Raymond Pacer

Maintenance Manual
Model 4100 and 4200

Stand-Up Counterbalanced Lift Truck
With The ACR System ™
Models Serial Numbers

4100 00001 and Up
4200
1060345B Re-issued: 01 Jul 2010

Replaces 1060345A Issued: 27 Aug 2007
This publication, 1060345B, applies to the Stand-Up Counterbalanced Lift Truck Model 4100
and 4200, S/N 00001 and up, and to all subsequent releases of this product until otherwise
indicated in new editions or bulletins. Changes occur periodically to the information in this
publication.
If you need assistance with your lift truck, or need to order additional copies of this manual,
contact your local authorized Raymond dealer. To locate your local authorized Raymond dealer,
go to www.raymondcorp.com.
©2010 The Raymond Corporation.
The following terms are trademarks of The Raymond Corporation: The ACR System, iPort, iAlert,
iControl, Maintenance Minder, and Raymond. All other brand and product names are trademarks
or registered trademarks of their respective companies.
Models 4100/4200 Maintenance Manual Table of Contents
Table of Contents
Page Revision Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Service Bulletin List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Product Improvement Notice List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Map of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Manual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Abbreviations and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Static Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Jacking Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Towing Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Lift Truck Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
FlashWare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Cold Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Scheduled Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Maintenance Minder™ Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Initial 90 Day/250 HD Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Every 180 Days or 500 Deadman Hours (HD) . . . . . . . . . . . . . . . . . . 4-6
Every 360 Days or 2000 Deadman Hours (HD) . . . . . . . . . . . . . . . . . 4-9
Contactor Tip Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Hydraulic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Symptom Tables: Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . 5-16
Symptom Tables: Drive Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Symptom Tables: Travel Functions . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Symptom Tables: Electrical Symptoms . . . . . . . . . . . . . . . . . . . . . . 5-22
Messages, Codes, and Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Summary List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Messages and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Digital Input Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Analog Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Output Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81
Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
List of Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Component Locator Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Steering and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Publication: 1060345, Re-issued: 01 Jul 2010 i

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

Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
Hydraulic Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
System Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Traction System Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Steering System Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Lift/Lower System Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Pinout Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Lubrication Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Thread Adhesives, Sealants, and Lubricants . . . . . . . . . . . . . . . . . . . A-3
Component Specific Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Torque Chart - Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Torque Chart - Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Torque Chart - Standard (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
ii Publication: 1060345, Re-issued: 01 Jul 2010

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

This section is a record of all revised pages in this manual. Whenever a page is revised, this section
is updated and included in the revision package.
Pages are revised due to technical and non-technical changes described as follows:
• Technical changes – These changes are identified by a vertical line (change bar) in the left
margin next to the change. Pages affected by technical changes are identified with
“Page Revised: Mo/Day/Yr” in the footer. These pages are also available on the Raymond iNet.
• Non-technical changes – These changes consist of typographical and grammatical corrections,
paragraph renumbering, repagination, and so on. Non-technical changes are not identified
with a change bar, however, affected pages are identified with “Page Revised: Mo/Day/Yr” in
the footer.

1060345A Original Issue . . . . . . . 27 Aug 2007
1060345B Re-issue . . . . . . . . . . . .01 Jul 2010
Publication: 1060345, Re-issued: 01 Jul 2010 iii

Service Bulletin List Models 4100/4200 Maintenance Manual
Service Bulletin List

The following Service Bulletins have been incorporated into this manual.
Use the blank rows below to log Service Bulletins when they are added to this manual.
Document Number Subject Date
CTB-08-001 VM Firmware Version 2.5 28 Feb 2008
CTB-08-003 Wrench Icon is Lit All of the Time 06 Jun 2008
CTB-08-008 VM Firmware Version 3.0 21 Jul 2008
CTB-08-005 Drive Motor Pinion Nut 21 May 2008
CTB-08-011 Mast Drifting on Quad Masts 02 Dec 2008
CTB-09-001 Aux/Steer Motor Improvements 11 Jun 2009
CTB-09-002 VM Firmware Update to 3.6 11 Aug 2009
CTB-10-001 Sideshift Carriage Lower Hooks 26 Jan 2010
iv Publication: 1060345, Re-issued: 01 Jul 2010

Models 4100/4200 Maintenance Manual Product Improvement Notice List
Product Improvement Notice List

The following Product Improvement Notices have been incorporated into this manual.
Use the blank rows below to log Product Improvement Notices when they are added to this manual.
Document Number Subject Date
GEN-08-R004 Terminal Torque on Curtis Power Amplifier P/N 1042226/XXX 01 Aug 2008
CTB-08-R004 Drive Wheel Fenders 08 Aug 08
Publication: 1060345, Re-issued: 01 Jul 2010 v

Product Improvement Notice List Models 4100/4200 Maintenance Manual
vi Publication: 1060345, Re-issued: 01 Jul 2010

Models 4100/4200 Maintenance Manual Section 1. How to Use This Manual
Section 1. How to Use This Manual
Publication: 1060345, Re-issued: 01 Jul 2010 1-1

Section 1. How to Use This Manual Models 4100/4200 Maintenance Manual
Map of the Manual
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1-2 Publication: 1060345, Re-issued: 01 Jul 2010

Manual Design
Manual Design • Section 7. Component Procedures gives

step-by-step procedures for testing,
removing, replacing, and servicing
This manual is designed with the following individual lift truck components.
objectives in mind: Components are grouped by lift truck
• provide technical coverage for expected system. To find a component procedure,
levels of user expertise you may use one of three methods:
• anticipate your needs and reduce your • Look up the component name in the
decisions regarding maintenance List of Component Procedures.
• reduce page flipping through a “one-stop • Look up the component name in the
shopping” approach maintenance manual Index.
• Section 8. Theory of Operation explains
The two-line running page header at the top of signal flow within the electrical and
each page tells you: hydraulic systems for various conditions
• Name of the manual of lift truck operation. This section also
(Model 4100/4200 Maintenance Manual) contains a detailed connection point table
(Pinout Matrix) designed to assist in
• Current Section Title
testing and troubleshooting the truck.
(for example, this page; Section 1. How to
Use This Manual) • Section A. Appendix contains reference
information such as torque values,
• Current topic
lubricants, and standard/metric
(for example, this page; Manual Design)
conversions.
This manual consists of the following sections: • Index lists subjects alphabetically.
• Section 1. How to Use This Manual
explains the manual format and design as
well as abbreviations and symbols used.
• Section 2. Safety explains warning and
caution notes and general safety rules, as
well as safety rules for batteries, static,
jacking, towing, and welding.
• Section 3. Systems Overview includes lift
truck specification plate, programming
instructions, and configuration menu.
• Section 4. Scheduled Maintenance
outlines the recommended schedule of
preventive services to keep the lift truck
working most efficiently.
• Section 5. Troubleshooting guides the
user from fault symptoms to a specific
sequence of tests in order to isolate a
failing component.
• Section 6. Messages, Codes, and Tests
lists the electrical fault codes and
procedures for running firmware-based
electrical tests.

