maintenance Manual is

“linked” to locations within the manual.
Clicking on a blue link automatically takes you
to the linked location.

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

A Ampere ESDS Electrostatic Discharge
AC Alternating Current Sensitive
Agnd analog ground
amp Ampere or amplifier FF Forks-first
approx approximately fpm feet per minute
Assy assembly FRC Fuse/Relay Card
aux auxiliary ft. foot or feet
AWG American Wire Gauge
gal. gallon or gallons
BSOC Battery State-of-Charge GM Guidance Manager
BWI brush wear indicator gm gram
Gnd ground
CAN Controller Area Network
CCC Carriage Control Card HA Heading Angle
CCW counterclockwise HD hours on deadman
CFP Contactor Fuse Panel Ht height
cm centimeter Hgt/Wgt Height/Weight
COP Computer Operating Hz Hertz
Program
CW clockwise in. inch or inches
CS cold storage
kg kilogram(s)
DC Direct Current kHz kilohertz
DFW Distance From Wire km/h kilometers per hour
Dgnd digital ground kPa kilo Pascal
DMM Digital Multi Meter
DVM Digital Voltmeter lb. pound or pounds
LED Light Emitting Diode
EE UL Electric Truck Type L/H Load Holding
Certification Rating where L/L Lift/Lower
electrical equipment is LPA Lift Power Amplifier
completely enclosed
LPC Lift Power Contactor
EMF ElectroMotive Force
EOA End-of-Aisle
mA milliampere
EPO Emergency Power Off
max maximum
EPROM Erasable Programmable Read
min minute or minimum
Only Memory
mm millimeter
ESD Electrostatic Discharge

Term/Symbol Definition Term/Symbol Definition

MM Maintenance Minder™ UL Underwriters Laboratories,
mph miles per hour Inc.
mS millisecond or milliseconds
mV millivolt or millivolts V Volt or Volts
mVAC millivolts - alternating VDC Volts Direct Current
current VM Vehicle Manager
wrt with respect to
No. number Wt Weight
NV non-volatile w/ with
NVM Non-Volatile Memory w/o without
Nm Newton Meter
@ at
OACH Overall Collapsed Height ® registered
OD Operator Display ™ trademark
OI Operator Interface © copyright
OSHA Occupational Safety and + plus or positive
Health Association – minus or negative
oz. ounce ± plus or minus
° degrees
prox proximity °F degrees Fahrenheit
pot potentiometer °C degrees Celsius
psi pounds per square inch < less than
PWM Pulse Width Modulation > greater than
P/N Part Number % percent
= equals
RAM Random Access Memory
RDP Raymond Data Port
rpm Revolutions per Minute
SAE Society of Automotive

Engineers
sec. second
SG specific gravity
SOL Solenoid
spec specification
SWM Supplier Wireless Module
temp Temperature
TF Tractor-first
TPA Traction Power Amplifier
TPC Traction Power Contactor
TS Traction Speed
T/S troubleshoot


Models 5400/5500/5600 Maintenance Manual Section 2. Safety
Section 2. Safety
Publication: 1031794C, Revised: 13 Jul 2015 2-1

Section 2. Safety Models 5400/5500/5600 Maintenance Manual
Definitions
Definitions
Throughout this manual, you will see two kinds
of safety reminders:
Warning means a potentially hazardous

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

situation exists, which, if not avoided,
may result in minor or moderate injury
or in damage to the lift truck or nearby
objects. It may also be used to alert
against unsafe practices.
2-2 Publication: 1031794C, Revised: 13 Jul 2015

General Safety
General Safety Before working on this lift truck, always turn

the key switch OFF and disconnect the lift
truck’s battery connector (unless this manual
Do not operate or work on this lift truck unless tells you otherwise).
you are trained, qualified, and authorized to do
so, and have read the Owner and Operator
Manuals.
Do not wear watches, rings, or jewelry when

working on this lift truck.
Know the lift truck’s controls and what they do.
Follow the scheduled lubrication, maintenance,

and inspection steps.
Do not operate this lift truck if it needs repair or
if it is in any way unsafe.
Follow exactly the safety and repair instructions

in this manual. Do not take “shortcuts.”
Operate this lift truck only from the operator’s
position.

General Safety
Do not use an open flame near the lift truck. Do not wash this lift truck with a hose.
Do not use gasoline or other flammable liquids Do not add to or modify this lift truck until you
for cleaning parts. contact your local Raymond Sales and Service
Center to receive written manufacturer
approval.
Clean up any hydraulic fluid, oil, or grease that

has leaked or spilled on the floor.
Do not park this lift truck in a cold storage area
overnight.
Always use and park this lift truck indoors.

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

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

explosive gas mixture forms within and
around each cell. If the area is not
correctly ventilated, this explosive gas
can remain in or around the battery for
several hours after charging. Make sure
there are no open flames or sparks in Make sure a shower and eyewash station are
the charging area. An open flame or nearby in case of an accident.
spark can ignite this gas, resulting in
serious damage or injury.
Battery electrolyte is a solution of

sulfuric acid and water. Battery
electrolyte causes burns. If any
electrolyte comes in contact with your
clothing or skin, flush the area
immediately with cold water. If the
solution gets on your face or in your
eyes, flush the area with cold water and A battery gives off explosive gases. Never
get medical help immediately. smoke, use an open flame, or use anything that
gives off sparks near a battery.
Read, understand, and follow procedures,
recommendations, and specifications in the
battery and battery charger manufacturer’s
manuals.
Keep the charging area well-ventilated to avoid

hydrogen gas concentration.
Wear personal protective equipment to protect

eyes, face, and skin when checking, handling,
or filling batteries. This equipment includes
Turn the key switch OFF before disconnecting

the battery from the lift truck at the battery
connector. Do not break live circuits at the

Battery Safety
battery terminals. A spark often occurs at the Make sure the vent holes in the filler plugs are
point where a live circuit is broken. open to allow the gas to escape from the cells.
Vent
Hole
Do not lay tools or metal objects on top of the

battery. A short circuit or explosion could
result.
Do not allow cleaning solution, dirt, or any

foreign matter to enter the cells.
Make sure you install the correct size battery. A

smaller or lighter weight battery could seriously
affect lift truck stability. See the lift truck’s
specification plate for more information.
Keep batteries clean. Corrosion causes shorts

to the frame and possibly sparks.
Keep plugs, terminals, cables, and receptacles

in good condition to avoid shorts and sparks.
Never plug a battery charger into the lift truck’s

battery connector. Plug the battery charger only
into the battery connector from the battery.
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.

Static Precautions
Static Precautions • If you are removing or installing

static-sensitive components, place them
on a correctly grounded anti-static mat.
Electronic circuit boards can contain
• To transport static sensitive components,
Electrostatic Discharge Sensitive (ESDS)
including failed components being
devices.
returned, place the components in an
anti-static bag or box (available from your
Static charges can accumulate from normal
local authorized Raymond Sales and
operation of the lift truck as well as movement
Service Center).
or contact between non-conductive materials
(plastic bags, synthetic clothing, synthetic soles
Test the wrist strap and related accessories
on shoes, styrofoam coffee cups, and so forth.)
before each use to make sure they are working
correctly.
Accumulated static electricity can be
discharged to a circuit board or component by
Figure 2-2 shows the components of the
touching the parts. Electrostatic Discharge
Raymond anti-static field service kit,
(ESD) is also possible through the air when a
P/N 1-187-059. The kit includes a wrist strap,
charged object is placed close to another
ground cord, and static-dissipative work
surface at a different electrical potential. Static
surface (mat). Follow the instructions packaged
discharge can occur without seeing or feeling it.
with the kit.
Whenever working on or near ESDS devices,
follow these precautions.
• Wear an ESD wrist strap. The wrist strap
should be equipped with a 1 megohm
resistor to dissipate static charges slowly.
• Connect the wrist strap plug to the ground
jack on the lift truck. See Figure 2-1. If
you cannot use the ground jack, connect
the ground clip to an unpainted, grounded
surface on the lift truck frame.
Figure 2-2. Anti-Static Kit with Wrist Strap and Mat
Wrist straps (P/N 1-187-058/001) are available

in quantities of 25.
A wrist strap tester (P/N 1-187-060/100) is also

available.
ESD Ground Jack Contact your local Raymond Sales and Service
Center for information.
Figure 2-1. ESD Ground Jack Location
• Handle circuit boards by the edges only.

Avoid touching the edge connectors.

Jacking
Jacking
Jacking Lift Truck Attach a chain to the top of the mast and
an overhead hoist to stabilize the mast if
When the lift truck is jacked up for any reason, jacking more than described in this
take the necessary precautions listed here to procedure.
make sure that the lift truck will not tip over.
• Lower the forks completely. Remove any Operator Platform
load.
• Place all controls in neutral. When it is necessary to perform a procedure
with the operator platform elevated, place a
• Block the wheels to prevent movement of safety stand between the carriage and baseleg
the vehicle. as follows.
• Turn the key switch OFF and disconnect 1. Use the lift knob and raise the operator
the battery connector. platform until you have enough clearance
• Place the jack under the designated to perform the procedure.
jacking points. See Figures 2-3 and 2-4. 2. Place a safety stand or block between the
• Always use solid blocks to support the carriage and a baseleg and carefully lower
vehicle. Never rely on jacks or chains to the operator platform onto the safety
hold the vehicle. stand. See Figure 2-5.
3. Turn the key switch OFF and disconnect
the battery connector.
Jack no more than 2 in. (51 mm) off floor

2
Figure 2-3. Jacking Drive Tire Off Floor
Safety Stand
Jack within this area - no more

than 1/2 in. (13 mm) off floor
Figure 2-5. Blocking Operator Platform
Figure 2-4. Jacking Side of Lift Truck

Emergency Lower Valve
Emergency Lower Valve

In the event that it is necessary to lower the
carriage from the ground, do the following:
1. Remove the tractor cover. The Emergency
Lower Valve is located on the lift/lower
manifold. See Figure 2-6.
2. Slowly turn the valve counterclockwise,
allowing the operator platform to lower by
its own weight.
NOTE: Leaving the valve open prevents the
operator platform from elevating.
3. Turn the valve clockwise to close. This
allows the operator platform to elevate
when the main lift control is operated.
Emergency
Lower Valve
21750_037.TIF
Figure 2-6. Emergency Lower Valve

Tie-Down for Transport
Tie-Down for Transport

Eye-bolts
Vertical Transport
To transport this lift truck in an over-the-road
vehicle or rail car, follow these steps:
1. Lower the operator platform and locate the
lift truck in the center of the transport
vehicle.
2
NOTE: If guide rollers are present, place straps Figure 2-7. Eye-Bolts Installed for Transport
through the guide rollers and secure to
the floor; skip to step 4.
3. If guide rollers (used for rail guidance) are
not present:
a. Install eye-bolts (3/4 in. [19 mm]
thread size) in the holes in the bumper. Eye-Bolts
See Figure 2-7.
b. Secure a chain from the eye-bolts to the
Block
vehicle bed. See Figure 2-8.
4. Strap the lift truck from the bumper or
guide roller to the floor of thetransport
vehicle.
5. Chock the drive wheel to prevent
tractor-first movement.
6. Place a block between the baselegs and
platform, 7.5 in. (190.5 mm) from the front Chock Vehicle Strap On
edge of the platform. Block Chains
Bed
7. Position an additional adjustable chain or 2
strap perpendicular to the forks, over Figure 2-8. Tie-Down for Vertical Transport
operator platform, and attach it to the
vehicle bed. This prevents tip-over during Horizontal Transport
transport. See Figure 2-8.
1. Remove forks from carriage.
2. Replace the cap and screen in the
hydraulic reservoir with shipping cap and
screws.
3. Band down the carriage and battery
rollers.
4. Remove the dipstick, and plug the drive
unit.
5. Remove the bottom two bumper plate bolts
(to be reinstalled after shipping).

Horizontal Transport
6. Use two hoists in conjunction and lay the

lift truck on the cradle.
7. Install long bolts through the holes in the
bumper and secure to the cradle.
8. Band the lift truck to the cradle.
9. Secure the forks to the cradle below the
mast.

Towing
Towing
To tow this lift truck, follow these steps:
1. Lower the operator platform and remove
any load.
the battery connector. Brake Release Bolts
3. Using a suitable towing vehicle, lift the
tractor end of the lift truck until the drive
tire is no more that 1 in. (25.4 mm) off the
floor.
2
4. Tow the lift truck slowly in the tractor-first Figure 2-10. Location of Stowed Brake Release Bolts
direction.
NOTE: If you must tow the lift truck flat on the

ground, you must install the brake
release bolts provided. See Figures 2-9
and 2-10.
Steering is disabled while you are
towing, so you will need to manually
turn the drive unit to steer.
Brake Release Bolt Holes
Figure 2-9. Brake Release Bolt Installation

Welding Safety
Welding Safety
Before removing a power amplifier,
discharge the amplifier’s internal
capacitor by jumpering the + and –
Flame cutting or welding on painted
terminals with a 100 ohm 25W resistor.
surfaces may produce potentially
harmful fumes, smoke, and vapors.
• Check for any shorts to the frame. See
Prior to performing flame cutting or
“Shorts to Frame Test” on page 5-3. If any
welding operations, remove the coating
shorts are detected, remove them before
in the vicinity where the operation(s)
you proceed with the welding operation.
will be performed.
• Clean the area to be welded.
Coating removal may be by mechanical • Protect all truck components from heat,
methods, chemical methods, or a weld spatter, and debris.
combination of methods. Perform flame • Attach the ground cable to a clean,
cutting and/or welding operations only unpainted surface as close to the weld
in well ventilated areas. Use local area as possible. Do not attach the ground
exhaust if necessary. cable to fasteners or other removable
components.
Before working on this truck, make sure that:
• Do not perform any welding operation
• Fire protection equipment is nearby.
near electrical components.
• You know where the nearest eyewash • If welding must be done near the battery
station is. compartment, remove the battery.
• When finished welding, perform all ground
tests and electrical inspections before the
vehicle is operated.
Disconnect the battery before you

attempt to inspect, service, or repair the
lift truck.

Welding Safety

Models 5400/5500/5600 Maintenance Manual Section 3. Systems Overview
Section 3. Systems Overview

Section 3. Systems Overview Models 5400/5500/5600 Maintenance Manual
Introduction
Introduction
This manual provides information for
maintenance and repair of Model
5400/5500/5600 Orderpicker lift trucks by
Raymond.
This manual contains the most current and

accurate procedures, drawings, and
photographs available at the time of
publication. Subsequent releases of this
product may differ slightly from that shown
here. Accordingly, some changes in parts,
layout, or procedures may not be reflected in
this manual.
For the latest information on your Raymond lift

truck, contact your local authorized Raymond
Sales and Service Center.

Lift Truck Specifications
Lift Truck Specifications

Specification Plate
This lift truck is rated for performance by load
center and load weight. Review the specification
plate for detailed load capacity and load center
information. See Figure 3-1.
Due to continuous product improvement,
specifications are subject to change without
notice or obligation.
Raymond Model # Serial number Approximate weight

of lift truck with
battery installed,
Nominal battery minus load and
voltage operator
*Max battery
weight for this lift
truck
Approximate weight
of lift truck minus
battery, load, and
operator *Min battery
weight for this
lift truck
Max Battery
Rated Capacity
Max load capacity of

this lift truck
*Battery weight must be between the

min and max weight.
3412-645.wmf
Figure 3-1. Lift Truck Specification Plate

General Information
General Information
Configuration
The vehicle configuration code is included in
the serial number of the lift truck. The
configuration code allows you to easily
determine performance and height.
Configuration Code Cross Reference
Code Model # Traction/Lift Configuration
5400 AC/DC 24V Hi-Pro
A 5500 AC/AC 24V High Performance
5600 AC/AC 36V High Performance
5400 AC/DC 24V Hi-Pro above 315 in.*
B 5500 AC/AC 24V High Performance above 315 in.*
5600 AC/AC 36V High Performance above 315 in.*
C 5400 AC/DC 24V
*At and below 315 in. uses the standard drive unit. Above 315 in. and in specific
customer applications, use the heavy duty unit.
Battery Specifications
Weight Min/Max
Width (in.) lb. (kg) Amp
Min Max Hours
13 920 (418) 2000 (907) 450/1085
13.69 1600 (726) 2000 (907) 600/775
14.12 920 (418) up to 241 in. (6121 mm) El. Ht

2000 (907) 450/1085
1600 (726) above 241 in. (6121 mm) El. Ht.
16.12 2000 (907) 2300 (1043) 600/930*
18.12 2300 (1043) 2600 (1179)

600/1240
21.12 2600 (1179) 2900 (1315)
*Maximum amps 775 with UL label Type “E” or UL label Type “EE”
UL note 583 specifies that a battery should

have no more than 0.5 in. (13 mm) movement in
any horizontal direction.

Fluid Capacities
Fluid Capacities
Heavy Duty Drive Hydraulic
Standard Drive Unit
Units Reservoir
Fill to middle line

on tank. Approx 7
0.5 gal. (1.9 liters) 0.75 gal. (2.9 liters)
to 8 gal. (26.5 to
30.28 liters)
Refer to “Lubrication Specification Chart” on

page A-2

Installation
Installation
Installation procedures must be performed by a
Raymond Certified Sales and Service
Technician to ensure warranty coverage.
During installation, a visual and functional
inspection must be performed. Refer to OPR Lift
Truck Installation Guide 1169845.

Operator Display
Operator Display Steering Indicator Lights

The steering indicator lights are located on the
The Operator Display (OD) displays data
Operator Display Console. The steer indicator
received from the Carriage Control Card. See
lights show the operator the approximate
Figure 3-2. The displayed data includes:
position of the drive unit.
• Time or calendar
• BSOC (Battery State-of-Charge) Wire Guidance LEDs
• Hour meters (hours on deadman [HD],
hours spent lifting [HL], total miles [TM]) The wire guidance LEDs are located on the
• Status/Fault messages Operator Display Console. The LEDs consist of
two green triangles and three yellow rectangles.
• Weight of load (option) The LEDs indicate when the wire guidance
• Fork Height (option) system is turned ON and the lift truck is locked
• Maintenance required indicator on the guide wire.
• Over-temperature indicator
• Lift-limit indicator (optional)
• Steering direction indicator
• Guidance indicator (optional)
The OD is not required for Run Mode or to pass

SelfTest.
Status/Fault Message Display

Steering Indicator Lift-Limit Indicator
Lights Over-Temperature Indicator
Maintenance Required Indicator
Wire Guidance
LEDs
3
Figure 3-2. Operator Display Messages

Modes of Operation
Modes of Operation If a problem occurs in the lift system, lift is

prevented. Travel, lower, horn, and
steering functions are still permitted.
This vehicle can operate in one of two modes of
operation: Tone 4. A continuous tone with the deadman
pedal pressed and the Auto/Manual switch in
• Run Mode
Manual indicates the lift truck is over the guide
• Program Mode wire.
Tone 5. Tone ramps up then repeats is an
Run Mode indication that the lift truck is seeking and
Run Mode is the normal operating mode for the aligning over the guide wire. The tone continues
vehicle. Run Mode is the only mode that normal until the lift truck is locked on the guide wire or
vehicle travel is allowed. In this mode, the the Auto/Manual switch is changed to Manual.
selectable display is shown on the Operator Tone 6. Descending tone (bomb drop) that
Display (OD). Run Mode starts automatically indicates an incorrect Password or Electronic
when Program Mode is exited or after SelfTest Passkey was entered.
passes.
The tones described do not repeat continuously.
A fault code and associated message scroll
Audible Alarm Description across the Operator's Display. The message
Within Run Mode, various lift truck situations repeats continuously until the key switch is
are identified using different audible tones and turned OFF.
patterns. Run Mode Tones describes the six
tones/patterns and possible cause for different Password Levels
operating conditions.
Two password levels are used with this system:
Run Mode Tones • Password
• SuperWord
Tone 1. A single tone that indicates:
• Up/Down buttons or Enter is depressed
Password
• Maximum steer request is reached
Password allows access to Configure Mode only.
Tone 2. Two tones (high/low) that indicate the Instructions for using Config are outlined on
TPC and LPC contactors are disabled (opened). page 3-13.
Travel, steering, and lift/lower are disabled and
the brake is applied until the problem is
corrected. SuperWord
Tone 3. Three tones (high/medium/low) that SuperWord (Superwrd) allows access to all
indicate: program levels available. Only qualified service
technicians should have access to SuperWord.
• A travel performance limitation
A travel performance limitation allows the Instructions for entering or changing Password
lift truck to travel at a maximum of 1 mph or SuperWord are described on page 3-9.
(1.6 km/h). Lift, lower, steering, and horn NOTE: It is strongly recommended that the
functions operate normally. SuperWord be changed from the factory
• A traction system shutdown default to something else during
installation so access to programming is
A traction system shutdown does not allow
limited to qualified personnel. With that
the lift truck to travel. Lift, lower, steering,
in mind, it is very important to
and horn functions operate normally.
remember the unique SuperWord code
• A shutdown in the lift system that was entered and saved. If the code
is lost or forgotten, it is necessary for a

Program Mode
technician to reset the lift truck to Static Maintenance Mode

factory default settings. This requires
This mode allows one function at a time to be
the reconfiguration of all variable
tested.
settings (Speed, Acceleration, Password,
SuperWord, and so on).
Active Maintenance Mode
This mode allows all input and analog tests to
Program Mode be active in Run Mode. Navigate through the
Program Mode is divided into three categories: OD using the Up/Down buttons, then enter
• Configure (Config) Analog or Input by pressing the Enter button.
You can now scroll through all input and
• Learn (Learn) output tests. There is no need to select items for
• Maintenance (Maint) - Static or Active Active Maintenance, and you are not limited to
the number of items, they are all available. To
Configure Mode return to the OD, navigate to Quit and press
Enter.
The Configure Mode (Config) is used to adjust
To access Maint, SuperWord must be used. For
the vehicle’s performance to specific customer
a detailed description of Maintenance Mode,
requirements. To access Config, Password or
refer to page 3-25.
SuperWord must be used. For a detailed
description of Configure Mode, refer to
page 3-13. Entering Program Mode
Program Mode can be entered by one of the
Learn Mode following two methods.
The Learn Mode is used to calibrate:
• Throttle potentiometer (VR1) (Controls) Method 1
• Lift/lower potentiometer (VR2) (Controls) 1. With the key switch OFF, hold the horn
• intellispeed sensor - height (optional) button in and move the lift/lower control
to full lift.
• Pressure transducer - weight (optional)
2. Turn the key switch to the ON position.
• Wire guidance frequency and offset
(optional)
A discussion of the Learn process for these
items is included in this section.
NOTE: To access Learn, SuperWord must be
used.
Maintenance Mode
The Maintenance Mode (Maint) is used to verify
the operation of various circuits of the lift truck.
In Maintenance Mode, individual circuits can
be energized and cycled to aid in
troubleshooting. Some tests can be performed
under both active and static conditions to
further aid in problem diagnosis.

Entering Program Mode
3. The OD will show all eight segments with a • Press the Down button to select letters
solid bar in each segment. See Figure 3-3. then numbers,
(Z Y X W V. . . . . . . . 4 3 2 1 0 ).
Repeat steps 2 and 3 for all character
positions in the Password or SuperWord.
_ _ _ _ _ _ _ _
NOTE: Initial factory set Password is 1.
Initial factory set Superword is 2.
4. When the Password or SuperWord is
displayed, press the Enter button once.
NOTE: If an invalid Password or SuperWord is
entered, the following message appears:
Invalid password...
To make a correction, repeat steps 2
thru 4.
NOTE: To reset the SuperWord to factory

Down Button Enter Button default, use FlashWare. See “FlashWare”
3 on page 3-27.
Figure 3-3. Operator Keypad and Display
5. The menus that can be accessed depend
Method 2 on whether SuperWord or Password was
entered. Refer to Table 3-1.
1. With the key switch OFF, press and hold Config is the first selection on the OD. If
the Enter button and Down button at the Config is the desired selection, press
same time. See Figure 3-3. Enter. If Learn or Maint is desired
2. Turn the key switch to the ON position. (available only if Program Mode is entered
3. The OD will show all eight segments with a with SuperWord), use the Up/Down
solid bar in each segment. buttons to scroll to that menu, then press
Enter.
Entering Password or SuperWord To exit Program Mode, use the Up/Down
buttons to scroll to Quit, then press Enter.
Refer to Figure 3-4.
NOTE: If the output tests are selected in Maint,
1. Observe the OD. The flashing bar at the the OD reminds the service technician
bottom of the left-most segment indicates to jack the lift truck so the drive tire is
the segment that is currently active. off the floor and to open the emergency
2. Hold the Enter button down and press the lowering valve while in Maintenance
Up button to move the cursor to the right. Mode. When Ready? appears on the OD,
Hold the Enter button down and press the press Enter to enter Maintenance Mode
Down button to move the cursor to the output tests.
left. Release the Enter button.
3. Once the segment that you want to change
is selected:
• Press the Up button to advance through
the numbers then letters,
(0 1 2 3 4 . . . . . . . . . X Y Z ).

Numbers and letters are displayed in each segment in the order shown below (then repeated)
when the UP button is pushed repeatedly.
-0123456789ABCDEFGHIJKLMNOPQRSTUVWXYZ
Pushing the DOWN button repeatedly scrolls the information in the opposite direction.
With the Enter button

depressed, press the
Up button to move the
cursor from left to
right. With the Enter button
- - - - - - - - depressed, press the
Down button to move
the cursor from right
to left.
Number Space (indicated by Letter

underscore)
Password or SuperWord
may be 1 - 8 characters
Enter the correct letter 3 a 7 t - 4 9 k in length, using
or number for each numbers, letters, spaces
segment that makes up (indicated by an
the Password or underscore), or any
SuperWord. combination of each.
3
Figure 3-4. Operator Display for Program Mode (Example)


Table 3-1. Program Mode Menu
PROGRAM MODE MENU – software version 5.1
Menu Item Selection Description
Quit Exits Program Mode
Config Enter Configure Mode - Refer to Configure Mode and

Table 3-2, Configure Mode Menu on page 3-14.
Learn Learn Mode - See Learn Mode on page 3-19.

(SuperWord only) Quit Lrn Exits Learn Mode
Controls
Hgt/Wgt
Guidance Automatically steer the lift truck while traveling in an aisle.
Steer Only on rail guided vehicles equipped with auto-steer
centering. Learn Mode menu no longer includes steer learn
with Version 3.4 or higher VM FlashWare. There is now a
catagory that is Guidance for Wire Guided vehicles only.
Maint Maintenance Mode - See Maintenance Mode on page 3-25.

(SuperWord only) Analog See Analog Input Tests on page 6-41.
Input See Input Tests on page 6-67.
Output See Output Tests on page 6-107.
PA Reset See Power Amplifier Reset on page 3-26.
WGReset Reset? N
Reset? Y
EvtLog See Event Log on page 3-26.
Act Maint See Active Maintenance Mode on page 3-25.
Enable
Disable
Quit Mnt Exits Maintenance Mode

Configure Mode The minimum number of characters is one, the

maximum is eight.
Configure Mode can be accessed with
SuperWord or Password, however some items in To change Password or Superwrd:
Config will only appear if SuperWord is entered. 1. Enter Config using the current password
Table 3-2 outlines all menus and submenus or superword.
available in Config. 2. Select Password or Superwrd (as
applicable) from the Config menu and
Quit Cfg is first displayed when Config is
press Enter.
selected. Use the Up/Down buttons until the
desired selection is displayed. Press Enter. This 3. Enter the new code using the Up/Down
takes you into the submenu for that item. and Enter buttons.
4. When the new code is displayed, press
Current values of configurable items or the
Enter. The display returns to the main
ability to enable/disable an option appear in
menu.
the submenu. To change the value, press the
Up/Down button. When the desired value
appears, press Enter. This selects the item
currently displayed and returns to the main
menu.
All possible lift truck configurations and options
are listed in these instructions. Only the
options associated with that particular lift truck
are displayed on the OD.
To save changes, select Quit Cfg from the Config
menu and press Enter. Select Save? Y to save
the changes made and exit Config.
To disregard changes made in Config, select
Save? N. Config exits without saving changes.
Default Settings
NOTE: Once defaults are reset (Reset? Y), the
previous settings cannot be recalled.
To reinstate factory default settings:
1. Select Defaults from the main menu and
press Enter. Select Reset? Y.
2. Select Quit Cfg.
Changing Password or SuperWord

Both Password and Superwrd can be changed
to any combination of letters and/or numbers.
Blank spaces are not allowed [spaces are
represented by a down bar ( _ )].
If Program Mode is entered with a password,
only Password can be changed. If Program
Mode is entered with a superword, both
Password and Superwrd be changed.

Table 3-2. Configure Mode Menu
CONFIGURE MODE MENU – software version 5.1

Can be entered with Password unless SuperWord is specified
Exits Configure Mode

Quit Cfg Save? Y Save changes and leave Configure Mode
Save? N Abandon changes and leave Configure Mode
Restore Factory Defaults - See Default Settings on page 3-13.

Defaults Reset? Y Restore to Factory Defaults
Reset? N (default) Do not restore to Factory Defaults
CAUTION: The previous settings cannot be recalled once
defaults are reset (Reset? Y).
iP Lim
®
Refer to iPORT Kit and Installation and Maintenance
Instructions P/N 1089339.
iP Spd
®
Refer to iPORT Kit and Installation and Maintenance
Set Max Speed 0.0 to 6.5 mph (0.0 to 10.46 km/h) (shown in
Speed X.X mph increments of 0.1 mph). Default setting depends on model.
Set End-of-Aisle Slowdown Speed

EOA Speed 1.0 mph (default) (0.0 to Maximum Speed)
(optional)
(SuperWord only)
Set Travel Acceleration

Hard
Accel Medium (default)
Soft
Long Set Coast

Coast Medium (default)
Short
Set Lift/Lower Start/Stop Acceleration

Hard
Lift Medium (default)
Soft
Set Lower Deceleration Speed. Set lowering speed below 24 in.

LwrDecel 0 thru 9 (610 mm). Select from 0 (no lower deceleration) thru 9 (highest
(SuperWord only) (default = 5) amount of deceleration)
BSOC Battery State-of-Charge Reset

(SuperWord only) 75 (default) Variable from 55 to 100 in increments of 1
ActMaint Enable (default) Set Active Maintenance

(SuperWord only) Disable
Select Battery Cutout Voltage: 0 to 50 in increments of 1

Cut Out 20 (default)
(SuperWord only)



Alt. C/O Refer to iBATTERY ™ Kit and Installation and Maintenance

Set the 24 in. (610 mm) mast switch speed from 0.5 to 2.5 mph
24 Speed 2.5 mph (default) (1.6 to 4 km/h)
(optional)
(SuperWord only)
Set Lift/Lower Bypass

L Bypass Enable (default)
(optional) Disable
(SuperWord only)
Set Lift Limit Bypass and Travel Cutout

LBPTrvCt Enable (default)
(optional) Disable
(SuperWord only)
Set Lift Limit Bypass Alarm

LBPAlarm Enable (default)
(optional) Disable
(SuperWord only)
Cust Int Customer Interlock Input - enabled in FlachWare

(SuperWord only) CITrav
CI Speed 0.1 mph increments
CI Lift
This option can limit or disable travel and/or lift based on the
state of the imput to the VM
Select English or Metric units of measure

Units English (default)
Metric
Language No selections
available
Select Wire Guidance Frequency

5.2 kHz 5.2 kHz and 6.25 kHz are for Factory use only
WireFreq 6.25 kHz Always select Other (default) with VM software 3.4 and above.
(optional) Other (default)
(SuperWord only)
Select between Wire and Rail Guidance (will only appear if both
Guidance Wire options are installed on the lift truck or if either option is
(optional) Rail installed on the lift truck.)
(SuperWord only)



Set Heading Angle and Distance From Wire Exit Guideset

Quit Gds
HA SLOW 0.6 to 2.0° in 0.2° increments
1.6 deg (default)
GuideSet HA STOP 2.0 to 4.0° in 0.2° increments
(optional) 3.0 deg (default)
(SuperWord only) DFW SLOW 0.6 to 1.6 in. (1.5 to 4.0 cm) in 0.2 in. (5 cm) increments
1.6 in (default)
DFW STOP 1.2 to 3.0 in. (3.5 to 4.0 cm) in 0.2 in. (5 cm) increments
3.0 in (default)
Set Acquire Speed (tractor-first only)

Acquire 1.0 mph (default) 1.0 to full speed in 0.1 mph (0.16 km/h) increments
(optional)
(SuperWord only) Note: Forks-first acquire speed is fixed at 1.0 mph.
Set Top Speed of lift truck when not in wire guidance mode
FreeSpd X.X mph 1.0 to full speed in 0.1 mph (0.16 km/h) increments
(optional) (default = Max
(SuperWord only) Speed)
WrSnLim Enable Set Wire Sense Creep Speed

Disable
WrSnSpd 1.0 mph 1.0 mph when enabled.
(optional)
(SuperWord only)
Factory Use Only

WGAM Enable
Disable
Enter New Electronic Key

Elec Key 3_ _ _ _ _ _ _ Display Current Elec Key
(optional) (factory setting)
(SuperWord only)
Enter New Password

Password 1_______ Display Current Password
(factory setting)
Enter New SuperWord

Superwrd 2_______ Display Current SuperWord
(SuperWord only) (factory setting)



Display Software Version

Quit Ver Exit Version
CCC XX.X Software version for Carriage Control Card
VM XX.X Software version for Vehicle Manager
VMB X.X Boot Code Software version for Vehicle Manager
Version GM XX.X Software version for Guidance Manager
PAT X.X Software version for Traction Power Amplifier
PTB X.XX Boot Code Software version for Traction Power Amplifier
PAL X.X Software version for Lift Power Amplifier
PLB X.XX Boot Code Software version for Lift Power Amplifier
APM Refer to iWAREHOUSE ™ Essential Installation and
Maintenance Instructions P/N 1154532
BSM Refer to iBATTERY ™ Kit and Installation and Maintenance
Instructions P/N 1139156
Trac Mod Traction Amplifier model number
XXXXXXXX (press Enter to access)
Trac S/N Traction Amplifier serial number
XXXXX (press Enter to access)
Lift Mod Lift Amplifier model number
XXXXXXXX (press Enter to access)
Lift S/N Lift Amplifier serial number
XXXXX (press Enter to access)
Serial # XXXXX Display the Serial Number Assigned to the lift truck
Set Time/Date
Time Set time of day (AM or PM)
HH:MM:SS
AM
Clock PM
Date
MM/DD/YY Set current date
Quit Clk Exit Clock
Set Alarm for Travel

None
AlarmT Both (default) On in Both directions
(optional) Fork Ld Fork Lead On/Off
(SuperWord only) Fork Trl Fork Trail On/Off
Set Alarm for Lift

None Exit
AlarmL Both (default) On in Both directions
(optional) Lift On/Off
(SuperWord only) Lower On/Off
Valve A Used with VM software versions below 3.4 to optimize lift/lower

B proportional value performance.
C



Setup for Maintenance Minder ™

Quit MM Quit Maintenance Minder Menu
Enable Turn on MM
Setup
300 (default) Hours on Deadman – 50 to 500 (in 50 hr increments)
Mnt Mind Msg Only Message Only
L Cutout Lift Cut-Out and Message
Reset Update MM to the Current Interval
Disable Turn off Maintenance Minder
Setup Setup the Maintenance Minder Interval (See Maintenance
Minder™ Tool on page 4-3.)
Set idle time for automatic shut-off

Disable (default)
10 Min
5 Min
Auto Off 4 Min
3 Min
2 Min
1 Min
Display Height of Upper Reference Switch

UPRrefSW XXX in. [145 to 160 in. (3683 to 4064 mm)]
(optional) CAUTION: If upper reference switch height is changed on an
(SuperWord only) intellispeed lift truck, Learn height must be run.
Aux Mast XX in. Set Aux Mast height in inches from 20-50. Default = 20

Learn Mode Learn Hgt/Wgt
Learn Mode is used to calibrate the control Learn Hgt/Wgt is only present if the intellispeed
circuits to the operator controls and the lift option is installed on the lift truck.
truck’s external sensors, [such as throttle The VM interprets the height and weight inputs
(VR1), lift/lower potentiometer (VR2), and the during Run. During Learn, the VM obtains a
optional flow sensor used with the advanced baseline for height and weight from where to
intellispeed system]. calculate those parameters. The position of the
After entering the SuperWord, Config is upper and lower reference switches is part of
displayed on the OD (see Table 3-1 on the information that is installed into the lift
page 3-12). Scroll Up/Down through the menu trucks primary memory at the factory or as a
until Learn is displayed, then press Enter. The result of a change with a Passkey.
alarm beeps, indicating that you are in Learn When Learn Hgt/Wgt is performed, the carriage
Mode. passes through both lower and upper reference
Select the item you want to learn. Follow the switches. As hydraulic fluid flows through the
instructions as they appear on the OD. Learn Flow Sensor to move the carriage, the Flow
instructions vary slightly between vehicles with Module produces two quadrature phased
different options. Instructions repeat until they pulsed outputs to the VM. The VM counts and
have been completed. stores the number of pulses between the
reference switches. The VM uses this
After the system is satisfied that the information to determine the position of the
instructions on the OD have been followed, the carriage as the lift truck is operated during Run
alarm beeps and the next instruction appears. Mode.
This continues until all required components
are learned. After all steps are satisfied, Quit Lrn The formula for calculating weight from the
is displayed, allowing Learn to be exited. pressure transducer voltage is programmed into
the VM, but it needs to know the reference
When to Run Learn voltage from where to start the calculation. It
monitors and stores the voltage from the
See Table 3-3 on page 3-20. pressure transducer as the carriage is lifted
between the reference switches during Learn.
Learn Controls This value is used for the reference voltage for
Learn Controls is necessary on all lift trucks. lifting an empty carriage.
During Learn Controls, the Vehicle Manager After the carriage is lifted between the reference
(VM) calibrates its control circuits to the output switches, the carriage elevates about
voltage from the Travel Potentiometer (VR1) and 12 in. (304mm) and pauses before lowering
the Lift Potentiometer (VR2). again. During this pause, the VM stores the
The VM measures and stores the neutral value that is produced from the pressure
voltage value and the maximum forward and transducer when an empty carriage is elevated
reverse voltage values from VR1. These values and stationary.
are used by the VM to determine direction and
speed requested by the operator during Run
Mode.
The VM also measures and stores the neutral
and the maximum lift and lower voltage values
from VR2. These values are used by the VM to
determine if lift or lower is being requested and
the percentage of full speed that is being
requested.

Table 3-3. When to Run Learn
Is Learn
Component Repaired/Adjusted Portion of Learn to run
Required?
Vehicle Manager Yes Controls, Height, Weight, Steer
Upper Mast Switch — No —
Lower Mast Switch — No —
Carriage Control Card (CCC) Yes — Controls
Carriage Control Card PROM Yes — Controls
Steer Position Proximity Home Sensor Yes — Learn Steer Zero or Learn
Deadman Switch (S2/S23) — No —
Lift Potentiometer (VR2) Yes — Controls
Guidance Manager Yes — Frequency and Offset
Pressure Transducer Yes — Height, Weight
Lift/Lower Solenoid — No —
Load Holding Solenoid — No —
Brake — No —
Throttle Potentiometer (VR1) Yes — Controls
Flow Sensor Module Yes — Height, Weight
Filter Card Yes — Frequency and Offset
Antenna Card Yes — Frequency and Offset
Home Proximity Sensor Yes — Steer
carriage immediately begins to lift. The display

continuously scrolls the following message:
Before Learning height and weight, the To abort, step off deadman
vehicle must be placed in an area where If all the parameters measured during Learn are
the platform is able to lift beyond the within tolerance, the following message
upper mast reference switch (156 in. appears:
[396 cm] plus the height of the carriage). Done learning
When Hgt/Wgt is selected, the following If, at any time during Learn, the operator steps
message appears: off the deadman pedal or the measurements fall
Carriage will automatically lift/lower outside a tolerance, the following message
between the reference switches appears:
Unable to learn...lower then press enter
The operator is prompted as follows: to continue
Step on deadman to start learn
This message scrolls continuously until the
operator steps on the deadman pedal. After the
operator steps on the deadman pedal, the

If the failure is not the result of stepping off the 3. Select WireFreq from the Learn menu and
deadman, attempt to learn again. If repeated press Enter. The following message
attempts to learn fail, run tests: appears:
• Test A13 - Pressure Sensor Voltage Center over wire, Then press enter
(optional) (Page 6-48) After enter is pressed, the following
• Test I02 - Lower Mast Reference (24 in.) message is displayed:
Switch (Page 6-70) Learning wire frequency
• Test I69 - Upper Mast Reference Switch NOTE: This process takes several seconds.
(Page 6-94)
4. When the frequency and amplitude of the
• Test I26 - Flow Sensor Count (Page 6-81)
guide wire is learned, the following
(use Active Maintenance)
message is displayed:
Learning Wire Frequency: Software Versons Wi r e f r e q
Below 3.4 5. Select Quit Lrn from the Learn menu and
press Enter to exit Learn Mode. Cycle the
Lift trucks equipped with an optional wire
key switch OFF, then ON. Re-enter Learn
guidance system can be configured as follows.
Mode prior to learning Wire Guidance
Three selections are available under WireFreq in
Offsets.
Config.
6. If a valid frequency is not found, or if at
If 5.2 kHz or 6.25 kHz is selected, the Guidance any time during the learning process, the
Manager utilizes preset guide wire strength operator presses the enter button, the
values and calculates only the wire guidance following message is displayed:
offsets (Wg Offset must be run).
Unable to learn. Press enter to continue
NOTE: The 5.2 kHz setting requires a guide wire 7. If repeated attempts to learn wire
output of 100 mA. The 6.25 kHz setting frequency fail, run the following tests:
requires a guide wire output of 225 mA.
• Test A51 - Left Tractor Guidance Coil
Other must be selected for all other
Voltage (Page 6-59)
guide wire outputs.
• Test A52 - Right Tractor Guidance Coil
If Other is selected, the Guidance Manager is
Voltage (Page 6-60)
calibrated to the frequency and amplitude of the
guide wire in order to correctly calculate wire • Test A53 - Left Load Guidance Coil
guidance offsets. Both scenarios are discussed Voltage (Page 6-61)
in the following paragraphs. • Test A54 - Right Load Guidance Coil
Voltage (Page 6-62)
Learn WireFreq • Test A55 - Tractor Near Wire Coil
WireFreq is visible in the Learn menu only if Voltage (Page 6-63)
Other is selected under WireFreq in Config. • Test A56 - Load Near Wire Coil Voltage
WireFreq must be learned before Wg Offset is (Page 6-64)
attempted. When Other is selected, the
Guidance Manager (GM) must learn the Learn Wire Guidance Offsets
frequency and strength of the AC current
flowing through the guide wire. This is done as For wire guidance to function correctly, the GM
follows: must calibrate its internal guidance circuits to
the voltage it receives from each guidance coil
1. Verify that the line driver is adjusted to the on the Antenna Card. The GM must also know
correct frequency and amplitude. the straight ahead position of the drive unit.
2. Center the lift truck over the guide wire to
within ±0.5 in. (±13 mm).

These values are obtained while learning the from the sensor coils. The GM would then
wire guidance offsets as follows: attempt to keep the lift truck in a position
other than centered over the wire. If the
NOTE: The Coast value in Config must be set to
drive unit was not straight ahead, the GM
Long and the lift truck driven in the
would learn an incorrect angle and the lift
tractor-first direction.
truck may wander on the wire. Re-learn
1. Center the lift truck over the guide wire as the wire guidance offsets as many times as
closely as possible. necessary to make the lift truck track
2. Set the Auto/Manual switch to Auto to within 0.5 in. (13 mm) of the guide wire.
initiate Learn. 6. If the Learn procedure is completed
3. Drive the lift truck tractor-first on the correctly, the following message is
guide wire for at least 60 ft. (18 meters). displayed:
Allow lift truck to coast to a stop. This is Done learning
done to allow the lift truck to center The lift truck should guide centered over
correctly to its neutral position. If the the guide wire.
brake or plugging is applied, the drive unit
If enter is pressed during the Learn
may shift position.
process, the session is aborted and the
4. After the lift truck has coasted to a stop, following message is displayed:
place the Auto/Manual switch in the
Unable to learn. Press enter to continue
Manual position. When the Auto/Manual
switch changes state, the GM stores the 7. Run Tests A51 thru A56.
voltage it measured from each guidance
sensor coil. This voltage value is used to Learn Steer Zero
determine the wire guidance offsets and This procedure removes the need to manually
establish the scale factors required to adjust the Home Proximity Switch to make the
determine Heading Angle (HA) and lift truck track centered over the wire.
Distance From Wire (DFW) when in Run
1. Center the lift truck over the guide wire.
mode.
2. Select Learn Steer Zero.
5. When the lift truck powered up, it auto
centered, and reset the pulse counter for 3. Place the Auto/Manual Switch in Auto and
steering position. As the lift truck was drive the lift truck in both directions over
traveling on the wire in step 3, the the guide wire. Maintain a speed of greater
Feedback Encoder was keeping track of than 1.2 mph (1.9 km/h) for more than 2
the deviation of the drive unit from the seconds. Once a change in speed of less
auto center position. When the than 1 mph (1.6 km/h) is seen for 2
Auto/Manual switch changed states in seconds, the Steer Zero position for that
step 4, the GM also stored the number of travel direction is stored and there is a
Feedback Encoder pulses between the Beep.
Auto Center position and the position that 4. After Learn for both travel directions is
the drive unit was located when the complete, select Quit Lrn from the Learn
Auto/Manual switch changed state. That menu and press Enter to exit Learn Mode.
is the value that the GM uses as straight Cycle the key switch OFF, then ON. Test
ahead when determining how to position the lift truck operation.
the drive unit to keep the lift truck
centered over the wire (sensor coil voltages Learning Wire Frequency: Software Version
at the learned value) as the lift truck 3.4 and Up
drives on the wire.
Lift trucks equipped with an optional wire
If the lift truck was not centered over the guidance system have three selections available
wire when the Auto/Manual switch under WireFreq in Config.
changed states in step 4, the GM would
learn incorrect values (lift truck position)

If 5.2 kHz or 6.25 kHz is selected, the Guidance NOTE: If the message “Learn Wire Failed” is
Manager utilizes preset guide wire strength displayed press Enter to retry or press
values and calculates only the wire guidance the Up arrow to abort the guidance learn
offsets (Wg Offset must be run). process. If still unable to learn the wire,
verify that the output of the line driver
NOTE: The 5.2 kHz setting requires a guide wire
conforms to Raymond specifications.
output of 100 mA. The 6.25 kHz setting
Then perform Analog tests A51 thru
requires a guide wire output of 225 mA.
A56.
Other must be selected for all other
guide wire outputs. 7. ODI automatically changes to “guide
tractor-first”. Pressing the Down arrow
If Other is selected, the Guidance Manager is
allows the Wire Guidance Offsets Learn
calibrated to the frequency and amplitude of the
process to be skipped and advance to step
guide wire in order to correctly calculate wire
8.
guidance offsets. Both scenarios are discussed
in the following paragraphs. 8. After tractor-first travel is initiated, the
ODI displays:
Learn WireFreq: gently coast to a stop then press Enter
1. Center the lift truck over the guide wire. NOTE: The ODI displays “wrong direction” if
2. Enter the Program Mode via Superword forks-first travel is attempted.
and select Configure Mode. Scroll to
After traveling more than 20 feet at a
Coast and set it to Long. Save change and
constant speed of more than 0.5 mph,
exit Configure Mode.
return the Travel Control Handle to
3. Select Learn Mode, Guidance, and Enter. neutral and allow the lift truck to gently
Pressing the Up arrow at any time aborts coast to a stop. Press Enter. The Wire
the guidance learn process. Guidance Offsets values are now written to
4. ODI displays: the EEPROM on the Guidance Manager.
step on deadman 9. ODI displays:
The ODI displays “press auto/man switch guide both directions until centered
to auto” if it is not already in that position. then press Enter
5. ODI displays: This is the “Learn Steer Zero” process for
calibraiting the guide Drive Unit position
center over wire then press Enter
relative to the Steer Center Proximity
NOTE: Pressing the Down arrow allows the Switch.
Learn Wire process to be skipped and Travel speed must be greater than 0.5
advances you to step 6. This step should mph and held constant. When these
be performed regardless of the wreFreq conditions are met for a period of 2
selection in Configure Mode unless the seconds, the alarm horn chirps and the
Learn Wire process is being intentionally “Steer Zero Value” for the current direction
skipped. If the lift truck was not is written.
previously centered over the wire, do it
now. Press Enter. NOTE: This chirp indicates the test is in
progress and getting good data, not
6. ODI displays: complete.
busy learning wire
Observe the lift truck’s tracking
After approximately 30 seconds, learning performance in both directions relative to
the frequency and field strength of the the guide wire. When satisfied the lift
floor signal is accomplished. Their values truck is tracking as centered as possible,
are written to the EEPROM on the press Enter to conclude the “Learn Steer
Guidance Manager. Zero” process and return to the main
“Learn” menu.

10. In the “Configure Mode”, return the Coast 10. Drive forward 10 ft. (3 meters). Measure
parameter to its original setting. the deviation of the lift truck from the
reference line. The deviation should be less
NOTE: Manual adjustment of the home
than 1 in. (25.4 mm). If not, proceed to the
proximity sensor to center the lift truck
next step. If it is less than 1 in. (25.4 mm)
over the guidewire is no longer required
proceed to step 13.
NOTE: DFW Stop is now adjustable from 11. Drive the lift truck back 10 ft. (3 meters) to
1.2 (30 mm) to 3 ins. (76 mm). the original position.
Previously, it was 1.6 (41 mm) to
3 ins. (76 mm). 12. Use the Up/Down arrows to adjust the
value on the display. More negative
Learn Auto Steer Center: numbers cause the lift truck to drive to the
right when driven tractor-first. Changing
Use this procedure on lift trucks with rail the value by one corresponds to a
guidance and auto steer centering option. deviation of about 0.25 in. (6 mm) over
Adjust the center position of the drive unit so 10 ft. (3 meters)
that the lift truck drives straight when in the
13. Repeat steps 9-11 until a deviation of
aisle.
1 in. (25.4 mm) in less over 10 ft. is
1. Place the lift truck in an area where there achieved.
is a straight line at least 20 ft. (6 meters) in
14. To save the value, press the Enter button.
length, with wire guidance grooves, yellow
The lift truck’s display will read “Save? N.”
aisle markers, or rails.
Press the Up/Down button arrows to
2. Depress the rail switch and secure it to display “Save? Y”, then press the Enter
simulate a rail. button.
3. Power the lift truck down and then power 15. Learn of steer center is complete.
it back up.
4. Enter Superword mode.
5. Select Learn->Steer. The display shows
“Str XXX” where XXX is a number between
-50 and 50. This is the steer proximity
offset from dead center in 10ths of degrees.
6. Step on the deadman pedal. Wait for the
lift truck to self-center the drive unit.
7. Select “Manual” on the auto/manual
switch. The lift truck is now in “seeking
mode” and can be driven with manual
steering.
8. Position the lift truck so that it drives
parallel to the reference line. Make small
corrections in the steering wheel position
until the lift truck can be driven
10 ft. (3 meters) without deviating from
the line more than 1/2 in. (13 mm)
without steering.
9. Drive back to the original position. Stop
the lift truck. Select “Auto” on the
Auto/Manual switch. The steer unit will
center and manual steer is disabled.

Maintenance Mode
Maintenance Mode allows service technicians to
test individual circuits within the system.
During Static Maintenance Output Tests,
Maintenance Mode is accessed through
always jack the drive tire off the floor
Program Mode after the SuperWord is entered.
and open the Emergency Lowering
Refer to page 3-9 for information on procedures
Valve.
for accessing Maintenance Mode.
NOTE: If the test does not appear in the Use extreme care whenever the lift truck
Maintenance Mode menu for an option is jacked up for any reason. Never block
when you think it should, either that the lift truck between the telescopic and
option is not enabled (through the floor. Use a suitable hoist to stabilize
FlashWare) or the lift truck does not the mast. Keep hands and feet clear
have the latest software. from beneath the vehicle while jacking.
Use jack stands or solid blocks to
General support the lift truck - do not rely on
jacks. Refer to page 2-8.
NOTE: If you need to enter Maint several times
to resolve a problem, it may save time if
By entering Static Maintenance Mode,
Superword is temporarily changed to a
the safety circuits associated with the
single digit code. Remember to re-enter
system are disabled. Extra precautions
the correct Superword when you are
must be exercised in Static Maintenance
done.
Mode. Follow all instructions contained
in this manual for each test. If you are
unsure how to conduct a test while in
Maintenance Mode, do not proceed with
Disconnecting wires or connectors to
the test. Contact a certified Raymond ®
integrated circuits with power ON can
technician.
result in premature failure of those or
other components. Always disconnect
Static Maintenance Mode
the battery before making or breaking
any connections. In Static Maintenance Mode, the lift truck is
inoperative. This mode allows the technician to
When removing a connector, do not pull on the test and operate individual circuits without
wires to separate the connection. operating the lift truck. All tests are available
during static testing.
All circuit cards are conformal coated. When
testing circuit cards, make sure a good If Digital Outputs are selected from Maint, the
electrical connection is made between the board OD displays:
test point and the probe. This eliminates false Warning jack up the drive wheel, press
results. enter when ready
Press Enter to start Maintenance Mode. The
Up/Down buttons are used to turn the test
ON/OFF.
Active Maintenance Mode

Active Maintenance Mode (Act Maint) permits
testing of various systems on the lift truck. In
Active Maintenance, all Analog and Digital tests
can be selected with the results displayed while
operating the lift truck in Run Mode. To enable
a test for Active Maintenance:

1. Enter Program Mode using Superword. To access the Event Log, use the Up/Down
2. Scroll to Maint and press Enter. buttons to scroll to Evtlog and press Enter.
3. Scroll to Act Maint and press Enter. If no errors are stored, Empty is displayed.
4. Select enable. This enables all Input and If errors have been logged, use the Up/Down
Analog tests. buttons to scroll through the list.
5. Scroll back to Act Maint, Quit Mnt, and To clear the log, use the Up/Down buttons to
press Enter. scroll to Clr log. Press Enter. Scroll to Clr yes
6. Quit Program Mode. The lift truck will go and press Enter.
through SelfTest.
7. When SelfTest completes, Analog and
Input are now visible when scrolling
through the display selections. Choose
either Analog or Input.
You may now choose any available Analog or
Input test to monitor while the lift truck is
operating in Run Mode.
To turn Active Maintenance OFF, follow steps 1
and 2 above. At step 3, scroll to Disable and
press Enter. Follow steps 4 and 5 to enter Run
mode. Tests will no longer be available when
scrolling through the display options.
All tests can be selected. Individual tests can be
turned OFF by going back to that test in Maint
and pressing Enter. The asterisk disappears.
The tests selected for Active Maintenance are
stored in memory even if the key switch is
turned OFF.
To select one of the Active Maintenance tests,
press the deadman pedal and use the Up/Down
buttons to select the test you want displayed
while operating the lift truck. The test selected
remains on the display until another test or
display selection is made.
Power Amplifier Reset

Power Amplifier Reset (PA Reset) returns the
power amplifier back to its default baud rate of
125K. This feature is helpful when the power
amplifier is to be returned to stock or installed
on a different model lift truck.
Event Log
The Event Log (Evtlog) stores the last twenty
error codes recorded on the lift truck. Entries
are stored in order of occurrence, with the most
recent error first.

FlashWare
FlashWare NOTE: A USB to Serial Adapter cable

(P/N 610-809/W7P) is available for
devices that do not have a serial port.
Overview 4. Connect the cable to the J9 connector on
the VM. See Figure 3-5.
FlashWare allows you to update software, view
and configure options on the lift truck through
Serial connector (J9)
the following features:
• Update Vehicle Manager software
• Clear Primary Memory
• Clear Vehicle Manager
• Reset factory default settings
• Update Power Amplifier Software
For more detailed FlashWare information, click

on Help and select Help Topics from the
FlashWare menu bar.
Figure 3-5. Lift Truck FlashWare Connections
FlashWare can be installed on any MicroSoft

(MS)-Windows compatible device. The device Starting FlashWare
communicates with the lift truck software via a
1. With the key switch ON, double-click the
serial (9 pin) or USB port.
FlashWare icon on the main desktop
screen or navigate via Start > Programs >
Installing FlashWare on a FlashWare. The lift truck Opening Screen
Windows Compatible Device appears. See Figure 3-6.
If you are a customer service technician, obtain

FlashWare from your Raymond Sales and
Service Center.
If you are a Raymond Sales and Service Center

technician, obtain FlashWare from the iNet
software download site.
To install FlashWare on the device, double-click

the installation file and follow the instructions
on the screen. The software package is a
self-extracting executable file. Read the
“Readme” file in the software package for the
latest detailed installation instructions. Figure 3-6. Lift Truck Opening Screen
NOTE: When entering or using FlashWare, it is

Connecting Device to Lift Truck normal for a 50 Series Code to be
1. Turn the key switch OFF. displayed.
2. Connect surge protector 2. From the menu bar, click
(P/N 154-010-801) to an available “Comm” “Communications”, then select the
port. applicable connection type:
3. Connect a standard 9-pin serial cable • COMx (9-pin Serial)
(P/N 610-809/201) to the surge protector.

Starting FlashWare
• COMx (USB)
NOTE: “x” numbers vary depending on the
computer configuration.
3. From the menu bar, click “Connect to
Truck”, then select “All Other Trucks”. If
the device is connected to a correctly
functioning Vehicle Manager, the Lift
Truck Setup screen is displayed.
NOTE: Refer to FlashWare Help for specific
FlashWare related topics.

Wire Guidance
Wire Guidance If the warehouse portion of the guidance system

has a different line driver output, refer to Learn
WireFreq on page 3-21.
Wire guidance is a means to automatically steer
the lift truck while traveling in an aisle. It offers
precise steering at full-speed travel in Very
Narrow Aisle (VNA) applications.
A wire guidance system consists of two
sub-systems.
• Warehouse-installed equipment includes a
guide wire and line driver. The guide wire
is installed in the floor and emits an
Alternating Current (AC) signal at a
specific frequency and amplitude
generated from the line driver.
• Lift truck-installed equipment includes:
• Two guidance sensors, tractor end and
load end
• Guidance Manager (GM)
• Steer feedback encoder
• Auto/Manual switch, on operator
console
• Associated cables and mounting
brackets
The lift truck must learn the amplitude
and frequency of the guidance signal to
correctly track the guide wire.
NOTE: This manual covers all lift
truck-installed equipment. For
information on warehouse-installed
equipment, refer to PDSS-0051,
Raymond Wire Guidance.
To operate wire guidance, refer to the Operator
Manual.
Wire Guidance Setup

This procedure should not normally have to be
performed. For the lift truck to guide correctly,
the following must be true:
• for 5.2 kHz, the current through the guide
wire must be 100 mA peak-to-peak ±10%
• for 6.25 kHz, the current through the
guide wire must be 225 mA peak-to-peak
±10%

Cold Storage
Cold Storage
Cold storage is an option that enables lift truck
operation in temperatures of –20°F (–28.86°C)
to 40°F (4°C).
On cold storage lift trucks, the electrical panel
on the tractor is completely enclosed to contain
heat. Components added to the lift truck for
cold storage are listed in the table below and
shown on the electrical schematic. See
Schematics on page A-17.
Heater Assemblies
Location
Components
Carriage Control Card Control Handle Deadman Pedal
Heating elements HTRC HTRH HTRDM
Thermostats S81 S91 S80
Fuses FU21 (10A) None FUDM (5A)

Storage
Storage NOTE: If the lift truck is going to be stored for

more than six months, spray hydraulic
components with a silicone protectant.
If the lift truck is going to be stored for any
Do not let silicone protectant spray get
length of time, cover the lift truck with canvas
on circuit cards.
or plastic.
If the lift truck is going to be stored for more Hydraulic Cylinders
than 30 days, jack and block the lift truck up
off the floor. Store the lift truck with the cylinder pistons
retracted. Coat all exposed chrome surfaces of
the piston with hydraulic fluid.
Use extreme care whenever the lift truck Lift Chains

is jacked up for any reason. Never block
the lift truck between the telescopic and Liberally coat all chains with oil to prevent rust
the floor. Use a suitable hoist to stabilize and corrosion.
the mast. Keep hands and feet clear
from beneath vehicle while jacking. Use Electronics
jack stands or solid blocks to support lift
truck. Do Not rely on the jack alone. See Make sure all electronics stay dry.
Jacking on page 2-8.
Warranty
The Raymond Corporation must be contacted
by an authorized Raymond Sales and Service
Center for the correct warranty procedures.
Motors
The brushes in DC motors must be lifted away
from the commutator surface. When preparing
the lift truck for service, the surface must be
inspected and polished, if necessary, using a
rubber abrasive polish. Polishers are
specifically made for polishing commutators. Do
Not use a stone.
Periodically rotate the motor shafts to coat the
bearings with lubricant, reducing the possibility
of oxidation and corrosion.
Hydraulic System
The hydraulic system will absorb moisture
when left standing for a long time. Make sure
the reservoir is full before storing. Before
returning the lift truck to service, drain the
reservoir and change the filter. Fill the reservoir
with new hydraulic fluid. Operate the hydraulic
systems slowly to allow internal components to
be lubricated.

UL Label “EE”
UL Label “EE”
Underwriters Laboratories (UL) ratings indicate
that specific criteria have been met by the
manufacturer, and tested and documented by
UL. “EE” designated lift trucks are electrically
powered units that have, in addition to all of the
requirements for “E” and “ES” units, electric
components completely enclosed. In certain
applications, an “EE” lift truck may be used
where an “E” or “ES” lift truck may not be
considered suitable.

Models 5400/5500/5600 Maintenance Manual Section 4. Scheduled Maintenance
Section 4. Scheduled Maintenance

Section 4. Scheduled Maintenance Models 5400/5500/5600 Maintenance Manual
Maintenance Guidelines
Maintenance Guidelines
A successful Scheduled Maintenance program:
• promotes maximum lift truck performance
• prolongs lift truck life
• reduces costly down time
• avoids unnecessary repairs
Scheduled Maintenance includes:

• lubrication
• cleaning
• inspection
• service
Perform all of the scheduled checks and

maintenance during the suggested intervals.
The time intervals given in this guide are based
on deadman hours under standard operating
conditions.
When operating under severe or extreme

conditions, perform these services more often
as indicated in the chart below.
Table 4-1. Maintenance Frequency

Operating Service
Working Environment
Conditions Frequency
Light to 180 days or 500
Moderate An eight hour shift of basic material handling hours, whichever
comes first
• Extended heavy duty operation 60 days or 250
• Freezer operation hours, whichever
Severe
• Sudden temperature changes such as going from freezer to room comes first
temperature.
• All UL Type EE rated lift trucks 30 days or 100
• Dusty or sandy conditions such as in cement plants, lumber or flour hours, whichever
Extreme mills, coal dust, or stone-crushing areas comes first
• High temperature areas such as in steel mills, foundries, enclosed
(Type EE) applications
• Corrosive atmosphere such as chlorine or salt-sea air environments

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

Option
Tool
The first time you enter the time interval menu,
Maintenance Minder Tool is a feature that alerts the Factory Suggested setting, followed by the
the operator when the lift truck is due for letters FS is displayed. Subsequently, when you
scheduled maintenance. enter the time interval menu, the last used
setting is displayed. Values from 50 to 500
Maintenance Minder, when configured and hours, in increments of 50, are available. Use
enabled, monitors the Hours on Deadman (HD) the Up/Down button to scroll to the desired
meter. When the time interval for scheduled time interval. With the desired value displayed,
maintenance is exceeded, the operator is press the Enter button.
informed in the following ways:
Use the Up/Down button to select the desired
• One of two messages scrolls on the
action option. Then press the Enter button.
Operator Display for at least 30 seconds
following the DAILY CHECKLIST message: • MSG ONLY causes the Operator Display to
show SCHEDULED MAINTENANCE DUE when the
Scheduled maintenance due
scheduled maintenance time interval is
or exceeded.
Lift cutout, scheduled maintenance due • L CUTOUT causes the Operator Display to
• A wrench icon flashes show LIFT CUT OUT, SCHEDULED MAINTENANCE
DUE when the scheduled maintenance time
• The audible alarm sounds the high-low
tone for approximately 5 seconds interval is exceeded. Lift is disabled the
next time the power circuits are cycled.
Lift Cutout, when active, does not disable the
lift function until power to the control circuits is Use the Up/Down button to select QUIT MM from
cycled (key switch OFF or battery the submenu. If the status has changed, you
disconnected). When control circuit power is are prompted to save changes. Press the Enter
cycled, lift is disabled until Maintenance Minder button.
is reset or disabled, or the lift cutout option is NOTE: From the Config Menu, exit by selecting
turned OFF. QUIT CFG. You will not be prompted again
to save changes, but any changes saved
Enabling when you QUIT MM are retained.
Once installed in the configuration options, Changing Time Interval or

MAINTENANCE MINDER appears in the Configure
Action Option
Mode menu. The initial factory setting is
DISABLE. To enable the feature, enter Configure
When Maintenance Minder is active, and you
Mode.
wish to change the time interval or action
NOTE: For instructions on selecting Modes of option, enter Configure Mode.
Operation, see Operator Display on
page 3-7. With Configuration Mode selected, use the
Up/Down button to display the MNT MIND item.
With Configuration Mode selected, use the Press the Enter button. When entered from an
Up/Down button to scroll to display enabled state, Maintenance Minder offers a
MAINTENANCE MINDER. Press the Enter button. submenu with the options QUIT MM, RESET,
When entered from a disabled state, DISABLE, and SETUP. Use the Up/Down button to
Maintenance Minder offers a submenu with the select SETUP, then press the Enter button. The
options QUIT MM and ENABLE. Use the Up/Down current time interval is displayed (hours).
button to select ENABLE. Press the Enter button.

Resetting Maintenance Minder
Proceed as described under Setting Time

Interval and Action Option.
Resetting Maintenance Minder

When Maintenance Minder is active, and, after
you have performed scheduled maintenance,
you wish to reset the reminder prompt, enter
Configure Mode.
With Configuration Mode selected, use the

Press the Enter button. Use the Up/Down
button to select Reset, then press the Enter
button. Select QUIT MM and press the Enter
button again. Save changes, as prompted.
Disabling
When Maintenance Minder is active and you
wish to disable it, enter Configure Mode.
With Configuration Mode selected, use the

Press the Enter button. Use the Up/Down
button to select DISABLE, then press the Enter
button. Select QUIT MM and press the Enter
button again. Save changes, as prompted.

Initial 90 Day/250 Deadman Hours (HD) Maintenance
Initial 90 Day/250
Deadman Hours (HD)
Maintenance
Perform the following maintenance tasks 90 days after the lift truck was put into service or at
250 HD, whichever comes first.
Component What to do
Drive Unit Break mounting bolts free and reapply thread-locking compound
(P/N 990-544). Re-torque standard drive unit mounting bolts to 180 ft. lb.
(244 Nm). Re-torque heavy duty drive unit mounting bolts to 350 ft. lb.
(475 Nm). Change fluid.
Hydraulic Tank Change hydraulic fluid and filter.
Power Amplifier(s) Torque power amplifier terminal bolts - 100 in. lb. (11.3 Nm).

Every 180 Days or 500 Deadman Hours (HD)
Every 180 Days or 500

Deadman Hours (HD)
Perform the following maintenance tasks every 180 days or 500 HD, whichever comes first.
Component What to do Refer to
Battery Check the weight stamped on the battery in the lift truck against the
minimum and maximum allowable weights on the specification tag
for the lift truck. Report any lift trucks that are running with Page 3-2
batteries under the minimum or over the maximum allowable weight.
Inspect all battery connectors and leads for damage and cuts in Page 5-2
protective coatings. Make sure the battery gates are in place and not
damaged. Make sure the battery has no more than 0.5 inch (13 mm)
free play in any direction.
Brakes In an open area, measure stopping distance. Traveling to 2 to 3 mph

(3.2 to 4.8 km/hr) empty, push the EPO switch; the empty lift truck Page 7-62
should stop within 2 to 4 feet (0.6 to 1.2 m). During normal
operation, with a rated load and traveling at top speed, the lift truck
should stop within approx. one and one-half lift truck lengths.
Stopping distance depends on the load, floor, and tire condition.
Examine for signs of oil on the pads or rotor. If oil is present,
disassemble brake, clean rotor and replace the pads. Check brake
gap.
Contactors Inspect contactor tips for burnt or pitted surfaces. Failure to replace
the tips may prevent the contactor from opening or closing causing
unscheduled downtime. With the key switch OFF and the battery
disconnected, check the plunger for smooth operation with no
binding. If binding occurs, the lift truck may malfunction or exhibit
intermittent fault codes.
Control Handle Verify travel function is smooth and responsive through full range of Page 7-21
motion. Check for play in center position of travel control. Verify all
handle switches function correctly.
Deadman Pedal Check for smooth operation with no binding. Check for correct Page 7-27
activation and deactivation of the deadman switch by the pedal.
Drive Unit Inspect for leaks. Check fluid level. Make sure O-ring is present on Page 7-29
the dipstick. Examine for radial ring wear. Apply grease to the steer
gear on the drive unit. Lubricate all grease points on the drive unit.
Electrical Cables Inspect all power cables for nicks or cuts. Give special attention to
cables that are not stationary, for example, cables to the drive motor.
Replace any cable that is damaged or shows signs of excessive heat.
Failure to do so causes intermittent system shutdowns and/or
electronic failures. Check the tension of the over-the-mast pulley
cables. Set tension so the cables just stay on the pulleys. Higher
tension causes premature failure. Maximum spring tension is 5 to 7
in. lb. (0.57 to 0.79 Nm).

Forks Examine for excessive wear, bends, cracks, welding arcs, excessive Page 7-123
heat, or unauthorized modifications. Replace if found. Check fork up
tilt. It must be between level and 0.5 in. (12.7 mm) maximum. Check
fork tip height. Verify they are within 0.25 in. (6.3 mm) of each other
(31 in. and longer) or 0.125 in. (3.2 mm) of each other (under 31 in.)
at the tips.
Frame and Baseleg General visual inspection of structural members for cracks, including
Checks but not limited to baselegs, main frame, and tractor.
Hardware Check bolt torque of major components (motors, pumps, brake, drive Appendix
unit and mast-to-tractor mounting bolts).
If the fastener was previously marked with a paint pen when torqued,
look at the markings to verify the fastener has not moved. If the
fastener has moved or is in question, remove the fastener, clean the
threads, and apply the appropriate thread-locking compound. Install
the fastener and torque to the correct value, turning it in the
tightening direction. Use a paint pen and mark the fastener for future
inspection.
If the fastener was not previously marked with a paint pen, determine
the correct torque values. Set the torque wrench to 85% of the
required torque value and check the torque of the fastener, turning it
in the tightening direction. If the fastener does not move, use a paint
pen and mark the fastener for future inspections. If the fastener
moves, remove the fastener, clean the threads, and apply the
appropriate thread-locking compound. Install the fastener and torque
to the correct value. Use a paint pen and mark the fastener for future
inspections.
Replace any broken or missing hardware.
Horn Check that the horn sounds correctly when activated. Check
mounting bracket insulators.
Hydraulic Hoses Inspect all hydraulic hoses for leaks, nicks, cut, chafing, and bulges.
Replace the damaged hoses as soon as possible. Inspect all fittings
for leaks. Repair any leaks immediately. Inspect over-the-mast hoses
for correct tension. Make sure over-the-mast pulleys spin freely and
show no signs of wear.
Hydraulic Tank Check fluid level.
Lift Chains Check adjustment. Inspect center cylinder chain anchors and Page 4-11
springs. Inspect for excessive stretch or wear (tool P/N 939-10606). Page 7-115
Lubrication Lubricate all grease points on the drive unit and load wheels. Apply Page A-2
grease to the steer gear on the drive unit. Coat all lift chains with
spray lubricant.
Mast Wipe old grease off mast uprights and apply new grease. Inspect
anti-rattle pads. Examine mast bearings. Inspect mast and carriage Page 7-115
stops for tightness and wear. Inspect rails for abnormal wear, metal
flakes or shavings. Repair any grooves worn in the mast deeper than
1/8 in. (3 mm).

Motors AC - Check cable lugs. Make sure they are tight to the terminal
studs. The outside nut should be torqued to the value listed on
page 7-74. Replace any cable that shows signs of excessive heat.
Check sensor wires for sound connection and condition. Blow out
inside of the motor with compressed air.
DC - Visually inspect brushes for excessive heat (discoloration of the

pigtails). If excessive heat is evident, inspect the armature circuit for
loose connections. Check the condition of the commutator per photos
on page 5-8. Find the shortest brush in the holder. Remove each
brush and check overall dimension per the table on page 7-76.
Inspect each brush for even wear over the full surface of the brush. If
the brush is not contacting the complete surface, replace the
brushes. Inspect the brush rigging for damage or loose brush
holders. Make sure the connections on the brush leads are tight.
Check the brush spring tension. Blow out the inside of the motor
with compressed air. Blow out the impeller and cooling fins. Make
sure cable lugs are tight to the terminal studs. The inside and outside
nuts should be torqued to the values listed on page 7-74. Replace any
cable that shows signs of excessive heat. Check sensor wires for
sound connection and condition.
Overhead Guard Inspect guard for physical damage. If structurally damaged, replace
the carriage.
Pallet Clamp Check operation of pallet clamp
Power Amplifier(s) Torque power amplifier terminal bolts - 100 in. lb. (11.3 Nm).
Safety Belt or Check for signs of wear, fraying, or damage

Harness and Tether
Shorts to Frame Check for electrical shorts to frame. Page 5-2
Skid Pads To check floor clearance, park the lift truck on a level and flat floor
surface. Measure the clearance between each skid pad and the floor.
Proper clearance is 0.31 to 0.56 inches (8 to 14 mm). If clearance
exceeds 0.75 inch (19 mm), the skid pads must be replaced.
Static Straps Make sure static straps are not worn or broken. Clean debris from
straps. Check resistance of resistor in standoff. Resistance must
measure >200K and <250K. EE lift trucks require a phosphor bronze
static strap; do not use steel braided cable on EE lift trucks.
Steering Check steering system function is smooth and responsive, without

binding and excessive play. Inspect teeth on the steer gear and drive
unit for wear.
Switches Check all switches for correct operation and adjust as needed.
Ventilation Slots Make sure ventilation slots in the tractor frame are clear of
obstructions and debris.
Warning Decals Replace any illegible or damaged decals.
Warning Lights Check for correct operation.

Wheels and Tires Examine for bond failure, chunking, and excessive or uneven wear.
Inspect load wheel bearings for binding or excessive play. Inspect
drive axle for excessive play.
Wire Guidance Check sensor assemblies for damage and mounting hardware for
tightness. Verify lift truck acquires and tracks the guide wire
correctly. Verify brake is applied when lift truck loses wire.

Every 360 Days or 2000

Deadman Hours (HD)
Drive Unit Change fluid. Page A-2
Hydraulic Reservoir Change fluid and filter. Page A-2
Lift Pump Separate lift pump and motor. Apply molybdenum anti-seize Page 7-100
compound (P/N 990-638) to the splines.

Chain Maintenance
Chain Maintenance
Inspection
Make sure chains are not damaged. Check the
chain for wear using a Chain Gauge
(P/N 939-10606). Replace the chains when
necessary with genuine Raymond spare parts.
Condition Cause Maintenance Procedure
Use a chain gauge or lay the chain on a flat

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

Rust and corrosion Oil chain frequently.
lift truck chains.
Infrequent oiling, rust, corrosion,

Cracked Plates
chain fatigue
Bent pins or plates Replace the chain.

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

Inspection

Models 5400/5500/5600 Maintenance Manual Section 5. Troubleshooting
Section 5. Troubleshooting

Section 5. Troubleshooting Models 5400/5500/5600 Maintenance Manual
Electrical Troubleshooting
Electrical Shorts to Frame

Troubleshooting “Shorts to frame” is an industry term for
unintentional current leakage paths between
normally isolated electrical circuits and their
General metal enclosures.
Shorts to frame may be metallic connections,

such as a wire conductor contacting metal
through worn insulation. More often, shorts to
Block the lift truck so that the drive tires frame are resistive “leakage” paths caused by
are off the floor whenever a contamination and/or moisture.
troubleshooting procedure requires
turning the key switch ON. This prevents These leakage paths can result in unwanted
accidents caused by unexpected lift electrical noise on the metallic lift truck
truck travel. structure and can cause incorrect operation.
Unless otherwise directed, disconnect Shorts to frame are caused by:

the battery connector when you check
electrical circuits or components with an • Accumulation of dirt
ohmmeter. Electrical current can damage • Battery electrolyte leakage
an ohmmeter. • Motor brush dust
• Many problems can be caused by a dirty • Motor brush leads touching the housing
battery. Make sure the battery is clean. • Breakdown in insulation
• Save time and trouble by looking for • Bare wires
simple causes first. • Pinched wiring harness
• Use a Digital MultiMeter (DMM) such as a • Incorrect mounting of circuit cards
Fluke meter for all measurements. Analog
meters can give inaccurate readings and Shorts to frame can occur at numerous
load down sensitive electronic circuits locations on a lift truck, including:
enough to cause failure. Make sure meter
cables are connected to the correct meter • Batteries
jacks and that the correct function and • Motors
scale are selected. • Cables, wiring, and harnesses
• Printed circuit boards are conformal • Heatsinks
coated. Make sure meter leads make a
good electrical connection with test points. • Bus bars
• When measuring voltage, connect the • Solenoids

positive meter lead to the connector or • Contactors
probe point marked (+) in the test. • Terminal strips
Connect the negative meter lead to the
connector or probe point marked (–). • Switches
• Whenever measuring resistance, turn the • Power panel insulation

key switch OFF and disconnect the battery • Circuit card mounts
connector. Battery current can damage an
ohmmeter. Isolate the component from the Shorts to Frame Test
circuit.