Abbreviations and Symbols
Abbreviations and
Symbols
The following abbreviations, acronyms, and symbols are used in this manual.
Term/Symbol Definition Term/Symbol Definition
A Ampere Gnd ground
Agnd analog ground
amp Ampere or amplifier HD hours on deadman
approx/Approx. approximately Ht height
Assy assembly Hgt/Wgt Height/Weight
Aux auxiliary
AWG American Wire Gauge in. inch or inches
BSOC Battery State-of-Charge kg kilogram(s)

kHz kilohertz
CAN Controller Area Network km/h kilometers per hour
CCW counterclockwise kPa kilo Pascal
cm centimeter
COP Computer Operating lb. pound or pounds
Program L/H Load Holding
CW clockwise L/L Lift/Lower
CS cold storage LPA Lift Power Amplifier
LPC Lift Power Contactor
Dgnd/D-GND digital ground LTPA Left Traction Power
DMLL Deadman Lift/Lower Amp
DMM Digital MultiMeter
DVM Digital Voltmeter mA milliampere
max maximum
EE UL Electric Truck Type min minute or minimum
Certification Rating mm millimeter
where electrical MM Maintenance Minder™
equipment is
completely enclosed mph miles per hour
EMF ElectroMotive Force mS millisecond or
milliseconds
EPO Emergency Power Off
mV millivolt or millivolts
ESD Electrostatic Discharge
mVAC millivolts - alternating
ESDS Electrostatic Discharge current
Sensitive
No. number
FF Forks-first
NV non-volatile
fpm feet per minute
NVM Non-Volatile Memory
FRC Fuse/Relay Card
Nm newton meter
ft. foot or feet
OACH Overall Collapsed

gal. gallon or gallons Height

Term/Symbol Definition Term/Symbol Definition

OD Operator Display wrt with respect to
OI Operator Interface Wt Weight
OSHA Occupational Safety w/ with
and Health Association w/o without
oz. ounce
@ at
prox proximity ™ trademark
pot potentiometer © copyright
psi pounds per square inch + plus or positive
PTC Positive Temperature – minus or negative
Coefficient
± plus or minus
(Thermistors)
° degrees
PWM Pulse Width Modulation
°F degrees Fahrenheit
P/N Part Number
°C degrees Celsius/
Centigrade
rpm Revolutions per Minute
< less than
R/R repair/replace
> greater than
RTPA Right Traction Power
% percent
Amp
= equals
SAE Society of Automotive

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


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

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

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

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

General Safety
General Safety Operate this lift truck only from the operator
position.
7J27011S.EPS
Do not operate or work on this lift truck unless

you are trained, qualified, and authorized to do
so, and you have read both the Owner Manual
and the Operator Manual.
1864_002.EPS1864_002.eps
Before working on this truck, turn the key

switch OFF and disconnect the battery
connector (unless this manual tells you
otherwise).
7J27012S.EPS
Do not operate or work on this lift truck unless

you know the truck’s controls and what they
do.
7J27009S.EPS
Always use and park this lift truck indoors.

7J27014S.EPS
Do not operate this lift truck if it needs repair or

if it is in any way unsafe.
7J27010S.EPS
Do not park in a cold storage area overnight

unless the lift truck is conditioned for cold
storage.

General Safety
Do not wear watches, rings, or jewelry when Do not use gasoline or other flammable liquids
working on this truck. for cleaning parts.
JEWELRY.EPS 3369_002.eps
Perform exactly the scheduled lubrication, Clean up any hydraulic fluid, oil, or grease that
maintenance, and inspection steps. has leaked or spilled on the floor.
SCHEDMNT.EPS
SPILLS.EPS
Follow exactly the safety and repair instructions Do not wash this lift truck with a hose. Do not
in this manual. Do not take shortcuts. steam clean inside compartments.
8B15008D.EPS
3369_001.eps
Do not use an open flame near the truck. Do not add to or modify this lift truck until you
7J27013S.EPS
contact your local authorized Raymond dealer

to receive written manufacturer approval.
7J27015S.EPS

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

without arm shields), and a rubber apron.
25L6S016.EPS
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
the charging area. An open flame or Make sure a shower and eyewash station are
spark can ignite this gas, resulting in nearby in case there is an accident.
04g6s059.eps
serious damage or injury.
Battery electrolyte is a solution of

sulfuric acid and water. Battery acid
causes burns. Should any electrolyte
come in contact with your clothing or
skin, flush the area immediately with
cold water. Should the solution get on
your face or in your eyes, flush the area
with cold water and get medical help
immediately. A battery gives off explosive gases. Never
smoke, use an open flame, or use anything that
Read, understand, and follow procedures, gives off sparks near a battery.
recommendations, and specifications in the 23L6S012.EPS
battery and battery charger manufacturer’s

manuals.
25L6S014.EPS
Keep the charging area well-ventilated to avoid

hydrogen gas concentration.
04G6S058.EPS
Wear personal protective equipment to protect

eyes, face, and skin when checking, handling,
or filling batteries. This equipment includes

Battery Safety
Turn the key switch OFF before disconnecting when water is added to the cells, or when the
the battery from the lift truck at the battery specific gravity is checked.
connector. Do not break live circuits at the
battery terminals. A spark often occurs at the Make sure vent holes in filler plugs are open to
point where a live circuit is broken. allow the gas to escape from the cells.
7J27012S.EPS 09G6S047.TIF
Vent Hole
Do not lay tools or metal objects on top of the

battery. A short circuit or explosion could
result.
04G6S057.EPS
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.
7J27011S.EPS
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.
27Y7S013.TIF
Never plug a battery charger into the truck’s

battery connector. Plug the battery charger only
into the battery connector from the battery.
7J27017S.EPS
Keep filler plugs firmly in place at all times

except when the electrolyte level is checked,

Static Precautions
Static Precautions • Handle circuit boards by the edges only.