Shorts to Frame
2. To test the battery for shorts to case, a. To identify the cause of the short to
connect a 12V test light to the battery case frame, disconnect circuit components
from battery B+, and then to the battery until the low resistance condition
case from battery B–. If the light disappears. Do not reconnect
illuminates at all, even momentarily, there components one at a time, but leave
is a serious problem with the battery, them disconnected until the low
either external contamination or internal resistance reading disappears. Prevent
damage. Do not continue until this disconnected terminals or connectors
condition is corrected. The meter may be from touching the lift truck frame or
damaged if you proceed before correcting other conductive surfaces.
this condition.
b. The most likely areas to check are:
Install another battery in the lift truck and • Motors
repeat this procedure from step 1. • Heatsinks
• Power cables
If the test light does not illuminate,
continue to the next step. • Power circuit components
3. Use a DMM set on the ampere function to • Control circuit components
measure the current leakage from the c. Repair or replace the component
battery case to battery B+ and from the causing the low resistance condition.
battery case to battery B– (not lift truck B+ Repeat step 4.
and B–). Begin measuring at the highest
d. Reconnect all other components
ampere scale and work toward the lowest.
previously disconnected, one at a time,
A reading of more than 0.001A (1mA)
measuring resistance between steps. If
indicates a serious short. Do not continue
a reading is <1000 ohms when
until this condition is corrected. The meter
reconnecting a component, that
may be damaged if you proceed before
component or its wiring is faulty; repair
correcting this condition.
or replace as appropriate.
Install another battery in the lift truck and e. When, after all components are
repeat this procedure from step 1. reconnected, you get readings
>1000 ohms, continue with the next
If the current is <0.0002A (0.2mA), go to step.
step 4. If the current is >0.0002A (0.2mA)
5. Reconnect the battery connector and turn
and <0.001A (1mA), remove the battery
the key switch ON. If the battery was
from the lift truck, then continue with
previously removed, make sure the battery
step 4. Make sure the battery case does
case does not touch the lift truck frame.
not touch the lift truck frame during the
remaining tests. NOTE: The functions being checked must be
energized. Example: to check for shorts
4. With the battery disconnected (or removed
to frame in the travel circuit, travel must
and disconnected) from the lift truck, use
be requested.
a DMM to measure the resistance from lift
truck frame to lift truck B+, to lift truck B– 6. Use a DVM set to the current function to
(not battery B+ and B–), and to all fuses measure current leakage to the lift truck
and motors. A reading of <1000 ohms frame from lift truck B+, lift truck B– (not
indicates a serious short. Do not continue battery B+ and B–), and all fuses and DC
until this condition is corrected. The meter motor terminals. Begin measuring at the
may be damaged if you proceed before highest ampere scale and work toward the
correcting this condition. To correct the lowest. If the current is <0.001A (1mA), go
condition, perform steps a. thru e. to step 7. If the current is more than

Battery State-of-Charge
0.001A (1mA), continue with the following assumes it is the same battery and continues to
steps. monitor the battery for discharge and updates
a. To identify the cause of the short to the Operator Display as required.
frame, disconnect circuit components
until the leakage current reads <0.001A If a different battery voltage is detected, BSOC
(1mA). Do not reconnect components assumes a different battery is installed and
one at a time, but leave them tests to determine the state-of-charge of the
disconnected until the leakage current replacement battery. The replacement battery
reads <0.001A (1mA). Prevent must meet one of the following criteria before
disconnected terminals or connectors the display resets and lift is restored.
from touching the lift truck frame or • The replacement battery must have a
other conductive surfaces. charge level at least 50% different from the
b. The most likely areas to check are: previously installed battery,
• The charge value of the replacement
• Motors
battery must be greater than the
• Heatsinks configured BSOC setting.
• Power cables
The criteria are determined in this way:
• Power circuit components
• BSOC compares the charge of the battery
• Control circuit components
that was connected to the lift truck with
c. Repair or replace the component(s) the replacement battery’s charge. A charge
causing the leakage current. difference of at least 50% between the two
Repeat step 6. batteries resets BSOC to show the
d. Reconnect all other components state-of-charge of the replacement battery,
previously disconnected, measuring that is, the measured state-of-charge of
current between steps. If a reading is the replacement battery minus the
more than 0.001A (1mA) when remembered state-of-charge of the old
reconnecting a component, that battery must equal or exceed 50%. This
component or its wiring is bad. Repair reset can be higher or lower than the old
or replace as appropriate. battery.
7. When, after all components are • BSOC looks at the configured reset point.
reconnected, you get a reading <0.001A BSOC reset is programmable from 55% to
(1mA) there is no short to frame condition 100% of total battery charge and can be
with the lift truck or the battery. If you changed by entering the Configure Mode
previously removed the battery from the using the Superword. The replacement
lift truck, re-install the battery. battery must be greater than the
configured percent of charge before BSOC
changes. Example - BSOC configured at
Battery State-of-Charge 95%. Plugging in a battery at anything
below 95% charge will not change the
Battery State-of-Charge (BSOC) is a feature that Operator Display. Older batteries or
monitors and remembers the charge level of the applications providing inadequate
battery connected to the lift truck and helps to charging time could require a lower
prevent excessive discharging of that battery. configured value for BSOC since older
Operating a lift truck using a discharged batteries might be unable to reach a
battery can damage both the battery and the higher percent charge. Therefore, some
electrical components of the lift truck. batteries could require BSOC configured
as low as 55% before lift cutout resets and
At power-Up, BSOC tests the battery voltage to the Operator Display shows the charge of
determine if it is the same as it was at the replacement battery.
power-down. If the voltage is the same, BSOC

Lift Cutout Adjustment
Setting Battery State-of-Charge

Cutout
1. Fill, charge, and install a battery that is
typical of the batteries normally used in
this application.
2. Have a customer operator use the lift
truck in the normal application until
cutout occurs.
3. Allow the battery to cool and stabilize for
at least two hours.
4. Before filling the battery, either take
specific gravity readings or measure open
circuit voltage of the battery cells.
5. Compare the measurements with the
battery manufacturer’s recommendations
for maximum discharge.
6. Adjust the cutout value as needed and
repeat the previous steps until battery
cutout occurs at the desired discharge
level.
Lift Cutout Adjustment

1. Run the lift truck until lift cutout is
activated.
2. Allow the battery to set unused for two
hours. Check the SG and compare to
manufacturer’s recommendations.
3. Adjust cutout in Config until the correct
discharge is obtained.
NOTE: Additional BSOC adjustment is available
using FlashWare.
Electrostatic Discharge
Electrostatic discharge can cause certain fault
codes, such as FP or FT. Over time, electrostatic
discharge can damage circuit cards. Static
tends to be higher in environments with low
relative humidity, such as freezers. See Static
Precautions on page 2-7.
Make sure static straps are installed on the lift

truck and work correctly.

Fuses
Fuses the fuses are held tightly in the clips. Fuse clips
should exert resistance on both legs of the fuse
when inserted. Loose clips should be tightened
Test /Inspection with pliers.
Examine the fuse for signs of overheating,
To test a fuse, remove it from the lift truck. The
discoloration, fracking, or other physical
resistance should be <1 ohm.
damage. Replace as necessary.
Table 5-1 lists the fuses for a lift truck with all
Inspect the fuse clip for damage or signs of
available options. Not all lift trucks will have all
corrosion, disconnect the Fuse/Relay Card
of the fuses listed.
connectors, and clean the clips with a brush or
dry rag as necessary. Damage may require
replacement of the Fuse/Relay Card. Make sure
Table 5-1. Fuse Chart
Fuse Function Location Amps
FU1 Power Fuse for Steer Power Amplifier 100
FU2 Power Fuse for Traction Power Amplifier 350

Contactor Panel
Power Fuse for Lift Power Amplifier - Model 5500, 5600 500
FU3
Power Fuse for Lift Motor - Model 5400 350/Hi-Pro - 500
FU5 Control Fuse for Vehicle Manager B+ 15
FU6 Control Fuse for Vehicle Manager B– 15
FU7 Control Fuse for Aux Power B+ 5
FU7 Control Fuse for Aux Power B+ with Cold Storage Fuse/Relay Card 15
Option
FU8 Control Fuse for Aux Power B– 5
FU8 Control Fuse for Aux Power B– with Cold Storage 15

Option
FU9 Control Fuse for RF Terminal B+ Carriage Console 2
FU10 Control Fuse for RF Terminal B– Plate 2
FU21 Control Fuse for Cold Storage CCC Heater CCC Heater Plate 10
Control Fuse for Cold Storage Deadman Heater Carriage Console 5

FUDM
Plate

DC Motor Troubleshooting
Mica
Motor Types Segment
Refer to Figure 5-1.

• A series-wound motor has only two NORMAL
external connections because the UNDERCUT
armature and field windings are connected
internally.
High Mica
• A permanent magnet motor has two
external connections. The field is produced
by an internal magnet.
NOTE: Field connections may be labeled A or S. HIGH MICA
Series wound motor field connections
may be labeled D. Figure 5-2. Mica Undercutting
The commutator must be smooth and clean to

Series-Wound Motor Permanent Magnet
provide maximum brush life. When
S/D Motor
commutators are not correctly maintained,
MS+
A2 carbon dust can collect in the grooves between
the segments. This can lead to a short circuit in
MS the armature.
MS– Remove the brushes from their box. Inspect the

A1
contact surface and brush length. If the brush
MP
surface has groove(s) or pit marks, it indicates
the presence of a burr on the commutator
A surface.
Figure 5-1. Motor Circuits Good commutation is indicated by a dark

brown polished commutator and an evenly
Inspection polished brush wearing surface. See
Commutator Surfaces on page 5-8.
Inspect the commutator for surface condition
and high mica. Most armatures have the mica If the commutator appears rough, pitted, or has
undercut. If the armature on your motor does signs of burning or heavy arcing between the
not, do not attempt to cut it. commutator bars, remove the motor for
servicing.

Servicing specified conditions. Refer to Polishing the

Commutator on page 7-76 for instructions.
Some conditions, identified in Table ,
“Commutator Surface,” on page 5-8, may be Some conditions can be resolved by recutting
resolved by cleaning the commutator with a the commutator on a lathe. This requires
special polishing stone. Polishing the special equipment and training and should only
commutator should only be attempted for the be attempted at a qualified DC motor repair
facility.
Table 5-2. Commutator Surfaces
Condition Probable Cause Commutator Surface

Good Condition-Light Uniform coloring indicates satisfactory operation of
BRUSHWEAR01.tif
Film the machine and brushes. Acceptable film color

may vary from light to dark due to film thickness.
Satisfactory This condition can appear in alternating bars as

BRUSHWEA03.tif
Condition-Light and Dark shown or every 3rd or 4th bar. This is caused by
Pattern imbalances in the windings or other motor
variances. It is not an indication of commutator
problems. The motor should have no issues
running, but the condition may indicate a need for
more frequent inspections.
Unsatisfactory Threading or streaked film on the commutator
BRUSHWEAR04.tif
Condition-Streaky Film surface. May be accompanied by rattling or loud

With No Commutator operation. This condition is frequently due to
Wear incorrect brush grade. Environmental conditions,
such as freezer or low humidity, can be a
contributing factor. This condition may be repaired
with a polishing stone if caught soon enough. Refer
to Polishing the Commutator on page 7-76.
Unsatisfactory Patchy colors of varying densities and shape. This
BRUSHWEAR05.tif
Condition-Uneven Film condition is generally due to unclean operating

conditions and does not indicate damage to the
commutator. Clean the commutator with a
polishing stone and compressed air (see Polishing
the Commutator on page 7-76). Consider more
frequent scheduled maintenance intervals.
Unsatisfactory Condition- Dark areas can be isolated or regular. This
BRUSHWEAR06.tif
Film With Dark Areas condition indicates a commutator is out-of-round.

Continued use may result in failure and damage to
other systems. The motor should be replaced or
recut at a qualified repair facility.
Unsatisfactory Bars are low on entry and leaving edges causing the
BRUSHWEAR07.tif
Condition-Example of brushes to ride on the middle of the bars.

Incorrect Commutator Continued use may result in failure and damage to
Machining other systems. The motor should be replaced or
recut at a qualified repair facility. Consider more

Condition Probable Cause Commutator Surface

Unsatisfactory Bars are low in the middle causing the brushes to
BRUSHWEAR08.tif
Condition-Example of ride on the entry and leaving bar edges. Continued

Incorrect Commutator use may result in failure and damage to other
Machining systems. The motor should be replaced or recut at a
qualified repair facility. Consider more frequent
scheduled maintenance intervals.
Unsatisfactory This is a further development of the third example.
BRUSHWEAR09.tif
Condition-Streaky Film Earlier corrective action should have been taken.

With Commutator Wear Continued use may result in failure and damage to
other systems. The motor should be replaced or
recut at a qualified repair facility. Consider more
Unsatisfactory Darkening of commutator in sequences two pole
BRUSHWEAR10.tif
Condition-Double Pole pitches apart. This condition may result from an

Pitch armature fault or some other fault. Continued use
may result in failure and damage to other systems.
The motor should be replaced or recut at a qualified
repair facility.
Unsatisfactory This condition may result from storage of the
BRUSHWEAR11.tif
Condition-Brush Contact machine for long periods with brushes in position. It

Mark may also result from operation in prolonged stall
conditions. Storage marks are easily removed with a
polishing stone, see Polishing the Commutator on
page 7-76. Stall marks should be cleaned and
inspected for damage or shorts. The motor should
be replaced if damage has occurred.
Unsatisfactory This condition is caused by high mica in every slot
BRUSHWEAR12.tif
Condition-Bar Edge and can be caused by incorrect or excessive

Burning-Cause High stoning. The same effect can occur on one bar only.
Mica Chattering or loud operation may also be noticed.
Continued operation will result in increased brush
wear and may result in commutator damage. The
motor should be replaced or recut at a qualified
repair facility.
Unsatisfactory This condition is due to sparking under the brush.
BRUSHWEAR13.tif
Condition-Small Bright This is caused by overloaded machines or low brush

Spots pressure. Check the brush spring tension, see
Motor Brush Spring Tension on page 7-75. If not
corrected, this condition will result in damage to the
commutator. This condition may be repaired with a
polishing stone if caught early and no scoring has
occurred, see Polishing the Commutator on page
7-76. If damaged, the motor should be replaced or
recut at a qualified repair facility.
Open Circuit Motor Test • a broken wire in the field or armature

winding
An open circuit is an electrical circuit within the • loose or bad connections
motor that is broken. This can be caused by:
• bad brushes or brush springs Refer to Figure 5-1 on page 5-7 for the following
procedure:

1. Isolate the motor from the lift truck circuit If the ohmmeter reads resistance of less than
by removing the power cables. Use two 100,000 ohms, the motor is grounded. Clean,
wrenches to avoid twisting the terminal repair, or replace the motor as necessary.
stud.
2. With the motor at room temperature, Short Circuited Armature or Field
connect the leads of a digital ohmmeter Winding
between the individual circuits in the
motor. A short circuited winding is one that the
3. Observe the following measurements: insulation on the field or armature has broken
down at two or more points. The breakdown
DC Motor Probe Points Resistance creates a low resistance path, allowing current
to flow from one turn of the coil to another
A to S <1 ohm
Lift adjacent coil turn, without actually flowing
A to Frame through the coil wire. The result is a decrease in
Steer MS+ or MS– to >100,000 ohms total resistance of the motor winding and an
frame increase in the current flow. The severity of the
short circuit depends on its location.
4. If the meter indicates high resistance in
A shorted motor may be indicated by:
the armature, check the condition of the
brushes before replacing the motor. • slow or sluggish operation
5. If you find an open circuit in a • running faster than normal (suggests a
series-wound motor, the motor must be short in the field)
disassembled by a motor rebuilding facility • overheating
to isolate the problem to the field or
• blowing a power fuse
armature circuit.
• burning of brush wires
Grounded Motor Test • severe burning or discoloration on the
armature coil
In a grounded motor, an electrical circuit exists • severe burning or discoloration on one or
between the current-carrying conductors and two commutator segments every 90° of
the motor housing. This can be caused either by rotation.
direct contact or through conductive foreign
material. These symptoms can be caused by problems
other than the motor itself, such as binding in a
The ground may be caused by: related pump, hose, or solenoid valve.
• insulation breakdown
Testing a motor for short circuited windings
• brush leads touching the motor housing
requires special equipment at a motor
• build-up of carbon dust or other materials rebuilding facility.
Isolate the motor from the lift truck circuit by

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

ohmmeter to a motor terminal and the other
lead to an unpainted surface of the motor
housing. Set the ohmmeter to the highest scale.

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

U motor will move erratically, as if hunting, and
there is a high-pitched sound.
Using a clamping ammeter, measure current in

each of the motor power cables. The shorted
phase will read significantly higher than the
AC other two phases.
3φ
V W
U
AC
V
3φ
W
Figure 5-3. AC Drive Motor Circuits

Wiring
Wiring
Visually inspect all wiring and electrical
components for:
• Loose connections or connectors
• Loose or broken terminals
• Damaged terminals, blocks, or strips
• Exposed wire at terminations, excessive
strip gap
• Abrasions, scrapes, nicks in the wire,
damage from overheating or burns, or
other general insulation damage
• Broken wire strands and shorted
conditions (especially those that are close
to metal edges or surfaces)
During troubleshooting and repairs, it may be

necessary to unplug a connector, move a
harness, cut a cable tie, or remove the wire
from a bracket. Note the location of the wire and
all protective or securing attachments before
moving the harness.
After repair, return or replace all protective

and/or securing hardware to its original
condition. Protective materials are necessary to
provide reliable performance of the interconnect
system.
Examine and maintain any added materials

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

cable harnesses. Avoid attaching cables to
hydraulic hoses that expand with pressure,
pinching the attached electrical cables.
Use a DMM to check for wiring continuity.

Electrical Connector Locations

Table 5-3. Connector Locations
Connector Function or Routing Location
FSUP Connector on Fan Suppressor Near Fan
HTR3 Connector for Deadman Heater Near Deadman
J1 Connector for Lift/Lower Pendant Near VM in Main Harness
JP1 Connector for Lights Light Assembly
JP1L Connector from Load Wire Guidance Antenna to Filter Card Load Antenna
JP1T Connector from Tractor Wire Guidance Antenna to Filter Card Tractor Antenna
JP2 Connector for Lights Light Assembly
JP10 Connector for Warning Light Under Warning Light
JPA7 Connector for Home Sensor Hydraulic Compartment
JPB– (–) Battery Connector

Battery Connector
JPB+ (+) Battery Connector
JPB1 Connector on Lift Motor Fan (EE only) Near Lift Motor
JPBR Connector for Brake Near Brake Assembly


JPC1 Connector for Steering Encoder
JPC2 Connector for Display Card
JPC3 Connector for 60 in. Limit Switch
JPC4 Connector for Lower Inhibit
JPC5 Connector for Lights/Fans
JPC6 Connector for Lift/Lower Bypass Switch
JPC7 Connector for Deadman Switches
JPC8 Connector for 24 in. Limit Switch
JPC9 Connector for Control Handle Carriage Control Card
JPC11 Connector for Over-the-Mast Cable #1
JPC12 Connector for Spare Power
JPC13 Connector for Sidegate Switches
JPC14 Connector for Sidegate Switches
JPC15 Connector for Light Display Card
JPC16 Connector for Over-the-Mast Cable #2
JPC17 Connector for Aux Card
JPC18 Connector for Aux Card
JPC19 Connector for Aux Lift and Lower Switch

Aux Card
JPC20 Connector for Aux Limit Switch
JPC21 Connector for Secondary Steer Input Encoder Carriage Control Card
JPC23 Connector on Aux Card for Aux Deadman Aux Card
JPE4 Connector for Steer Motor Encoder Hydraulic Compartment
JPF1 B– Aux Power and B+ Power Amps Connector
JPF2 B+ Key Switch Relays Connector

Fuse/Relay Card
JPF3 B– Connector
JPF4 Key Switch, EPO, Battery Sense Connector
JPLA1 Lift Amp Connector Lift Amplifier
JPLA2 Lift Motor Encoder Connector

Near bottom of Lift Motor
JPLA3 Lift Motor Temperature Sensor Connector
JPLA4 Lift Motor Encoder/Temperature Sensor Connector Hydraulic Compartment
JPS1 Contactor Panel Interface Connector Contactor Panel


JPS2 Wire Guidance Power Connector

Guidance Manager Card
JPS4 Wire Guidance Communications Connector
JPS8 Connector for 120”/150” Limit Switch

Behind Fuse/Relay Card
JPS10 Connector for Lift Inhibit Switch
JPS15 Connector for Travel Alarm Near Lift Amp
JPS16 Connector for Travel Cutout Switch
JPS25 Connector for Over-the-Mast Cable #1 Behind Fuse/Relay Card
JPS26 Connector for Over-the-Mast Cable #2
JPS27 Connector for Over-the-Mast wires for optional equipment Over-the-Mast wiring
JPS28 Connector for 180” Limit Switch Behind Fuse/Relay Card
JPS50 Connector for Pressure Transducer A

Hydraulic Compartment
JPS51 Connector for Flow Module
JPS52 Connector for Lift/Lower Alarm Behind Fuse/Relay Card
JPS53 Connector for Rail Sense Switch Near Horn Assembly
JPS54 Connector for Aisle Detect Sensor #1

Hydraulic Compartment
JPS55 Connector for Aisle Detect Sensor #2
JPS57 Connector for Lift Cutout Behind Fuse/Relay Card
JPSC1 Splice for CAN Bus Below Battery Connector
JPSC2 Splice for CAN Bus Behind Drive Motor
JPT2 USB Connector
JPT4 Connector
JPT6 Electric Steer Connector
JPT9 FlashWare Connector
JPT10 CAN Digital Inputs and Outputs Connector
JPT12 Lift Pendant Connector Vehicle Manager
JPT14 B+, B–, CAN Communications Connector
JPT18 Coil Drivers Connector
JPT20 Proportional Coil Drivers Connector
JPT22 Digital Inputs Connector
JPT24 Analog Inputs Connector
JPTA1 Traction Amp Connector Traction Amplifier


JPTA2 Traction Motor Encoder Connector Near Bottom of Drive

JPTA3 Traction Motor Temperature Sensor Connector Motor
JPTA4 Traction Motor Encoder and Temperature Connector Top of Drive Motor Power
Cables
JPW1 Connector for Load Sensor

Filter Card
JPW2 Connector for Tractor Sensor
JPY1 Connector for Flow Module
JPY2 Connector for Flow Sensor Temperature Sensor

Flow Module
JPY6 Connector for Flow Sensor Channel 1
JPY7 Connector for Flow Sensor Channel 2

Carriage Control Card Connectors
PC11
PC16
TP3
TP2
PC12
IL3
TP5
PC9
IL1
PC8
TP1
PC15
PC2
M11
PC6
IL2
PC5
M10
TP4
PC1
PC7
PC21 PC4
PC3 PC14 PC13
PC10
PC18 PC17
5
Figure 5-4. Carriage Control Card Connectors

Vehicle Manager Connectors
5MOTOR_AC3PHASEA.EPS
MOTOR_AC3PHASEB.EPS
Figure 5-5. Vehicle Manager Connectors
Guidance Card Connectors
DSP1 P1 P2 P3 P4 P5
MOTOR_AC3PHASEB.EPS
Figure 5-6. Guidance Card Connectors

Filter Card Connectors
JW2
JW1
MOTOR_AC3PHASEB.EPS
Figure 5-7. Filter Card Connectors
Fuse Relay Card
15A 15A
PF1
PF1
1 4
FU7
FU8
FU5
FU6
FU8 FU7 FU5 FU6
K3 K2 K4 K1
K3 K2 K4 K1
13 1 7 1 10 1
PF4 PF2 PF3

PF4 PF2 PF3
MOTOR_AC3PHASEB.EPS
Figure 5-8. Fuse Relay Card Connectors

Auxiliary Card Assembly
Figure 5-9. Auxiliary Card Connectors

Fuse/Relay Card Troubleshooting
Fuse/Relay Card approximately 1100 ohms. Replace as

necessary.
Troubleshooting
Refer to “Fuse Relay Card Connectors” for
Fuse/Relay Card component and connector
location information.
4. Measure the resistance between circuits 2
Fuses and 3. Welded tips will have a resistance
<0.5 ohm. Otherwise, there should be an
Fuses for system power (FU5 and 6) and Aux open circuit. Replace as necessary.
power (FU7 and 8) are present on the
Fuse/Relay Card. Refer to page 5-6 for Removal and Replacement
inspection and testing of fuses.
Remove relays by carefully cutting the strap
Relays securing them to the socket. Pull the relay out
straight to avoid bending or damaging the pins.
Install the relay by aligning the pins with the
Relays should be checked when indicated by a
corresponding sockets. Firmly press the relay
test or when troubleshooting any of the
straight into the socket until it is fully seated.
symptoms listed in the following table.
Secure the relay with a new strap.
Relay Circuit Possible Symptoms
Key-ON Key-ON options do not
Capacitor and FGND
K1
Aux Power power up with the lift truck.
Problems with the filter capacitors (C1, C2, or
Subsystem Contactors, solenoids,
C3) are most frequently observed on lift trucks
K2 Power brake, horn, or fans do not
operate.
equipped with an RF scanner unit. Visually
inspect the capacitors for any sign of damage.
Amp Amps do not power up or The capacitors may be physically different from
K3 Power have stopped
the one pictured. Inspect the mounting screw in
communicating.
the upper left mounting hole of the Fuse/Relay
Keep Alive Keep-alive accessories for Card (marked FGND). See Figure 5-10. If
K4 Power Cold Storage do not necessary, clean or replace this screw to make
function.
sure of a solid connection to the frame.
Inspection
Visually inspect the relay and socket for

discoloration, melting, or other signs of heating.
Replace as necessary. If the socket is melted or
damaged, replace the Fuse/Relay Card.
Test
1. Perform Test O32 - Toggle Relay Enable
(Page 6-119).
2. Turn the key switch OFF and remove the
relay (refer to Removal and Replacement).
3. Measure the resistance across pins 1-A
and 1-B. Resistance should measure

To test, measure the resistance from the FGND are tested in the reverse direction. Replace the
screw to any piece of bare metal on the frame Fuse/Relay Card as necessary.
with a DMM. Resistance should be <0.5 ohm.
Figure 5-11: Early version
CR5
Figure 5-10: Fuse/Relay Card Ground Screw
Input Diodes
NOTE: Remove connectors JP1 thru JP4 before
performing this test.
CR6
To test the relay coil input diodes, locate CR5
and CR6 on the Fuse/Relay Card for your card
version. See Figure 5-11 and Figure 5-12. Using
a DMM set to the “diode” function, measure the
voltage by putting the black probe on the
banded (right) side of the diode and the red
probe on the non-banded (left) side. Voltage
should be approximately 0.5V across each
diode. An open circuit is displayed if the diodes
Figure 5-12: Current version
Inrush Protection
A resettable fuse protects the VM battery sense

circuit and can be reset by turning the lift truck

OFF momentarily. Opening of the fuse

requently manifests as an FH code along with
other F-series codes.
NOTE: This test should be performed after the
lift truck has had a chance to come to
room temperature.
To test, remove JPF4 from the Fuse/Relay

Card. Measure the resistance from PF4-1 to
PF4-7. Resistance should rise slowly from near
zero to approximately 1.3 ohms. Replace the
Fuse/Relay Card as necessary.

Drive Unit Troubleshooting
Drive Unit
Troubleshooting
Refer to page 7-31 for standard drive unit repair
procedures and page 7-50 for heavy duty drive
unit repair procedures.
Table 5-4.
Symptom Probable Cause Required Action
Oil leaks Damaged sealing rings Replace sealing rings, bearing shims, and
drive shaft bearings.
Worn or damaged drive shaft Replace sealing rings, bearing shims, drive
shaft bearings, and drive shaft.
Housing/cover joint Reseal
Worn or damaged housing Replace drive unit.
Drive wheel Worn or damaged drive shaft bearings Replace sealing rings, bearing shims, and
wobbles drive shaft bearings.
Worn or damaged drive shaft Replace sealing rings, bearing shims, drive
shaft bearings, and drive shaft.
Loose wheel mounting hardware Inspect housing and drive shaft for damage.
Re-torque mounting hardware.
Noise Worn or damaged drive shaft bearing Replace sealing rings, bearing shims, and
drive shaft bearings.
Worn or damaged pinion bearings Replace pinion bearing and pinion shaft nut.
Worn or damaged gear set (drive shaft is Replace sealing rings, bearing shims, drive
in good condition) shaft bearings, pinion bearings, pinion shaft
nut, and gear set.
Worn or damaged gear set (drive shaft is Replace sealing rings, bearing shims, drive
worn or damaged) shaft bearings, pinion bearings, pinion shaft
nut, gear set, and drive shaft.
Worn or damaged helical gear and pinion Replace helical gear and pinion.
Steering Inadequate bearing lubrication Grease steering bearing.

binds
Worn or damaged steering bearing Replace radial rings and ball bearings.

Communication Error Code Troubleshooting
Communication Error Code Communication Code Every Time Key

Troubleshooting Is Turned ON
Troubleshoot per the code on the display using

Intermittent Communication Codes
Test I23 - CAN Bus (Page 6-77).
If possible, determine what the operator was
doing when the codes were generated; driving,
plugging, lifting, sounding horn, and so on.
Focus on these circuits for shorts to frame and

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

least 5 seconds before turning it back to the ON
position. Test the key switch for high
resistance. If nothing is found in the following
steps, replace the key switch.
1. Test for shorts to frame. See Shorts to
Frame on page 5-2.
2. If equipped with an optional light/fan
package, disconnect PC5. If the code goes
away, troubleshoot the light/fan circuitry.
NOTE: The condition of the light/fan
suppressor module cannot be checked
with a DMM. If the suppressor module is
suspected to be bad, replace it.
During Travel and/or Plugging
If the lift truck is equipped with an optional

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

page 5-2.

Troubleshooting Aisle Exit Error Code J2
Troubleshooting Aisle
Exit Error Code J2
Refer to the “sub-codes” in Table 5-5 when
troubleshooting Code J2 - Aisle Exit Error
(VM S/W V4.6 and up).
Table 5-5. Code J2 Sub-Codes
Sub-Code Description
01 The 2nd member of an End-Of-Aisle (EOA) magnet pair has not been detected after more than
40 in. (102 cm) of travel. Aisle status indicated “In-Aisle” at the time the initial magnet was
encountered.
02 Same as Sub-code 01, except aisle status indicated “Out-of-Aisle” at the time the initial magnet
was encountered.
03 Guidance switch was not switched to AUTO while aisle status indicated “In-Aisle” and the lift
truck has traveled more than 30 ft. (9.1 m) down the aisle in MANUAL guidance mode.
04 Same as Sub-code 03. This is a redundant check.
05 Shorted sensor. The lift truck has traveled more than 5 ft. (1.5 m) with the sensor continuously
indicating the presence of a magnet.
06 Deadman was released (hard plug mode) as it passed over a magnet and speed is >1 mph
(1.6 km/h).
07 Lift truck powered up while parked directly over a magnet. The lift truck must be keyed ON in a
position where it is away from any magnets.
08 Same as Sub-code 05. This is a redundant check.
11 Same as Sub-code 01, except it was recorded when the Guidance Switch was in Manual,
indicating the lift truck passed over a magnet while lift truck was free roaming.
12 Same as Sub-code 02, except it was recorded when the Guidance Switch was in Manual,
indicating the lift truck passed over a magnet while lift truck was free roaming.
98 “In-Aisle” or “Out-of-Aisle” is stored and remembered when the key switch is turned OFF.
Non-volatile RAM expects to see “In-Aisle” or “Out-of-Aisle” during key ON. This event is logged if
the information that is seen is neither of the two at power-Up.
99 J2 code is remembered at key ON. If a J2 is detected in non-volatile RAM at power-Up, the error
is displayed again. This creates a duplicate entry in the error log. Event 99 is logged to indicate
this code was not cleared prior to key OFF so it is not assumed to be another J2 occurrence.

Symptom Tables: Hydraulic Functions
Symptom Tables:
Hydraulic Functions
NOTE: If it is determined that a component
failed as a result of hydraulic fluid
contamination, replace the failed
component and flush, fill, and bleed the
hydraulic system.
NOTE: Use these symptom tables in
conjunction with the electrical and
hydraulic schematics.
Intermittent Lift/Lower
Possible Cause Action

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

Bad battery Adjust lift cutout as necessary. Replace the battery
with a fully-charged battery.
Bad optional lift limit switch Run Test I05 - Lift Inhibit Switch (optional)
(Page 6-73) and Test I04 - Lift/Lower Inhibit
Bypass (optional) (Page 6-72).
12 Volts to the encoder is open. The motor will Run Test I20 - Lift Motor RPM (AC lift only)
turn very slow and the amperage will go high. (Page 6-76).
Slow Lift - Carriage: Lift motor runs

Bad battery Adjust lift cutout as necessary. Replace the battery
with a fully-charged battery. Test the battery for
bad cells. See Battery Procedures on page 7-70.
Emergency lowering valve not seated correctly Make sure the emergency lowering valve is closed.
Check for contamination. If contamination is
present, clean the valve, flush, fill, and bleed the
hydraulic system.
Bad proportional lift/lower valve Inspect for binding. Run Test O12 - Proportional
Solenoid PWM Ramp (Page 6-111).
Relief valve REL1 stuck open Test system pressure. Check for contamination. If
contamination is present, replace the valve, flush,
fill, and bleed the hydraulic system.

Lower Function

Plugged or malfunctioning flow control valve Check for contamination in the hydraulic fluid. If
in lift cylinder contamination is present, inspect and clean the
relief valve, replace the flow control valves, flush,
fill, and bleed the hydraulic system.
Bad lift pump Test system pressure.
Binding in the mast Inspect the mast and bearings for signs of binding.
Bad lift motor DC Lift Trucks: Test the lift motor. See DC Motor
Troubleshooting on page 5-7. Check amp draw.
AC Lift Trucks: Run Test O28 - Ramp Lift Motor
(AC lift only) (Page 6-116).
Bad lift motor encoder Run Test I20 - Lift Motor RPM (AC lift only)
(Page 6-76).
Unable to Pick Up a Load

Battery problems Adjust lift cutout as necessary.
Replace battery with fully-charged battery.
Test battery for bad cells. See Battery Procedures
on page 7-70.
Incorrect lift pressure adjustment Check and adjust lift pressure setting.
Bad lift pump Test system pressure.
Bad lift motor DC Lift Trucks: Test lift motor. See DC Motor
Troubleshooting on page 5-7. Check amp draw.
AC Lift Trucks: Run Test O28 - Ramp Lift Motor
(AC lift only) (Page 6-116).
Optional Pressure Switch and/or 2 stage See “Test I70 - Pressure Switch (optional)” on
Solenoid not functioning correctly. page 6-95. and Test O25 - Toggle 2 Stage Select
Note: This may not be seen until you Solenoid (optional) on page 6-115
transition out of Freelift; then the lift motor
may stall.
Lower Function
Slow Lower

Binding proportional valve Check the proportional valve operation. Run Test
O12 - Proportional Solenoid PWM Ramp
(Page 6-111).
Mechanical binding in bearings or telescopic Adjust or replace the bearings. If still slow, check
the mast shimming.
Plugged or malfunctioning flow control valve Open the emergency lower valve. If still slow,
remove and inspect the flow control valves. Check
for contamination in the hydraulic fluid. If
contamination is present, inspect and clean the
relief valve, flush, fill, and bleed the hydraulic
system. If no contamination is found, replace the
flow control valves in the main lift cylinders.

Lower Function
Intermittent Lower

Bad load holding solenoid Run Test O11 - Toggle Load Holding Solenoid
(Page 6-110).
Binding proportional valve Check the proportional valve operation. Run Test
O12 - Proportional Solenoid PWM Ramp
(Page 6-111).
Plugged or malfunctioning flow control valve Open the emergency lower valve. If still slow,
remove and inspect. Check for contamination in
the hydraulic fluid. If contamination is present,
inspect and clean the relief valve, flush, fill, and
bleed the hydraulic system. If no contamination is
found, replace the flow control valves in the main
lift cylinders.
Load Drifting/Settling

Incorrect lift pressure adjustment Check and adjust the lift pressure setting.
Load holding solenoid Run Test O11 - Toggle Load Holding Solenoid
(Page 6-110). Check for contamination in the
hydraulic fluid. If contamination is present,
inspect and clean the relief valve, flush, fill, and
bleed the hydraulic system.
Load too large for lift truck capacity Check load weight. Check lift pressure setting.
Emergency lower valve leaking Replace the emergency lower valve.

Symptom Tables: Travel Functions
Symptom Tables: Travel

Functions
Slow or Sluggish Acceleration

Dragging brake Adjust the brake.
Worn wheel bearings Replace the wheel bearings.
Debris in wheel axle Remove debris.
Binding drive unit Remove the drive motor and check drive unit
movement.
Slow Travel

Note: Determine if problem is mechanical or electrical.
Mechanical:
Dragging brake Adjust the brake.
Debris in wheel axle Remove debris.
Binding drive unit Remove the drive motor and check drive unit
movement.
Binding in control handle Run Test A22 - Traction Throttle Request
(Page 6-53) to determine if the controller is still
seeing a 100% request.
Electrical:
Bad mast speed limit switch (S10 or S11) or Run Test I02 - Lower Mast Reference (24 in.)
associated wiring Switch (Page 6-70), Test I69 - Upper Mast
Reference Switch (Page 6-94), or Test I03 - 60 in.
Limit Switch (Page 6-71).
Incorrect configuration Reconfigure the lift truck.
Speed limited due to drive motor or power Run Test A08 - Traction Motor Temperature
amplifier temperature (temperature icon (Page 6-44) or Test A10 - Traction Power Amplifier
illuminated) Temperature (Page 6-46).
Bad encoder pulses from drive motor encoder Run Test I19 - Traction Motor RPM (Page 6-75).

Symptom Tables: Electrical Symptoms
Symptom Tables:
Electrical Symptoms
NOTE: Use these symptom tables in
conjunction with the electrical and
hydraulic schematics.
NOTE: For intermittent issues with optional
devices such as RF units, check the
Fuse/Relay Card Capacitor and FGND.
Refer to Troubleshooting Aisle Exit Error
Code J2 on page 5-26.
Electrical Motors
Motor Arcing

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

Dragging brake Adjust the brake. See Brake on page 7-62.
Application exceeds designed workload -- Check with Raymond Sales And Service Center
short runs with plugging/acceleration or Service Manager to verify this is a correct
heavy-duty lifting cycles application.
Using deadman pedal to stop all the time
Bad battery Check the battery voltage, both open circuit and
under load. Replace if necessary with fully-charged
good battery.
Incorrect BSOC Cutout value Check the battery specific gravity at cutout, after
the battery has stabilized. Compare to the battery
manufacturer specifications for discharged
battery. Adjust the BSOC Cutout as needed.
Cable, terminal, or wiring problems. Look for Replace the wiring or cables as necessary. See
discolored terminals, loose or damaged crimps Power Cables on page 7-72.
Check the cable connection torque. See Power
Cable Terminal Torques on page 7-74.
Worn, damaged, or bad brushes or springs Inspect the motor brushes.
Check the brush spring tension.
Binding gearbox or pump Check the gearbox or pump for binding. Clean,
repair, or replace as necessary.
Hydraulic fluid viscosity too high or too low Replace the hydraulic fluid with the correct fluid.
See Lubrication Specification Chart on page A-2.
Pressure relief set too high Adjust the pressure relief.

Operator Display Problems
Scrambled or Intermittent Display

Loose JPC15 harness or Reseat cards and harness connections.
card connectors
Intermittent wires or Test for continuity while flexing the harness. If discontinuity is found,
connectors in harness replace the wiring harness.
Electrical noise in Check the tightness of motor power cable connections (see page 7-74).
motors Check the motor brushes for arcing. Replace if necessary.
Bad key switch Replace the key switch.
Worn or missing static Replace as necessary.
straps
Dead Lift Truck
Display is Dark - No functions operate

No LEDs illuminated Refer to Pin-Out Matrix on page 8-19 and the Electrical Schematics. Check
on circuit cards for B+ at the following locations wrt TP4:
• FU5
• JPF4-10
• JPC16-8
• JPC6-1
• JPC6-2
• JPC16-6
• JPF4-8
• JPF4-11
• JPT14-12
Check for B– at the following locations wrt TP1:
• FU6
• JPF3-3, 4, 5, 6, 7, 8 and 12
• JPT14-1, 2, 8, 9 and 10
• JPC16-4
• JPT14-3
• JPC11-6
If all of the above locations have the correct voltages, refer to the Diagnosis
and Repair table in Test A14 - VM +12V Power Supply (Page 6-49).

Auto Steer Center Problem
Intermittent Lift Truck Error Codes

Noise, shorts to frame See “Shorts to Frame” on page 5-2.
Calculated position of Error Code G2 displayed, see CODE G2 Inform service on page 6-36
the drive unit bad Check the adjustment of the home prox sensor.
Large correction to Steer motor encoder, steering amp, or VM may be bad. Check the home
steering prior to braking prox sensor adjustment.
Mechanical issue, worn Repair or replace as necessary.
radial ring
Lift Truck Codes After Deadman Pedal Depressed

Steering will move in See “Test I25 - Steer Motor Encoder” on page 6-80.
both directions during
auto center
Steering only in one Check the home proximity sensor adjustment. See “Test I24 - Home
direction Position Proximity Sensor” on page 6-79. Run Test O44 - Steer Motor
(Page 6-125)
No movement in Run Test O44 - Steer Motor (Page 6-125). Repair or replace as
steering. Mechanical necessary.
issue, worn radial ring
Lift Truck Codes Before Deadman Pedal Depressed

Low voltage measured Replace the VM.
between JPT6-6 and
JPT6-4
Fuse FU1 open Replace fuse FU1
High resistance Check the brushes, replace the steer motor.
measured between Steer
Motor terminals.
Bad Steer Amplifier Replace the steer amplifier.
Bad VM Replace the VM.


Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes, and Tests
Section 6. Messages, Codes, and Tests

Section 6. Messages, Codes, and Tests Models 5400/5500/5600 Maintenance Manual
Summary List
Summary List
Messages
LPA Approaching Overtemperature (temp icon only) . . . . . . . . . . . . . . . .. . .. . . 6-7
TPA Approaching Overtemperature (temp icon only) . . . . . . . . . . . . . . . .. . .. . . 6-7
Truck Travel Inhibited. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . 6-7
Aligning: Wire Is Sensed Truck Is Now Aligning . . . . . . . . . . . . . . . . . . . .. . .. . . 6-7
Battery State-of-Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . 6-8
The height tracking system needs to recalibrate position. . . . . . . . . . . . .. . .. . . 6-8
End of Aisle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . 6-8
EPO Depressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . 6-8
EPO has been depressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . 6-8
Incorrect FlashWare Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . 6-9
Guidance Not Learned. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . 6-9
24 in. Limit Switch Not Sensed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . 6-9
Interlock activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . 6-9
Truck will not pass SelfTest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . 6-9
Battery Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-10
Scheduled Maintenance Reminder . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-10
Installed battery is too light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-10
Truck Lift Speed Inhibited. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-10
Truck is disabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-10
RDP has timed out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-10
Load Coil Pair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-11
Tractor coil pair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-11
Lost wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-11
Lower Side Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-11
Truck Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-12
Press auto/manual switch to auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-12
Switch (S24) Activated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-12
Truck Lowering Inhibited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-12
Aux Buttons Depressed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-12
Both Pendant Buttons Pressed Before Time-out . . . . . . . . . . . . . . . . . . .. . .. . 6-13
Truck Lift/Lower Inhibited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-13
Control Handle Moved Before Deadman Pressed . . . . . . . . . . . . . . . . . . .. . .. . 6-13
Release lift to resume operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-13
Scheduled Maintenance Reminder . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-13
Seeking: AUTO/MAN Switch Is In Auto . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-14
TPA not receiving Motor RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-14
Speed Limited Due To Steer Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-15
Truck Speed Limited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-15
Truck Stalled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-16
Truck Steering Inhibited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-16
Truck Travel Inhibited. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-16
Truck Travel Inhibited. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-16
View SWM Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-16
Codes
Code 10: SelfTest Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Codes
Code 1H: TPA Out-of-Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Code 2A: Traction Motor Approaching Overtemperature. . . . . . . . . . . . . . . . . . 6-17
Code 2E: Traction Motor Temp Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . . 6-17
Code 2G: Phase Open on Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 2H: Failure Detected in Traction Motor Speed Feedback Encoder . . . . . . 6-18
Code 2M: TPA Pre-Charge Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 2T: TPA Current Calibration Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 2U: TPA Overcurrent or Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 2V: High DC BUS Voltage – TPA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 2W: TPA Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 2X: TPA Power Supply Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 2Y: Incorrect Traction Power Amplifier Installed . . . . . . . . . . . . . . . . . . . 6-19
Code 42: LPC Detected Closed When Commanded Open . . . . . . . . . . . . . . . . . 6-20
Code 43: LPC Detected Open When Commanded Closed . . . . . . . . . . . . . . . . . 6-20
Code 4C: FU1 Sense Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 4F: TPC Detected Closed When Commanded Open . . . . . . . . . . . . . . . . . 6-20
Code 4G: TPC Detected Open After Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 4H: TPA, TPC Contactor Coil or Coil Driver Open or Shorted . . . . . . . . . . 6-21
Code 4K: LPA, LPC Contactor Coil or Coil Driver Open or Shorted . . . . . . . . . . 6-21
Code 50: No VM Communications Received by CCC. . . . . . . . . . . . . . . . . . . . . 6-21
Code 51: No CCC Communications Received by VM. . . . . . . . . . . . . . . . . . . . . 6-21
Code 59: CAN Transmission Buffer Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code 5A: CAN BUS Error Overflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code 5B: Communication Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code 5E: No Guidance Manager CAN Communications Received by the VM. . . 6-22
Code 5G: No Communications Received by VM from TPA . . . . . . . . . . . . . . . . . 6-22
Code 5J: No communications Received by VM from LPA . . . . . . . . . . . . . . . . . 6-22
Code 5M: No communications received by TPA from VM. . . . . . . . . . . . . . . . . . 6-23
Code 5P: No communications received by LPA from VM. . . . . . . . . . . . . . . . . . 6-23
Code 61: 24 in. Limit Switch Not Sensed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code 63: Upper and Lower Reference Switches Do Not Agree . . . . . . . . . . . . . . 6-23
Code 64: No Flow Sensor Pulses When Lift/Lower Requested. . . . . . . . . . . . . . 6-24
Code 66: Calculated Height Does Not Match at
Upper Reference Switch (150 in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Code 67: Calculated Height Does Not Match at Lower Reference Switch (24 in.) 6-24
Code 6D: Lift Pressure Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Code 6F: Lift Motor Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Code 6K: 60 in. Switch Does Not Agree with Lower Mast Reference . . . . . . . . . 6-25
Code 6M: 60 in. and/or 24 in. Switch Disconnected . . . . . . . . . . . . . . . . . . . . 6-25
Code 6N: Flow Sensor Temperature Out-of-Range . . . . . . . . . . . . . . . . . . . . . . 6-25
Code 6P: 60 in. Limit Switch Out-of-Sequence with Upper
Reference Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Code 7E: Lift Motor Temperature Sensor Out-of-Range . . . . . . . . . . . . . . . . . . 6-26
Code 7F: LPA Temp Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Code 7G: LPA Motor Phase Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Code 7H: Failure Detected in Lift Motor Feedback Encoder . . . . . . . . . . . . . . . 6-26
Code 7M: LPA Failed to Precharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Code 7T: LPA Current Sensor Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Code 7U: LPA Overcurrent or Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Code 7V: LPA High Voltage on DC BUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Code 7W: LPA Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Code 7X: LPA Power Supply Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

Codes
Code 7Y: Incorrect Lift Power Amplifier Installed . . . . . . . . . . . . . . . . . . . . . .. . 6-28

Code 80: Throttle Potentiometer (VR1) Voltage Out-of-Range . . . . . . . . . . . . .. . 6-28
Code 81: Lift/Lower Potentiometer (VR2) Voltage Out-of-Range . . . . . . . . . . .. . 6-28
Code 83: Throttle Potentiometer (VR1) Out-of-Neutral . . . . . . . . . . . . . . . . . .. . 6-28
Code 84: Brake Inoperable; Not Applied . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-28
Code 88: Lift and/or travel Potentiometer Voltage Out of Range . . . . . . . . . .. . 6-29
Code 8C: Deadman Switches Do Not Agree . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-29
Code 8F: Lift/Lower Potentiometer Out-of-Neutral. . . . . . . . . . . . . . . . . . . . .. . 6-29
Code 8L: Electric Brake Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-29
Code 91: Drive Unit Turned >10° while Guiding on Wire . . . . . . . . . . . . . . . .. . 6-29
Code 92: Tracking Limits Exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-30
Code 93: Not Near Wire; Tractor Coil Pair . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-30
Code 94: Not Near Wire; Load Coil Pair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-30
Code 9A: Bad Wire Guidance Learn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-31
Code 9B: Bad SDO (CAN - Service Data Object) Data Received . . . . . . . . . . .. . 6-31
Code 9E: Track And Hold Signal Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-31
Code 9F: Filter Card Not Connected to Guidance Manager . . . . . . . . . . . . . .. . 6-32
Code 9G: No Input; Load Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-32
Code 9H: No Input; Tractor Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-32
Code 9J: Load Antenna Input Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-32
Code 9K: Tractor Antenna Input Too High . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-33
Code A0: Incorrect Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-33
Code A2: Software Compatibility Issue with VM and TPA. . . . . . . . . . . . . . . .. . 6-33
Code A4: Software Compatibility Issue with VM and LPA. . . . . . . . . . . . . . . .. . 6-33
Code AH: Bad CCC Checksum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-33
Code AL: VM Battery Backed Up RAM Failed. . . . . . . . . . . . . . . . . . . . . . . . .. . 6-34
Code AP: TPA Software Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-34
Code AT: LPA Software Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-34
Code F8: Microcontroller COP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-34
Code FE: Internal VM Circuit for BSOC Not Calibrated . . . . . . . . . . . . . . . . .. . 6-34
Code FG: +5V Reference Voltage and +12V Power Supply Failure . . . . . . . . .. . 6-35
Code FH: Battery Voltage Out-of-Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-35
Code FN: Relays Did Not Open at Power Off . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-35
Code FP: VM In-Circuit Hardware Failure . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-35
Code FT: VM Internal Software Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-36
Code G0: Steer Tiller Encoder 1 is Intermittent or Failed . . . . . . . . . . . . . . . .. . 6-36
Code G2: Auto Steer Center Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-36
Code G3: Home Prox Switch Not Functioning Correctly . . . . . . . . . . . . . . . . .. . 6-36
Code G4: Open Detected in Steer Control Circuit . . . . . . . . . . . . . . . . . . . . .. . 6-37
Code G5: Short Detected in Steer Power Circuit . . . . . . . . . . . . . . . . . . . . . .. . 6-37
Code G7: Steer Tiller Encoder 2 is Intermittent or Failed . . . . . . . . . . . . . . . .. . 6-37
Code GD: No Steer Motor Encoder Pulses Seen . . . . . . . . . . . . . . . . . . . . . . .. . 6-37
Code GE: Both Steer Tiller Encoders Failed . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-38
Code GF: Wire Guidance Position Out-of-Range . . . . . . . . . . . . . . . . . . . . . .. . 6-38
Code J2: Aisle Exit Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-38
Code J4: Aisle Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-38
Code VC: The CAN Chip will not Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-39
Code X3: 180 in. Limit Switch Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-39
Code X4: Lift Cutout Switch Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-39
Code X5: Lift Inhibit Switch Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-39

Analog Tests
Analog Tests
Test A04 - Throttle Potentiometer Voltage . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-42
Test A05 - Lift/Lower Potentiometer Voltage . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-43
Test A08 - Traction Motor Temperature . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-44
Test A09 - Lift Motor Temperature . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-45
Test A10 - Traction Power Amplifier Temperature . . . . . . . . . . . . .. .. . .. . .. . 6-46
Test A11 - Traction Motor Current . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-47
Test A13 - Pressure Sensor Voltage (optional) . . . . . . . . . . . . . . . .. .. . .. . .. . 6-48
Test A14 - VM +12V Power Supply . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-49
Test A15 - Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-50
Test A19 - Lift Power Amplifier Temperature (AC lift only) . . . . . . .. .. . .. . .. . 6-51
Test A20 - Lift Motor Current (AC lift only) . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-52
Test A22 - Traction Throttle Request . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-53
Test A23 - Lift Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-54
Test A34 - Lift/Lower Current . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-55
Test A35 - Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-56
Test A37 - Steer Power Amplifier Current . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-57
Test A51 - Left Tractor Guidance Coil Voltage . . . . . . . . . . . . . . . .. .. . .. . .. . 6-59
Test A52 - Right Tractor Guidance Coil Voltage . . . . . . . . . . . . . . .. .. . .. . .. . 6-60
Test A53 - Left Load Guidance Coil Voltage . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-61
Test A54 - Right Load Guidance Coil Voltage . . . . . . . . . . . . . . . .. .. . .. . .. . 6-62
Test A55 - Tractor Near Wire Coil Voltage . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-63
Test A56 - Load Near Wire Coil Voltage . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-64
Tests A96 thru A100 - iBATTERY Tests . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-65
Input Tests
Test I00 - Carriage Deadman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-68
Test I01 - Brake Deadman Switch (S2) . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-69
Test I02 - Lower Mast Reference (24 in.) Switch . . . . . . . . . . . . . . . . . . .. . .. . 6-70
Test I03 - 60 in. Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-71
Test I04 - Lift/Lower Inhibit Bypass (optional) . . . . . . . . . . . . . . . . . . . .. . .. . 6-72
Test I05 - Lift Inhibit Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-73
Test I15 - Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-74
Test I19 - Traction Motor RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-75
Test I20 - Lift Motor RPM (AC lift only) . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-76
Test I23 - CAN Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-77
Test I24 - Home Position Proximity Sensor . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-79
Test I25 - Steer Motor Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-80
Test I26 - Flow Sensor Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-81
Test I35 - Steer Tiller Encoder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-82
Test I36 - Steer Tiller Encoder 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-83
Test I38 - EPO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-84
Test I39 - Neutral Pulses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-85
Test I41 - Aux Mast Lift Switch S32 . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-86
Test I42 - Aux Mast Lower Switch S33 . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-87
Test I44 - Aux Mast Lift Ref Switch S34 . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-89
Test I65 - Rail Guidance Switch (optional) . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-90
Test I66 - Auto/Manual Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-91
Test I67 - Sidegate Switches (optional) . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-92
Test I68 - Travel Cutout Switch (optional) . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-93

Output Tests
Test I69 - Upper Mast Reference Switch . . . . ............... .. . .. .. . .. . 6-94

Test I70 - Pressure Switch (optional) . . . . . . ............... .. . .. .. . .. . 6-95
Test I72 - End-of-Aisle Sensor 2 (optional) . . ............... .. . .. .. . .. . 6-96
Test I73 - End-of-Aisle Sensor 1 (optional) . . ............... .. . .. .. . .. . 6-98
Test I74 - Lower Inhibit Switch (optional) . . . ............... .. . .. .. . .. 6-100
Test I75 - 180 in. Limit Switch (optional) . . . ............... .. . .. .. . .. 6-101
Test I76 - Lift Cutout Switch (optional) . . . . . ............... .. . .. .. . .. 6-102
Test I91 - iPORT Communication . . . . . . . . . ............... .. . .. .. . .. 6-103
Test I92 - iPORT Error Bitmap . . . . . . . . . . . ............... .. . .. .. . .. 6-104
Test I93 - End Of Aisle EOA . . . . . . . . . . . . . ............... .. . .. .. . .. 6-105
Output Tests
Test O00 - Toggle the Traction Power Contactor . . . . . . . . ... .. .. . .. .. . .. 6-108
Test O02 - Toggle the Lift Power Contactor . . . . . . . . . . . . ... .. .. . .. .. . .. 6-109
Test O11 - Toggle Load Holding Solenoid . . . . . . . . . . . . . ... .. .. . .. .. . .. 6-110
Test O12 - Proportional Solenoid PWM Ramp . . . . . . . . . . ... .. .. . .. .. . .. 6-111
Test O18 - Toggle Horn . . . . . . . . . . . . . . . . . . . . . . . . . . ... .. .. . .. .. . .. 6-112
Test O19 - Audible Alarm . . . . . . . . . . . . . . . . . . . . . . . . . ... .. .. . .. .. . .. 6-113
Test O20 - Travel Alarm (optional) . . . . . . . . . . . . . . . . . . ... .. .. . .. .. . .. 6-114
Test O25 - Toggle 2 Stage Select Solenoid (optional) . . . . . ... .. .. . .. .. . .. 6-115
Test O28 - Ramp Lift Motor (AC lift only) . . . . . . . . . . . . . ... .. .. . .. .. . .. 6-116
Test O29 - Ramp Traction Motor . . . . . . . . . . . . . . . . . . . ... .. .. . .. .. . .. 6-117
Test O30 - Toggle Brake Solenoid . . . . . . . . . . . . . . . . . . . ... .. .. . .. .. . .. 6-118
Test O32 - Toggle Relay Enable . . . . . . . . . . . . . . . . . . . . ... .. .. . .. .. . .. 6-119
Test O39 - Display Lights . . . . . . . . . . . . . . . . . . . . . . . . . ... .. .. . .. .. . .. 6-120
Test O40 - Lift/Lower Alarm (optional) . . . . . . . . . . . . . . . ... .. .. . .. .. . .. 6-121
Test O41 - Aux Select Solenoid (optional) . . . . . . . . . . . . . ... .. .. . .. .. . .. 6-122
Test O42 - Main Select Solenoid (optional) . . . . . . . . . . . . ... .. .. . .. .. . .. 6-123
Test O43 - Aux Load Hold Solenoid (optional) . . . . . . . . . . ... .. .. . .. .. . .. 6-124
Test O44 - Steer Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . ... .. .. . .. .. . .. 6-125

Models 5400/5500/5600 Maintenance Manual Section 6. Messages, Codes and Tests
Messages and Codes
Messages and Codes

Section 6. Messages, Codes and Tests
NOTE: Codes C46 and C47 are iPORT® related

codes. Refer to iPORT Kit Installation
and Maintenance Instructions. All "M"
Series codes are iBATTERY™ related
error codes. Refer to iBATTERY Battery
Monitoring System Installation and
Maintenance Instructions.
Icon Code Title/Reason Tests to Run Notes/Corrective Action
None
LPA Approaching Overtemperature Test A19 - Lift Power Cycle the key switch to clear
(temp icon only) Amplifier Temperature after the lift power amplifier
The VM senses the lift power amplifier (AC lift only) (Page 6-51) has cooled.
temperature is approaching 185°F
(85°C). Lift performance is limited.
None
TPA Approaching Overtemperature Test A10 - Traction Power Cycle the key switch to clear
(temp icon only) Amplifier Temperature after the traction power
The VM senses the traction power (Page 6-46) amplifier has cooled.
amplifier temperature is approaching
185°F (85°C). Traction performance is
limited.
ADF, PDF, AHA, PHA

Truck Travel Inhibited None Turn off WGAM in Configure
WGAM has been left turned ON in Mode.
Configure Mode.
Aligning
Aligning: Wire Is Sensed Truck Is None None
Now Aligning
The AUTO/MAN switch is in the Auto
position. The guide wire is sensed. The
lift truck is trying to acquire the wire.

Section 6. Messages, Codes and Tests Models 5400/5500/5600 Maintenance Manual
EPO Rekey
Battery low, no lift

Battery State-of-Charge If charging or changing the Lift is disabled. The battery
Lift interrupt has occurred due to the battery does not clear the needs to be charged or
battery state-of-charge. message, run Test A15 - changed.
Battery Voltage
(Page 6-50)
Cross upper or lower limit switch

The height tracking system needs Test I02 - Lower Mast Move the forks past either
to recalibrate position. Reference (24 in.) Switch the 24" or 150" switch.
The 24" switch is open, indicating the (Page 6-70)
forks are elevated, and the system has Test O12 - Proportional
counted over 1024" of accumulated Solenoid PWM Ramp
fork up and down movement without (Page 6-111)
detection either 24" of 150" switches. Test I69 - Upper Mast
Reference Switch
(Page 6-94)
End of aisle
End of Aisle Test I93 - End Of Aisle Not an error.
The message is displayed until the EOA (Page 6-105)
truck slows down or stops as it exits Test I72 - End-of-Aisle
the end of the aisle and the operator Sensor 2 (optional)
releases the travel control. (Page 6-96)
Test I73 - End-of-Aisle
Sensor 1 (optional)
(Page 6-98)
EPO Depressed
EPO Depressed Test I38 - EPO Switch Lift the EPO button and
CCC or VM senses the EPO switch is (Page 6-84) cycle the key switch to clear.
open (IN).
EPO Rekey
EPO has been depressed Test I38 - EPO Switch Make sure the EPO button is
CCC or VM senses the EPO switch was (Page 6-84) lifted and cycle the key
depressed, then lifted, without key switch to clear.
switch being cycled.

FlashWare options incorrectly configured
FlashWare options incorrectly configured

Incorrect FlashWare Options Use FlashWare to set a Cycle the key switch
FlashWare options incorrectly valid configuration. OFF/ON to clear.
configured/ verify options are
configured correctly in FlashWare.
Guidance not learned

Guidance Not Learned None Learn Guidance to clear.
When the AUTO/MAN switch was
placed in the Auto position, the wire
guidance parameters were
out-of-range.
Initialize to allow full speed travel

24 in. Limit Switch Not Sensed Test O12 - Proportional Travel is limited to
Too much time has passed without Solenoid PWM Ramp 2.5 mph (4 km/h). Make
crossing the 24 in. limit switch while (Page 6-111) sure the Emergency Lower
the lift request is above a certain Test I02 - Lower Mast Valve is closed. Cycle the key
threshold. Reference (24 in.) Switch switch to clear.
(Page 6-70)
Interlock activated, clear to resume

Interlock activated None Cycle the key switch
OFF/ON to clear.
Invalid password
Truck will not pass SelfTest None Enter the correct password
Incorrect password has been entered. or default using FlashWare.

Lift cut-out pending ... low battey
Lift cut-out pending ... low battey

Battery Low None Message is displayed for five
minutes, then lift is
disabled. Change the
battery.
Lift cutout, Scheduled maintenance due

Scheduled Maintenance Reminder None Lift is disabled. Reset Mnt
This code occurs when configure mode Mind in Configure mode.
Maintenance Minder has been set to
request it be activated.
Lift limited...Installed battery is too light

Installed battery is too light None Replace the battery with a
The battery in the truck is below correct size battery. Refer to
minimum allowable battery weight. iBATTERY ™.
Lift speed Limited

Truck Lift Speed Inhibited Test I20 - Lift Motor RPM Cycle the key switch
This code is generated by the Lift (AC lift only) (Page 6-76) OFF/ON to clear.
Power Amplifier after not receiving
encoder pulses.
Log in to enable truck

Truck is disabled None Refer to iPORT Kit
RDP has the initial speed set to zero. Installation and
Maintenance Instructions.
Loss of connection to the SWM

RDP has timed out None Refer to iPORT Kit
RDP has a problem with the local Installation and
communications. Maintenance Instructions.

Lost LCP
Lost LCP
Load Coil Pair Test A53 - Left Load Check that the truck did not
Not near wire. This is the antennae on Guidance Coil Voltage run off the wire. Re-run
the fork end of the truck. (Page 6-61) Learn procedure. Travel is
Test A54 - Right Load limited to 1 mph (1.6 km/h).
Guidance Coil Voltage Set the AUTO/MAN switch
(Page 6-62) to Manual. Check the wiring
Test A56 - Load Near Wire between the Guidance
Coil Voltage (Page 6-64) Manager and the VM.
Replace the Guidance
Manager. Cycle the key
switch to clear.
Lost TCP
Tractor coil pair Test A51 - Left Tractor Check truck did not run off
Not near wire. This is the antennae on Guidance Coil Voltage wire. Re-run Learn
the tractor end of the truck. (Page 6-59) procedure. Travel is limited
Test A52 - Right Tractor to 1 mph (1.6 km/h). Set the
Guidance Coil Voltage AUTO/MAN switch to
(Page 6-60) Manual. Check the wiring
Test A55 - Tractor Near between the Guidance
Wire Coil Voltage Manager and the VM.
(Page 6-63) Replace the Guidance
switch to clear.
Lost wire
Lost wire Check the line driver Travel is limited to
The electronics on the truck can no output per W. G. Manual. 1 mph (1.6 km/h). Set the
longer detect a signal from the wire Check truck did not run AUTO/MAN switch to
that is buried just below the surface of off wire. Re-run Learn Manual. Check the wiring
a floor. procedure. between the Guidance
Manager and the VM.
switch to clear.
Lower sidegates to resume operation

Lower Side Gate Test I67 - Sidegate Lower Sidegates to clear.
While standing on the Deadman Pedal, Switches (optional)
a sidegate is detected UP when you (Page 6-92)
attempt to travel or lift.

Overheated, allow time to cool
Overheated, allow time to cool

Truck Overheated This is the actual Allow time for the lift truck
The system has detected that an over message: depending on to cool. Check the lift truck
temperature condition exists. what motor is over heated Event Log to determine what
will determine if the motor or amp is causing the
Traction or Lift speed is code.
reduced.
Press auto/manual switch to auto

Press auto/manual switch to auto Test I66 - Auto/Manual The near coil has detected
This appears on wire guidance Switch (optional) the presence of the wire
equipped trucks when the system (Page 6-91) guidance floor signal, or the
senses the wire. It occures on rail Test I65 - Rail Guidance guide rail switch input.
guidance system based on switch Switch (optional)
input. (Page 6-90)
Press bypass switch to continue lifting

Switch (S24) Activated Test I05 - Lift Inhibit Lift is disabled unless the
Lift Inhibit Switch (S24) has been Switch (optional) bypass switch is activated.
crossed or open. (Page 6-73) Lower the vehicle below the
lift inhibit switch.
Press bypass switch to continue lowering

Truck Lowering Inhibited Test I74 - Lower Inhibit Lower is disabled unless the
Lower Inhibit Switch (S25) has been Switch (optional) bypass switch is activated.
crossed. (Page 6-100) Lift above the lower inhibit
switch.
Release aux buttons to resume operation

Aux Buttons Depressed Test I41 - Aux Mast Lift Cycle the key switch
Auxiliary deadman and auxiliary lift or Switch S32 (Page 6-86) OFF/ON to clear.
lower switches are activated at Test I42 - Aux Mast Lower
start-up. Switch S33 (Page 6-87)

Release buttons
Release buttons
Both Pendant Buttons Pressed None Allow more time between
Before Time-out pressing the buttons.
Both buttons are pressed at the same
time. Must have at least a two second
delay between pressing the first and
second.
Release bypass switch

Truck Lift/Lower Inhibited Test I04 - Lift/Lower Release the switch.
Will happen with either lift or lower Inhibit Bypass (optional)
bypass switch (S7) activated for an (Page 6-72)
extended period of time.
Release control handle to resume operation

Control Handle Moved Before Test A04 - Throttle Release the throttle, step on
Deadman Pressed Potentiometer Voltage the deadman and resume
(Page 6-42) travel.
Release lift to resume operation

Release lift to resume operation Test A05 - Lift/Lower Check for excessive
Control handle was moved before the Potentiometer Voltage mechanical play in the lift
deadman pedal was depressed at (Page 6-43) control knob. Release the lift
start-up. control knob, step on the
deadman and resume
operation.
Scheduled maintenance due

Scheduled Maintenance Reminder None Reset Mnt Mind in Configure
This code occurs when configure mode mode.
Maintenance Minder has been set to
request it be activated.

Seeking
Seeking
Seeking: AUTO/MAN Switch Is In None None
Auto
The guide wire has not been sensed.
The lift truck is trying to find the wire.
Speed limited
TPA not receiving Motor RPM Test I19 - Traction Motor Travel speed is limited. Cycle
This code is generated by the Traction RPM (Page 6-75) the key switch OFF/ON to
Power Amplifier after not receiving clear.
encoder pulses.

Speed limited due to steer angle
Speed limited due to steer angle

Speed Limited Due To Steer Angle Test I02 - Lower Mast Straighten the drive unit to
A speed limiting condition due to a Reference (24 in.) Switch within 10° of straight ahead
combination of steering angle and (Page 6-70) or lower the carriage below
height is in effect. Test I03 - 60 in. Limit the 24 in. lower mast
Switch (Page 6-71) reference switch.
Test I69 - Upper Mast 1. If the operator platform
Reference Switch height is between 24 in.
(Page 6-94) (610 mm) and 60 in.
Test I75 - 180 in. Limit (1520 mm) and the
Switch (optional) steering angle is >10°,
(Page 6-101) max travel speed is
limited to 2.5 mph
(4 km/h).
2. If the operator platform
height is between 60 in.
(1520 mm) and 150 in.
(3810 mm)
(w/intellispeed) or the
upper reference switch
(S10) (w/o intellispeed)
and the steering angle
is >10° then max travel
speed is limited to
1 mph (1.6 km/h).
3. If the height of the
operator platform is
greater than or equal to
50 in. (3810mm)
(w/intellispeed) or the
Upper Mast Reference
Switch (S10) (w/o
intellispeed) and
steering is greater than
10°, then travel is not
permitted.
Speed limited due to unknown height... lower to reference switch

Truck Speed Limited Test I02 - Lower Mast Lower the lift truck below the
Lift truck powered ON when above 24 Reference (24 in.) Switch 24 in. limit switch.
inch limit switch. (Page 6-70)

Stalled, release control handle to resume operation
Stalled, release control handle to resume operation

Truck Stalled Travel speed limited. Test Travel speed or lift speed is
No encoder pulses are received by the I19 - Traction Motor RPM limited depending on which
Power Amplifier. (Page 6-75). Lift speed amplifier is not receiving
limited. Test I20 - Lift encoder pulses. Cycle the
Motor RPM (AC lift only) key switch OFF/ON to clear.
(Page 6-76)
Steer limited due to height

Truck Steering Inhibited None Lower the lift truck below the
Lift truck is elevated above the upper upper reference switch.
reference switch and a steering
request of more than 10 degrees has
been requested.
Travel cutout
Truck Travel Inhibited Test I68 - Travel Cutout Travel is disabled. Lower the
Lift truck has been elevated above Switch (optional) lift truck below the travel
travel cutout switch. (Page 6-93) cutout switch.
Travel Cutout is also used by
the battery gate switches.
Travel Interlock Activated

Truck Travel Inhibited None Lower the lift truck below the
This occurs when the lift truck is limit switch.
configured with lift limit w/bypass and
configure mode is choosing to not
allow travel when above the lift limit
switch.
View SWM Display

View SWM Display None View display. Refer to SWM
The SWM has instructed the RDP to documents.
throw up a message to tell the
operator to look at it.

CODE 10 Inform Service
CODE 10 Inform Service

Code 10: SelfTest Failed Test A35 - Brake All functions are disabled.
The brake test did not pass SelfTest. (Page 6-56) Make sure the EPO is not
Test O00 - Toggle the depressed. The TPC must
Traction Power Contactor close during SelfTest.
(Page 6-108) Check the battery voltage.
Check the brake wires.
Cycle the key switch to clear.
CODE 1H Inform service

Code 1H: TPA Out-of-Range Test A10 - Traction Power Cycle the key switch to clear
The Traction Power Amplifier has Amplifier Temperature after the traction power
reported its internal temperature is (Page 6-46) amplifier has returned to
less than –40°F (–40°C) or greater than ambient temperature.
+203°F (+95°C).
CODE 2A Overheated Allow time to cool

Code 2A: Traction Motor Test A08 - Traction Motor Travel speed is linearly
Approaching Overtemperature Temperature (Page 6-44) derated starting at 266°F
The traction amplifier senses the (130°C). Travel speed is
traction motor is approaching limited to 1 mph (1.6 km/h)
overtemperature. Traction at 300°F (149°C). Cycle the
performance is limited. key switch to clear after the
traction motor has cooled.
Version 4.6 corrects this
intermittent code.
CODE 2E Inform service

Code 2E: Traction Motor Temp Test A08 - Traction Motor Travel is limited to 2.5 mph
Sensor Out-of-Range Temperature (Page 6-44) (4.0 km/h). Clears when the
The traction motor temperature sensor reason for the fault is
is open or shorted. corrected.
CODE 2G Inform service

Code 2G: Phase Open on Traction Test O29 - Ramp Traction Travel is disabled. Cycle the
Motor Motor (Page 6-117) key switch to clear.
The traction power amplifier has
detected no current draw in one of the
three phases of the motor.


Code 2H: Failure Detected in Test I19 - Traction Motor Travel is limited to
Traction Motor Speed Feedback RPM (Page 6-75) 1 mph (1.6 km/h). If a single
Encoder channel is bad, this code is
displayed during Run. If one
or both channels are bad at
SelfTest, STALLED is
displayed. Cycle the key
switch to clear.
CODE 2M Inform service

Code 2M: TPA Pre-Charge Failed None Travel is disabled. Check for
Traction power amplifier failed to B+ at TPA+. Cycle the key
precharge correctly. switch to clear. If the code
will not clear, replace the
traction power amplifier. The
VM cannot cause this code.
Remove the power fuse for
the Steer Amp (FU1) and
turn the key switch ON. If
Code 2M is no longer
displayed, replace the Steer
Amp. The lift contactor can
also cause this code.
CODE 2T Inform service

Code 2T: TPA Current Calibration None Travel is limited to 2.5 mph
Error (4.0 km/h). Cycle the key
The traction power amplifier has switch to clear. If the code
sensed a current calibration error. will not clear, replace
Load VM S/W 5.1 before
updating the Curtis Amp
with OS S/W 12.87. Failure
to do so will result in an AP
or AT code.

CODE 2U Inform service

Code 2U: TPA Overcurrent or Short None Travel is disabled. Cycle the
Circuit key switch to clear. Check
The traction power amplifier has for shorted traction motor
sensed current in excess of 400A. power cables. If the code will
not clear, replace the
CODE 2V Inform service

Code 2V: High DC BUS Voltage – TPA Test A15 - Battery Voltage If the voltage is OK, replace
The traction power amplifier has (Page 6-50) the TPA. Cycle the key
detected an overvoltage condition at switch to clear. The VM
the + terminal. cannot cause this code.
Version 4.6 solves this
intermittent code.
CODE 2W Inform service

Code 2W: TPA Internal Fault None Cycle the key switch to clear.
Traction power amplifier internal Replace the traction power
circuitry has malfunctioned. amplifier.
CODE 2X Inform service

Code 2X: TPA Power Supply None Cycle the key switch to clear.
Out-of-Range Disconnect the (+) wire to
The power supply output in the the temp and speed sensors.
traction power amplifier is less than If OK, troubleshoot the wires
4.5V, greater than 5.5V, or too much and sensors. If not OK,
current is being drawn by an external replace the TPA. The VM
component. cannot cause this code.
CODE 2Y Inform service

Code 2Y: Incorrect Traction Power None Replace with a correct power
Amplifier Installed amp. Travel is limited to 2.5
mph (4.0 km/h).

CODE 42 Inform service

Code 42: LPC Detected Closed When Test O02 - Toggle the Lift Cycle the key switch to clear.
Commanded Open Power Contactor
AC Lift - the lift power amplifier has (Page 6-109)
detected an incorrect voltage at the B+
terminal on the amplifier.
DC Lift - the VM has detected an
incorrect voltage at JPT18-9.

Code 43: LPC Detected Open When Test O02 - Toggle the Lift Cycle the key switch to clear.
Commanded Closed Power Contactor
AC Lift - the lift power amplifier has (Page 6-109)
DC Lift - the VM has detected an
incorrect voltage at JPT18-9.
CODE 4C Inform service

Code 4C: FU1 Sense Validation None Check FU1and FU1 Sense
FU1 detected open by the VM. This is line (JPT22-19). If FU1 opens
a sense lead validation. If fuse is bad during Run, Code G4 is
during Run mode, another error code displayed. Cycle the key
will detect it. switch to clear.
CODE 4F Inform service

Code 4F: TPC Detected Closed When Test O00 - Toggle the Travel is disabled.
Commanded Open Traction Power DC Lift - lift is also disabled.
The traction power amplifier has Contactor (Page 6-108) Cycle the key switch to clear.

Code 4G: TPC Detected Open After Test O00 - Toggle the Travel is disabled.
Power-Up Traction Power DC Lift - lift is also disabled.
The traction power amplifier has Contactor (Page 6-108) Cycle the key switch to clear.
detected the TPC open after power-Up.


Code 4H: TPA, TPC Contactor Coil Test O00 - Toggle the Cycle the key switch to clear.
or Coil Driver Open or Shorted Traction Power
Contactor (Page 6-108)
CODE 4K Inform service

Code 4K: LPA, LPC Contactor Coil or Test O02 - Toggle the Lift Lift is disabled. Cycle the key
Coil Driver Open or Shorted Power Contactor switch to clear.
AC lift only. (Page 6-109)

Code 50: No VM Communications Test I23 - CAN Bus All functions are disabled.
Received by CCC (Page 6-77) See Communication Error
The Carriage Control Card has not Code Troubleshooting on
received correct communications from page 5-25. Cycle the key
the VM. switch to clear.
Note: This code is displayed during
FlashWare procedure.

Code 51: No CCC Communications Test I23 - CAN Bus All functions are disabled.
Received by VM (Page 6-77) See Communication Error
The VM has not received correct Code Troubleshooting on
communications from the CCC. page 5-25. Cycle the key
switch to clear.

Code 59: CAN Transmission Buffer Test I23 - CAN Bus All functions are disabled.
Error (Page 6-77) See Communication Error
The VM has detected a CAN Code Troubleshooting on
transmission buffer error. page 5-25. Cycle the key
switch to clear.

CODE 5A Inform service
CODE 5A Inform service

Code 5A: CAN BUS Error Overflow Test I23 - CAN Bus All functions are disabled.
CAN BUS error overflow detected by (Page 6-77) See Communication Error
VM. Code Troubleshooting on
page 5-25. Cycle the key
switch to clear.
CODE 5B Inform service

Code 5B: Communication Error Test I23 - CAN Bus All functions are disabled.
There is no space in the CAN queue for (Page 6-77) Check for a short to frame or
the current message to be received. a bad connection in the bus
wiring. See Communication
Error Code Troubleshooting
on page 5-25.
Replace the VM, then the
CCC. Cycle the key switch to
clear.

Code 5E: No Guidance Manager CAN Test I23 - CAN Bus Travel is disabled in AUTO
Communications Received by the (Page 6-77) mode. Travel is allowed in
VM MANUAL mode. Check to see
if something is dragging the
GM down, for example,
antenna/cable filter card.

Code 5G: No Communications Test I23 - CAN Bus Travel is disabled. Cycle the
Received by VM from TPA (Page 6-77) key switch to clear.
The VM has not received CAN
communications from the traction
power amplifier.
CODE 5J Inform service

Code 5J: No communications Test I23 - CAN Bus Lift is disabled. Cycle the key
Received by VM from LPA (Page 6-77) switch to clear.
AC Lift only - The VM has not
received CAN communications from
the lift power amplifier.


Code 5M: No communications Check wiring, Replace the required part
received by TPA from VM. Maintenance Mode Test and Cycle the key switch to
The TPA has not received CAN I23 - CAN Bus clear.
communications from the VM for over (Page 6-77)
1 minute after power was applied to If the VM is not working,
pin 1 at the amp. you cannot get into
history. Troubleshoot
per general
communications
methods. If the lift truck
displays a code after
checking the wires,
replace the VM.
CODE 5P Inform service

Code 5P: No communications Check wiring, Test I23 - Replace the required part
received by LPA from VM. CAN Bus (Page 6-77) and Cycle the key switch to
The LPA has not received CAN If the VM is not working, clear.
communications from the VM for over the code cannot get into
1 minute after power was applied to listing. Troubleshoot per
pin 1 at the amp. general communications
methods. If the lift truck
displays a code after
checking the wires,
replace the VM.

Code 61: 24 in. Limit Switch Not Test I02 - Lower Mast Travel is limited to 2.5 mph
Sensed Reference (24 in.) Switch (4.0 km/h). Make sure the
Too much time has passed without (Page 6-70) Emergency Lower Valve is
crossing the 24 in. limit switch while Test O12 - Proportional closed. Cycle the key switch
lift request is above a certain Solenoid PWM Ramp to clear.
threshold. (Page 6-111)

Code 63: Upper and Lower Test I02 - Lower Mast Travel is limited to
Reference Switches Do Not Agree Reference (24 in.) Switch 1 mph (1.6 km/h). Cycle the
The VM has sensed that the positions (Page 6-70) key switch to clear.
of the upper (S10) and the lower (S11) Test I69 - Upper Mast
reference switches were out of Reference Switch
sequence. (Page 6-94)


Code 64: No Flow Sensor Pulses Test I02 - Lower Mast Travel is limited to
When Lift/Lower Requested Reference (24 in.) Switch 1 mph (1.6 km/h). Lift or
No pulses were seen from the flow (Page 6-70) lower past one of the mast
sensor when lifting past one of the two Test I26 - Flow Sensor reference switches. Cycle the
mast reference switches (24 and 150 Count (Page 6-81) key switch to clear.
in.). (intellispeed only) Test I69 - Upper Mast
Reference Switch
(Page 6-94)

Code 66: Calculated Height Does Test I26 - Flow Sensor Travel is limited to
Not Match at Upper Reference Count (Page 6-81) 1 mph (1.6 km/h). Cycle the
Switch (150 in.) Test I69 - Upper Mast key switch to clear.
intellispeed count and calculated Reference Switch
height of the upper reference switch (Page 6-94)
(S10) are out of tolerance. (intellispeed
only)

Code 67: Calculated Height Does Test I02 - Lower Mast Travel is limited to
Not Match at Lower Reference Reference (24 in.) Switch 1 mph (1.6 km/h). Cycle the
Switch (24 in.) (Page 6-70) key switch to clear.
intellispeed count and calculated Test I26 - Flow Sensor
height of the lower reference switch Count (Page 6-81)
(S11) are out of tolerance. (intellispeed
only).
CODE 6D Inform service

Code 6D: Lift Pressure Sensor Test A13 - Pressure Code is displayed for five
Out-of-Range Sensor Voltage (optional) seconds. Display will then
The VM has determined that the (Page 6-48) change to "----". Cycle the
pressure sensor voltage has exceeded key switch to clear.
the programmed limits.
(intellispeed only)

CODE 6F Overheated Allow time to cool
CODE 6F Overheated Allow time to cool

Code 6F: Lift Motor Overheated Test A09 - Lift Motor Lift is disabled. Allow time to
AC Lift only - Lift motor temperature Temperature (Page 6-45) cool. Cycle the key switch to
has exceeded 300°F (149°C). clear.

Code 6K: 60 in. Switch Does Not Test I02 - Lower Mast Travel is limited to 2.5 mph
Agree with Lower Mast Reference Reference (24 in.) Switch (4.0 km/h). Lower, then lift
The 60 in. switch (S28) is out of (Page 6-70) past the first mast limit
sequence with the lower reference Test I03 - 60 in. Limit switch (S11), then Cycle the
switch (S11). Switch (Page 6-71) key switch to clear.
(non-intellispeed only)

Code 6M: 60 in. and/or 24 in. Test I02 - Lower Mast Lower, then lift past the
Switch Disconnected Reference (24 in.) Switch lower reference switch (S11).
The system detected that the 60 in. (Page 6-70) Cycle the key switch to clear.
(S28) and/or the 24 in. (S11) switch Test I03 - 60 in. Limit
are disconnected. Switch (Page 6-71)
CODE 6N Inform service

Code 6N: Flow Sensor Temperature None Cycle the key switch to clear.
Out-of-Range Only shown during Learn.
The VM has sensed that the voltage is Learn values will still be
out-of-range. (intellispeed only) stored.
CODE 6P Inform service

Code 6P: 60 in. Limit Switch Test I03 - 60 in. Limit Travel is limited to 1 mph
Out-of-Sequence with Upper Switch (Page 6-71) (1.6 km/h). Cycle the key
Reference Switch Test I69 - Upper Mast switch to clear.
The system senses that the 60 in. limit Reference Switch
switch and the upper reference switch (Page 6-94)
are out of sequence.
(non-intellispeed only)


Code 7E: Lift Motor Temperature Test A09 - Lift Motor Lift performance is disabled
Sensor Out-of-Range Temperature (Page 6-45) by the power amplifier. Cycle
Lift motor temperature sensor voltage the key switch to clear.
is out-of-range.

Code 7F: LPA Temp Out-of-Range Test A19 - Lift Power Lift is disabled. Cycle the key
The lift power amplifier has reported Amplifier Temperature switch to clear.
its internal temperature is less than (AC lift only) (Page 6-51)
–40°F (–40°C) or greater than +203°F
(+95°C).

Code 7G: LPA Motor Phase Open Test O28 - Ramp Lift Lift is disabled. Cycle the key
The lift power amplifier has detected Motor (AC lift only) switch to clear.
no current draw in one of the three (Page 6-116)
phases of the motor.

Code 7H: Failure Detected in Lift Test I20 - Lift Motor RPM Lift is limited to approx. 10
Motor Feedback Encoder (AC lift only) (Page 6-76) feet per minute. Cycle the
The lift power amplifier has detected key switch to clear.
incorrect pulses from the lift motor
encoder.

Code 7M: LPA Failed to Precharge None Lift is disabled. If cycling the
The lift power amplifier failed to key switch does not clear
precharge. this code, the amplifier must
be replaced. The VM cannot
cause this code.


Code 7T: LPA Current Sensor Fault None. Lift is limited to 60% of
Internal lift power amplifier circuitry maximum request. If cycling
that measures current has detected a the key switch does not clear
fault. this code, the amplifier must
be replaced. The VM cannot
cause this code.

Code 7U: LPA Overcurrent or Short None Lift is disabled. Cycle the key
Circuit switch to clear. The VM
The lift power amplifier has sensed cannot cause this code.
current in excess of 500A.
CODE 7V Inform service

Code 7V: LPA High Voltage on DC None Lift is disabled. Test the
BUS voltage at the LPA+. If OK,
The lift power amplifier has detected replace the LPA. Cycle the
that the voltage at the + terminal is key switch to clear. The VM
overvoltage. cannot cause this code.
CODE 7W Inform service

Code 7W: LPA Internal Fault None Cycle the key switch to clear.
Internal coil driver sensed open or If the code will not clear,
shorted. replace the lift power
amplifier. The VM cannot
cause this code.
CODE 7X Inform service

Code 7X: LPA Power Supply None Cycle the key switch to clear.
Out-of-Range Disconnect the (+) wire to
The power supply output in the lift the temp and speed sensors.
power amplifier is less than 4.5V, If OK, troubleshoot the wires
greater than 5.5V, or too much current and sensors. If the code will
is being drawn by an external not clear, replace the lift
component. power amplifier. The VM
cannot cause this code.


Code 7Y: Incorrect Lift Power None Replace with a correct power
Amplifier Installed amp.
(AC lift only)

Code 80: Throttle Potentiometer Test A04 - Throttle Travel is disabled. Cycle the
(VR1) Voltage Out-of-Range Potentiometer Voltage key switch to clear.
(Page 6-42)

Code 81: Lift/Lower Potentiometer Test A05 - Lift/Lower Lift is disabled. Cycle the key
(VR2) Voltage Out-of-Range Potentiometer Voltage switch to clear.
(Page 6-43)

Code 83: Throttle Potentiometer Test A04 - Throttle Travel is disabled. Cycle the
(VR1) Out-of-Neutral Potentiometer Voltage key switch to clear.
Throttle potentiometer (VR1) out of (Page 6-42)
learned neutral value.

Code 84: Brake Inoperable; Not Test O30 - Toggle Brake Travel is disabled at
Applied Solenoid (Page 6-118) start-up. Make sure the
The drive motor bearing encoder brake release bolts are
indicated movement during SelfTest. removed from the brake
assembly. Cycle the key
switch to clear.
Version 4.6 solves this
intermittent code.


Code 88: Lift and/or travel Test A04 - Throttle Lift and Travel are disabled.
Potentiometer Voltage Out of Potentiometer Voltage Relearn the handle. Cycle
Range (Page 6-42) the key switch to clear.
Out-of-range based on the learned Test A05 - Lift/Lower
neutral value. Potentiometer Voltage
(Page 6-43)
CODE 8C Inform service

Code 8C: Deadman Switches Do Not Test I00 - Carriage Travel, lift, lower, and brake
Agree Deadman (Page 6-68) are disabled. Cycle the key
Deadman switches S2 and S23 do not Test I01 - Brake Deadman switch to clear.
agree or the steering encoder is Switch (S2) (Page 6-69)
disconnected.

Code 8F: Lift/Lower Potentiometer Test A05 - Lift/Lower Lift and lower are disabled.
Out-of-Neutral Potentiometer Voltage Cycle the key switch to clear.
Lift/Lower potentiometer (VR2) out of (Page 6-43)
learned neutral value.
CODE 8L Inform service

Code 8L: Electric Brake Feedback Test A35 - Brake Travel is limited to 1 mph
The VM senses the brake coil current (Page 6-56) (1.6 km/h). Cycle the key
is incorrect. switch to clear.

Code 91: Drive Unit Turned >10° Test I25 - Steer Motor Lift truck plugs to 0 mph.
while Guiding on Wire Encoder (Page 6-80) Set the AUTO/MAN switch
to Manual. Cycle the key
switch to clear.


Code 92: Tracking Limits Exceeded Test A51 - Left Tractor Lift truck plugs to 0 mph.
Guidance Coil Voltage Set the AUTO/MAN switch
(Page 6-59) to Manual. Cycle the key
Test A52 - Right Tractor switch to clear.
Guidance Coil Voltage
(Page 6-60)
Test A53 - Left Load
(Page 6-61)
Test A54 - Right Load
(Page 6-62)
CODE 93 Lost TCP Lost Wire

Code 93: Not Near Wire; Tractor Coil Test A51 - Left Tractor Lift truck plugs to 0 mph.
Pair Guidance Coil Voltage Set the AUTO/MAN switch
(Page 6-60)
Test A55 - Tractor Near
Wire Coil Voltage
(Page 6-63)
CODE 94 Lost LCP Lost Wire

Code 94: Not Near Wire; Load Coil Test A53 - Left Load Truck plugs to 0 mph. Set
Pair Guidance Coil Voltage the AUTO/MAN switch to
(Page 6-61) Manual. Cycle the key
Test A54 - Right Load switch to clear.
(Page 6-62)
Test A56 - Load Near Wire
Coil Voltage (Page 6-64)

CODE 9A Inform Service
CODE 9A Inform Service

Code 9A: Bad Wire Guidance Learn None Re-run Learn procedure.
The Learn Procedure did not complete Travel is limited to 1 mph
successfully. (1.6 km/h). Set the
AUTO/MAN switch to
Manual. Check the wiring
between the Guidance
Manager and the VM.
switch to clear.
CODE 9B Inform Service

Code 9B: Bad SDO (CAN - Service If error occurred while Travel is limited to 1 mph
Data Object) Data Received learning Wire Guidance, (1.6 km/h). Set the
VM received bad data from the re-run Learn procedure. AUTO/MAN switch to
Guidance Manager. Manual. Check the wiring
between the Guidance
Manager and the VM.
Re-learn Guidance. Replace
the Guidance Manager. If the
code re-occurs, replace the
VM. Cycle the key switch to
clear.

Code 9E: Track And Hold Signal Test A51 - Left Tractor Lift truck plugs to 0 mph.
Failed Guidance Coil Voltage Set the AUTO/MAN switch
The lift truck is moving on the wire and (Page 6-59) to Manual. Cycle the key
the guidance signals are not Test A52 - Right Tractor switch OFF/ON to clear.
fluctuating at all. Guidance Coil Voltage
(Page 6-60)
Test A53 - Left Load
(Page 6-61)
Test A54 - Right Load
(Page 6-62)


Code 9F: Filter Card Not Connected Check the connection Hard plug to 0 mph. Cycle
to Guidance Manager between the filter card the key switch OFF/ON to
When the AUTO/MAN switch is and the Guidance clear.
switched to AUTO and the Guidance Manager. Replace the The new Guidance Manager
Manager does not sense the filter card. filter card first then the circuit card (1181302/001)
Guidance Manager. requires new compatible
firmware
(073-802-083/040).

Code 9G: No Input; Load Antenna Test A53 - Left Load Lift truck plugs to 0 mph.
The signal from the load antenna is Guidance Coil Voltage Set the AUTO/MAN switch
not being received by the Guidance (Page 6-61) to Manual. Cycle the key
Manager. Test A54 - Right Load switch OFF/ON to clear.
(Page 6-62)

Code 9H: No Input; Tractor Antenna Test A51 - Left Tractor Lift truck plugs to 0 mph.
The signal from the tractor antenna is Guidance Coil Voltage Set the AUTO/MAN switch
not being received by the Guidance (Page 6-59) to Manual. Cycle the key
Manager. Test A52 - Right Tractor switch OFF/ON to clear.
(Page 6-60)
CODE 9J Inform service

Code 9J: Load Antenna Input Too Test A53 - Left Load Lift truck plugs to 0 mph.
High Guidance Coil Voltage Set the AUTO/MAN switch
Test A54 - Right Load switch to clear.
(Page 6-62)


Code 9K: Tractor Antenna Input Too Test A51 - Left Tractor Lift truck plugs to 0 mph.
High Guidance Coil Voltage Set the AUTO/MAN switch
(Page 6-60)
CODE A0 Inform service

Code A0: Incorrect Software None Travel, lift, and lower are
Incorrect VM installed in lift truck or disabled. Cycle the key
Flashed with incorrect software. switch to clear. If this code
appears, upgrade the
software in the lift truck
using FlashWare.

Code A2: Software Compatibility None Travel is disabled. Cycle the
Issue with VM and TPA key switch to clear. If this
code appears, upgrade the
software in the lift truck
using FlashWare.

Code A4: Software Compatibility None Lift is disabled. Cycle the key
Issue with VM and LPA switch to clear. If this code
AC lift only. appears, upgrade the
software in the lift truck using
FlashWare.
CODE AH Inform service

Code AH: Bad CCC Checksum None Lift and Travel are disabled.
Replace the CCC.

CODE AL Inform service
CODE AL Inform service

Code AL: VM Battery Backed Up None Travel, lift, and lower are
RAM Failed disabled. Cycle the key
switch to clear. If the code
will not clear, replace the
VM.
CODE AP Inform service

Code AP: TPA Software Fault None Travel is disabled. Cycle the
key switch to clear. If the
code will not clear, Flash the
traction power amplifier with
the latest software. Also see
“Code 2T: TPA Current
Calibration Error”
CODE AT Inform service

Code AT: LPA Software Fault None Lift is disabled. Cycle the key
AC lift only. switch to clear. If the code
will not clear, Flash the lift
power amplifier with the
latest software. Also see
“Code 2T: TPA Current
Calibration Error”
CODE F8 Inform service

Code F8: Microcontroller COP None Lift and Travel are disabled.
Timer is not functioning correctly. Re-install the VM software.
Replace the VM. Cycle the
key switch to clear.
CODE FE Inform service

Code FE: Internal VM Circuit for None Code is displayed for 30
BSOC Not Calibrated seconds. Replace the VM.
If intermittent, test the
Inrush Protection circuit.
See “Inrush Protection” on
page 5-22.

CODE FG Inform service
CODE FG Inform service

Code FG: +5V Reference Voltage and Test A14 - VM +12V Power Travel, lift, and lower are
+12V Power Supply Failure Supply (Page 6-49) disabled. Brake will engage.
page 5-22.
CODE FH Inform service

Code FH: Battery Voltage Test A15 - Battery Voltage Travel, lift, and lower are
Out-of-Range (Page 6-50) disabled. Brake will remain
Wrong voltage battery or voltage engaged. Cycle the key
out-of-range. switch to clear.
page 5-22.
CODE FN Inform service

Code FN: Relays Did Not Open at Test O32 - Toggle Relay Travel, lift, and lower are
Power Off Enable (Page 6-119) disabled. Brake remains
engage. Cycle the key switch
to clear.
CODE FP Inform service

Code FP: VM In-Circuit Hardware None Travel, lift, and lower are
Failure disabled. Brake remains
engaged. Cycle the key
switch to clear. Replace the
VM.
See “Troubleshooting” on
page 5-1.

CODE FT Inform service
CODE FT Inform service

Code FT: VM Internal Software Error None Travel, lift, and lower are
disabled. Brake will remain
engaged. Cycle the key
switch to clear. If the code
will not clear, Flash the VM
with the latest software.
See “Troubleshooting” on
page 5-1.
CODE G0 Inform service

Code G0: Steer Tiller Encoder 1 is Test I35 - Steer Tiller Coasts to 2.5 mph (4.0
Intermittent or Failed Encoder 1 (Page 6-82) km/h). Travel is limited to
Determined by channel A and/or B 2.5 mph (4.0 km/h). Cycle
not functioning correctly when the key switch to clear.
compared with Steer Tiller Encoder 2.

Code G2: Auto Steer Center Failed See “Test O44 - Steer Moderate plug to 0.0 mph.
1. Home switch is more than 10 Motor” on page 6-125. Step off, then back on the
degrees from the initial value saved See “Auto Steer Center deadman pedal to allow
during a successful auto steer center. Problem” on page 5-33. travel again. Max travel
2. Auto steer center time-out - greater speed is limited to 1.0 mph
than 2 seconds. 3. No encoder pulses (1.6 km/h). Cycle the key
sensed during auto steer center. switch OFF/ON to clear.

Code G3: Home Prox Switch Not See “Test O44 - Steer All steer indicator lights will
Functioning Correctly Motor” on page 6-125. flash. Travel speed is limited
See “Auto Steer Center to 1.0 mph (1.6 km/h). Cycle
Problem” on page 5-33. the key switch OFF/ON to
clear.


Code G4: Open Detected in Steer See “Test O44 - Steer Aggressive plug to 0.0 mph.
Control Circuit Motor” on page 6-125. Step off, then back on the
No neutral pulses detected when the See “Auto Steer Center deadman pedal to allow
lift truck is not moving and operator is Problem” on page 5-33. travel again. Max travel
on the deadman pedal. speed is set to 1.0 mph (1.6
km/h).
Cycle the key switch
OFF/ON to clear.

Code G5: Short Detected in Steer Test A37 - Steer Power Moderate plug to 0.0 mph.
Power Circuit Amplifier Current Step off, then back on the
Steer motor encoder pulses or (Page 6-57) deadman pedal to allow
command detected and no steer tiller See “Test O44 - Steer travel again. Max travel
encoder pulses detected. Motor” on page 6-125. speed is set to 1.0 mph (1.6
Test I25 - Steer Motor km/h).
Encoder (Page 6-80) Cycle the key switch
OFF/ON to clear.

Code G7: Steer Tiller Encoder 2 is Test I36 - Steer Tiller Coasts to 2.5 mph (4.0
Intermittent or Failed Encoder 2 (Page 6-83) km/h). Travel is limited to
Determined by the connect detect 2.5 mph (4.0 km/h). Cycle
circuit for the CD Supply and Gnd the key switch to clear.
connections or by channel A and/or B
not functioning correctly when
compared with Steer Tiller Encoder 1.
CODE GD Inform service

Code GD: No Steer Motor Encoder Test I25 - Steer Motor Lift truck plugs to 0 mph.
Pulses Seen Encoder (Page 6-80) Travel is limited to 1 mph
No steer motor encoder pulses seen Test O44 - Steer Motor (1.6 km/h). More steer tiller
when requesting a steer correction, (Page 6-125) rotations are required to
travel is >0.1 mph or during auto steer turn the drive unit. Cycle the
center. key switch to clear.

CODE GE Inform service
CODE GE Inform service

Code GE: Both Steer Tiller Encoders Test I35 - Steer Tiller Lift truck plugs to 0 mph.
Failed Encoder 1 (Page 6-82) Travel is limited to 1 mph
Determined by the connect detect Test I36 - Steer Tiller (1.6 km/h). Cycle the key
circuit. Encoder 2 (Page 6-83) switch to clear.
CODE GF Inform service

Code GF: Wire Guidance Position Re-run Learn Procedure. Lift and Travel are disabled.
Out-of-Range Set the AUTO/MAN switch
A steer request received from the to Manual. Replace the Wire
Guidance Mnager was out-of-range. Guidance Manager. Cycle
From the center, any request over -90 the key switch to clear.
degrees out-of-range.
CODE J2 Inform service

Code J2: Aisle Exit Error Test I72 - End-of-Aisle Plugs to stop, speed is
Only one magnet was sensed when the Sensor 2 (optional) limited to 1 mph. While out
guided aisle was exited. (Page 6-96) of the aisle, switch the
Test I73 - End-of-Aisle AUTO/MAN switch to
Sensor 1 (optional) manual. Turn the drive unit
(Page 6-98) >10° and travel until the
code clears.
Go into lift truck history and
see what subcode was
thrown. See Table 5-5 on
page 5-26
CODE J4 Inform service

Code J4: Aisle Sensor Error Test I72 - End-of-Aisle Travel is limited to 1 mph
Sensor 2 (optional) (1.6 km/h).
(Page 6-96)
Sensor 1 (optional)
(Page 6-98)

CODE VC Inform service
CODE VC Inform service

Code VC: The CAN Chip will not Test I23 - CAN Bus All functions are disabled.
Reset (Page 6-77) See Communication Error
Most likely this is due to an internal Code Troubleshooting on
fault in the VM. page 5-25.
Replace the VM. Cycle the
key switch to clear.
CODE X3 Inform service

Code X3: 180 in. Limit Switch Test I75 - 180 in. Limit Travel is limited to 1.0 mph
Mismatch Switch (optional) (1.6 km/h). Cycle the key
The 180 in. Switch (S100) is out of (Page 6-101) switch OFF/ON to clear.
sequence with a standard mast
switch.

Code X4: Lift Cutout Switch Test I76 - Lift Cutout Cycle the key switch
Mismatch Switch (optional) OFF/ON to clear.
Lift Cutout Switch (S124) mismatch (Page 6-102) Up arrow icon flashes and
with standard mast switch. message lift cutout - max ht
reached.

Code X5: Lift Inhibit Switch Test I05 - Lift Inhibit Cycle the key switch
Mismatch Switch (optional) OFF/ON to clear.
Lift Inhibit Switch (S24) mismatch (Page 6-73)
with standard mast switch.


Analog Input Tests
Analog Input Tests

A Diagnosis and Repair table is provided for
most tests. If a test fails, refer to the Diagnosis
and Repair table. Through the process of
elimination, these tables provide the technician
with a step-by-step approach to diagnosing a
problem and the necessary corrective action.
See the table below.
Example Diagnosis and Repair Table
Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting
This column
identifies the
action(s) required
(if any) before
testing the
circuit. If no
instructions are
given, all circuits
must be
The next
connected. The next
This is the Connection Connection action to be
Note: If action to be
order that point for point for The reading performed if
something was performed if
the testing the Positive the required to consider the
disconnected in the Expected
must be (+) meter Negative (–) the step a success. Expected
the prior step, Results are
performed. lead. meter lead. Results are
reconnect it met.
not met.
before
performing the
next step.
This column also

identifies the
required setting
on the meter for
this step.

Test A04 - Throttle Potentiometer Voltage
Test A04 - Throttle Run test:

Potentiometer Voltage The test is a success if the voltage displayed is
within these limits:
This test displays the voltage the CCC produces Throttle Position Voltage Displayed
based on input from the throttle potentiometer
(VR1). Full forward position
0.30 to 1.21V
Tractor-first (TF)
NOTE: Learn must be run whenever the throttle
assembly is replaced, repaired, or Neutral position 1.23 to 1.83V
adjusted. See Learn Controls on
Full reverse position
page 3-19. 1.85 to 2.80V
Forks-first (FF)
For information on using Maintenance Mode,

refer to page 3-25. If the voltage reading is outside these limits or
does not change in a smooth linear fashion, the
test has failed. Any voltage fluctuation indicates
a bad cable or VR1.
The voltage reading should decrease when the

throttle is moved from the reverse to the
forward position. If these results are not
observed, the test has failed. Perform diagnosis
and repair.
Diagnosis and Repair

Action/
Setting
1 JPC9 PC9-7 Perform step 2

disconnected/ PC9-8 5.3V Replace CCC
2 DCV PC9-9 Perform step 3
Neutral: 1.23-1.83V
Replace pot
3 DCV JPC9-9 JPC9-7 FF: increase Replace CCC
(VR1)
TF: decrease

Test A05 - Lift/Lower Potentiometer Voltage
Test A05 - Lift/Lower Run test:

Potentiometer Voltage The test is a success if the voltage displayed is
This test displays the voltage the CCC produces Lift/Lower
based on input from the lift/lower pot (VR2). Voltage Displayed
Control Position
NOTE: Run this test if the voltage output by the Full lift position 0.15 to 0.95V
lift/lower potentiometer (pot) exhibits
problems. Neutral position 0.97 to 1.46V
NOTE: Learn must be run when the lift/lower Full lower position 1.48 to 2.40V
pot is replaced, repaired, or adjusted.
See Learn Controls on page 3-19. If the voltage reading is outside these limits or
does not change in a smooth linear fashion, the
For information on using Maintenance Mode, test has failed. Any voltage fluctuation indicates
refer to page 3-25. a bad cable or VR2.
The voltage reading should decrease when the

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

Action/
Setting
1 JPC9 PC9-4 Perform step 2

PC9-5 5.3V Replace CCC
2 disconnected/DCV PC9-6 Perform step 3
Neutral: 0.97-1.46V
Replace pot
3 DCV JPC9-6 JPC9-4 Lower: increase Replace CCC
(VR2)
Lift: decrease

Test A08 - Traction Motor Temperature
Test A08 - Traction Motor the lift truck up by driving it hard for
approximately 30 minutes. As the motor heats,
Temperature the temperature will increase.
For information on how to use Maintenance

This test displays the temperature of the Mode, refer to page 3-25.
traction motor.
Limits Run test:

• Normal operation: ambient to 258°F 1. With the lift truck at rest and at ambient
(125°C) temperature, compare the temperatures
• Between 266°F (130°C) and 300°F (149°C), obtained from those obtained using
speed is linearly reduced to 1.0 mph Maintenance Mode to the ambient
(1.6 km/h). temperature.
• Temperature icon lights at 275°F (135°C) 2. If the temperatures are not within several
degrees, the test has failed.
• Fault Code 2A and travel disabled at 300°F
(149°C) 3. If the lift truck is not at ambient
temperature, use the diagnosis and repair
While operating, the VM continually monitors chart to isolate the cause.
the temperature of the traction motor. If the
temperature gets too high, performance is
reduced until the motor cools down.
Use Active Maintenance to see the actual

temperature from the temperature sensor. Heat
Action/
Setting
JPTA1
1 disconnected/ JTA1-8 JTA1-7 <1200 Ohms if Replace TPA Perform step 2
Ohms motor is cool
JPTA3 >1200 Ohms if T/S traction
motor is hot Replace traction
2 disconnected/ JTA3-2 JTA3-1 motor temp
motor temp sensor
Ohms sensor

Test A09 - Lift Motor Temperature
Test A09 - Lift Motor

Temperature
This test displays the temperature of the AC lift
motor.
Limits
• Normal operation: ambient to 294°F
(145°C)
• Temperature icon lights at 295°F (146°C)
• Fault Code 6F and lift shutdown at 300°F
(149°C)

refer to page 3-25.
Run test:
As lift is operated, the readings should increase
evenly over time. If not, the test has failed.
Perform diagnosis and repair.

Action/
Setting
JPLA1
1 disconnected/ JLA1-8 JLA1-7 <1200 Ohms if Replace LPA Perform step 2
Ohms motor is cool
JPLA3 >1200 Ohms if
motor is hot T/S lift motor Replace lift motor
2 disconnected/ JLA3-2 JLA3-1
temp sensor temp sensor
Ohms

Test A10 - Traction Power Amplifier Temperature
Test A10 - Traction

Power Amplifier
Temperature
This test displays the temperature of the
Traction Power Amplifier (TPA).
Limits
• Normal operation: ambient to 175°F (79°C)
• Starting at 176°F (80°C), speed is linearly
reduced by the Traction Power Amplifier to
0.0 mph at 239°F (115°C), when traction is
disabled.
• Temperature icon lights at 185°F (85°C)
• Fault Code 1H at 203°F (95°C)

refer to page 3-25.
Run test:
The Operator Display shows the heatsink
temperature that the traction power amplifier
reads.
As drive is operated, the readings should

increase evenly over time. If not, the test has

Action/
Setting
Is TPA heatsink If not hot, replace

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

Test A11 - Traction Motor Current
Test A11 - Traction Motor Diagnosis and Repair

NOTE: Check all motor and power amplifier
Current connections for tightness and corrosion.
This test displays the current in the traction Check individual phase currents with a
motor power circuits. clamping ammeter. The current should ramp
evenly as the lift truck accelerates and
Limits: decelerates. Phase currents must be
approximately equal. Gross differences indicate
• Above 266°F (130°C) current is reduced
a problem.
linearly
• Maximum current up to 540A when If readings are not within reference limits, the
deadman pedal is released, unaffected and test has failed.
unreduced by temperature
1. If any one phase differs significantly from
the other two, check power cable
continuity. Replace cables as necessary.
refer to page 3-25.
See Power Cables on page 7-72.
NOTE: This test shows best results in Active • If power cable continuity is OK,
Maintenance. troubleshoot the traction motor. See AC
Motor Troubleshooting on page 5-11.
Run test: • If all phases give high readings, the
drive unit may be binding. Check the
The Operator Display shows the current that drive unit.
the traction power amplifier reads from the
2. The power amplifier may be bad. Run Test
traction motor.
O29 - Ramp Traction Motor (Page 6-117).
System Condition Current Displayed
Static at Rest <20A
Travel at Full Speed <150A
Because Test A11 measures only one phase, the

test may not always reveal a problem.

Test A13 - Pressure Sensor Voltage (optional)
Test A13 - Pressure

Sensor Voltage
(optional)
This test displays the voltage from the pressure
sensor used for load weight sensing.

refer to page 3-25.
Limits
The operator display shows the voltage present

with various load weights.
Load Weight Voltage
0 (no load) approx. 1.0V
3000 lbs. approx. 3.0V
If the weight sensor is disconnected at the

Vehicle Manager, the operator display shows
0V.
Run test:
The voltage shown on the operator display
should increase and decrease in a linear
fashion as the load weight is either increased or
decreased. If it does not, the test has failed. If
the weight display is inaccurate, the test has

Action/
Setting
1 JPT20-5 JPT24-10 Step 2 Replace VM

DCV 10.5 to 13V
2 JPS50-1 Step 3 T/S harness
JPS50-3 Replace
3 Attach pressure JPS50-2 1V @ 0 psi: 1V increase Step 4 Pressure
gauge to G1/DCV per 1000 psi Transducer
4 JPT24-18 JPT24-10 Replace VM T/S harness

Test A14 - VM +12V Power Supply
Test A14 - VM +12V

Power Supply
This test displays the output of the internal
+12V power supply of the Vehicle Manager.

refer to page 3-25.
Run test:
The display should read 10.8-13V. If the voltage
fluctuates more than 0.8V in 10 seconds, the
test has failed. Perform diagnosis and repair.

Action/
Setting
Remove wire from PT14-5

1 Step 2 Step 4
JPT14-5/DCV (VM side)
JPC11 Replace mast

2 Step 3
disconnected/DCV cable
Disconnect all wires

supplying 12 or
5.3V from the Plug in wires
3 connectors at the TP4 10.5 to 13V Replace CCC
and connectors
CCC. Disconnect JPT14-5 one at a time.
JPC15 and Troubleshoot
JPC2/DCV the circuit that
Disconnect all wires pulls down the
supplying 12V from 12V.
4 Replace the VM
the connectors at
the VM/DCV

Test A15 - Battery Voltage
Test A15 - Battery Run test:

Voltage The test is a success if the voltage displayed is
This test displays the voltage the VM is reading PC must be closed.
from the battery sense line.
Nominal Battery
Voltage Displayed
A successful test proves the VM is correctly Voltage
reading BATTERY_SENSE_IN at JPT24-24.
24V 22.0 to 26.0V
NOTE: This voltage is used by the VM to
36V 33.0 to 39.0V
calculate the battery state-of-charge.
For information on using Maintenance Mode, If the reading fluctuates by more than 0.8V in
refer to page 3-25. 10 seconds with the lift truck not moving or
lifting, the test has failed. Perform diagnosis
and repair.
NOTE: If FH Code occurs, verify that the model
number viewed in FlashWare matches
the vehicle model before replacing the
VM.

Action/
Step Meter (+) Lead (–)Lead Expected Results Step Passed Step Failed
Setting
Check battery
voltage/ specific
1 TP1 Perform step 2
gravity. T/S battery
cables.
24V truck: 16 to 32V T/S harness TP1 to

2 DCV JPF4-1 TP4 Perform step 3
36V truck: 28 to 44V TP4.
3 JPF4-7 Perform step 4 T/S Fuse Relay Card.
T/S harness from

4 JPT24-24 Replace VM Fuse Relay Card to
VM.

Test A19 - Lift Power Amplifier Temperature (AC lift only)
Test A19 - Lift Power

Amplifier Temperature
(AC lift only)
This test displays the temperature of the Lift
Power Amplifier (LPA) heatsink.
Limits
• Normal operation: ambient to 175°F (79°C)
• Starting at 176°F (80°C), speed is linearly
reduced to 0 fpm at 239°F (115°C), when
lift is disabled
• Temperature icon illuminates at 185°F
(85°C)
• Fault Code 7F at 203°F (95°C)

refer to page 3-25.
Run test:
The Operator Display shows the heatsink
temperature that the lift power amplifier reads.
As the lift is operated, the readings should

increase evenly over time. If not, the test has
Action/
Setting
Is LPA heatsink If not hot, replace

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

Test A20 - Lift Motor Current (AC lift only)
Test A20 - Lift Motor If readings are not within reference limits, the
test has failed.
Current (AC lift only) 1. If any one phase differs significantly from
the other two, check power cable
This test displays the lift motor current through continuity. Replace cables as necessary.
the lift power amplifier. See Power Cables on page 7-72.
• If power cable continuity is OK,
troubleshoot the lift motor. See AC
Motor Troubleshooting on page 5-11.
The lift carriage and forks will move • If all phases give high readings, the lift
during this test. pump may be binding.
2. The power amplifier may be bad. Run Test
O28 - Ramp Lift Motor (AC lift only)
(Page 6-116).
The area around the forks must be clear.
The ceiling clearance should allow for
the highest lift.
Limits
• 0 to 500A lifting
• Maximum current 675A
Test requires the use of Active Maintenance to

see correct test results.

refer to page 3-25.
Run test:
The Operator Display shows the current that
the lift power amplifier reads from one phase of
the lift motor.
NOTE: Because only one phase is measured, a
current problem may not be revealed.

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

clamping ammeter. The current should ramp
evenly as the lift truck accelerates and
decelerates. Phase currents must be
approximately equal. Gross differences indicate
a problem.

Test A22 - Traction Throttle Request
Test A22 - Traction

Throttle Request
This test displays the percentage of traction
throttle request from VR1 being read by the VM.

refer to page 3-25.
Run test:
NOTE: Run Learn after you replace, repair, or
adjust the throttle assembly. See Learn
Controls on page 3-19.
The Operator Display shows the percentage of

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

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

the test has failed. Perform diagnosis and
repair.
NOTE: Any speed limiting conditions will result
in less than 100 shown on the display.
Action/
Setting
Test should pass. Check traction

Run Test A04 -
Compare Test A04 system for speed
Throttle
results with the limits due to motor
1 Potentiometer N/A N/A Replace the TPA
results from A22. temperature, limit
Voltage
Max throw should switches, or
(Page 6-42)
show max values. configured speed.

Test A23 - Lift Request
Test A23 - Lift Request

This test displays the percentage of lift throttle
request from VR2 being read by the VM.

refer to page 3-25.
Run test:
NOTE: Run Learn after you replace, repair, or
adjust the lift/lower potentiometer
(VR2). See Learn Controls on page 3-19.
The Operator Display shows the percentage of

lift request that the VM reads from the lift
potentiometer (VR2).
Throttle Position Percentage Displayed
Full Lower 0 to –100
Neutral 0
Full Lift 0 to +100
The values must change smoothly and evenly

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

repair.
NOTE: Any lift limiting conditions will result in
less than 100% shown on display.
Action/
Setting
Test should pass.

Run Test A05 -
Compare Test A05 Check lift system
Lift/Lower
results with the for limits due to
1 Potentiometer N/A N/A Replace the LPA
results from A23. motor temperature
Voltage
Max throw should or switches.
(Page 6-43)
show max values.

Test A34 - Lift/Lower Current
Test A34 - Lift/Lower

Current
This test displays the current the proportional
lift/lower solenoid coil is drawing.

see Correct test results.

refer to page 3-25.
Run test:
State Current
Neutral Approx. 0.70A
Full Lower Approx. 1.3A
If results do not match the preceding table. the

Perform Test O12 - Proportional Solenoid PWM

Ramp (Page 6-111).

Test A35 - Brake
Test A35 - Brake

The brake coil is activated by a coil driver
located inside the Vehicle Manager. This test
displays the voltage measured across that coil
driver.

refer to page 3-25.
NOTE: This test can only be run in Active
Maintenance.
Run test:
When the test is run, observe the following
results:
State of Brake Display
Brake deactivated B+
Deadman Pedal
Approx. 12V (36V trucks)
Depressed/Travel
Approx. 0V (24V trucks)
Requested
If results do not match the preceding table, the


Action/
Setting
JPT20 and
JPF2 T/S wires and
1 JT20-14 JF2-2 Approx. 13 ohms Perform step 2
disconnected/ coil
Ohms
If no B+, T/S
Brake de-energized: B+ Fuse Relay Card.
Inspect brake
Brake energized: If voltage does
2 DCV JP20-14 TP4 assembly for
36V truck = approx. 12V not drop when
binding
24V truck = 0V energized,
replace the VM

Test A37 - Steer Power Amplifier Current
Test A37 - Steer Power report something higher than zero

current in maintenance mode.
Amplifier Current If the results do not match the preceding table,
This test displays the current that the steer repair.
motor is drawing.


refer to page 3-25.
Run Test:
You should see:
State of Motor Display
At rest <2A
Clockwise (CW) Steering –30 to –50A
Counterclockwise (CCW) Steering 30 to 50A
NOTE: CW and CCW is drive unit direction.
NOTE: On a fully functional truck, this test

reports OA in maintenance mode
because the steer is not being moved in
maintenance mode. If the steer amp is
unplugged or other errors in steer
current feedback occur, the test will

Action/
Setting
At rest: approx. 2.5V

Replace Steer
1 DCV JPT6-3 TP4 Steering CCW: <V at rest Replace VM
Amplifier
Steering CW: >V at rest

Run Test:
Tractor Near Wire -

Test A55 - Tractor
Tractor Left - Test A51 Near Wire Coil
- Left Tractor Voltage (Page 6-63)
Guidance Coil Voltage Tractor Right - Test
(Page 6-59) A52 - Right Tractor
(Page 6-60)
Load Near Wire - Test

A56 - Load Near Wire
Coil Voltage
(Page 6-64)
Load Left - Test A53 - Load Right - Test A54

Left Load Guidance - Right Load Guidance
Coil Voltage Coil Voltage
(Page 6-61) (Page 6-62)
6
Figure 6-1. Location of Wire Guidance Coils and Related Tests

Test A51 - Left Tractor Guidance Coil Voltage
Test A51 - Left Tractor For information on using Maintenance Mode,

refer to page 3-25.
Run test:
This test displays the percentage of the left
NOTE: Center the lift truck over the wire prior
tractor guidance coil voltage sensed by the
to running the test. If it will not track, it
Guidance Manager.
may not be centered and voltages will
fail per the test.
Refer to Figure 6-1 on page 6-58 to determine
what coil this test checks.
The test is a success if the percentage displayed
is between 40 and 70%. If the reading is outside
Make sure the lift truck is set to the correct
these limits, the test has failed. Perform
frequency. If the frequency used is not
diagnosis and repair.
standard, it must first be Learned. See Learn
Test line driver output. Refer to Raymond

Publication PDSS-0051.
Action/
Setting
Cable JW2-1, 2, 3, J1T-1, 2,

1 disconnected/ 5, 6, 7, 8, 14, 3, 5, 6, 7, 0 Ohms Perform step 2 Replace cable
Ohms 15 8, 14, 15
JPW2
2 disconnected/ PW2-15 PW2-14 Perform step 4 Perform step 3
DCV
JP1-A13
JP1-B1 (Filter Approx 11.5V
(Filter
Filter Card Card Replace Steer
Card Replace Filter
3 removed/ connection Controller
connection Card
DCV on Steer Card
on Steer
Card)
Card)
Bumper Centered: 32mV

Replace
4 removed/ JPW2-3 1.5 in. left: 15mV Perform step 5
Antenna Card
mVAC 1.5 in. right: 76mV
B–
Bumper Centered: 1.1V
Replace Steer Replace Filter
5 removed/ JP1-A15 1.5 in. left: 0.6V
Controller Card Card
DCV 1.5 in. right: 2.8V
NOTE: Steps 4 and 5 are approximate readings.

Floor settings will cause them to vary. If
a similar change in values is seen, the
test has passed.

Test A52 - Right Tractor Guidance Coil Voltage
Test A52 - Right Tractor Run test:

Guidance Coil Voltage NOTE: Center the lift truck over the wire prior
This test displays the percentage of the right fail per the test.
tractor guidance coil voltage sensed by the
Guidance Manager. The test is a success if the voltage percentage
displayed is between 40 and 70%.
what coil this test checks. If the reading is outside these limits, the test
has failed. Perform diagnosis and repair.


refer to page 3-25.
Action/
Setting
Cable dis- JW2-1, 2, 3, J1T-1, 2,

1 connected/ 5, 6, 7, 8, 14, 3, 5, 6, 7, 0 Ohms Perform step 2 Replace cable
Ohms 15 8, 14, 15
JPW2 dis- Perform step

2 PW2-15 PW2-14 Perform step 4
connected/DCV 3
JP1-A13
JP1-B1 (Filter
(Filter Approx 11.5V
Card Replace Filter
connection Card
DCV on Steer Card
on Steer
Card)
Card)

Replace
Antenna Card
B–
JP1-A16 Replace Steer Replace Filter
5 removed/ 1.5 in. left: 0.6V
(Filter Card) Controller Card Card

test has passed.

Test A53 - Left Load Guidance Coil Voltage
Test A53 - Left Load Run test:

This test displays the percentage of the left load fail per the test.
guidance coil voltage sensed by the Guidance
Manager. The test is a success if the voltage percentage


refer to page 3-25.
Action/
Setting
Cable dis- JW2-1, 2, 3, J1L-1, 2,

1 connected/ 5, 6, 7, 8, 14, 3, 5, 6, 7, 0 Ohms Perform step 2 Replace cable
Ohms 15 8, 14, 15
JPW1
DCV
JP1-A13
(Filter
Card Replace Filter
connection Card
DCV on Steer Card
on Steer
Card)
Card)

Replace
Antenna Card
B–
JP1-A7 (Filter Replace Steer Replace Filter
Card) Controller Card Card

test has passed.

Test A54 - Right Load Guidance Coil Voltage
Test A54 - Right Load Run test:

This test displays the percentage of the right fail per the test.
load guidance coil voltage sensed by the


refer to page 3-25.
Action/
Setting
Cable JW1-1, 2, 3, J1L-1, 2,

1 disconnected/ 5, 6, 7, 8, 14, 3, 5, 6, 7, 0 Ohms Perform step 2 Replace cable
Ohms 15 8, 14, 15
JPW1
DCV
Approx 11.5V
Filter Card JP1-A13
JP1-B1 (Filter Replace Filter Replace Steer
3 removed/ (Filter
Card) Card Controller Card
DCV Card)

Replace
Antenna Card
B–
Replace Steer Replace Filter
5 removed/ JP1-A15 1.5 in. left: 0.6V
Controller Card Card
DCV 1.5 in. right: 100mV

test has passed.

Test A55 - Tractor Near Wire Coil Voltage
Test A55 - Tractor Near Run test:

Wire Coil Voltage NOTE: Center the lift truck over the wire prior
This test displays the percentage of the tractor fail per the test.
near wire guidance coil voltage sensed by the
Guidance Manager. The test is a success if the percentage displayed
is between 80 and 110%.


refer to page 3-25.
Action/
Setting
JPW2 and
JW2-1, 2, 3, J1T-1, 2,
JP1T
1 5, 6, 7, 8, 14, 3, 5, 6, 7, 0 Ohms Perform step 2 Replace cable
disconnected/
15 8, 14, 15
Ohms
JPW2
DCV
JP1-A13
(Filter
Filter Card Card
Card Replace Filter Replace Steer
3 removed/ connection
connection Card Controller Card
DCV on Steer
on Steer
Card)
Card)

Replace
Antenna Card
B–
JP1-A15 Replace Steer Replace Filter
(Filter Card) Controller Card Card

test has passed.

Test A56 - Load Near Wire Coil Voltage
Test A56 - Load Near Run test:

Wire Coil Voltage NOTE: Center the lift truck over the wire prior
This test displays the percentage of the load fail per the test.
near wire guidance coil voltage sensed by the


refer to page 3-25.
Action/
Setting
JPW1 and
JW1-1, 2, 3, J1L-1, 2,
JP1L
1 5, 6, 7, 8, 14, 3, 5, 6, 7, 0 Ohms Perform step 2 Replace cable
disconnected/
15 8, 14, 15
Ohms
JPW1
DCV
JP1-A13
(Filter
Card Replace Filter
connection Card
DCV on Steer Card
on Steer
Card)
Card)

Replace
Antenna Card
B–
JP1-A6 (Filter Replace Steer Replace Filter
Card) Controller Card Card

test has passed.

Tests A96 thru A100 - iBATTERY Tests
Tests A96 thru A100 -

iBATTERY Tests
Tests A96 thru A100 are iBATTERY™ related
tests. Refer to iBATTERY Monitoring System
Installation and Maintenance Instructions
P/N 1139156.

Tests A96 thru A100 - iBATTERY Tests

Input Tests
Input Tests
with a step-by-step approach to diagnosing a
Action/
Setting
This column
identifies the
action(s) required
(if any) before
testing the
circuit. If no
instructions are
given, all circuits
must be
The next
connected. The next
reconnect it met.
not met.
before
performing the
next step.
This column also

identifies the
required setting
on the meter for
this step.

Test I00 - Carriage Deadman
Test I00 - Carriage

Deadman
This test shows what the VM is reading from
S23. The switch is hard wired through the CCC
to the VM.

refer to page 3-25.
Run test:
The state of the switch is displayed:
Deadman Pedal Operator Display
Up Up
Down Down
If these results are not observed, the test has


Action/
Setting
JPC7
1 disconnected PC7-5 PC7-6 Perform Step 2 Replace CCC
/DCV
10.7 to 13V
2 JPC7-5 Perform Step 3
S23-3 Repair/replace wire
3 Perform Step 4
S23-1
4 S23-2 Pedal down: Perform Step 5 Adjust/replace S23
10.7 to 13V
5 JPC7-5 JPC7-4 Pedal up: 0V Perform Step 6 Repair/replace wires
DCV
6 JPC11-6 Perform Step 7 Replace CCC
Pedal down: B+ Repair/replace

7 B+ JPS25-5 Perform Step 8
Pedal up: 0V over-the-mast cable
8 JPT22-8 Replace VM Repair/replace cable

Test I01 - Brake Deadman Switch (S2)
Test I01 - Brake

Deadman Switch (S2)
This test shows what the VM is reading from
S2. The switch is hard wired through the CCC
to the VM.

refer to page 3-25.
Run test:
The state of the switch is displayed:
Deadman Pedal Operator Display
Up Up
Down Down


Action/
Setting
JPC7
1 disconnected/ PC7-2 PC7-3 Perform Step 2 Replace CCC
DCV
10.7 to 13V
2 JPC7-2 Perform Step 3 Repair/replace
S2-3
3 Perform Step 4 wire
S2-1
4 S2-2 Perform Step 5 Adjust/replace S2
Pedal down: 10.7 to 13V
Pedal up: 0V Repair/replace
5 DCV JPC7-2 JPC7-1 Perform Step 6
wires
7 JPS25-4 Pedal down: 0V Perform Step 8 Replace

B–
Pedal up: 10V over-the-mast
8 JPT22-7 Replace VM cable

Test I02 - Lower Mast Reference (24 in.) Switch
Test I02 - Lower Mast Use Active Maintenance to check that the
display indicates the lower mast reference
Reference (24 in.) Switch switch is Belw at all positions below 24 in.
(61 cm). Check that the display indicates the
24 in. (61 cm) switch is Abve at all positions
This test monitors the state of the lower mast above 24 in. (61 cm).
reference switch (S11). This test displays what
the CCC is reading from the switch.

refer to page 3-25.
Run test:
results:
Carriage Switch Operator

Height Actuator Display
Below 24 in.
Depressed Belw
(61 cm)
Above 24 in.
Released Abve
(61 cm)


Action/
Step Meter (+)Lead (–) Lead Expected Results Step Passed Step Failed
Setting
JPC8
/DCV
6 to 13V
S11-3 Repair/replace wires
3 Perform Step 4
DCV S11-1
4 S11-2 S11 Perform Step 5 Adjust/replace S11
Closed (below): 6-13V
5 JPC8-2 JPC8-1 Open (above): 0V Replace CCC Repair/replace wires

Test I03 - 60 in. Limit Switch
Test I03 - 60 in. Limit If these results are not observed, the test has
failed.
Switch Using Active Maintenance, check that the
display indicates the 60 in. switch is Belw at all
Using this test, the state of the 60 in. limit positions below 60 in. Check that the display
switch (S28) can be monitored. This test indicates Abve for all positions above the 60 in.
displays what the CCC is reading from the switch.
switch.
NOTE: This switch is not used with the Lift trucks without S28 require a jumper
intellispeed option. (P/N 114-008-958/002) between JPC3-3 and
JPC3-1.
refer to page 3-25.
Run test:
results:
Operator
Carriage Height Switch
Display
Below 60 in. Depressed Belw
Above 60 in. Extended Abve
Action/
Step Meter (+)Lead (–) Lead Expected Results Step Passed Step Failed
Setting
JPC3
/DCV
6 to 13V
S28-3
3 Perform Step 4
DCV S28-1 Repair/replace wires
4 S28-2 S28 Perform Step 5
Closed (below): 6-13V
5 JPC3-2 JPC3-1 Open (above): 0V Replace CCC

Test I04 - Lift/Lower Inhibit Bypass (optional)
Test I04 - Lift/Lower

Inhibit Bypass (optional)
Using this test, the state of the lift inhibit
bypass switch (S7) can be tested. This test
displays what the CCC is reading from the
switch. This test is only visible on lift trucks
equipped with the Lift/Lower inhibit bypass
option.

refer to page 3-25.
Run test:
results.
Lift Inhibit Switch (S7) Operator Display
Up Out
Depressed In


Action/
Setting
JPC6 Verify option Repair/replace wires

Released: open circuit
1 disconnected/ JC6-6 JC6-5 is turned ON. and/or switch S7
Depressed: 0 ohms
Ohms Replace CCC

Test I05 - Lift Inhibit Switch (optional)
Test I05 - Lift Inhibit

Switch (optional)
Using this test, the state of the lift inhibit
switch (S24) can be monitored. This test
displays what the VM is reading from the
switch. This test only works on lift trucks
equipped with the lift inhibit option.

refer to page 3-25.
Run test:
results:
Operator Carriage Operator Display
Below Switch (closed) Belw
Above Switch (open) Abve


Action/
Step Meter (+) Lead (–) Lead ExpectedResults Step Passed Step Failed
Setting
Pull pin from

JPT20-10.
1 JPT24-3 Perform Step 2 Replace VM
Backprobe
connection. 10.7 to 13V
2 JPT20-10 Perform Step 3 Repair/replace
S24-1
3 DCV Perform Step 4 harness
S24-3 Adjust or replace
4 S24-2 Perform Step 5
S24 S24
Closed: 10.7 to 13V Verify option is
Open: approx. 0V Repair/replace
5 JPT20-10 JPT22-2 turned ON.
harness
Replace VM

Test I15 - Horn Switch
Test I15 - Horn Switch

This test checks the input from the horn switch
(S3) to the CCC at JPC9-3 and JPC9-4.

refer to page 3-25.
Run test:
results:
Horn Switch Position Operator Display
Out Out
Depressed In


Action/
Setting
S3 Repair/replace
1 DCV JPC9-3 JPC9-4 Closed: < 0.6V Replace CCC wires and/or
Open: Approx. 5.35V switch S3

Test I19 - Traction Motor RPM
Test I19 - Traction Motor

RPM
This test displays the output from the speed
encoder on the traction motor as seen by the
traction power amplifier.
Do this test in an area free of

obstructions with ample room for
maneuvering.

refer to page 3-25.
This test requires the use of Active Maintenance

to see correct test results.
Run Test:
NOTE: The Operator Display shows RPM as
measured by the traction power
amplifier. The RPM reading should show
a linear increase to maximum RPM.
You should see:
Lift Truck Type Maximum RPM
Standard Duty 5532
Heavy Duty 4424
If not perform diagnosis and repair.

Action/
Setting
1 JPTA1-26 Perform Step 2 Replace TPA

JPTA1-7
2 4.5 to 5.5V Perform Step 3 Troubleshoot/replace
JPTA2-1
3 JPTA2-4 Perform Step 4 harness
4 DCV JPTA1-31 Perform Step 5 Perform Step 6

Stationary: >3.5V
5 JPTA1-32 or <0.5V Replace TPA Perform Step 7
JPTA1-7
6 JPTA2-3 Running: approx.
2V Repair/replace Replace traction motor
7 JPTA2-2 harness speed encoder

Test I20 - Lift Motor RPM (AC lift only)
Test I20 - Lift Motor RPM

(AC lift only)
This test displays the input from the speed
encoder on the lift motor as seen by the lift
power amplifier.
Do this test in an area free of

obstructions with ample room for lifting.

refer to page 3-25.

Run test:
NOTE: The Operator Display shows RPM as
measured by the lift power amplifier.
The RPM reading should show a linear
increase to maximum RPM.
During lift, 2400 rpm max must be displayed.

Action/
Step Meter Setting (+) Lead (–) Lead Expected Results Step Passed Step Failed
1 JPLA1-26 Perform Step 2 Replace LPA

JPLA1-7
2 4.5 to 5.5V Perform Step 3 Troubleshoot/replace
JPLA2-1
3 JPLA2-4 Perform Step 4 harness
4 DCV JPLA1-31 Perform Step 5 Perform Step 6

Stationary: >3.5V or
5 JPLA1-32 <0.5V Replace LPA Perform Step 7
JPLA1-7
6 JPLA2-3 Running: approx.
2V Repair/replace Replace lift motor
7 JPLA2-2 harness speed encoder

Test I23 - CAN Bus
Test I23 - CAN Bus

This test verifies the VM is communicating with
the Traction Power Amplifier, Lift Power
Amplifier, and Guidance Manager.

refer to page 3-25.
Run test:
NOTE: To enter this test, press and hold
both the UP and DOWN buttons and
turn the key switch ON.
The Operator Display shows:

• V if the Vehicle Manager is communicating
with the Carriage Control Card
• T if the Traction Power Amplifier is
communicating with the Carriage Control
Card
• L if the Lift Power Amplifier is
Card (AC lift only)
• W if the Guidance Manager is
Card (Wire Guidance only)
NOTE: Wait at least 60 seconds after the test
shows on the display for letters to be
displayed.
If V, T, L, or W are not displayed, the test has


Run test:

Action/
Expected
Step Meter (+) Lead (–) Lead Step Passed Step Failed
Results
Setting
If letter V is missing:
1 DCV JPTA1-1 B– B+ Perform Step 2 T/S B+ from K3 Relay
2 JPT14 and JPT14-11 JPSC1-2

JPSC1 Repair/replace
JPT14-4 JPSC1-1 0 ohms Replace VM
3 disconnected/ harness
Ohms
If letter L is missing (AC Lift only):
1 DCV JPLA1-1 B– (on amp) B+ Perform Step 2 T/S B+ from K3 Relay
2 JPLA1 and JPLA1-23 JPSC2-2

JPSC2 Replace Lift Repair/replace
JPLA1-35 JPSC2-1 0 ohms
3 disconnected/ Amplifier harness
Ohms
If letter T is missing:
1 DCV JPTA1-1 B– (on amp) B+ Perform Step 2 T/S B+ from K3 Relay
2 JPTA1 and JPTA1-23 JPSC1-2

Replace
JPSC1 Repair/replace
JPTA1-35 JPSC1-1 0 ohms Traction
3 disconnected/ harness
Amplifier
Ohms
If letter W is missing (Wire Guidance only):
1 JPS2-11 JPS2-24 Perform Step 4 Perform Step 2
2 JPT20-19 TP4 Perform Step 3 Replace VM

DCV B+
Perform Step 1 Replace Fuse/Relay
3 TP1 JPF3-9
Card
Disconnect T/S wires and Replace Guidance

JPW1 and 2 Antenna Cards. Manager
W shows on
4 and Filter Card N/A N/A If OK, replace
display
at Guidance Filter Card
Manager
If no letters are displayed:
Perform Step 2 Repair/replace shorted

1 JPLA1, JPTA1, JT14-4 Open
Bus +/– cable
JPT14, JPS4
and JPC11 JT14-11 JTA1-23,
disconnected/ JLA1-23, Repair/replace
2 0 Ohms Perform Step 3
Ohms JS4-6, harness
JC11-3
One at a time, Letters for the Replace

disconnect all other devices disconnected
3 N/A N/A Replace CCC
devices on the come back on component
Bus display

Test I24 - Home Position Proximity Sensor
Test I24 - Home Position

Proximity Sensor
This test displays what the VM sees from the
Home Proximity Sensor.

refer to page 3-25.
Run test:
results:
Home
Operator Red LED on
Proximity
Display Sensor
Sensor
Over metal On On
Away from
Off Off
metal

NOTE: If the test fails in Active Maintenance,
pass a screwdriver or metal ruler under
the sensor to activate it. If the test
passes, adjust the switch. See Home
Proximity Sensor Adjustment on
page 7-20.

Action/
Setting
1 JPA7-3 JPA7-2 Perform Step 3 Perform Step 2

10.5 to 13V Replace/replace
2 JPT20-9 JPT22-11 Replace VM
harness
DCV Adjust/replace
3 JPA7-3 JPA7-1 Sensor over metal: Perform Step 4
approx. 10V sensor
Sensor not over Replace/replace
4 JPT22-3 JPT20-9 metal: approx. 6V Replace VM
harness

Test I25 - Steer Motor Encoder
Test I25 - Steer Motor

Encoder
This test displays the counts from the steer
motor encoder.

refer to page 3-25.

Run test:
A three digit number is displayed representing
the number of steer motor encoder counts.
When the count exceeds 255, it starts over at 0.
If the count goes below 0, it starts over at 255.
NOTE: Turn the steering slowly to make sure
that the display shows the encoder
count correctly.
If these results are not seen, perform diagnosis

and repair.

Action/
Setting
1 JPE4-1 10.5 to 13V Perform Step 2 Perform Step 6
2 JPE4-3 JPE4-4 Perform Step 3 Replace steer motor

Stationary: encoder
3 JPE4-2 >4V or <0.5V Perform Step 4
4 DCV JPT22-9 Turning: Perform Step 5

approx. 2.5V Repair/replace
5 JPT22-10 Replace VM harness
JPT10-9
Repair/replace
6 JPT20-7 10.5 to 13V Replace VM
harness

Test I26 - Flow Sensor Count
Test I26 - Flow Sensor Run test:

Count A three digit number is displayed representing
the number of flow pulses counted. When the
NOTE: This test applies to lift trucks equipped count exceeds 255, it starts over at 0. If the
with the intellispeed option. count goes below 0, it starts over at 255.
This test displays the flow sensor pulses that Place test in Active Maintenance. The count
the VM reads. A successful test proves the VM should increase during lift and decrease during
is correctly reading pulses from the flow sensor. lower. If these results are not observed, the test
refer to page 3-25. This test must be run from
Active Maintenance.

Action/
Setting
1 JPY7-1 J21-A Perform Step 2
2 JPY7-2 J21-B Perform Step 3 Repair/replace

Ohms 0 Ohms
3 JPY6-1 J22-A Perform Step 4 wires
4 JPY6-2 J22-B Perform Step 5
5 JPY1 JPT20-2 JPY24-11 Perform Step 6 Replace VM

disconnected/ 12V Repair/replace
6 DCV JPY1-5 JPY1-3 Perform Step 7
wires
7 JPY7-1 JPY7-3 Perform Step 8 Replace cable

DCV 2.6V
8 JPY6-1 JPY6-3 Perform Step 9 and sensor
9 JPY7-2 JPY7-3 At rest: <2mV Perform Step 10

Lift/Lower: Ramps from
Lift or Lower/ Clean flow
approx 0 to between 200
10 mVAC JPY6-2 JPY6-3 Perform Step 11 sensor turbine
and 300mV as speed
increases
11 JPY1-1 Perform Step 12 Replace cable

12 JPY1-2 Perform Step 13 and sensor
Lift or Lower/ At rest: 0 to 5V
B–
13 DCV JPT22-13 Lift/Lower: approx 2.8V Perform Step 14 Repair/replace
14 JPT22-14 Replace VM wires

Test I35 - Steer Tiller Encoder 1
Test I35 - Steer Tiller

Encoder 1
This test displays the value that the CCC sees
from the Steer Tiller Encoder at JPC1. A
successful test proves the CCC is reading the
encoder correctly.
The VM uses the input from the CCC to

determine the rate and direction of steering.
The displayed number varys between 0 and
255. The value has little correlation to the
actual steering angle. The displayed value
should change as the drive unit is steered.


refer to page 3-25.
Run test:
If the number displayed does not vary or the
count only changes from 0 to 1 or 0 to 255, the

Action/
Setting
1 PC1-1 PC1-2 Perform Step 2

JPC1at CCC
2 disconnected/ PC1-3 PC1-2 5.3V Perform Step 3 Replace CCC
DCV
Will be either approx.

5.3V or approx. 0V
when the tiller is
JPC1-3 (CHB-E2) JPC1-2 Replace steer
4 DCV stationary. Replace CCC
JPC1-4 (CHA-E2) JPC1-2 encoder
Somewhere between
0 and 5V when tiller
is moving.

Test I36 - Steer Tiller Encoder 2
Test I36 - Steer Tiller Run test:

Encoder 2 If the number displayed does not vary or the
count only changes from 0 to 1 or 0 to 255, the
This test displays the value that the CCC sees test has failed. Perform diagnosis and repair.
from the Steer Tiller Encoder at JPC21. A
successful test proves the CCC is reading the
encoder correctly.
The VM uses the input from the CCC to

determine the rate and direction of steering.
The displayed number varys between 0 and
255. The value has little correlation to the
actual steering angle. The displayed value
should change as the drive unit is steered.
This test Requires the use of Active

Maintenance to see correct test results.

refer to page 3-25.

Action/
Setting

JPC21@CCC
2 disconnected PC21-3 PC21-2 5.3V Perform Step 3 Replace CCC
/DCV
Will be either approx.

5.3V or approx. 0V
when the tiller is
JPC21-3 (CHB-E2) JPC21-2 Replace steer
4 DCV stationary. Replace CCC
JPC21-4 (CHA-E2) JPC21-2 encoder
Somewhere between
0 and 5V when the
tiller is moving.

Test I38 - EPO Switch
Test I38 - EPO Switch

This test monitors the state of the Emergency
Power Off (EPO) switch. A successful test proves
the CCC is correctly reading the EPO switch.

refer to page 3-25.
Run test:
results:
Emergency Off Button Operator Display
Out Out
In In

NOTE: After activating the EPO switch, cycle
the key switch OFF/ON.

Action/
Setting
Repair/replace wires or
switch

DCV B– B+ Replace over-the-mast
4 JPF4-5 Perform Step 5
cable
5 JPF4-6 Perform Step 6 Replace Fuse Relay Card
Repair or replace wire

6 JPT22-21 Replace VM
from Fuse Relay Card

Test I39 - Neutral Pulses
Test I39 - Neutral Pulses

This test displays the neutral pulses seen by
the VM from the Steer Power Amplifier.

refer to page 3-25.
Run test:
This test requires use of Active Maintenance to
You should see:
Off Deadman On Deadman
Quickly toggles
ON
between ON and OFF

NOTE: If an error code exists, Active
Maintenance will not work. Refer to
“Test O44 - Steer Motor” for
troubleshooting.

Action/
Setting
1 JPT6-6 10.5 to 13V Perform Step 2 Replace VM
DCV JPT6-4 Repair wiring or

2 JPT6-1 Deadman pedal up: >4V Replace VM replace Steer Power
Amplifier

Test I41 - Aux Mast Lift Switch S32
Test I41 - Aux Mast Lift If results do not match the preceding table, the
Switch S32
This test monitors the state of the auxiliary lift
switch (S32). This switch causes the auxiliary
mast to lift. This test displays what the CCC is
reading from the switch.
NOTE: S31 (Aux liftleft-hand deadman) must
also be depressed during this test.
Run test:
You should see:
Aux Mast Lift Switch Operator Display
Out OFF
Depressed On

Action/
Setting
JPC19
1 disconnected PC19-3 Perform Step 3 Perform Step 2
/DCV
B+ B+
Aux Card
Replace Aux
2 disconnected PC18-3 Replace CCC
Card
/DCV
JPC19
3 disconnected PC19-3 PC19-1 6 to 13V Perform Step 7 Perform Step 4
/DCV
4 JC18-8 JC18-1 B+ Perform Step 5
5 Aux Card JC18-5 5.3V Perform Step 6

disconnected Replace CCC
/DCV JC18-3 Replace Aux
6 JC18-7 12V Card, then
CCC
JPC19
connected,
Repair/replace wires
7 S31 and S32 B+ PC19-1 B+ Replace CCC
or switch
activated
/DCV

Test I42 - Aux Mast Lower Switch S33
Test I42 - Aux Mast

Lower Switch S33
This test monitors the state of the auxiliary
lower switch (S33). This switch causes the
auxiliary mast to lower. This test displays what
NOTE: S31 (Aux lift left-hand deadman) must
also be depressed during this test.
Run test:
You should see:
Aux Mast Lower

Operator Display
Switch
Out OFF
Depressed On


Run test:

Action/
Setting
JPC19
1 disconnected PC19-3 Perform Step 3 Perform Step 2
/DCV
B+ B+
Aux Card
Replace Aux
2 disconnected PC18-3 Replace CCC
Card
/DCV
JPC19
/DCV

CCC
JPC19
connected,
Repair/replace wires
7 S31 and S33 B+ PC19-2 B+ Replace CCC
or switch
activated
/DCV

Test I44 - Aux Mast Lift Ref Switch S34
Test I44 - Aux Mast Lift

Ref Switch S34
This test monitors the state of the auxiliary lift
Reference switch (S34). This switch causes the
auxiliary mast to lift. This test displays what
NOTE: S31 (Aux left-hand deadman pedal)
must also be depressed during this test.
Run test:
You should see:
Aux Mast Lift Ref

Operator Display
Switch
Switch Activated Belw
Switch Not Activated Abve


Action/
Setting
JPC20
/DCV

CCC
S34 Closed: 6-12V Repair/replace wires

5 DCV JPC20-2 JPC20-2 Replace CCC
Open: <1.5V or switch

Test I65 - Rail Guidance Switch (optional)
Test I65 - Rail Guidance

Switch (optional)
NOTE: This test applies to lift trucks equipped
with rail guidance.
Using this test, the state of the rail guidance

switch (S15) can be verified.

refer to page 3-25.
Run test:
results:
Rail Guidance Switch

Operator Display
(S15)
Depressed In
Released Out


Action/
Setting
Pull pin from

JPT18-4.
Backprobe
DCV S15-1
3 Perform Step 4 harness
S15-3
4 S15-2 S15 Perform Step 5 Adjust or replace S15
Closed: 10.7 to 13V Repair/replace
5 JPT18-4 JPT22-22 Open: <1V Replace VM
harness

Test I66 - Auto/Manual Switch (optional)
Test I66 - Auto/Manual

Switch (optional)
This test displays the position of the AUTO/
MANUAL switch (S4). A successful test proves
the CCC is correctly reading the
AUTO/MANUAL switch.

refer to page 3-25.
Run test:
results:
Switch Position Operator Display
O (open) Auto
| (closed) Manu

NOTE: If the wire between the AUTO/MANUAL
switch and the CCC becomes
disconnected, the system defaults to
AUTO.
Operation of the AUTO/MANUAL switch and

CCC can also be checked by observing the
green triangles on the display. The green
triangles should illuminate when the switch is
in AUTO and extinguish when the switch is in
MANUAL.

Action/
Setting
JPC9 Verify option is

Auto: open circuit Troubleshoot wires
1 disconnected JC9-1 JC9-2 turned ON.
Manual: 0 ohms and switch
/Ohms Replace CCC

Test I67 - Sidegate Switches (optional)
Test I67 - Sidegate Run test:

Switches (optional) The state of the sidegate switch is displayed.
Both sidegates must be down for the display to
Use this test to test the state of the sidegate change states.
switches (S60, S61). This test displays what the Sidegates Operator Display
CCC is reading from the switch. This test only
works on lift trucks equipped with the sidegate One sidegate up Up
switch option.
Both sidegates up Up
For information on using Maintenance Mode, Both sidegates down Down

refer to page 3-25.

Action/
Setting
Right Sidegate - Switch S60
JPC14
/DCV
10.7 to 13V
S60-3
S60-1
4 DCV S60-2 Perform Step 5 Adjust or replace S60
S60
Closed: 6 to 12V Repair/replace
5 JPC14-2 JPC14-1 Open: 1V Replace CCC
harness
Left Sidegate - Switch S61
JPC13
/DCV
10.7 to 13V
S61-3
S61-1
4 DCV S61-2 Perform Step 5 Adjust or replace S61
S61
5 JPC13-2 JPC13-1 Open: <1V Replace CCC
harness

Test I68 - Travel Cutout Switch (optional)
Test I68 - Travel Cutout

Switch (optional)
This test monitors the state of the travel cutout
switch (S27). This test displays what the VM is

refer to page 3-25.
Run test:
results.
Carriage Position
Operator Display
(wrt S27)
Below Belw
Above Abve


Action/
Setting
Pull pin from

JPT20-6.
Backprobe
DCV S27-1
S27-3
Closed: 6 to 12V Repair/replace
5 JPT20-6 JPT22-6 Open: <1.5V Replace VM
harness

Test I69 - Upper Mast Reference Switch
Test I69 - Upper Mast Use Active Maintenance to check that the
display indicates the upper reference switch is
Reference Switch closed at all positions below the upper reference
switch. Check that the display indicates the
upper reference switch is not closed at all
This test monitors the state of the upper mast positions above upper reference switch.
reference switch (S10). This test shows what the
VM is reading from the upper mast reference
switch at JPT20-1 wrt JPT22-1. A successful
test proves the VM is correctly reading the
upper mast reference switch.

refer to page 3-25.
Run test:
results:
Switch Operator
Carriage Height
Actuator Display
Below Upper
Depressed Belw
Reference Switch
Above Upper
Released Abve
Reference Switch


Action/
Setting
Pull pin from JPF3-8

JPT20-1. (Fuse
1 Perform Step 2 Replace VM
Backprobe Relay
connection. Card) 10.5 to 13V
DCV S10-1
S10-3
5 JPT20-1 JPT22-1 Open: <6.5V Replace VM
harness

Test I70 - Pressure Switch (optional)
Test I70 - Pressure

Switch (optional)
NOTE: This test applies to 24V lift trucks
equipped with HiPro (except lift trucks
with EE option).
This test checks the input from the pressure

switch (PRESS SW1) to the VM at JPT22-5 and
JPT18-5.

refer to page 3-25.
Run test:
results:
Switch Operator
Weight
Position Display
Greater than
Open Off
1000 lb.
Less than
Closed On
1000 lb.

NOTE: If the test fails in Active Maintenance,
make sure the pressure switch is set per
Pressure Switch Adjustment on
page 7-101.

Action/
Setting
With forks elevated 1 Test wires, adjust/

JPT22 and
ft. (304.8 mm) replace pressure
JPT18
1 JPT22-5 JPT18-5 0 lbs. on forks: <1 ohm Replace VM switch (see Pressure
disconnected
1000 lbs. (453.6 Kg) on Switch Adjustment on
/Ohms
forks: >2 megohms page 7-101).

Test I72 - End-of-Aisle Sensor 2 (optional)

Sensor 2 (optional)
with End-of-Aisle Detect.
This test displays what the VM sees from Aisle

Detect Sensor 2. Sensor 2 (S47A and B) is
located on the left side of the Antenna Card
bracket as you stand on the platform facing the
tractor.

refer to page 3-25.
Run test:
You have two choices when running this test:
Statically: If this test is to be run statically,

park the lift truck away from any magnets in
the floor. Obtain a magnet (P/N 591-552/002)
and pass the magnet under the sensor.
Remember that this is a transitional state.
The sensor reverts to its original position even if

the magnet remains under the sensor. It may be
helpful if two people are available for this test.
When a magnet is placed under the sensor, the
OD shows On briefly. Even if the magnet
remains under the sensor, the display changes
back to Off.
Active Maintenance: To run this test in Active

Maintenance, position the lift truck away from
any floor magnets. Select this test for Active
Maintenance. Have this test on the operator
display. While observing the display, drive the
lift truck so the sensor passes over a floor
magnet. The OD shows On briefly. Even if the
magnet remains under the sensor, the display
changes back to Off.


Run test:

Action/
Setting
Pull pin
JPT10-7.
1 Approx. 10.5V Perform Step 2 Replace VM
Backprobe
connection
JPT24-9 T/S harness for
opens and shorts.
2 JPT10-7 Approx. 7.9V Perform Step 3 If OK, replace
sensor S47A or
S47B
If <4V, replace
3 S47B-5 Perform Step 4
S47A or S47B
DCV
S47B-8 Approx. 4V If <4V,
repair/replace
4 S47A-6 Perform Step 5
harness from
S47B-5 to S47A-6
If approx. 10.5V,
5 JPT10-7 Approx. 7.9V Perform Step 6 replace sensor
S47A
JPT24-9 S47A or S47B T/S harness for
Closed (sees magnet): 3.7V opens and shorts.
Open (no magnet): approx If OK, replace bad
7.8V sensor

Test I73 - End-of-Aisle Sensor 1 (optional)

Sensor 1 (optional)
with End-of-Aisle Detect or Auto Steer
Center.
This test displays what the VM sees from Aisle

Detect Sensor 1. Sensor 1 (S46A and B) is
located on the right side of the Antenna Card
bracket as you stand on the platform facing the
tractor.

refer to page 3-25.
Run test:
You have two choices when running this test:
Statically: If this test is to be run statically,

park the lift truck away from any magnets in
the floor. Obtain a magnet (P/N 591-552/002)
and pass the magnet under the sensor.
Remember that this is a transitional state.
The sensor will revert to its original position

even if the magnet remains under the sensor. It
may be helpful if two people are available for
this test. When a magnet is placed under the
sensor, the OD shows On briefly. Even if the
Active Maintenance: To run this test in Active

Maintenance, position the lift truck away from
any floor magnets. Select this test for Active
Maintenance. Have this test on the operator
display. While observing the display, drive the
lift truck so the sensor passes over a floor
magnet. The OD shows On briefly. Even if the


Run test:

Action/
Setting
Pull pin
JPT10-6.
1 Approx. 10.5V Perform Step 2 Replace VM
Backprobe
connection
JPT24-8 T/S harness for
opens and shorts.
2 JPT10-6 Approx. 7.9V Perform Step 3 If OK, replace
sensor S46A or
S46B
If <4V, replace
3 S46B-5 Perform Step 4
S46B
DCV
S46B-8 Approx. 4V If <4V, repair/
replace harness
4 S46A-6 Perform Step 5
from S46B-5 to
S46A-6
If approx. 10.5V,
5 JPT10-6 Approx. 7.9V Perform Step 6 replace sensor
S46A
JPT24-8 S46A or S46B T/S harness for
Closed (sees magnet): 3.7V opens and shorts.
Open (no magnet): approx If OK, replace bad
7.8V sensor

Test I74 - Lower Inhibit Switch (optional)
Test I74 - Lower Inhibit

Switch (optional)
This test monitors the state of the lower inhibit
switch (S25). This test displays what the CCC is

refer to page 3-25.
Run test:
The state of the lower inhibit switch (S25) is
displayed.
Carriage Position
Operator Display
(wrt S25)
Below Belw
Above Abve

Using Active Maintenance, check that the

display indicates the carriage is Belw at all
positions below the lower inhibit switch. Check
that the display indicates Abve for all positions
above the lower inhibit switch.

Action/
Step Meter (+) Lead (–) Lead Expected
Results Step Passed Step Failed
Setting
JPC4
/DCV
10.7 to 13V
S25-3
S25-1
4 DCV S25-2 S25 Perform Step 5 Adjust or replace S25
Closed: 10.5 to
13V Repair/replace
5 JPC4-2 JPC4-1 Replace CCC
Open: 0V harness

Test I75 - 180 in. Limit Switch (optional)
Test I75 - 180 in. Limit

Switch (optional)
This test monitors the state of the 180 in. limit
switch (S100). This test displays what the CCC
is reading from the switch.

refer to page 3-25.
Run test:
The state of the 180 in. limit switch (S100) is
displayed.
Carriage Position
Operator Display
(wrt S100)
Below Belw
Above Abve



Action/
Setting
Pull pin from

JPT24-1.
Backprobe 10.5 to 13V
connection.

DCV S100-1
3 10.7 to 13V Perform Step 4 harness
S100-3
harness

Test I76 - Lift Cutout Switch (optional)
Test I76 - Lift Cutout

Switch (optional)
This test monitors the state of the lift cutout
switch (S124). This test displays what the CCC
is reading from the switch.

refer to page 3-25.
Run test:
The state of the lift cutout switch (S124) is
displayed.
Carriage Position
Operator Display
(wrt S124)
Below Belw
Above Abve



Action/
Setting
Pull pin from

JPT20-8.
1 JPT18-7 10.5 to 13V Perform Step 2 Replace VM
Backprobe
connection.

DCV S124-1 10.7 to 13V
S124-3
harness

Test I91 - iPORT Communication
Test I91 - iPORT

Communication
Test I91 is an iPORT® related code. Refer to
iPORT Kit Installation and Maintenance

Test I92 - iPORT Error Bitmap
Test I92 - iPORT Error

Bitmap
This test is for factory use only.

Test I93 - End Of Aisle EOA
Test I93 - End Of Aisle

EOA
This test displays position status used by the
EOA software. It displays either 0 or 1 to
indicate wheather the program currently
considers the truck in or out of aisle.

refer to page 3-25.
Run test:
This test requires use of Active Maintenance to
see proper test results.
You should see:
Truck Position Operator Display
Truck is in the aisle 0
Truck is out of the aisle 1

test has failed.
NOTE: One of the magnets could have been
inadvertently tripped or the truck is in
the aisle. Refer to tests “Test I72 -
End-of-Aisle Sensor 2 (optional)” and
“Test I73 - End-of-Aisle Sensor 1
(optional)”

Run test:

Output Tests
Section 6. Messages, Codes and Tests
Output Tests
with a -by-step approach to diagnosing a
Action/
Setting
This column
identifies the
action(s) required
(if any) before
testing the
circuit. If no
instructions are
given, all circuits
must be
The next
connected. The next
reconnect it met.
not met.
before
performing the
next step.
This column also

identifies the
required setting
on the meter for
this step.

Test O00 - Toggle the Traction Power Contactor
Test O00 - Toggle the

Traction Power
Contactor
This test toggles the TPC ON and OFF.

Mode, refer to page 3-25.
Run test:
PC Contactor Operator Display
Closed In
Open Out
The test is a success if the TPC contactor tracks

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

Action/
Setting
JPTA1
1 disconnected JPTA1-6 JPTA1-13 Approx. 38 ohms Perform Step 2 T/S wires and coil
/Ohms
2 JPTA1-13 TP4 B+ Perform Step 3

Replace Traction
DCV Test ON: B+ Test contactor
3 B+ JPTA1-6 Power Amplifier
Test OFF: 0V for binding

Test O02 - Toggle the Lift Power Contactor
Test O02 - Toggle the Lift Run test:

Power Contactor LPC Contactor Operator Display
Closed In
This test toggles the LPC ON and OFF.
Open Out
Mode, refer to page 3-25. The test is a success if the LPC contactor tracks
the In/Out shown on the display. If these results
are not observed, the test has failed. Perform
diagnosis and repair.
Open the emergency lowering valve
before starting this test.