Avoid touching the edge connectors.
• If you are removing or installing
Electronic circuit boards can contain
static-sensitive components, place them
Electrostatic Discharge Sensitive (ESDS)
on a correctly grounded antistatic mat.
devices.
• To transport static sensitive components,
Static charges can accumulate from standard including failed components being
operation of the lift truck as well as movement returned, place the components in an
or contact between non-conductive materials antistatic bag or box (available from your
such as plastic bags, synthetic clothing, local authorized Raymond dealer).
synthetic soles on shoes, and styrofoam coffee
cups. Test the wrist strap and related accessories
before each use to make sure they are working
Accumulated static electricity can be correctly.
discharged to a circuit board or component by
touching the parts. Electrostatic Discharge Figure 2-2 shows the components of the
(ESD) is also possible through the air when a Raymond antistatic field service kit
charged object is placed close to another P/N 1-187-059.
surface at a different electrical potential. Static
discharge can occur without seeing or feeling it. Figure 2-2. Anti-Static Kit with Wrist Strap and Mat
MAT2.TIF
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 protect against shock hazard. If
the resistor is open, replace the strap.
• 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 2-1. Ground Jack Location

10715_068.tif
The kit includes a wrist strap, ground cord, and

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

in quantities of 25. A wrist strap tester
(P/N 1-187-060) is also available.
Contact your local authorized Raymond dealer

for information.

Jacking Safety
Jacking Safety Figure 2-4. Jacking Tractor

8D14047S.TIF
Some maintenance procedures require the lift

truck to be jacked up. Observe the safety
precautions that follow when jacking the truck.
1. Lower the forks completely to the floor.
Remove any load.
2. Place all controls in neutral.
3. Block the wheels to prevent movement of
the vehicle.
4. Turn the key switch OFF and disconnect
the battery connector.
Jacking the Drive Wheel

Use extreme care whenever the truck is
To jack the drive wheel:
jacked up. Never block the truck
between the telescopic and the floor. 1. Place the jack in the designated jacking
Use a suitable hoist to stabilize the mast. position. See Figure 2-3.
Keep hands and feet clear from vehicle 2. Jack the truck up just high enough to
while jacking the truck. After the truck is raise the drive wheel off the floor.
jacked, place solid blocks beneath it to
3. Place a block under the frame as shown in
support it. Do not rely on the jack alone
Figure 2-3.
to support the truck.
5. Place the jack under the designated Jacking the Tractor

jacking points. See Figure 2-3 and
Figure 2-4. To jack the tractor:
1. Place the jack in the designated jacking
Figure 2-3. Jacking Drive Wheel
8D14044S.TIF
position near the steerable wheel. See
Figure 2-4.
2. Jack the truck so that the steerable wheel
is off the floor no more than 1 in. (25 mm).
3. Block under the frame as shown in
Figure 2-4.
NOTE: After working on a vehicle, test all
controls and functions to verify correct
operation.

Towing Safety
Towing Safety
To safely tow this truck: When towing is complete, remove the
1. Lower the carriage and remove any load brake release bolts. Failure to do so can
from the forks. cause serious injury.
3. Install the brake release bolts.
NOTE: The brake release bolts are stowed on
the tractor frame above the left traction
motor.
Figure 2-5. Brake Release Bolt Installation

8D14047S.TIF
4. Using a suitable towing vehicle, lift the

truck until the steer tire is no more than
1 in. (25 mm) off the floor.
5. Tow the truck slowly in the tractor-first
direction.

Welding Safety
Welding Safety
Disconnect the battery before you
attempt to inspect, service, or repair the
lift truck.
Flame cutting or welding on painted 7J27012S.EPS
surfaces may produce potentially

harmful fumes, smoke, and vapors.
Prior to performing flame cutting or
welding operations, remove the coating
in the vicinity where the operation(s)
will be performed.
Coating removal may be by mechanical

methods, chemical methods, or a
combination of methods. Perform flame
cutting and/or welding operations only
in well ventilated areas. Use local
exhaust if necessary.
Before removing a power amplifier,
Before working on this truck, make sure that: discharge the amplifier’s internal
capacitor by jumpering the + and –
• Fire protection equipment is nearby.
terminals with a 100 ohm 25W resistor.
• You know where the nearest eyewash
station is. • Check for any shorts to the frame. See
04G6S059.EPS
“Shorts to Frame Test” on page 5-3. If any
shorts are detected, remove them before
you proceed with the welding operation.
• Clean the area to be welded.
• Protect all truck components from heat,
weld spatter, and debris.
• Attach the ground cable as close to the
weld area as possible.
• Do not perform any welding operation
near electrical components.
• If welding must be done near the battery
compartment, remove the battery.
• When finished welding, perform all ground
tests and electrical inspections before the
vehicle is operated.

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

Section 3. Systems Overview Models 4100/4200 Maintenance Manual
Introduction
Introduction
This manual provides information for
maintenance and repair of the Model
4100/4200 Stand-Up Counterbalanced lift
truck 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
dealer.

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.
Figure 3-1. Lift Truck Specification Plate

P412-858-B.eps
Raymond Model # Serial number Nominal battery voltage
*Max battery
weight for this lift
Approximate weight
truck
of lift truck with Raymond Corporation
P.O. Box 130
Greene, New York 13778
battery installed, Battery Volts/Nominal Width
Model Serial Number (in./mm)
minus load and Max Battery
operator Truck Weight (lb./kg) Battery Weight (lb./kg) Battery Max. Rated Capacity
Rated Capacity
With Maximum Battery Maximum (A.H.)
Without Battery Minimum z Attachment
Approximate weight HORIZONTAL MOTION OF BATTERY MUST NOT EXCEED 0.5 INCHES/ 12.7MM.
ATTACH RESTRAINT TO BATTERY COMPARTMENT AS REQUIRED.
of lift truck minus

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

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

FlashWare
FlashWare Connecting PC to Truck

There are two methods available to connect the
Overview PC to a manager:
• USB to USB - this method requires the
The FlashWare program allows you to update correct drivers to be installed on the PC.
software, view, and configure options on Model Typically, this type of connection is much
4100 and 4200 trucks through the following faster than a serial connection. With the
features: key switch OFF, connect cable P/N
• Vehicle Manager software 610-809/210 to a USB port on the PC and
• Clear primary memory the P3 connector on the manager. See
Figure 3-2.
• Reset factory default settings
• Serial to Serial - this method requires a
• Download Software surge protector (P/N 154-010-801) to be
NOTE: For more detailed information about connected in series with the cable to
FlashWare, click on Help, and select protect the PC. With the key switch OFF,
Help Topics from the menu bar. connect a standard 9-pin serial cable to a
serial port on the PC and the J9 connector
on the manager. See Figure 3-2.
Requirements
Figure 3-2. Truck FlashWare Connections
FlashWare can be installed on an 1750_026.tif
IBM-compatible PC. The PC communicates with Serial connector (J9) USB connector (P3)
the truck software through a 9-pin serial cable.
NOTE: A USB to 9-pin serial adapter
(P/N 610-809/USB) is available for
computers that do not have a serial
port.
To protect your PC from possible

electrostatic discharge or voltage surge,
we recommend using the surge
protector (P/N 154-010-801). Starting FlashWare
1. With the key switch ON, double-click the
Installing FlashWare on PC FlashWare icon on the main desktop
screen or navigate via Start > Programs >
If you are a customer service technician, obtain
FlashWare. The Truck Opening Screen
FlashWare from your Raymond dealer.
appears. See Figure 3-3.
If you are a Raymond dealer technician, obtain
FlashWare from the iNet software download
site.
To install FlashWare on the PC, double-click the

installation file and follow the instructions on
the screen. The software package is a
self-extracting executable file. Read the
“Readme” file in the software package for the
latest detailed installation instructions.