Action/
Setting
AC Lift
JPLA1
T/S wires and
1 disconnected JPLA1-6 JPLA1-13 Approx. 18 ohms Perform Step 2
coil
/Ohms
2 JPLA1-13 TP4 B+ Perform Step 3

Replace Lift
DCV Test ON: B+ Test contactor
3 B+ JPLA1-6 Power Amplifier
Test OFF: 0V for binding
DC Lift
JPT18 and
JPF2 T/S wires and
1 JPF2-1 Approx. 38 ohms Perform Step 2
disconnected coil
/Ohms
If B+ is not
present, T/S
JPT18-9 JPF2-1 on the
Contactor Test contactor Relay Fuse Card.
2 DCV TP4 Energized: approx. -0V for mechanical If voltage does
De-energized: B+ binding not change when
the test is
toggled, replace
the VM

Test O11 - Toggle Load Holding Solenoid
Test O11 - Toggle Load

Holding Solenoid
This test turns the Load Holding (L/H) Solenoid
(SOL1) ON and OFF.
Make sure the operator platform is fully

lowered before performing this test.
Turning the Load Holding Solenoid ON

during this test causes the operator
platform to lower because the
proportional lift/lower valve is open in
Maintenance Mode.

Run test:
1. Lower the operator platform to the floor.
2. Disconnect the wire from the Load Holding
solenoid L/H-1.
3. Connect an ammeter in series with the
L/H solenoid as follows:
• (–) lead to terminal of L/H-1
• (+) lead to wire removed from L/H-1
Ammeter Operator
L/H Solenoid
Reading Display
Open 0.5 to 1.0A On
Closed 0.0 to 0.02A Off

failed. Reconnect the wire to L/H-1.
Action/
Setting
JPT18 and JPF2

T/S wires and
1 disconnected/ JPT18-10 JPF2-5 Approx. 38 ohms Perform Step 2
coil
Ohms
T/S relays and

2 DCV JPF2-5 TP4 B+ Replace VM
Fuse Relay Card

Test O12 - Proportional Solenoid PWM Ramp
Test O12 - Proportional cover to expose the connector terminals.

Reconnect the connector.
Solenoid PWM Ramp 3. Connect the (–) lead of a DVM to L/L-2 and
the (+) lead to L/L-1.
This test ramps the proportional Lift/Lower 4. Turn the key switch ON and run this test.
(L/L) solenoid from 0% to 90%.
Voltmeter
Operator Display
A successful test proves the wiring, related Reading
circuitry in the VM, and proportional L/L 0 to 24V Ramp (15% increments)
solenoid coil driver are all functioning correctly.
It also proves the harness is electrically 0 to 1V 0%
functional. It does not prove the L/L solenoid
itself is mechanically functional. The percentage shown on the display starts at
0%. Use the Up (▲) button to increase the
Ramping the proportional L/L solenoid should percentage up to 90% in 15% increments.
not allow the operator platform to lower, since
the Load Holding (L/H) valve must be closed. If If the voltage ramps proportionally, the wiring
there is a fault in the L/H circuit or a fault in and related circuitry are functional. (It does not
L/H solenoid itself, the operator platform may prove the L/L solenoid itself is mechanically
lower. To guard against unexpected motion of functional.)
the operator platform, fully lower the operator
platform before entering this test. If these results are not observed, the test has
failed.
Run test:
1. Turn the key switch OFF.
2. Loosen the screw that secures the 90°
connector to the L/L solenoid. Unplug the
connector from the solenoid. Remove the

Action/
Setting
JPT20 dis-
T/S wires and
1 connected/ JPT20-16 JPT20-15 Approx 25 ohms Perform Step 2
coil
Ohms
2 DCV JPT20-15 B+ Perform Step 3
Check valve for

Test ON B– 24V truck: ramp B+ to 0V mechanical Replace VM
3 JPT20-16
/DCV 36V truck: ramp B+ to 12V binding or
contamination

Test O18 - Toggle Horn
Test O18 - Toggle Horn

This test toggles the horn ON and OFF.

Run test:
The horn should sound when the test is
activated. If these results are not observed, the
test has failed.

Action/
Step Meter Setting
(+) Lead (–) Lead Expected Results Step Passed Step Failed
T/S wires and

1 H2 TP4 B+ Perform Step 2
Fuse Relay Card
2 DCV H1 Replace horn Perform Step 3

Horn OFF: <0.5V
TP1 T/S wires to
3 JPT18-16 Horn ON: B+ Replace VM
horn

Test O19 - Audible Alarm
Test O19 - Audible

Alarm
Using this test, the operation of the audible
alarm in the CCC can be verified.
A successful test proves the audible alarm is

functioning.

Run test:
Operator
Alarm
Display
Sounding Ramp
OFF Off
This test generates a sound on the audible

alarm in the CCC.

failed.
Replace Carriage Control Card.

Test O20 - Travel Alarm (optional)
Test O20 - Travel Alarm Run test:

(optional) Connect a voltmeter at JPT20-17 wrt JPT18-18.
Operator
This test verifies the operation of the travel Voltage Output
Display
alarm.
0.0 to 1.0V Off
A successful test proves the wiring and related
22.0V On
circuitry in the VM are functioning correctly.
For information on how to use Maintenance When the display shows ON, the optional device
Mode, refer to page 3-25. must be activated.
NOTE: In order to test the output portion of the If these results are not observed, the test has
Vehicle Manager, a device that causes a failed.
load in the circuit is required. The load
holding coil on the hydraulic manifold
can be used for testing purposes.
Remove the load holding coil and
carefully connect wires into the circuit.
Use extreme caution and make sure that
the wires do not short to any
components.

Action/
Setting
1 AL– Approx. 22V Replace alarm Perform Step 2

AL+
2 B+ Perform Step 3 Test wire to AL+
DCV
TP4 24V truck: approx. 2V
Repair/replace
3 JPT18-18 36V truck: approx. Replace VM
wire to AL–
14V
Connect Load
4 Holding JPT20-17 JPT18-18 Approx. 22V Replace alarm Replace VM
Coil/DCV

Test O25 - Toggle 2 Stage Select Solenoid (optional)
Test O25 - Toggle 2 4. Reconnect the battery connector and turn

the key switch ON. Run the test and
Stage Select Solenoid observe the following results.
(optional) Ammeter
Reading
Operator
Display
This test toggles the solenoid OFF and ON, 0.0 to 0.02A Off
verifying its correct operation electrically. 1.0 to 2.0A On
NOTE: This test does not prove that the
solenoid valve is mechanically If the above results are not observed, the
functional. test has failed.
A successful test proves that the solenoid coil,
the battery connector. Remove the
coil driver, wiring and related circuitry in the
ammeter from the circuit and reconnect
VM are functioning correctly.
the wire.
Run test:
2. Disconnect the wire from the solenoid coil
at SOL-1.
3. Connect a digital ammeter in series with
the solenoid: (–) lead to SOL-1, (+) lead to
the wire removed from SOL-1.

Action/
Setting
JPT18 and JPF2

T/S wires and
1 disconnected/ JPF2-5 JPC18-1 Approx. 28 ohms Perform Step 2
coil
Ohms
T/S Fuse Relay

2 DCV JPT18-1 B– B+ Replace VM
Card

Test O28 - Ramp Lift Motor (AC lift only)
Test O28 - Ramp Lift Run test:

Motor (AC lift only) The requested rpm is displayed. Use the Up
button to increase the rpm in increments of 25,
This test ramps the lift motor by gradually from a minimum of 775 rpm to a maximum of
increasing the command to the lift power 1500 rpm.
amplifier via the CAN bus. This test verifies that NOTE: To prevent lift pump damage due to very
the lift power amplifier can drive the lift motor. low rpm, the minimum lift motor speed
request is 775 rpm.
When the maximum requested rpm is reached,

Running this test for an extended period
press Down to reset the request to 0. Press the
of time can cause damage the motor,
Enter button to exit the test.
power amplifier, or wiring.
Open the emergency lowering valve

before performing this test. See
“Emergency Lower Valve” on page 2-9.


Action/
Setting
If current does not ramp to

one or two phases, test the
Current cables to the motor. If OK,
probe Current must be replace the motor. If phases
(amp even on all phases Replace Lift are low or unequal, replace
1 N/A N/A
clamp) on and ramp up as the Amplifier the Lift Amplifier. If phases
phases U, percentage increases. are equal and high but the
V, and W motor runs slow, check for
binding. If no binding,
replace the lift motor.

Test O29 - Ramp Traction Motor
Test O29 - Ramp Traction Run test:

Motor Step on the deadman pedal and run the test.
This test ramps the traction motor by gradually The requested rpm is displayed. Use the Up
increasing the command to the traction power button to increase the rpm in increments of 25,
amplifier via the CAN bus. This test verifies that from 0 to a maximum of 1500 rpm.
the traction power amplifier can generate
current and drive the traction motor. When the maximum requested rpm is reached,
press down to reset the request to 0. Press the
Enter button to exit the test.
Running this test for an extended period

of time can cause damage to the traction
motor, power amplifier, or wiring.
The traction motor will rotate during this

test. Jack the drive wheel off the floor.
Use extreme care whenever the lift truck
the lift truck between the telescopic and
the floor. Use a suitable hoist to stabilize
from beneath vehicle while jacking. Use
jack stands or solid blocks to support lift
truck. DO NOT rely on the jack alone.
See Jacking on page 2-8.


Action/
Setting
If current does not ramp to

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

Test O30 - Toggle Brake Solenoid
Test O30 - Toggle Brake

Solenoid
This test checks for correct brake coil operation.

Run test:
Observe the following results:
Operator Display Brake
Up Applied
Down Released
NOTE: Deadman pedal must be depressed

while performing this test. Use Enter
button to cycle the test.

failed.
If this test passes, check brake adjustment. See
“Brake Adjustment” on page 7-62.

Action/
Setting
JPT20 and
JPF2
1 JT20-14 JF2-2 Approx. 13 ohms Perform Step 2 T/S wires and coil
disconnected/
Ohms
If no B+, T/S Fuse

Brake de-energized: B+ Relay Card. If
Inspect brake
Brake energized: voltage does not
2 DCV JP20-14 TP4 assembly for
36V truck = approx. 12V drop when
binding
24V truck = 0V energized, replace
the VM

Test O32 - Toggle Relay Enable
Test O32 - Toggle Relay NOTE: Removing K1 disables any key-power

accessories installed on the lift truck.
Enable If results do not match the preceding table, the
test has failed. Refer to diagnosis and repair.
This test toggles Fuse/Relay Card relays K1,
K2, K3, and K4 ON and OFF.
Run test:
NOTE: OFF is displayed when entering the test
even if the relays are closed.
Press the Enter button to toggle the test.
The following table gives the expected value at

each relay test point during the test.
Expected Values
Relay Lead Toggled Key
(+) (–) ON OFF OFF
K1 JPF2-9 or *TP1
K2 JPF2-1 or *TP2 <1V
TP4 B+ <1V
K3 JPF1-5 or *TP3
K4 JPF2-4 or *TP4 <1V
* TPs located on Fuse/Relay Card
It may be possible to quickly test a relay by

swapping K1 or K4 with the suspected relay
and performing the test again. Refer to relay
troubleshooting procedures on page 5-26.

Action/
Setting
T/S Fuse
1 JF4-13 Perform Step 2
Relay Card
Check diodes on
the Fuse/Relay
Test OFF: B+ Card (refer to
DCV TP4 T/S wire to
Test ON: <1V Section 5). If bad,
2 JPC14-6 Fuse Relay
replace the
Card
Fuse/Relay Card
and VM. If OK,
replace the VM.

Test O39 - Display Lights
Test O39 - Display Lights Run test:

When the test is turned ON, 13 LEDs on the
This test verifies all the lights operate correctly
display should light. See Figure 6-2. If all the
on the Operator Display.
LED’s do not light, the test has failed.
Yellow LED Yellow LED Red LED

Green LED
Red LED
Yellow LED
Green LED
6
Figure 6-2. Operator Display LED Identification

Action/
Setting
Display not
1 JPD15-16 JPD15-15 illuminated. Perform Step 2
Perform Step 3
DCV Approx. 5.3V
Display not
2 JPC15-16 JPC15-15 illuminated. Replace CCC
Replace display
Disconnect Display not

JC15-1 JD15-1
JPC15 from illuminated,
3 thru thru Continuity Replace display
CCC and repair/replace
JC15-24 JD15-24
Display /Ohms cable

Test O40 - Lift/Lower Alarm (optional)
Test O40 - Lift/Lower Run test:

Alarm (optional) Use the Enter button to toggle the test ON and
OFF. The operator display shows ON or OFF.
This test toggles the Lift/Lower Alarm ON and
OFF. Connect a voltmeter at JPT20-17 wrt JPT20-18.
Operator
For information on how to use Maintenance Voltage Output
Display
0.0 to 1.0V Off
NOTE: In order to test the output portion of the
Vehicle Manager, a device that causes a 22.0V On
load in the circuit is required. The load
holding coil on the hydraulic manifold
can be used for testing purposes.
Remove the load holding coil and
carefully connect wires into the circuit.
Use extreme caution and make sure that
the wires do not short to any
components.

Action/
Setting
Lift/Lower
1 Approx. 22V Replace alarm Perform Step 2
Alarm –
Lift/Lower
DCV Test wire to
Alarm +
2 TP4 B+ Perform Step 3 Lift/Lower
Alarm +
Disconnect Lift/Lower Repair/replace

3 JPT20-18 0 Ohms Perform Step 4
JPT20/Ohms Alarm – wire
Connect Load
4 Holding JPT20-17 JPT20-18 Approx. 22V Replace alarm Replace VM
Coil/DCV

Test O41 - Aux Select Solenoid (optional)
Test O41 - Aux Select 4. Reconnect the battery connector and turn
Solenoid (optional) observe the following results.
Ammeter Operator
This test toggles the Aux Select Solenoid OFF Reading Display
and ON, verifying its correct operation
0.0 to 0.02A Off
electrically.
1.0 to 2.0A On
A successful test proves that the Aux Select
Solenoid coil, coil driver, wiring, and related
If the above results are not observed, the
test has failed.
NOTE: This test does not prove that the Aux 5. Turn the key switch OFF and disconnect
Select Solenoid valve is mechanically the battery connector. Remove the
functional. ammeter from the circuit and reconnect
For information on how to use the wire.
Maintenance Mode, refer to page 3-25.
Run test:
2. Disconnect the wire from the Aux Select
Solenoid coil at AUX SEL SOL-X.
the Aux Select Solenoid: (–) lead to AUX
SEL SOL-X terminal, (+) lead to the
removed wire.

Action/
Setting
JPT18 and
JPF2 T/S wires and
1 JPT18-15 JPF2-3 Approx. 38 ohms Perform Step 2
disconnected coil
/Ohms
T/S relays and

2 DCV JPF2-3 TP4 B+ Replace VM Fuse Relay
Card

Test O42 - Main Select Solenoid (optional)
Test O42 - Main Select SEL SOL-X terminal, (+) lead to the
removed wire.
Solenoid (optional) 4. Reconnect the battery connector and turn
This test toggles the Main Select Solenoid OFF observe the following results.
and ON, verifying its correct operation
Ammeter Operator
electrically. Reading Display
A successful test proves that the Main Select 0.0 to 0.02A Off
1.0 to 2.0A On
NOTE: This test does not prove that the Main If the above results are not observed, the
Select Solenoid valve is mechanically test has failed.
functional.
For information on how to use Maintenance the battery connector. Remove the
Mode, refer to page 3-25. ammeter from the circuit and reconnect
the wire.
Run test:
2. Disconnect the wire from the Main Select
Solenoid coil at MAIN SEL SOL-X.
the Main Select Solenoid: (–) lead to MAIN

Action/
Setting
JPT18 and
JPF2 T/S wires and
disconnected coil
/Ohms
T/S relays and

Card

Test O43 - Aux Load Hold Solenoid (optional)
Test O43 - Aux Load 4. Reconnect the battery connector and turn
Hold Solenoid (optional) observe the following results.
Ammeter Operator
This test toggles the Aux Load Hold Solenoid Reading Display
OFF and ON, verifying its correct operation
0.0 to 0.02A Off
electrically.
1.0 to 2.0A On
A successful test proves that the Aux Load Hold
If the above results are not observed, the
test has failed.
NOTE: This test does not prove that the Aux 5. Turn the key switch OFF and disconnect
Load Hold Solenoid valve is the battery connector. Remove the
mechanically functional. ammeter from the circuit and reconnect
the wire.
Run test:
2. Disconnect the wire from the Aux Load
Hold Solenoid coil at AUX L/H SOL-X.
the Aux Load Hold Solenoid: (–) lead to
AUX L/H SOL-X terminal, (+) lead to the
removed wire.

Action/
Setting
JPT18 and
JPF2 T/S wires and
disconnected coil
/Ohms
T/S relays and

Card

Test O44 - Steer Motor
Test O44 - Steer Motor

This test ramps the steer motor by gradually
increasing the command to the steer amplifier.
This test verifies that the steer amplifier can
generate current and cause steering to occur in
both clockwise and counterclockwise direction.
The value ranges from -50 to +50 in steps of 5
and is an approximate percentage of full steer
command. To prevent damage to the steer
amplifier, this test limits the steer current to
100A for about 10 seconds. Running the test for
an extended period of time can cause damage to
the steer motor or steer amplifier. Normal
current while steering on a smooth floor, lift
truck not traveling, is approximately 50 amps.
If it is considerably higher, check for binding.
Run test:
1. The requested % of on-time is displayed.
Use the Up and Down buttons to increase
or decrease the steer request in
increments of 5%, from 0 to 50% and 0 to
-50%. Press the Enter button to exit the
test. Negative values steer to the left;
positive to the right.
Action/
step Meter (+) Lead (-) Lead Expected Results Step Passed Step Failed
Setting
While changing the

value from 5 to 50 Check
MS+ cable removed and -5 to -50, the brushes.
MS+
1 from motor MS- voltage should ramp Replace steer Perform Step 2
cable
steer/DCV from 0 to approx. motor if
11.5 volts positive necessary
and negative.
While changing the

DCV/Motor lead values from 5 to 50,
Perform Step
2 removed to prevent JPT6-5 JPT6-4 voltage should ramp Replace VM
3
movement. from approx. 11.5
to 8.00 volts.
While changing the

DCV/Motor lead value from -5 to Replace
3 removed to prevent JPT6-2 JPT6-4 -50, voltage should Steering Replace VM
movement. ramp from approx. Amplifier
11.5 to 8.00 volts.

Run test:

Models 5400/5500/5600 Maintenance Manual Section 7. Component Procedures
Section 7. Component Procedures

Section 7. Component Procedures Models 5400/5500/5600 Maintenance Manual
List of Component Procedures

Component Locator Photos . . . . . . . . . . 7-5 Housing Bearing Cup and
Steering and Controls . . . . . . . . . . . . . 7-17 Shim Assembly . . . . . . . . . . . . . . . 7-41
Steer Motor/Gearbox . . . . . . . . . . . . . . . . 7-18 Helical Gear/Spiral Pinion
Encoder Bearing Replacement . . . . . . . 7-18 Gear Assembly . . . . . . . . . . . . . . . . 7-42
Radial Rings . . . . . . . . . . . . . . . . . . . . 7-19 Axle Assembly . . . . . . . . . . . . . . . . 7-43
Home Proximity Sensor Adjustment . . . . . 7-20 Measuring Backlash. . . . . . . . . . . . 7-45
Control Handle . . . . . . . . . . . . . . . . . . . . 7-21 Pivot Ring Assembly . . . . . . . . . . . . 7-46
Removal . . . . . . . . . . . . . . . . . . . . . . . 7-21 Housing Cover Installation . . . . . . . 7-49
Disassembly . . . . . . . . . . . . . . . . . . . . 7-21 Drive Unit - Heavy Duty . . . . . . . . . . . . . 7-50
Lift/Lower Potentiometer and Pivot Ring Inspection . . . . . . . . . . . . . 7-50
Spring Replacement . . . . . . . . . . . . 7-22 Drive Unit Removal. . . . . . . . . . . . . . . 7-50
Horn Switch Replacement . . . . . . . . 7-22 Pivot Ring Disassembly. . . . . . . . . . . . 7-51
Assembly. . . . . . . . . . . . . . . . . . . . . . . 7-22 Main Cover and
Travel Pot (VR1) Replacement . . . . . . . 7-23 Output Shaft Disassembly . . . . . . . . . 7-52
Travel Spring and Pinion . . . . . . . . . . . 7-24 Spiral Pinion Disassembly . . . . . . . . . 7-53
Disassembly . . . . . . . . . . . . . . . . . . 7-24 Assembly Procedures . . . . . . . . . . . . . 7-54
Assembly . . . . . . . . . . . . . . . . . . . . 7-24 Spiral Pinion Assembly. . . . . . . . . . 7-54
Lift/Lower Knob Main Cover and
Installation/Adjustment . . . . . . . . . . . 7-25 Output Shaft Assembly . . . . . . . . . 7-55
Cleaning and Inspection . . . . . . . . . . . 7-25 Helical Gear Assembly . . . . . . . . . . . . 7-57
Hand Soldering Procedures . . . . . . . . . 7-26 Calculate Shim Formulas . . . . . . . . 7-57
Installation . . . . . . . . . . . . . . . . . . . . . 7-26 Installing and Testing Shims . . . . . 7-58
Deadman Pedal . . . . . . . . . . . . . . . . . . . . 7-27 Measuring Backlash. . . . . . . . . . . . 7-59
Switch Replacement . . . . . . . . . . . . . . 7-27 Main Cover Installation . . . . . . . . . 7-59
Lift Trucks S/N 00100 thru 00133 . 7-27 Pivot Ring Assembly . . . . . . . . . . . . 7-60
Lift Trucks S/N 00134 and Higher . 7-27 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62
Drive and Brake . . . . . . . . . . . . . . . . . 7-29 Brake Adjustment. . . . . . . . . . . . . . . . 7-62
Traction Motor . . . . . . . . . . . . . . . . . . . . . 7-30 Brake Rotor Replacement . . . . . . . . . . 7-63
Removal/Installation . . . . . . . . . . . . . . 7-30 Removal/Disassembly . . . . . . . . . . 7-63
Drive Unit - Standard . . . . . . . . . . . . . . . 7-31 Assembly/Installation . . . . . . . . . . 7-63
Pivot Ring Inspection . . . . . . . . . . . . . . 7-31 Drive Wheel. . . . . . . . . . . . . . . . . . . . . . . 7-66
Drive Unit Removal . . . . . . . . . . . . . . . 7-31 Removal . . . . . . . . . . . . . . . . . . . . . . . 7-66
Pivot Ring Disassembly . . . . . . . . . . . . 7-32 Installation . . . . . . . . . . . . . . . . . . . . . 7-66
Drive Unit Housing Disassembly . . . . . 7-33 Drive Tire Replacement. . . . . . . . . . . . 7-66
Radial Ring Removal . . . . . . . . . . . . 7-34 Electrical Components . . . . . . . . . . . . 7-69
Axle Shaft and Bevel Gear Removal . 7-34 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Spiral Gear and AC Motor Service. . . . . . . . . . . . . . . . . . . 7-77
Helical Gear Removal . . . . . . . . . . . 7-35 AC Motor Temperature Sensor . . . . . . 7-77
Bearing Cup and Shim Removal . . . 7-36 Traction Motor Replacement: . . . . . 7-77
Spur Gear Removal . . . . . . . . . . . . . 7-37 Lift Motor Replacement: . . . . . . . . . 7-77
Housing Cleaning and Inspection . . 7-37 AC Motor Bearing Encoder . . . . . . . . . 7-78
Axle Shaft Disassembly. . . . . . . . . . 7-37 Traction Motor Replacement: . . . . . 7-78
Bevel Gear Disassembly . . . . . . . . . 7-38 Lift Motor Replacement: . . . . . . . . . 7-79
Spiral Gear Disassembly . . . . . . . . . 7-38 Power Amplifiers . . . . . . . . . . . . . . . . . . . 7-80
Assembly Procedures. . . . . . . . . . . . . . 7-39 Installation . . . . . . . . . . . . . . . . . . . . . 7-80
Gear Set Assembly . . . . . . . . . . . . . 7-39 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81
Calculate Shim Formulas . . . . . . . . 7-39 Carriage Control Card Replacement . . . . 7-82
Spiral pinion gear shim calculation: 7-39 EPROM/Microprocessor
Bevel gear shim calculation: . . . . . . 7-40 Removal/Replacement . . . . . . . . . . . . . . 7-83
Removal . . . . . . . . . . . . . . . . . . . . . . . 7-83

Installation . . . . . . . . . . . . . . . . . . . . . 7-83
Hydraulic Components . . . . . . . . . . . . 7-95
Flow Sensor Service Notes . . . . . . . . . . . . 7-96
O-Ring Replacement . . . . . . . . . . . . . . 7-96
Disassembly . . . . . . . . . . . . . . . . . . . . 7-97
Assembly . . . . . . . . . . . . . . . . . . . . . . . 7-98
High Pressure Relief Valve Adjustment . . . 7-99
Lift/Lower and Load Holding Valves . . . . 7-100
Bleeding Lift Cylinders . . . . . . . . . . . . . . 7-101
Side Lift Cylinders . . . . . . . . . . . . . . . 7-101
Center Cylinder . . . . . . . . . . . . . . . . . 7-101
Lift Pump and Motor . . . . . . . . . . . . . . . 7-102
Removal. . . . . . . . . . . . . . . . . . . . . . . 7-102
Installation . . . . . . . . . . . . . . . . . . . . 7-102
Pressure Switch Adjustment. . . . . . . . . . 7-103
Side Lift Cylinder . . . . . . . . . . . . . . . . . . 7-104
Remove . . . . . . . . . . . . . . . . . . . . . . . 7-104
Installation . . . . . . . . . . . . . . . . . . . . 7-104
Cushion Service. . . . . . . . . . . . . . . . . 7-105
Cleaning . . . . . . . . . . . . . . . . . . . . . . 7-106
Seal Repacking . . . . . . . . . . . . . . . . . 7-107
Center Lift Cylinder . . . . . . . . . . . . . . . . 7-108
Installation . . . . . . . . . . . . . . . . . . . . 7-108
Service of Cylinder with Cushions . . . 7-108
Cushion Replacement . . . . . . . . . . 7-108
Seal Replacement . . . . . . . . . . . . . . . 7-110
Mast Section . . . . . . . . . . . . . . . . . . . 7-111
Carriage . . . . . . . . . . . . . . . . . . . . . . . . . 7-112
Removal. . . . . . . . . . . . . . . . . . . . . . . 7-112
Installation . . . . . . . . . . . . . . . . . . . . 7-113
Mast Disassembly and Shimming . . . 7-118
Shimming Main Frame to
Outer Telescopic . . . . . . . . . . . . . . 7-118
Shimming Outer Telescopic to
Inner Telescopic . . . . . . . . . . . . . . 7-119
Shimming Inner Telescopic to
Carriage . . . . . . . . . . . . . . . . . . . . 7-120
Center Cylinder Ride
Spring Chain Anchors . . . . . . . . . . . . . . 7-124
Inspection . . . . . . . . . . . . . . . . . . . . . 7-124
Removal. . . . . . . . . . . . . . . . . . . . . . . 7-125
Installation . . . . . . . . . . . . . . . . . . . . 7-125


Component Locator Photos

Tether Attachment Point
Dome Light
Working Lights
Battery
Compartment
Sidegate
Storage
Compartment
Pallet Clamp Release
Skid Pads
Pallet Clamp
Deadman Pedal
Load Wheels
Forks
78C04050S.TIF
Figure 7-1. Model 5600 - Overall View

Steering Indicator Lights Operator Display Key Switch

(Electronic Steering/Wire Guidance) Emergency
Guidance Indicator Lights Key Pad Power Off
Steer Tiller Lift/Lower Horn Switch Direction/Speed

Control Control
78C11036H.TIF
Figure 7-2. Operator Console

Reservoir
Lift Motor
Lift Pump Lift/Lower

Solenoid
Lift/Lower
Manifold
High Pressure
Relief Valve
Load Holding
Solenoid (SOL2)
Pressure test
connection
Emergency
Lower Valve
7
Figure 7-3. Hydraulic Compartment Components

Fuse/Relay
Card
Vehicle
Manager
Pendant
Steer Motor Connection
Contactor
Brake Panel
Assembly
Lift Power
Drive Motor
Amplifier
Guidance
Manager
Home Horn
Proximity
Sensor
7
Figure 7-4. Electrical Compartment Components

Traction Power Steer

Amplifier Amplifier
TP4 Fuse/Relay
Card
7
Figure 7-5. Electrical Compartment Components (located on Upper Deck of Tractor)

Steering Encoder Assembly

(behind steer tiller)
Carriage
Control Card
Pallet Clamp
Release
Deadman
Pedal
7
Figure 7-6. Platform Components

Special Tools and Decals
Special Tools and Decals


Special Tools Special Tools and Decals
Special Tools
The following tools are available from your local
authorized Raymond Sales and Service Center.
Table 7-1. Special Tools
Tool Part Number Purpose
Anti-static Field Kit 1-187-059
Anti-static Wrist Straps 1-187-058/001 ESD Protection.
Anti-static Wrist Strap Tester 1-187-060/100
Center Cylinder Service 401-000-058 To prevent damage to packing at the top of cylinder.
Driver
Center Cylinder Service 401-000-059 To prevent damage to packing at the top of cylinder.
Guide
Chain Gauge 939-10606 Lift chain inspection.
Connector Unlatching 950-042 Separate AMP connectors.
Crimp Tool 1069861 Crimp power cable lugs.
Center Lift Cylinder w/ decel and staging end cap

End Cap 1090761/002
removal/installation.
EPROM Extractor 950-032 Removing EPROM chips from socket on circuit board.
Fork Wear Caliper 922-369 Fork inspection.
Lift/Lower Pendant 114-020-848 Lift and Lower platform for service,
Lock Nut Wrench 761-870/T03 Removing End Play in Drive Unit Bearings.
Magnet 591-552/002 Testing EOA sensor.
Nut Driver Tool 761-870/T04 Removing End Play in Drive Unit Bearings.
Nut Driver Tool 761-870/T07 Removing End Play in Drive Unit Bearings.
Pin Extraction 950-009 AMP connector pin extraction.
Pin Extraction 950-026 MOLEX connector pin extraction.
Seal Pressing Ring 828-004-901 Prevents damage to seals during installation.
Side Cylinder Service Driver 401-000-050 To prevent damage to packing at the top of cylinder.
Side Cylinder Service Guide 401-000-051 To prevent damage to packing at the top of cylinder.
ESD/voltage surge protection for serial type FlashWare

Surge Protector 154-010-801
connections.
FlashWare connection to lift truck for devices that do not

USB to serial adapter cable 610-809/W7P
have a serial port.
9-pin serial cable 610-809/201 FlashWare connection to lift truck.
7-12 Publication: 1031794C, Re-Issued: 7/14/06

Special Tools and Decals Decals and Tags
Decals and Tags

Table 7-2. Decal and Tag Location Chart
Decal and Specification Tag Locations
Identifier Description
1 Raymond 21 in. (2 places)
2 Raymond 11in.
3 ACR (2 places)
4 Emergency Lower (inside tractor)
5 Emergency Lower (top of tractor)
6 Main Specification Tag
7 Attachment Tag
8 Mast Specification Tag
9 Battery Removal Warning (2 places)
10 Driver Operating
11 Overhead Guard ANSI/ITSDF conformance
12 Operator General Safety Decal
13 Bumper (optional)
14 Drive Unit Warning
15 EE Compliance (optional)
16 Attention
Note: Items in italics are safety decals.

Decals and Tags Special Tools and Decals

Figure 7-7. Decal and Specification Tag Locations
16
3
WARNING
11
15
14

Special Tools and Decals Decals and Tags

Figure 7-7 (Cont.). Decal and Specification Tag Locations
12
7
6
10
4
13

Decals and Tags Special Tools and Decals

Steering and Controls


Spur Gear Orientation
Steer Motor/Gearbox 9. Torque the bolts holding the motor to the

gear reducer to approx. 85 in. lb. (9.9 Nm).
B Side
Encoder Bearing Replacement End Bell
NOTE: Replace the shaft seal, the B side
bearing, and the brushes while the
motor is apart.
2. Remove the steer motor/gearbox.
A Side
3. Remove the B side end bell and brush End Bell
retainers. See Figure 7-8.
4. Remove the A side end bell bolts and pull
the end bell and rotor from the motor
housing. Push the wires and rubber
grommet out of the housing slot.
5. Loosen the two phillips head screws that
are used with the small clips to retain the
bearing in the A side end bell.
6. Remove the A side end bell from the rotor.
7. Use a press to remove the old bearing. 7
Figure 7-8. Steer Motor and Gearbox

New encoder bearings are mounted like
regular bearings except induction Spur gear installation is different between
heaters must not be used because they standard and heavy duty drive units. Install the
demagnetize the encoder. Also, care spur gear as shown in Figure 7-9.
must be taken against ESD. See
page 2-7.
NOTE: When pressing a bearing onto a shaft,

press on the inner race, never the outer
race.
8. Press on the new bearing and reassemble
the motor. Place a small amount of good
quality grease between the new bearing
and the shaft seal. Take care to not
damage the pinion gear in the end of the
motor shaft.

Standard Drive Unit

Heavy Duty Drive Unit
Note: Make sure that the spur gear teeth mesh fully
with the teeth of the gear on the drive unit.
7
Figure 7-9. Spur Gear Orientation
Radial Rings
Any time the steering motor is repaired or
replaced, make sure the radial rings on the
drive unit are not binding. Make sure to rotate
the drive unit full left and full right while
pumping grease into the radial rings at both
grease fittings.

Home Proximity Sensor

Adjustment
2. Loosen the two lock nuts securing the
sensor to the bracket. See Figure 7-10.
Figure 7-10. Home Proximity Sensor
3. Adjust the vertical gap between the sensor

and the sensor rail to 0.060 +0.010/
–0.040 in. (1.5 +0.254/–1.016 mm).
Tighten the lock nuts.
the key switch ON.
5. Center the drive wheel. The sensor must
be located horizontally just over the end of
the sensor rail.

Control Handle NOTE: Carefully slide the two fiber washers,

lift/lower spring, and third fiber washer
off the lift pot shaft. See Figure 7-11.
Removal
the battery connector. Fiber
Washer
2. Disconnect JPC9 and remove the Control
Handle from the lift truck.
NOTE: Observe the orientation of switches,
potentiometers (pot), and the routing of L/L Spring
cables/wires as the handle is
disassembled to make reassembly
easier.
7
Figure 7-11. Spacer Washer and L/L Spring Removal
3. Remove the three 3 mm socket head cap

Observe correct ESD precautions. See screws from the handle assembly. See
Static Precautions on page 2-7. Figures 7-12 and 7-13. Separate the cover
from the handle.
Before disassembly, determine what
components require replacement:
• Lift/Lower Pot, Spring, and/or Horn
Switch
• Travel Pot
• Travel Spring and/or Pinion
• Lift/Lower Knob
Disassembly
1. Remove the two 3/32 socket head nylon
7
set screws in the lift/lower knob (thumb Figure 7-12. Cover Retaining Screws - Bottom
lever). If stripped, use a small 1/8 in.
(3.2 mm) blade flat screwdriver and
carefully back out the set screw.
2. Loosen the two metal set screws in the
lift/lower knob two full turns and remove
the lift/lower knob.
Figure 7-13. Cover Retaining Screw - Top

Lift/Lower Potentiometer and Spring Horn Switch Replacement

Replacement 1. Disconnect the horn switch connector. See
NOTE: Before sliding the potentiometer (pot) Figure 7-15.
bracket off the pot shaft, identify what
slot in the pot bracket is used to hold
the pot anti-rotate tab. The anti-rotate Plastic Nut
tab must be located in the slot furthest
from the pin in the pot bracket.
1. Remove the lift/lower pot and bracket
from the cover. See Figure 7-14.
Tab
Slot Cable Tie Connector
Figure 7-15. Horn Switch Removal
2. Remove plastic nut and external tooth

washer securing horn switch. Remove the
cable tie.
3. Install new horn switch assembly into the
Bracket handle cover. Install external tooth washer
7
and plastic nut. Cable tie all wires
Figure 7-14. Anti-Rotate Tab together.
NOTE: The button, pin, and spring can easily Assembly

slide apart. Identify the correct position
of these components before 1. Make sure all wires are routed correctly.
disassembly. Tuck the common ground wire into the
handle between the bottom of the
2. If replacing the pot, carefully remove heat potentiometer and the screw boss to
shrink tubing from the terminals. Identify prevent the wire from being pinched or
the wires so they can be installed in the interfering with the horn button.
same location on the new pot.
2. Install the cover onto the handle assembly
3. Carefully unsolder the harness wires from with the three socket head cap screws.
the lift/lower pot. Torque to 15-20 in. lb. (1.7-2.25 Nm).
4. Carefully solder harness wires to the 3. Install a fiber washer and lift/lower spring
correct terminals on the new lift/lower (lightly greased with P/N 990-635) on the
pot. Refer to Hand Soldering Procedures lift/lower pot shaft. Install the spring with
on page 7-26. the tangs straddling the pot bracket pin.
5. Slide lift/lower pot bracket onto the shaft. See Figure 7-11.
Make sure the anti-rotation tab is inserted
NOTE: Replace the spring if the tangs are not
into the correct slot on the bracket. See
parallel. Do not bend the spring.
Figure 7-14.
6. Press the lift/lower pot and bracket into 4. Install the two remaining fiber washers.
the handle cover. Make sure the key on the 5. Install the lift/lower knob. See “Lift/Lower
bracket engages the keyway in the handle Knob Installation/Adjustment” on
cover. page 7-25.

Travel Pot (VR1) Replacement 3. Loosen the set screw on the gear two full
turns and slide the gear off the shaft. See
1. Remove the four hex head cap screws from Figure 7-19.
the front of the travel pot enclosure and
4. Remove the retaining nut and lock washer
remove cover. See Figure 7-16.
from the pot and separate from the
bracket. See Figure 7-19.
Remove screws
4 places Set Screw
Retaining Nut and

Lock Washer
7 7
Figure 7-16. Travel Pot Cover Removal Figure 7-19. Travel Pot/Bracket Disassembly
2. Remove the two pan head machine screws 5. Carefully remove heat shrink tubing from
from the back of the enclosure. Carefully the terminals and identify the wires so
pull the travel pot/bracket assembly from they can be installed in the same location
the enclosure. See Figures 7-17 and 7-18. on the new pot.
6. Carefully unsolder the harness wires.
7. Slide 3/8 in. (9.5 mm) long shrink sleeving
over previously sleeved wires.
8. Solder all electrical components to the
harness. See “Hand Soldering Procedures”
on page 7-26.
9. Shrink sleeving as necessary.
10. Assemble the pot and bracket. Install the
retaining nut and lock washer. When
installing the travel pot into the bracket,
7
leave the mounting nut finger tight. See
Figure 7-17. Travel Pot Bracket Screws Figure 7-19.
11. Install the gear on the pot shaft, aligning
the set screw with the flat portion of the
Travel Spring shaft.
12. Install the travel pot/bracket assembly
into the enclosure. Engage the travel pot
Button
Head Screw
gear with the shaft gear (there is one large
tooth that is used to align the gears).
Tighten the pot gear set screw and torque
to 3 to 4 in. lb. (0.3 to 0.4 Nm).
Figure 7-18. Travel Pot Enclosure (Cover Removed)

It is very easy to over torque and ruin
the gear.

13. Tighten the two pan head machine screws spring is installed, the spring sits on an
on the back of the enclosure while moving even edge of the pin and not on the gap.
the handle to make sure there is no
NOTE: Replace the spring if the tangs are not
binding. See Figure 7-17.
parallel. Do not bend the spring.
14. Install the handle in the lift truck.
b. Make sure the washer and shims are
15. Adjust the travel pot. Run Test A04 - correctly aligned to allow the handle
Throttle Potentiometer Voltage (Page 6-42) shaft to slide easily through the
and adjust the travel pot voltages to the enclosure. See Figure 7-20.
values given.
16. Tighten the retaining nut.
17. Install the cover on the travel pot
enclosure with the four hex head cap
screws. See Figure 7-16.
18. Run Learn. See “Learn Mode” on
page 3-19.
Travel Spring and Pinion

Disassembly Washers/Shims
1. Remove the four hex head cap screws from 7
the front of the travel pot enclosure and Figure 7-20. Travel Pot/Bracket Assembly Installation
remove cover. See Figure 7-16.
2. Use a pin removal tool and pull pins 3 thru 2. Route the lift/lower pot and horn wires
6 from JC-9. These wires pass through the through the enclosure. Carefully slide the
shaft to the lift/lower pot and horn switch. shaft through the enclosure, passing
through the shaft gear assembly, washer,
NOTE: The washer and shims can easily slip off and shims.
the shaft gear. Observe the correct 3. Align the screw hole in the handle shaft
position of these components before with the hole in the shaft gear. Apply
disassembling them. thread-locking compound (P/N 990-412)
to the threads in the shaft and on the
3. Remove the button head screw from the
button head screw. Install the screw and
shaft gear and slide the shaft out of the
torque to 8 to 12 in. lb. (0.9 to 1.3 Nm).
enclosure. See Figure 7-18.
4. Reinstall the wire pins into the connector.
4. Carefully rotate the shaft gear assembly to
disengage the spring tangs from the pin. 5. Inspect the tab on the plate ground to
Remove the shaft gear assembly from the make sure that it is in contact with the
enclosure. bronze handle shaft bushing. See
Figure 7-21.
Assembly
1. Slide the shaft gear assembly back into
enclosure. Engage the travel pot gear with
the shaft gear (there is one large tooth that
is used to align the gears).
a. Make sure the spring tangs straddle the
pin (tangs must be parallel). If the
spirol pins were replaced, make sure
they are installed such that when the

3. Rotate the lift/lower knob fully

counterclockwise and tighten the metal set
screws to 6 to 8 in. lb. (0.7 to 0.9 Nm).
Plate Ground 4. Check the potentiometer for correct
operation and spring return to neutral.
Correct any binding.
5. Install and tighten the two nylon set
screws on top of the metal set screws.
6. Verify the potentiometer reference
voltages. Refer to Test A05 - Lift/Lower
Potentiometer Voltage on page 6-43.
7. Run Learn. See “Learn Mode” on
page 3-19.
7
Figure 7-21. Plate Ground

Cleaning and Inspection
6. Install the cover on the travel pot
enclosure with the four hex head cap
screws. See Figure 7-16.
When cleaning plastic parts, use a dry
rag or a cleaner that is safe on plastics.
Lift/Lower Knob Most chemicals can damage plastic.
Installation/Adjustment
While performing a repair on the Control
1. Rotate the lift/lower potentiometer shaft
Handle, clean and inspect the parts listed in
fully counterclockwise.
Table 7-3.
2. Install the lift knob on the potentiometer
shaft. The pin on the knob must fit
between the tangs of the potentiometer
return spring.
Table 7-3. Control Handle Checks
Part Check for:
Horn button assembly Cracks or deformation
Lift/lower pot bracket Cracks, deformation, loose dowel pin, over round or oversized shaft hole
Travel pot gear Cracks, gear deformation, stripped threads
Travel shaft gear assembly Cracks, gear deformation, or loose spirol pin
Travel pot enclosure Cracks, loose spirol pin, stripped threads, deformation or indents on external
stops
Handle halves Cracks, damage or deformation/indents on external stops
Lift/lower knob Cracks, deformation, stripped threads, loose dowel pin
Plate ground Check for continuity between the control handle shaft and the lift truck frame
Other hardware Stripped threads. All screw threads must be cleaned.

Hand Soldering Procedures

When hand soldering is performed on solid
state potentiometers, the following is
recommended:
• Flux - rosin base
• Solder - 60/40 rosin core or equivalent
• Solder Iron - 55 watt max.
• Tip Size - 0.118 in. (3 mm) dia. x 1.182 in.
(30 mm) long screwdriver
• Tip Temperature - 500°F (260°C) max.
• Terminal Contact Time - 6 seconds max.
NOTE: Apply light soldering iron pressure on
the terminal. Make sure the tip is clean.
A dirty tip does not transfer heat well,
therefore requiring longer dwell time
and greater tip pressure.
Contact contamination can occur if

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

dampened with an alcohol based cleaner. Make
sure cleaner does not seep into the electrical
component.
NOTE: Components damaged due to solvent
saturation will not be covered under
warranty.
Installation
1. Install the control handle on the lift truck.
Connect JPC9.
2. Connect the ground wire to the lift truck
frame.
the key switch ON.
4. Perform Learn Controls and test lift truck
operation before returning to service. See
“Learn Mode” on page 3-19.

Deadman Pedal 8. Replace bad switch(es). See Figure 7-23.
Deadman
Switch Replacement Pedal
There are two deadman switches (S2 and S23).

Return
Springs (2)
Lift Trucks S/N 00100 thru 00133 Washers (2)
1. Raise the operator platform high enough
(at least 3 ft. [91.44 cm]) to access the
bottom of the deadman pedal from under
the platform.
Deadman
2. Block the operator platform with a 4 x 4 Switches
in. (100 x 100 mm) wooden block.
3. Turn the key switch OFF and disconnect 77k10131s
the battery connector. Figure 7-23. Deadman Pedal Components
4. Remove the snap ring from the bottom of 9. Reconnect wires.

the deadman pedal post. See Figure 7-22.
10. Align washers with holes.
5. While holding the two return springs in
11. While holding the two return springs in
place, lift the pedal straight up.
Remove two screws mounting deadman switch to bracket.
place, install the pedal assembly. See
Figure 7-23.
Deadman 12. Install a snap ring on the bottom of the
Pedal Post
deadman pedal post.
the key switch ON. Test the lift truck
operation before returning to service.
Lift Trucks S/N 00134 and Higher

1. Raise the operator platform high enough
(at least 3 feet [91.44 cm]) to access the
bottom of the deadman pedal from under
the platform.
71447_019.tif
2. Block the operator platform with a
Figure 7-22. Deadman Pedal Post Under Platform 4 x 4 in. (100 x 100 mm) wooden block.
6. Remove the two screws mounting the the battery connector.
deadman switch to the bracket.
7. Disconnect the wires from the deadman
switch(es). Note the location and mark if
necessary for recognition later.

4. Remove the three lock nuts and washers

that secure the deadman pedal assembly
to the operator platform. See Figure 7-24.
77k10131s
Figure 7-24. Deadman Lock Nuts and Washers
5. Remove the two screws mounting the

deadman switch(es) to the bracket.
6. Disconnect wires from switch(es). Note the
location and mark if necessary for
recognition later.
7. Replace bad switch(es).
8. Reconnect wires.
9. Align the pedal assembly with holes in the
platform.
10. Install a washer and lock nut on the
bottom of each deadman pedal assembly
post. See Figure 7-24.
the key switch ON. Test the lift truck
operation before returning to service.

Drive and Brake


Traction Motor 5. Remove the traction motor.

6. For reassembly, reverse steps 1 thru 5
noting the following:
Refer to AC Motor Service on page 7-77 for
traction motor temperature sensor and encoder • Clean motor mounting flange and drive
bearing replacement procedures. unit. Install a new gasket.
• Mount the motor to the drive unit. Refer
Removal/Installation to Component Specific Service/Torque
Chart on page A-4.
• Torque the power cable nuts to 18 ft. lb.
(24.4 Nm). See Power Cable Terminals
2. Remove the brake assembly including the on page 7-74.
rotor hub nut and rotor hub. See • Check brake adjustment. See Brake
Figure 7-25. Note the number of spacers Adjustment on page 7-62.
used.
7. If the pinion on the drive motor needs to
be installed:
Brake Assembly a. Clean threads using thread-locking
compound primer (P/N 990-666).
b. Install the key and gear.
c. Apply thread-locking compound
(P/N 990-669) to the threads of the
motor and nut.
d. Torque the nut to 45 ft. lb. (61 Nm).
Figure 7-25. Drive Motor
3. Identify and remove the power cables from

the traction motor.
4. Remove the drive motor retaining screws.

Drive Unit - Standard

Pivot Ring Inspection
The fit of pivot ring bearings in the drive unit is
such that some play is expected. However, as
the rings wear, the play may increase. If the
play is permitted to become extreme, it will
become quite noticeable in the drive unit.
If worn rings are suspected as the cause of
excessive play in the drive unit, inspect the
drive housing to determine if the bearing radial Bumper Gate
rings must be replaced:
7
1. Jack the tractor of the lift truck up just Figure 7-26. Removing Drive Unit
enough to permit the drive tire to clear the
3. If the lift truck is wire guided, remove the
floor.
sensor mounted on the backside of the
bumper gate.
4. If the drive tire is to be removed, loosen the
lug nuts.
is jacked up. Keep hands and feet clear 5. Remove the proximity sensor and
from the vehicle while jacking the lift associated hardware on the drive unit
truck. After the lift truck is jacked, place casting.
solid blocks beneath it to support it. Do 6. Remove the traction motor. See Traction
not rely on the jack alone to support the Motor on page 7-30.
lift truck.
NOTE: If the drive unit is the only item
requiring service, separating the brake
2. Place a magnetic base dial indicator on the
assembly from the traction motor is not
deck plate and position the indicator point
necessary.
on top of the drive unit top cover.
3. Adjust the dial indicator to zero, then
lower the lift truck to the floor.
4. Note the new indicator reading. If the
reading is 0.089 in. (2.26 mm) or less, the
radial rings do not have to be replaced. If
the reading exceeds 0.089 in. (2.26 mm),
the rings must be replaced. If the reading
is between 0.055 and 0.089 in. (1.4 and
2.26 mm), the bearing rings must be
jack stands or solid blocks to support
checked during future scheduled
the lift truck. DO NOT rely on the jack
maintenance visits.
alone. See Jacking on page 2-8.
Drive Unit Removal 7. Jack and block the tractor so the drive tire
is off the floor.
the battery connector. 8. Drain the oil from the drive unit.
2. Remove the bumper gate. See Figure 7-26. 9. Unbolt the lift/lower manifold from the
drive unit casting.

10. Remove the steering motor/gear reducer 2. Remove the bearing filler plug with grease
assembly. fitting.
11. Remove the cap screws holding the drive 3. Remove the steel balls through the bearing
unit assembly to the tractor frame. filler plug hole. To work the steel balls
12. Lift the drive unit out of tractor frame forward, insert a putty knife between the
using a suitable lifting device. pivot ring and the housing. See
Figure 7-29. Use care to prevent damaging
13. Clean the outside of the drive unit the radial rings. Move the pivot ring
thoroughly and drain any remaining oil slightly from side to side while working the
from the drive unit by removing the drain putty knife toward the bearing filler plug
plug. hole.
NOTE: If the pivot ring will not spin or even
turn, it is an indication of damaged
radial rings and/or excessive wear to the
channel in the housing. If this is the
case, replace the entire drive unit. No
further disassembly is necessary.
71826_006.tif
Figure 7-27. Inspect Housing for Hub Wear
14. Visually inspect the outside of the housing

for damage, wear, or cracks. Pay particular
attention to the area where hub wear may
be evident.
1826_014.tif
Pivot Ring Disassembly Figure 7-29. Remove Steel Ball Bearings
1. Remove the bearing filler plug screws 4. After removing all the steel balls, remove
using a 1/2 in. socket. See Figure 7-28. the pivot ring by lifting it off, toward the
drive end of the housing. See Figure 7-30.
71826_011.tif
Figure 7-28. Bearing Filler Plug Screws Removal 71826_015.tif
Figure 7-30. Pivot Ring Removal

5. Use a screwdriver to remove the radial

rings and thrust ring from the pivot ring.
See Figure 7-31.
71826_022.tif
Figure 7-33. Grease Fitting Removal
8. Use a punch and mallet to remove the two

71826_018.tif
roll pins that are used to hold the radial
Figure 7-31. Radial and Thrust Ring Removal
rings in position. See Figure 7-34. Inspect
the roll pins. If they are worn, replace with
new roll pins when reassembling the pivot
ring.
Due to normal or excessive wear, the
edges of the radial rings could be very
sharp.
6. Use a mallet and a punch to remove the

spherical bearing and brass bushing from
the pivot ring. See Figure 7-32.
71826_024.tif
Figure 7-34. Roll Pin Removal
9. Clean the grease from the radial ring

channel in the pivot ring. Inspect the
channels for wear. If there is excessive
wear, replace the pivot ring.
71826_020.tif
Figure 7-32. Spherical Bearing and Brass Bushing

Removal Drive Unit Housing Disassembly
7. Remove the grease fittings using a punch Excessive housing wear in the channel, pivot
and a mallet. See Figure 7-33. ring, or hub areas are signs of a damaged
housing. If this occurs, replace the entire drive
unit. No further disassembly is necessary.

Radial Ring Removal need to use an Allen wrench if access is

limited.
1. Use a screwdriver to remove the radial
rings from the housing. See Figure 7-35.
71826_027.tif
Figure 7-37. Loosen Clamp Nut Set Screw

71826_025.tif
Figure 7-35. Radial Ring Removal from Housing 2. Use a screwdriver in the clamp nut slot to
turn the clamp nut off. See Figure 7-38.
Due to normal or excessive wear, the

edges of the radial rings could be very
sharp.
2. Clean the grease from the radial ring

channel in the housing. Inspect the
channel for uneven wear. See Figure 7-36.
If there is excessive wear, no further
disassembly is necessary. The housing
must be replaced.
71826_029.tif
Figure 7-38. Turn Clamp Nut Off
3. Remove the axle from the housing using a

large mallet. See Figure 7-39.
71826_026.tif
Figure 7-36. Inspect Housing Channel
Axle Shaft and Bevel Gear Removal

1. Loosen the set screw locking the clamp
71826_030.tif
nut using a 4 or 5 mm Allen socket and a
Figure 7-39. Remove Axle from Housing
breaker bar. See Figure 7-37. You may

4. The bevel gear can now be lifted from the

housing. In cases where severe chipping is
present, you may need a mallet to knock
the bevel gear loose. See Figure 7-40.
71826_042.tif
Figure 7-42. Remove Clamp Nut
3. Use a brass drift punch and mallet to drive

the spiral pinion gear shaft through the
71826_038.tif
housing. The brass drift punch will
Figure 7-40. Lift Out Bevel Gear
prevent damage to the threads on the end
of the spiral shaft. See Figure 7-43.
Spiral Gear and Helical Gear
Removal NOTE: It may be necessary to remove the spiral
pinion gear with a press or pressing
1. Turn the drive unit housing over to remove device equivalent.
the clamp nut from the spiral gear. Loosen
the set screw locking the clamp nut using
a 4 or 5 mm Allen wrench. See
Figure 7-41.
71826_043.tif
Figure 7-43. Remove Spiral Pinion
4. Lift the helical gear and spacer from the

71826_041.tif housing. See Figure 7-44.
Figure 7-41. Remove Clamp Nut Set Screw
2. Use a screwdriver in the clamp nut slot to

turn the clamp nut off. Inspect the clamp
nut for damage. See Figure 7-42.

71826_045.tif 71826_053.tif
Figure 7-44. Lift Helical Gear from Housing Figure 7-46. Spiral Gear Bearing Cup Removal
5. Inspect the helical gear and the spiral gear 2. Use the mallet and a punch to drive the
for damage or wear. helical gear bearing cup from the housing.
See Figure 7-47.
NOTE: The bevel gear and spiral gear are a
matched set. Their alignment is critical.
Do not replace them separately.
6. Lift the bearing the spiral shaft goes
through from the housing to remove it. See
Figure 7-45.
71826_055.tif
Figure 7-47. Helical Gear Bearing Cup Removal
3. Remove the axle shaft bearing cup from

the housing using the punch and mallet.
See Figure 7-48.
71826_047.tif
Figure 7-45. Lift Bearing from Housing

Bevel Gear
Bearing Cup and Shim Removal Bearing Cup
NOTE: The bearing cups and cones are usually

damaged during removal. They must be
replaced as sets.
1. Use the mallet and a long punch to drive
the spiral gear bearing cup from the
Axle Shaft
housing. Take care not to damage the Bearing Cup
shims. Save the shims for reference in
reassembly. See Figure 7-46. 71826_057.tif
Figure 7-48. Axle Shaft and Bevel Gear Bearing Cup

Removal

4. Use the mallet and a punch to drive the

bevel gear bearing cup from the housing.
Take care not to damage the shims. Save
the shims for reference in reassembly.
5. Visually inspect the housing bores and
sealing surfaces for damage or wear.
Spur Gear Removal
Check the spur gear for damage or wear. If the

spur gear is damaged, use a drift punch and
mallet to remove it from the housing. See
Figure 7-49. 71826_032.tif
Figure 7-50. Bearing Removal
3. Lift the axle seal from the axle. See

Figure 7-51.
71826_059.tif
Figure 7-49. Spur Gear Removal
Housing Cleaning and Inspection

71826_034.tif
Thoroughly degrease the housing. Visually Figure 7-51. Lift Seal Removal
inspect the entire housing again for excessive
damage, cracks, or wear. 4. Inspect the axle for damage or wear. See
Figure 7-52.
Axle Shaft Disassembly
Always watch for pinch points when

using a press or pressing tools.
1. Place a bearing puller clamp between the

axle seal and beneath the axle bearing
cone.
2. Press the bearing from the axle using a
bearing press and a 6 in. tube. See
Figure 7-50. 71826_035.tif
Figure 7-52. Axle Inspection

Bevel Gear Disassembly

1. Place the bearing puller clamp on the bevel

gear beneath the bearing. See Figure 7-53.
71826_051.tif
Figure 7-55. Puller Clamp on Spiral Gear
2. Press the bearing from the spiral gear

using a bearing press. See Figure 7-56.
71826_039.tif
Figure 7-53. Puller Clamp on Bevel Gear
2. Press the bearing from the bevel gear

using a bearing press and an 8 in. tube.
See Figure 7-54.
71826_052.tif
Figure 7-56. Pressing Bearing from Spiral Gear
71826_040.tif
Figure 7-54. Press Bearing from Bevel Gear
Spiral Gear Disassembly

1. Place a bearing puller clamp beneath the
bearing cone on the spiral gear. See
Figure 7-55.

Assembly Procedures
Bearing Cone
Safety glasses are required.
Prepare the housing for assembly by running a

Spiral Gear
tap through all bolt and screw holes. Cleaning
the threads makes sure that there is no
damage. It also enables you to determine the
correct tooling to use in the assembly process.
Before beginning assembly of the drive unit, 71018_015.tif
record the bearing seat data stamped on the Figure 7-58. Press Bearing onto Spiral Gear
housing. Record the setting distance
information stamped on the bevel and spiral
gears. This data is used in the formula to
determine shim thickness later on.
Gear Set Assembly
1. Press the bearing cone on the bevel gear 3. Use a bearing zero offset tool and the
until it is seated. Place the matching formulas on page 7-39 to determine the
bearing cup on the bearing cone for shim thickness that is required to
measuring purposes. See Figure 7-57. assemble the gear set in the housing.
Calculate Shim Formulas
Spiral pinion gear shim calculation:

• A = Dimension A (See Figure 7-59.)
stamped on housing (4.438)
• B = Number (See Figure 7-60.) etched on
gear (S/D 2.378)
• C = Zero Offset (See Figure 7-61.)
Use a dial indicator to determine the zero
offset. Turn the spiral gear as if seating the
bearings. Record the data from the dial
71826_064.tif
indicator to use in the formula.
Figure 7-57. Press Bearing on Bevel Gear
• D = Plug Height (2.025)
2. Press the bearing cone on the spiral gear • E=B+C+D
until it is seated. Place the matching
• F=A-E
bearing cup on the bearing cone for
measuring purposes. See Figure 7-58. F = Shim thickness required
This calculation is used to determine the shim

amount behind the bearing cup in the main
housing. The shim(s) positions the spiral gear
for correct backlash.

Bevel gear shim calculation:

• G = Dimension B (see Figure 7-62)
stamped on housing (2.506)
• H = Number (see Figure 7-63) etched on
gear (S/D 0.541)
• J = Zero Offset (see Figure 7-64)
Use a dial indicator to determine the zero
offset. Turn the bevel gear as if seating the
bearings. Record the data from the dial
indicator to use in the formula.
• K = Plug height (1.875)
71826_060.tif
Figure 7-59. Record Bearing Seat Data from Housing • L=H+J+K

• M=G-L
M = Shim thickness required
This calculation is used to determine the shim

amount behind the bearing cup in the main
housing. The shim(s) positions the bevel gear
for correct backlash.
71826_071.tif
Figure 7-60. Record Bearing Seat Data from Spiral Gear
71826_061.tif
Figure 7-62. Record Bearing Seat Data from Housing
7pingear.tif
Figure 7-61. Check Zero Offset of Spiral Gear
71826_072.tif
Figure 7-63. Record Bearing Seat Data from Bevel Gear

Spiral Gear
Bearing Cup
71018_014.tif
Figure 7-66. Drive In Bearing Cup
3. Place the bevel gear shim in the housing,

7crngear.tif
followed by the bearing cup. Use a press or
Figure 7-64. Check Zero Offset of Bevel Gear mallet to press the bearing cup into the
housing bore. See Figure 7-67.
Housing Bearing Cup and Shim NOTE: Make sure to wipe away any chips or
Assembly excess metal pieces resulting from
driving the race to seat it.
1. Place the spiral gear shims in the housing,
then place the bearing cup in the housing.
See Figure 7-65.
71826_080.tif
Figure 7-67. Bevel Gear Bearing Cup Installation
71826_076.tif
4. Place the drive axle bearing cup in the
Figure 7-65. Spiral Gear Bearing Cup Installation
housing. Use a mallet or press to seat the
axle bearing cup in the housing. See
2. Install the bearing cup into the housing
Figure 7-68.
bore. See Figure 7-66.

71826_084.tif 71826_087.tif
Figure 7-68. Axle Bearing Cup Installation Figure 7-70. Preheat Bearing Cone
5. Turn the drive unit housing over. Install NOTE: Steps 2 thru 5 need to be completed
the helical bearing cup in the housing. Use before the bearing cools to provide a
a press or mallet to seat the bearing cup in correct installation.
the housing. See Figure 7-69.
2. Install the heated bearing cone in the
bearing cup in the housing.
3. Place the spacer over the bearing cone,
then place the helical gear into the
housing.
71826_085.tif
Figure 7-69. Helical Bearing Cup Installation
Helical Gear/Spiral Pinion Gear

Assembly
71826_089.tif
NOTE: The pinion shaft and bevel gear are a Figure 7-71. Install Helical Gear
Do not replace them separately. 4. Install the spiral pinion gear shaft up
through the helical gear. Push up until the
spiral gear bearing is seated against its
race. See Figure 7-72.
Bearing can become extremely hot. Use

gloves to protect hands from burns.
1. Preheat the bearing cone with a bearing

heater. See Figure 7-70.

71826_091.tif 71018_028.tif
Figure 7-72. Spiral Pinion Gear Installation Figure 7-74. Removing End Play
5. Apply 3 vertical lines of thread-locking 7. Tighten the clamp nut the distance of a
compound (P/N 990-669) to the pinion spanner nut space to preload the gears.
shaft. Place the clamp nut on the end of 8. Back the nut off, then hand tighten.
the spiral pinion gear shaft and hand
tighten until the bearing cools. See 9. Apply thread-locking compound (P/N
Figure 7-73. 1013829 ) to the bolt in the clamp nut.
Torque the clamp bolt to 128 in. lbs.
(14.5 Nm). Make sure the open end of the
clamp nut does not touch. See
Figure 7-75.
71018_027.tif
Figure 7-73. Install Clamp Nut
6. When the bearing has cooled, spin the

helical gear to check for end play. Remove 71826_094.tif
any end play in the bearings between the Figure 7-75. Applying Locking Compound to screw
helical gear and the spiral gear using a nut
driver tool (P/N 761-870/T04) and a 10. Spin the helical gear to make sure there is
wedge. Slowly tighten the clamp nut on no end play or that the bearings are not
the end of the spiral gear until there is no too tight.
end play between the gears. Use a spin
and tighten method to tighten clamp nut Axle Assembly
as the bearings are seating in the races.
1. Lubricate the oil seal. Place the seal over
See Figure 7-74.
the axle shaft with the spring side toward
the oil.

71826_096.tif 71826_100.tif
Figure 7-76. Axle Seal Installation Figure 7-78. Apply Gasket Compound to Sealing Surface
2. Place the axle bearing cone over the axle 4. Place the bevel gear into the housing. See
shaft. Press the bearing cone on the axle Figure 7-79.
shaft until it is seated. See Figure 7-77.

71826_101.tif
Figure 7-79. Bevel Gear Installation
5. Place a seal pressing ring

(P/N 828-004-901) beneath the axle seal.
Install the axle shaft through the bevel
gear. See Figure 7-80.
71826_097.tif
Figure 7-77. Axle Bearing Cone Installation
3. Apply a thin layer of gasket compound to

the housing to seal the axle seal. See Seal Pressing Ring
Figure 7-78.
71826_102.tif
Figure 7-80. Axle Seal Pressing Ring

6. Press the axle into the housing until the 12. Loosen the clamp nut, then retighten to
seal is fully installed. See Figure 7-81. 5 ft. lbs. (7 Nm) using the rotate, tightening
process until the clamp nut does not turn
any further.
13. Apply thread-locking compound (P/N
1013829) to the bolt in the clamp nut. See
Figure 7-83. Torque the bolt to 128 in. lbs.
(14.5 Nm). Make sure the open end of the
clamp nut does not touch.
71826_103.tif
Figure 7-81. Press Axle into Housing

71826_107.tif
7. Remove the seal pressing ring. Figure 7-83. Applying Locking Compound to clamp screw
8. Apply three verticle lines of thread-locking

compound (P/N 990-669) to the threads of Measuring Backlash
the axle. NOTE: Backlash tolerance is critical to the
9. Install the clamp nut shoulder side down. performance of the drive unit.
Hold the axle to keep it from turning as Incorrectly adjusted units will
the clamp nut is tightened. experience premature failure.
10. Use clamp nut tool (P/N 761-870/T07) 1. Place a gear-locking tool on the helical
and torque the clamp nut to 18 ft. lbs. gear and secure. See Figure 7-84.
(24 Nm). See Figure 7-82.
71826_106.tif
Figure 7-82. Tighten Clamp Nut to Seat Bearings 7gearfixt.tif
Figure 7-84. Gear Locking Tool

11. Rotate the axle and tighten the clamp nut.
Repeat this step six times to make sure the 2. Position the probe of the dial indicator at
bearing cones are seated into the cups. the heel of the bevel gear tooth. Position

the dial indicator probe perpendicular to Repeat steps 1 thru 3 of this procedure
the gear tooth surface. until the backlash is between 0.004 and
0.006.
5. When backlash is within the acceptable
range, install the pivot ring.
Pivot Ring Assembly

1. Place a light coating of thread-locking
compound (P/N 990-544) in the hole on
the pivot ring assembly.
2. Line up the grease fitting hole with the
grease fitting port. See Figure 7-87.
7dial.tif
Figure 7-85. Dial Indicator Position
3. Zero the indicator. Clasp the bottom of the

gear and rotate it. Read the backlash
measurement on the dial indicator. Total
backlash tolerance is between 0.004
and 0.006 in.
71826_111.tif
Figure 7-87. Spherical Bearing Alignment
3. Install the spherical bearing using a mallet

or press. See Figure 7-88.
7backlsh.tif
Figure 7-86. Measure Backlash
4. If the tolerance is not within the

acceptable limits, calculate any necessary
71826_112.tif
adjustments to the shims. Remove the
Figure 7-88. Install Spherical Bearing
clamp nut, axle assembly, and bevel gear.
Install the correct amount of shims, and 4. Install the grease fitting in the pivot ring
repeat steps 3 and 4 of “Housing Bearing assembly using a grease fitting driver and a
Cup and Shim Assembly” procedure on mallet or press. See Figure 7-89.
page 7-41.

Radial Rings
71826_113.tif 71018_036.tif
Figure 7-89. Grease Fitting Installation Figure 7-91. Radial Ring Installation
5. On the inside of the pivot ring, make sure 8. Install the brass bushing using a mallet or
the roll pins are installed and in good press. See Figure 7-92.
condition on either side of the bearing filler
plug hole. If they are missing or damaged,
install new roll pins. See Figure 7-90.
Pivot Ring
Roll Pin
71826_125.tif
Figure 7-92. Brass Bushing Installation
71018_035.tif
Figure 7-90. Roll Pin Installation
6. Clean the surface of the radial ring grove.

7. Install the radial rings so that the gap
aligns with the bearing hole. Install the flat
radial ring on the inside flat surface of the
pivot ring. Then install the chamfered radial
rings to the pivot ring. The chamfered edges
will face the steel balls. The ends of the
radial ring are against the roll pins. See
Figure 7-91.

Drive Unit Assembly
Drive Unit Assembly

\
1. Install the radial rings on the housing.

Stagger the ends of the rings around the
housing so the gaps are off-set at 3, 6, and
9 o’clock. The beveled edges will face the
steel balls. See Figure 7-93.
71018_038.tif
Figure 7-95. Ball Bearing Installation
4. Place the bearing filler plug in the filler

hole. The grease fitting should face the
spur gear.
71826_116.tif
Figure 7-93. Radial Ring Installation on Housing
2. Install the pivot ring assembly to the

housing. The spherical bearing should face
the spur gear. See Figure 7-94.
71826_119.tif
Figure 7-96. Bearing Filler Plug Installation
5. Install the filler plug bolts and flat washers

on each side of the grease fitting. Tighten
to 17 ft. lbs. (23 Nm). See Figure 7-97.
71826_117.tif
Figure 7-94. Pivot Ring Installation
3. Place one steel ball at a time into the pivot

ring filler hole. Use a screwdriver to direct
the steel balls first to one side then the
other. See Figure 7-95.
NOTE: Count the steel balls as they are
inserted in the pivot ring assembly for
correct pivot ring operation. The 71826_121.tif
standard drive unit requires 67 balls. Figure 7-97. Filler Plug Bolt Installation
Too many balls will cause binding and
too few balls will cause excessive 6. Grease and then test the pivot ring. Check
motion. to see that it spins freely.

Drive Unit Assembly
Housing Cover Installation

1. Clean old sealant from the gear housing
and cover plate. Remove any paint from
the sealing surface of the inside face of the
plate.
2. Clean the sealing surfaces of the gear
housing and cover plate with an alcohol
based cleaner.
3. Apply liberal amounts of Silicone sealing
compound (P/N 990-659) in a continuous
bead around the perimeter on the surface
71826_124.tif
of gear housing. Go completely around the
Figure 7-99. Tighten Cover Bolts
bolt holes. Start the bead on a flat surface
between holes. Make sure there is a 0.5 in. 6. Apply thread-locking compound
overlap when completing the bead. The (P/N 990-626) to the drain plug.
bead width should be 0.12 in. minimum
and 0.25 in. maximum. See Figure 7-98. 7. Install the drain plug in the cover plate and
tighten.
4. Install the cover plate with the unpainted
surface contacting the RTV. 8. Fill the gear housing with oil.
71826_123.tif
Figure 7-98. Apply Gasket Compound
5. Install six screws and torque in a star

pattern and repeat. Refer to Component
Specific Service/Torque Chart on page A-4
See Figure 7-99.

Drive Unit Assembly
Drive Unit - Heavy Duty

Pivot Ring Inspection
The fit of pivot ring bearings in the drive unit is
such that some play is expected. However, as
the radial rings wear, the play may increase. If
the play is permitted to become extreme, it will
become quite noticeable in the drive unit.
If worn rings are suspected as the cause of
excessive play in the drive unit, inspect the
drive housing to determine if the bearing radial Bumper Gate
rings must be replaced:
7
1. Jack the tractor of the lift truck up just Figure 7-100. Removing Drive Unit
enough to permit the drive tire to clear the
3. If the lift truck is wire guided, remove the
floor.
sensor mounted on the backside of the
bumper gate.
4. If the drive tire is to be removed, loosen the
lug nuts.
is jacked up. Keep hands and feet clear 5. Remove the proximity sensor and
from vehicle while jacking the lift truck. associated hardware on the drive unit
After the lift truck is jacked, place solid casting.
blocks beneath it to support it. Do not 6. Remove the traction motor. See Traction
rely on the jack alone to support the lift Motor on page 7-30.
truck.
NOTE: If the drive unit is the only item
requiring service, separating the brake
2. Place a magnetic base dial indicator on the
assembly from the traction motor is not
deck plate and position the indicator point
necessary.
on top of the drive unit top cover.
3. Adjust the dial indicator to zero then lower
the lift truck to the floor.
4. Note the new indicator reading. If the
reading is 0.089 in. (2.26 mm) or less, the
radial rings do not have to be replaced. If
the reading exceeds 0.089 in. (2.26 mm),
the rings must be replaced. If the reading
is between 0.055 and 0.089 in. (1.4 and
2.26 mm), the bearing rings must be
jack stands or solid blocks to support
checked during future scheduled
the lift truck. DO NOT rely on the jack
maintenance visits.
alone. See Jacking on page 2-8.
Drive Unit Removal 7. Jack and block the tractor so the drive tire
is off the floor.
the battery connector. 8. Drain the oil from the drive unit.
2. Remove the bumper gate. See 9. Unbolt the lift/lower manifold from the
Figure 7-100. drive unit casting.

Drive Unit Assembly
10. Remove the steering motor/gear reducer

assembly.
11. Remove the cap screws holding the drive
unit assembly to the tractor frame.
12. Lift the drive unit out of the tractor frame
using a suitable lifting device.
13. Clean the outside of the drive unit
thoroughly and drain any remaining oil
from the drive unit by removing the drain
plug.
14. Visually inspect the outside of the housing
for damage, wear, or cracks. 71018_002.tif
Figure 7-102. Remove Steel Ball Bearings

Pivot Ring Disassembly 3. After removing all the steel balls, remove
1. On the pivot ring, remove the grease fitting the pivot ring by working it off toward drive
and the bearing filler plug. Inspect the end of the housing. See Figure 7-103.
bearing filler plug hole for uneven wear.
See Figure 7-101.
Bearing Filler
Plug
71018_004.tif
Pivot Ring
Figure 7-103. Pivot Ring Removal
71018_003.tif
Figure 7-101. Grease Fitting and Filler Plug Removal 4. Remove the radial rings from the channel in
the housing and inside the pivot ring. See
2. Turn the pivot ring to remove the steel balls Figure 7-104.
through the bearing filler plug hole. See
Figure 7-102.
NOTE: If the pivot ring will not spin or even Radial Rings
turn, it is an indication of damaged
radial rings and/or excessive wear to the
channel in housing. If this is the case,
replace the entire drive unit. No further
disassembly is necessary.
71018_001.tif
Figure 7-104. Radial Ring Removal

Drive Unit Assembly
5. Remove the roll pins and grease fittings

from the pivot ring to enable thorough
cleaning.
Due to normal or excessive wear, the Safety glasses are required after this
edges of the radial rings could be very point in disassembly.
sharp.
6. Place the main cover assembly, gear side
6. Clean the grease from the radial ring down, on the tube under press. Press the
channel in the housing. Inspect the output shaft down slightly to create a
channel for uneven wear. Also clean and space between the bevel gear and the
inspect the inside of the pivot ring. output bearing spacer. See Figure 7-106.
Main Cover and Output Shaft

Disassembly Output Shaft
1. Visually inspect the housing around the
main cover for wear outside the cover
bolts.
NOTE: Excessive housing wear outside the
cover bolts can make them difficult to
remove. If this occurs, replace the entire Bevel Gear
drive unit. No further disassembly is
necessary.
71018_010.tif
2. Remove the main cover bolts. Figure 7-106. Press Down Output Shaft
3. Using a mallet, knock the flanged output
7. Tighten a bearing puller clamp under the
shaft to break the seal on the main cover.
lip of the output bearing spacer, being
4. Remove the main cover and output shaft careful not to catch the exterior retaining
assembly. See Figure 7-105. ring. See Figure 7-107.
Main Cover
71018_005.tif
71018_010.tif
Figure 7-105. Cover and Output Shaft Removal Figure 7-107. Bearing Puller Clamp Installation
5. A press and 8 x 6 in. tube are required to 8. Place the main cover assembly, gear side
remove the bearing cup on the end of the up, on a 12 x 6 in. tube so the bearing
output shaft. puller clamp is resting on the tube. Press

Drive Unit Assembly
out the flanged output shaft and the

output bearing spacer.
9. Remove the exterior retaining ring.
10. To remove the bevel gear, support the
main cover assembly on an 8 x 6 in. tube
under press. Press the output shaft down Output Bearing
through the bevel gear. The bearing cone is Cone
removed at the same time. See
Figure 7-108.
71018_009.tif
Figure 7-110. Output Shaft Bearing Cone Removal
Output Shaft 14. Remove the shims from the housing bore.
Save shims for reference only, as they are
usually damaged when removing the
bearing cone.
15. Remove the cover shims. Save the shims
for reference only.
71018_012.tif
Figure 7-108. Bevel Gear Removal Spiral Pinion Disassembly

NOTE: The spiral pinion and bevel gear are a
11. Remove the bearing cup from the main
cover with a race driver and pry bars.
Do not replace them separately.
12. Remove the lip seal from the main cover.
See Figure 7-109. 1. Loosen the set screw on the clamp nut on
the spiral pinion gear shaft. Using Tool
761-870/T03, remove the clamp nut. See
Figure 7-111.
Lip Seal
Clamp Nut
71018_003.tif
Figure 7-109. Bearing Cup and Lip Seal Removal
13. Remove the output shaft bearing cone in 71018_006.tif
the base of the housing using two pry Figure 7-111. Clamp Nut Removal
bars. Insert the pry bars under the bottom
edge of the cone on opposite sides. Apply 2. Using a brass punch and hammer, drive
even pressure on both tools to lift the cone the spiral pinion gear shaft out of the
out. See Figure 7-110. housing. See Figure 7-112.

Drive Unit Assembly
NOTE: You may need to remove the spiral Assembly Procedures

pinion with a press or pressing device
equivalent.
Prepare the housing for assembly by running a

tap through all bolt and screw holes. Cleaning
the threads also makes sure that there is no
damage.
Spiral Pinion Assembly

1. Using a press or mallet, install the bearing
cup into the housing bore. See
Figure 7-114.
71018_007.tif
Figure 7-112. Spiral Pinion Removal
3. Remove the helical gear and the bearing

cone from the housing.
4. Drive out the bearing cup. Inspect the
bearing cup and housing bores for wear.
See Figure 7-113.
NOTE: The bearing cups and cones are usually
damaged during removal. They must be
replaced as sets.
Bearing Cup
71018_014.tif
Figure 7-114. Bearing Cup Installation
2. Install the second bearing cup into the

Bearing Cup housing bore on the opposite side.

3. Press the bearing cone onto the spiral

71018_008.tif pinion gear shaft until it is seated. See
Figure 7-113. Bearing Cup Removal Figure 7-115.
Thoroughly wash the housing and visually

inspect the entire housing again for excessive
damage, wear, or cracks.

Drive Unit Assembly
Bearing Cone Output Bearing Cup
Spiral Pinion
71018_015.tif 71018_017.tif
Figure 7-115. Pressing Bearing onto Spiral Pinion Figure 7-117. Pressing Output Bearing Cup
Main Cover and Output Shaft 4. Push down on the bearing and turn to seat
the bearing into the cup.
Assembly
5. Using dial indicators, measure dimension
1. Before installing the output shaft lip seal, D from the edge of the bearing cone to the
apply a thin layer of sealing adhesive main cover flange surface. See
around the seal surface of the main Figure 7-118.
housing. Install the lip seal, spring side
down, in the housing. See Figure 7-116.
Lip Seal
71826_127.tif
Figure 7-118. Bearing Cone to Flange Measurement

71018_016.tif
Figure 7-116. Press Lip Seal 6. The reading on the two dial indicators
should be the same. If they are different,
2. Press the lip seal into the housing until it repeat steps 4 and 5 until the readings are
is just below flush with the housing identical. Record final reading as
surface. dimension D on the flange surface. This is
3. Press the output bearing cup into the required during final assembly.
main cover until it is seated. Place the 7. Remove the bearing cone in preparation
bearing cone into the bearing cup. See for installing the flanged output bearing
Figure 7-117. shaft.
8. Use a light oil on the surface of the lip seal
and inside the bearing cup.
9. Place the main cover down over the output
shaft, flange side up. Place the bearing

Drive Unit Assembly
cone down over the output shaft. See

Figure 7-119.
Bevel Gear
Bearing Cone
Bearing Cone
71018_022.tif
Output Shaft Figure 7-121. Pressing On Bevel Gear

71018_021.tif
12. Install the external retaining ring on the
Figure 7-119. Install Main Cover and Bearing Cone
output shaft. Pull up on the bevel gear to
10. Press the bearing cone onto the output make sure the external retaining ring is
shaft. See Figure 7-120. installed securely.
13. Place the output bearing spacer, with the
recessed area down, over the output shaft.
Place the bearing cone on top of the output
shaft. See Figure 7-122.
71018_020.tif
Figure 7-120. Pressing Bearing Cone

Output Bearing Spacer
11. Place the bevel gear down over the output
shaft, teeth side up. Press the bevel gear 71018_023.tif
down, seating the bearing cone into the Figure 7-122. Pressing Down Bearing Cone
bearing cup. See Figure 7-121.
14. Press the bearing cone down until it is
fully seated against the spacer and snap
ring.
15. Press the bearing cone into place. At the
same time, pull the gear sideways to
eliminate any backlash in the spline area.
See Figure 7-123.

Drive Unit Assembly
Bearing can become extremely hot. Use

gloves to protect hands from burns.
1. Preheat the bearing cone with a bearing

heater. Install the heated bearing cone in
the bearing cup in the housing.
NOTE: Steps 2 thru 4 need to be completed
before the bearing cools.
71018_024.tif
2. Place the helical gear into the housing.
Figure 7-123. Eliminate Backlash 3. Install the spiral pinion gear shaft up
through the helical gear.
16. Place a bearing cup onto the bearing and
4. Apply 3 verticle lines of thread-locking
rotate the cup while applying downward
compound (P/N 990-669) to the pinion
pressure to seat the bearing. See
shaft. Put the clamp nut on the end of the
Figure 7-123.
spiral pinion gear shaft and hand tighten
17. Using dial indicator(s), check that the until the bearing cools. See Figure 7-125.
bearing is correctly seated. The readings
on the two dial indicators should be the
same. If they are different, repeat steps 15
and 16 until the readings are identical. Clamp Nut
See Figure 7-124.
Helical Gear
71018_027.tif
Figure 7-125. Helical Gear and Pinion Installation
5. While the bearing cone is cooling,

calculate the formula for determining the
71826_130.tif required shim thickness.
Figure 7-124. Bearing Cup to Flange Measurement
Calculate Shim Formulas
18. Record final readings as Dimension E.
This is required during final assembly. • A = Dimension A stamped on housing
(2.102/2.108)
Helical Gear Assembly • B = Dimension B stamped on housing
(3.409/3.412)
NOTE: The pinion shaft and bevel gear are a
matched set. Their alignment is critical. • C = Number etched on back of gear
Do not replace them separately. (nominal 1.812)
• D = Distance from bearing to flange
surface (see Figure 7-126)

Drive Unit Assembly
• E = Distance from bearing cup to flange

surface (see Figure 7-127)
71018_028.tif
Figure 7-128. Removing End Play

71826_127.tif
2. Preload the helical gear for 0.000 to
Figure 7-126. Bearing Cone to Flange Measurement
0.002 in.
3. Remove any oil from the clamp nut. Apply
thread-locking compound (P/N 1013829)
to the bolt in the clamp nut. Tighten the
bolt to 128 in. lbs. (14.5 Nm). Make sure
the open end of the clamp nut do not
touch.
4. Spin the helical gear to make sure that the
bearings are not too tight.
5. One tooth on the spiral gear is etched or
marked with an X. With a marker, mark
that tooth surface for the purpose of lining
up the spiral and bevel gears to check
71826_130.tif
backlash. One tooth on the matching bevel
Figure 7-127. Bearing Cup to Flange Measurement gear is also marked. Mark that tooth
surface also. See Figure 7-129.
S1 = (B - A - E + D + C)
S1 = Shim amount behind bearing cup in main Spiral Gear

housing to position gear for correct backlash
(S1).
S2 = E + S1 - B - 0.006 preload
S2 = Shim amount between cover plate face to

set preload of bearings for output shaft (S2).
Installing and Testing Shims

1. Remove any end play in the bearings 71018_029.tif
between the helical gear and the spiral Figure 7-129. Marking Spiral and Bevel Gears
gear using lock nut wrench (P/N
761-870/T03). Wedge the helical gear and 6. Place the predetermined shims into the
tighten the clamp nut until there is no end housing bore for the bearing cup. Install
play between the gears. See Figure 7-128.

Drive Unit Assembly
the bearing cup into the housing bore over Measuring Backlash
the shims. See Figure 7-130.
7. Install the cover shims. See Figure 7-130.
Backlash tolerance is critical to the

performance of the drive unit.
Incorrectly adjusted units will
Bearing Cup Shims experience premature failure.
1. Wedge the helical gear, then slightly turn

the output shaft to determine backlash.
Backlash reading on the dial indicator
must be between 0.004 and 0.006 in. See
Figure 7-132.
Cover Shims
71018_030.tif
Figure 7-130. Cover Shims Installation
8. Place the main cover assembly over the

shims, making sure to line up the marked
teeth on both the spiral and bevel gears.
See Figure 7-131.
Spiral and
Bevel Gears
71826_131.tif
Figure 7-132. Measuring Backlash
2. Calculate any necessary adjustments to

the shims. Remove the main cover
assembly and the bearing cup, and adjust
the shims.
Repeat steps 6 thru 9 in “Installing and
Testing Shims” until backlash is between
71018_031.tif
0.004 and 0.006 in.
Figure 7-131. Lining Up Spiral and Bevel Gears
3. When backlash is within acceptable range,
9. Install four housing cover bolts, evenly remove the main cover assembly and the
spaced, and tighten to 40 ft. lbs. (54 Nm). cover shims.
Main Cover Installation

1. Clean the cover mating surface on the
housing, then apply thread-locking
compound (P/N 990-411) sparingly.
2. Install the cover shims and the main cover
assembly. Install the main cover bolts and
torque to 40 ft. lbs. (54 Nm).

Drive Unit Assembly
5. On the housing, install the radial rings. See

Figure 7-135.
Pivot Ring Assembly

Radial Rings
1. On the inside of the pivot ring, make sure
the roll pins are installed and in good
condition on either side of the bearing filler
plug hole. If they are missing or damaged,
install new roll pins. See Figure 7-133.
Pivot Ring
71018_037.tif
Figure 7-135. Outer Radial Ring Installation
Roll Pin 6. Lift the drive end of housing and slide the
pivot ring over the housing, being careful
not to jar the radial rings out of place.
Slide the pivot ring into place just behind
the steering ring gear.
7. Make sure that the pivot ring bearing filler
71018_035.tif plug hole is on top, in preparation for
Figure 7-133. Roll Pin Installation installing the steel balls.
8. Put one ball at a time into the pivot ring
2. Install the grease fitting on the outside of filler hole. Use a screwdriver to direct the
the pivot ring. steel balls first to one side then the other.
3. Screw in the grease fitting in the bearing Continue until all 70 balls are installed.
filler plug. See Figure 7-136.
4. Using radial rings, install the flat radial
\
ring on the inside flat surface of the pivot

ring. Place the ends of the chamfered
radial rings against the roll pins to install
them in the pivot ring. See Figure 7-134.
71018_038.tif
Figure 7-136. Install Ball Bearings
Radial Rings
71018_036.tif
Figure 7-134. Radial Ring Installation

Drive Unit Assembly
9. Fit the bearing filler plug with the grease

fitting pointing toward the steering ring
gear. See Figure 7-137.
71018_040.tif
Figure 7-137. Bearing Filler Plug Installation
10. Install the bolts and washers on either side

of the bearing filler plug and tighten to
17 ft. lbs. (23 Nm).
11. Grease and then test the pivot ring,
checking to see that it spins freely.

Drive Unit Assembly
Brake
The brake assembly is mounted on top of the Use extreme care whenever the lift truck
traction motor. The brake is spring applied and is jacked up for any reason. Never block
electrically released. The brake can be manually the lift truck between the telescopic and
released by installing the brake release bolts. the floor. Use a suitable hoist to stabilize
See Figure 7-138. the mast. Keep hands and feet clear
from beneath the vehicle while jacking.
Use jack stands or solid blocks to
support lift truck. DO NOT rely on the
When brake release bolts are used, jack alone. See Jacking on page 2-8.
make sure they are removed before the
lift truck is returned to service. If the 1. Jack and block the tractor so the drive tire
bolts are not removed, the brake will is off the floor.
not work correctly. 2. With the brake de-energized (fully applied),
use a feeler gauge to measure the total
Brake Adjustment gap. See Figure 7-138.
3. Take measurements at three
Perform the brake gap inspections on a regular equally-spaced locations around the
schedule. armature disk. The total gap must be
0.010 to 0.015 in. (0.25 to 0.38 mm). The
gap must be uniform all the way around
the armature disk. Brake wear is indicated
if the total gap is greater than 0.015 in.
(0.38 mm).
NOTE: Different thickness shims and spacers
are available to maintain correct brake
gap.
4. Add/remove shims as necessary to achieve
the correct gap.
Assy
Compression Spring (Qty. 8) Brake Release Bolt
Screw (Qty. 3) (Qty. 2)
normally stowed on frame
Shims (can be
located above or
below the spacer)
Brake Coil Assy
Armature Total Gap
Disk
Spacer
(Qty. 3)
Brake Rotor Mounting Brake Assy Mtg

(wearable mat’l) Plate Bolt (Qty. 3)
7
Figure 7-138. Brake Assembly Components

Drive Unit Assembly
Brake Rotor Replacement Assembly/Installation

1. Slide the new rotor into the assembly. The
Replace the rotor if worn to a thickness of rotor is positioned between the armature
0.236 in. (6 mm) or less. disk and the brake mounting plate. See
Figures 7-139 and 7-140.
Removal/Disassembly 2. Install the one assembly screw removed to
1. Turn the key switch OFF and disconnect replace the rotor. Make sure to install any
the battery connector. spacers removed. Torque the three M6
2. Remove the covers from the tractor. screws that secure the coil to the assembly
to 9 ft. lb. (12 Nm) with the threads
3. Disconnect the electrical cable to the lubricated.
brake assembly.
3. Carefully center the rotor within the
4. Remove the three screws that secure the assembly and remove the brake release
brake to the drive unit. bolts.
5. Remove the cable support.
4. Measure the total gap as shown below. The
6. Lift the brake unit up and off the drive total gap must be between 0.010 in.
unit. Take the assembly to a workbench. (0.25 mm) and 0.015 in. (0.38 mm). If the
You will need the brake release screws gap is not within tolerance, add or remove
located on the tractor. shims and/or spacers as necessary.
7. Insert the brake release screws into the Different thickness shims and spacers are
brake assembly. Tighten the two brake available.
release screws to release the brake
completely.
8. Remove one of the three screws that hold If the total gap exceeds 0.015 in.
the brake assembly together. Use care not (0.38 mm), brake release problems will
to lose any shims that may be used. result particularly when the brake is hot
9. Slide the rotor out of the assembly. and/or the battery is low.
Shims (can be located above Brake Release Bolt (Qty. 2)

or below the spacer) normally stowed on tractor frame
Total Gap
Spacers Armature Disk Mounting Plate Brake Rotor

7
Figure 7-139. Installing Brake Rotor

Drive Unit Assembly
Brake Coil Assy Rotor Hub Nut

(Normal coil resistance at room torque to 75 ft. lb. (105 Nm)
temp is approx 13.5 ohms)

Rotor Hub
(part of brake assy)
Assy Screw
torque to 9 ft. lb. (12.6 Nm) Brake Release Screws
(normally stowed on tractor frame)
Mounting Screw
torque to 12 ft. lb.
(16.8 Nm)
Traction Motor
7
Figure 7-140. Brake Assembly - Section View
5. After the correct gap is achieved, torque 9. Secure the brake assembly to the traction
the assembly screws as specified in step 2. motor. Apply thread-locking compound
6. Inspect the splines on the rotor hub (on (P/N 990-462). Torque the three mounting
the traction motor). If the splines on the screws to 12 ft. lb. (16.8 Nm).
rotor hub have excessive wear, replace the 10. Connect the brake to the lift truck
hub before proceeding. Using a rotor hub electrical circuit.
with worn splines may cause rotor damage 11. If the rotor hub nut was removed, apply
when the lift truck is driven. thread-locking compound (P/N 990-462)
7. Carefully install the brake assembly on the to the threads on the rotor hub nut. Install
traction motor. It is critical that the splines the rotor hub nut on the rotor hub. Torque
on the rotor are not damaged during to 25 ft. lb. (35 Nm).
assembly.
Damaging the splines on the brake rotor

may cause brake failure.
8. Install the cable clamp that holds the

power cables on the traction motor.

Drive Unit Assembly
Make sure the brake release bolts are

removed before placing the lift truck
back into service. If the brake release
bolts are not removed, the brake will
not work correctly.

the key switch ON.
If the brake does not work while

performing the next step, the lift truck
will not stop but will coast for
approximately 30 ft. (9 m).
13. Test the brake. In an open area allowing

for travel over a long distance, perform the
following:
a. Drive the lift truck approximately 2-3
mph (3.2-4.8 km/h).
b. Push the EPO switch. The lift truck
should stop within approximately 2 to 4
ft. (0.6 to 1.2 m).
Stepping off the deadman pedal does

not test the brake.
NOTE: During acceleration a slight rattle from

the brake rotor is considered normal
and does not affect brake durability or
function.
14. Install covers.

Drive Unit Assembly
Drive Wheel Drive Tire Replacement
Removal
Any misalignment of the tire and hub
1. Turn the steering wheel all the way to the while the tire is being pressed onto the
right so you can access the drive wheel hub can damage the hub. For this
mounting bolts. reason, chamfers are provided on the
2. Turn the key switch OFF and disconnect outside edge of the hub and on the end
the battery connector. of the inside diameter of the tire’s metal
insert. The chamfers help to center the
hub and tire during the pressing
operations and reduce the possibility of
misalignment. To prevent damage, the
hub must be installed on the circular
is jacked up. Never block the lift truck
ram with its chamfered side up.
between the mast and the floor. Keep
hands and feet clear from vehicle while the gggggggggggg
jacking the lift truck. After the lift truck

is jacked, place solid blocks beneath it Outside of Hub
to support it. DO NOT rely on the jack and Tire Assembly
alone to support the lift truck. For
details, see Jacking on page 2-8.
New Tire
3. Jack and block lift truck under the tractor
frame.
4. Remove the bumper plate. Worn Tire
5. Remove the drive wheel mounting bolts.
6. Remove the drive wheel.
Circular Ram
Installation
1. Install the drive wheel on the drive wheel
shaft. Press Table
7
2. Install the drive wheel mounting bolts. Figure 7-141. Drive Tire Installation
Torque to 170 ft. lbs. (230 Nm).
3. Install the bumper plate. 1. Check the inside surface of the metal
insert on new tire. Use sandpaper to
4. Remove the block and lower the tractor remove any scaling or rust. Clean the
with a jack. inside of the metal insert and lubricate it
5. Reconnect the battery connector and turn with a soap solution.
the key switch ON. Test the lift truck 2. Place a circular ram on the press table.
operation before returning to service. See Figure 7-141. The length of the ram
must be longer than the width of the old
tire to allow complete removal of old tire.
The outside diameter of the ram must be
small enough to fit loosely in the insert of
tire but must be large enough to rest
squarely on the flat surface on the outer
edge of the hub.

Drive Unit Assembly
3. If the outside edge of the hub is not flush

with theeedge of the metal insert in the old
tire, measure how far the hub is recessed
inside the tire. The new tire must be
placed in the same position the old tire
was installed on the hub. You can use a
spacer (slightly smaller in diameter than
the inside diameter of tire insert and the
same thickness as the depth of the recess)
to obtain the correct amount of recession.
4. Position the hub assembly with the old tire
on top of the circular ram so the outside of
the wheel is positioned upward. The
outside edge of the 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
the hub.
5. Center the hub assembly on top of the ram
and make sure that they mate squarely.
6. Position the new tire with its chamfered
insert facing the hub. Align the new tire
and hub so that they are concentric.
7. Begin pressing the new tire onto the hub
and the old tire off the wheel. Run the
press slowly for the first few inches of
travel, because this is the critical stage of
the operation. If the tire begins to cock to
one side, stop the press and realign the
tire. A sharp jar with soft-headed mallet
usually realigns the tire on the hub.
NOTE: If the new tire does not press on with a
minimum of 5 tons (68,947 kPa)
pressure, replace the hub.
8. Release the press. Remove the wheel, tire
assembly, and old tire from the press
table. Inspect the wheel and tire assembly.

Drive Unit Assembly

Electrical Components

Battery Procedures
Battery Procedures touching and causing a short circuit.

Do not allow the metal cable end to
touch the battery. Use insulated tools
and avoid contact with battery case or
cable ends.
Before working on the battery, review
1. To remove a cable from the connector,
“Battery Safety”, beginning on
push the retainer down while pulling the
page 2-5. Batteries for this lift truck
battery cable towards the rear and out of
weigh between 1980 and 3250 lb. (898
the connector. See Figure 7-142 and
to 1475 kg). Use extreme care during
Figure 7-143.
replacement. Use a suitable battery
moving device or hoist for lifting. Do not
extend a battery more than 1/3 of its
length outside the battery compartment
without being attached to a
battery-moving device.
Battery Connector/Cables
Inspection
2. Check the battery connector for damaged
cables.
3. Check to see if the battery cables are
pulling out of the connector.
Figure 7-142. Battery Cable and Connector
4. Check the cables at the battery terminals.
Connections should be tight, with no
corrosion.
5. Look inside the connector. Check all
internal contacts for damage, dirt, or
corrosion. Do not use a metal object to
clean the connector.
NOTE: Some degreasers and parts cleaners
cause the connector shell to
disintegrate. Avoid contacting battery
connectors with solvents.
Removal, Replacement, and

Installation
The cables to either half of the connector have a

lip on their forward end. This lip snaps over a
spring-loaded retainer that is part of the Figure 7-143. Battery Cable Removal from Connector
connector.
NOTE: When replacing battery cable ends, 2. Do not attempt to repair battery cables by
remove only one end at a time from the crimping new terminals. Replace the
connector, to avoid the cable ends cable.

Battery Connector/Cables
Battery Exterior Cleaning 6. Wash dirty batteries (or any that have had
electrolyte spilled on them) with a solution
1. Read, understand, and follow procedures, of 1 lb. (0.45 kg) of baking soda added to
recommendations and specifications in the 0.5 gal. (1.9 liters) of hot water.
battery and battery charger
manufacturer’s manuals. 7. Use a brush with flexible bristles to clean
the entire top of the battery with the soda
solution. Wait until all foaming stops,
indicating that the battery exterior is
neutralized.
8. Rinse the battery with clean water.
9. Dry the battery completely before
reinstalling it.
10. Reinstall the battery in the lift truck, using
a suitable battery moving device.
2. Wear personal protective equipment. See Reconnect the battery connector.
“Battery Safety” on page 2-5.
3. Turn the key switch OFF and disconnect Testing, Charging, and Maintenance
the battery connector. Remove the battery
from the lift truck. For information on testing, charging, and
maintaining your lift truck battery, consult the
4. Inspect the battery cables to make sure battery manufacturer’s specifications and
they are not frayed or loose. Inspect the instruction manual.
battery connector to make sure there is no
foreign material inside the connector. NOTE: Never plug the battery charger into the
Make sure the filler plugs are tight and the lift truck. This severely damages the lift
vent holes in the filler plugs are open. truck’s electrical system. Plug the
charger only into the connector from the
battery.
Battery Cable
Filler Plug
Vent Hole
Battery State-of-Charge
Figure 7-144. Battery Cable and Filler Plug
Battery State-of-Charge (BSOC) is a feature that
5. Keep the top of the battery clean and dry. monitors and remembers the charge level of the
Corrosion, dust, and moisture provide a battery connected to the lift truck and prevents
conducting path to short-circuit cells or excessive discharging of that battery. Operating
create shorts to ground. a lift truck using a discharged battery can
NOTE: Do not clean the top of the battery with damage both the battery and the electrical
the soda solution while it is installed in components of the lift truck. See page 5-4 for a
the lift truck. Water can seep into the detailed description of how BSOC works and
electrical components and cause serious the procedure for setting BSOC Cutout.
damage.

Power Cables
Power Cables Table 7-4. Cable Jacket Strip Length - Short Barrels
AWG Lug P/N Strip Length
Check power cables for: 1/0 1002215/001-004 11/16 in. (17 mm)
• evidence of overheating 2/0 1002215/005-008 13/16 in. (21 mm)
• burned spots in the cable
3/0 1002215/009-012 1 in. (25 mm)
• nicks in the insulation
4/0 1002215/013-015 1-1/16 in. (27 mm)
• damaged or overheated terminal lugs
• damaged mounting hardware or brackets Table 7-5. Cable Jacket Strip Length - Long Barrels
Replace damaged cables or mounting hardware AWG Lug P/N Strip Length
as necessary. 1/0 1002217/001-003
Power cables are marked on the terminal lug 2/0 1002217/004-006 1-9/16 in. (40 mm)
with the location where they belong. If the
3/0 1002217/007-009
marking is missing or is not readable, remark
the cable with the correct information. 4/0 1002217/010-011 1-11/16 in. (43 mm)
NOTE: Terminal lugs may be replaced in the
field using the appropriate crimping 5. Insert the cable into the terminal.
tools. Crimping tool, lugs, and 6. Place the cable and terminal into the tool
heat-shrink are available through the die and crimp. Refer to Figures 7-145 and
Parts Distribution Center. Failure to use 7-146.
correct cables, terminal hardware, and
torque values can result in overheating
and damage to components.
Power Cable Repair

Traditional lug crimping techniques for power
cables on DC motors may not meet the higher
current requirements of AC motors. Use
Manual Crimp Tool (P/N 1069861) when
crimping power cables for all AC motors. This
tool may also be used to repair power cables for
DC motors.
1. Remove the bad cable(s).
2. Using the removed cable(s) for reference,
cut an appropriate amount of replacement
cable of the same gauge.
Figure 7-145. Short Barrel Terminal
3. Set the adjustment screw on the manual
crimp tool head to match the cable gauge.
4. Strip the cable jacket to fit the terminal to
be crimped. Refer to Table 7-4 and
Table 7-5.

Power Cable Repair
Figure 7-146. Long Barrel Terminals
7. Apply heat-shrink tubing (P/N 611-035) to

the terminal after crimping.
a. For short barrels, use 1.75 in. (45 mm)
of tubing. Apply 1 in. (25 mm) over the
jacket extending 0.75 in. (19 mm) over
the barrel.
b. For long barrels, use 2.5 in. (64 mm) of
tubing. Apply 1 in. (25 mm) over the
jacket extending 1.5 in. (38 mm) over
the barrel.

General
Motors DC Motor Service

Motor Brushes
General
Inspection
Power Cable Terminals
Table 7-6. Power Cable Terminal Torques
Location/Stud
Torque
Size/Type
Traction Motors Top Nut: 12.5 to 18.4 ft. lb.

(23 to 25 Nm)
Lift Motor - AC Bottom Nut: 10.7 to 11 ft. lb.
(14.5 to 15 Nm)
Top Nut: 7.5 to 9.2 ft. lb.

(10.2 to 12.4 Nm)
Lift Motor - DC
Bottom Nut: 9.2 to 11.6 ft. lb.
(12.4 to 15.8 Nm)
Top Nut: 7.5 to 9.2 ft. lb.

(10.2 to 12.5 Nm)
Steer Motor
Bottom Nut: 9.2 to 11.7 ft. lb.
(12.5 to 15.9 Nm)
95 to 105 in. lb. Figure 7-147. Motor Brush Location

Power Amplifiers
(10.7 to 11.8 Nm)
Conduct a partial inspection of the motor
Contactor - M6 during scheduled maintenance. If the lift truck
50 in. lb. (5.6 Nm)
steel is operated in a severe or caustic environment
Contactor - M8 or is used in an extended duty cycle
180 in. lb. (20.3 Nm) application, inspect the motor more frequently.
steel
Contactor - M8 Set up and rigidly adhere to a strict inspection

70 in. lb. (7.8 Nm)
brass/copper schedule to obtain the maximum efficiency
from the electrical equipment.
DC Motor Troubleshooting Each partial inspection of the motor must

include:
See “DC Motor Troubleshooting” on page 5-7.
1. Inspect the brushes for wear and for
correct contact with the commutator.
AC Motor Troubleshooting Record the level of wear on the brushes.
This history provides an indication of
See “AC Motor Troubleshooting” on page 5-11. whether a brush must be changed or if it
can wait until the next inspection. Refer to
Table 7-7, “Minimum Brush Length and
Spring Tension,” on page 7-76 for
acceptable brush length.
NOTE: Overloading a unit is ultimately reflected
in the motor and brush wear; therefore,
you must take this into account when
considering brush replacement.

DC Motor Service
2. Check brush spring tension. Refer to 4. Remove the sandpaper.

“Motor Brush Spring Tension”. 5. Blow any dust out of the motor with clean,
3. Clean brushes and holders. Wipe the compressed air at a maximum of 30 psi
commutator with a dry, lint-free cloth. Do (207 kPa).
not use lubricants of any kind on or
around the commutator. Motor Brush Spring Tension
4. Check brush holders for a solid connection
to the mounting support. Tighten the Inspection
mounting screws as necessary. 1. Turn the key switch OFF and disconnect
5. Check the cap screws that hold the brush the battery connector.
cross-connectors to the brush holder 2. Remove the tractor covers.
body.
3. Slide the brush up slightly in its holder.
6. Make sure the motor terminals are
secured tightly to the motor frame. Use 4. Insert a paper strip between the brush
care not to strip the threads or crush the face and the commutator. See
insulating parts. See “Power Cable Figure 7-148.
Terminals” on page 7-74.
7. Check all the cap screws around the frame Spring
Scale
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.
Replacement
NOTE: If one brush needs replacement, always
replace the entire set of brushes. Leather
Loop
Use only genuine Raymond brushes. Using

another type of brush could cause damage to
the commutator or cause excessive brush wear
and voids your warranty.
Paper
If the end of the brush is not already contoured
to fit the commutator, seat the brush to the
commutator:
NOTE: If the motor commutator is not
accessible, form the brush contour
Rotation
using a brush seating stone.
Pull paper in direction of rotation
1. Move the motor brush springs out of your
way. Figure 7-148. Motor Brush Spring Tension Inspection
2. Wrap a piece of 00 sandpaper around the
commutator. Do not use emery cloth to 5. Place a small leather loop around the coil
seat brushes. spring for the brush. If the brush spring
has a loop at the brush, hook the spring
3. Move the brushes back down into their scale directly to the spring.
holders. Rotate the armature until the face
of the brushes are contoured to match the 6. Attach a 5 lb. (2.27 kilogram) spring scale
curve of the commutator. to the leather loop.

Polishing the Commutator
7. While gently pulling the scale outward,

slowly pull the paper strip in the direction
that the commutator normally rotates.
8. When the paper strip begins to move
freely, the spring scale will read the brush
spring tension.
9. Refer to Table 7-7 for correct spring
tension.
10. Repeat steps 3 thru 9 for the remaining
brushes.
Table 7-7. Minimum Brush Length and Spring Tension
Brush Length Brush Spring Tention
Motor Minimum Maximum New Worn
in. mm in. mm oz. gr oz. gr
Lift 0.62 16 1.3 35 65 1820 40 1120
Steer 0.50 12.7 N/A
Polishing the Commutator 4. Using minimal pressure, run the stone

back and forth across the commutator
NOTE: Wrap the stone with narrow (1/2 to 3/4 until it is polished. Do not pass the stone
inch wide) masking tape in a spiral over the ends of the commutator
configuration. Leave only enough stone segments.
exposed to make contact with the
5. Thoroughly blow out the motor with
commutator. As the length of the stone
compressed air.
becomes shorter with use, peel back and
remove portions of the tape. 6. Inspect the commutator. Reinstall the
armature or brush and any removed
covers.
7. Check operation.
Make sure loose clothing and hair are
tied back. Do not wear jewelry. Wear
insulated gloves to protect your hands
during this procedure.
1. If the motor has four or more brushes,

remove an accessible brush from the
motor with the motor still installed in the
truck. If the motor only has 2 brushes or
the commutator is not accessible with the
stone, the armature must be installed in a
lathe or replaced. If so, go to step 4.
2. Activate the motor.
3. With the motor turning, carefully insert
the commutator stone into the brush box
area.

AC Motor Service 8. Install the top end bell in the position that
was previously marked. Verify correct
stator installation and install the snap
AC Motor Temperature Sensor ring.
9. Secure the top end bell to the bottom end
Temperature sensors in the AC traction and lift bell using the four bolts previously
motors are integral to the motor. When a motor removed.
temperature sensor fails, it can be replaced 10. Install the brake mounting motor flange
using the procedures below. with new mounting bolts.
11. Re-install the brake assembly including
Traction Motor Replacement: the rotor hub mount and rotor hub.
1. Turn the key switch OFF and disconnect 12. Check the brake adjustment. See “Brake
the battery connector. Adjustment” on page 7-62.
2. Remove the brake assembly including the 13. Install the terminal board, reconnect
rotor hub nut and rotor hub. Note the JPTA3, and power cables. Torque the
number of spacers used. motor cable securing nuts to 18 ft. lb. (24
• Disconnect the temperature sensor Nm).
connector JPTA3. 14. Reconnect the battery connector and turn
• Disconnect the power cables making the key switch ON.
sure that you note locations for
reassembly later. Lift Motor Replacement:
• Remove the terminal board. 1. Turn the key switch OFF and disconnect
Use correct electrostatic discharge

precautions. See “Static Precautions” on Use correct electrostatic discharge
page 2-7. precautions. See “Static Precautions” on
page 2-7.
3. Mark the position of the top end bell and
bottom end bell relative to the stator, then 2. Disconnect the temperature sensor
remove the snap ring. connector JPLA3.
4. Remove the brake mounting motor flange. 3. Disconnect the cables and motor harness
(Note: Use new flange mounting bolts connections, making sure that you note
when reassembling.) locations for reassembly later.
5. Remove the four bolts that secure the top 4. Separate the pump assembly from the lift
end bell to the bottom end bell. pump motor and remove the lift pump
6. Remove the top end bell using a puller. motor. See “Lift Pump and Motor” on
Use care that the encoder bearing remains page 7-100.
in the bottom end bell to reduce the 5. Remove the four bolts that secure the top
chance of damaging the bearing. end bell to the bottom end bell.
7. Install a new temperature sensor using 6. Remove the top end bell. Use care that the
high temperature silicone (neutral curing). bearing remains in the bottom end bell to
Mount the sensor close to the location of reduce the chance of damaging the
the original. Secure the cable with a cable bearing.
tie to one of the power leads for stress
relief. 7. Install a new temperature sensor using the
high temperature silicone (neutral curing)
supplied with the temperature sensor.

Mount the sensor close to the location of 6. Mark the position of the top end bell and
the original. Secure the cable with a cable bottom end bell relative to the stator, then
tie to one of the power leads for stress remove the snap ring.
relief. 7. Remove the brake mounting motor flange.
8. Carefully press the top end bell to the (Note: Use new flange mounting bolts
stator. Do not pinch the cables or allow when reassembling.)
contact with the rotor. Verify correct stator 8. Remove the four bolts that secure the top
installation. end bell to the bottom end bell.
9. Secure the top end bell to the bottom end 9. Remove the top end bell and bottom end
bell using the four bolts previously bell using a puller.
removed.
10. Remove the clamps that secure the
10. Reinstall the lift motor to the lift pump encoder bearing cable.
assembly.
11. Remove the encoder bearing from the rotor
11. Reconnect JPLA3, and power cables. using a suitable puller, pulling on the
12. Reconnect the battery connector and turn outer race only.
the key switch ON. 12. Remove the oil seal to allow pressing of the
bottom end bell to the stator for later
AC Motor Bearing Encoder reassembly.
13. Make sure that the O-ring and wave
Traction Motor Replacement: washer are correctly positioned in the
bottom bell bearing pocket.
14. Position the new encoder bearing in the
bottom end bell with the cable oriented in
2. Remove the brake assembly including the the middle of the notch in the side of the
rotor hub nut and rotor hub. Note the bearing pocket.
number of spacers used.
15. Use an assembly bushing on the outer
• Disconnect the temperature sensor race and press the bearing into place. Do
connector JPTA3. not press on the encoder part of the
• Disconnect the bearing encoder bearing.
connector JPTA2. 16. Re-install the encoder bearing cable
• Disconnect the power cables making clamps.
sure that you note locations for 17. Install the top end bell in the position that
reassembly later. was previously marked. Verify correct
• Remove the terminal board. stator installation and install the snap
ring.
18. Carefully press the bottom end bell to the
stator.
precautions. See “Static Precautions” on 19. Secure the top end bell to the bottom end
page 2-7. bell using the four bolts previously
removed. Re-install the oil seal.
3. Remove the steering position reference 20. Install the key, pinion gear, and nut to the
bracket. bottom of the traction motor. Re-install the
4. Remove the traction motor. See “Traction traction motor. See “Traction Motor” on
Motor” on page 7-30. page 7-30.
5. Remove the nut that secures the pinion 21. Install the brake mounting motor flange
gear. Remove the gear and key using a with new mounting bolts.
suitable puller.

22. Re-install the brake assembly including 10. Secure the top end bell to the bottom end
the rotor hub mount and rotor hub. bell using the four bolts previously
23. Check the brake adjustment. See “Brake removed.
Adjustment” on page 7-62. 11. Install the lift motor and reconnect the lift
24. Install the terminal board, reconnect pump assembly. See “Lift Pump and
JPTA2, JPTA3, and power cables. Torque Motor” on page 7-100.
the motor cable securing nuts to 18 ft. lb. 12. Reconnect JPLA2, JPLA3, and the power
(24 Nm). cables.
25. Re-install the steering position reference 13. Reconnect the battery connector and turn
bracket and filler tube if previously the key switch ON.
removed.
the key switch ON.
Lift Motor Replacement:


precautions. See “Static Precautions” on
page 2-7.
2. Disconnect the bearing encoder sensor

connector JPLA2.
3. Disconnect connectors JPLA2, JPLA3,
cables, and motor harness connections,
making sure that you note locations for
reassembly later.
4. Separate the pump assembly from the lift
pump motor and remove the lift pump
motor. See “Lift Pump and Motor” on
page 7-100.
5. Remove the four bolts that secure the top
end bell to the bottom end bell.
6. Remove the top end bell using a suitable
puller.
7. Remove the encoder bearing from the
rotor, pulling on the outer race only.
8. Install the new encoder bearing by
applying steady pressure to the inner ring.
9. Carefully press the top end bell to the
stator. Do not pinch the cables or allow
contact with the rotor. Verify correct stator
installation.

Removal
Power Amplifiers 2. Position the power amplifier and install the

four mounting screws.
NOTE: If the power amplifier being removed is 3. Tighten the mounting screws to 7.4 ft. lb.
to be returned to stock, a power (10 Nm).
amplifier reset must be performed. See
page 3-26.
Do not attempt to repair power cable
Removal terminal lugs without approved tools. If
a power cable has worn or damaged
lugs, either replace the cable or replace
the lugs. Refer to “Power Cable Repair”
on page 7-72. Failure to use correct
Before removing a power amplifier, cables, flanged nuts, and torque values
discharge the amplifier’s internal can result in overheating and damage to
capacitor by jumpering the + and – components.
terminals with a 100 ohm 25W resistor.
4. Reconnect the power cables to the correct
1. Turn the key switch OFF and disconnect terminals. Torque to 85 to 94 in. lb. (9.6 to
the battery connector. 10.6 Nm).
2. Disconnect JT1 from the power amplifier.
NOTE: When correctly torqued, the cable and
3. Disconnect the power cables from the terminal can rotate up to 5° in either
power amplifier. direction.
4. Remove the four mounting screws. 5. Reconnect JT1.
5. Lift the power amplifier off the mounting 6. Reconnect the battery connector and turn
plate. the key switch ON.
75077_037.TIF
Figure 7-149. Traction Power Amplifier
Installation
1. Install new thermal conductive material
(provided with new power amplifier)
between the base of the power amplifier
and the heatsink.

Horn Removal
Horn
NOTE: For replacement parts information refer
to the Parts Manual.
Horn Removal
2. Remove the tractor cover.
3. Disconnect the wires from the horn.
4. Remove the horn mounting bolt.
Horn Installation
1. Attach the horn to the floor of the tractor
frame and tighten the mounting bolt. See
“Horn” on page 7-8 for location. Make sure
the horn bracket is isolated from the lift
truck frame.
2. When replacing an old style three prong
horn with a new style two prong horn
install 0.5 in. (12.7 mm) heat shrink
tubing over the unused spade connector.
3. Connect Horn (+) and Horn (-) wires to the
new horn.
4. Fasten the unused wire back to the
harness using a cable-tie or equivalent.
the key switch ON.
6. Test the horn operation.
7. Install the tractor cover before returning
the lift truck to service.

Horn Installation
Carriage Control Card 1. Correctly position the E3 jumpers, E3

jumper should be in the A (IN) position, E4
Replacement jumper should be in the B position.
2. On lift trucks without the 60 in. limit
switch option, a jumper/resistor assembly
must be installed at JPC3. Remove the
assembly from the original CCC and
Observe proper ESD precautions. See install it on the new one.
Static Precautions on page 2-7. 3. Remove the EPROM from the original CCC
and install it in the new card or install a
The CCC has lift truck specific information new EPROM. See “EPROM/Microprocessor
programmed in the microprocessor. See Removal/Replacement” on page 7-83.
Figure 7-150. This information includes Model
Number, Serial Number (S/N), Date of 4. Enter Configure Mode and verify the lift
Manufacture, Hour Meters, and a list of enabled truck S/N stored in the CCC matches the
Options. A backup copy of this information is S/N on the lift truck Specification Tag. If
also stored in the VM. not, a new pre-programmed CCC must be
obtained and installed prior to operating
the lift truck.
Microprocessor
5. Reset all of the information in the
Configure Menu to the customer’s
EPROM specifications.
6. Run the complete Learn process.
7vvv
Figure 7-150. Carriage Control Card Chip Locations
If a blank CCC is installed, the information

from the VM is uploaded into the CCC. A
Pre-programmed CCC must be ordered and
installed any time the Error Code corrective
actions tells you to or if the CCC and VM are
being replaced at the same time. Another way to
retain the correct programming for the specific
lift truck is to remove the microprocessor from
the CCC being replaced and install it in the new
CCC. See “EPROM/Microprocessor
Removal/Replacement” on page 7-83. This can
be done only if the error code being corrected
does not instruct you to install a
pre-programmed CCC. Some error codes
indicate the possible corruption of the data
stored in the microprocessor.

Horn Installation
EPROM/Microprocessor Installation
Removal/Replacement 1. Inspect the chip. Make sure there are no
bent, broken or missing pins or other
signs of physical damage. See
Removal Figure 7-152.
2. Make sure there is no corrosion on the
firmware chip or socket. If present, remove
and insert the chip (M11) several times
using the “Removal” procedure.
Observe proper ESD precautions. See Good Bad

Static Precautions on page 2-7.
Failure to use approved EPROM

Extraction Tool (P/N 950-032) may
result in damage to the chip or socket.
2. Look at the circuit chip’s socket on the

circuit board. Of the four slots in the Damaged Pins
corners of the socket, two diagonally 71896_015.TIF
opposite slots open into the chip cavity. Figure 7-152. Chip Inspection
These holes receive the prongs of the
removal tool. 3. Notice the beveled corner and the arrow in
3. Insert the prongs of the extraction tool into the socket. Notice the beveled corner and
the holes identified in step 2. Hold the tool the dot on the beveled edge of the chip.
straight up. See Figure 7-151. 4. Apply a thin bead of Nyogel (P/N
4. Gently but firmly squeeze the jaws of the 1180917/001) on the electrical contact
tool together. The prongs will retract, surfaces of the sockets.
lifting and loosening the chip from its 5. Position the chip so the dot is aligned with
socket. Do not rock or pull on the chip to the arrow on the socket and the beveled
release it. corner is aligned with the beveled corner of
the socket.
6. Gently press the chip into the socket with
your thumb. Make sure it is completely
seated on all four edges. See Figures 7-153
and 7-154.
Beveled
Corner
71896_011.TIF
Figure 7-151. Chip Removal

Horn Installation
Not Fully Seated
71896_013.TIF
Figure 7-153. Chip Incorrectly Seated In Socket
Fully Seated
71896_014.tif
Figure 7-154. Chip Fully Seated In Socket

Wiring and Harness Repair
Wiring and Harness When replacing wires, follow these guidelines:

• Use the appropriate tools to remove and
Repair insert terminations at each connector.
• Remove damaged terminations and
discard. Never reuse a termination from a
General Connector Repair wire.
Procedures
• Do not cut away a terminal lug and reuse
the wire strands that were crimped into
Inspection the original lug.
Whenever working on the lift truck, use care • When stripping wire, use new wire strands
around wiring harnesses. for new terminations. Make sure to use a
new wire with extra length to allow for
• Carefully connect and disconnect all cutting and stripping of the ends to install
connections. new terminations.
• Do not pry connectors apart with • Use a new wire that is the same gauge
unspecified tools. (typically gauge 18 AWG), size, type, and
color as the wire it is replacing.
There should be a wire marker at each
termination. If the marker is missing or • Use a hand stripper capable of stripping
unreadable, remark the wire to allow easier by wire gauge number. Use care not to
identification. nick or cut any of the wire strands.
Discard and replace a wire with damaged
NOTE: It is normal to find unused connectors strands. Insert the wire strands the
for uninstalled options that have had correct length into termination before
heat shrink applied over them and have crimping.
been strapped to the harness.
Soldering Procedures
Repair
To prevent damage from excessive heat when
soldering small components in assemblies,
follow these guidelines:
• Make sure the soldering tip is clean. A
precautions. See “Static Precautions” on
dirty tip does not transfer heat well and
page 2-7.
encourages long dwell time and greater
pressure. Apply light pressure on the
When pulling a wire out through a bundle, cut
terminal.
off the pin or socket so it does not snag. When
replacing wires, in some cases you can tape or • Flux: rosin base
solder one end of a new wire to one end of the • Solder: 60/40 rosin core or equivalent
failed wire. Then you can pull the old wire out of
• Solder Iron: 15-25 watt “pencil-type”
the bundle and pull the new wire into the
maximum
bundle, all at the same time. Make sure to
disconnect the old wire from the new wire. • Tip Size: 3 mm (0.118 in.) diameter x
30 mm (1.182 in.) long screwdriver tip.
In other cases, it is easier to secure a new wire Make sure the tip is clean.
to the outside of the existing wire bundle with • After soldering, clean the terminals with a
cable ties of an appropriate size. The failed wire brush dampened with an alcohol based
can be left in the bundle, or can be pulled by cleaner. Do not allow any cleaner to seep
one end to remove it from the bundle. into the switches or potentiometers, or
contact contamination may occur.

Molex Connectors
Molex Connectors Pin Extraction
Molex connectors have pins with locking ears To remove a pin from a Molex connector, use
that engage ridges in the plastic connector pin extraction tool P/N 950-026. See
body. See Figure 7-155. Figure 7-156.
1. Insert the extraction tool over the pin and
Pin push all the way into the connector. This
releases the locking ears on the pin.
2. Pull the wire and pin from the connector.
Socket
Pin Insertion
1. To insert a pin into a Molex connector,
insert the pin into the back side of the
Locking Ears connector and push the wire all the way in
until it clicks.
Figure 7-155. Molex Connectors - End View 2. The locking ears have now engaged the
connector.
To remove a pin from a Molex connector, these
locking ears must be depressed far enough to
clear the ridge in the connector.
Tool Inserted Over Pin

Top View
Locking Ears
Extraction Tool
Side View
Figure 7-156. Pin Extraction Tool

AMP Water-Resistant Connectors
AMP Water-Resistant
Connectors
AMP connectors provide water-resistant
connection by the use of seals between wires
and connectors and between the mating
connector halves. See Figure 7-157.
Wire Seal
Interface
Seal
Contact
Cavity
Wire Seal Jack

Housing
Pin Contact
Pin Housing
Sealing Plug
Figure 7-157. AMP Water-Resistant Connector

Extraction Tool
To maintain the integrity of water-resistant
seals, use the following procedures when
working with AMP connectors.
Pin Extraction
To aid in separating AMP connectors, use

unlatching tool Raymond P/N 950-042. To
remove a pin from an AMP connector, use pin
extraction tool Raymond P/N 950-009.
1. While holding the wire seal, push the Locking
selected wire forward, then insert the Lance
extraction tool into the contact socket. See
Figure 7-158. Figure 7-158. AMP Pin Extraction
2. Pull the wire gently until you feel the

contact locking lances disengage.
3. Holding the wire seal and connector
housing together, rotate the wire while
pulling it through the wire seal. This
prevents damage to the seal. See
Figure 7-159.

Rotate and Pull

Pin Contact
Figure 7-159. Removing Wire
Figure 7-161. Wire Insertion

Pin Insertion
1. Make sure the connector has a wire seal Seals
attached to the connector back. See
Figure 7-160. 1. Use a wire seal at the back (wire end) of
each connector half. See Figure 7-160.
2. Plug unused pin positions with sealing
Wire Seal
plugs. See Figure 7-162.
3. Align the split tapered end of the sealing
plug with the unused opening in the wire
seal. Push the plug through the wire seal
into the connector until it snaps into
position.
4. Remove sealing plugs by pulling with
Pin Housing
needle-nose pliers while grasping the wire
seal and connector.
Figure 7-160. Wire Seal
Sealing Plug
2. If re-inserting a wire previously removed,
check the pin contact locking lances to
make sure they are extended to their
original position.
3. Grasp the wire close behind the contact
insulation barrel and push the wire
straight through the wire seal into the
socket until it clicks. Pull back gently to
make sure the contact is locked in place.
See Figure 7-161.
Figure 7-162. Sealing Plug
5. Use an interface seal between pin and jack

halves of the connector. To prevent
damage to the seal, use the matching
connector cap to slide the interface seal
over the contact silos on the pin housing. See Figure 7-163.

Interface
Seal
Pin Housing
Figure 7-163. Interface Sea
6. When mating connectors, make sure

polarized silos are correctly oriented. Push
pin and jack halves of the connector
together until locking latches engage. See
Figure 7-164.
Locking
Latches
Figure 7-164. Latching AMP Connector

AMP Harness/Traction Power Amplifier Connector
AMP Harness/Traction Power

Amplifier Connector
Connector Components
Figure 7-165. Power Amp Connector Components Contact Insertion
The axial concentricity of the crimped contact

Disassembly (Contact Removal) must fall into an area defined by a 2 mm
diameter cylinder whose center is the centerline
1. Insert a 4.8 mm screwdriver blade between of the contact front end. See Figure 7-167.
the mating seal and one of the red wedge
lock tabs. See Figure 7-165.
Assembly
2. Pry the wedge lock to the open position.
3. While rotating the wire back and forth over Make sure the wedge lock is open.
a half turn (1/4 turn in each direction), 1. To insert a contact, push it straight into
gently pull the wire until the contact is the appropriate circuit cavity as far as it
removed. See Figure 7-166. goes. See Figure 7-167. (a) and (b).
2. Pull back on the contact wire with a force
of 1 or 2 lbs. to make sure the retention
fingers are holding the contact. See
Figure 7-167. (c).
Figure 7-166. AMP JPT1 Connector

Figure 7-167. Contact Insertion
3. After all contacts are inserted, close the

wedge lock to its locked position. Release Be very careful when putting the wedge
the locking latches by squeezing them lock in the locked position. Forcing the
inward. See Figure 7-168. wedge lock can cause damage to the
connector. Make sure the wedge lock is
aligned correctly. If resistance is felt,
slightly adjust the wedge lock until it
slides in freely.
4. Slide the wedge lock into the housing until

it is flush with the housing. See
Figure 7-169.
Figure 7-168. Wedge Lock Latches

Figure 7-169. Wedge Lock Flush With Housing
Testing
Do not pierce wire insulation with a sharp point

while troubleshooting.
The wedge lock has slotted openings in the

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

Hydraulic Components

Flow Sensor Service 5. Run Test I26 - Flow Sensor Count

(Page 6-81) to make sure the pickup
Notes functions correctly.
Servicing of the hydraulic flow sensor is limited

to checking the turbine assembly inside the J22 not visible in photo
hydraulic flow sensor for cleanliness and
freedom of movement. Flow Sensor
NOTE: The flow sensor is electrically isolated
from the lift truck chassis with
insulating material and orange
non-conductive hydraulic hose. Be
careful that the connector plugs do not
cause shorts between the body of the
flow sensor and the lift truck chassis.
J21
The flow sensor must be electrically
isolated. When servicing the flow
sensor, make sure there is at least 2
megohm resistance between the body of
the flow sensor and the lift truck chassis
with JPY6 and JPY7 disconnected from
the flow sensor pickups.
Make sure the connectors are reconnected to

the correct pickup. Identify connector
placement for correct reassembly. See
Figure 7-170.
Figure 7-170. Flow Sensor
O-Ring Replacement
1. To make sure of correct alignment during
reassembly, use a pencil to mark the block
and pickup on the small black nut, the
large gold nut and the main block in a
straight line.
2. Remove the assembly by unscrewing the
large gold nut closest to the main block.
Make sure the small black nut does not
turn in relation to the large gold nut or the
calibration of the pickup is altered.
3. Remove the bad O-ring and install a new
one.
4. Install the pickup back into the main
block and tighten the large gold nut. Make
sure the marks made in step 1 are aligned.

Disassembly
Flow
Disassemble the flow sensor in a clean area to Snap Turbine Sensor
Ring
prevent contamination from entering the
turbine section of the flow sensor.
1. Remove the retaining ring from the inlet
port. See Figure 7-171.
Figure 7-173. Turbine Assembly Removed
3. With the turbine assembly removed,

inspect the turbine blades for damage
and/or for debris that may have become
entangled around the turbine. If the
turbine is damaged, the entire assembly
must be replaced.
4. Wash the turbine assembly in clean
mineral spirits (or equivalent) and shake
dry.
7
Figure 7-171. Retaining Ring Removal
2. Using a soft object (eraser end of a pencil Do not use compressed air to dry the
will do), carefully push the turbine turbine. Compressed air may
assembly out of the sensor body from the over-speed the turbine, damaging the
outlet end. See Figures 7-172 and 7-173. bearing surfaces.
5. With the longer section of the turbine

assembly pointed up, compress the
turbine shaft and spin the turbine using
your fingers. The turbine should spin
freely for several seconds without
chattering. If the turbine does not spin
freely, the entire flow sensor assembly
must be replaced.
Figure 7-172. Removing Turbine Assembly

Assembly
1. Reinstall the turbine assembly in the body
of the sensor so that one of the vanes of
the straightening section is between two
stake marks located in the turbine bore.
See Figure 7-174.
Stake Marks
Vane Positioned
Between Stake
Flow Sensor
Marks as Shown
Figure 7-174. Reinstalling Turbine Assembly in Flow Sensor
2. Using the pencil eraser, depress the

turbine assembly and reinstall the inlet
snap ring.
3. Reinstall the flow sensor in the lift truck.
4. Bleed the hydraulic system and refill the
reservoir. Check for leaks.
5. Run Learn. See Learn Hgt/Wgt on
page 3-19.

High Pressure Relief

Valve Adjustment
1. Install a calibrated pressure gauge
(3000 psi/20,682 kPa) in the test port. See
Figure 7-175.
2. Back-out the high pressure relief.
3. Check to see that the Emergency Lower
Valve is closed.
4. Place a rated load plus 200 lb. (90.7 kg) on
the forks.
5. Start the lift system and turn the pressure
relief screw clockwise until the platform
starts to lift. Note the pressure required
when the platform starts to elevate.
Continue lifting until the third stage of the
mast starts lifting. Record the pressure
reading.
6. Lower the platform and remove the weight.
7. Chain the mast sections together and lift
or lift against the stops.
8. Adjust the pressure relief valve to a
pressure 100 to 300 psi (689.4 to
2068 kPa) greater than the values
recorded in step 5.
9. After the adjustment is complete, tighten
the relief valve lock nut.
10. Check the lift system for correct operation.
Emergency
High Pressure Lower Valve
Relief Valve
Test Port
Figure 7-175. High Pressure Relief Valve Adjustment

Lift/Lower and Load 4. Inspect the sealing surface for

contaminants. Clean the surface as
Holding Valves necessary.
5. Lubricate O-rings with clean hydraulic
Use this procedure when it is necessary to fluid.
remove and install a lift/lower or load holding 6. Install the valve. See Figure 7-176.
valve.
When servicing hydraulic components,

keep the work area clean.
Contaminants can cause damage to
hydraulic system.
1. Make sure the operator platform is

completely lowered.
3. Remove the valve.
Tighten the valve cartridge 1/2 turn,

then loosen 1/4 turn. Continue this
sequence until a torque value of
120-150 in. lb. (13.6-17.0 Nm) is
achieved. (Tightening the valve in this
manner reduces the chance of
damaging the seal.)
20°-30°
30-35 in. lb.

(3.38-3.95 Nm)
(4 places)
Tighten nut holding coil to 4-5 ft. lb. (5.6-7 Nm)
7
Figure 7-176. Lift/Lower and Load Holding Valves Installation

Bleeding Lift Cylinders

Bleed the lift cylinders after maintenance or
Bleed Screw
when operation indicates that air has entered Access Holes
the system (such as a bouncing operator
platform).
Side Lift Cylinders

NOTE: For lift trucks with an OACH of less than
95 in. (241 cm), see Figure 7-177.
1. For lift trucks with an OACH above 95 in.
(241 cm), elevate the operator platform
approx 3 in. (7.6 cm).
2. Loosen, do not remove, the bleed screw
near the top of the side cylinder just
enough to bleed the air from the cylinder.
The bleed screw should only be

loosened enough to allow the air to
escape. 7
Figure 7-177. Bleed Screw Access - lift trucks with OACH of

less than 95 in. (241 cm)
3. When only oil flows from the cylinder,
tighten the bleed screw. Repeat the
process on the other cylinder.
Center Cylinder
To bleed the center cylinder:
1. Elevate the operator platform enough to
extend the center cylinder approx 3 in.
(7.6 cm).
2. Carefully loosen (do not remove) the bleed
screw located on the left side of the center
cylinder.
3. When only oil flows from the cylinder,
tighten the bleed screw.

Lift Pump and Motor 10. Check the lift pump for leaks.
For 36V lift trucks, refer to “AC Motor Service”

Suction Hose
on page 7-77 for traction motor temperature
sensor and encoder bearing replacement
procedures.
Removal
1. Turn the key switch OFF and disconnect Motor
2. Clamp the suction hose closed. See
Figure 7-178.
3. Remove the two mounting bolts securing
the lift pump to the lift motor.
4. Carefully separate the pump from the
motor, taking care not to damage the Pump
toothed spline.
5. Remove the hydraulic fittings from the lift
pump.
Installation
1. Attach the hydraulic fittings to the pump.
2. Apply molybdenum anti-seize compound
(P/N 990-638) to the mating surfaces of
the lift motor spline and pump.
3. Apply thread-locking compound
(P/N 1013829) to the lift pump mounting
bolts. 7
4. Carefully mate the lift pump spline to the Figure 7-178. Lift Pump and Motor
lift motor and attach the lift pump to the
lift motor with the two mounting bolts.
Torque lift pump mounting bolts to 43 ft.
lb. (58 Nm) AC motors; 15 ft. lb. (20 Nm)
DC motors.
5. Unclamp the suction hose and add
hydraulic fluid to the reservoir if
necessary.
the key switch ON.
7. Adjust the high pressure relief valve. See
page 7-97.
8. Bleed the hydraulic system.
9. Test the lift function for smooth and
correct operation.

Pressure Switch
Adjustment
This procedure applies to all 24V
non-intellispeed lift trucks equipped with the
High Performance Lift (Hi-Pro) option (except EE
rated lift trucks).
1. Disconnect JPT18 and JPT22 at the
Vehicle Manager.
2. Connect a meter across terminals JPT22-5
and JPT18-5.
3. Raise the operator platform approximately
2 ft. (610 mm) with a 1000 lb. (454 kg)
load on the forks for a model 5400 lift
truck and a 2500 lb. (1134 kg) load for a
model 5500 lift truck,
4. Adjust the screw on the back of the switch
until the switch just closes.
5. Turn the screw until the switch just
opens.
6. Adjust the screw until the switch
re-closes.

Side Lift Cylinder 7. Remove the snap ring from the bottom of
the cylinder. See Figure 7-180.
NOTE: A mirror enables you to see the snap
ring at the bottom of each cylinder
housing in the side lift cylinder
procedures.
Washer
Remove
1. Elevate the carriage just enough to access
the tubing connected to the bottom of the
side lift cylinder but not far enough to Snap Ring
extend the side cylinder. Block the
carriage.
2. Remove the tubing from the bottom block
on the cylinder that is to be removed. Cap 7
both the tubing and the fitting to the side Figure 7-180. Bottom View of Housing (Using Mirror)
lift cylinder.
8. Remove the bolt that attaches the cylinder
housing to the main frame of the lift truck.
See Figure 7-181.
Side Lift Cylinder
Hydraulic Tubing
Connector
Cylinder
Retaining
7
Bolt
Figure 7-179. Hydraulic Connection, Side Cylinder, Bottom
3. Unblock and lower the carriage to the

floor.
4. Remove the bolt in the top of the side lift 7
cylinder that connects it to the bracket on Figure 7-181. Side Cylinder

the mast.
5. Elevate the carriage until it clears the 9. Remove the side lift cylinder from the lift
cylinder assembly enough to allow cylinder truck.
removal.
6. Block the carriage. Installation
1. Install the cylinder in the lift truck.
2. Install the bolt that attaches the cylinder
housing to the main frame of the lift truck.
3. Install the snap ring on the bottom of the
cylinder housing.

4. Unblock and lower the carriage enough to 6. Push the cushion into the piston at the
collapse the other outer cylinder but still base of the piston.
have access to the fitting at the bottom of
the cylinder.
5. Block the carriage. Connect the tubing to
the bottom of the cylinder. The cushion is under extreme pressure.
6. Unblock and lower the carriage to the Keep pressure on the cushion when
floor. Install the bolt in the top of the side removing the items in the next step.
lift cylinder that connects it to the bracket Failure to do so could cause injury from
on the mast. projectile parts.
7. Bleed the hydraulic system. See Bleeding
7. Remove the snap ring and retaining ring.
Lift Cylinders on page 7-99.
See Figure 7-183.
8. Lift and lower the carriage completely to
check lift function.
Piston
Spring
Cushion Service
Seal Cushion
1. Remove the cylinder from the lift truck.
See Side Lift Cylinder on page 7-102.
2. Remove the snap ring and wiper. See
Figure 7-182. Retaining
Ring
Adapter
(Brass) Snap Ring
7
Seal
Figure 7-183. Cushion, Removed
Wiper 8. Release the pressure on cushion. Pull the

cushion out of the piston. See
Retaining Figure 7-183.
Ring 9. Remove the spring.
Snap
Rings
Figure 7-182. Piston Removal
3. Remove the snap ring in the cylinder

housing.
4. Pull the piston until the piston stop
pushes the retaining ring, packing, and
adapter out of the cylinder.
See Figure 7-182.
5. Pull the piston out of the housing. Place
the piston on a cushioned stand. Do not
damage the piston surface.

10. Remove the seal from the cushion. 12. Install the spring. Make sure it is fully
seated in the cushion piston.
13. Install the cushion piston.
14. Install the retaining ring and snap ring.
15. Install the cylinder in the lift truck. See
Side Lift Cylinder on page 7-102.
Cushion
1
2 Piston
3
Figure 7-184. Cushion Piston Seal Kit, Shown In Order of

Installation
Do not separate the piston from the 7
piston plug unless necessary. If Figure 7-186. Cushion Assembly

disassembly is required, use a strap
wrench only. Do not damage the piston Cleaning
surface.
1. Flush the inside of the housing.
NOTE: When repacking the cylinder, replace all 2. Wipe the piston with clean kerosene or a
packings. See the Parts Catalog for suitable industrial solvent.
packing kits. 3. Inspect all surfaces for galling or heavy
11. Install the seal kit on the cushion piston. scratches. Remove minor damage with a
See Figure 7-184. fine emery cloth.
Tip: Twisting the fiber rings prior to installation 4. Inspect all parts. Replace as necessary.
helps them retain their “memory.” See
Figure 7-185.
Fiber
Ring
Figure 7-185. Twisting Fiber Rings

Seal Repacking
1. Remove the cylinder. See Side Lift Cylinder Ram
on page 7-102. Housing
Adapter Service
(Brass) Service Driver
Guide
Seal
Wiper
Retaining
Ring 7
Figure 7-188. Using Cylinder Service Tools

Snap
Rings 5. Slide the brass adapter on the piston.
6. Install the piston assembly into the
7
housing.
Figure 7-187. Packing Components on Side Cylinder
7. Install the service guide. See Figure 7-188.
8. Dip the seal in oil and slide over the
piston, back first.
Do not damage the chrome plating on 9. Drive the seal into the assembly with a
the piston. service driver. See Figure 7-188.
10. Remove the service guide.
2. Remove the snap rings, seals, retaining
11. Install the packing backup ring.
ring, and brass adapter. See Figure 7-187.
12. Install a snap ring.
3. Dip all packings in clean hydraulic fluid.
13. Install the wiper.
4. Lubricate the inside of the cylinder
housing with hydraulic fluid. 14. Install a snap ring.
NOTE: To prevent damage to packings at the 15. Install the cylinder. See Side Lift Cylinder
top of the cylinder, use the following on page 7-102.
tools:
• Service driver, P/N 401-000-050
• Service guide, P/N 401-000-051

Removal
Center Lift Cylinder Service of Cylinder with

Cushions
Removal Cushion Replacement
1. Remove the carriage. See Carriage on
Refer to Figure 7-192 on page 7-108 for the
page 7-110.
following steps.
Snap Snap
Ring Ring
Washer
Figure 7-189. Center Cylinder, Bottom View
2. Remove the snap ring and washer from the

bottom of the center cylinder. See
Figure 7-190. Center Cylinder, Top View
Figure 7-189.
3. Remove and cap the hydraulic hoses. 1. Remove the snap ring for older production
4. Remove the U-shaped bracket. cylinders. See Figure 7-190.
5. Remove the center cylinder.
7
Installation
1. Install the center cylinder. Make sure the
bushing is on the mounting bolt.
2. Install the washer and snap ring to the
bolt under the center cylinder. See
Figure 7-189.
3. Install the U-shaped bracket.
4. Install the carriage. See Carriage on
page 7-110.
5. Install the end cap and hydraulic hoses on
the center cylinder. Figure 7-191: Threaded End Cap, Side View
6. Reconnect the battery connector and turn 2. Remove threaded end cap with Raymond
the key switch ON. tool (P/N 1090761/002) for current
7. Bleed the hydraulic system. See Bleeding production. See Figure 7-191.
Lift Cylinders on page 7-99. 3. Remove the top bearing.
NOTE: When the snap ring or end cap is
correct operation.
removed, a spring behind the top
bearing may push the bearing out of the
housing.

Removal
4. Remove the spring and pressure ring.

5. Remove the three staging screws located
about 6 in. from the top of the housing.
6. Remove the piston from the cylinder
housing.
7. Remove the cushion assembly.
8. Coat the threads of the new cushion
assembly with thread-locking compound
primer (P/N 990-666). Allow the primer to
cure a minimum of 1 minute.
990-575) on the internal threads of the
piston rod.
10. Start threading the cusion assembly into
the piston.
990-575) on the external threads of the
cushion assembly.
12. Continue installing the assembly into the
piston.
NOTE: Assemble components within 30
seconds of application as the
thread-locking compound begins to cure
immediately.
13. Allow the assembly to cure a minimum of
10 minutes.
14. Re-install the piston assembly in the
cylinder housing.
15. Re-install the three staging screws.Refer to
Component Specific Service/Torque Chart
(Page A-4).
16. Lightly oil a new seal. Install the seal in
the pressure ring. Check to make sure the
small orifice in the pressure ring is not
obstructed.
17. Install the spring.
18. Remove the bad parts from the top
bearing.
19. Lightly oil a new seal, O-ring, backup ring
and wiper. Install them into the top
bearing.
20. Install the top bearing.
21. Install the snap ring for older model
cylinders or threaded end-cap for current
production. Refer to Component Specific
Service/Torque Chart (Page A-4).

Removal
Seal Wiper
End Cap
Cushion Assembly Spring
Top end, Current style
See View B See View A
Piston
Staging Screw
Backup
Pressure O-Ring Ring Top Seal Wiper
Ring Seal Bearing
Bleed Screw Retaining Ring
View A
View B
Figure 7-192. Center Lift Cylinder, Three-Stage with Cushions
6. Lightly oil a new seal, O-ring, backup ring,

and wiper. Install them into the top
bearing.
7. Install the top bearing.
Seal Replacement 8. Install the retaining ring for older model
cylinders or threaded end-cap for current
Refer to Figure 7-192 for the following steps.
production. Refer to Component Specific
Service/Torque Chart (Page A-4).
1. Remove the snap ring or threaded
end-cap, depending on your style cylinder,
and the top bearing.
NOTE: When the snap ring or end-cap is
removed, a spring behind the top
bearing may push the bearing out of the
housing.
2. Remove the spring and pressure ring.
3. Check to make sure the small orifice in the
pressure ring is not obstructed.
4. Lightly oil a new seal and install in the
pressure ring.
5. Remove the bad parts from the top
bearing.

Mast Section

Carriage Snap Ring Chain

Rocker
Assembly
Removal
2. Remove the operator console cover. Center
Cylinder
3. Remove the electrical over-the-mast cable
from the bottom pulley on the carriage.
See Figure 7-193.
4. Disconnect the cable tension spring from
the carriage. See Figure 7-193.
7
Figure 7-194. Center Cylinder, Top View

Cable
Tension 8. Attach a suitable hoist to the carriage and
Spring lift approximately 1 ft. (30.5 cm).
9. Remove the rocker assembly, its
associated hardware, and chain from the
Cable
center cylinder. Place the chain on the
operator platform.
Pulley 10. Remove the end cap from the center

cylinder.
11. Remove the carriage stops (2) from the
inner telescopic. Pound in the locator pins
7
until the carriage can clear the telescopic.
Figure 7-193. Electrical Over-the-Mast Cable See Figure 7-195 and Figure 7-196.
5. Disconnect JPC8 and JPC9 from the Locator

Carriage Manager. Cut the cable tie from Pin
the tractor side.
Do not place hands between the masts

before blocking the carriage.
6. Feed the cable through the carriage to the

tractor.
Carriage
7. Use 90° snap ring pliers to remove the Stop
snap ring holding the chain rocker
assembly to the center cylinder. See 7
Figure 7-194. Figure 7-195. Inner Telescopic, Top Corner

4. Position the operator platform 3 ft. (1 m)

from the floor.
5. Install the rocker assembly, its associated
hardware, and the chain on the center
Locator cylinder. See Figure 7-194.
Pin
6. Install the end cap pulley on the center
cylinder.
7. Feed the chains for the center cylinder and
over-the-mast cable.
8. Feed the over-the-mast cable through the
back of the carriage to the Carriage
Manager. Connect to JPC8 and JPC9.
9. Use cable ties to secure the electric cables
7
to the operator platform.
Figure 7-196. Inner Telescopic, Top Corner, Stops Removed
10. Install the carriage stops at the top of the
12. Remove the operator platform. inner telescopic. See Figure 7-195.
11. Lower the carriage. Install the cable on the
Installation bottom pulley of the carriage. Install the
cable retainer spring. See Figure 7-193.
1. With a suitable hoist, lower the bottom
bearings on the carriage into the channel NOTE: There is 5 1/2 in. (140 mm) from the top
on the inner telescopic. of the spring on the carriage to the
center of the bolt in the cable clamp.
2. Make sure there are sufficient shims to
prevent side play. See Upper Mast Bearing 12. Mate the tractor to the mast, engaging the
Replacement on page 7-115. locating pins in the tractor with the holes
in the mast frame.
3. Make sure the two switches (S36 and S37)
at the bottom of the carriage are riding on 13. From the battery compartment, thread 12
their switch rail correctly. See hex head bolts and 5 socket flat head bolts
Figure 7-197. through the tractor frame in the center,
left side and right side, into the mast. See
Figure 7-198.
Switches
Switch
Rail
Figure 7-197. Underside of Carriage

Flat Head
Mounting Bolts
Qty. 5
Hex Head
Mounting Bolts
Qty. 12
Figure 7-198. View of Battery Compartment
14. Torque the hex head bolts. Refer to

“Component Specific Service/Torque
Chart” on page A-4.
15. Install the console cover.
16. Install the mast guard.
the key switch ON.
18. Lift and lower the platform fully. Check the
functions of the lift system. Look for:
• Hydraulic fluid leaks
• Cables on pulleys
• Switch actuation
• Unusual bearing noise

Mast Shimming
Mast Shimming Compare the wear pattern on the rail (where the
roller rides) to the examples shown in
Figure 7-199.
Shimming a mast makes a smooth running unit
• If the wear pattern is optimal, shimming is
that is not too tight or too loose. If you find any
adequate.
marks within the telescopics or main frame
where the rollers have been running, remove • If the wear pattern is excessive, shimming
them using a sanding disc and 80 grit paper. Do is too tight.
not attempt to remove all marks, only the • If the wear pattern varies between optimal
ridges. Shim the bearings to the tightest spot on and excessive, the telescopic weldment is
the assembly (as the rollers run up and down suspect.
the rail). Buff small areas that are slightly
higher than the rest of the web to avoid NOTE: Uneven wear can also indicate if a
shimming the major portion of the rail too loose. bearing set is too tight.
The shims used under each roller bearing come
in the following sizes: thin, medium, and thick. Approx. 1 in. (25.4 mm)
Although you can use different combinations of wide wear pattern
shims to obtain the correct adjustment, you
should try to maintain equal shim thickness on
each side of the mast.
OPTIMAL
Mast and Bearing Inspection WEAR
PATTERN
Shimming is
Observe mast operation in free and main lift adequate
with no load.
• When stopping a lift or lower, there should
be a slight bounce.
• If the bounce dampens out quickly, the
mast may be shimmed too tight. Side of rail bearing rides on
Observe the mast operation at full elevated

height, just short of hitting the hard stops, with
no load.
EXCESSIVE
• The telescopics should all act as one. WEAR
PATTERN
• The interface between the telescopics Shimming is
should be snug with no excessive relative too tight
motion between the telescopics when the
lift truck is moved back and forth slightly.
If motion is excessive, the mast may be
shimmed too loose. Example of good wear
Wear pattern greater than pattern on mast with
• If a 0.010 in. feeler gauge can be inserted several hundred hours
1 in. (25.4 mm) wide
between the roller and beam web at the
tightest spot, they are shimmed too loose. Figure 7-199. Mast Bearing Wear Patterns
Some telescopics can be narrower at the
top or bottom, therefore shimming
clearance should be measured at the
tightest location.

Shimming Procedure
Shimming Procedure prevent the bearing from walking on the

stud shaft.
1. Elevate the mast to gain access to the
bearings.
2. Place a block between the outer telescopic
crosstie and the main frame.
3. Fully lower the carriage.
NOTE: When removing the upper bearings, use
caution not to let the bearing fall down
into the mast assembly. If the bearings
are worn or damaged, replace them.
5. Remove the bolt and roller stud sleeve
securing the roller bearing to the
respective mast or telescopic.
Figure 7-200. Inner Race
6. Remove the bearing.
NOTE: It may be necessary to drive a wedge 14. Install the bearing assembly into its
between the respective telescopics to respective mast or telescopic. Make sure
provide clearance for removal and that the flat spot of the bearing stud aligns
installation. with the welded stop on the mast or
telescopic.
7. Remove the socket head cap screw and
washer retaining the bearing on the stud. 15. Install the roller stud sleeve.
NOTE: Shim the main frame top bearing and
(P/N 1013829) to the threads of the
the outer telescopic lower bearing set to
mounting bolt and torque to 260 ft. lb.
a 0.000 ±0.010 in. overall interference.
(352.5 Nm).
8. Shim the outer telescopic upper bearing 17. Reconnect the battery connector and turn
set to 0.000 ±0.010 in. overall the key switch ON.
interference with the inner telescopic after
the top main frame bearings have been 18. Remove the block from between the outer
correctly shimmed. telescopic and the main frame.
9. Shim the inner telescopic lower bearing set 19. Test the operation of the elevating
to 0.000 ±0.010 in. overall interference assembly.
with the outer telescopic after the outer
telescopic lower bearings have been set.
10. Install or remove the required amount of
shims.
11. Install the bearing on the shaft.
(P/N 990-536) to the socket head cap
screw and fasten the screw and washer in
place.
13. If the inner race of the bearing does not
protrude past the end of the bearing stud
when the bearing is fully seated, bend the
flat washer to contact the bearing to

Upper Mast Bearing Replacement
Upper Mast Bearing

Replacement Do not damage the telescopic when
prying with the screwdriver.
NOTE: For the upper mast bearings, wedge a

screwdriver between the roller bearing
Use extreme care when blocking the and the mast to prevent the bearing
mast for any reason. Never remove the from falling.
block when it is supporting the mast. NOTE: When removing the roller bearing, use
caution not to let the bearing fall down
1. Slightly elevate the carriage to gain access into the mast assembly.
to the bearings.
4. Remove the bolt securing the roller
2. Block the carriage before you attempt to bearing to the respective mast or
remove the roller bearing. See telescopic.
Figure 7-201.
NOTE: If the bearings are worn or damaged,
replace them.
5. Install the same number of shims under
the bearing that were removed.
6. Make sure the roller bearing mounting
bolts are clean before you install them.
(P/N 1013829) on the threads. Torque the
bolts per Table 7-8.
the key switch ON.
9. Lift the carriage and mast and unblock the
mast.
10. Test the operation of the telescopics.
11. Return the lift truck to service.
709G6S001.TIF Table 7-8. Mast Bearing Stud Retaining Bolt Torque Values
Figure 7-201. Blocking Carriage
Location *Torque
You may also use a lift hoist to pull the Main Frame 300 ft. lb. (406.7 Nm)
carriage upward to gain access to the
roller bearing. Put a strap suitable to Outer Tele Upper 250 ft. lb. (339 Nm)
handle the weight of the carriage around
*After torquing, back bolt off 1/4 to 1/2 turn.
the uppermost crosstie. Once the carriage
is raised in place, block it into position.

Mast Disassembly and 13. Remove the upper roller bearing bosses
and roller bearings from the outer
Shimming telescopic.
This section describes procedures for: 14. Remove the telescopics and main frame
stops.
• Disassembling the three-stage mast
15. Slide the inner telescopic out of the top of
• Shimming main frame to outer telescopic
the outer telescopic. Attach the hoist to
• Shimming outer telescopic to inner the outer telescopic.
telescopic
16. Remove the upper roller bearing bosses
• Shimming inner telescopic to carriage and roller bearings from the main frame.
17. Slide the inner telescopic out of the top of
Mast Disassembly the main frame.
1. Remove the forks and mast guard.
2. Fully lower the carriage and make sure the
Shimming Main Frame to Outer
pressure is out of the cylinders. Telescopic
3. Turn the key switch OFF and disconnect 1. Install the mast roller bearings at the
the battery connector. Remove the battery. bottom of the outer telescopic.
4. Disconnect the over-the-mast cables and 2. Use a suitable lifting device and insert the
hoses inside the tractor compartment and outer telescopic into the main frame all the
plug the hoses. Disconnect the lift hose to way to the bottom.
the side cylinders inside the tractor 3. Using a pry bar, move the outer telescopic
compartment and plug. Disconnect all and roller bearing to one side.
other cables that run from the tractor to
the mast. 4. Use spare shim(s) as a gauge to determine
the amount required to move the roller
5. Secure the main carriage and telescopics bearings outward to make contact with the
so they cannot move. main frame.
6. Remove the tractor from the mast and 5. Remove the outer telescopic from the main
block each securely. frame.
7. Disconnect and remove the lift chains 6. Remove the roller bearings from both roller
from the center lift cylinder. Remove the bearing bosses at the bottom of the outer
over-pulley-cables and hoses. Remove the telescopic.
center cylinder end cap assembly.
7. Install half of the total shim thickness
8. With a suitable hoist, carefully lay the required to each roller bearing boss at the
mast assembly down and block securely in bottom of the outer telescopic. (Applying
place. Remove the carriage stops from the one half of the total shim thickness to each
inner telescopic. side of the telescopic maintains the center
9. Remove the main carriage by sliding it out line of the mast assembly.)
the top of the inner telescopic. Set it aside 8. Reinstall the roller bearings. Torque the
for later reassembly. bolts per Table 7-8 on page 7-115.
10. Remove the lift chains, chain pulleys, hose 9. Use a suitable lifting device and reinstall
pulleys, and cable pulleys. the outer telescopic into the main frame.
11. Disconnect and remove the lift cylinders Check for tightness while moving the outer
from the telescopics. telescopic to the bottom of the main frame.
12. Attach the hoist to the inner telescopic. Add/remove shims as necessary to
maintain a snug, but free-running, fit.
NOTE: If the outer telescopic hangs up, a pry
bar may be used to move the telescopic.