Starting FlashWare
Figure 3-3. Truck Opening Screen
9600FW_3-15.jpg
NOTE: When entering or using FlashWare, it is

normal for Code 50 to display.
2. From the menu bar, click
“Communications”, then select the
applicable connection type:
• COMx (9-pin Serial)
• 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 PC is connected to a correctly
functioning Vehicle Manager, the Truck
Setup screen is displayed. See Figure 3-4.

Truck Setup Screen
Truck Setup Screen

The Truck Setup screen feature allows you to:
• enable options
• check the serial number, model number,
software, and hour meters.
See Figure 3-4.
Figure 3-4. Truck Setup Screen

Truck Setup Screen
To Change an Option Setting: • Operator Compartment Sensor - enables

option that requires the operator
The list box in the middle of the Truck Setup compartment threshold to remain
screen shows the Truck Options. unblocked
• Ambient Temp Sensor - sensor used to
To enable an option, check the adjacent check determine if handle heater assembly
box. To disable an option, uncheck the check should remain ON even with key switch
box. See Figure 3-4. When the options are OFF
correctly configured, click the “SEND Changes
• Battery Gates* - enables option requiring
to Truck” button.
both battery gates to be installed to allow
NOTE: Options displayed in red require travel
authorization codes. When these options • Breakaway QD* - enables breakaway
are selected, a pop up window appears quick disconnect option
requesting the authorization code.
Contact your local Raymond dealer for • iPort Basic* - used to select iPort Basic
the correct forms and procedure for • iAlert* - used to select iAlert as part of the
obtaining the authorization code. iPort Premium package
• iControl* - used to select iControl as part
Options include (but are not limited to): of the iPort Premium package
• Electronic Key* - requires operator to • 4200 Handle Type* - used to identify type
enter a code prior to operating the vehicle of handle installed on truck (standard,
• Weight - enables weight of load to be optional, lever controls)
displayed on Operator Display
• High Speed Limit - reduces top travel *These options require a passkey to be enabled.
speed based on mast mounted switch To obtain a passkey, a Form S-207, Field
placement Modification Request Form, must be submitted.
• Travel Alarm - enables alarm to sound

when truck is moving Vehicle Manager Software
• Aux Attachments - configuration The Vehicle Manager Software dialog box is
dependant used to load/upload VM software. See
• HSA2 Enabled* - used to select between Figure 3-5.
two high speed auxiliary functions
Figure 3-5. VM Software Dialog Box
• Lift Limit w/Bypass - limits lift height
based on mast mounted switch placement
• EE Truck* - must be checked for EE
configured trucks
• Bottlers Tilt* - enables reduced speed
and/or forward tilt based on mast
mounted switch(es)
• Quad Mast* - enables correct weight
sensor calibration for trucks with a Quad
Mast installed
• 2 Speed Tilt* - enables reduced tilt speed
on trucks equipped with a Quad mast,
based on placement of mast switch

Truck Setup Screen
From the VM Software dialog box, users can 3. If the user selects No, the action is
perform the following functions: cancelled. If the user selects Yes, a new
• Check the current VM software version dialog box appears, prompting the user to
remove the cleared memory prior to
• Select Software Version, if multiple restarting the truck. See Figure 3-7. Click
versions are loaded (selected version is OK.
displayed in window in upper right of
screen) Figure 3-7. Remove Cleared Memory Dialog Box
• Load VM with Selected Software Version
(Update Existing)
• Install VM Software Version into Directory
• Delete Selected Software Version from
Directory
• Upload (Extract) Software from VM to a file
on the PC
When VM software management tasks are

complete, click EXIT to return to the main
Do not cycle the key switch. Primary
Truck Setup screen.
memory will be restored to the current
truck configuration if the key switch is
Clear Primary Memory cycled.
The Clear Primary Memory feature is used to 4. Remove the VM.

clear the truck’s identity in the Operator
Display. Configuration
NOTE: If Clear Primary Memory and Clear
Vehicle Manager are performed at the Select the Configuration button on the right of
same time, the primary vehicle identity the Truck Setup screen. The Configuration
and back-up identity are removed. A dialog box displays. See Figure 3-8.
programmed Operator Display is
required to remedy this. Figure 3-8. Configuration Dialog Box
ConfigScreen.tif
Select the Clear Primary Memory function by

clicking the Clear Primary Memory button on
the right of the Truck Setup screen. See
Figure 3-4.
1. On the Truck Setup screen, click the Clear
Primary Memory button.
2. The Clear Primary Memory dialog box
appears to confirm the user really wants to
clear primary memory. See Figure 3-6.
Figure 3-6. Clear Primary Memory Dialog Box
BSOC Calibration (Adjusts Time to 0%)
Occasionally, additional adjustment is required

outside of Configure Mode to obtain correct
Battery State-of-Charge readings.

Truck Setup Screen
Battery State-of-Charge (BSOC) Calibration in 1. Select the Clear Vehicle Manager button
FlashWare specifies the average voltage on the right of the Truck Setup screen. See
required in order to be considered at 0% (5 is Figure 3-4.
the factory default): 2. The Erase Vehicle Manager Software dialog
• setting this number lower (down to 1) box is displayed. Click on View Software
lowers the average voltage that will be Model Number Table. Do not select
zero, resulting in increasing the time to 0% ERASE unless the software model number
and using more of the battery is incorrect.
• setting this number higher (up to 9) 3. Select Erase. VM memory is cleared and
increases the average voltage that will be the correct software model number can
zero, resulting in decreasing the time to now be selected and loaded.
0% and using less battery.
If operators state they are not using all of the

battery, the technician can lower the number.
If operators state they are draining the battery

too much, the technician can increase the
number.
Reset Factory Defaults
Use this feature to reset truck configuration.