10. Assemble the two top main frame roller outward to make contact with the outer
bearings and bosses without shims. telescopic.
11. Install the roller bearing assemblies, 5. Remove the inner telescopic from the outer
attach with a retaining bolt, and snug up telescopic.
to the main frame. 6. Remove the bearings from both roller
NOTE: Failure to snug the assemblies to the bosses at the bottom of the inner
main frame will result in the wrong telescopic.
amount of shims, since the studs are 7. Install half the total shim thickness
canted. required to each roller boss at the bottom
12. With the outer telescopic fully nested, use of the inner telescopic.
a pry bar and carefully move the outer 8. Reinstall the roller bearings. Torque the
telescopic to the opposite side. Using spare bolts per Table 7-8 on page 7-115.
shims between the bearing and outer 9. Use a suitable lifting device and reinstall
telescopic, determine the amount of shims the inner telescopic into the outer
required to remove side play. telescopic. Check for tightness while
13. Remove the roller bearing assemblies. moving the inner telescopic to the bottom
14. Install half of the total shim thickness to of the outer telescopic.
each roller bearing assembly. NOTE: If the inner telescopic hangs up, a pry
15. Install the roller bearing assemblies and bar may be used to move the telescopic.
attach with the mounting bolts and 10. With the inner telescopic fully nested, use
tighten. a pry bar to check for bearing tightness. If
16. With the outer telescopic fully nested, use a thin shim can be inserted between the
a pry bar to check for bearing tightness. If bearing and the outer telescopic, remove
more shims can be inserted between the the inner telescopic and install the shim
bearing and the outer telescopic, remove between the bearing and the roller boss.
the roller bearing assembly and install the Torque the bearing stud retaining bolt per
shim(s). Reinstall the bearing assembly. Table 7-8 on page 7-115. Leave the lifting
17. Check for correct shimming by pulling the device connected to the outer telescopic.
outer telescopic out and then pushing it in Do not apply excessive pressure to the
all the way. The outer telescopic should bearings with the pry bar.
not hang up while moving it in and out. 11. Assemble the two roller bearings and
Torque the bearing stud retaining bolts bosses for the top inner telescopic without
per Table 7-8 on page 7-115. shims.
18. Install the stops in the main frame. 12. Insert the bearing/boss assemblies and
attach with the retaining bolts. Draw the
Shimming Outer Telescopic to Inner bearing bosses up snug to the outer
telescopic.
Telescopic
NOTE: Failure to snug the assemblies to the
1. Install the mast roller bearings at the
main frame will result in the wrong
bottom of the inner telescopic.
amount of shims, since the studs are
2. Use a suitable lifting device and insert the canted.
inner telescopic into the outer telescopic
all the way to the bottom. 13. Use a pry bar and carefully move the inner
telescopic to the other side. Using spare
3. Use a pry bar and carefully move the inner shims between the bearing and inner
telescopic and bearings to one side. telescopic, determine the number of shims
4. Use spare shim(s) as a gauge to determine required to remove side play.
the amount required to move the bearings 14. Remove the bearing/boss assemblies.

15. Install half the total shim thickness to 9. Use a suitable lifting device and reinstall
each bearing/boss assembly. the carriage into the inner telescopic.
16. Install the bearing/boss assemblies into Check for tightness while moving the
the outer telescopic/inner telescopic. carriage to the bottom of the inner
Attach with a mounting bolt and tighten. telescopic.
17. With the inner telescopic fully nested, use 10. Use a pry bar to check for bearing
a pry bar to check for bearing tightness. If tightness. If a thin shim can be inserted
more shims can be inserted between the between the bearing and the inner
bearing and the inner telescopic, remove telescopic, remove the carriage and install
the bearing/boss assembly and install the the shim between the bearing and the
shim(s). Reinstall the bearing/boss roller boss. Do not apply excessive
assembly. Torque the bearing stud pressure to the bearings with the pry bar.
retaining bolt per Table 7-8 on page 7-115. 11. Use a suitable lifting device and reinstall
18. Check for correct shimming by pulling the the carriage, checking for tightness. Make
inner telescopic out and then pushing it in sure the carriage can be moved in and out
all the way. The inner telescopic should by hand.
not hang up while moving it in and out. 12. When the correct fit is obtained, measure
19. Install the stops at the upper crosstie. the gap between the top of the platform
and the inner telescopic on both sides. If
20. Install the outer lift cylinders. the gap between the platform and the
21. Install the chain rollers and lift chains. inner telescopic is not within 1/16 in.
22. Install the center lift cylinders (1.59 mm) of each other, remove the
platform.
Shimming Inner Telescopic to 13. Take shims from the top roller on the side
that is farthest away and install them on
Carriage
the opposite side. Repeat this procedure
1. Install the mast roller bearings on the until 1/16 in. (1.59 mm) is obtained. If all
carriage roller bosses. shims are on one side of the top rollers,
2. Use a suitable lifting device and insert the remove shims from the bottom roller on
carriage into the inner telescopic all the the side that is farthest away and install
way to the bottom. them on the opposite side.
14. Repeat this procedure until the required
NOTE: The carriage may have to be removed
clearance at the top of the platform is
several times to obtain the correct fit.
obtained.
3. Using a pry bar, move the bottom carriage 15. Install the carriage and the carriage stops.
bearings to one side.
16. Install the pulleys for the over-mast-hoses
4. Use spare shim(s) as a gauge to determine and cables.
the amount required to move the bearings
outward to make contact with the inner 17. Secure the main carriage and telescopics
telescopic. in place so that they do not move while
standing the assembly back up.
5. Move the carriage to the top of the inner
18. Install all the other items removed during
telescopic and repeat the process for the
the disassembly process after laying the
top set of bearings.
assembly down.
6. Remove the carriage from the inner
telescopic. 19. Attach the hoist to the mast assembly and
stand the mast back up. Install all the
7. Install half of the total shim thickness other items removed during the
required to each roller boss. disassembly process prior to laying the
8. Reinstall the roller bearings. assembly down.
20. Attach the tractor to the mast.

21. Install the remaining components.

22. Connect the hoses and cables inside the
tractor compartment.
Make sure all mast stops are installed

and securely tightened before operating
the lift truck.
23. Reinstall the battery.

the key switch ON.
25. Adjust the main lift chain so the top of the
inner telescopic is even with the outer
telescopic +/- 0.125 in. (3.2 mm) and both
chains have equal tension.
26. Adjust the free lift chains so the top of the
fork just in front of the platform is at a
minimum of 2.75 in. (70 mm) from the
floor and the tips are at a maximum of 3.5
in. (89 mm) from the floor.
27. Install the forks and mast guard.
28. Check for correct operation.
29. Grease the channels.
30. Bleed the lift cylinders. See Bleeding Lift
Cylinders on page 7-99.

Lift Chains, Three-Stage
Lift Chains, Three-Stage

Side Chain
Cylinder Anchor
Use extreme care whenever the lift truck Anchor

is jacked up. Never block the lift truck Block
between the telescopic and the floor.
Keep hands and feet clear from the
vehicle while jacking the lift truck. After
the lift truck is jacked, place solid blocks
beneath it to support it. Do not rely on
the jack alone to support the lift truck.
7
See Jacking on page 2-8. Figure 7-202. Lower Anchor Block
Center Cylinder Chain Side Cylinder Chains

Replace Replace
1. Turn the key switch OFF and disconnect 1. Inspect the lift chain for wear or broken
the battery connector. links. See Lift Chain on page 7-127.
2. Inspect the lift chain for wear or broken 2. Lift the carriage enough to block between
links. See Lift Chain on page 7-127. the carriage and inner telescopic.
3. Attach a suitable hoist. Lift the carriage 3. Place blocking between the carriage and
approximately 3 feet (0.9 m) and block. the inner telescopic.
4. Disconnect the chain from the chain 4. Turn the key switch OFF and disconnect
anchor and feed out of the lift truck. the battery connector.
5. Replace the chain as necessary. 5. Disconnect the chain from chain anchors.
6. Feed the chain over the pulley. Connect Feed the chain off the pulley. See
the chain to the chain anchor. Figure 7-202 and Figure 7-203.
7. Remove the block and hoist. 6. Replace the chain as necessary. See
8. Reconnect the battery connector and turn Figure 7-204.
the key switch ON.
correct operation before returning the lift
truck to service.

Side Cylinder Chains
7. Feed the chain over the pulley. Connect

the chain to the anchors. See Figure 7-202
and Figure 7-203.
Chain
Pulley
Chain
Anchor
7
Figure 7-205. Inside Chain Anchor, View from Operator

Platform
7
8. Remove the block and hoist.
Figure 7-203. Upper Chain Anchor and Pulley 9. Reconnect the battery connector and turn
the key switch ON.
correct operation before returning the lift
truck to service.
Figure 7-204. Master Link of Lift Chain

Side Cylinder Chains
Center Cylinder Ride

Spring Chain Anchors
Inspect the chain anchors and pivot rocker any
time that the chains are lubricated and
adjusted.
Inspection
1. Remove the operator compartment console
cover and tractor cover.
With chains slack,
2. Lift the operator platform just high enough
inspect the chain
to have the chain anchor/pivot rocker
anchor
visible through the opening under the
operator control panel.
3. Place blocking under the operator
platform. Lower the platform onto the
support.
the battery connector. Open the
7
emergency lower valve.
Figure 7-206: Chain Anchors
The center cylinder moves down and the
chains go slack. If the center cylinder does 5. Inspect the chain anchor and pivot rocker
not go down far enough to slacken the for wear and replace if necessary.
chains, push down on the top of the 6. Close the emergency lower valve.
cylinder. This allows the chain anchor to Reconnect the battery connector and turn
be visible for inspection. See Figure 7-206. the key switch ON.
7. Lift the platform slowly to take slack out of
the chains and to clear the support from
beneath it.
8. Remove the support and lower the
platform.
9. Reinstall all covers.

Forks
Forks 6. Drive out the pivot pin. The fork, washers,

or shim will drop.
7. Replace the damaged fork.
Removal
1. Raise operator platform high enough to Installation
reach the bottom of the forks.
1. Hold new fork in place under the operator
2. Block the operator platform. platform.
3. Secure the fork to a hoist using a suitable 2. Install the pivot pin through fork.
strap or chain. See Figure 7-207.
NOTE: Always use new snap rings when
4. Remove the cap screw from underneath assembling components.
the fork at the tractor end of the fork.
3. Install a new snap ring in the pivot pin.
4. Install the correct amount of washers or
Socket Head Fork shims at the tractor end of the fork to
Cap Screw maintain a level fork. See Figure 7-209.
Shims
Figure 7-207. Fork Removal
5. Remove the snap ring from the pivot pin in

the fork mounting block. See 7
Figure 7-208. Figure 7-209. Installing Forks and Shims
5. Install the socket head cap screw through

the fork and shims at the tractor end of
the fork.
6. Remove blocking from the operator
platform.
7. Lower the operator platform to the floor
Snap and make sure forks are level. The top
Ring surface of the forks should be within 0.25
in. (6.3 mm) of each other (31 in. and
longer) or 0.125 in. (3.2 mm) of each other
7
(under 31 in.) at the tips. If the forks are
Figure 7-208. Snap Ring, Pivot Pin, and Mounting Block not level, add more shims to the fork.
8. Check the fork up tilt. It must be between
level and 0.5 in. (12.7 mm) maximum.
The fork will drop in step 6. It weighs

approx 150 lb. (68 kg).

Pallet Clamp
Pallet Clamp between the pallet clamp and the left-hand

pallet support. Torque the remaining hex
nut to 21 ft. lbs. (29 Nm).
Tension Spring
Pallet Clamp
Pedal Weld
Pivot Bracket
Figure 7-210. Pallet Clamp Assembly, Underside
Install
1. Install the pallet clamp assembly on the
platform front plate. Secure it with four (4)
M10 x 20 screws. Torque to 30 ft. lbs.
(41 Nm).
2. Install the pedal assembly to the platform
main support plate. Secure it with two (2)
M8 x 20 screws. Torque to 15 ft. lbs.
(20 Nm).
3. Hook the tension spring into the 1/4-inch
holes in the pivot bracket and pedal weld
in the pedal assembly. See Figure 7-210.
4. To extend the spring so you can connect
the cable assembly, slide a two inch-wide
block between the left-hand pallet support
and the pallet clamp on the pallet clamp
assembly.
5. Install the cable bracket on the pedal
assembly. Secure it with the M8 x 10
shoulder bolt and M8 hex nut. Torque to
15 ft. lbs. (20 Nm).
6. Place the cable assembly in the cable
bracket and secure with the M6 hex nuts.
Finger-tighten the hex nut closest to the
pedal mounting and leave the other nut
loose.
7. Remove the two inch block you used in
step 4.
8. Adjust the hex nut closest to the pedal
mounting until there is a 90° angle

Load Wheels
Load Wheels 10. Connect the battery connector and turn

the key ON.
11. Raise the operator platform and remove
the block between the platform and the
baseleg.
is jacked up. Keep hands and feet clear
from the vehicle while jacking the lift
truck. After the lift truck is jacked, place
solid blocks beneath it to support it. Do
not rely on the jack alone to support the
lift truck. See Jacking on page 2-8.
Snap Ring
Axle
Figure 7-211. Load Wheel
1. Raise the operator platform approximately

1 ft. (0.3 m) from the floor. Place a 4 x 4 in.
(100 x 100 mm) block across the top of
baselegs underneath the platform.
battery connector.
3. Jack up the baseleg high enough to clear
the load wheel from under the baseleg.
Block under the baseleg.
4. Remove the snap ring from the axle. See
Figure 7-211.
5. Drive the axle out of the wheel and
baseleg. The load wheel will fall out of the
baseleg. See Figure 7-211.
6. Replace the load wheel assembly.
7. Drive the axle in through the wheel and
baseleg.
8. Install the snap ring.
9. Remove the block from under the baseleg
and lower the truck to the floor.

Skid Pads
Skid Pads
Location
There are two skid pads on each lift truck.
Inspection
1. Check the clearance between each skid
pad and the floor.
2. If clearance is more than 3/4 inch
(19.1 mm) on either side, replace the skid
pad. See procedure below.

is jacked up. Keep hands and feet clear
of from the vehicle while jacking the lift
truck. After the lift truck is jacked, place
solid blocks beneath it to support it. Do
not rely on the jack alone to support the
lift truck. See Jacking on page 2-8.
Replacement
Weld a new skid pad inside the worn skid pad.
Clearance from the floor should be 3/4 inch
(19.1 mm). See Welding Safety on page 2-13.

Lift Chain
Lift Chain stressed precision chains require periodic

maintenance to deliver maximum service life.
Refer to Table , “Lift Chains,” on page 4-7
Lift chains are important components of the lift
truck. The chain system on the mast is
designed for efficient, reliable transmission of
lifting force from the hydraulic cylinder to the
forks. Safe, uninterrupted use of the lift truck
depends on correct care and maintenance of the
lift chain.
Lift Chain Adjustment

1. Loosen the locking nut on the chain
anchor, See Figure 7-212.
Locking Nut
Figure 7-212. Lift Chain Locking Nut
2. Tighten the adjusting nut until the chain

is free of any twist and in correct tension.
Lift chain tension is correct if the lift chain
can be forced sideways approximately 1/2
to 1 inch (13 to 25.4 mm) before the lift
frame raises slightly.
3. Retighten the locking nut on the chain
anchor.
Lift Chain Maintenance

Unsatisfactory chain performance is traced
directly to inadequate maintenance. Highly

Lift Chain Maintenance

Models 5400/5500/5600 Maintenance Manual Section 8. Theory of Operation
Section 8. Theory of Operation

Section 8. Theory of Operation Models 5400/5500/5600 Maintenance Manual
System Architecture
System Architecture
Section 8. Theory of Operation
The following table identifies the various

electronic components found on this lift truck
and their function.
Ident Component Function
Controlling manager for the lift truck. See Vehicle Manager on

VM Vehicle Manager
page 8-3.
Powers the traction motor. See Traction Power Amplifier on

TPA Traction Power Amplifier
page 8-4.
Powers the lift motor on AC lift systems. See Lift Power

LPA Lift Power Amplifier
Amplifier on page 8-4.
Distributes B+/– throughout the lift truck. Houses the B+/–

FRC Fuse/Relay Card
control fuses. See Fuse/Relay Card on page 8-4.
Interfaces with the operator and various components on the

CCC Carriage Control Card
carriage. See Carriage Control Card on page 8-3.
Interfaces with the guidance coils and VM. See Guidance

GM Guidance Manager
Manager on page 8-4.
Located within the GM. Filters and conditions the voltage from
Filter Card
the guidance coils. See Filter Card on page 8-4.
Receives and conditions the output from the guide wire. See
Antenna Cards
Antenna Cards on page 8-4.
Contactor/Fuse Panel Contactors and power fuses are located on this panel.
Provides for the connection of the electrical devices required for

Auxiliary Card
the optional Auxiliary Mast. See Auxiliary Card on page 8-5.
Processes inputs used for height calculation. See intellispeed

intellispeed Module and Sensor
Module and Sensor on page 8-5.
Displays information and fault codes to the operator. Also

Operator Interface Card contains the push button entry keys. See Operator Interface
Card on page 8-4.

Systems Overview
Systems Overview directly monitors and controls the steering

system of the lift truck in both Auto and
The Orderpicker control system uses five Manual modes of operation, but does not
“intelligent” devices working together to control current limit the steering motor. The VM
the lift truck and respond to operator calculates and maintains the platform height
commands. These devices pass information to count based on direct inputs from the
each other via the communications (CAN) Bus. intellispeed Flow Module. The VM reduces the
The devices are: travel speed of the lift truck as necessary, based
on the platform height and load weight as well
• Vehicle Manager
as traction motor temperature. When in the
• Carriage Control Card guided mode, the VM receives information
• Traction Power Amplifier regarding the lift truck’s position relative to the
wire from the Guidance Manager (GM). During
• Lift Power Amplifier (AC Lift only)
guided operation, the VM receives steering
• Guidance Manager (Wire Guidance Option correction requests from the GM. It is the VM
only) that slows or stops the lift truck as Heading
Angle (HA) and Distance From Wire (DFW)
The system utilizes up to six other limits are reached or exceeded. The VM
“non-intelligent” devices, depending on options. contains a power supply that provides a
The following devices may also be installed on regulated +12V and +5V. It provides +12V to the
the lift truck: CCC. The VM calculates the Battery
• Filter Card (Wire Guidance Option only - State-of-Charge (BSOC) from the voltage
located within GM) measured at Battery Sense In.
• Antenna Cards (Wire Guidance Option
Carriage Control Card
only)
• Operator Interface Card Although the Carriage Control Card (CCC)
• Fuse/Relay Card contains a microprocessor, a communications
chip, and a firmware chip, it has very limited
• Steering Amplifier
decision making ability and communicates only
• intellispeed Module with the VM. The CCC and the VM share
control of the brake release circuitry. The CCC
Intelligent Devices functions primarily as an Input/Output (I/O)
board for the devices connected to it, such as:
Vehicle Manager • deadman switches, sidegate switches, and
lower limit switches
The Vehicle Manager (VM) controls the
• steering tiller encoder
Orderpicker control system. It communicates
with all other devices that are on the • travel and lift potentiometers
communications Bus. It receives, via the CAN
Bus, all requests for travel and lift. The VM also The CCC converts the voltages it reads from
receives information on the status of all these inputs into a message that it sends to the
carriage switches such as the Deadman, VM that takes any action required. The CCC
sidegate, and height switches. It also receives also drives the display and is the only manager
traction motor speed, direction, and that can put codes on the display. The only
temperature information from the Traction code that the CCC can actually precipitate is
Power Amplifier (TPA); and lift motor speed and Code 50 (no VM communications received by
temperature information from the Lift Power the CCC). The VM commands all other codes,
Amplifier (LPA). The VM determines allowable but must go to the CCC that causes the codes
vehicle operation based on those inputs and to be placed on the display. The CCC receives
operator requests. The VM and CCC share +12V from the VM. The CCC then regulates that
control of the brake release circuitry. The VM

Systems Overview
voltage to +5.3V for the various devices that it Guidance Manager

powers.
The Guidance Manager (GM) communicates
Traction Power Amplifier with the VM only. The learned values for wire
guidance are stored in the GM. It determines
The Traction Power Amplifier (TPA) the position of the lift truck relative to the wire
communicates only with the VM, from where it when in the guided mode. The GM uses inputs
receives all commands regarding travel from the Filter Card to calculate the position of
direction and speed. The TPA monitors both the the lift truck relative to the wire. It then reports
traction motor encoder and temperature the lift truck position along with a command for
sensor. It determines, based on the encoder steering direction to the VM over the CAN Bus.
feedback and the travel request, if the lift truck
should be in travel, plugging, or regenerative Non-intelligent Devices
braking, and determines if the performance has
achieved the travel command from the VM. If it Filter Card
has not, the TPA adjusts the motor control
voltage or sends a fault code to the VM, as The Filter Card, attached both physically and
appropriate. The TPA is solely responsible for electrically to the GM, provides voltages from
controlling traction motor current. The TPA the guide wire to the Guidance Manager. The
sends the traction motor temperature to the Filter Card contains circuitry that provides the
VM. The VM then alters the travel request if GM with the guidance voltage levels required for
necessary depending on the traction motor correct operation of the guidance system. It is
temperature. The TPA monitors its internal also connected electrically to the Antenna
temperature and limits current or travel speed Cards that are located under the tractor and
as required by its internal programming. The platform of the lift truck.
TPA also checks the operation of the TPC, the
charging of the amplifiers, and various internal Antenna Cards
operating parameters. It also sends fault codes
to the VM if anything is operating incorrectly. The two Antenna Cards are located along the
center line of the lift truck. The Tractor Antenna
Lift Power Amplifier Card is attached behind the center bumper
plate in front of the drive tire. The Load End
The Lift Power Amplifier (LPA) is used on AC lift Antenna Card is located under the operator
models only. The LPA only communicates with platform between the baselegs. The Antenna
the VM, from where it receives all commands Cards contain circuitry that receives the signal
regarding lift speed. The LPA monitors both the from the floor wire and passes it to the Filter
lift motor encoder and temperature sensor. It Card.
determines from the encoder feedback if the
motor has achieved the commanded speed Operator Interface Card
request. The LPA is solely responsible for
controlling lift motor current. It sends the lift The Operator Interface Card is mounted on the
motor temperature to the VM. The VM then carriage and connected to the CCC. It contains
determines if the motor must be shut down due the data entry push buttons and the character
to motor temperature. The LPA monitors its display that messages and codes are displayed
internal temperature and limits current or lift on. It is driven by the CCC from where it
speed as required by its internal programming. receives all its inputs.
The LPA also checks the operation of the LPC,
the charging of the amplifiers, and various Fuse/Relay Card
internal operating parameters. It also sends
fault codes to the VM if anything is operating The Fuse/Relay Card is a control power
incorrectly. distribution board. It contains the B+ and B–
control fuses and the K1 thru K4 relays. It

Systems Overview
provides B+ and B– to the VM, TPC, LPC, and

CCC.
Steer Amplifier
The Steer Amplifier is an amplifier only. It takes

a low level steering input from the VM and
amplifies it to drive the steering motor. Steer
motor current is limited by the Steer Amplifier.
The Steer Amplifier also provides a steer motor
current feedback voltage and a voltage called
neutral pulse, which confirms amplifier
operation, back to the VM.
intellispeed Module and Sensor
The intellispeed module amplifies the inputs

from the flow sensor and passes them on to the
VM.
Auxiliary Card
The Auxiliary Card acts as an interface between

all switches for the optional aux mast and the
Carriage Control Card.
Stored Value Locations
Value Location
Primary Memory The Primary Memory in this lift

truck is stored in the CCC.
There is a backup copy in the
VM. If the CCC is blank or has
garbled memory, the VM will
send a copy up if the cards can
communicate. If both cards are
valid, but different, then the
CCC will overwrite the VM.
Configure Mode Configure Mode settings are

Settings stored in both the CCC and the
VM.
Learn Mode Learn Mode values are stored

Values in the VM.
Date and Time Date and time are calculated

and stored in the VM. There is
no clock chip on the CCC.
Hour Meters The hour meters (Hours

Deadman, Hours Lifting, Key
Hours, and Traction Miles) are
stored in the CCC.

Traction System
Traction System Travel

When the deadman is depressed, the brake is
Deadman Pedal Depressed released. During Learn Mode, the VM learns the
neutral position for the travel (VR1) and lift
When the Deadman Pedal is depressed, (VR2) potentiometers and stores those values in
switches S2 (Brake Deadman) and S23 memory. During normal use, the VM learns the
(Carriage Deadman) are closed. These switches extreme values for full forward/reverse and full
are connected to the Carriage Control Card. The lift/lower. These values are also stored in
output of S2 is hard wired through the CCC memory in the VM. Refer to page 3-9 for a
and over the mast at JPC11-5 to JPT22-8 as an complete description of Learn Mode. The CCC is
input to the VM processor. The Carriage in constant communication with the VM
Deadman voltage is not used by the CCC. It is through messages that report the status of the
only used by the VM. When S2 closes, it control potentiometers and carriage switches to
switches Carriage Deadman voltage from a high the VM. When the VM receives the message, it
state (>4.5VDC) to a low state (<0.7VDC). When compares the pot position information to the
the VM processor detects a low state at S2, it values that it stored when it learned the pots.
also needs to receive information that S23 is
closed. When the control handle is moved from neutral,
the CCC detects a different voltage at JPC9-9
When S23 closes, it activates a circuit on the from VR1. The CCC updates the VR1 position
CCC that provides a high input (>4.5VDC) value in the next message sent to the VM. When
through the connect detect jumper (steering the VM receives the new position value, it
request encoder connector JPC1-8 and 9) to the compares that position value to the learned
processor on the CCC. The purpose of this value for VR1 to determine the direction and
connect detect jumper is to make sure that the magnitude of the travel request. The VM then
steering card is connected before the brake is looks at all speed limiting inputs such as motor
released. When the processor receives that temperature, height, weight, steering angle, and
voltage, it performs two operations fault codes to determine if the requested speed
simultaneously. It sends a message over the is allowable. The VM then initiates a command
communications bus telling the VM that the for the appropriate direction and speed to the
Brake Deadman is depressed. When the VM TPA over the communications Bus. The CCC is
receives that message, it acknowledges to the constantly monitoring the travel request at VR1
CCC that the message was received. The CCC and updating the VR1 position value to the VM.
also activates a circuit on the CCC that The VM therefore, constantly updates the travel
switches the output Brake Deadman (JPC11-4) command to the TPA.
from a high state (>4.5VDC) to a low state
(<0.7VDC). The output Brake Deadman is hard When the TPA receives a travel command from
wired from the CCC at JPC11-4 to the VM at the VM, it produces a control output to the
JPT22-7 through the over-the-mast cable. traction motor. All operational parameters that
affect travel motor torque and speed are
To release the brake, the VM must know that all controlled exclusively by the TPA. It monitors
deadman switches are operational and that the motor current, voltage, and RPM, and from
steering encoder is connected. When the VM them, can determine motor performance. The
receives the communication message that S23 TPA will alter its control output to the traction
is closed, and detects low inputs at both motor to match the motor performance to the
JPT22-7 (Brake Deadman) and JPT22-8 travel command from the VM. As the travel
(Carriage Deadman), it knows that all the request from the CCC to the VM changes, so
required conditions are met. The VM then does the travel command from the VM to the
provides B– to JPT20-14 (Brake) that energizes TPA that in turn, alters motor operation to track
the brake coil and releases the brake. the travel request from the operator. The TPA
also monitors drive motor temperature and the

Travel
internal temperature of the amplifier and can

alter travel based on the TPA temperature. The
TPA sends motor temperature to the VM, and
the VM alters the travel command based on
traction motor temperature.
When the lift truck is moving and the travel

control handle is moved to request the opposite
direction, the same sequence of events takes
place. The VM does not request plugging or
regeneration: it just requests travel in the
opposite direction at whatever speed the CCC
communicated. The TPA, that calculates both
direction and speed, determines whether the
travel command from the VM must be met with
a travel, a plug, or a regeneration control
output to the traction motor.

Steering System
Steering System the steering motor to obtain the movement that

was requested from the tiller.
This section contains a description of the Both steering encoders in the dual encoder
steering system. For wire guided steering must be operational for full travel speed. If only
information, refer to page 8-13. one steering encoder is operational, travel speed
is limited to 2.5 mph (4.0 km/h).
System Components
The VM monitors steer current (JPT6-3), the
• Steering Request Encoder – a dual Steer Motor Encoder, and Neutral Pulse to
encoder located behind the steer wheel on determine that the steering system is operating
the carriage converts the operator request correctly. The VM supplies +12VDC to the Steer
into electronic pulses Amplifier at JPT6-6 to power the circuits inside
• Carriage Control Card - converts the the Steer Amplifier. When the deadman is
inputs from the steering request encoder depressed, the VM energizes the TPC contactor,
into a message sent to the Vehicle providing B+ to TP2 on the Steer Amplifier to
Manager power the steer motor.
• Vehicle Manager - the controlling
manager of the steering system. Generates Functional Description
commands to the steer amplifier based on
the message from the Carriage Control The dual steering encoder is connected to the
Card CCC at JPC1 (encoder 1) and JPC21
(encoder 2). Each encoder has a +5.3V supply,
• Steer Amplifier - amplifies the steering
a DGND, two quadrature phased channels
commands from the Vehicle Manager and
(CHA and CHB), and a jumper that is used as a
drives the steer motor
connect detect to make sure that the steering
• Electric Steer Motor/Gear Reducer - encoder is connected to the CCC before normal
positions the drive unit operation of the lift truck is allowed by the VM.
• Steer Motor Encoder - located inside the
steer motor and used to determine if the When the tiller is moved, each encoder
motor is responding to the commands of produces an output pair (CHA and CHB from
the VM encoder 1 and CHA-E2 and CHB-E2 from
encoder 2). If the tiller is turned faster, the
• Home Sensor Prox - used by the steering
frequency of the output from the encoder
system to position the drive unit straight
increases. Each pair is converted into a positive
ahead during Auto Steer Center
or negative steering count that contains
information on the direction and speed of the
System Overview steering request from the tiller. This is sent over
the communications bus to the VM. If either of
The Steering Request Encoder is attached to the the steering counts are missing, the VM will
steer tiller on the carriage. The Steering Request cause a steering code to be displayed;
Encoder is a dual encoder. It contains two
• Code G0 if CHA/CHB is missing
encoders in a single package.
• Code G7 if CHA-E2/ CHB-E2 is missing
Each encoder produces two channels that are
quadrature phased and are used by the CCC to When the VM receives the steering count from
produce a steering request (steering count) that the CCC, it produces the appropriate steering
is sent to the VM over the communications bus. command for the Steer Amplifier. This steering
The VM, in turn, sends steering commands for command is sent to the Steer Amplifier at
either clockwise or counterclockwise rotation to JPT6-5 (CCW-PWM for CCW rotation) or JPT6-2
the Steer Amplifier. The Steer Amplifier drives (CW-PWM for CW rotation). Although these
commands are a PWM voltage, either can be

Functional Description
measured as a DC voltage with a Digital Multi that the encoder is not connected and the VM
Meter. The voltage will vary from approx. causes a Code G7. If the jumper is intact and
11VDC when the steering tiller is stationary, encoder 2 fails, the CCC will send a count for
and decreases as the steer tiller is moved faster. encoder 1 and not encoder 2, to the VM, and
A slow request is represented by a voltage of the VM will still cause a Code G7. Either failure
about 9VDC and a fast request is represented will cause the same code.
by a voltage of approx. 5VDC measured with
respect to (wrt) B–. Because the VM is
monitoring both the steer motor current and
the output from the Steer Motor Encoder, it
knows that the steer motor moves when
requested.
When the steer motor is not moving, there is no

input to the VM from either the steer motor
current or the steer motor encoder. This
situation can occur when driving in a straight
line. The VM needs a way to make sure the
steer system is operational. This is
accomplished through the Neutral Pulse. When
the Steer Amplifier has an input at the
CW-PWM line, it drives the Neutral Pulse
output low (<0.5VDC). When the Steer Amplifier
has an input on the CCW-PWM, it drives the
Neutral Pulse high (>4VDC). When the
deadman is depressed and there is no input on
either the CW-PWM or the CCW-PWM lines, the
VM dithers the CW-PWM and CCW-PWM
control lines, causing the Neutral Pulse line to
toggle between high and low states. The VM
detects the Neutral Pulse is toggling as the
CW-PWM and CCW-PWM lines vary, thereby
informing the VM that the steering system is
operational.
The connect detect jumper for encoder 1 is

JPC1-8 and 9 and is called BRKDMAN/
DEADMAN. If that jumper is open or JPC1 is
disconnected, the hard wired voltage, BRAKE
DEADMAN, from the CCC to the VM is
interrupted and the VM will cause a Code 8C. If
the jumper is intact and the encoder fails, the
VM will lose steering encoder one and the VM
will cause a Code G0.
The connect detect jumper for encoder 2 is

JPC21-5 and 6 and is called CD SUPPLY/CD.
This jumper connects a 5VDC supply to an
input on the CCC processor. When the voltage
is present, the CCC sends a message to the VM
that the steering encoder is connected. If the
voltage is not present, the message to the VM is

Lift/Lower System
Lift/Lower System enough to start elevating the side cylinders. Oil

flow spins the turbine in the flow sensor. As the
turbine spins, the vanes pass by the magnetic
Emergency Lower pickups screwed into the flow sensor housing.
This creates a series of high and low pulses (or
Provisions are made to lower the carriage from counts) that go into the flow sensor module. The
the ground. When the Emergency Lower Valve pickups are 90° out of phase. This allows the
is opened, hydraulic fluid is allowed to pass system to determine if the carriage is elevating
through the emergency lower valve at a or lowering, based on the direction the vanes
constant rate. are spinning. The flow sensor module passes
these counts to the VM. The VM determines the
direction of travel and the number of counts.
Variable Speed DC Lift with The VM uses this information to calculate fork
intellispeed height, which it uses to determine speed
reductions at elevated height.
NOTE: For lift trucks without intellispeed, all
functions are the same excluding When the VM first commands the activation of
references to the flow sensor, the lift system, it is looking for the feedback
intellispeed Manager, and height counts. from the flow sensor. If the lift is commanded to
activate and no counts from the flow sensor are
The CCC is constantly monitoring the output present, the VM will flag an error condition and
voltage of VR2 and sending it to the VM over the assume it is at maximum elevated height for
BUS. The VM compares this voltage to the speed limiting. Travel speed is reduced linearly
voltages stored during the Learn process. The by about 0.5 mph (0.8 km/h) for every
VM checks the battery voltage (for lift cutout), 18 in. (45.7 cm) from full speed down to 1 mph
all enabled options and switches that could (1.6 km/h), between the lower reference switch
prevent the activation of the lift system. When and 240 inches (610 cm). A low volume of fluid
satisfied that no criteria are present to prevent flow will not cause the turbine to spin. Because
lift, it then determines the requested percentage of this, if the lift system is feathered often, an
of full speed lift. It then activates the lift/lower error is registered. If the intellispeed option is
proportional valve fully open and closes the lift not on the lift truck, the travel is reduced each
pump contactor by taking the coils to B–. time a mast limit switch is opened while
elevating.
Opening the lift/lower valve fully prevents
sudden movement of the platform when the lift The VM monitors the P Sense line to determine
pump is first activated by allowing the fluid to the condition of the P contactor and verify the
return to the tank. As soon as the command to lift motor is spinning. When a lift request has
close the P contactor is activated, the VM looks finished (VR2 has either returned to neutral or
at the P Sense input, verifying the contactor through neutral to a lower request), the VM
closed as commanded. It then slowly reduces monitors the P Sense line for back
the PWM output to the coil for the lift/lower ElectroMotive Force (EMF) from the motor to
proportional valve to match the percentage of determine that the lift motor has stopped
full speed lift requested. As the lift/lower spinning. As long as the VM senses voltage on
proportional valve closes, hydraulic fluid passes the P Sense line, it will provide voltage to the
through the 5 psi (34 kPa) check valve, the lift/lower proportional coil, keeping the valve
normally closed check valve in the load holding open to allow the fluid from the pump to return
valve, through the flow sensor to the flow to tank. This makes sure that the cylinders do
controls at the bottom of the lift cylinders. The not continue lifting after the request has ended.
flow control in the center cylinder allows Once the lift motor has completely stopped
unrestricted fluid flow to the center lift ram. The spinning, the VM removes voltage to the
center ram elevates first because less pressure lift/lower coil, closing the lift/lower
is required. Once the platform hits the stops on proportional valve.
the inner telescopic, the pressure increases

24V Lift Trucks With Hi-Pro Option
24V Lift Trucks With Hi-Pro The LPA monitors the input from the bearing
encoder in the lift motor and determines the
Option RPM of the motor. It adjusts the output to the
motor to maintain the requested RPM. The
24V lift trucks with the Hi-Pro Option have a
hydraulic fluid passes through the 5 psi
two stage lift pump. This lift pump has a 2nd
(34 kPa) check valve, the normally closed check
stage select solenoid on the bottom of the
valve in the load holding valve, through the flow
pump. This solenoid is activated whenever
sensor to the flow controls at the bottom of the
there is less than 1000 lb. (454 kg) on the forks.
lift cylinders. The flow control in the center
When activated, the fluid from the second pump
cylinder allows unrestricted oil flow to the
is ported to the lift system to increase lift speed.
center lift ram. The center ram elevates first
The weight calculation is done with either a
because less pressure is required. Once the
pressure transducer or a pressure switch (lift
platform hits the stops on the inner telescopic,
trucks without intellispeed) located on the
the pressure increases enough to start elevating
hydraulic manifold. The input from the
the side cylinders. As the lift cylinders start to
pressure switch goes directly to the VM and
elevate, the fluid flow starts to spin the turbine
activates a circuit to turn off the 2nd stage
in the flow sensor once the volume is large
select solenoid. On lift trucks with the pressure
enough. As the turbine spins, the vanes pass by
transducer, the VM calculates the weight and
the magnetic pickups screwed into the flow
turns off the solenoid when a reading of 1000
sensor housing. This creates a series of high
lb. (454 kg) or more is registered.
and low pulses (or counts) that go into the flow
sensor module. The pickups are 90° out of
Variable Speed AC Lift with phase. This allows the system to determine if
intellispeed the carriage is elevating or lowering, based on
the direction the vanes are spinning. The flow
NOTE: For lift trucks without intellispeed, all sensor module passes these counts to the VM.
functions are the same excluding The VM determines the direction of travel and
references to the flow sensor, the number of counts. The VM uses this
intellispeed Manager, and height counts. information to calculate the fork height that it
uses to determine speed reductions at elevated
The CCC is constantly monitoring the output height. When the VM first commands the
voltage of VR2 and sending it to the VM over the activation of the lift system, it is looking for the
BUS. The VM compares this voltage to the feedback from the flow sensor. If the lift is
voltages stored during the Learn process. The commanded to activate and no counts from the
VM checks the battery voltage (for lift cutout), flow sensor are present, the VM flags an error
all enabled options, and all switches that could condition and assumes it is at maximum
prevent the activation of the lift system. elevated height for speed limiting. Travel speed
is reduced linearly, about 0.5 mph (0.8 km/h)
When satisfied that no criteria are present to every 18 in. (45.7 cm), from full speed down to
prevent lift, the VM then determines the 1 mph (1.6 km/h), between 60 (152 cm) and
requested percentage of full speed lift. It then 240 inches (610 cm). A low volume of fluid flow
sends an RPM command over the BUS to the will not cause the turbine to spin. Because of
Lift Power Amplifier. The LPA activates the LPC this, if the lift system is feathered often, an
contactor by taking the coil to B– internally in error is registered. If the intellispeed option is
the LPA. As soon as the command to close the P not on the lift truck, the travel is reduced each
contactor is activated, the LPA looks at the (+) time a mast limit switch is opened.
input from the LPC verifying the contactor
closed as commanded. It then slowly increases
the voltage output to the lift motor to match the
RPM requested. As the voltage is increased to
the lift motor, the motor and pump spin faster,
increasing the output of oil to the lift system.

Variable Speed Lower Activation
Variable Speed Lower the forks get hung up while lowering, there is a
180 psi (1241 kPa) check valve in series with
Activation the side lift cylinders and a 100 psi (689 kPa)
check valve in the manifold for the center
The following is based on a lower request from a
cylinder. If the pressure on these valves is
full speed lift situation.
reduced below their rated pressure, the check
valve closes, stopping the lower function. This
VR2 passes through neutral to a full speed
keeps fluid from draining out of the cylinders
lower request. The CCC sends the voltage to the
and keeps the over the pulley hoses, cables,
VM over the BUS. The VM recognizes the
and lift chains from falling off the pulleys.
change and realizes full speed lower is required.
All enabled options and switches that can
prohibit lower are checked.
Once the VM is satisfied that lower can be

allowed, it monitors the back EMF of the lift
motor through the P Sense line. The VM
monitors the P Sense line to determine the
condition of the P contactor and verifies the lift
motor is spinning. When a lift request has
finished (VR2 has either returned to neutral or
through neutral to a lower request), the VM
monitors the P Sense line for back EMF from
the motor to determine that the lift motor has
stopped spinning. As long as the VM senses
voltage on the P Sense line, it provides voltage
to the lift/lower proportional coil, keeping the
valve open to allow the fluid from the pump to
return to tank. This makes sure that the
cylinders do not continue lifting after the
request has ended.
Once the lift motor has completely stopped

spinning, the VM removes voltage to the
lift/lower coil, closing the lift/lower
proportional valve. The Load Holding solenoid is
activated by the VM, opening the valve. The VM
then gradually opens the lift/lower solenoid to
the percentage of requested lower. This allows
the oil to flow from the side lift cylinders
through the flow controls at the bottom of the
cylinders, the 180 psi (1241 kPa) telescopic
hang up valve, the flow sensor, the load holding
valve, the lift/lower prop valve, the 100 psi
(689 kPa) platform hang up valve, the filter, and
back to the reservoir. The telescopics lower first
due to the greater amount of pressure on the
hydraulic fluid in the side cylinders. Once the
telescopics fully lower, the center cylinder
begins to lower. Lowering causes the turbine in
the flow sensor to spin in the opposite direction
of lift and reverses the counts to the VM. The
VM counts down, lowering the height count. If

Wire Guidance System
Wire Guidance System signal conditioning inputs to the

Antenna Cards as dictated by the
frequency selection in Configure Mode
This section contains a description of the wire and other program constraints.
guidance system. For manual steering
Guidance Card - calculates the
information, refer to page 8-8.
position of the lift truck relative to the
guide wire using the voltages received
System Components from the Filter Card. The Guidance
Card informs the VM of the necessary
• Auto/Manual Switch (S4) – located on the
steering corrections to keep the lift
dashboard near the speed control handle.
truck over the wire, guidance system
This switch is used by the operator to
error codes, distance from wire, and
select manual steering or wire guided
heading angle information.
operation.
• Antenna Cards - there are two of these
• Carriage Control Card - located behind
antenna assemblies. The Tractor Sensor is
the console cover and below the steer tiller
located behind the center bumper plate in
assembly. It monitors the state of the
front of the Drive Unit. The Load Sensor is
Auto/Manual switch and advises the VM if
located on a bracket between the baselegs
it is open (Auto) or closed (Manual). Also
beneath the operator platform. Each
operates the wire guidance icon LEDs on
sensor card has 4 coils mounted on it. The
the Carriage Light Display card.
center pair are the Nearwire Coils and the
• Vehicle Manager - located in the tractor outer coils are the Guidance Coils. These
compartment. It is the controlling manager sensor coils have an AC voltage induced
for the steering and travel systems. When into them by the magnetic field being
it is advised that the Auto/Manual switch radiated from the guide wire. These AC
is in the Auto position, it uses the lift truck voltages are then amplified and sent to the
position information supplied by the Filter Card.
Guidance Manager to provide steering
• Steer Motor Encoder - when the steer
control for the lift truck. The VM also
motor armature is rotating, the steer
provides direction and speed information
motor encoder produces a pair of
to the Guidance Manager that enables it to
quadrature phased square waves that are
provide correctly oriented steering
used by the VM to determine steer motor
commands for either forward or reverse
speed and direction of rotation. The VM
directions of travel.
then checks this information against the
• Steer Amplifier - located at the rear wall steering commands from the GM to verify
on the top deck of the tractor correct operation.
compartment. It amplifies the steering
• Home Reference Prox Sensor - used by
commands from the VM and provides the
the VM to determine “Home” or straight
high power drive necessary to control the
ahead position of the drive unit.
steer motor.
• Guide Wire - a wire that is buried in the
• Guidance Manager (GM) - located on the
facility floor that radiates a magnetic field
right side of the drive tire wheel well
when an AC current flows through it.
housing in the tractor compartment. This
assembly is comprised of two physically
and electrically connected printed circuit
cards:
Filter Card - conditions and amplifies
the AC guidance voltages received from
the Antenna Cards and converts them
into DC voltages usable by the
Guidance Card. It also supplies digital

System Overview
System Overview The GM then tells the VM to put the lift truck
into Seeking Mode and try to acquire the wire.
When the lift truck is in the wire guided mode, Travel speed is limited to 1 mph (1.6 km/h) in
the lift truck steering functions the same way as the forks-first direction and limited to the
when in the manual steering mode with one Acquire speed that is set in Configure Mode for
exception. Steering requests do not come from tractor-first travel. If the Wire Sense Creep
the CCC when in wire guided mode as they do (WrSnCrp) option is enabled in Configure Mode,
in manual steering. In the wire guided mode, lift truck speed is limited to 1 mph (1.6 km/h)
steering requests originate in the GM. To switch whenever S4 is detected closed (Manual
from manual steering to the wire guided mode, position) and the GM reports that a guide wire
several events need to occur. is detected. During Seeking Mode, an audible
tone is generated and the green LED triangles of
First, the CCC needs to detect that the the wire guidance icon (on the Carriage Light
Auto/Manual switch (S4) is open (Auto Display card) will blink. Steering at this time
position). Next, the CCC needs to advise the VM will still be in manual control because the lift
that S4 is open. When the VM is advised that truck has not acquired the wire. The operator
S4 is in the Auto position, it transfers steering must be steering the lift truck toward the guide
control from the Steering Encoder to the GM. wire location to help the lift truck acquire the
The GM calculates the position of the lift truck wire.
relative to the wire and advises the VM what
direction and how far to steer the drive unit. As either the tractor end or the load end center
During wire guided operation, the GM is pair of sensor coils (Nearwire coils) approach
constantly updating the VM with corrections the guide wire, they begin to detect the
since the lift trucks position relative to the magnetic field around the guide wire. If the
guide wire is constantly changing. If the lift Nearwire coils do not detect this magnetic field
truck exceeds the deviation values for Distance for any reason, the lift truck will not acquire the
from Wire (DFW) or Heading Angle (HA) that are wire, even if the outer coils (guidance coils)
set in Configure, the GM informs the VM to detect the magnetic field. The magnetic field
either slow or stop the lift truck depending on around the guide wire causes an AC voltage to
the magnitude of the deviation. be induced into the sensor coils that is sent to
the Filter Card (GM) for conditioning. The Filter
Card removes any noise that was picked up by
Functional Description the antenna coils and also converts this AC
voltage into a DC voltage to be used by the
During normal manual steering operation, the
Guidance Card. As either the tractor end or the
CCC is in constant communication with the
load end Nearwire coils get closer to the wire,
VM, updating the VM with the status of the
the value of the DC voltage to the Guidance
components connected to it such as switches,
Card increases. When the Nearwire coils get
the control handle, and the Steering Encoder.
close enough (to the wire), and the voltage is
Likewise, the GM is constantly attempting to
high enough, the Guidance Card tells the VM to
calculate the position of the lift truck relative to
release full control of issuing the steering
the guide wire. The VM is constantly being
commands to the Guidance Card.
updated as to the position of the drive unit
relative to home position as well as travel speed
When the Guidance Card takes over issuing
and direction that it in turn communicates to
steer commands, the lift truck is in an Aligning
the GM. When the CCC detects that S4 is
Mode. While in Aligning Mode, the VM ignores
opened (Auto position), it advises the VM that
the steering request from the CCC and all the
S4 is open. The VM determines that the lift
wire guidance icon LEDs on the Carriage Light
truck is ready for wire guided operation and
Display Card will blink. The lift truck is now
transfers the steering control from the Steering
auto steering and no longer responds to
Encoder to the GM.
operator steer tiller inputs. The Guidance Card
also monitors the DC voltages from the Filter

System Overview
Card representing the AC voltages being picked magnets or by traveling and turning the
up by the outer coils (Guidance Coils) on both steering more than 10°. This allows the lift
the tractor end and the load end sensors as the truck to be powered down inside the aisle and
lift truck begins to align over the wire. When the remember that it is in an In-Aisle-State when
voltages that the lift truck detects from the load powered back up. System operation is not
end and tractor end guidance coils begin to changed upon aisle entry.
balance out and match the Learned Offset When the lift truck is exiting an aisle and each
values for those coils, the Guidance Card will sensor is activated by magnets within 10 in.
switch from Aligning Mode to Locked on Wire or (254 mm) of each other, the lift truck will plug
Guided Mode. At that time, all of the wire to reduce speed until the speed is reached that
guidance icon LEDs on the Carriage Light is stored in the Configuration Menu. Once this
Display Card will illuminate solid and full travel speed is reached, travel speed is limited by the
speed is allowed in either direction. VM to the speed programmed in the
Configuration Menu until the control handle is
The Guidance Card constantly monitors the returned to neutral and travel is requested
voltages from each of the four guidance coils via again. During the plugging sequence, the
the Filter Card. It compares the voltage from operator can override the plugging strength
each coil to the value for each coil that was with a request for a more aggressive plug from
obtained through the Learn procedure. By the control handle. When the sensors are
comparing the actual values for all four activated by magnets that are more than 11 in.
guidance coils with the learned values stored in (279 mm) but less than 30 in. (762 mm) apart,
the memory, the Guidance Card can issue the the VM plugs the lift truck to a complete stop.
appropriate steering commands to the VM to The operator must then return the control
keep the lift truck centered over the guide wire. handle to neutral and request travel again.
Also, using these values, the Guidance Card
calculates the Heading Angle (HA - angle of the End-of-Aisle Configurations
lift truck to the wire) and the Distance From
Wire (DFW - how far the lift truck is from the Figure 8-1 shows the various EOA
wire) and issues the appropriate Slow or Stop configurations possible within a system.
commands to the VM when DFW or HA values
set in Configure Mode are exceeded. See
Table 3-2, “Configure Mode Menu,” on End-of-Aisle Magnet Installation
page 3-14. Information
If there are consistent, repetitive problems with

End-of-Aisle Control
end-of-aisle operation, and the lift truck
appears to be OK, the magnets may have been
The End-of-Aisle system consists of lift truck
installed out of tolerance. Figure 8-2 and
mounted components and magnets embedded
Figure 8-3 depict the correct location of the
in the floor inside of the aisle. The lift truck
magnets.
mounted hardware consists of four magnet
sensors mounted between the baselegs under
the operator's platform. They are connected
directly to the VM. When the system is
activated, the VM monitors the inputs from the
sensors. When entering the aisle and both
sensors cross a magnet in less than 24 in. (610
mm), the VM recognizes this as In-Aisle-State.
This information is stored in Non Volatile
Memory (NVM). NVM cannot be changed by a
loss of power to the system. The only way to
change it is by another input. This input can
only be initiated by crossing another set of

System Overview
Vehicle will slow to configured end-of-aisle

speed when parallel magnets are crossed.
Magnets Parallel
Vehicle will plug to a stop when

staggered magnets are crossed
(or just one magnet is sensed).
Magnets Staggered
Vehicle will slow to configured end-of-aisle speed when

parallel magnets are crossed.
Vehicle will plug to a stop when staggered magnets are

crossed (or just one magnet is sensed). Magnets parallel at one end
and staggered at the other.
Magnets parallel in one aisle and staggered in the next.

Vehicle will slow to configured speed in aisle that has parallel magnets and plug to a stop
in aisle that has staggered magnets.
8
Figure 8-1. End-of-Aisle Configurations
20 ft. ±3 in. (6.1 m ±7.6 cm) 4.5 in. ±1/2 in.

Both Ends (114 mm ±13 mm)
Both Ends
Guide Wire*
4.5 in. ±1/2 in.

(114 mm ±13 mm)
Magnet
Both Ends
Magnet Position for Deceleration
* In rail guided applications, use the center of the aisle as the reference point for the dimensions.
8
Figure 8-2. End-of-Aisle Magnet Position (Deceleration)

End-of-Aisle Slow Down
20 ft. ±3 in. (6.1 m ±7.6 cm)

Both Ends
4.5 in. ±1/2 in.
(114 mm ±13 mm)
Both Ends
Guide Wire*
4.5 in. ±1/2 in.

(114 mm ±13 mm)
Magnet
Both Ends
24 in. ±1 in.
(610 mm ±26 mm) Both Ends
Magnet Position for Auto Stop
*In rail guided applications, use the center of the aisle as the reference point for the dimensions.
8
Figure 8-3. End-of-Aisle Magnet Position (Auto Stop)
20 ft (6.1 m) 20 ft
(6.1 m)
4.50 in.
4.50 in. (11.4 cm)
(11.4 cm)
Center of Aisle Magnet
8
Figure 8-4. End of Aisle Magnet Location
End-of-Aisle Slow Down whichever the system is configured for. If the

AUTO/ MANUAL switch is moved to the
MANUAL position prior to crossing the
With Wire Guidance magnets, the system will not look for the
magnets. Steering is reverted to the operator
When the lift truck is locked on the guide wire,
and normal operation is resumed. Once out of
the VM will start looking for the input from the
the aisle and the steering is turned more than
magnet sensors. When a set of magnets is
10° while traveling, the aisle state is reset to
crossed entering the aisle, the system functions
out-of-aisle.
as described in End-of-Aisle Control. If the
magnets are crossed while exiting the aisle with
the AUTO/MANUAL switch in the AUTO
position, the lift truck will slow down or stop;

End-of-Aisle Slow Down
With auto steer center in a rail

guided system WITH a rail switch
installed on one guide roller
assembly.
When the lift truck enters the rails, the switch

mounted on the guide roller assembly is closed.
When the switch is activated, a tone will sound
and the lift truck is speed limited until the
AUTO/MANUAl switch is placed in the AUTO
position. When the switch is placed in the
AUTO position, the drive unit auto steer centers
and steering control is taken away from the
operator. The speed restriction is removed and
full speed travel is allowed. The VM then starts
looking for floor magnet inputs. When exiting
the aisle, if the magnets are crossed with the
AUTO/MANUAL switch in the AUTO position,
the lift truck will slow down or stop, depending
on system configuration. If the AUTO/MANUAL
switch is moved to the MANUAL position prior
to crossing the magnets, the system will not
look for the magnets. Steering is reverted to the
operator and normal operation is resumed. An
audible tone sounds until either the
AUTO/MANUAL switch is turned back to AUTO
or the rail switch on the guide roller opens.
Once out of the aisle and the steering is turned
more than 10° while traveling, the aisle state is
reset to out-of-aisle.
With auto steer center in a rail

guided system WITHOUT a rail switch
installed on the guide roller
assembly.
When the lift truck is in the aisle and the

AUTO/MANUAL switch is in AUTO, the VM will
start looking for the input from the magnet
sensors. When a set of magnets is crossed
entering the aisle, the system functions as
described in “End-of-Aisle Control” on
page 8-15. When exiting the aisle, if the
magnets are crossed with the AUTO/MANUAL
switch in either position, the lift truck will slow
down or stop, depending on how the system is
configured.

Models 5400/5500/5600 Maintenance Manual Section 8. heory of Operation
Pin-Out Matrix
Pin-Out Matrix • Normal Level: the approximate voltage

Section 8. heory of Operation
that must be seen on that wire for the

state indicated. Unless otherwise
The pinout matrix chart lists functions and indicated, voltages are measured with
normal voltages of terminals and harness respect to (wrt) B– at TP4.
connector pins. The matrix columns have the • Signal Source: the device or connection
following meanings: that supplies the signal directly to the
• Item: sequential number to aid in wire.
reference. • Signal User: the device or connection
• Connection: the actual wire numbers or where the wire directly delivers the signal.
component abbreviations on the electrical
schematic.
• Function Description: brief definition of
the signal carried on the wire.
• Theory of Operation:
• A detailed description of the signal
carried on the wire. If the signal can be
variable, the state of a related
component that will cause the signal to
vary is indicated.
• Identifies possible causes for lack of
correct signal.
Function Signal Signal

Item Connection Theory of Operation Normal Level
Description Source User
1 JPC1-1 +5.3V Supplies +5.3V to the Steering Request >5V CCC Steering
Encoder. It is dependent on the +12VP Request
from the VM and JPC11-1. Encoder
2 JPC1-2 DGND B– for the circuits of the Steering Request <0.3V wrt TP4 CCC Steering
Encoder. Request
Encoder
3 JPC1-3 CHA One part of the steering request from 0-5V nominal Steering CCC
the Steering Request Encoder when the w/tiller moving; Request
steering tiller is moved. It is a square >4.5V or <0.5V Encoder
wave signal (0V and 5V) identical to w/tiller
CHB but different phase. The CCC uses stationary
the phase relationship of CHA/CHB to
determine the direction and speed of the
steering request.
4 JPC1-4 CHB One part of the steering request from 0-5V nominal Steering CCC
the Steering Request Encoder when the w/tiller moving; Request
steering tiller is moved. It is a square >4.5V or <0.5V Encoder
CHA but different phase. The CCC uses stationary
the phase relationship of CHA/CHB to
determine the direction and speed of the
steering request.

Section 8. heory of Operation Models 5400/5500/5600 Maintenance Manual
Pin-Out Matrix

5 JPC1-8 BRAKE Output of the Brake Deadman switch >5V w/pedal CCC VM
DEADMAN (S2 at JPC7-1) that is looped back to the depressed;
CCC at JPC1-9 and sent to the VM to <0.5V w/pedal
inform the VM of the status of S2. If the released
Steering Request Encoder Cable
becomes unplugged, the VM will not
release the brake.
6 JPC1-9 BRAKE Receives output from JPC1-8 and sends >5V w/pedal CCC VM
DEADMAN the VM the status of S2. If the Steering depressed;
Request Encoder Cable becomes <0.5V w/pedal
unplugged, the VM will not release the released
brake.
7 JPC2-1 DGND B– for the Operator Interface Card. <0.3V wrt TP4 Fuse/Relay Operator
Card Interface
8 JPC2-2 UP ARROW The CCC monitors this input to >5V w/switch Operator CCC
determine when the up arrow on the open; Interface
Operator Interface is depressed. <0.5V w/switch
closed
9 JPC2-3 DN ARROW The CCC monitors this input to >5V w/switch Operator CCC
determine when the down arrow on the open; Interface
Operator Interface is depressed. <0.5V w/switch
closed
10 JPC2-4 ETR/SHFT The CCC monitors this input to >5V w/switch Operator CCC
determine when the Enter/Shift button open; Interface
on the Operator Interface is depressed. <0.5V w/switch
closed
11 JPC2-17 Not Usable
12 JPC3-1 60” LIMIT The voltage on this line changes when <1V w/switch CCC CCC
the platform crosses S28 (60” Limit closed;
Non-intellispeed Switch). This change in voltage is used >9V w/switch
lift trucks by the CCC to limit travel speed. S28 open
opens when the platform is above the
60 in. switch and speed is limited to
1 mph (1.6 km/h) maximum. When the
platform is below 60 in. (1524 mm),
S28 is closed and the speed is
configurable from 0.5 to 2.5 mph (0.8
to 4.0 km/h).
Intellispeed Lift There is a jumper on the CCC at JPC3.

Trucks Travel speed above S28 is determined
by height. The lift truck will have full
configured speed to 60 in.
13 JPC3-2 6-12VF 12V supply to S28 (60” Limit Switch). 6-8.8V VM S28
w/switch
connected;
>8.8V w/switch
disconnected
14 JPC3-3 PGND B– for S28 (60” Limit Switch). <0.3V wrt TP4 VM S28

Pin-Out Matrix

15 JPC4-1 LOWER INHIBIT Output from S25 used by the CCC to <1V w/platform S25 CCC
detect the location of the operator below switch;
platform. approx. 10V
with platform
above switch
16 JPC4-2 +12VF 12V supply to S25 (Lower Inhibit 10.8-13V VM S25

Switch). w/key switch
ON
17 JPC4-3 PGND B– for S25. <0.3V wrt TP4 VM S25
18 JPC5-1 B+KEY B+ that is switched by the key switch B+ w/key CCC Light and
and powers the optional light and fan. switch ON Fan
package
19 JPC5-2 B–F B– for the optional light and fan. <0.3V wrt TP4 CCC Light and
Fan
package
20 JPC5-3 B–F B– for the CCC power option (Control <0.3V wrt TP4 CCC Handle
Handle Heater). Heater
21 JPC5-4 B+KEY B+ that is switched by the key switch B+ w/key CCC Handle
and powers the CCC power option switch ON Heater
(Control Handle Heater).
22 JPC6-1 B+F B+F to S1 (Key Switch). If B+ is not B+ wrt TP4 Fuse/Relay S1

present, check for B+ at JPC16-3. w/battery Card
connected and
FU5 good
23 JPC6-2 B+KEY B+ switched by the key switch. If B+ is B+ w/key Fuse/Relay All

missing, check for B+ at JPC6-1. switch ON and Card
FU5 good
24 JPC6-2 B+KEY B+ for Security Start Switch Relay. B+ CCC K2 Relay

for
Security
Start
Switch
25 JPC6-3 B+ESTOP B+ after going through S21 (ESTOP B+ when ESTOP CCC Fuse/
switch). If B+ is missing, the CCC will button is up Relay
display EPO depressed. Check for B+ at (closed) Card
JPC6-4.
26 JPC6-4 B+KEY B+ Key from JPC6-2 to supply B+ Estop B+ from JPC6-1 S1 S21
when S21 is out (closed).
27 JPC6-5 DGND B– for S7. <0.3V wrt TP4 VM S7
28 JPC6-6 L/L INHIBIT Determines whether the CCC will allow >5V w/S7 CCC CCC
BYPASS lift or lower when either lift or lower limit closed (up);
is reached. When S7 is closed, <0.5V w/S7
lift/lower is prevented when the cutout open (down)
switch is activated. When S7 is open,
lift/lower is allowed.

Pin-Out Matrix

29 JPC7-1 BRAKE The CCC monitors the state of S23 >4V up CCC VM and
DEADMAN (Brake Deadman) directly. The VM (released); CCC
detects the state of S23 at JPT22-8. The <0.5V down
CCC and the VM communicate S23 (depressed)
status and must agree that it is
depressed before the brake is released.
30 JPC7-2 +12VF 12V supply to S2 (Carriage Deadman 10.8-13V VM S2

ON
32 JPC7-4 CARRIAGE The CCC monitors the voltage on this >10V w/S2 up; CCC VM and
DEADMAN line to determine the state of S2. This <0.5V w/S2 CCC
signal is looped through the Steering down
Request Encoder at JPC1-8 and 9 and
sent to the VM at JPT22-7.
33 JPC7-5 +12VF 12V supply to S23 (Brake Deadman 10.8-13V VM S23

ON
35 JPC8-1 24 IN. LIMIT The voltage on this line changes when <1V w/S11 CCC CCC
the platform crosses S11. The change in closed;
voltage is used by the VM to reset the >9V w/S11
height counter and enable correct open
speed. S11 opens when the platform is
above 24 in. and speed is determined
by height. When the platform is below
24 in., S11 is closed and full speed is
allowed.
36 JPC8-2 6-12VF 12V supply to S11 (24 in. Limit Switch). 6-8.8V w/S11 VM S11
connected;
>9.0V w/S11
disconnected
38 JPC9-1 AUTO/MAN The CCC monitors the state of the S4 <1V in manual; CCC VM
(Auto/Manual Switch) to determine if >5V on wire/in
the lift truck is in manual steering or rail
Wire Guidance/Rail Guidance mode.
40 JPC9-3 HORN This input is monitored by the CCC. >5V Open; CCC CCC
When S3 (Horn Switch) is depressed, <0.5V Closed
the CCC tells the VM to blow the horn.
41 JPC9-4 DGND B– for S3 and VR2 (Lift/Lower Pot). If <0.3V wrt TP4 VM S3
missing, Code 81 is displayed.
42 JPC9-5 +5.3V Supply voltage for VR2 (Lift/Lower Pot). >5V CCC VR2

Pin-Out Matrix

43 JPC9-6 L/L Variable voltage from VR2 wiper. The 1.3V Neutral; CCC VM
CCC monitors this voltage and sends it 0.4V Full Lift;
to the VM. Voltage must be between 0.4 2.1V Full Lower
and 4.6V. If not, Code 81 is displayed.
44 JPC9-7 DGND B– for VR1. <0.3V wrt TP4 VM VR1
45 JPC9-8 +5.3V Supply voltage for VR1 (Travel Pot). >5V CCC VR1
46 JPC9-9 TRAVEL Variable voltage from VR1 wiper. The 1.3V Neutral; CCC VM
CCC monitors this voltage and sends it 0.8V Full Fwd;
to the VM. Voltage must be between 0.4 2.6V Full Rev
and 4.6V. If not, Code 80 is displayed.
47 JPC9-10 Not Used
48 JPC11-1 +12VF Supplies working voltage to the CCC. 10.8-13V VM CCC

w/key switch
ON
49 JPC11-2 BUS– Carries the negative component of the 2.0V CCC LPA, TPA
digital communications between the and VM
CCC and the managers on the tractor
side of the communications bus.
50 JPC11-3 BUS+ Carries the positive component of the 3.0V CCC LPA, TPA
digital communications between the and VM
CCC and the managers on the tractor
side of the communications bus.
51 JPC11-4 BRAKE Sent by the CCC to the VM to energize >6V with CCC VM
DEADMAN the brake when all other conditions are deadman up
met. This output is sent when S2 is and brake
closed. applied;
<0.5V with
deadman down
and brake
released
52 JPC11-5 CARRIAGE Sent by the CCC to the VM to energize >6V with CCC VM
DEADMAN the brake when all other conditions are deadman up
met. This output is sent when S23 is and brake
closed. applied;
<0.5V with
deadman down
and brake
released
53 JPC11-6 DGND Reference and negative for the circuits <0.3V wrt TP4 VM CCC
on the CCC. Although it eventually
connects to B–, it is kept separate from
the other grounds to help reduce the
effects of noise on system operation.
54 JPC12-2 B–F SPARE B– for Security Start Switch Relay. B– CCC K2 Relay
for
Security
Start
Switch

Pin-Out Matrix

55 JPC13-1 SIDEGATE LEFT Output from S61 used by the CCC to 10.8-13V VM CCC
detect the position of the left sidegate. w/key switch
The VM will prohibit travel if the ON
sidegate is up or the switch is open.
56 JPC13-2 +12VF 12V supply to S61 (Left Sidegate 10.8-13V VM CCC

ON
57 JPC13-3 PGND B– for S61. <0.3V wrt TP4 VM CCC
58 JPC14-1 SIDEGATE RIGHT Output from S60 used by the CCC to <1V with S60 CCC
detect the position of the right sidegate. sidegate down;
The VM will prohibit travel if the approx. 10V
sidegate is up or the switch is open. w/sidegate up
59 JPC14-2 +12VF 12V supply to S60 (Right Sidegate 10.8-13V VM S60

ON
60 JPC14-3 PGND B– for S60. <0.3V wrt TP4 VM CCC
61 JPC15-1 Not Used
62 JPC15-15 DGND B– for the Carriage Control Light <0.3V wrt TP4 VM Light
Display Card. Display
Card
63 JPC15-16 5.3V Supply voltage for the Carriage Control >5V CCC Light
Light Display Card. Display
Card
64 JPC15-24 Not Used
65 JPC16-1 B+EPO Present when both the Key Switch and B+ CCC Fuse/
EPO switch are closed. Supplies B+ Relay
Estop to the Fuse/Relay Card where it is Card
used by the K1, K2, and K3 relays.
66 JPC16-2 B–FUSEDS B– for the Spare Power Connector <0.3V wrt TP4 Fuse/Relay CCC
(JPC12-2) on the CCC. Supplies B– for Card (FU8)
the optional lights, fan, and RF unit.
67 JPC16-3 B+FUSEDS B+ for the Spare Power Connector B+ wrt TP4 Fuse/Relay CCC
(JPC12-1) on the CCC. Supplies B+ for w/battery Card (FU7)
the optional lights, fan, and RF unit. connected
68 JPC16-4 B–FUSED B– for the CCC from the Fuse/Relay <0.3V wrt TP4 Fuse/Relay CCC
Card. Card (FU6)
69 JPC16-5 B+EPO B+EPO Spare. B+ CCC Spare
70 JPC16-6 B+KEY B+ that is switched by the Key Switch B+ w/S1 closed CCC Fuse/
(S1) and sent from the CCC to supply Relay
B+ Key to the Fuse/Relay Card. Card
71 JPC16-7 B+FUSEDS B+ Fused Spare. B+ CCC Spare
72 JPC16-8 B+FUSED Main B+ supply to the CCC and is fused B+ wrt TP4 Fuse/Relay CCC
through FU5 on the Fuse/Relay Card. Card (FU5)

Pin-Out Matrix

73 JPC21-1 +5.3V Supplies +5.3V to the E2 Steering >5V CCC E2

Request Encoder. It is dependent on the Steering
+12VP from the VM at JPC11-1. Request
Encoder
74 JPC21-2 DGND B– for the circuits of the E2 Steering <0.3V wrt TP4 CCC E2
Request Encoder. Steering
Request
Encoder
75 JPC21-3 CHA–E2 One part of the steering request from 0-5V nominal E2 Steering CCC and
the E2 Steering Request Encoder when w/tiller moving; Request VM
the steering tiller is moved. It is a square >4.5V or <0.5V Encoder
CHB-E2 but different phase. The CCC stationary
sends this information to the VM.
76 JPC21-4 CHB-E2 One part of the steering request from 0-5V nominal E2 Steering CCC and
the E2 Steering Request Encoder when w/tiller moving; Request VM
the steering tiller is moved. It is a square >4.5V or <0.5V Encoder
CHA-E2 but different phase. The CCC stationary
sends this information to the VM.
77 JPC21-5 CD SUPPLY 5.3V output from the CCC power >4V CCC CCC
supply. This voltage is dependent on
+12VP from the VM at JPC11-1. This
voltage goes back to the CCC
microprocessor to let the CCC know that
JPC21 is connected. If not connected,
Code G0 is displayed.
78 JPC21-6 CD +5.3V output from the CCC power >5V CCC CCC
supply. This voltage is dependent on
+12VP from the VM at JPC11-1. This
voltage goes back to the CCC
microprocessor to let the CCC know that
JPC21 is connected. If not connected,
Code G0 is displayed.
79 JPF1-1 B– B– for FU8 (15A/5A) Fuse for optional <0.5V TP4 Aux
Aux power. Power
80 JPF1-2 B– B– for FU8 (15A/5A) Fuse for optional <0.5V TP4 Aux
Aux power. Power
81 JPF1-3 Not Used
82 JPF1-4 B–F B–F from FU8 for optional Aux Power. <0.5V FU8 to B– Aux
Power
83 JPF1-5 Not Used

Pin-Out Matrix

84 JPF1-6 B+F or B–F Provides either B+F or B–F to B+K3 on B– w/K3 FU5 when LPA and
the Lift and Travel Power Amplifiers. At De-energized; K3 is TPA
Startup the K3 coil is energized, B+ w/K3 energized;
providing B+ to the pre-charge circuit Energized FU6 when
and logic circuits in the power K3 is
amplifiers. With the K3 coil de-energized
de-energized, JPF1-6 is at B– to
discharge the amplifier precharge
circuits.
85 JPF2-1 B+K2 B+ that is present when the K2 relay tips B+ w/K2 closed Fuse/Relay LPC Coil
close (DC lift only). Card
86 JPF2-2 B+K2 B+K2 to power the horn. B+ with K2 K2 tips Horn

energized
87 JPF2-3 B+K2 B+K2 when the K2 relay tips are closed. B+ K2 tips VM
88 JPF2-3 B+K2 B+ supplied to the Aux Mast solenoids. B+ Fuse/Relay Aux Mast
Card Solenoids
89 JPF2-4 N/A
90 JPF2-5 B+K2 B+K2 to power Load Holding Solenoid. B+ with K2 K2 tips L/H Sol.
energized.
93 JPF2-8 N/A
94 JPF2-8 B+K2 B+ supplied to the 2 Stage Select B+ Fuse/Relay 2 Stage

Solenoid. Card Select
Sol.
95 JPF2-9 B+KEY B+ Key for warning light when K1 tips B+ CCC Warning
are closed. Light
96 JPF3-1 B– B– for FU6 (15A) that provides B– to the <0.5V TP4 VM

Vehicle Manager.
97 JPF3-2 B– B– for FU6 (15A) that provides B– to the <0.5V TP4 VM

Vehicle Manager.
98 JPF3-3 B–F B–F for DGND on the VM. <0.5V FU6 VM
99 JPF3-4 B–F B–F for DGND on the VM. <0.5V FU6 VM
100 JPF3-5 B–F B–F for the VM. <0.5V FU6 VM
103 JPF3-8 B–F B–F for S10 (150 or 120 in. Limit <0.5V FU6 S10
Switch) on the mast.
104 JPF3-9 B–F B–F for wire guidance. <0.5V Fuse/Relay Guidance
Card (FU6) Manager

Pin-Out Matrix

105 JPF3-11 B–F B–F for the warning light. <0.5V FU6 Warning
Light
106 JPF3-12 B–F B–F for the CCC. <0.5V FU6 CCC
107 JPF4-1 B+ B+ from TP1 to FU5 (15A) to supply K2, B+ TP1 VM

K4 relay tips. This also supplies
Battery_Sense_In on the VM.
108 JPF4-2 B+ B+ from TP1 to FU5 (15A) to supply K2, B+ TP1 FU5 and
K4 relay tips. This also supplies VM
Battery_Sense_In to the VM.
109 JPF4-3 B+ B+ from TP1 to FU7 (15A/5A) to supply B+ TP1 FU7 and
Aux power option. Aux
Power
110 JPF4-4 B+ B+ from TP1 to FU7 (15A/5A) to supply B+ TP1 FU7 and
Aux power option. Aux
Power
111 JPF4-5 B+EPO B+ supply from EPO to K1, K2 and K3. EPO EPO K1, K2,
All functions associated with these Closed: B+; K3
relays are inoperable when the EPO is Open: 0.05V
open.
112 JPF4-6 B+EPO B+ to the EPO_Sense on the VM. Tells EPO EPO VM, EPO
the VM if the EPO is open or closed. Closed: B+; Sense
Open: 0.05V
113 JPF4-7 B+ B+ present when the battery is plugged B+ (there should TP1 VM
in. It is supplied through a thermistor on be no voltage
the Relay Control Fuse Panel. This is drop)
used by the VM to determine that the
correct battery is connected. It will
accept between 28 and 45V (36V
Battery) or 18 and 30V (24V Battery). If
the correct battery is sensed,
Relay_Enable is energized during
startup. After startup, this voltage is used
to determine BSOC.
114 JPF4-8 B+KEY B+ Key from the CCC. B+ CCC VM and

Warning
Light
115 JPF4-10 B+ B+ Fused to the CCC. B+ FU5 CCC
116 JPF4-11 B+KEY B+ Key for VM. B+ CCC VM
117 JPF4-12 Not Used

Pin-Out Matrix

118 JPF4-13 RELAY ENABLE Return path for relays K1, K2, K3, and B+ w/Key VM K1, K2,
K4. This is dependant on Switch ON and K3 and
Battery_Sense_In being between 28 all relays K4
and 45V (36V Battery). de-energized;
<0.5V w/Key
Switch OFF or
ON and any
relay energized
119 JPF4-14 RELAY ENABLE Return path for relays K1, K2, K3, and B+ w/Key VM K1, K2,
K4. This is dependant on Switch ON and K3 and
Battery_Sense_In being between 18 all relays K4
and 30V (24V Battery). de-energized;
<0.5V w/Key
Switch OFF or
ON and any
relay energized
120 JPF4-15 B+ B+ for battery connected Aux Power. B+ FU7 Aux

Power
121 JPLA1-1 B+K3 B+ present when K3 is energized. This B+ w/K3 K3 LPA

is used to power the control circuits of energized
the LPA.
122 JPLA1-6 TPC Control path for the LPC. The LPA LPC LPA LPC
CONTACTOR supplies a path for B– for the contactor de-energized;
by way of the B– terminal. B+
energized:
14.7V
123 JPLA1-7 DGND Return path for the bearing encoder in <0.5V LPA Lift
the lift motor. Velocity
Sensor
124 JPLA1-8 L TEMP+ Analog voltage that varies with the lift 75°F (24°C) Lift Motor LPA
motor temperature. Used by the LPA to approx. 1V Temp.
adjust motor performance. Sensor
125 JPLA1-11 ID0 B+ present at the LPA with K3 tips B+ w/K3 K3 LPA
energized. It is used as an identifier to energized
determine correct connection.
126 JPLA1-11 ID0 ID0 on the LPA has B+ applied. This B+ Fuse/Relay LPA
voltage tells the amplifier what amp it is. Card
127 JPLA1-12 ID1 Not Used by the Lift Power Amp.
128 JPLA1-13 B+K3 B+ for the LPC. The LPA supplies B+ for B+ LPA LPC
the LPC.
129 JPLA1-23 BUS+ Carries the positive component of 3.0V CCC LPA, VM
digital communications between the
LPA, VM, and CCC.
130 JPLA1-25 Not Used

Pin-Out Matrix

131 JPLA1-26 L VEL SENSOR + 5V supply to the bearing encoder on the 4.98V LPA Lift
lift motor. This voltage is produced by Velocity
the Lift Power Amp from B+K3. Sensor
134 JPLA1-31 L VEL PHASE A Generated when there is movement of Motor Lift Velocity LPA
the bearing encoder in the lift motor. It is Stationary: Sensor
a square wave that is either high (>3V) 4.06 or 0.03V;
or low (<1V). The frequency varies Motor Turning:
directly with motor speed. Identical to 2.3V
L VEL Phase B except for phase. The LPA
uses the relationship between phases to
determine lift speed.
135 JPLA1-32 L VEL PHASE B Generated when there is movement of Motor Lift Velocity LPA
the bearing encoder in the lift motor. It is Stationary: Sensor
a square wave that is either high (>3V) 4.06 or 0.03V;
or low (<1V). The frequency varies Motor Turning:
directly with motor speed. Identical to 2.3V
L VEL Phase A except for phase. The LPA
uses the relationship between phases to
determine lift speed.
136 JPLA1-35 BUS– The wire that carries the negative 2.3V CCC LPA, VM
component of the digital
communications between the LPA, VM,
and the CCC.
137 JPS2-11 B+ESTOP B+ESTOP is present when both the key B+ with S1 and VM Guidance
switch and EPO switch are closed. It is EPO closed. Manager
supplied to the Guidance Manager from
B+K2 on the VM. If the key switch or
EPO are open, K2 is de-energized.
138 JPS2-24 B–F B– for the Guidance Manager. It is <0.5V wrt TP4 Guidance VM
fused through FU6 on the Fuse/Relay Manager
Card.
139 JPS4-6 BUS+ Carries the positive component of the Not Usable VM Guidance
digital communications between the VM Manager
and the Guidance Manager.
140 JPT4-2 Not Used
141 JPT4-3 LIFT CUTOUT Voltage from S124 (Lift Cutout Switch) Open: 4.8V; S124 VM
that indicates the open or closed state of Closed: <0.3V
the switch.
142 JPT6-1 NEUTRAL_PULSE This input tells the VM that the Steer Deadman up: Steer Power VM
Power Amplifier is connected and 4.8V; Amplifier
functioning. CCW steer:
0.2V;
CW steer:
4.8V;
No steering:
voltage varies

Pin-Out Matrix

143 JPT6-2 CW_PWM This is a control voltage used to rotate At rest: 11.9V; VM Steer
the drive unit in the CW direction. The CW fast: 4V; Power
average DC value will vary depending CW slow: Amplifier
on the amount and speed of steering 11.8V
requested.
144 JPT6-3 STEER_CURRENT Analog voltage that varies with the steer Steering Steer Power VM
motor current and is sent from the Steer CW: 2.9V; Amplifier
Power Amplifier to the VM. This voltage At rest: 2.5V;
is used by the VM to establish current Steering
reading for current limit. CCW: 2.1V
145 JPT6-4 DGND Reference for the control circuits in the <0.5V VM Steer
Steer Power Amplifier. If missing, the Power
Steer Power Amplifier will not be Amplifier
powered up.
146 JPT6-5 CCW_PWM This is a control voltage used to rotate At rest: 11.9V; VM Steer
the drive unit in the CCW direction. The CCW fast: 4V; Power
average DC value will vary depending CCW slow: Amplifier
on the amount and speed of steering 11.8V
requested.
147 JPT6-6 +12VP Operating voltage from the VM for the 10.7-13V VM Steer
control circuits in the Steer Power Power
Amplifier. If missing, steering is Amplifier
inoperable.
148 JPT10-2 SENSOR 1 Voltage from the S46A and S46B aisle 10.8-13V when VM S46A/B
detect switches that indicates a magnet is not Aisle
transition over a Floor Magnet. sensed; Detect
<1V for Sensors
0.1 sec. after
magnet is
sensed, then
10.8-13V
149 JPT10-6 +12VP 12V supply to S46A and S46B (Aisle 10.8-13V VM S46A and
Detect Sensors). B
150 JPT10-7 +12VP 12V supply to S47A and S47B (Aisle 10.8-13V VM S47A and
Detect Sensors). B
151 JPT10-8 SENSOR 2 Voltage from S47A and S47B (Aisle 10.8-13V when VM S46A/B
Detect Sensors) that indicates a magnet is not Aisle
transition over a floor magnet. sensed; Detect
<1V for Sensors
0.1 sec. after
magnet is
sensed, then
10.8-13V
152 JPT10-9 DGND Reference for the steer motor encoder. <0.5V VM Steer
Motor
Encoder
153 JPT12-5 LIFT Emergency L/L For MVP. VM S112

(down)

Pin-Out Matrix

154 JPT12-6 LOWER Emergency L/L For MVP. VM S111 (up)
155 JPT12-12 DGND Emergency L/L For MVP. VM VM
156 JPT14-1 B–F This connects B–F on the VM to TP4(B–) <0.5V Fuse/Relay VM
through FU6 on the Fuse/Relay Card. Card
These B– provide the return for
everything not using DGND or AGND
as reference.
157 JPT14-2 DGND This connects DGND on the VM to TP4 <0.5V Fuse/Relay VM
(B–) through FU6 on the Fuse/Relay Card
Card. This is the reference for all circuits
on the lift truck that reference DGND.
158 JPT14-3 DGND This is the negative path for the 12V <0.5V VM CCC
supply to the CCC. If this is not present,
the CCC will not function. 5V is made
from the 12V on the CCC.
159 JPT14-4 BUS_I– The wire that carries the negative 2.3V VM LPA, TPA
component of the digital and CCC
communications between the VM, TPA,
LPA, and CCC.
160 JPT14-5 +12VP This is the positive path for the 12V 10.8-13V VM CCC
supply to the CCC. If this is not present,
the CCC will not function. 5V is made
from the 12V on the CCC.
161 JPT14-6 RELAY_ENABLE Control path for K1, K2, K3 and K4 on Relays VM K1, K2,
the Fuse/Relay Card. After S1 is closed, OFF: B+, K3, K4
all relays are energized simultaneously Relays
during SelfTest if the voltage at ON: <0.5V
Battery_Sense_In is between 28 and
45V (36V Battery) or 18 and 30V (24V
Battery).
162 JPT14-7 B+K2 B+ provided to the VM when the K2 B+ K2 Relay VM,

relay tips are closed. They are Brake
de-energized when the EPO is open. Coil
Note: Also used by the VM for Brake
Coil Suppression.
163 JPT14-8 B–F This connects B–F on the VM to TP4 (B–) <0.5V Fuse/Relay VM
as reference.
164 JPT14-9 B–F This connects B–F on the VM to TP4 (B–) <0.5V Fuse/Relay VM
as reference.

Pin-Out Matrix

165 JPT14-10 DGND This connects DGND on the VM to TP4 <0.5V Fuse/Relay VM
(B–) through FU6 on the Fuse/Relay Card
Card. This is the reference for all circuits
on the lift truck that reference DGND.
166 JPT14-11 BUS_I+ The wire that carries the positive 3.0V VM LPA, TPA
component of the digital and CCC
communications between the VM, TPA,
LPA, and CCC.
167 JPT14-12 B+KEY B+ that is switched by S1 (Key Switch) S1 closed: B+; S1 VM

and used to power functions on the VM S1 open: 0.3V
that are initiated after S1 is closed and
are not affected by the EPO. This
includes the VM power supplies, the
operation of the microprocessor, and
execution of the firmware.
168 JPT14-13 B+K2 B+ provided to the VM when the K2 B+ K2 relay VM

relay tips are closed. They are
de-energized when the EPO is open.
169 JPT14-14 B+K2 B+ provided to the VM when the K2 B+ K2 relay VM

relay tips are closed. They are
de-energized when the EPO is open.
170 JPT18-1 2 STAGE SOL Negative path for the 2nd Stage Select <0.1V Fuse/Relay 2 Stage
Solenoid 24V High Performance Lift. Card Select
Sol.
171 JPT18-4 +12VP 12V supply for S15 (Rail Sense Switch). 10.8-13V VM S15
172 JPT18-5 DGND Negative path for the Pressure Switch <1V Pressure VM
24V High Performance Lift. Switch
173 JPT18-16 HORN Control path for the horn that is B+ VM Horn
switched to B– by the VM. de-energized;
<0V energized
174 JPT18-7 DGND Return path for S124 (Lift Cutout <0.5V S124 VM
Switch).
175 JPT18-9 LIFT_ B– for the LPC coil (DC lift only). 24V Lift Truck: VM LPC Coil
CONTACTOR B+ w/coil
de-energized;
1V w/coil
energized
36V Lift Truck:
B+ w/coil
de-energized;
11-12V w/coil
energized
176 JPT18-10 L/H Control path for the load holding B+ VM L/H Sol.
solenoid that is switched to B– by the de-energized;
VM to energize the L/H solenoid coil. 12.7V
energized

Pin-Out Matrix

177 JPT18-12 AUX L/H Negative path for the Aux Mast L/H <1V Aux. L/H VM
Solenoid. Sol.
178 JPT18-15 AUX SEL Negative path for the Aux Mast Select <1V Aux. Select VM
Solenoid. solenoid
179 JPT18-14 MAIN SEL Negative path for the Aux Mast Main <1V Aux.Main VM
Select Solenoid. Select Sol.
180 JPT18-18 ALARM_TRAVEL Return path for Travel Alarm. B+ Travel Alarm VM
de-energized;
<0V energized
181 JPT20-1 +12VF 12V supply to S10 (120/150 in. +10.7 -13V VM S10
Switch).
182 JPT20-2 +12VP 12V supply for the Flow Sensor. 10.8-13V Flow Sensor VM
183 JPT20-3 Not Used
185 JPT20-5 +12VP 12V supply to the Pressure Transducer. 10.8-13V VM Pressure
Trans-
ducer
186 JPT20-6 +12VP 12V supply to S27 (Travel Cutout 10.8-13V VM S27
Switch).
187 JPT20-7 +12VP 12V supply for the steer motor encoder. 10.8-13V VM Steer
Motor
Encoder
188 JPT20-8 +12VP 12V supply to S124 (Lift Cutout). 10.8-13V VM S124
189 JPT20-9 +12VP 12V supply to the Home Sensor Prox by +10.7-13V VM Home
the VM. Sensor
Prox
190 JPT20-10 +12VP 12V supply to the S24 (Lift Inhibit 10.8-13V VM S24
Switch).
191 JPT20-14 BRAKE Control path for the electrically released B+ VM Brake
brake on the traction motor. de-energized:
26V energized
192 JPT20-15 B+L/L B+ supplied to lift/lower solenoid when B+ VM L/L

K2 tips are closed.
193 JPT20-16 L/L Control path for the lift/lower De-energized: VM L/L
proportional solenoid. B+;
Full Lift: 28V;
Full Lower:11V;
Feather Lift:
34V;
Decel: 27.7V
194 JPT20-17 B+ALARM B+ supplied to the lift/lower alarm when B+ VM Alarm

K2 tips are closed. Travel/Lift

Pin-Out Matrix

195 JPT20-18 ALARM_LIFT Control path for the lift/lower alarm. B+ Alarm_Lift VM
de-energized;
<0.0V
energized
196 JPT20-19 B+K2 B+ supplied to the Guidance Manager B+ VM Guidance

when the K2 tips are closed. Manager
197 JPT22-1 120/150 IN. Input to the VM from S10. Open: 4.8V; S10 VM
LIMIT Closed: <0.03V
198 JPT22-2 LIFT INHIB Voltage from S24 that indicates the Open: 4.8V; S24 VM
open/closed state of the switch. Closed: <0.03V
199 JPT22-3 HOMESENSE Voltage that the VM uses to determine Off Metal: Home VM
on or off metal. 5.2V; Sensor Prox
On Metal:
0.03V
200 JPT22-4 180_LIM Voltage from S100 (180 in. Limit Open: 4.8V; S100 VM
Switch) that indicates the open/closed Closed: <0.03V
state of the switch.
201 JPT22-5 PRESS_SW 5V supply for the Pressure Switch 4.7V VM PRESS
(PRESS SW1). SW1
202 JPT22-6 TRVL CUTOUT Voltage from S27 that indicates the Open: 4.8V; S27 VM
open/closed state of the switch. Closed: <0.03V
203 JPT22-7 BRAKE Voltage from CCC to VM that indicates 6.1V released; S2 VM
DEADMAN the open/closed state of switch S2. 0.1V depressed
204 JPT22-8 CARRIAGE Voltage from CCC to VM that indicates 4.8V released; S23 VM
DEADMAN the open/closed state of switch S23. 0.1V depressed
205 JPT22-9 CHANNELA_4 Part of the steering position feedback Not Turning: Steer Motor VM
from the steer motor encoder when the either 0V or 5V; Encoder
drive unit is rotated. It is a square wave Turning either
signal identical to Channel B_4 but direction: 2.4V
different phase. The VM uses the phase
relationship of the two channels to
determine that the direction and speed
of the steering response is the same as
that requested.
206 JPT22-10 CHANNELB_4 Part of the steering position feedback Not Turning: Steer Motor VM
from the steer motor encoder when the either 0V or 5V; Encoder
drive unit is rotated. It is a square wave Turning either
signal identical to Channel A_4 but direction: 2.4V
different phase. The VM uses the phase
relationship of the two channels to
determine that the direction and speed
of the steering response is the same as
that requested.
207 JPT22-11 DGND B– for the Home Sensor Prox. <0.5V Home VM
Sensor Prox

Pin-Out Matrix

209 JPT22-13 FLOW_A Square waves generated whenever Approx. 2.7V Flow Sensor VM
there is movement of the turbine in the during lift at
flow sensor. The frequency varies 1/3 speed or
directly with the speed of the turbine greater;
that is driven by fluid flowing through >5V or <0.5V
the sensor. The VM uses the quadrature when stopped
phase relationship between Flow_A
and_B to determine flow direction and
speed to calculate carriage height.
210 JPT22-14 FLOW_B Square waves generated whenever Approx. 2.7V Flow Sensor VM
there is movement of the turbine in the during lift at
flow sensor. The frequency varies 1/3 speed or
directly with the speed of the turbine greater;
that is driven by fluid flowing through >5V or <0.5V
the sensor. The VM uses the quadrature when stopped
phase relationship between Flow_A
and_B to determine flow direction and
speed to calculate carriage height.
211 JPT22-19 FU1_SENSE B+ when there is not an open between Closed: B+; PC1 VM
battery positive and PC1. This voltage is Open: voltage
used by the VM to determine the state of drops very
FU1 and the PC1 contactor tips. slowly
212 JPT22-20 FU3 SENSE B+ when there is not an open between Closed: B+; PC2 VM
B+ and PC2. This voltage is used by the Open: voltage
VM to determine the state of FU3 and drops slowly to
the LPC contactor tips (DC lift only). 0V
213 JPT22-21 EPO_SENSE Sense wire used by the VM to determine EPO closed: B+; EPO VM
when the EPO is open. This is used to EPO open:
initiate braking and display a message. <0.5V
214 JPT22-22 RAIL_SEN Read by the VM to determine if the lift closed:<1V; S15 VM
truck is in or out of the rail. The VM open: approx.
communicates lift truck position to the 10V
CCC, limiting travel speed based on lift
truck location and position of the
Auto/Man switch. When the lift truck is
in the rail, S15 is closed.
215 JPT24-1 +12VP 12V supply for S100 (180 in. Limit 10.8-13V S100 VM
Switch).
216 JPT24-3 DGND Return path for S24 (Lift Inhibit Switch). <0.5V S24 VM
217 JPT24-5 DGND Return path for S15 (Rail Sense Switch). <0.5V S15 VM
218 JPT24-6 DGND Return path for S27 (Travel Cutout <0.5V S27 VM
Switch).
219 JPT24-7 DGND Return path for S100 (180 in. Limit <0.5V S100 VM
Switch).
220 JPT24-8 DGND Return path for S46A and S46B (Aisle <0.5V S46A and VM
Detect Sensors). S46B

Pin-Out Matrix

221 JPT24-9 DGND Return path for S47A and S47B (Aisle <0.5V S47A and VM
Detect Sensors). S47B
222 JPT24-10 DGND Return path for Pressure Transducer A. <0.5V Pressure VM
transducer
223 JPT24-11 DGND Return path for the intellispeed Flow <0.5V Flow Sensor VM
Sensor.
225 JPT24-18 P/T_A Analog DC voltage that varies directly 1V with forks Pressure VM
with the weight on the carriage. fully lowered Transducer
Approx. 0.5V per 1000 lbs. (454 kg). It
is necessary to have the VM supply
approx. 12V as well as DGND in order
for the transducer to function correctly.
226 JPT24-19 FS_TEMP Variable voltage that is representative of 0.2-4.86V; Flow Sensor VM
the temperature of the fluid in the lift approx. 3.2V
system. @86°F
227 JPT24-24 BATTERY_ B+ present when the battery is plugged B+ (there should TP1 VM
SENSE_IN in. It is supplied through a thermistor on be no voltage
the Relay Control Fuse Panel. This is drop)
used by the VM to determine that the
correct battery is connected. It will
accept between 28 and 45V (36V
Battery) or 18 and 30V (24V Battery). If
the correct battery is sensed, Relay
Enable is energized during start-up.
After start-up, this voltage is used to
determine BSOC.
228 JPTA1-1 B+K3 B+ present when K3 is energized. This B+ w/K3 K3 TPA

is used to power the control circuits of energized
the TPA.
229 JPTA1-6 TPC Control path for the TPC. The TPA TPC TPA TPC
CONTACTOR supplies a path for B– for the contactor de-energized:
by way of the B– terminal. B+
energized:
14.7V
230 JPTA1-7 DGND Return path for the bearing encoder in <0.5V Travel TPA
the traction motor. Velocity
Sensor
231 JPTA1-8 T TEMP+ Analog voltage that varies with the Approx. 1V Traction TPA
traction motor temperature. Used by the @75°F (24°C) Motor Temp.
TPA to adjust motor performance. Sensor
232 JPTA1-11 ID0 Not Used by the Traction Power Amp.
233 JPTA1-12 ID1 B+ present at the TPA with K3 tips B+ w/K3 K3 TPA
energized. It is used as an identifier to energized
determine correct connection.

Pin-Out Matrix

234 JPTA1-13 B+K3 B+ for the TPC. The TPA supplies B+ for B+ TPA TPC
the TPC.
235 JPTA1-14 Not Used
236 JPTA1-23 BUS+ The wire that carries the positive 3V CCC TPA, VM
communications between the TPA, VM,
and CCC.
238 JPTA1-26 T VEL SENSOR + 5V supply to the bearing encoder on the 4.95V TPA Travel
traction motor. This voltage is produced Velocity
by the Traction Power Amp from B+K3. Sensor
241 JPTA1-31 T VEL PHASE A This is generated when there is Motor Travel TPA
movement of the bearing encoder in the Stationary: Velocity
traction motor. It is a square wave that is 4.06 or 0.03V; Sensor
either high (>3V) or low (<1V). The Turning: 2.3V
frequency varies directly with the speed
of the traction motor. Identical to T VEL
Phase B, except for phase. The TPA uses
the relationship between phase A and B
to determine travel speed and direction.
242 JPTA1-32 T VEL PHASE B This is generated when there is Motor Travel TPA
movement of the bearing encoder in the Stationary: Velocity
traction motor. It is a square wave that is 4.06 or 0.03V; Sensor
either high (>3V) or low (<1V). The Turning: 2.3V
frequency varies directly with the speed
of the traction motor. Identical to T VEL
Phase A, except for phase. The TPA uses
the relationship between phase A and B
to determine travel speed and direction.
243 JPTA1-35 BUS– The wire that carries the negative 2.3V CCC TPA, VM
communications between the TPA, VM,
and CCC.
244 JS27-2 O.T.M. Cable Spare over-the-mast wire for future B– VM Option
option.
245 LPA (+) LPA + B+ to the LPA used to produce the AC B+ with LPC LPC LPA
phases U,V, and W when the LPC is closed
closed to power the lift motor.
246 LPA (–) LPA B– B– from TP4 on the power panel. It is <0.5V TP4 LPA
used for the power circuits on the LPA.
Without B–, U, V, and W cannot be
produced and the lift motor will not turn.

Pin-Out Matrix

247 LPA (U) Lift Motor Phase One of three phases from the LPA to the VAC between LPA Lift Motor
U Lift Motor. This AC voltage is produced two phases:
by the LPA and is dependent on B+ at Stationary:
the + terminal and B– on the LPA. This 0VAC;
AC voltage is measured between any Full Travel:
two phases and varies from 0VAC at 24VAC;
rest to about 24VAC at full RPM. Stall: approx.
4VAC
248 LPA (V) Lift Motor Phase One of three phases from the LPA to the VAC between LPA Lift Motor
V Lift Motor. This AC voltage is produced two phases:
4VAC
249 LPA (W) Lift Motor Phase One of three phases from the LPA to the VAC between LPA Lift Motor
W Lift Motor. This AC voltage is produced two phases:
4VAC
250 PC12-1 B+F (SPARE) B+ power for optional Work Lights or RF B+ wrt TP4 Fuse/Relay Work
Unit. Present when the battery is w/battery Card Lights and
connected. It is fused through FU5 on connected RF Unit
the Fuse/Relay Card.
251 PC12-2 B–F (SPARE) B– power for optional Work Lights or RF <0.3V wrt TP4 Fuse/Relay Work
Unit. Present when the battery is Card Lights and
connected. It is fused through FU6 on RF Unit
the Fuse/Relay Card.
252 TPA (+) TPA B+ B+ to the TPA used to produce the AC B+ w/TPC B+ from TPC TPA
phases U, V and W when the TPC is closed
closed to power the traction motor.
253 TPA (B–) TPA B– B– from TP4 on the power panel. It is <0.5V TP4 TPA
used for the power circuits on the TPA.
Without B–, U, V and W cannot be
produced and the traction motor will not
turn.
254 TPA (U) Traction Motor One of three phases from the TPA to the VAC between TPA Traction
Phase U traction motor. This AC voltage is two phases: Motor
produced by the TPA and is dependent Stationary:
on B+ at TPA (+) and B– at TPA (B–). This 0VAC;
rest to about 24VAC at full acceleration. Stall: approx.
4VAC

Pin-Out Matrix

255 TPA (V) Traction Motor One of three phases from the TPA to the VAC between TPA Traction
Phase V traction motor. This AC voltage is two phases: Motor
rest to about 24VAC at full acceleration. Stall: approx.
4VAC
256 TPA (W) Traction Motor One of three phases from the TPA to the VAC between TPA Traction
Phase W traction motor. This AC voltage is two phases: Motor
rest to about 24VAC at full acceleration. Stall:
approx. 4VAC

Pin-Out Matrix

Models 5400/5500/5600 Maintenance Manual Section A. Appendix
Section A. Appendix
Publication: 1031794C, Re-Issued: 7/14/06 A-1

Section A. Appendix Models 5400/5500/5600 Maintenance Manual
Lubrication Specification Chart
Lubrication Specification Chart

Approved Raymond Lubricants
Where Used Type Specification Raymond Part Number
75W-90 Synthetic
Drive Unit Gear Case Gear 990-655/001 (1 qt./0.9 liters)
Gear Oil
(all applications) Lubricant 990-655/003 (1 gal./3.8 liters)
API Service GL-5
Hydraulic Reservoir 990-616/04 (1 qt./0.9 liter)

(Non-CS lift trucks) 990-616/01 (1 gal./3.8 liters)
Hydraulic Fluid ISO VG 46
+50°F to +120°F 990-616/02 (2 gal./7.6 liters)
(+10°C to +49°C) 990-616/03 (5 gal./18.9 liters)
Hydraulic Reservoir 1017238

(CS lift trucks - in and Note: Do not mix with any other
out of freezer) Hydraulic Fluid ISO VG 32 type of hydraulic fluid. Install
0°F to +50°F decal (P/N 1074515) on the
(–18°C to +10°C) hydraulic unit.
Hydraulic Reservoir
(CS lift trucks - confined
990-618/TX1 (1 gal./3.8 liters)
to freezer) Hydraulic Fluid MIL-H-5606E
990-618/01 (1 gal./3.8 liters)
–20°F to 0°F
(–29°C to –18°C)
Mast Uprights, Bearings,

and so forth
(all-weather) Grease NLGI 2 1012992
–20°F to +120°F
(–29°C to +49°C)
High Performance/
1151877/001 (Rexoil)
Lift Chains High Load Chain Aerosol
1151877/002 (Rocol)
Spray
A-2 Publication: 1031794C, Revised: 13 Jul 2015

Thread Adhesives, Sealants, and Lubricants
Thread Adhesives, Sealants, and Lubricants

Loctite*
Raymond P/N Application
Number/Color
990-403 Thread-locking 1/4 in. and below 222/Purple
990-411 Anaerobic Gasket Maker 518
990-445 Cold Storage Silicone Sealing Compound
990-452 Anti-Seize Lubricant, Heavy Duty High Temperature
990-463 Thread-locking 1 in. and under, contamination tolerant 603/Green
990-533 Thread-locking Primer T7471
990-538 Thread-locking Cleaner 707
990-544 Thread-locking 1 in. and under 271/Red
990-552 Hydraulic Sealant 569
990-556 Gasket Sealant Compound
990-571 Thread-locking 1 in. and over 277/Red
990-575 Retaining compound-high strength for cylinder Assemblies 680/Green
990-626 Permatex Thread Sealant 56521
990-638 Molybdenum Anti-Seize Compound (Molykote) Silver
990-644 Corrosion Inhibitor Coating
990-659 RTV Silicone Sealant 5900/Black
990-666 Thread-locking Primer 7649 (19269)
990-669 Thread-locking, primerless high strength 2760
243 or 2440
1013829 Thread-locking 1/4 to 3/4 in. medium strength
7242 (Cyberbond)
1180917/001 Lubricant, Nyogel
Note: *Loctite is a registered trademark of the Loctite Corporation. Brand endorsement is not implied
here, but listed only as a commonly identified product.


Thread-Locking Torque to:
Compound (use Dry values for hardware with
pre-applied thread-locking compound)
(not applicable if using
Component Sub-Component(s) hardware with
pre-applied Lubricated Dry
thread-locking
compound) ft. lb. (Nm) ft. lb. (Nm)
Adjust the switch so it is flush with outside

switch
Battery gate edge.
bracket P/N 1013829 8 (11.3) 11 (15.1)
Brake traction motor P/N 1013829 12 (16)
Drive Unit - Standard mounting bolts P/N 1013829 180( 244) N/A
Drive Unit - Heavy Duty mounting bolts P/N 1013829 325 (441)
Drive Unit housing cover mounting bolts P/N 1013829 16 (22) 17 (23)
Drive Wheels mounting bolts N/A 170 (230)
Finger tighten, then use socket to tighten an

EPO N/A
additional 1/4 turn.
Refer to “Torque Chart - Thread Forming

Horn N/A
Screws” on page A-12
threaded end caps 200 (271)
Lift Cylinders bleed screws N/A 40 in. lb. (4.5)
staging screws 60 in. lb. (6.8)
mounting bolts P/N 1013829 20( 27) 27 (37)
Top Nut:
Lift Motor - AC - Appy anti-seize 17 to 18.4
compound (P/N 990-638) to pump (23 to 25)
spline and mating surfaces. power cables N/A
Bottom Nut:
10.7 to 11
(14.5 to 15)
mounting bolts P/N 1013829 20 (27) 27 (37)
Top Nut:
Lift Motor - DC - Appy anti-seize 8.3 to 10
compound (P/N 990-638) to pump (11.3 to 13.6)
spline and mating surfaces. power cables N/A
Bottom Nut:
11.7 to 13.3
(15.8 to 18.1)
Lift Pump - AC - Appy anti-seize

compound (P/N 990-638) to pump mounting bolts P/N 1013829 49 (67) 66 (90)
spline and mating surfaces.
Lift Pump - DC - Appy anti-seize

compound (P/N 990-638) to pump mounting bolts P/N 1013829 15 (20) 19 (26)
spline and mating surfaces.

Thread-Locking Torque to:

Compound (use Dry values for hardware with
pre-applied thread-locking compound)
(not applicable if using
Component Sub-Component(s) hardware with
pre-applied Lubricated Dry
thread-locking
compound) ft. lb. (Nm) ft. lb. (Nm)
mounting bolts P/N 1013829 8 (11.3) N/A

manifold 35 - 40
Valves N/A
(48 - 54)
mounting bolts, rear N/A N/A 22 (30)

Platform Extensions
mounting bolts, front N/A N/A 21 (28)
mounting bolts P/N 1013829 8 (11.3) 11 (15.1)

Power Amplifiers
power cables 8.3 (11.3)
Top Nut:
40 to 50 in.lb.
N/A (4.5 to 5.6)
power cable
Bottom Nut:
Steer Motor 50 to 60 in.lb.
(5.6 to 6.8)
N/A
Mounting bolts P/N 1013829 15 (20)
Steer Reference (Home)Proximity bracket mounting

P/N 1013829 6 (8.2) N/A
Sensor screws (qty 2)
A minimum pressure of 5 tons (4536 kg) is required to press on a new

Tire Replacement
tire. If the minimum pressure is not met, replace the hub.
mounting bolts P/N1013829 21 (28) 28 (38)
Top Nut:
12.5 to 18.4
Traction Motor (23 to 25)
power cables
Bottom Nut:
N/A 10.7 to 11
(14.5 to 15)
hex head bolts 170 (230)

Tractor-to-Mast
socket flathead bolts 130 (176)

Torque Chart - Hydraulic Fittings
Torque Chart - Hydraulic Fittings

JIC SAE Straight Thread Steel Plugs
SAE
Thread (37° Flare Thread)
Dash Hollow Hex Head Plug HP50N Hex Head Plug P50N
Size
Size
ft. lb. Nm ft. lb. Nm ft. lb. Nm
-2 5/16-24 3 ±1 4 ±1 3 ±0.5 4 ±0.6 7.5 ±0.5 10 ±0.6
-3 3/8-24 6 ±1 8 ±1 5 ±0.5 7 ±0.6 14 ±1 19 ±1
-4 7/16-20 12 ±1 16 ±1 11 ±1 15 ±1 18 ±1 24 ±1
-5 1/2-20 15 ±1 20 ±1 15 ±1 20 ±1 22 ±1 30 ±1
-6 9/16-18 21 ±1 28 ±1 18 ±1 24 ±1 27 ±2 37 ±3
-8 3/4-16 45 ±2 61 ±3 46 ±2 62 ±3 48 ±2 65 ±3
-10 7/8-14 60 ±5 81 ±7 75 ±5 102 ±7 90 ±5 122 ±7
-12 1 1/16-12 85 ±5 115 ±7 85 ±5 115 ±7 110 ±5 149 ±7
-14 1 3/16-12 105 ±5 142 ±7 130 ±6 176 ±8 145 ±6 197 ±8
-16 1 5/16-12 120 ±5 163 ±7 135 ±6 183 ±8 160 ±6 217 ±8
-20 1 5/8-12 170 ±10 230 ±14 225 ±12 305 ±16 225 ±12 305 ±16
-24 1 7/8-12 200 ±15 271 ±20 250 ±12 339 ±16 250 ±12 339 ±16
-32 2 1/2-12 270 ±20 366 ±27 325 ±15 441 ±20 325 ±15 441 ±20

Torque Chart - Straight Thread Face Seal O-Rings
Torque Chart - Straight Thread Face Seal O-Rings

SAE Dash Tube Size
ft. lb. Nm
Size Thread Size
-4 9/16-18 18 ±1 24 ±1
-6 11/16-18 27 ±2 37 ±3
-8 13/16-16 40 ±2 54 ±3
-10 1-14 63 ±3 85 ±4
-12 1 3/16-12 90 ±4 122 ±5
-14 1 5/16-32 95 ±6 129 ±8
-16 1 7/16-12 120 ±8 163 ±11
-20 1 11/16-12 140 ±8 190 ±11
-24 2-12 165 ±8 224 ±11
-32 2 1/2-12 360 ±10 488 ±14

Torque Chart - Standard (Ferrous)
Torque Chart - Standard (Ferrous)
Grade
None
Marking
SAE Grade 2 Bolts SAE Grade 5 Bolts SAE Grade 7 Bolts SAE Grade 8 Bolts
Tightening Torque Tightening Torque Tightening Torque Tightening Torque
Size
Dry** Oiled* Dry** Oiled* Dry** Oiled* Dry** Oiled*
in. lb Nm in. lb Nm in. lb Nm in. lb Nm in. lb Nm in. lb Nm in. lb Nm in. lb Nm
4-40 5 0.56 4 0.45 8 0.9 6 0.68 11 1.5 8 0.9 12 1.4 9 1.0
4-48 6 0.68 5 0.56 9 1.0 7 0.8 12 1.4 9 1.0 13 1.5 10 1.1
6-32 10 1.1 8 0.9 16 1.8 12 1.4 20 2.2 15 1.7 23 2.6 17 1.9
6-40 12 1.4 9 1.0 18 2.0 13 1.5 22 2.5 17 1.9 25 2.8 19 2.1
8-32 19 2.1 14 1.6 29 3.3 22 2.5 36 4.1 27 3.0 41 4.6 31 3.5
8-36 20 2.2 15 1.7 31 3.5 23 2.6 38 4.3 29 3.3 44 5.0 33 3.7
10-24 27 3.0 21 2.4 42 4.8 32 3.6 52 5.9 39 4.4 60 6.8 45 5.1
10-32 31 3.5 24 2.7 48 5.4 36 4.1 60 6.8 45 5.1 68 7.7 51 5.8
1/4-20 66 7.5 49 5.5 100 11.3 76 8.6 125 14.1 94 10.6 143 16.2 107 12.1
1/4-28 75 8.5 56 6.3 120 13.6 87 9.8 143 16.2 107 12.1 164 18.5 123 13.9
ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm
5/16-18 11 15.1 8 10.9 17 23.0 13 18 21 29 16 22 25 34 18 24
5/16-24 12 16.3 9 12.2 19 26 14 19 24 33 18 24 25 34 20 27
3/8-16 20 27 15 20 30 41 23 31 40 54 30 41 45 61 35 47
3/8-24 23 31 17 23 35 47 25 34 45 61 30 41 50 68 35 47
7/16-14 32 43 24 33 50 68 35 47 60 81 45 61 70 95 55 75
7/16-20 35 47 25 34 55 75 40 54 70 95 50 68 80 109 60 81
1/2-13 50 68 35 47 75 102 55 75 95 129 70 95 110 150 80 109
1/2-20 55 75 40 54 85 115 65 88 105 143 80 109 120 163 90 122
9/16-12 70 95 50 68 110 150 80 109 135 183 100 136 150 203 110 150
9/16-18 80 109 60 81 120 163 90 122 150 203 110 150 170 231 130 177
5/8-11 95 129 70 95 150 203 110 150 190 258 140 190 220 298 170 231
5/8-18 110 150 85 115 170 231 130 177 210 285 160 217 240 326 180 244
3/4-10 170 231 130 177 260 353 200 272 330 448 240 326 380 515 280 381
3/4-16 190 258 140 190 300 407 220 298 370 502 280 381 420 569 320 434
7/8-9 170 231 125 169 430 583 320 434 530 719 400 544 600 813 460 624
7/8-14 185 252 140 190 470 637 350 475 580 786 440 598 660 895 500 680
1-8 250 339 190 258 650 881 480 651 800 1085 600 813 900 1224 680 925
1-12 275 373 205 278 700 949 520 705 860 1166 660 895 1000 1360 740 1003
1 1/8-7 350 475 270 366 800 1085 600 813 1120 1519 840 1139 1280 1136 960 1302
1 1/8-12 400 544 300 407 880 1193 660 895 1260 1708 940 1274 1440 1952 1080 1464
1 1/4-7 500 680 375 509 1120 1523 840 1139 1580 2142 1200 1627 1820 2468 1360 1884
1 1/4-12 550 746 420 569 1240 1681 920 1247 1760 2386 1320 1790 2000 2720 1500 2034
1 3/8-6 650 881 490 664 1460 1980 1100 1491 2080 2820 1560 2115 2380 3227 1780 2413
1 3/8-12 750 1017 560 759 1680 2278 1260 1708 2380 3227 1780 2413 2720 3688 2040 2766
1 1/2-6 870 1180 650 881 1940 2630 1460 1980 2780 3769 2080 2820 3160 4298 2360 3200
1 1/2-12 980 1329 730 990 2200 2983 1640 2224 3100 4203 2340 3173 3560 4857 2660 3606
NOTE: * Use “oiled” values for bolts with liquid thread-locking compound applied at point of use.
NOTE: ** Use “dry” values for bolts with pre-applied, chemical thread-locking compound.

Torque Chart - Metric (Ferrous)
Torque Chart - Metric (Ferrous)

Ferrous Metric Bolts, Coarse Thread
(The grade rating is stamped on the head of the bolt.)
Grade 4.8 Grade 8.8 Grade 10.9 Grade 12.9
Size Dry** Oiled* Dry** Oiled* Dry** Oiled* Dry** Oiled*
in.
in. lb. Nm Nm in. lb. Nm in. lb. Nm in. lb. Nm in. lb. Nm in. lb. Nm in. lb. Nm
lb.
M1.6-0.35 0.8 0.09 0.6 0.07 1.6 0.18 1.2 0.14 2.2 0.25 1.7 0.19 2.6 0.30 2.0 0.22
M2-0.40 1.7 0.19 1.3 0.14 3.3 0.37 2.5 0.28 4.6 0.52 3.4 0.39 5.3 0.60 4.0 0.45
M2.5-0.45 3.5 0.40 2.6 0.30 6.7 0.76 5.1 0.57 9.3 1.1 7.0 0.79 11 1.2 8.2 0.93
M3-0.5 6.2 0.70 4.7 0.53 12 1.4 9 1.0 17 1.9 12 1.4 19 2.2 15 1.7
M3.5-0.6 9.8 1.1 7.3 0.83 19 2.1 14 1.6 26 3.0 20 2.2 31 3.5 23 2.6
M4-0.7 14 1.6 11 1.5 28 3.2 21 2.4 39 4.4 29 3.3 45 5.1 34 3.8
M5-0.8 29 3.3 22 2.5 57 6.4 42 4.8 78 8.9 59 6.6 91 10.4 69 7.8
ft. lb. Nm ft. lb. Nm ft. lb. Nm ft. lb. Nm ft. lb. Nm ft. lb. Nm ft. lb. Nm ft. lb. Nm
M6-1 – – – – 8 10.9 6 8.2 11 15.1 8 11.3 13 17.6 10 13.2

M8-1.25 – – – – 19 26 15 20 27 37 20 27 31 43 24 32
M8-1 – – – – 21 29 16 22 29 39 22 30 34 6 25 34
M10-1.5 – – – – 38 52 29 39 53 72 40 54 62 85 47 63
M10-1.25 – – – – 41 56 30 41 56 76 42 57 66 90 49 67
M12-1.75 – – – – 65 88 50 68 90 122 70 95 110 150 80 109
M12-1.25 – – – – 75 102 55 75 100 136 75 102 120 163 90 122
M14-2 – – – – 105 143 80 109 150 204 110 150 175 238 130 177
M14-1.5 – – – – 115 156 85 116 160 218 120 163 190 258 140 190
M16-2 – – – – 165 224 125 170 230 313 170 231 270 367 200 272
M16-1.5 – – – – 175 238 130 177 245 333 185 252 280 381 215 292
M20-2.5 – – – – 325 442 240 326 450 612 340 462 520 707 400 544
M20-1.5 – – – – 360 490 270 367 500 680 375 510 580 789 440 598
M24-3 – – – – 560 762 420 571 780 1061 580 789 900 1224 680 925
M24-2 – – – – 610 830 460 626 850 1156 640 870 1000 1360 740 1006
M30-3.5 – – – – 1120 1523 840 1142 1550 2108 1160 1578 1800 2448 1350 1836
M30-2 – – – – 1240 1686 920 1251 1700 2312 1280 1741 2000 2720 1500 2040
M36-4 – – – – 1950 2652 1460 1986 2700 3671 2000 2720 3160 4298 2350 3196
M36-2 – – – – 2200 2992 1640 2230 3000 4080 2250 3060 3500 4760 2650 3604
NOTE: * Use “oiled” values for bolts with liquid thread-locking compound applied at point of use.
NOTE: ** Use “dry” values for bolts with pre-applied, chemical thread-locking compound.

Torque Chart - Standard (Brass)
Torque Chart - Standard (Brass)

Brass MS63 Standard Bolts, Coarse Thread
Torque (with bolts oiled*)
Size
in. lb. Nm
0-80 0.5 0.05
1-64 0.9 0.10
1-72 1.0 0.11
2-56 1.5 0.17
2-64 1.6 0.18
3-48 2.3 0.26
3-56 2.5 0.28
4-40 3.3 0.37
4-48 3.6 0.40
5-40 4.8 0.54
5-44 5.3 0.60
6-32 6.1 0.69
6-40 6.8 0.77
8-32 11 1.24
8-36 11 1.24
10-24 14 1.58
10-32 17 1.92
12-24 23 2.59
12-28 25 2.82
1/4-20 35 3.96
1/4-28 40 4.52
5/16-18 73 8.25
5/16-24 81 9.15
3/8-16 130 14.69
3/8-24 147 16.61
NOTE: * Use ”oiled” values for bolts with
thread-locking compound.

Torque Chart - Metric (Brass)
Torque Chart - Metric (Brass)

Brass MS63 Metric Bolts, Coarse Thread
Diameter Torque (with bolts oiled*)

(in millimeters) Inch pounds Newton meters
2 1.2 0.14
2.5 2.5 0.29
3 4.4 0.5
3.5 7.0 0.79
4 10 1.2
5 19 2.2
6 34 3.9
8 79 9

Torque Chart - Thread Forming Screws
Torque Chart - Thread Forming Screws

Standard Thread-Forming Screws Metric Thread-Forming Screws
Nearest Plate Torque Nearest Plate Torque
Size
Thickness (in.) in. lb. Nm Size Thickness
in. lb. Nm
0.0469 4 0.5 in. (mm)
2-56 0.0625 4 0.5 0.039 (1.0) 9 1.0
0.0938 5 0.6 M3 x 0.5 0.079 (2.0) 9 1.0
0.0625 6 0.7 0.118 (3.0) 14 1.6
3-48 0.0938 7 0.8 0.079 (2.0) 16 1.8
0.1250 7 0.8 M4 x 0.7 0.118 (3.0) 29 3.3
0.0312 6 0.7 0.157 (4.0) 38 4.3
4-40 0.0625 9 1.0 0.098 (2.5) 25 2.8
0.0938 11 1.2 M5 x 0.8 0.138 (3.5) 53 6.0
0.0625 12 1.4 0.197 (5.0) 62 7.0
5-40 0.0938 18 2.0 0.118 (3.0) 44 5.0
0.1250 20 2.3 M6 x 1.0 0.177 (4.5) 89 10.0
0.0625 14 1.6 0.236 (6.0) 89 10.0
6-32 0.0938 20 2.3 0.157 (4.0) 177 20.0
0.1250 22 2.5 M8 x 1.25 0.236 (6.0) 248 28.0
0.0938 30 3.4 0.315 (8.0) 266 30.0
8-32 0.1250 45 5.1 0.197 (5.0) 266 30.0
0.1875 45 5.1 M10 x 1.5 0.315 (8.0) 398 45.0
0.0938 35 4.0 0.394 (10.0) 487 55.0
10-24 0.1250 45 5.1 0.236 (6.0) 531 60.0
0.1875 55 6.2 M12 x 1.75 0.354 (9.0) 575 65.0
0.0938 35 4.0 0.472 (12.0) 885 100.0
10-32 0.1250 50 5.6
0.1875 70 7.9
0.1250 65 7.3
12-24 0.1875 75 8.5
0.2500 85 9.6
0.1250 85 9.6
1/4-20 0.1875 125 14.1
0.2500 125 14.1
0.1875 160 18.1
5/16-18 0.2500 225 25.4
0.3125 250 28.2
0.2500 350 39.5
3/8-16 0.3125 400 45.2
0.3750 450 50.8
0.3125 500 56.5
7/16-14 0.3750 600 67.8
0.5000 700 79.1
0.2500 500 56.5
1/2-13 0.3750 850 96.0
0.5000 1000 113.0

Decimal Equivalent Chart

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
1/64 .016 .02 .397
1/32 .031 .03 .794
3/64 .047 .05 1.191
1/16 .062 .06 1.587
5/64 .078 .08 1.984
3/32 .094 .09 2.381
7/64 .109 .11 2.778
1/8 .125 .12 3.175
9/64 .141 .14 3.572
5/32 .156 .16 3.969
11/64 .172 .17 4.366
3/16 .188 .19 4.762
13/64 .203 .20 5.159
7/32 .219 .22 5.556
15/64 .234 .23 5.593
1/4 .250 .25 6.350
17/64 .266 .27 6.747
9/32 .281 .28 7.144
19/64 .297 .30 7.540
5/16 .312 .31 7.937
21/64 .328 .33 8.334
11/32 .344 .34 8.731
23/64 .359 .36 9.128
3/8 .375 .38 9.525
25/64 .391 .39 9.922
13/32 .406 .41 10.319
27/64 .422 .42 10.716
7/16 .438 .44 11.112
29/64 .453 .45 11.509
15/32 .469 .47 11.906
31/64 .484 .48 12.303
1/2 .500 .50 12.700
33/64 .516 .52 13.097
17/32 .531 .53 13.494
35/64 .547 .55 13.891
9/16 .562 .56 14.288
37/64 .578 .58 14.684
19/32 .594 .59 15.081
39/64 .609 .61 15.478
5/8 .625 .62 15.875
41/64 .641 .64 16.272
21/32 .665 .66 16.669
43/64 .672 .67 17.065
11/16 .688 .69 17.462
45/64 .703 .70 17.859
23/32 .719 .72 18.256
47/64 .734 .73 18.653
3/4 .750 .75 19.050
49/64 .766 .77 19.447
25/32 .781 .78 19.844
51/64 .797 .80 20.241
13/16 .812 .81 20.637

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
53/64 .828 .83 21.034
27/32 .844 .84 21.431
55/64 .859 .86 21.828
7/8 .875 .88 22.225
57/64 .891 .89 22.622
29/32 .906 .91 23.019
59/64 .922 .92 23.416
15/16 .938 .94 23.812
61/64 .953 .95 24.209
31/32 .969 .97 24.606
63/64 .984 .98 25.003
1.000 1.00 25.400

Standard/Metric Conversions
To Convert... Multiply, Add, or Subtract...
Area
Square Inches to Square Centimeters Square Inches x 6.452
Square Centimeters to Square Inches Square Centimeters x 0.155
Square Feet to Square Meters Square Feet x 0.093
Square Meters to Square Feet Square Meters x 10.753
Square Yards to Square Meters Square Yards x 0.836
Square Meters to Square Yards Square Meters x 1.196
Distance
Inches to Millimeters Inches x 25.4
Millimeters to Inches Millimeters x 0.039
Inches to Centimeters Inches x 2.54
Centimeters to Inches Centimeters x 0.394
Feet to Meters Feet x 0.305
Meters to Feet Meters x 3.281
Yards to Meters Yards x 0.914
Meters to Yards Meters x 1.094
Miles to Kilometers Miles x 1.609
Kilometers to Miles Kilometers x 0.621
Mass
Ounces to Grams Ounces x 28.35
Grams to Ounces Ounces x 0.035
Ounces to Kilograms Ounces x 0.028
Kilograms to Ounces Kilograms x 35.27
Pounds to Kilograms Pounds x 0.454
Kilograms to Pounds Kilograms x 2.2
Pressure
Pounds per Square Inch (PSI) to kiloPascals PSI x 6.894
kiloPascals to Pounds per Square Inch (PSI) kiloPascals x 0.145
Speed
Miles per hour to Kilometers per hour Miles per hour x 1.609
Kilometers per hour to Miles per hour Kilometers per hour x 0.6214
Temperature
Fahrenheit to Celsius (°F minus 32) x 0.555
Celsius to Fahrenheit (°C x 1.8) plus 32
Torque
Inch Pounds (in. lb.) to Newton Meters (Nm) Inch Pounds x 0.113
Newton Meters (Nm) to Inch Pounds (in. lb.) Newton Meters x 8.85
Foot Pounds (ft. lb.) to Newton Meters (Nm) Foot Pounds x 1.3568
Newton Meters (Nm) to Foot Pounds (ft. lb.) Newton Meters x 0.737
Volume
Pints to Liters Pints x 0.473
Liters to Pints Liters x 2.113
Quarts to Liters Quarts x 0.946
Liters to Quarts Liters x 1.057
Gallons to Liters Gallons x 3.785
Liters to Gallons Liters x 0.26


Models 5400/5500/5600 Maintenance Manual Section I. Index
Index
Index 10 . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Section I. Index
1H . . . . . . . . . . . . . . . . . . . . . . . . 6-17
2A . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
A 2E . . . . . . . . . . . . . . . . . . . . . . . . 6-17
2G . . . . . . . . . . . . . . . . . . . . . . . . 6-17
2H . . . . . . . . . . . . . . . . . . . . . . . . 6-18
AC Motor Troubleshooting . . . . . . . . . 5-11
2M . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Active Maintenance Mode . . . . . . 3-9, 3-25
2T . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
AMP Connectors . . . . . . . . . . . . . . . . 7-87
2U . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Analog Tests . . . . . . . . . . . . . 6-41 to 6-65
2V . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Antenna Cards . . . . . . . . . . . . . . . . . . 8-4
2W . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Audible Alarms . . . . . . . . . . . . . . . . . . 3-8
2X . . . . . . . . . . . . . . . . . . . . . . . . 6-19
2Y . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
B 42 . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
43 . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Battery 4C . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Cables . . . . . . . . . . . . . . . . . . . . . 7-70 4F . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Charging . . . . . . . . . . . . . . . . . . . 7-71 4G . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Checks . . . . . . . . . . . . . . . . . . . . . 4-6 4H . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Cleaning Exterior . . . . . . . . . . . . . 7-71 4K . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Maintenance . . . . . . . . . . . . . . . . 7-71 50 . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Safety . . . . . . . . . . . . . . . . . . . . . . 2-5 51 . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
State-of-Charge (BSOC) . . . . . 5-4, 7-71 59 . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Testing . . . . . . . . . . . . . . . . . . . . 7-71 5A . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Bearings 5B . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Mast, Shimming . . . . . .7-113 to 7-119 5E . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Bleeding Cylinders . . . . . . . . . . . . . . 7-99 5G . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Brake 5J . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Adjustment . . . . . . . . . . . . . . . . . 7-62 5M . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Rotor Replacement . . . . . . . . . . . 7-63 5P . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Brushes . . . . . . . . . . . . . . . . . . . . . . 7-74 61 . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
BSOC (Battery State-of-Charge) . . 5-4, 7-71 63 . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Setting BSOC Cutout . . . . . . . . . . . 5-5 64 . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Bulletins, Service . . . . . . . . . . . . . . . . .i-iii 66 . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
67 . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
C 6D . . . . . . . . . . . . . . . . . . . . . . . . 6-24
6F . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
6K . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Cables, Power . . . . . . . . . . . . . . . . . . 7-72
6M . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Carriage . . . . . . . . . . . . . . .7-110 to 7-112
6N . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Carriage Control Card Replacement . . 7-82
6P . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Caution, Definition . . . . . . . . . . . . . . . 2-2
7E . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Chains
7F . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Center Cylinder, 3-Stage . . . . . . .7-120
7G . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Inspection . . . . . . . . . . . . . . . . . . 4-11
7H . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Maintenance . . . . . . . . . . . . . . . . 4-11
7M . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Side Cylinders, 3-Stage . . . . . . . .7-120
7T . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Chains, Maintenance . . . . . . . . . . . . 4-11
7U . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Cleaning
7V . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Lift Truck . . . . . . . . . . . . . . . . . . . 2-4
7W . . . . . . . . . . . . . . . . . . . . . . . . 6-27
CODE . . . . . . . . . . . . . . . . . . . . . . . . 6-17
7X . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Code
7Y . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Publication: 1031794C, Revised: 13 Jul 2015 I-1

Section I. Index Models 5400/5500/5600 Maintenance Manual
Index
80 . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 Heater Assemblies . . . . . . . . . . . . 3-30

81 . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 Communication Error Code
83 . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 Troubleshooting . . . . . . . . . . . . . . 5-25
84 . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 Commutator, Motor . . . . . . . . . . . . . . . 5-7
88 . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 Component Locator Photos . . . . 7-5 to 7-10
8C . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 Configuration Codes . . . . . . . . . . . . . . 3-31
8F . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 Configure Mode . . . . . . . . . . . . . . . . . . 3-9
8L . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 Connector
91 . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 Battery . . . . . . . . . . . . . . . . . . . . . 7-70
92 . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 Connectors
93 . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 AMP . . . . . . . . . . . . . . . . . . .7-86, 7-87
94 . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 General . . . . . . . . . . . . . . . . . . . . 7-85
9A . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Molex . . . . . . . . . . . . . . . . . . . . . . 7-86
9B . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Power Amp . . . . . . . . . . . . . . . . . . 7-90
9E . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Repair . . . . . . . . . . . . . . . . . . . . . 7-85
9F . . . . . . . . . . . . . . . . . . . . . . . . . 6-32 Contactor Test
9G . . . . . . . . . . . . . . . . . . . . . . . . . 6-32 PC . . . . . . . . . . . . . . . . . . . . . . . 6-108
9H . . . . . . . . . . . . . . . . . . . . . . . . . 6-32 Contactor Test, P . . . . . . . . . . . . . . . 6-109
9J . . . . . . . . . . . . . . . . . . . . . . . . . 6-32 Control Handle
9K . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 Cleaning . . . . . . . . . . . . . . . . . . . . 7-25
A0 . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 Inspection . . . . . . . . . . . . . . . . . . 7-25
A2 . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 Installation . . . . . . . . . . . . . . . . . . 7-26
A4 . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 Lift/Lower Knob . . . . . . . . . . . . . . 7-25
AH . . . . . . . . . . . . . . . . . . . . . . . . 6-33 Removal . . . . . . . . . . . . . . . . . . . . 7-21
AL . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 Repair/Replacement Procedures 7-21 to
AP . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 7-26
AT . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 Soldering Procedures . . . . . . . . . . 7-26
F8 . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 Travel Pot Repair/Replace . . . . . . 7-23
FE . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 Control Handle Assembly . . . . . . . . . . 7-81
FG . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Conversion
FH . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Decimal to Fraction . . . . . . . . . . . A-13
FN . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Fraction to Decimal . . . . . . . . . . . A-13
FP . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Conversions, Standard/Metric . . . . . . A-15
FT . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 Cylinder
G0 . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 Storage Preparation . . . . . . . . . . . 3-31
G2 . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 Cylinders
G3 . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 Bleeding . . . . . . . . . . . . . . . . . . . . 7-99
G4 . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 Center . . . . . . . . . . . . . . . . . . . . 7-106
G5 . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
G7 . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 D
GD . . . . . . . . . . . . . . . . . . . . . . . . 6-37
GE . . . . . . . . . . . . . . . . . . . . . . . . 6-38
DC Motor
GF . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Brushes . . . . . . . . . . . . . . . . . . . . 7-74
J2 . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
DC Motor Troubleshooting . . . . . . . . . . 5-7
J4 . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Deadman Pedal
VC . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Depressed, Theory . . . . . . . . . . . . . 8-6
X3 . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Rectangular . . . . . . . . . . . . . . . . . 7-27
X4 . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Round . . . . . . . . . . . . . . . . . . . . . 7-27
X5 . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Decals and Plates . . . . . . . . . . . . . . . . 7-13
Codes and Messages . . . . . . . . . . . . . . .6-7
Decimal to Fraction Conversion . . . . . A-13
Codes, Configuration . . . . . . . . . . . . . 3-31
Display Messages . . . . . . . . . . . . . . . . . 3-7
Cold Storage . . . . . . . . . . . . . . . . . . . . 3-30
Drive Motor
I-2 Publication: 1031794C, Revised: 13 Jul 2015

Index
Remove/Install . . . . . . . . . . . . . . 7-30 Learning Wire Frequency . . . . . . . 3-21

Drive Tire . . . . . . . . . . . . . . . 7-66 to 7-67
Drive Unit H
Checks . . . . . . .. . . . . . . . . . . . . . 4-6
Heavy Duty . . . .. . . . . . . . . . . . . 7-50
Harness
Removal . . . . . .. . . . . . . . . 7-31, 7-50
Connectors . . . . . . . . . . . . . . . . . . 7-85
Standard . . . . . .. . . . . . . . . . . . . 7-31
Soldering Procedures . . . . . . . . . . 7-85
Troubleshooting . . . . . . . . . . . . . 5-24
Heater Assemblies . . . . . . . . . . . . . . . 3-30
Drive Wheel . . . . . . .. . . . . . . 7-66 to 7-67
High Pressure Relief Valve Adjustment 7-97
Home Proximity Sensor
E Adjustment . . . . . . . . . . . . . . . . . . 7-20
Horn . . . . . . . . . . . . . . . . . . . . . . . . . 7-81
Electrostatic Discharge Hydraulic
See Static Precautions Bleeding Cylinders . . . . . . . . . . . . 7-99
Emergency Lower Valve . . . . . . . . . . . . 2-9 Flow Sensor Service Notes . . . . . . . 7-94
Emergency Lower Valve, Theory . . . . . 8-10 System Storage Preparation . . . . . 3-31
End-of-Aisle Hydraulic Components
Code J2 . . . . . . . . . . . . . . . . . . . . 5-26 Center Cylinder . . . . . . . . . . . . . . 7-106
EPROM
Removal/Replacement . . . . . . . . . 7-83 I
ESD . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
ESD Ground Jack . . . . . . . . . . . . . . . . 2-7
IETM . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Input Tests . . . . . . . . . . . . . . 6-67 to 6-102
F Inspection
Battery Connector . . . . . . . . . . . . . 7-70
Filter Card Motor Brushes . . . . . . . . . . . . . . . 7-74
Theory of Operation . . . . . . . . . . . . 8-4 Wiring/Harness . . . . . . . . . . . . . . 7-85
FlashWare Installation . . . . . . . . . . . . . . . . . . . . . . 3-7
Starting . . . . . . . . . . . . . . . . . . . . 3-27 Interactive Electronic
FlashWare Program . . . . . . . . . . . . . . 3-27 Technical Manuals . . . . . . . . . . . . . 1-3
Flow Sensor . . . . . . . . . . . . . . . . . . . 7-94
Assembly . . . . . . . . . . . . . . . . . . . 7-96 L
Disassembly . . . . . . . . . . . . . . . . 7-95
O-Ring Replacement . . . . . . . . . . 7-94
L/L Pot Test . . . . . . . . . . . . . . . . . . . . 6-43
Forks
Learn
Checks . . . . . . . . . . . . . . . . . . . . . 4-7
Controls . . . . . . . . . . . . . . . . . . . . 3-19
Installation . . . . . . . . . . . . . . . . .7-123
Guide Wire Offsets . . . . . . . . . . . . 3-21
Removal . . . . . . . . . . . . . . . . . . .7-123
Ht/Wt . . . . . . . . . . . . . . . . . . . . . . 3-19
Fraction to Decimal Conversion . . . . . A-13
Mode . . . . . . . . . . . . . . . . . . . . . . . 3-9
Fuse Relay Card . . . . . . . . . . . . . . . . . 8-4
When to Run . . . . . . . . . . . . . . . . 3-19
Fuse/Relay Card
Wirefreq . . . . . . . . . . . . . . . . . . . . 3-21
Troubleshooting . . . . . . . . . . . . . 5-21
LEDs
Wire Guidance . . . . . . . . . . . . . . . . 3-7
G Lift
Motor . . . . . . . . . . . . . . . . . . . . . 7-100
Ground Jack, ESD . . . . . . . . . . . . . . . 2-7 Pump . . . . . . . . . . . . . . . . . . . . . 7-100
Grounded DC Motor Test . . . . . . . . . 5-10 Lift Chain
Guidance Manager Adjustment . . . . . . . . . . . . . . . . . 7-127
Theory of Operation . . . . . . . . . . . . 8-4 Maintenance . . . . . . . . . . . . . . . . 7-127
Guide Wire Lift Chain Storage Preparation . . . . . . 3-31
Learn Wirefreq . . . . . . . . . . . . . . . 3-21 Lift Chains

Index
3-Stage . . . . . . . . . . . . . 7-120 to 7-121 Motors . . . . . . . . .5-7 to 5-11, 7-74 to 7-79

Maintenance . . . . . . . . . . . . . . . . . 4-11 AC
Lift Cylinder Bearing Encoder . . . . . . . . . . . 7-78
Three-Stage Center w/Cushions Open Winding . . . . . . . . . . . . . 5-11
Cushion Replacement . . . . . . 7-106 Service . . . . . . . . . . . . . . . . . . 7-77
Seal Replacement . . . . . . . . . 7-108 Shorted Winding . . . . . . . . . . . 5-11
Service . . . . . . . . . . . . . . . . . 7-106 Temperature Sensor . . . . . . . . 7-77
Lift Power Amplifier . . . . . . . . . . . . . . . 7-80 Commutator . . . . . . . . . . . . . . . . . . 5-7
Theory of Operation . . . . . . . . . . . . .8-4 DC
Lift/Lower Field Winding Test . . . . . . . . . 5-10
Knob Installation/Adjustment . . . . 7-25 Grounded Motor Test . . . . . . . 5-10
System Theory . . . . . . . . . . . . . . . 8-10 Open Circuit Test . . . . . . . . . . . 5-9
Valve . . . . . . . . . . . . . . . . . . . . . . . 7-98 Short Circuited Armature . . . . 5-10
Lights Tests . . . . . . . . . . . . . . . 5-9 to 5-10
Steering Indicator . . . . . . . . . . . . . .3-7 Power Cable Terminals . . . . . . . . . 7-74
Wire Guidance LEDs . . . . . . . . . . . .3-7 Troubleshooting
Load Holding Valve . . . . . . . . . . . . . . . 7-98 AC . . . . . . . . . . . . . . . . . . . . . 5-11
Load Wheels . . . . . . . . . . . . . . . . . . . 7-125 DC . . . . . . . . . . . . . . . . . . . . . . 5-7
Locator Photos . . . . . . . . . . . . .7-5 to 7-10
Loctite® O
See Thread Adhesives
Lubrication Specification Chart . . . . . . .A-2
Open Circuit DC Motor Test . . . . . . . . . 5-9
Open Winding AC Motor . . . . . . . . . . . 5-11
M Operator Display . . . . . . . . . . . . . . . . . 3-7
Steering Indicator Lights . . . . . . . . . 3-7
Maintenance Minder . . . . . . . . . . . . . . .4-3 Output Tests . . . . . . . . . . . 6-107 to 6-125
Disabling . . . . . . . . . . . . . . . . . . . . .4-4
Enabling . . . . . . . . . . . . . . . . . . . . .4-3 P
Maintenance Mode . . . . . . . . . . . 3-9, 3-25
Active . . . . . . . . . . . . . . . . . . 3-9, 3-25
Pallet Clamp . . . . . . . . . . . . . . . . . . 7-124
Static . . . . . . . . . . . . . . . . . . 3-9, 3-25
Password . . . . . . . . . . . . . . . . . . . . . . . 3-8
Mast
How to Change . . . . . . . . . . . . . . . 3-13
Bearing
Photos, Locator . . . . . . . . . . . . 7-5 to 7-10
Shimming . . . . . . . . 7-113 to 7-119
Pin Extraction
Inner Tele to Carriage . . . . 7-118
AMP Connectors . . . . . . . . . . . . . . 7-87
Main Frame to
Pin Insertion
Outer Telescopic . . 7-116
AMP Connectors . . . . . . . . . . . . . . 7-88
Outer Tele to Inner Tele . . 7-117
Pin-Out Matrix . . . . . . . . . . . . 8-19 to 8-39
Bearing Replacement
Power Amplifier
Upper . . . . . . . . . . . . . . . . . . 7-115
Connectors . . . . . . . . . . . . . .7-86, 7-90
Checks . . . . . . . . . . . . . . . . . . . . . .4-7
Replacement . . . . . . . . . . . . . . . . . 7-80
Disassembly . . . . . . . . . . . . . . . . 7-116
Power Amplifier Replacement . . . . . . . 7-80
Messages and Codes . . . . . . . . . . . . . . .6-7
Power Cables . . . . . . . . . . . . . . . . . . . 7-72
Microprocessor Removal/Replacement 7-83
Power Cables, Motor . . . . . . . . . . . . . . 7-74
Modes of Operation
Pressure Switch Adjustment . . . . . . 7-101
Program Mode . . . . . . . . . . . . . . . . .3-9
Program Mode . . . . . . . . . . . . . . . . . . . 3-9
Run Mode . . . . . . . . . . . . . . . . . . . .3-8
Configure Mode . . . . . . . . . . . . . . . 3-9
Motor
LEARN . . . . . . . . . . . . . . . . . . . . . . 3-9
Checks . . . . . . . . . . . . . . . . . . . . . .4-8
Maintenance . . . . . . . . . . . . . . . . . . 3-9
Drive, Remove/Install . . . . . . . . . . 7-30
Pump
Lift . . . . . . . . . . . . . . . . . . . . . . . 7-100
Lift . . . . . . . . . . . . . . . . . . . . . . . 7-100
Storage Preparation . . . . . . . . . . . . 3-31

Index
R Steering and Controls . . . . . . . . . . . . . 7-17

Storage
Relief Valve Hydraulic Cylinders . . . . . . . . . . . 3-31
Adjustment . . . . . . . . . . . . . . . . . 7-97 Hydraulic System . . . . . . . . . . . . . 3-31
Run Mode . . . . . . . . . . . . . . . . . . . . . . 3-8 Lift Chains . . . . . . . . . . . . . . . . . . 3-31
Motors . . . . . . . . . . . . . . . . . . . . . 3-31
Warranty Issues . . . . . . . . . . . . . . 3-31
S SuperWord . . . . . . . . . . . . . . . . . . . . . . 3-8
How to Change . . . . . . . . . . . . . . . 3-13
Safety Switch Adjustment . . . . . . . . . . . . . . . . A-4
Battery . . . . . . . . . . . . . . . . . . . . . 2-5 Switch Gap . . . . . . . . . . . . . . . . . . . . . . A-4
Decals . . . . . . . . . . . . . . . . . . . . . 7-13 Switches
Definitions . . . . . . . . . . . . . . . . . . . 2-2 Deadman Replacement . . . . . . . . . 7-27
Emergency Lower Valve . . . . . . . . . 2-9 Pressure Switch Adjustment . . . . 7-101
ESD . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Tests
General . . . . . . . . . . . . . . . . . . . . . 2-3 S10 . . . . . . . . . . . . . . . . . . . . . 6-94
Static Precautions . . . . . . . . . . . . . 2-7 S11 . . . . . . . . . . . . . . . . . . . . . 6-70
Welding . . . . . . . . . . . . . . . . . . . . 2-13 S15 . . . . . . . . . . . . . . . . . . . . . 6-90
Scheduled Maintenance S2 . . . . . . . . . . . . . . . . . . . . . . 6-69
360 Day . . . . . . . . . . . . . . . . . . . . 4-10 S21 . . . . . . . . . . . . . . . . . . . . . 6-84
60 Day . . . . . . . . . . . . . . . . . . . . . 4-6 S23 . . . . . . . . . . . . . . . . . . . . . 6-68
Guidelines . . . . . . . . . . . . . 4-2 to 4-10 S24 . . . . . . . . . . . . . . . . . . . . . 6-73
Sealants, Specifications . . . . . . . . . . . . A-3 S25 . . . . . . . . . . . . . . . . . . . . 6-100
Sensor S27 . . . . . . . . . . . . . . . . . . . . . 6-93
Flow . . . . . . . . . . . . . . . . . . . . . . 7-94 S28 . . . . . . . . . . . . . . . . . . . . . 6-71
Sensors S3 . . . . . . . . . . . . . . . . . . . . . . 6-74
Home Prox Adjustment . . . . . . . . 7-20 S4 . . . . . . . . . . . . . . . . . . . . . . 6-91
Service Bulletins . . . . . . . . . . . . . . . . . .i-iii S46 . . . . . . . . . . . . . . . . . . . . . 6-98
Service/Torque Chart, S47 . . . . . . . . . . . . . . . . . . . . . 6-96
Component Specific . . . . . . . . . . . . A-4 S60 & 61 . . . . . . . . . . . . . . . . . 6-92
Shimming Mast Bearings . .7-113 to 7-119 S7 . . . . . . . . . . . . . . . . . . . . . . 6-72
Inner Tele to Carriage . . . . . . . . .7-118 System Architecture . . . . . . . . . . 8-2 to 8-5
Main Frame to Outer Telescopic . .7-116 Systems
Outer Tele to Inner Tele . . . . . . . .7-117 Theory of Operation . . . . . . . . . . . . 8-3
Shorted Winding AC Motor . . . . . . . . 5-11
Shorts to Frame Test . . . . . . . . . . . . . . 5-2
T
Skid Pads . . . . . . . . . . . . . . . . . . . . .7-126
Soldering Procedures . . . . . . . . . . . . . 7-85
Solenoid Terminals, Motor Power Cable . . . . . . 7-74
Main Load Hold Tests
Test . . . . . . . . . . . . . . . . . . . .6-110 A04 (VR1) . . . . . . . . . . . . . . . . . . . 6-42
Special Tools . . . . . . . . . . . . . . . . . . . 7-12 A05 (VR2) . . . . . . . . . . . . . . . . . . . 6-43
Specification Plate . . . . . . . . . . . . . . . . 3-3 A08 (TM Temp) . . . . . . . . . . . . . . . 6-44
Specifications, Vehicle . . . . . . . . . . . . . 3-3 A09 (LM Temp) . . . . . . . . . . . . . . . 6-45
Standard/Metric Conversions . . . . . . A-15 A10 (TPA Temp) . . . . . . . . . . . . . . 6-46
Static A11 (TM Current) . . . . . . . . . . . . . 6-47
Precautions . . . . . . . . . . . . . . . . . . 2-7 A13 (Press Sensor) . . . . . . . . . . . . 6-48
Static Maintenance Mode . . . . . . 3-9, 3-25 A14 (VM +12V) . . . . . . . . . . . . . . . 6-49
Steer Motor/Gearbox . . . . . . . . . . . . . 7-18 A15 (Batt) . . . . . . . . . . . . . . . . . . . 6-50
Encoder Bearing Replacement . . . 7-18 A19 (LPA Temp) . . . . . . . . . . . . . . 6-51
Steering A20 (LM Current) . . . . . . . . . . . . . 6-52
Indicator Lights . . . . . . . . . . . . . . . 3-7 A22 (Traction Request) . . . . . . . . . 6-53
A23 (Lift Request) . . . . . . . . . . . . . 6-54

Index
A34 (L/L Current) . . . . . . . . . . . . . 6-55 Emergency Lower Valve . . . . . . . . 8-10

A35 (Brake) . . . . . . . . . . . . . . . . . . 6-56 Filter Card . . . . . . . . . . . . . . . . . . . 8-4
A37 (Steer PA Current) . . . . . . . . . 6-57 Fuse/Relay Card . . . . . . . . . . . . . . 8-4
A51 (Left Tractor Guidance Coil) . . 6-59 Guidance Manager . . . . . . . . . . . . . 8-4
A52 (Right Tractor Guidance Coil) . 6-60 Intellispeed . . . . . . . . . . . . . . . . . . . 8-5
A53 (Left Load Guidance Coil) . . . . 6-61 Lift Power Amplifier . . . . . . . . . . . . 8-4
A54 (Right Load Guidance Coil) . . . 6-62 Lift/Lower System . . . . . . . . . . . . 8-10
A55 (Tractor Near Wire Coil) . . . . . 6-63 Emergency Lower . . . . . . . . . . 8-10
A56 (Load Near Wire Coil) . . . . . . . 6-64 Hi-Pro . . . . . . . . . . . . . . . . . . . 8-11
Analog . . . . . . . . . . . . . . . . 6-41 to 6-65 Lower . . . . . . . . . . . . . . . . . . . 8-12
DC Motor . . . . . . . . . . . . . .5-9 to 5-10 Variable Speed DC Lift . . . . . . 8-10
I00 (S23) . . . . . . . . . . . . . . . . . . . . 6-68 Variable Speed with AC Lift . . . 8-11
I01 (S2) . . . . . . . . . . . . . . . . . . . . . 6-69 Operator Interface Card . . . . . . . . . 8-4
I02 (S11) . . . . . . . . . . . . . . . . . . . . 6-70 Pin-Out Matrix . . . . . . . . . 8-19 to 8-39
I03 (S28) . . . . . . . . . . . . . . . . . . . . 6-71 Steering . . . . . . . . . . . . . . . . . . . . . 8-8
I04 (S7) . . . . . . . . . . . . . . . . . . . . . 6-72 Systems Overview . . . . . . . . . . . 8-8
I05 (S24) . . . . . . . . . . . . . . . . . . . . 6-73 Systems Overview . . . . . . . . . . . . . . 8-3
I15 (S3) . . . . . . . . . . . . . . . . . . . . . 6-74 Traction Power Amplifier . . . . . . . . 8-4
I38 (S21) . . . . . . . . . . . . . . . . . . . . 6-84 Vehicle Manager . . . . . . . . . . . . . . . 8-3
I65 (S15) . . . . . . . . . . . . . . . . . . . . 6-90 Wire Guidance . . . . . . . . . . . . . . . 8-13
I66 (S4) . . . . . . . . . . . . . . . . . . . . . 6-91 Systems Overview . . . . . . . . . . 8-14
I67 (S60 & 61) . . . . . . . . . . . . . . . . 6-92 Thread Adhesives, Specifications . . . . . A-3
I68 (S27) . . . . . . . . . . . . . . . . . . . . 6-93 Thread-Forming Screws, Torque Chart A-12
I69 (S10) . . . . . . . . . . . . . . . . . . . . 6-94 Throttle Pot Test . . . . . . . . . . . . . . . . 6-42
I72 (S47) . . . . . . . . . . . . . . . . . . . . 6-96 Tie-Down for Transport . . . . . . . . . . . 2-10
I73 (S46) . . . . . . . . . . . . . . . . . . . . 6-98 Tire, Drive . . . . . . . . . . . . . . . 7-66 to 7-67
I74 (S25) . . . . . . . . . . . . . . . . . . . 6-100 Tools, Special . . . . . . . . . . . . . . . . . . . 7-12
Input . . . . . . . . . . . . . . . . 6-67 to 6-102 Torque Chart
O00 (TPC) . . . . . . . . . . . . . . . . . . 6-108 Brass, Metric . . . . . . . . . . . . . . . . A-11
O02 (LPC) . . . . . . . . . . . . . . . . . . 6-109 Brass, Standard . . . . . . . . . . . . . . A-10
O11 (SOL1) . . . . . . . . . . . . . . . . . 6-110 Face Seal O-Rings . . . . . . . . . . . . . A-7
O12 (Ramp L/L SOL) . . . . . . . . . . 6-111 Ferrous, Metric . . . . . . . . . . . . . . . . A-9
O18 (Horn) . . . . . . . . . . . . . . . . . 6-112 Hydraulic Fittings . . . . . . . . . . . . . . A-6
O19 (Audible Alarm) . . . . . . . . . . 6-113 Thread-Forming Screws . . . . . . . . A-12
O20 (Travel Alarm) . . . . . . . . . . . 6-114 Towing . . . . . . . . . . . . . . . . . . . . . . . . 2-12
O25 (2 Stage Select SOL) . . . . . . . 6-115 Traction Motor
O28 (Ramp LM) . . . . . . . . . . . . . . 6-116 Power Cable Terminal Nuts . . . . . 7-74
O29 (Ramp TM) . . . . . . . . . . . . . . 6-117 Traction Power Amplifier . . . . . . . . . . 7-80
O30 (Brake SOL) . . . . . . . . . . . . . 6-118 Theory of Operation . . . . . . . . . . . . 8-4
O32 - Toggle Relay Enable . . . . . . 6-119 Traction Power Amplifiers . . . . . . . . . 7-80
O39 (OD Lights) . . . . . . . . . . . . . 6-120 Traction System
O40 (L/L Alarm) . . . . . . . . . . . . . 6-121 Functional Operation . . . . . . 8-6 to 8-7
O41 (Aux Sel SOL) . . . . . . . . . . . . 6-122 Travel Pot (VR1) Replacement . . . . . . . 7-23
O42 (Main Sel SOL) . . . . . . . . . . . 6-123 Travel, Theory . . . . . . . . . . . . . . . . . . . 8-6
O43 (Aux Load Hold SOL) . . . . . . 6-124 Troubleshooting
Output . . . . . . . . . . . . . 6-107 to 6-125 Aisle Exit Error Code J2 . . . . . . . . 5-26
Shorts to Frame . . . . . . . . . . . . . . .5-2 Chains . . . . . . . . . . . . . . . . . . . . . 4-11
Wire Guidance . . . . . . . . . 6-59 to 6-64 Communication Error Codes . . . . 5-25
Theory of Operation Drive Unit . . . . . . . . . . . . . . . . . . . 5-24
Antenna Cards . . . . . . . . . . . . . . . .8-4 Electrical . . . . . . . . . . . . . . . . . . . . 5-2
BSOC . . . . . . . . . . . . . . . . . . . . . . .5-4 Electrical Symptoms . . . . . 5-31 to 5-32
Carriage Control Card . . . . . . . . . . .8-3 ESD . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Index
Fuse/Relay Card . . . . . . . . . . . . . 5-21

Hydraulic Functions . . . . 5-27 to 5-29
Motors
AC . . . . . . . . . . . . . . . . . . . . . 5-11
DC . . . . . . . . . . . . . . . . . . . . . . 5-7
Pin-Out Matrix . . . . . . . . 8-19 to 8-39
Shorts to Frame Test . . . . . . . . . . . 5-2
Travel Functions . . . . . . . . . . . . . 5-30
Types . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Valve
High Pressure Relief
Adjustment . . . . . . . . . . . . . . 7-97
Valves
Emergency Lower . . . . . . . . . . . . . 2-9
High Pressure Relief Adjustment . 7-97
Lift/Lower . . . . . . . . . . . . . . . . . . 7-98
Load Holding . . . . . . . . . . . . . . . . 7-98
Vehicle
Specifications . . . . . . . . . . . . . . . . 3-3
Vehicle Manager
Theory of Operation . . . . . . . . . . . . 8-3
VR1 Test . . . . . . . . . . . . . . . . . . . . . . 6-42
VR2 Test . . . . . . . . . . . . . . . . . . . . . . 6-43
Warning, Definition . . . . . . . . . . . . . . . 2-2

Warranty
Storage Issues . . . . . . . . . . . . . . . 3-31
Welding Safety . . . . . . . . . . . . . . . . . . 2-13
Wheels
Drive . . . . . . . . . . . . . . . . 7-66 to 7-67
Load . . . . . . . . . . . . . . . . . . . . . .7-125
Wire Guidance . . . . . . . . . . . . . . . . . 3-29
End-of-Aisle Configurations . . . . . 8-15
End-of-Aisle Control, Theory . . . . 8-15
End-of-Aisle Magnet Installation . 8-16
End-of-Aisle Slow Down, Theory . 8-17
LEDs . . . . . . . . . . . . . . . . . . . . . . . 3-7
Setup . . . . . . . . . . . . . . . . . . . . . 3-29
Tests . . . . . . . . . . . . . . . . 6-59 to 6-64
Wiring
Connectors . . . . . . . . . . . . . . . . . 7-85
Soldering Procedures . . . . . . . . . . 7-85
Wrist strap, ESD . . . . . . . . . . . . . . . . . 2-7

Schematics
Models Serial Numbers

5400, 5500, 5600 00100 and Up This publication applies to the all subsequent releases of this product until
otherwise indicated in new editions or bulletins. Changes occur periodically to
the information in this publication.
If you need assistance with your lift truck, or to order additional copies of this
document, contact your local authorized Raymond Dealer. To locate your local
authorized Raymond Dealer, go to www.raymondcorp.com.
Publication: 1123010B Issued: 13 Jul 2015 Use with Maintenance Manual 1031794C
©2015 The Raymond Corporation.