1. Record customer-specific configurations
from the Truck Config Dialog Box before
resetting defaults.
2. Select the Reset Factory Defaults button
on right side of the Configuration Dialog
Box.
3. A warning dialog box appears to confirm
the user really wants to reset factory
defaults.
Figure 3-9. Configuration Reset Dialog Box

39600FW_3-24.jpg
Clear Vehicle Manager
The Clear Vehicle Manager feature deletes all

memory and software from a VM so that it can
be used in a different model truck.

Truck Setup Screen
Display Manager/Power Amp

Software
This feature is used to view and/or change

power amplifier software.
1. Click Display Manager/Power Amp
Software button on the Truck Setup
screen.
NOTE: Models 4100/4200 do not have a
Display Manager.
2. When the Display Manager/Power
Amplifiers dialog box appears, follow
prompts on the screen to load/upload
software. See Figure 3-10.
Figure 3-10. Display Manager/Power Amp Software Dialog Box

Operator Display
Operator Display
The Operator Display (OD) displays
alphanumeric data received from the Vehicle
Manager.
The displayed data includes:

• Time or calendar
• BSOC (Battery State-of-Charge)
• Hour meters (hours on deadman [HD],
hours spent lifting [HL], total miles [TM])
• Status/Fault messages
• Weight of load (option)
• Fork Height (option)
• Service required indicator
• Overtemperature indicator
• Lift-limit indicator (optional)
Figure 3-11. Operator Display

9600FW_3-24.jpg
Up Down Key Switch
Operator Display
Overtemperature
Indicator
Battery Discharge Service Required Enter Emergency

Indicator Indicator Power Off

Modes of Operation
Modes of Operation factory. Configuration settings should be

documented for that truck before a reset is
performed.
There are three modes of operation for this
3. Set Forward Max Speed - Use to set
truck:
maximum forward speed. Default is 6.8
• RUN MODE - the standard working mode mph for Model 4100 and 7.2 mph for
for the truck. Model 4200. Can be set as low as 1 mph,
• CONFIGURE MODE - use to enter the in increments of 0.1 mph.
truck’s software and change parameters. 4. Set Reverse Max Speed - Same as item 3,
• MAINTENANCE MODE - use to access for reverse travel.
Learn Mode, perform various tests needed 5. Set Travel Accel - Software control of how
for troubleshooting, enable Active quickly the truck is permitted to change
Maintenance, view logged errors, and speeds; useful when the truck operates in
adjust sideshift (tilt) speed. high or very low traffic environments.
Options are Soft, Medium, and Hard.
Run Mode Default is Medium.
6. Set Coast Distance - Software control that
When the truck is powered ON and SelfTest is establishes the distance the truck travels
completed, the truck automatically enters Run once the control handle is released and
Mode, the default mode of operation. Run Mode returns to the neutral position. Options
is also entered when the truck exits Configure are Long, Medium, and Short. Default is
Mode. Short.
7. Set Lift Accel - Software control of how
Configure Mode quickly the truck is permitted to lift and
lower loads; useful for limiting new
Configure Mode is used to change individual operators, or when large loads are
truck performance parameters for specific expected. Options are Slow, Medium, and
customer requirements. Refer to Table 3-1. Hard. Default is Hard.
8. Set Lift Cutout Point - Use to set the
When Configure Mode is entered, the current lowest state-of-charge the battery can have
value selected is displayed first, followed by a and still lift. It is adjusted to keep from
description of the setting being modified. over-discharging the battery. Optional
value is from 0% to 50% in increments of
For example, item 3 is displayed on the OD 5%. Default is 20%.
initially as 7.0 mph, then changes to Set
9. Enter New Configuration Password -
Forward Maximum Speed.
Allows the password used to enter Config
Mode to be changed. Default password is
The following is a list of each configurable
1 _ _ _ _ _ _ _. See “Passwords” on
parameter’s displayed description and a
page 3-18.
detailed explanation. Refer to Table 3-1,
Configure Mode Menu on page 3-14. 10. Set Units for Messages - Used to specify
the unit of measure displayed on the OD:
1. Exit Configuration Mode - Allows exit of
English (lbs, inch) or Metric (kg, mm).
Config Mode, either because the operator
Default is English.
entered Config accidently, or because all
necessary truck configuration values have 11. Setup Maintenance Minder - Use to turn
been entered and accepted. Select Yes to off, quit, or setup Maintenance Minder
save changes. Select No to abandon (MM). Options are Quit MM, Enable,
changes before leaving Configure Mode. Reset, Disable, or Setup. See Table 3-2,
Maintenance Minder Menu (after Enable is
2. Restore Factory Defaults - Restores all
Activated). Note that Disable, Reset, or
initial truck values established at the

Configure Mode
Enable are not displayed if their value is 25. Set the Speed Limit Switch Speed - Use to
already true. set speed when speed limit switch is
12. Enter the Auto Power-Off Time - Use to activated.
turn ON/OFF sleep mode. Disables the 26. Set the Lift Limit W/Bypass - Use to turn
truck’s power after a preset time of ON/OFF lift limit with bypass.
inactivity. Values are Disabled, 1 Min, 2 27. Set the Battery Gate Action - Use to assign
Min, 3 Min, 4 Min, 5 Min, 10 Min. Default what happens if the battery gate switch is
is Disabled. activated. Options are Shutdown or Off.
13. Set Time and Date - Use to set truck’s 28. Select the Weight Sensor - Use to turn
internal clock. Options are; Quit; 24 ON/OFF the weight sensor. When On,
Hour? Y/N (Select 12 or 24-Hour Clock); weight on forks is displayed on the OD.
DayLtS? Y/N (Daylight Savings Time); Set
Time (10:41PM=10:41 PM or 2241=10:41 29. Lift/Lower when Off Deadman - Use to
PM); Set Date (mm/dd/yy). turn OFF the lift function when the
Deadman pedal is released (Off). When
14. Vehicle Manager Software Version - enabled (On), allows approx. five feet of lift.
Displays version number. Format is Return control to neutral to repeat.
VM_XX.X.
30. Enable Sideshift - Use to turn ON/OFF
15. VM Boot Software Version - Displays boot standard sideshift function.
version number internal to VM. Format is
VMB_X.X.
16. Left Traction Amp Software Version -
Displays version number. Format is
LTPAXX.X.
17. Left Traction Amp Boot Version - Displays
boot version number internal to power
amp. Format is LTABX.XX.
18. Right Traction Amp Software Version -
Displays version number. Format is
RTPAXX.X.
19. Right Traction Amp Boot Version -
Displays boot version number internal to
power amp. Format is RTABX.XX.
20. Lift Amp Software Version - Indicates
version number loaded into the truck.
Format is LPA_XX.X.
21. Lift Amp Boot Version - Displays boot
version number internal to power amp.
Format is LPABX.XX.
22. Enter New Electronic Key Password -
Option that permits password protection
before a truck is put in service. Format is
3 _ _ _ _ _ _ _.
23. Set Travel Alarm - Use to assign when the
alarm sounds. Options are Forks, Tractor,
Both, None. Default is Both.
24. Select Optional Hydraulic Attachment -
See “Attachment Control” on page 3-20.

Configure Mode
Table 3-1. Configure Mode Menu
Initial or Text Displayed (V02.2 shown)
Item Selections/Parameters
Default Value (* Rows are Options)
1 Quit Exit Configuration Mode Save? Yes; Save? No
2 Default Restore Factory Defaults Yes; No
3 6.8 mph (4100) Set Forward Max Speed 4100: 1.0 to 6.8 mph (2.0 to
or 10.9 Km/h)
7.2 mph (4200) 4200: 1.0 to 7.2 mph (2.0 to
11.5 Km/h)
4 6.8 mph (4100) Set Reverse Max Speed 4100: 1.0 to 6.8 mph (2.0 to
or 10.9 Km/h)
7.2 mph (4200) 4200: 1.0 to 7.2 mph (2.0 to
11.5 Km/h)
5 Medium Set Travel Accel Soft; Medium; Hard
6 Long Set Coast Distance Long; Medium; Short
7 Hard Set Lift Accel Soft; Medium; Hard
8 20 Set Lift Cutout Point 0% - 50% in 5% increments
9 1_______ Enter New Configuration Password See “Passwords” on page 3-18.
10 English Set Units for Messages English; Metric
11 Mnt Mind Setup Maintenance Minder Quit MM; Enable; Reset;

Disable; Setup (See Table 3-2)
12 APOFF Enter the Auto Power-Off Time Disabled; 1 Min; 2 Min; 3 Min;
4 Min; 5 Min; 10 Min
13 Clock Set Time and Date Quit; 24 Hour? Y; 24 Hour? N;

DayLtS? Y; DayLtS? N; Set
Time; mm/dd/yy
14 VM XX.X Vehicle Manager Software Version Read Only
15 VMB X.X VM Boot Software Version Read Only
16 LTPAXX.X Left Traction Amp Software Version Read Only
17 LTABX.XX Left Traction Amp Boot Version Read Only
18 RTPAXX.X Right Traction Amp Software Version Read Only
19 RTABX.XX Right Traction Amp Boot Version Read Only
20 LPA_XX.X Lift Amp Software Version Read Only
21 LPABX.XX Lift Amp Boot Version Read Only
22 * 3_______ Enter New Electronic Key Password See “Passwords” on page 3-18.
23 * Both Set Travel Alarm Forks; Tractor; Both; None
24 * HydOpt Select Optional Hydraulic Attachment See “Attachment Control” on

page 3-20.

Configure Mode
Initial or Text Displayed (V02.2 shown)

Item Selections/Parameters
Default Value (* Rows are Options)
25 * 6.0MPH Set the Speed Limit Switch Speed 1.0 to 6.0 mph (1.6 to
9.6 Km/h)
26 * LftLimit Set the Lift Limit W/ Bypass (OFF is Default) ON; OFF
27 * Bat Gate Set the Battery Gate Action (OFF is Default) Shutdown; OFF
28 * Weight Select the Weight Sensor (OFF is Default) ON; OFF
29 * DMLL On Lift/Lower when Off Deadman (Default is ON) ON; OFF
30 * Sideshft Enable Sideshift (Default is ON) ON; OFF
Table 3-2. Maintenance Minder Menu (after Enable is Activated)

Item Values Description
Setup 50 to 500 See MNT MIND in Table 3-1, Configure Mode Menu
(in 50 Hr. increments) Hours of use (Deadman Pedal) (Factory Set at 500)
Msg. Only Message Only
L Cutout Cutout Lift Function and Message

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

maintenance password. See “Entering a
Password” on page 3-18.
Learn - required after replacing the VM, control

handle, control handle pots, or optional weight
transducer.
_ 2 _ _ _ _ _ _ - Maintenance Mode password.

See “Entering a Password” on page 3-18.
D Inputs - brings up Input Test sub-menu.

Allows individual input test to be run.
A Inputs - brings up Analog Test sub-menu.

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

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

Allows individual output test to be run.
Active Maintenance - allows the menu to appear

on the display to toggle between Analog and
Input tests while the truck is in Run Mode.
# of Errors Logged - error code log capable of

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

and 4.5 seconds.

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

Quit
_2______ Enter New Maintenance Password. (Default is _ 2 _ _ _ _ _ _ ) _2______
D Inputs See Digital Input Tests beginning on page 6-29.
A Inputs See Analog Tests beginning on page 6-47.
Outputs See Output Tests beginning on page 6-81.
Active Select Active Maintenance

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

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

Item Values Text Displayed/Action
Enter See Learn in Table 3-3, Maintenance Mode Menu

Quit Exit Learn Mode
Weight Learn the Weight Sensor (Optional)
Travel Return Control to Neutral, then Press Enter
Lift Return Control to Neutral, then Press Enter
Tilt Return Control to Neutral, then Press Enter (Optional handle only)
Sideshft Return Control to Neutral, then Press Enter (Optional handle only)

Passwords
Passwords To illustrate this procedure, assume you

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

feature that permits the customer to establish
an operator password.

Passwords
When the key switch is turned ON, the operator

is prompted to enter the electronic key
(password).
The truck does not enter Run Mode unless the

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

electronic key the same, the lift truck
recognizes only the password.
Changing a Password
NOTE: When entering the default value
Configuration password, you must enter
the password in the beginning space.
For the Maintenance password, you
leave the beginning space blank.
1. After entering either the Configuration or
Maintenance password, the screen scrolls
and asks if you want to change the
password.
• Example: Enter New Maint Password
• Press the ENTER key. The screen stops
scrolling. Enter a new password.
2. Press the ENTER key to cursor all the way
to the right until you are asked to enter a
new password again.
3. Scroll UP or DOWN, selecting Quit until
you get to a Save prompt. Select Yes.