Models 5400/5500/5600 High-Level Orderpicker Lift Truck Schematics
Section A. Appendix
Figure 1. Power Distribution Diagram Sheet 1 (AC Lift)

JPTA1
TPC -6
NOTES: CONTACTOR CARRIAGE
-13
1. CONNECTED TO JPF4-14 ON 24V TRUCKS WITH AC LIFT. TPC SUPPLY CONTROL IDENT. DESCRIPTION
(B+K3) LIGHTS AND FAN (OPTION)
CARD BRAKE ELECTRIC BRAKE
SUPPRESSOR NETWORK
TA FAN JPC5
CONTACTOR - + FL-2 2
S43
1 6+ -1
1 CD COIL DRIVER CIRCUIT
PANEL FAN
5 AMP FL-1 S41
TPC 2 1 FSUP CONNECTOR ON FAN SUPPRESSOR
BALLAST
TP1 -2 -12 2,3,4 5- -2
ID1 FL-1 FU1 POWER FUSE FOR STEER
1 DOME
2 FU2 POWER FUSE FOR TRACTION
LIGHTS -3
B-
-4 FU3 POWER FUSE FOR LIFT
1 WARNING FU5 CONTROL FUSE FOR VEHICLE MANAGER B+ 15A
LPC FU2 LIGHT
FU1 2 (350A) BALLAST (OPTION) FU6 CONTROL FUSE FOR VEHICLE MANAGER B- 15A
(100A)
FU7 CONTROL FUSE FOR AUX. POWER B+ 15A/5A
TP2 FU3 TP5 U
JP (500A) U 5 AMP FU8 CONTROL FUSE FOR AUX. POWER B- 15A/5A
B+ -1
JPS1-1, -2 X Y JPS1-8 V B+K3 FU9 CONTROL FUSE FOR RF TERMINAL B+ 2A
TP3 TPC TM V S40
SLL-1 SLL-2 2 1
W FU10 CONTROL FUSE FOR RF TERMINAL B- 2A
-3, -4 W
+
S1 JPC6
SLR-1 SLR-2 WORKING 2 1 -1 FU11 10A B+ FUSE ON CARRIAGE FOR 10A POWER HOOKUP OPTIO
LIGHTS FU12 10A B- FUSE ON CARRIAGE FOR 10A POWER HOOKUP OPTIO
JPS1-11 5 AMP -2
FU30 15A B+ FUSE ON TRACTOR FOR 10A POWER HOOKUP OPTIO
-3 FU31 15A B- FUSE ON TRACTOR FOR 10A POWER HOOKUP OPTION
JPLA1 NC
LPC -6 BALLAST 1
CONTACTOR S21 H (HRN)HORN
2
LPC SUPPLY -13 NO -4
(B+K3)
JP10 CONNECTOR FOR WARNING LIGHT
JPB- BATTERY CONNECTOR -
LA JPB+ BATTERY CONNECTOR +
JPBR CONNECTOR FOR BRAKE
-1 -11 JPC5 CONNECTOR ON C.C.C. FOR LIGHTS/FANS
ID0
JPC6 CONNECTOR ON C.C.C. FOR LIFT/LOWER BYPASS SWITCH
VEHICLE (OPTION) JPC12 CONNECTOR ON C.C.C. FOR SPARE POWER
X Y JPS1-9 JPC12
LPC B- MANAGER 2 FU9 1 TS12-1 -1 JPC16 CONNECTOR ON C.C.C. FOR OVER THE MAST CABLE #2
RF
TERMINAL -2 JPF1 B- AUX POWER, B+ POWER AMPS CONNECTOR ON FUSE/REL
2 FU10 1 TS12-2 JPF2 B+ KEY SWITCH RELAYS CONNECTOR ON FUSE/RELAY CARD
JPS1-5 JPS1-10 JPF3 B- CONNECTOR ON FUSE/RELAY CARD
SPL2-B+
U JPF4 KEY SWITCH, EPO, BATTERY SENSE CONNECTOR ON FUSE/R
U -1
B+K3 JPLA1 LIFT AMP CONNECTOR
V
SPL1-B-
LM V JPS1 CONTACTOR PANEL INTERFACE CONNECTOR
JP W W
+ +12V
JPS2 CONNECTOR ON TRUCK TRACKER FOR POWER
B- WORK LTS
+5V JPS25 CONNECTOR FOR OVER THE MAST CABLE #1
DGND JPS26 CONNECTOR FOR OVER THE MAST CABLE #2
JPS29 CONNECTOR FOR 10 AMP POWER HOOKUP OPTION ON TRAC
FSUP- JPS30 CONNECTOR FOR 10 AMP POWER HOOKUP OPTION ON CAR
JPT20 -6
-15 JPT14 B+, B-, CAN COMMUNICATIONS CONNECTOR ON VM
TP4 TP2 -4
CD JPT18 COIL DRIVERS CONNECTOR ON VM
MS+ L/L -16 FSUP -3
+ 1 2 -1 JPT20 PROPORTIONAL COIL DRIVERS CONNECTOR ON VM
JPT22 DIGITAL INPUTS CONNECTOR ON VM
MS SA
B- 1 JPT24 ANALOG INPUTS CONNECTOR ON VM
- JPTA1 TRACTION AMP CONNECTOR
MS-
TP4 JPT22
-19 B+ 2
FAN K1 KEYSWITCH RELAY-OPTIONS
JPT14-2, -10 DGND
K2 KEYSWITCH RELAY-SOLENOIDS, ATTACHMENTS, HORN
2 NO K3 KEYSWITCH RELAY-POWER AMPS
-1, -8, -9 B-F S56
JPS2 1 NO K4 KEYSWITCH RELAY-AUX. VM POWER
-11 JPT20-19
MANAGER CARD
B+ESTOP
L/H LOAD/HOLD SOLENIOD
(OPTION)
JPF3-3, -4
L/L LIFT/LOWER SOLENOID
GUIDANCE
-5, -6, -7
JPF1-3
JPF1-5
JPF2-1
JPF1-6
JPS2 LA LIFT POWER AMPLIFIER

-24
B-F
-12
-11
-9
LM AC LIFT MOTOR OR DC LIFT MOTOR

LPC LIFT POWER CONTACTOR
T° T° HRN
FU6 (15A) -NEG JPT18
JPF3-1, -2
H -IN H-1 -16 MS STEER MOTOR
1 2
T° K3 -POS H-2
JPF1-1, -2 FU8 (15A/5A) JPF1-4 S1 KEY SWITCH
1 2 JPF4-15 S21 EPO SWITCH
FU7 (15A/5A) K1 JPBR-2
JPF4-3, -4 JPF2-9 JPT20 S40 SWITCH FOR WORKING LIGHTS
1 2 -1 -14
CD S41 SWITCH FOR DOME LIGHTS
JPF2-2
S43 SWITCH FOR FAN
BRAKE JPT18
-5 -10 JPC16 S56 SWITCH FOR FAN
L/H CD -1
1 1 2 JPT14 -2 SA STEER POWER AMPLIFIER
JPF4-13 -6
JPT22 CD -3
-14
-6 -21 -4 TA TRACTION POWER AMPLIFIER
K4 K3 K2 K1 JP10-1
-5 WARNING LIGHT TM AC TRACTION MOTOR
-6
-12 -2 TP1 TIE POINT ON B+
JPT14
-11 -12 -8 TP2 TIE POINT ON STEER MOTOR FUSE
-8 TP3 TIE POINT ON LIFT MOTOR FUSE
JPF4-1, -2 FU5 (15A) OTM CABLE
-10 TP4 TIE POINT ON B-
1 2
K2 K4 TP5 TIE POINT ON TRACTION MOTOR FUSE
JPF2-4 JPT14 JPS30 JPS29
-7,-13,-14 TPC TRACTION POWER CONTACTOR
-3,-6,-7, -1 -1
TS12 TERMINAL STRIP FOR SPARE POWER
T° JPF4-7 JPT24-24 TP1
BATTERY_SENSE_IN FU30 FU11
B+
JPF2-8 (15A) (10A)
FUSE/
JPS26
-4
-2 -2
AC LIFT
RELAY -2 TP4
B- FU31 FU12
CARD -3 (15A) (10A)
-1
-6
-8
10 AMP POWER HOOKUP OPTION
Publication: 1123010B, Issued: 13 Jul 2015 2

Figure 2. Power Distribution Diagram Sheet 2 (DC Lift)
JPTA1
TPC -6
CONTACTOR CARRIAGE
-13
TPC SUPPLY CONTROL
LIGHTS AND FAN (OPTION)
(B+K3) CARD
SUPPRESSOR NETWORK
TA FAN JPC5 IDENT. DESCRIPTION
CONTACTOR - + FL-2 2
S43
1 6+ -1 BRAKE ELECTRIC BRAKE
1
PANEL FAN
5 AMP FL-1 S41 CD COIL DRIVER CIRCUIT
TPC 2 1
BALLAST
TP1 -2 -12 2,3,4 5- -2
ID1 FL-1 DOME
2 1 LIGHTS FSUP CONNECTOR ON FAN SUPPRESSOR
B- -3
-4 FU1 POWER FUSE FOR STEER
1 WARNING FU2 POWER FUSE FOR TRACTION
LPC FU2 LIGHT
FU1 2 (350A) BALLAST (OPTION) FU3 POWER FUSE FOR LIFT
(100A)
FU5 CONTROL FUSE FOR VEHICLE MANAGER B+ 15A
TP2 FU3 TP5
JP (500A) U U FU6 CONTROL FUSE FOR VEHICLE MANAGER B- 15A
-1 5 AMP
B+ JPS1-1, -2 B+K3
X Y JPS1-8 V FU7 CONTROL FUSE FOR AUX. POWER B+ 15A/5A
TP3 TPC TM V S40
SLL-1 SLL-2 2 1 FU8 CONTROL FUSE FOR AUX. POWER B- 15A/5A
-3, -4 W W
+
S1 JPC6 FU9 CONTROL FUSE FOR RF TERMINAL B+ 2A
SLR-1 SLR-2 WORKING 2 1 -1
LIGHTS FU10 CONTROL FUSE FOR RF TERMINAL B- 2A
A1 + JPS1-11 5 AMP -2 FU11 10A B+ FUSE ON CARRIAGE FOR 10A POWER HOOKUP OPTION
A2 -3 FU12 10A B- FUSE ON CARRIAGE FOR 10A POWER HOOKUP OPTION
LM BALLAST NC FU30 15A B+ FUSE ON TRACTOR FOR 10A POWER HOOKUP OPTION
1
S21 FU31 15A B- FUSE ON TRACTOR FOR 10A POWER HOOKUP OPTION
S1 - 2
NO -4
H (HRN) HORN
JP10 CONNECTOR FOR WARNING LIGHT

JPB- BATTERY CONNECTOR -
JPB+ BATTERY CONNECTOR +
JPBR CONNECTOR FOR BRAKE
VEHICLE (OPTION) JPC5 CONNECTOR ON C.C.C. FOR LIGHTS/FANS
X Y JPC12
LPC
JPS1-9 MANAGER 2 FU9 1 TS12-1 -1
JPC6 CONNECTOR ON C.C.C. FOR LIFT/LOWER BYPASS SWITCH
RF
-2 JPC12 CONNECTOR ON C.C.C. FOR SPARE POWER
TERMINAL
2 1 JPC16 CONNECTOR ON C.C.C. FOR OVER THE MAST CABLE #2
FU10 TS12-2
JPT22-20 JPF1 B- AUX POWER, B+ POWER AMPS CONNECTOR ON FUSE/RELAY C
JPS1-5 JPS1-6 JPS1-10
JPF2 B+ KEY SWITCH RELAYS CONNECTOR ON FUSE/RELAY CARD
SPL2-B+
JPF3 B- CONNECTOR ON FUSE/RELAY CARD
SPL1-B-
JPF4 KEY SWITCH, EPO, BATTERY SENSE CONNECTOR ON FUSE/RELA
JP +12V JPS1 CONTACTOR PANEL INTERFACE CONNECTOR
B- WORK LTS
+5V JPS2 CONNECTOR ON TRUCK TRACKER FOR POWER
DGND JPS25 CONNECTOR FOR OVER THE MAST CABLE #1
JPS26 CONNECTOR FOR OVER THE MAST CABLE #2
FSUP- JPS29 CONNECTOR FOR 10 AMP POWER HOOKUP OPTION ON TRACTOR
JPT20 -6 JPS30 CONNECTOR FOR 10 AMP POWER HOOKUP OPTION ON CARRIAG
TP4 TP2 -15
-4 JPT14 B+, B-, CAN COMMUNICATIONS CONNECTOR ON VM
MS+ -16 CD FSUP -3
L/L JPT18 COIL DRIVERS CONNECTOR ON VM
+ 1 2 -1
JPT20 PROPORTIONAL COIL DRIVERS CONNECTOR ON VM
MS SA JPT18-9 JPT22 DIGITAL INPUTS CONNECTOR ON VM
CD B- 1
- JPT24 ANALOG INPUTS CONNECTOR ON VM
MS-
JPT22 JPTA1 TRACTION AMP CONNECTOR
TP4 B+ 2
-19
JPT14-2, -10 DGND FAN
K1 KEYSWITCH RELAY-OPTIONS
2 NO K2 KEYSWITCH RELAY-SOLENOIDS, ATTACHMENTS, HORN
-1, -8, -9 B-F S56
1 NO K3 KEYSWITCH RELAY-POWER AMPS
JPS2
-11 JPT20-19 K4 KEYSWITCH RELAY-AUX. VM POWER
B+ESTOP
MANAGER CARD
(OPTION)
L/H LOAD/HOLD SOLENIOD
JPF3-3, -4
GUIDANCE
-5, -6, -7
L/L LIFT/LOWER SOLENOID

JPF1-3
JPF1-5
JPF2-1
JPF1-6
JPS2
-24
B-F
-12
-11
-9
LM DC LIFT MOTOR
LPC LIFT POWER CONTACTOR
T° T° HRN
JPF3-1, -2
H -IN H-1 -16 MS STEER MOTOR
1 2
T° K3 -POS H-2
JPF1-1, -2 FU8 (15A/5A) JPF1-4 S1 KEY SWITCH

1 2 JPF4-15 S21 EPO SWITCH
FU7 (15A/5A) K1 JPBR-2
JPF4-3, -4 S40 SWITCH FOR WORKING LIGHTS
JPF2-9 JPT20
1 2 -1 -14 S41 SWITCH FOR DOME LIGHTS
JPF2-2 CD
S43 SWITCH FOR FAN
BRAKE JPT18
-5 -10 JPC16 S56 SWITCH FOR FAN
L/H CD -1
2 JPT14 SA STEER POWER AMPLIFIER
1 -2
JPF4-13 -6
JPT22 CD -3
-14
-6 -21 -4 TA TRACTION POWER AMPLIFIER
K4 K3 K2 K1 JP10-1
-5 WARNING LIGHT TM AC TRACTION MOTOR
-6
-12 -2 TP1 TIE POINT ON B+
JPT14
-11 -12 -8 TP2 TIE POINT ON STEER MOTOR FUSE
-8 2 STAGE SELECT TP3 TIE POINT ON LIFT MOTOR FUSE
JPF4-1, -2 FU5 (15A) SOL (OPTION) OTM CABLE TP4 TIE POINT ON B-
-10 JPT18-1
1 2 CD TP5 TIE POINT ON TRACTION MOTOR FUSE
K2 K4 JPT14
JPF2-4 TPC TRACTION POWER CONTACTOR
-7,-13,-14 JPS30 JPS29
-3,-6,-7, -1 -1 TS12 TERMINAL STRIP FOR SPARE POWER
T° JPF4-7 JPT24-24
BATTERY_SENSE_IN TP1
B+ FU30 FU11
JPF2-8 (15A) (10A)
-2 -2
FUSE/ JPS26
-4 DC LIFT
RELAY -2 TP4
FU31 FU12
B-
CARD -3 (15A) (10A)
-1
-6
-8 10 AMP POWER HOOKUP OPTION

Figure 3. Electrical Schematic Sheet 1 (AC Lift)
A B C D E F G H
SEE SHEET 5, D6
MOTOR VELOCITY JPTA2 JPTA4 JPTA1
JPTA1 TABLE A
JPS4-6
JPS4-5
NOTES: RED -1 -6 -26 T VEL -6
TPC AUX. POWER
SEE PAGE 6. SENSOR + CONTACTOR
BLACK -4 -5 -7 OPTION STD C.S.
TME T VEL SENSOR - -13 FU7 5A 15A
-31 TPC JPS25
WHITE -3 -4
-2 FU8 5A 15A
T VEL PHASE A SUPPLY
2 BLUE -2 -3 -32
T VEL PHASE B (B+K3)
-3
-6
CONTACTOR RED JPTA3-2 -8
-8
-1
T TEMP+ -23
PANEL TMT RED/BLK -1 -7
BUS+
-35
-11 BUS-
-1
OVER THE MAST CABLE

TPC MOTOR ID0
TP1 TEMPERATURE -2 -12
ID1
VEHICLE JPC11
2 1 CURTIS TA MANAGER -1 +12V
AC TRACTION -2 BUS-
DETAIL A 11 -25 B- AMPLIFIER -3
1 +12V BUS+
JPS25 BRAKE DEADMAN
LPC FU2 -28 JPT22-7 -4 -4
FU1 SERIAL Tx BRAKE DEADMAN BRAKE DEADMAN
2 (350A)
(100A) -29 JPT22-8 -5 CARRIAGE DEADMAN -5
CARRIAGE DEADMAN CARRIAGE DEADMAN
FU3 TP5 SERIAL Rx JS27
TP2 U JS31-1 -1 -6
JP JPS1-2 (500A) U DGND
B+ -1
-1 X Y JPS1-8 V B+K3 -2 -2
TP3 TPC TM V B+KEY +12V
-4
-3 W W
+
-14 +5V
PROGRAM
DGND DGND CARRIAGE
JPS1-11 CONTROL
3 MOTOR VELOCITY
JPLA2 JPLA4 JPLA1 JPLA1
CARD
RED -1 -6 -26 L VEL -6
LPC
-7 SENSOR + CONTACTOR
BLACK -4 -5
L VEL SENSOR - LPC -13
-3 -4 -31 SEE SHEET 3
LME WHITE
JPSC2-2
JPSC1-2
L VEL PHASE A SUPPLY
BLUE -2 -3 -32 (B+K3) JPT14
L VEL PHASE B -5
JPLA3 -8 +12VP
RED -2 -8 L TEMP+ -23 -11
RED/BLK
-1 -7 BUS+ BUS_I+
-35 -4
LMT -11 BUS- BUS_I-
-1
JPSC1-1
JPSC2-1
ID0 -3
MOTOR -2 -12 DGND
TEMPERATURE ID1
11
X Y JPS1-9 DETAIL A B-
LPC -25
+12V CURTIS LA
-28 AC LIFT
SERIAL Tx AMPLIFIER
120 IN. LIMIT

150 IN. LIMIT
JPS1-5 JPS1-10 -29 S10
SERIAL Rx JPT20-1 JPS8-1 -3 + +VS
U +12VF
U -1 JPT22-1 JPS8-2 -2 0
4 LM V
V
B+K3 150_LIM
JPS8-3 -1
OUT
- GND
S10
JP W W
+
-14
B- PROGRAM
JPT6
TP4 TP2 -6
+12VP
MS+ -5
CCW_PWM JPT20
+ -2 -16
CW_PWM L/L L/L
SA -3 2 1
MS STEER_CURRENT (B+K2)B+L/L -15
-4
DGND
- -1
MS- NEUTRAL_PULSE
TP4 JPT22
-19 FU1_SENSE
JPT14
-10
DGND
-2
DGND
-1
5 -8
-9 B-F
HOME SENSOR
HOME JPT22 JPA7 HOME
SENSE -3 -1 0
JPF1-3
JPF1-5
JPF2-1
JPF1-6
JPF3-3
SENSOR
PROX
DGND -11 -2 -
-12
-11
JPT20
-4
-5
-6
-7
-8
+12VF -9 -3 +
JPF3-1 T° T° HRN
-2 -IN H-1 -16
1 2 H HORN
JPF1-1 T° K3 -POS H-2
-2 FU8 (15A/5A) JPF1-4

1 2 JPF4-15 STEER
FU7 (15A/5A) K1 JPBR-2 MOTOR
JPF4-3 JPF2-9 JPT20 +12VP JPT20-7 JPE4-1 RED ENCODER
-4 1 2 -1 -14 JPT22-9 -3
BRAKE BRAKE CHANNELA_4 WHT
JPF2-2
OVER THE MAST CABLE

-10 -2 BLU
-3 DETAIL B 11 JPT18 CHANNELB_4
-5 -10 JPT10-9 -4 BLK JPC16
DGND
6 JPF4-13 8 1
L/H
2 JPT14
-6
L/H -1
-2
B+EPO
B-FU8
COMMUNICATIONSFLASHWARE
RELAY_ENABLE -3 B+FU7
-14 JPT22 JPT9
-6 -21 -4 B-FU6
EPO_SENSE TXD -2
K4 K3 K2 K1 JP10-1
-5 WARNING LIGHT RXD -3
-6 B+KEY
-2 DGND -5
-12 JPT14
-11 -12 -8 B+FU5
B+KEY
-8 JPT2
VBUS -1
-1 FU5 (15A)
-10 D+ -2
USB
1 2 D- -3
K2 K4 JPT14
-2 JPF2-4 -7 -4
AC LIFT
B+K2 DGND
-6 -13 9
B+K2
-7 -14
B+K2
T° JPF4-7 JPT24-24
BATTERY_SENSE_IN
JPF2-8
JPS26
FUSE/ -4
RELAY -2
CARD -3
7 -1
-6
-8
JPS30-1 JPS29-1
-2 -2

Figure 4. Electrical Schematic Sheet 2 (DC Lift)
A B C D E F G H
MOTOR VELOCITY
JPTA2 JPTA4 JPTA1 SEE SHEET 5, D6 TABLE A
-26 JPTA1
RED -1 -6 T VEL TPC
JPS4-6
JPS4-5
-6 AUX. POWER
-7 SENSOR + CONTACTOR
BLACK -4 -5 OPTION STD C.S.
T VEL SENSOR - -13 FU7 5A 15A
WHITE -3 -4 -31 TPC JPS25
TME T VEL PHASE A -2 FU8 5A 15A
SUPPLY
2 BLUE -2 -3 -32
-8
T VEL PHASE B (B+K3)
-3
-6
CONTACTOR RED JPTA3 -2 -8 -23 -1
T TEMP+
PANEL RED/BLK -1 -7
BUS+
-35
TMT -11 BUS-
-1
OVER THE MAST CABLE

TPC ID0
MOTOR
VEHICLE
JPSC1-1
JPSC1-2
TP1 -2 -12 JPC11
TEMPERATURE ID1
1 2
CURTIS TA
MANAGER -1 +12V
11 -2 BUS-
DETAIL A -25 AC TRACTION -3
B- BUS+
1 +12V AMPLIFIER JPS25
LPC FU2 -28 JPT22-7 -4 -4
FU1 2 SERIAL Tx BRAKE DEADMAN BRAKE DEADMAN
(350A)
(100A) -29 JPT22-8 -5 -5
CARRIAGE DEADMAN CARRIAGE DEADMAN
FU3 TP5 SERIAL Rx JS27
TP2 U
JP JPS1-2 (500A) 2 U -1
JS31-1 -1 -6
DGND
B+ B+K3
-1 X Y JPS1-8 V -2 -2
TP3 TPC TM V B+KEY +12V
-4
-3 W W
+
-14 +5V
PROGRAM
DGND DGND CARRIAGE
JPS1-11 CONTROL
3 A1 +
CARD
A2
LM SEE SHEET 3
JPT14
-5
S1 - +12VP
-11
BUS_I+
-4
BUS_I-
-3
DGND
X Y JPS1-9
LPC
120 IN. LIMIT

150 IN. LIMIT
JPS1-5 JPS1-6 JPS1-10 S10
JPT20-1 JPS8-1 -3 + +VS
+12VF
JPT22-1 JPS8-2 -2 0
4 150_LIM
JPS8-3 -1 -
OUT
GND
S10
JP
B-
JPT18
-9
LIFT_CONTACTOR
JPT6
TP4 TP2 -6
+12VP
MS+ -5
CCW_PWM JPT20
+ -2 -16
CW_PWM L/L L/L
MS SA -3
STEER_CURRENT -15
2 1
-4 (B+K2)B+L/L
DGND
- -1
MS- NEUTRAL_PULSE
TP4 JPT22
-19 FU1_SENSE
JPT14
-10
DGND
-2
DGND
-1
5 -8
-9 B-F
HOME SENSOR
JPT22 JPA7
HOME -3 -1 0 HOME
JPF1-3
JPF1-5
JPF2-1
JPF1-6
JPF3-3
SENSE SENSOR
-11 -2 - PROX
-12
-11
DGND JPT20
-8
-4
-5
-6
-7
-9 -3 +
JPT22 +12VF
-20 FU3_SENSE
JPF3-1 T° T° HRN
-2 -IN H-1 -16
1 2 H HORN
T° K3 -POS H-2
JPF1-1
-2 FU8 (15A/5A) JPF1-4
1 2 JPF4-15
JPBR-2 STEER
JPF4-3 FU7 (15A/5A) K1 JPT20-7 JPE4-1 RED
JPF2-9 JPT20 +12VP MOTOR
-4 1 2 -1 -14 JPT22-9 -3 ENCODER
BRAKE CHANNELA_4 WHT
JPF2-2
OVER THE MAST CABLE

BRAKE 11 -10 -2 BLU
-3 DETAIL B JPT18 CHANNELB_4
JPT10-9 -4 BLK JPC16
6 -5
JPF4 1
L/H
2
-10
JPT14
-6
L/H DGND -1
-2
B+EPO
B-FU8
-13
COMMUNICATIONSFLASHWARE
RELAY_ENABLE -3 B+FU7
-14 JPT9
-6 JPT22-21 -4 B-FU6
K4 K3 K2 K1
EPO_SENSE TXD -2
JP10-1
-5 WARNING LIGHT RXD -3 -6 B+KEY
-12 -2 DGND -5
JPT14
-12 -8 B+FU5
-11 B+KEY
-8 JPT2
VBUS -1
-1 FU5 (15A)
-10 D+ -2
1 2 -3
JPT14 D-
USB
-2 K2 K4 -7 -4
JPF2-4
DC LIFT
B+K2 DGND
-6 -13 9
B+K2
-7 -14
B+K2
T° JPF4-7 JPT24-24
BATTERY_SENSE_IN
JPF2-8
JPS26
FUSE/ -4
RELAY -2
7 CARD -3
-1
-6
-8
JPS30-1 JPS29-1
-2 -2

Figure 5. Electrical Schematic Sheet 3
A B C D E F G H
2 JPTA4-1
JPTA1-11
JPLA4-1
JPLA1-11
JPTA4-2
JPTA1-12 JPLA4-2
JPLA1-1
JPLA1-12
JPF1-6
JPC1
-1
VEHICLE +5.3V
JPTA1-1
JPF1-6
-2
DGND
MANAGER -3
CHA
-4
JPS4 JPS25 JPC11 CHB
INPUT STEER ENCODER

(SEE SHEET 1 & 2)
-5 -2 -2 -8
BUS- BRKDMAN
{
SEE
( ) -6 -3 -3 -9
OVER THE MAST CABLE

JPT14 SHEET 5 BUS+ DEADMAN STEERING
11 -5 -1 -1 ENCODER
DETAIL A1 +12V +12V JPC21
-3 -1
-6 -6 +5.3V
DGND DGND -2
JPT22 DGND
-3
-7 -4 -4 CHA-E2
BRAKE DEADMAN BRAKE DEADMAN -4
CHB-E2
-8 -5 -5 -5
SPL2 SPL1 CARRIAGE DEADMAN CARRIAGE DEADMAN CD SUPPLY
JPTA1-12 JPLA1-11 -6
-1 -2 -1 -2 CD
JPLA1-1
3
JPTA1-1
CARRIAGE
JPF1-6
JPF1-6
CONTROL
FOR TRACTION CONTROLLER FOR LIFT CONTROLLER
CARD
OPTIONS
DETAIL A2 11
VEHICLE MANAGER
JPS53 JPS53 S15
JPT18-4 -2 -2 -3 + +VS
+12VP S15
RAIL SENSE
JPT22-22 -1 -1 -2 0
RAIL_SEN
*INCLUDES CPU, CAN & ROM

OUT
H-2
JPT24-5 -3 -3 -1 - GND
DGND
JPXBR-2
JPBR-2
JPC6
-1 1 2
B+F
4 JPXBR-1 JPS53B S16 B+KEY

-2 S1
EPO/ KEY
JPBR-1 JPT20-14 -2 -3
-3 + +VS B+ESTOP NC
S16 1
-1 -2 0 S21
OUT -4 2
B+ KEY NO
-3 -1 - GND
DETAIL B1 11 DETAIL B2 11
DUAL ASC SWITCHES
JPC8 S11
-2 -1 + +VS
6-12VF S11
24" LIMIT
24" LIMIT -1 -2 0
S46A
CARRIAGE CONTROL
RIGHT OUT
LIGHT DISPLAY CARD

-1 JPC15
DGND -3 -3 - GND
CARRIAGE CONTROL
-1 -1
-2
LIGHT DISPLAY
ALL PINS USED

-3 JPC7 S2
-15 -15 DGND
CARD
-2 -1 + +VS
-4 +12VF S2
DEADMAN SWITCHES
-16 -16 +5.3V
5 -6 BRK DEADMAN
-1 -2 0
OUT
-8 -24 -24
-3 -3 - GND
DGND
S23
S47A RIGHT -5 -1 + +VS
JPC2 +12VF
INTERFACE CARD
-1 -1 -1 DGND S23
-4 -2 0
OPERATOR
CARRIAGE DEADMAN
-2 -2 -2 UP ARROW OUT
ALL PINS USED

OPERATOR
INTERFACE
-3 -3 DN ARROW -6 -3 - GND
-3 DGND
-4 -4 ETR/SHFT
OPTIONS -4
-6 -17 -17 S28
JPC3
-8 -2 -1 + +VS
6-12VF
S28
60" LIMIT
VEHICLE MANAGER 60" LIMIT
-1 -2 0
OUT
5
-3 -3 - GND
PGND
JPT10 JPS54
-6 -1
+12VP
-2 -2
SENSOR 1 CONTROL HANDLE
JPC9
AISLE DETECT
6 -8
CONTROL HANDLE/ AUTO MANUAL SW

JPT24-8 -3 +5.3V
DGND
-9 TRAVEL
S47B LEFT TRAVEL
VR1
-1 -7
JPT10 JPS55 DGND
-7 -1 -3
+12VP -5
-8 -5 +5.3V
SENSOR 2
-2 FUSE/RELAY -6
-7 LIFT/LOWER
CARD L/L
VR2
JPT24-9 -3 -8 -4
DGND DGND
(SEE SHEET 1 & 2) S3
-3 + +VS
JPS26 JPC16 -3 -2 0
S46B LEFT JPF4-5 -1 -1 HORN
B+EPO B+EPO OUT S3
-1 JPF1-4 -2 -2 -1 -
OVER THE MAST CABLE

B-FU8 B-FU8 GND HORN
-3 JPF4-15 -3 -3
B+FU7 B+FU7
JPF3-12 -4 -4
-5 B-FU6 B-FU6
-7
JPF4-8 -6 -6 -1 1 2
B+KEY B+KEY AUTO/MAN
-8 S4
-2 (OPTION)
-8 DGND
-8
7 ALTERNATE END OF AISLE
B+FU5
JPF4-10 B+FU5

A B C D E F G H
OTM CABLE
SUPPRESSOR
NETWORK
2 IN S43
FAN
JPS30 JPS29 PC5-1 +1 4 1 2 + -

WHITE
-1 -1 FAN
IN
PC5-2 -2 3,5,6
BLACK S81
TP1
FU30 FU11 S40 JPC12 TS12-1 HTRC
B+ FL-L FL-L 1 2 1 2
1 2 -1
(15A) (10A) B+FU7
6A SPARE
WORKING 1
LIGHTS HTR3
-2 -2 FU21 10A HTRDM FUDM
-2 1 2 1 2
2
-2 5A
B-FU8
TP4 FL-R FL-R TS12-2 1
B- FU31 FU12
S80
(15A) (10A)
HTR3 2
-1
HTR3
-1
3 S41
-2
10 AMP POWER HOOKUP OPTION 1 2
SLL-1 SLL-2
COLD STORAGE OPTION COLD STORAGE OPTION

DOME
LIGHTS SLR-1 DEADMAN HEATER
SLR-2
CARRIAGE CONTROL CARD HEATER
COLD STORAGE / INCANDESCENT
SUPPRESSOR
NETWORK
FAN
S43
PC5-1 +6 1 1 2 + -
FAN
CONNECTOR TO CONNECTOR TO
4 THIRD PARTY DEVICE RAYMOND TM
-5 2,3,4
BLUE
JP1-6
VEHICLE
RXD TXD PC5-2
JRDP1-1 PT9-2 BLUE JP1-4
S41 -4 S15B
JP1-1 FU1 MANAGER JPS16 JPBGS2
TXD RXD 1 2 RED -4
-2 -3 JPT20-6 -1 -1 +
BALLAST
DOME 5 AMP
BULB
SHLD LGHT 1 -2
BULB
-5 LIGHTS JP1-2 LGHT 2
WHITE JPT22-6 -2 0
DGND
-3
JP1-3 -1 -1 JPT24-6 -3 -3 -
BATT-
-5
BATT+ JP1-5
BLACK
-6 S15A
JPBGS1
FU35
TP1
TP4
2 AMP -1 +
125VDC
BATT+BATT- JP2-3 JP1-7 -2 0
BLACK
iPORT SUPPLIER WIRELESS MODULE -4 -3 -

S40
1 2 JP2-1 FU2 -4
RED
BATTERY GATE SENSOR (OPTION)
BALLAST
BULB
WORKING 5 AMP
BULB
LIGHTS
5 JP2-2
WHITE
-1 -1
BLUE
JP1-8
BLUE JP2-4
STANDARD / FLUORESCENT
JPX1 JPC16
-1 -1 OTM CABLE
-2 -2
JPS26 JPSI26 JPS16 JPC16
-3 -3 S22 -1 -1 -1 -1
B+EPO
-4 -4 1 2 -2 -2 -2 -2
JPC14 680Ù EPO B-FU8
SIDEGATE SWITCHES
-5 -5 CARRIAGE
CARRIAGE GARD
-2
MAIN HARNESS
+12VF JPS26 -3 -3 -3 -3
-6 -6 CONTROL -4 -4 B+FU7
SIDEGATE RIGHT -1
CARD -2 -2 -4 -4 -4 -4
-7 -7
B-FU6
6 -8 -8 PGND -3
-3
-1
-3
-1
-5 -5
B+EPO
-6 -6 -6 -6 -6 -6
TS12 JPC13 -8 -8 B+KEY
+12VF -2 0 -7 -7
B+FUSEDS
SIDEGATE LEFT -1
- SENSOR -8 -8 -8 -8
1 2 PROX B+FU5
PGND -3 + VM
JPT12 JP1MPV
-4 JC5-2 OF LIGHT & FAN PACKAGE
FU12 LIFT -5 S112 (UP) TS13
10 AMP 1 2
-6 -3 JC5-1 OF LIGHT & FAN PACKAGE
LOWER S111 (DOWN) B-FU13 1
FU11 1 2
10 AMP -12 -9 B+FU12
GND TP4 FU13
B- (15A) 2
JC5-3 OF CONTROL HANDLE HEATER
ORIGINAL 10 AMP POWER
HOOKUP OPTION JC5-4 OF CONTROL HANDLE HEATER
MPV OPTION TP1 FU12
B+ (15A)
7 9 FUSE RELAY CARD HARNESS (P/N 1057487 AND 1057488)

A B C D E F G H
S31 JPC19 OPTIONS
S46A -2 -1 -2 -3
-1 RIGHT DGND JPC14 S60
-2 +
CARRIAGE
SIDEGATE SWITCHES
-2 +12VF -2 -1 +VS
-3 AUX LIFT JPC17
CONTROL 0
2 -4
-6
S33
LOWER
S32
LIFT
& LOWER
-1
-2
-1
-2
CARD
SIDEGATE RIGHT -1 -2
OUT
S60
-8 -1 -1 -1 -3 -3 -3 -3 - GND
LIFT PGND
-4 -4
-2
LOWER -5 -5
S46B JPC13 S61
-1 S34 JPC20 -6 -6 +
+12VF -2 -1 +VS
6
-3 +VS -1 -2 -7 -7
+12VF 0
-2 -1 -8 -8 SIDEGATE LEFT -1 -2
-5 S34 AUX LIMIT S61
OUT -9 -9 OUT
OPTIONS -7
4
GND -3 -3 -3 - GND
-8 DGND JPC18 PGND -3
-1 -1
LOWER BYP INHIB

VEHICLE MANAGER S47A -2 -2
PGND
JPC4 S25
LEFT
AUX CARD
-1 -2 + +VS
AUX MAST
-3 -3 +12VF -1
TRANSDUCER A
JPS50 -2 DGND
-4 -4 -1 -2 0
+ -1 JPT20-5 JPT10 JPS54 -3 LOWER INHIBIT
PRESSURE
+12VP -5 -5 S25
JPT24-18 -6 -1 +5.3V OUT
PRESS0 A -2
P/T A +12VP -4 -6 -6
-3 JPT24-10 -2 -2 -6 -3 -3 - GND
AISLE DETECT
DGND SENSOR 1 -7 -7 PGND
- +12VF
DGND -8 -8 -8
INTELLISPEED JPT24-8 -3 B+KEY
DGND -9 -9
JPY7 S47B JPC6
3 A P -1 VR
JPT10 JPS55 -1
-6
/L/ BYP INHIB

B -2 IN2 -7 -1 -3 L/L INHIBIT BYP
JPY1 JPS51
FLOW SENSOR
+12VP 1
-3 SHLD -1 -1 JPT22-13 FLOW A -8 -2 -5
S7
FLOW MODULE
SENSOR 2 S7
JPY6 -2 -2 JPT22-14 FLOW B -7
P -1 VR -3 -3 JPT24-11 DGND JPT24-9 -3 -8 -5 2
A DGND DGND
-2 IN1 -4 -4 JPT24-19 FS TEMP
FLOW SENSOR
-3 SHLD -5 -5 JPT20-2 +12VP JPS53 S15
B
RAIL SENSE
JPT18-4 -2 -3 + +VS
JPY2 +12VP
-1 GND JPT22-22 -1 -2 0 S90
RAIL_SEN S15
-2 F/S TEMP OUT
JPT24-5 -3 -1 - GND
DGND 4 3
JPS10 S24 6
LIFT INHIBIT
JPT20-10 -1 + +VS 7 4 A
-3
+12VP
J1 JPT22-2 -2 -2 0 DA60 K12
JPT12 LIFT INHIB S24
LIFT PENDANT
OUT 1
-4 -5 K12
LIFT JPT24-3 -3 -1 - GND B
1
TRAVEL CUTOUT
DGND S1-2
-3 -6 (SHEET 3)
LOWER
JPS16 S27 JPC12
POWER
FU9
SPARE
-9 -12 JPT20-6 -1 + 2 1 TS12-1 -1
-3 +VS B+FU7 JPC12-2
4
SWITCH
HIDDEN
DGND +12VP RF
JPT22-6 -2 -2 0 -2 B-FU8
TRVL CUTOUT S27 TERMINAL B-FU8 JPC6-2
KEY
OUT 2
FU10 1 TS12-2 B+KEY
JPT24-6 -3 -1 - GND
DGND
S124 JPS57
LIFT DECEL
+ -3 -1 JPT20-8 +12VP JPS28 S100
180 IN. LIMIT

O -2 -2 JPT4-3 JPT24-1 -1 -3 + +VS
S124 LIFT DECEL +12VP
JPT22-4 -2 -2 0
- JPT18-7 180_LIM 180 IN. LIMIT
-1 -3 DGND OUT S100
SPL2-B+
JPT24-7 -3 -1 - GND
DGND JPC5
-1
SPL1-B-
B+KEY CONTROL HANDLE HEATER
JPS15
TRAVEL
ALARM
-2 -2
OPTION
JPT20-17 AL+
POWER
B+ALARM (B+K2) TRAVEL WORK LTS B-F
JPT18-18 -1 AL- A 1 SPL5
ALARM_TRAVEL ALARM
-3
B-F
LIFT/LOWER
-4
B+KEY S75 HTRH
JPS52-1 +
ALARM
JPT20 1 2
ALARM_LIFT -18 -2
FSUP-
5
-
ELECTRONIC
-6
HORN
-4
JPT18-16 H-2(-) -
HORN
FSUP -3
H1
H-1(+) HRES + -1
1 2
1
X X X B- 1
AUX AUX MAIN

L/H SEL SEL
SOL SOL SOL WIRE GUIDANCE B+ 2
Y Y Y JPT18 FAN
AUX MAST
-14 JPS2 JPW2 JP1T

MAIN SEL -1 -1 RIGHT JPC9
-15 JPT20-19 -11
AUX SEL 6 B+WG (B+K2) B+ESTOP -2 -2 NEAR WIRE
-12 AUX L/H 2 NO -3
-3 -3 LEFT iPORT
PERFORMANCE LIFT
S56
RS-232
-5 -5 T0 NO TP1 TRUCK
-6 -6 T1 1 -2
PRESS SW1
TRACTOR
JPT22-5 VM
SENSOR
PRESS_SW JPS4 -7 -7 T2 B+
6 -5
SEE INSTALLATION MANUAL FOR DETAILS

24V HIGH
NC -5 -8 -8 T3
JPT18-5 BUS- -14 -14 AGRD
DGND
GUIDANCE MANAGER
-15 -15 +12VF

-13
iWAREHOUSE-RED SYSTEM
JPT18-1 SEE SHEET 1
2 STAGE SOL
JPW1 JP1L
-1 -1 RIGHT
2 STAGE -6 -2 -2 NEAR WIRE
SELECT BUS+ -3 -3 LEFT
LOAD SENSOR
SOL
-5 -5 T0
FUSE/RELAY CARD -6 -6 T1
-7 -7 T2
JPF2-8 -8 -8 T3
B+K2
-14 -14 AGRD
JPS2
JPF3-9 -24 -15 -15 +12VF
B-FU6
( )
JPF2-3 SEE B-F -13
B+K2
SHEET 1 & 2
JPB1-2 JPB1-1 JPF2-4 B-
B+K4
7 LIFT MOTOR FAN

36V EE ONLY JPF2-2
JPF3-11 B+K2
B-FU6
TP4

Figure 8. Electrical Schematic Legend
NOTES: LEGEND
1 36V TRUCK ONLY. IDENT. SHEET ZONE DESCRIPTION IDENT. SHEET ZONE DESCRIPTION
IDENT. SHEET ZONE DESCRIPTION
2 350A FUSE REPLACES 500A FUSE ON SINGLE STAGE LIFT PUMP TRUCKS.
2 STAGE SEL SOL 5 B6 TWO STAGE LIFT PUMP SOLENOID JPE4 1,2 F6 CONNECTOR FOR STEER MOTOR ENCODER LA 1 D4 LIFT POWER AMPLIFIER
3. SCHEMATIC SHOWS TRUCK SWITCHED OFF, DEADMAN SWITCHED OFF,
JPF1 1,2,3 MULTI B- AUX POWER, B+ POWER AMPS CONNECTOR ON FUSE/RELAY CARD LM 1,2 C4,B3 AC LIFT MOTOR OR DC LIFT MOTOR
AND CARRIAGE FULLY LOWERED.
AL- 5 D5 NEGATIVE SIDE OF ALARM JPF2 1,2,5 MULTI B+ KEY SWITCH RELAYS CONNECTOR ON FUSE/RELAY CARD LME 1 C3 LIFT MOTOR ENCODER
5 60 INCH LIMIT SWITCH NOT USED ON
INTELLISPEED TRUCKS. JPF3 1,2,3,5 MULTI B- CONNECTOR ON FUSE/RELAY CARD LMT 1 C4 LIFT MOTOR TEMPERATURE SENSOR
AL+ 5 D5 POSITIVE SIDE OF ALARM
6 OPR W/AUX LIFT OPTION.
JPF4 1,2,3 MULTI KEY SWITCH, EPO, BATTERY SENSE CONNECTOR ON FUSE/RELAY CARD LPC 1,2 C4 LIFT POWER CONTACTOR
7 REFERENCE POWER DISTRIBUTION DIAGRAMS D20009008
AND D20009239. BRAKE 1,2 D6 ELECTRIC BRAKE JPLA1 1 D3 LIFT AMP CONNECTOR
8 CONNECTED TO JPF4-14 ON 24V TRUCKS WITH AC LIFT. JPLA2 1 C3 LIFT MOTOR ENCODER CONNECTOR
SEE FUSE RELAY CARD HARNESS ILLUSTRATION ON PAGE 4, JPLA3 1 C3 LIFT MOTOR TEMPERATURE SENSOR CONNECTOR MS 1,2 B5 STEER MOTOR
9 APPLIES TO TRUCKS WITH INCANDESCENT LIGHT AND FAN FSUP 5 F6 CONNECTOR ON FAN SUPPRESSOR
PACKAGE BETWEEN S/N 5XX-XX-X01011 AND 5XX-XX-X04700 JPLA4 1 C3 CONNECTOR FOR LIFT MOTOR ENENCODER/TEMP SENSOR CONNECTOR
FU1 1,2 B3 POWER FUSE FOR STEER
11 FOR MAIN HARNESS P/N 1040198/XXX USE DETAIL A1 AND B1; FU2 1,2 B3 JPS1 1,2 MULTI CONTACTOR PANEL INTERFACE CONNECTOR PRESS SW1 5 B6 PRESSURE SWITCH FOR 24V HI PERF LIFT
POWER FUSE FOR TRACTION
FOR MAIN HARNESS P/N 1109225/XXX USE DETAIL A2 AND B2
ON PAGE 3. JPS2 5 D5,D7 CONNECTOR ON TRUCK TRACKER FOR POWER
FU3 1,2 B3 POWER FUSE FOR LIFT
FU5 1,2 B6 JPS4 5 D6 S1 3 F4 KEY SWITCH
CONTROL FUSE FOR VEHICLE MANAGER B+ 15A
FU6 1,2 B6 JPS8 1,2 F4 CONNECTOR FOR 120"/150" LIMIT SWITCH S2 3 G5 DEADMAN SWITCH (BRAKE DEADMAN)
CONTROL FUSE FOR VEHICLE MANAGER B- 15A
FU7 1,2 B6 JPS10 5 D4 CONNECTOR FOR LIFT INHIBIT SWITCH S3 3 F6 HORN SWITCH
CONTROL FUSE FOR AUX. POWER B+ 15A/5A
FU8 1,2 B6 JPS15 5 D5 CONNECTOR FOR TRAVEL ALARM S4 3 F7 AUTO/MANUAL SWITCH
CONTROL FUSE FOR AUX. POWER B- 15A/5A
FU9 5 F4 JPS16 5 D4 CONNECTOR FOR TRAVEL CUTOUT SWITCH S7 5 H4 LIFT/LOWER INHIBIT BYPASS SWITCH
CONTROL FUSE FOR RF TERMINAL B+ 2A
FU10 5 F4 JPS25 1,2,3 F2E3 CONNECTOR FOR OVER THE MAST CABLE #1 S10 1,2 F4 150" LIMIT SWITCH OR 120" LIMIT SWITCH
CONTROL FUSE FOR RF TERMINAL B- 2A
FU11 4 B6 JPS26 1,2,3 D7,E7 CONNECTOR FOR OVER THE MAST CABLE #2 S11 3 F5 24" LIMIT SWITCH
10A FUSE FOR 10A POWER HOOKUP OPTION
FU12 4,4 F6,B6 JPS27 1,2 F3 CONNECTOR FOR SPARE OVER THE MAST WIRES S15 5 D3 RAIL SENSE SWITCH
CONTROL FUSE FOR EXTRA F/R HARNESS B+FU12 15A AND/OR FUSE FOR 10A POWER HOOKUP OPTION
FU13 4 F6 JPS28 5 D4 CONNECTOR FOR 180" LIMIT SWITCH S21 3 F4 EPO SWITCH
CONTROL FUSE FOR EXTRA F/R HARNESS B-FU13 15A
FU21 4 F3 JPS50 5 B3 CONNECTOR FOR PRESSURE TRANSDUCER A S22 4 D6 EMERGENCY POWER OFF
CONTROL FUSE FOR COLD STORAGE C.C.C. HEATER, 10A
FUDM 4 H2 JPS51 5 B3 CONNECTOR FOR FLOW MODULE S23 3 F5 DEADMAN SWITCH (CARRIAGE DEADMAN)
CONTROL FUSE FOR COLD STORAGE DEADMAN HEATER, 5A
JPS52 5 D5 CONNECTOR FOR LIFT/LOWER ALARM S24 5 D3 LIFT INHIBIT SWITCH
H1 5 E5 ELECTRONIC HORN JPS53 5 D3 CONNECTOR FOR RAIL SENSE SWITCH S25 5 H3 LOWER INHIBIT SWITCH
H (HRN) 1,2 D6 HORN JPS54 3,5 B6,D3 CONNECTOR FOR AISLE DECTECT SENSOR 1 S27 5 D4 TRAVEL CUTOUT SWITCH
HRES 5 D5 ELECTRONIC HORN RESISTOR JPS55 3,5 B6,D3 CONNECTOR FOR AISLE DETECT SENSOR 2 S28 3 F6 60" LIMIT SWITCH
HTR3 4 F3,G3 CONNECTOR FOR DEADMAN HEATER JPS57 5 B4 CONNECTOR FOR LIFT CUTOUT S29 5 B4 SLACK CHAIN (MAIN #1)
HTRC 4 F2 C.C.C. HEATER JPS58 5 B5 CONNECTOR FOR SLACK CHAIN SWITCH S30 5 B4 SLACK CHAIN (MAIN #2)
HTRDM 4 G2 DEADMAN HEATER JPS59 5 B5 CONNECTOR FOR SLACK CHAIN SWITCH S31 5 E2 AUX LIFT LEFTHAND DEADMAN
HTRH 5 H5 CONTROL HANDLE HEATER JPSC1 1,2 D4,D3 SPLICE FOR CAN BUS S32 5 E2 AUX LIFT
JP1L 5 E6 CONNECTOR FROM LOAD W.G. ANTENNA TO FILTER CARD JPSC2 1 D4 SPLICE FOR CAN BUS S33 5 E2 AUX LOWER
JP1MPV 4 D6 EMERGENCY LIFT LOWER CONNECTION JPT2 1,2 F6 USB CONNECTOR ON VM S34 5 E3 AUX LIFT LIMIT SWITCH #1/REARGATE #1
JP1T 5 E5 CONNECTOR FROM TRACTOR W.G. ANTENNA TO FILTER CARD JPT4 5 C4,C5 CONNECTOR ON VM S36 5 E3 SLACK CHAIN CARRIAGE #1
JP1
JP10 1,2 D6 CONNECTOR FOR WARNING LIGHT JPT6 1,2 E5 ELECTRIC STEER CONNECTOR ON VM S37 5 E4 SLACK CHAIN CARRIAGE #2
JPA7 1,2 F5 CONNECTOR FOR HOME SENSOR PROX JPT9 1,2 F6 CONNECTOR ON VM FOR FLASHWARE
JPB- 1,2 A4 BATTERY CONNECTOR - JPT10 1,2,3,5 E6,B6,C3 CAN, DIGITAL INPUTS AND OUTPUTS CONNECTOR ON VM S40 4 C5 SWITCH FOR WORKING LIGHTS
JPB+ 1,2 A3 BATTERY CONNECTOR + JPT12 5 C4 LIFT PENDANT CONNECTOR ON VM S41 4 C4 SWITCH FOR DOME LIGHTS
JPBR 1,2 D6 CONNECTOR FOR BRAKE JPT14 1,2,3 MULTI B+, B-, CAN COMMUNICATIONS CONNECTOR ON VM S43 4 C4 SWITCH FOR FAN
JPC1 3 F2 CONNECTOR ON C.C.C. FOR STEERING ENCODER JPT18 1,2,5 MULTI COIL DRIVERS CONNECTOR ON VM S46A 3,5 C5,D2 AISLE DETECT SENSOR 1
JPC2 3 E5 CONNECTOR ON C.C.C. FOR DISPLAY CARD JPT20 1,2,5 MULTI PROPORTIONAL COIL DRIVERS CONNECTOR ON VM S46B 3,5 C5,D2 AISLE DETECT SENSOR 1
JPC3 3 F6 CONNECTOR ON C.C.C. FOR 60" LIMIT SWITCH JPT22 1,2,3,5 MULTI DIGITAL INPUTS CONNECTOR ON VM S47A 3,5 C6,D3 AISLE DETECT SENSOR 2
JPC4 5 G3 CONNECTOR ON C.C.C. FOR LOWER INHIBIT JPT24 1,2,5 MULTI ANALOG INPUTS CONNECTOR ON VM S47B 3,5 C6,D3 AISLE DETECT SENSOR 2
JPC5 4,5 B4,G5 CONNECTOR ON C.C.C. FOR LIGHTS/FANS JPTA1 1,2 D2 TRACTION AMP CONNECTOR S56 5 F6 SWITCH FOR FAN
JPC6 3,5 F4,G3 CONNECTOR ON C.C.C. FOR LIFT/LOWER BYPASS SWITCH JPTA2 1,2 C2 TRACTION MOTOR ENCODER CONNECTOR S60 5 H2 SIDEGATE RIGHT SWITCH
JPC7 3 F5 CONNECTOR ON C.C.C. FOR DEADMAN SWITCHES JPTA3 1,2 C2 TRACTION MOTOR TEMPERATURE SENSOR CONNECTOR S61 5 H3 SIDEGATE LEFT SWITCH
JPC8 3 F5 CONNECTOR ON C.C.C. FOR 24" LIMIT SWITCH JPTA4 1,2 C2 CONNECTOR FOR TRACTION MOTOR ENCODER AND TEMPERATURE S75 5 H5 CONTROL HANDLE HEATER THERMOSTAT
JPC9 3 F6 CONNECTOR ON C.C.C. FOR CONTROL HANDLE JPW1 .5 .D6 CONNECTOR ON FILTER CARD FOR LOAD SENSOR S80 4 H3 DEADMAN HEATER THERMOSTAT
JPC11 1,2,3 G2,E3 CONNECTOR ON C.C.C. FOR OVER THE MAST CABLE #1 JPW2 5 D6 CONNECTOR ON FILTER CARD FOR TRACTOR SENSOR S81 4 F2 C.C.C. HEATER THERMOSTAT
JPC12 4,5 F2,F4 CONNECTOR ON C.C.C. FOR SPARE POWER JPXBR 3 B3 CONNECTOR FOR SEPERATE BRAKE HARNESS S90 5 H4 SECURITY START SWITCH
JPC13 5 G3 CONNECTOR ON C.C.C. FOR SIDEGATE SWITCHES JPX1 4 A5 CONNECTOR FOR 10X AUX POWER S100 5 D4 180" LIMIT SWITCH
JPC14 5 G2 CONNECTOR ON C.C.C. FOR SIDEGATE SWITCHES JPY1 5 B3 CONNECTOR ON FLOW MODULE S111 4 E7 MPV/EMERGENCY LOWER SWITCH
JPC15 3 E5 CONNECTOR ON C.C.C. FOR LIGHT DISPLAY CARD JPY2 5 B3 CONNECTOR ON FLOW MODULE TO FLOW SENSOR TEMPERATURE SENSOR S112 4 E7 MPV/EMERGENCY LIFT SWITCH
JPC16 1,2,3 G6,E6 CONNECTOR ON C.C.C. FOR OVER THE MAST CABLE #2 JPY6 5 B3 CONNECTOR ON FLOW MODULE TO FLOW SENSOR CHANNEL 1 S124 5 B4 LIFT DECEL SWITCH
JPC17 5 F2 CONNECTOR ON C.C.C. FOR AUX CARD JPY7 5 B3 CONNECTOR ON FLOW MODULE TO FLOW SENSOR CHANNEL 2 SA 1,2 B5 STEER POWER AMPLIFIER
JPC18 5 F3 CONNECTOR ON C.C.C. FOR AUX CARD SPL1 3 B2 BUTT SPLICE FOR LIFT AMP TO FUSE RELAY CARD
JPC19 5 F2 CONNECTOR ON AUX CARD FOR AUX LIFT & LOWER SWITCH K1 1,2 C6 KEYSWITCH RELAY-OPTIONS SPL2 3 A2 BUTT SPLICE FOR TRACTION AMP TO FUSE RELAY C
JPC20 5 F3 CONNECTOR ON AUX CARD FOR AUX LIMIT SWITCH K2 1,2 C6 KEYSWITCH RELAY-SOLENOIDS, ATTACHMENTS, HORN TA 1,2 D2 TRACTION POWER AMPLIFIER
JPC21 3,5 F3,F3 CONNECTOR ON C.C.C FOR SECONDARY STEER INPUT ENCODER K3 1,2 B6 KEYSWITCH RELAY-POWER AMPS TM 1,2 C3 AC TRACTION MOTOR
JPC22 5 F4 CONNECTOR ON AUX CARD FOR AUX SLACK CHAIN K4 1,2 C6 KEYSWITCH RELAY-AUX. VM POWER TME 1,2 C2 TRACTION MOTOR ENCODER
JPC23 5 F4 CONNECTOR ON AUX CARD FOR AUX DEADMAN K12 5 H4 HIDDEN KEY SWITCH RELAY TMT 1,2 C2 TRACTION MOTOR TEMPERATURE SENSOR
JPB1 5 B7 CONNECTOR FOR LIFT MOTOR FAN TP1 1,2 B2 TIE POINT ON B+
L/H 1,2 D6 LOAD/HOLD SOLENIOD TP2 1,2 B3 TIE POINT ON STEER MOTOR FUSE
L/L 1,2 F5 LIFT/LOWER SOLENOID TP3 1,2 B3 TIE POINT ON LIFT MOTOR FUSE
TP4 1,2 B4 TIE POINT ON B-
TP5 1,2 B3 TIE POINT ON TRACTION MOTOR FUSE
TPC 1,2 B2 TRACTION POWER CONTACTOR
TS12 5,4 F5,F3 TERMINAL STRIP FOR SPARE POWER
TS13 4 G6 TERMINAL STRIP FOR EXTRA F/R HARNESS
VR1 3 F6 VARIABLE RESISTOR FOR THROTTLE
VR2 3 F6 VARIABLE RESISTOR FOR LIFT/LOWER

Figure 9. Hydraulic Schematic, Single Speed Lift

Figure 10. Hydraulic Schematic, Variable Speed Lift

Figure 11. Hydraulic Schematic, Variable Speed Lift with Auxiliary Lift

RAYMOND SERVICE INFORMATION
The Raymond Corporation

Corporate Headquarters
P O Box 130
Greene, New York 13778-0130
RSI MUL-17-001 Models

August 15, 2017 Multiple
SUBJECT: Scheduled Maintenance Changes
GENERAL The Initial 90 Day/250 Deadman Hour Hydraulic Reservoir oil change is no longer
INFORMATION: required for the following models:
• 4150/4250
• 5200
• 5400/5500/5600
• 7200/7300/7310
• 7500/7520
• 7700/7720
• 9300/9400
• 9600/9700
Note: The filter change is still required at the Initial 90 Day/250 Deadman Hour
service interval.
The Initial 90 Day/250 Deadman Hour Drive Unit oil change is no longer required
for the models listed below:
• 3010/3020
• 4150/4250
• 5200
• 5400/5500/5600
• 7200/7300/7310
• 7500/7520
• 7700/7720
• 6210
• 8210/8250
• 8310/8410/8510/8610/8900
• 9600/9700
• 9800
®
Raymond is a registered trademark of The Raymond Corporation RSI MUL-17-001
2017 The Raymond Corporation. Page 1 of 2
FOTP-0060/1-2-17/H
PARTS N/A
AVAILABILITY:
FILING File this notice in the following maintenance manuals:

INSTRUCTIONS:
• 1134255A next to page 4-3 (3010/3020)
• 1193671B next to page 4-5 (4150/4250)
• 1043922B next to page 4-3 (5200)
• 1031794C next to page 4-5 (5400/5500/5600)
• 1146947B next to page 4-3 (6210)
• 1188937A next to page 4-5 (7200/7300/7310)
• 1112860E next to page 4-5 (7500/7520)
• 1137893E next to page 4-5 (7700/7720)
• 1146945B next to page 4-3 (8210/8250)
• 1152122C next to page 4-3 (8310/8410/8510/8610)
• 1087856D next to page 4-3 (8900)
• 1089026A next to page 4-3 (9300/9400)
• 1089040C next to page 4-5 (9600/9700)
• 1203870A next to page 4-1 (9800)
®
FOTP-0060/1-2-17/H

P O Box 130

August 8, 2017 Multiple
SUBJECT: Elimination of 90 Day Inspection
GENERAL As announced at the 2017 Summit meeting, the requirement for a 90 Day Inspection has
INFORMATION: been eliminated. See below.
SERVICE Service Centers may still choose to use the 90 Day Inspection process as a tool to
INFORMATION: complete follow-up calls on their customers, however you are no longer required to enter
the completion of this activity into SAP.
NOTE: This does not change the requirement for the Initial 90 Day/250 Deadman
Hours Maintenance, which is addressed in RSI MUL-17-001.
Please contact Warranty Administration at warrantyinfo@raymondcorp.com with any

questions about this new process, or call Amber Fogarty at 607-656-2811.
PARTS N/A
AVAILABILITY:
FILING File this notice in the Warranty Administration Guide.

INSTRUCTIONS:
®
FOTP-0060/1-2-17/H
PARTS N/A
AVAILABILITY:
FILING File this notice in the following maintenance manuals:

INSTRUCTIONS:
• 1134255A next to page 4-3 (3010/3020)
• 1193671B next to page 4-5 (4150/4250)
• 1043922B next to page 4-3 (5200)
• 1031794C next to page 4-5 (5400/5500/5600)
• 1146947B next to page 4-3 (6210)
• 1188937A next to page 4-5 (7200/7300/7310)
• 1112860E next to page 4-5 (7500/7520)
• 1137893E next to page 4-5 (7700/7720)
• 1146945B next to page 4-3 (8210/8250)
• 1152122C next to page 4-3 (8310/8410/8510/8610)
• 1087856D next to page 4-3 (8900)
• 1089026A next to page 4-3 (9300/9400)
• 1089040C next to page 4-5 (9600/9700)
• 1203870A next to page 4-1 (9800)
®
FOTP-0060/1-2-17/H

P O Box 130
RSI OPR-17-002A Models

May 30, 2017 5000 Series Orderpickers
SUBJECT: Deadman Pedal Switch Replacement
GENERAL Deadman pedal switch P/N 1-150-356/001 is no longer available. Replace it with
INFORMATION: Kit P/N 1-150-356/K02.
SERVICE Install switch Kit P/N 1-150-356/K02 per the following instructions.
INFORMATION: The following parts are required for field retrofit:
Item Part Number Description Qty.
1 1247520/001 Switch 1
2 1-010-282 Terminal, Faston 4
3 611-013 Shrink Tubing 3 in.
4 611-069/002 Shrink Tubing 0.125 in.
• If the switch being replaced is installed

in a bolt-on type Deadman Pedal Assy,
perform Installation Procedure A.
• If the switch being replaced

is installed in a welded type
Deadman Pedal Assy, perform
Installation Procedure B.
NOTE: Special tool required – Dremel
or band sander to modify switch
opening.
®
Raymond is a registered trademark of The Raymond Corporation RSI OPR-17-002A
FOTP-0060/1-2-17/H
SERVICE INSTALLATION PROCEDURE A
INFORMATION: Switch Replacement for “Bolt-on” Type Deadman Pedal
(continued)
1. Raise the carriage of the truck to a height where the deadman pedal can easily be
accessed.
2. Turn the key switch OFF and disconnect the battery connector.
3. Remove the deadman pedal cover.
4. Unplug electrical connector(s) at deadman switch(es).

5. Remove deadman pedal assembly.
6. The Normally Closed (NC) terminal of the new switch is not used. Cover it with shrink
tubing (item 4) or install a Faston terminal (item 2) to insulate it as shown below.
7. Remove old switch(es) and install new switch(es).

8. Reinstall deadman pedal assembly.
9. Cut wires at connector(s) that were plugged into the switch(es).
10. Strip wire insulation 0.25 in. (6.3 mm) and crimp a Faston terminal (item 2) on each
wire.
NOTE: For S2, only the red and black wires are required. For S23, only the orange and
green wires are required.
11. Install shrink tubing and embed the blue wire (S2) and/or the white wire (S23) within
the tubing.
12. Connect wires to the new switch(es) as follows:
a. S2 – connect the black wire to the “NO” terminal and the red wire to the “COM”
terminal.
b. S23 – connect the orange wire to the “NO” terminal and the green wire to the
“COM” terminal.
13. Secure the harness as necessary. Make sure it will not contact any moving parts.
14. Reinstall deadman pedal cover.
15. Connect the battery connector and turn the key switch ON.
16. Test deadman pedal for correct operation.
®
FOTP-0060/1-2-17/H
SERVICE INSTALLATION PROCEDURE B
INFORMATION: Switch Replacement for “Welded” Type Deadman Pedal
(continued)
1. Raise the carriage of the truck to a height where the deadman pedal can easily be
accessed.
2. Turn the key switch OFF and disconnect the battery connector.
3. Remove the deadman pedal cover.
4. Unplug electrical connector(s) at deadman switch(es).

5. Remove deadman pedal assembly.
6. Remove old switches.

7. Grind the bracket until the new switch(es) can be assembled without rubbing against
the bracket.
8. File all edges smooth where the harness enters the bracket.
®
FOTP-0060/1-2-17/H
SERVICE 9. The Normally Closed (NC) terminal of the new switch is not used. Cover it with shrink
INFORMATION: tubing (item 4) or install a Faston terminal (item 2) to insulate it as shown below.
(continued)
10. Install new switch(es).

11. Reinstall deadman pedal assembly.
12. Cut wires at connector(s) that were plugged into the switch(es).
13. Strip wire insulation 0.25 in. (6.3 mm) and crimp a Faston terminal (item 2) on each
wire.
NOTE: For S2, only the red and black wires are required. For S23, only the orange and
green wires are required.
14. Install shrink tubing and embed the blue wire (S2) and/or the white wire (S23) within
the tubing.
15. Connect wires to the new switch(es) as follows:
a. S2 – connect the black wire to the “NO” terminal and the red wire to the “COM”
terminal.
b. S23 – connect the orange wire to the “NO” terminal and the green wire to the
“COM” terminal.
16. Secure the harness as necessary. Make sure it will not contact any moving parts.
17. Reinstall deadman pedal cover.
18. Connect the battery connector and turn the key switch ON.
19. Test deadman pedal for correct operation.
PARTS Now available through the Parts Distribution Center.

AVAILABILITY:
FILING File this notice in maintenance manuals:

INSTRUCTIONS: • 1043922B next to page 7-73 (5200)
• 1031794C next to page 7-1 (5400/5500/5600)
®
FOTP-0060/1-2-17/H

P O Box 130
RSI OPR-17-001 Models

May 30, 2017 5000 Series Orderpickers
SUBJECT: Switch Replacement
GENERAL Switch P/N 1-150-356/001 (used in multiple applications) is no longer available. If the
INFORMATION: switch is installed in a housing as shown in Figure 1, order Kit P/N 1250848/001
which includes a replacement switch and the parts required for a field retrofit.
Figure 1
SERVICE Order Part Kit P/N 1250848/001 and install per the following instructions.
INFORMATION: Item Part Number Description Qty.
1 1245707/001 Limit Switch 1
2 1247450/001 *Adapter Harness 1
3 611-029 Ty-Wrap 4
4 611-013 *Shrink Tubing 3
*May not be required – see below.
Identify the type of connector that is connected to the old switch. Type A connectors (on
truck harness side) require the supplied adapter harness (item 2). Type B connectors (on
truck harness side) plug directly into the new switch (item 1).
Type A Type B
®
Raymond is a registered trademark of The Raymond Corporation RSI OPR-17-001
FOTP-0060/1-2-17/H
SERVICE INSTALLATION INSTRUCTIONS
INFORMATION:
1. Remove connector from switch assembly.
(continued)
2. Remove and discard the old switch/housing assembly. See Figure 1.
3. Install new switch assembly (item 1). See Figure 2.
Figure 2
4. For connector Type A, perform Steps 4.a. thru 4.d. For connector Type B, proceed
to Step 5.
a. Connect adapter harness (item 2) connector PX to the connector that was
originally plugged into the old switch (see Figure 3).
Figure 3
b. Secure the truck cable to the adapter harness. Use the notches to hold the ty-wrap
(item 3) in place (see Figure 4).
Figure 4
c. Slide the shrink tubing (item 4) over the connectors (see Figure 5).
Figure 5
d. Heat the shrink tubing until it is tight over the connection (see Figure 6).
Figure 6
5. Connect the harness to the new switch (see Figure 7).
Figure 7
6. Make sure the harness is secure and does not interfere with any moving parts.
7. Test operation of new switch.
®
FOTP-0060/1-2-17/H
AVAILABILITY:
FILING File this notice in maintenance manuals:

INSTRUCTIONS: • 1043922B next to page 7-73 (5200)
• 1031794C next to page 7-1 (5400/5500/5600)
®
FOTP-0060/1-2-17/H

P O Box 130
RSI OPR-16-002 Model

JUNE 16, 2016 5400, 5500, 5600
SUBJECT: Minimum Brush Length and Spring Tension table.
GENERAL The brush wear information for the lift motor needs to be updated.
INFORMATION:
SERVICE Replace Table 7-6. Minimum Brush Length and Spring Tension with the following table.
INFORMATION:
Min. Brush
Motor Spring Tension
Length
0.62 in. 40 to 65 oz.
Lift
(15.7 mm) (1134 to 1842 grams)
0.50 in.
Steer N/A
(13 mm)
PARTS N/A
AVAILABILITY:
FILING File this notice in Maintenance Manual 1031794C (Model 5400, 5500, 5600) next to
INSTRUCTIONS: page 7-78.
®
FOTP-0060/1-7-16/G

P O Box 130
RSI OPR-16-001 Models

May 25, 2016 5400, 5500, 5600
SUBJECT: New Software Release
GENERAL
INFORMATION: VM Software Version 5.4 and Curtis Software Version 12.115 are available.
SERVICE
INFORMATION: Highlights of the new Software:
• VM Software Version 5.4 and Curtis Software Version 12.115 must be loaded
as a pair, or Code AP and Code AT will be displayed. Install VM Software first.
• Guide Wire sensing has been expanded, so that the “Switch to Auto” message
displays sooner. “WrSnLim” must be enabled in configure mode.
• A steady beeping sound has been added when the “Aligning” message is
displayed.
• Changes have been made to eliminate a false code A0 when replacing the VM.
• Improvements have been made to reduce nuisance occurrences of Codes

43 and 4G.
PARTS
AVAILABILITY: Now available through the Raymond Portal.
FILING
INSTRUCTIONS: File this notice in Maintenance Manual 1031794C (5400, 5500, 5600),
before page 6-2 and make notes on pages 6-20 (Codes 43 and 4G), 6-33 (Code A0),
and 6-34 (Codes AP and AT)
®
FOTP-0060/1-7-16/G

P O Box 130

February 19, 2016 Multi-Product
SUBJECT: New Horn Available
GENERAL A new horn (P/N 1233519/XXX), designed to perform better in cold storage
INFORMATION: environments, is available to replace horn P/N 1047433/XXX.
SERVICE Order and install P/N 1233519/XXX. Refer to Figure 1 for correct bracket configuration.
INFORMATION:
To install the new horn:
Connect Horn(+) and Horn(–) wires to the new horn. Make sure the horn bracket is
isolated from the truck frame.
Figure 1
NOTE: If necessary (3-wire to 2-wire conversion), install ½ in. heat shrink tubing
(P/N 611-013) over the unused spade connector and wire. Fasten the unused wire back
to the harness using a ty-rap (P/N 611-029) or equivalent.
®
FOTP-0060/1-7-15/F
AVAILABILITY:
FILING File this notice in Maintenance Manuals:

INSTRUCTIONS: • PDMM-0080-01 (EF) next to page 7-109
• PDMM-0092 (TRT) next to page 7-148
• 1010298-2 (RCS20/30/40, RSS22/30/40 & RRS30) next to page 233
• 1031794B (5400/5500/5600) next to page 7-61
• 1031940A (ET-F) next to page 7-53
• 1034066E (8300/8400/8500/8600) next to page 7-45
• 1043922A (5200) next to page 7-47
• 1087856D (8900) next to page 7-3
• 1089026A (9300/9400) next to page 7-41
• 1089040B (9600/9700) next to page 7-39
• 1106240D (8300/8400/8500/8600) next to page 7-63
• 1112860B (7500/7520) next to page 7-69
• 1119828C (4150/4250) next to page 7-51
• 1119847A (EZ-C/EZ-D) next to page 7-77
• 1134255A (3010/3020) next to page 7-45
• 1137893B (7700/7720) next to page 7-59
• 1146947A (6210) next to page 7-54
• 1193671A (4150/4250) next to page 7-49
®
FOTP-0060/1-7-15/F

P O Box 130
RSI OPR-15-005 Model

November 4, 2015 5200, 5400/5500/5600
SUBJECT: New Free Lift Cylinder Piston Plunger
GENERAL Harsh staging when the free lift cylinder fully extends, may be caused by a broken spring
INFORMATION: in the cushion. A new piston plunger (P/N 1219150) is available to extend the life of
the spring (P/N 1003289). Install a new spring when you are installing the new piston
plunger.
SERVICE 1. Remove the free lift cylinder from the truck by following the procedure in the
INFORMATION: applicable Maintenance Manual.
2. Remove the threaded piston ram (end) cap with Raymond tool
(P/N 1090761/002) for current production cylinders. Refer to Figure 1.
3. Remove the snap ring and top bearing for older production. Refer to Figure 1.
Figure 1
Staging Screws
Compression Spring
Piston Plunger
Ram Cap or Snap Ring
Note: When the snap ring or ram cap is removed, a spring behind the top bearing may
push the bearing out of the housing.
Note: Leave the ram cap or top bearing, spring, and pressure ring on the rod to prevent
damaging the seals.
®
FOTP-0060/1-7-15/F
4. Remove the three staging screws located about 6 in. from the top of the housing.
5. Remove the piston from the cylinder housing.
6. Disassemble the cushion assembly by removing the snap ring.
7. Remove the piston plunger and compression spring from the cushion assembly.
Clean any contamination from inside the housing.
8. Install the new piston plunger (PN 1219150), and spring (PN 1003289) and
secure it with the ring retainer and snap-ring.
9. Lightly oil any visible seals with hydraulic oil during reassembly.
10. Re-install the piston assembly in the cylinder housing.
11. Re-install the three staging screws. Torque to 60 in. lbs. (6.8 Nm).
12. Install the threaded piston ram cap for current production cylinders. Install the
snap ring for older style cylinders.
13. Tighten the piston ram cap to 200 ft. lbs. ± 5 ft. lbs. (271 ± 6.8 Nm).
14. Re-Install the cylinder into the truck. Check for leaks and correct lift/lower
operation.

AVAILABILITY:
FILING File this notice in Maintenance Manuals 1031794C (5400/5500/5600) next to page
INSTRUCTIONS: 7-108, and 1043922B (5200) next to page 7-93.
®
FOTP-0060/1-7-15/F

P O Box 130
RSI MUL-15-009 Model(s)

October 29, 2015 Multiple
SUBJECT: New Steering Encoder
GENERAL A new Steering Encoder is available. P/N 1215575/XXX is available as a kit. Refer to
INFORMATION: the table below for the correct kit for each model.
SERVICE Order the required kit(s) listed in the following table and install per the instructions
INFORMATION: included with the kit.
Model Kit Part Number
5200 1215575/005
5400/5500/5600 1215575/006
7500/7520 Dockstance 1215575/001
7500/7520 Fore/Aft 1215575/002
7700/7720 1215575/003
9600/9700 1215575/007
TRT 1215575/008
PARTS Now available through the Parts Distribution Center

AVAILABILITY:

INSTRUCTIONS: • 1043922A next to page 7-2 (5200)
• 1031794C next to page 7-2 (5400/5500/5600)
• 1112860B next to page 7-26 (7500/7520)
• 1137893B next to page 7-22 (7700/7720)
• 1089040B next to page 7-2 (9600/9700)
• PDMM-0092E next to page 7-38 (TRT)
®
FOTP-0060/1-7-15/F

P O Box 130

October 1, 2015 Multiple
SUBJECT: New Pump Spline Lubricant
GENERAL A new lubricant (P/N 1223184) has been approved for use on motor and pump spline
INFORMATION: joints for all trucks. This new lubricant replaces Anti-Seize Compound P/N 990-638 for
pump spline applications only.
SERVICE Separate the motor and pump. Clean old grease off the splines. Fill the motor cavity
INFORMATION: (including the space below the splines) to within 0.5 in. (12.7 mm) of the top of the cavity
(see figure below). Assemble the motor and pump.

AVAILABILITY:
FILING File this notice in the appropriate Maintenance Manuals next to the Scheduled
INSTRUCTIONS: Maintenance Section.
®
FOTP-0060/1-7-15/F

P O Box 130
RSI MUL-15-007 Model

September 10, 2015 Multi-Product
SUBJECT: Electrical Troubleshooting
GENERAL Many electrical components are being replaced and, when tested, no problems are found
INFORMATION: with the component.
SERVICE Before replacing an electrical component, disconnect and clean all jack/pin connectors
INFORMATION: on the component(s) with contact cleaner (P/N 996-600/CC2). Reconnect and retest
truck.

AVAILABILITY:

INSTRUCTIONS: • 1010183C (102XM) next to page 5-4
• 1134255A (3010/3020) next to page 5-3
• 1043922A (5200) next to page 5-6
• 1031794B (5400/5500/5600) next to page 5-13
• 1152122B (8310/8410/8510/8610) next to page 5-3
• 1087856D (8900) next to page 5-12
• 1112860B (7500/7520) next to page 5-2
• 1137893B (7700/7720) next to page 5-2
• 1089026A (9300/9400) next to page 5-2
• 1113065A (4450) next to page 5-5
• 1160093A (4700) next to page 5-7
• 1193671A (4150/4250) next to page 5-2
• 1089040B (9600/9700) next to page 5-2
• 1055925B (RAS 20/25) next to page 5-3
• 1010298-2 (RCS20/30/40 RSS22/30/40 RRS30) next to page 198
®
FOTP-0060/1-7-15/F

5400-5500-5600 00100-Up MM 1031794

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Models 5400/5500/5600 Maintenance Manual Visual Table of Contents

Messages and Codes

Publication: 1031794C, Revised: 13 Jul 2015

Publication: 1031794C, Revised: 13 Jul 2015

High-Level Orderpicker Lift Truck

Models Serial Numbers

1031794C Revised: 13 Jul 2015

©2015 The Raymond Corporation.

i Publication: 1031794C, Revised: 13 Jul 2015

List of Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

ii Publication: 1031794C, Revised: 13 Jul 2015

Pin-Out Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

Publication: 1031794C, Revised: 13 Jul 2015 i-iii

i-iv Publication: 1031794C, Revised: 13 Jul 2015

Document Revision History

Document Revision History

1013794A 27 Jan 2006 Inital Release

1013794B 14 July 2006 General Update

Service Information List

RPIN OPR-06-R004 Adjustment procedure rail guidance A.S.C.

RPIN OPR-06-R005 Incandescent Light Wiring Changes

RPIN OPR-06-R007 Error codes 5M & 5P

RPIN OPR-06-R008 Terminal stud movement

RPIN OPR-06-R009 Schematic Revision

RPIN OPR-06-R011 Addition to scheduled maintenance

RPIN GEN-06-R004 Servicing of Power Cables Used on AC Motors

RPIN OPR-07-R002 Center lift cylinder end-cap design change

RPIN OPR-07-R003 Steer motor on gear box replacement

RPIN OPR-07-R006 Wire guidance

RPIN OPR-08-R001 New error codes

RPIN OPR-08-R002 Enabling active maintenance tests

RPIN GEN-08-R003 New Cylinder End Cap Wrenches

RPIN GEN-08-R004 Terminal Torque on Curtis Power Amplifier P/N 1042226/XXX

RPIN OPR-08-R005 Steer motor test, O44

RPIN OPR-08-R008 Steer motor gear orientation

RPIN GEN-09-R002 Intermittent issues on truck with optional alarms

RPIN OPR-09-R004 Error Code AH

RPIN OPR-10-R002 Scheduled Maintenance Task Update

Publication: 1031794C, Revised:13 Jul 2015 iii

Service Information List

RPIN GEN-10-R004 Recommended Chain Lubrication

RSB OPR-06-006 Drive Unit Leaking

RSB OPR-06-007 This bulletin supersedes RPIN OPR-06-R005

RSB OPR-08-002 Drive Motor Pinion Nut

RSB OPR-08-003 Incandescent Light Wiring

RSB OPR-08-004 Software Update 3.5

RSB OPR-09-001 Drive Unit Leakage

RSB OPR-09-003 VM Software Version 4.6

RSI OPR-11-002 Correction to Test A34

RSI OPR-12-001 Motor Terminal Stud Torque

RSI GEN-12-002 Static Strap Resistance

RSI GEN-12-004 Shorts to Frame Test

RSI OPR-13-001 Fuse/Relay Card Troubleshooting

RSI GEN-13-002 Fuse/Relay Card Troubleshooting

RSI OPR-13-002A Carriage Control Card (CCC) Firmware Troubleshooting

RSI OPR-13-003 OPR Wire Guidance Configure Mode Settings Revision C

MM Update. Additional info. needs to be added to the symptom

RSI MUL-14-001 Carriage/Mast Shimming and Bearing Inspection

RSI OPR-14-001 Lift Chain and Fork Adjustment

RSI MUL-14-002 Intermittent 2T Codes

RSI OPR-14-003 Drive Unit Radial Ring Inspection

RSI MUL-14-004 Temperature Sensor Replacement

RSI OPR-14-004 Code 2M