Attachment Control
Attachment Control
Several types of hydraulic attachments can be
installed on Model 4100/4200 lift trucks.
Attachment 1
If an attachment is added to the truck that

requires only one set of hoses to operate, the
hydraulic lines are connected to ports AC and
AR on the hydraulic manifold. The flow rates
associated with this connection are
configurable under Attach 1 in the HydOpt
menu. See Table 3-5, Hydraulic Attachment
Sub-Menu.
Attachment 2
If the attachment requires two sets of hoses, the

second set of hoses are connected to SSR and
SSL on the manifold. The flow rates associated
with this connection are configurable under
Attach 2 in the HydOpt menu. See Table 3-5.
Vehicles with this configuration cannot be
equipped with integral sideshift.
Table 3-5. Hydraulic Attachment Sub-Menu

Item Values Description
HydOpt Set Optional Hydraulic

Attachment
Attach 1 Enter Flow: Attachment 1 (Setup)

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

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

Attachment Control
Setup and Operation
Refer to Table 3-6 for specific attachment setup

information.
Refer to Table 3-7, “Attachment Operation,” on

page 3-22 for specific attachment operation
information.
Table 3-6. Attachment Setup

Operator Display: Adjustment
Hydraulic Hose
Function Action Config or Maintenance Mode Range for Flow
Ports
Menu Action Rate
Sideshift Enable Sideshift Sideshift speed configurable SSR (Sideshift Set SS Speed -
checkbox via Maintenance Mode menu Right) 60% to 90%
item SS. SSL (Sideshift
Left)
Push/Pull Enable Config Menu: Navigate to AC (Aux Cap) Begin with

Attachments HydOpt and press Enter. AR (Aux Rod) 7 GPM and
checkbox _Select Attach1 adjust as needed
___Select flow rate or specified by
_____Set clamp=N manufacturer*.
Fork Positioner Enable Config Menu: Navigate to AC (Aux Cap) Begin with
___Select flow rate or specified by
_____Set clamp=N manufacturer*.
Clamp Enable Config Menu: Navigate to AC (Aux Cap) Begin with

__Select flow rate or specified by
___Set clamp=Y (see Note 1) manufacturer*.
____Set PSI (see Note 2)
Clamp with roll Enable Config Menu: Navigate to SSR (Sideshift Begin with
(see Note 3) Attachments HydOpt and press Enter. Right) 3 GPM and
checkbox and _Select Attach2 SSL (Sideshift adjust as needed
disable the __Select flow rate Left) or specified by
Sideshift manufacturer*.
checkbox
*Flow rate can be adjusted in Configure Mode in 1 GPM increments; 2 to 7 (4100), 2 to 11 (4200).
Note 1: Any clamp function, carton clamp or barrel clamp, must be connected to AC and AR, never to SSR
and SSL.
Note 2: MAX PSI is fixed at 2300. Default values are High=1250, Med=1000, Low=750. Overall Range is 250
to 2250 PSI, but values cannot overlap. Example, the highest setting for Low depends on what medium is set
to. The highest value for medium depends on what High is set to.
Note 3: Use SSR and SSL for the roll function on the clamp with roll attachment.

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

(Push/Pull, Clamp) activation is required to unclamp
load.
Attachment Function Function 1 and Function 2 The input for the second function of
added to the truck that Sideshift Left and Sideshift the attachment requires the use of
requires 2 functions Right the sideshift input.
(Barrel Clamp with
Roll, Fork Positioner
with Sideshift)
Adjusting Attachment Pressure Figure 3-13. UP/DOWN Keys on Operator Display

1238_016.EPS
1. Press the top attachment button

momentarily to activate the clamp. See
Figure 3-12.
Figure 3-12. Top Attachment Button

1238_014.EPS
NOTE: Several pressure settings are available:

Low, Med, High, and Max (Max is the
auxiliary relief pressure setting).
2. The clamp pressure is shown on the OD.

3. To select another pressure, use the
UP/DOWN keys on the OD. See
Figure 3-13. The clamp pressure you
select remains active until another is
selected; even if the lift truck is turned
OFF.

Cold Storage
Cold Storage • all terminals on the horn

• terminals of the key switch and EPO
switch
Cold Storage (CS) is an option that enables
truck operation in temperatures of –20°F • terminals on lift motor
(–28.86°C) to 40°F (4°C). • terminals of the steer motor
• terminals on both traction motors
On cold storage trucks, the electrical panel on
the tractor is completely enclosed to contain 4. Install the recommended hydraulic fluid
heat. and gear case oil. Refer to “Lubrication
Specification Chart” on page A-2.
Cold Storage Conditioning
Perform Cold Storage conditioning with the
items listed below:
Description Part Number
Silicone Grease 990-564
Sealing Compound 990-542
LPS3 Spray 990-644
NOTE: Optional Handle is Cold Storage ready.

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

Storage
Storage Before returning the truck to service, drain the

reservoir and change the filter. Fill the reservoir
with new hydraulic fluid.
When storing the truck for any length of time,
cover the truck with canvas or plastic. Operate the hydraulic systems slowly at first to
allow lubrication of internal components.
If storing the truck for more than 30 days, jack
and block the truck up off the floor. NOTE: If the truck is going to be stored for more
than six months, spray hydraulic
components with a silicone protectant.
Do not let silicone protectant spray get
on circuit cards.
jacked up for any reason. Never block
the truck between the telescopic and the Hydraulic Cylinders
floor. Use a suitable hoist to stabilize the
mast. Keep hands and feet clear from Store the truck with the cylinder pistons
beneath vehicle while jacking. Use jack retracted. Coat all exposed chrome surfaces of
stands or solid blocks to support truck. the piston with hydraulic fluid.
Do Not rely on the jack alone. See
“Jacking Safety” on page 2-8. Lift Chains
Warranty Liberally coat all chains with oil to prevent rust
and corrosion.
The Raymond Corporation must be contacted
by an authorized Raymond dealer for the Electronics
correct warranty procedures.
Make sure all electronics stay dry.
DC Motors
The brushes in DC motors must be lifted away
from the commutator surface. When preparing
the truck for service, the surface must be
inspected and polished, if necessary, using a
rubber abrasive polish. Polishers are
specifically made for polishing commutators. Do
Not use a stone.
While in storage, periodically rotate the DC

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

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

Section 4. Scheduled Maintenance Models 4100/4200 Maintenance Manual
Scheduled Maintenance Guidelines
Scheduled Maintenance
Guidelines
A successful scheduled maintenance program:
• promotes maximum truck performance
• prolongs truck life
• reduces costly down time
• avoids unnecessary repairs
Scheduled maintenance includes:

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

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

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

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

Option
Tool
The first time you enter the time interval menu,
Maintenance Minder Tool is a feature that the Factory Suggested setting, followed by the
allows a customer to be prompted when the letters FS, is displayed. Subsequently, when
truck is due for scheduled maintenance. you 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. Scroll
enabled, monitors the Hours on Deadman (HD) to the desired time interval and press ENTER.
meter. When the time interval for scheduled
maintenance is exceeded, the operator is Scroll to the desired action option and press
informed in the following ways: ENTER.
• One of two messages scrolls on the • MSG ONLY causes the Operator Display to
Operator Display for at least 30 seconds show SCHEDULED MAINTENANCE DUE
following the Daily Checklist message: when the scheduled maintenance time
interval is exceeded.
• Scheduled Maintenance Due
• L CUTOUT causes the Operator Display to
• Lift Cutout, Scheduled Maintenance Due show LIFT CUT OUT, SCHEDULED
• A wrench icon flashes. MAINTENANCE DUE when the scheduled
• The audible alarm sounds the high-low maintenance time interval is exceeded. Lift
tone for approx. five seconds. 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 Scroll to QUIT MM from the sub-menu. If the
cycled (key switch OFF or battery status has changed, you are prompted to save
disconnected). changes. Press ENTER.
When the control circuit power is cycled, lift is From the Config Menu, exit by selecting QUIT
disabled until Maintenance Minder is reset or CFG. You will not be prompted again to save
disabled, or the lift cutout option is turned OFF. changes, but any changes saved when you QUIT
MM are retained.
Enabling Changing Time Interval or Action

Once installed in the configuration options, Option
MAINTENANCE MINDER appears in the
Configure Mode menu. The default factory When Maintenance Minder is active and you
setting is DISABLE. To enable the feature, enter want to change the time interval or action
Configure Mode. option, enter Configure Mode.
NOTE: For instructions on selecting Modes of With Configuration Mode selected, scroll to MNT
Operation, see Modes of Operation on MIND and press ENTER. When entered from an
page 3-12. enabled state, Maintenance Minder offers a
sub-menu with the options QUIT MM, RESET,
With Configuration Mode selected, scroll to DISABLE, and SETUP. Scroll to SETUP, then
display MAINTENANCE MINDER and press press ENTER. The current time interval is
ENTER. When entered from a disabled state, displayed (hours). Proceed as described under
Maintenance Minder offers a sub-menu with the Setting Time Interval and Action Option.
options QUIT MM and ENABLE. Scroll to
ENABLE and press ENTER.

Disabling
Resetting Maintenance Minder
When Maintenance Minder is active and, after

you have performed scheduled maintenance,
you want to reset the reminder prompt, enter
Configure Mode.
With Configuration Mode selected, scroll to MNT

MIND and press ENTER. Scroll to Reset, then
press ENTER. Select QUIT MM and press
ENTER again. Save changes, as prompted.
Disabling
When Maintenance Minder is active and you
want to disable it, enter Configure Mode.
With Configuration Mode selected, scroll to MNT

MIND and press ENTER. Scroll to DISABLE,
then press ENTER. Select QUIT MM and press
ENTER again. Save changes, as prompted.

Initial 90 Day/250 HD Maintenance
Initial 90 Day/250 HD Maintenance

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

Every 180 Days or 500 Deadman Hours (HD)

Perform the following maintenance tasks every 180 days or 500 HD, whichever comes first.
Component Task
Check the weight stamped on the battery in the lift truck against the minimum
and maximum allowable weights on the spec tag for the lift truck. Report any lift
trucks that are running with batteries under the minimum or over the maximum
Battery
allowable weight. Inspect all battery connectors and leads for damage and cuts in
protective coatings. Make sure battery gates are in place and not damaged. Make
sure the battery has no more than 0.5 in. (13 mm) free play in any direction.
In an open area, measure stopping distance. Traveling 2 to 3 mph (3.2 to

4.8 Km/hr) empty, push the EPO switch; the empty lift truck should stop within
2 to 4 feet (0.6 to 1.2 m). During normal operation, with a rated load and
traveling at top speed, the lift truck should stop within approx. one and one-half
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
Brakes
and clean the pads and rotor.
Measure for correct gap: Check the gap between the armature disc and the brake
coil. The gap should measure 0.004 and 0.020 in. (0.1 and 0.5 mm). If gap
exceeds 0.020 in. (0.5 mm), remove and disassemble the brake assembly to
check components. Failure to keep brakes adjusted causes premature pad and
rotor wear and excessive motor heat. Refer to Brakes on page 7-38.
Inspect contactor tips for burnt or pitted surfaces. See Contactor Tip Inspection
on page 4-10. Failure to replace the tips may prevent the contactor from opening
Contactors 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.
Verify lift/lower function is smooth and controllable. Verify travel function is

smooth and responsive through full range of motion. Check for play in the center
Control Handle position of lift or travel control; repair/replace control handle if necessary. Verify
no codes on display. Verify function of all switches. Make sure nylon insert is in
the lift knob set screw hole.
The deadman pedal must operate smoothly with no binding. Check for correct
Deadman Pedal
activation and deactivation of the deadman switch.
Beneath deadman pedal and in battery compartment - make sure the drain holes
Drain Holes
are not blocked by any debris.
Check oil level. See Adding Oil on page 7-25. Inspect for leaks. Check drive axle
Drive Units
for play.
Inspect all power cables for nicks or cuts. Replace any cable that is damaged or
shows signs of excessive heat. Failure to do so causes intermittent system
Electrical Cables 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.

Component Task
Check fork mounting surfaces for wear. Make sure fork positioning lock is
working correctly. Examine for excessive wear, bends, cracks, welding arcs,
excessive heat, or unauthorized modifications. Replace if found. Measure fork
Forks
thickness (Tool P/N 922-369). Visually inspect fork markings. Inspect
straightness of the blade and shank, fork height, and fork angle. See Fork
Inspection on page 4-12.
Perform general visual inspection of structural members for cracks, including,

Frame Checks
but not limited to, main frame and tractor.
Check bolt torque of major components (motors, pumps, brake, drive units,
manifolds, mast-to-tractor mounting bolts, overhead guard). Tighten any loose
Hardware
hardware. Replace any broken or missing hardware. Refer to Component Specific
Torque Chart on page A-4 for torque values.
Horn Check that horn sounds when activated. Check mounting bracket insulators.
Inspect all hydraulic hoses for leaks, nicks, cuts, chafing, and bulges. Replace
bad hoses as soon as possible. Inspect all fittings for leaks. Repair any leaks
Hydraulic Hoses
immediately. Inspect over-the-mast hoses for correct tension. Make sure
over-the-mast pulleys spin freely and show no signs of wear.
Hydraulic Reservoir Check fluid level.
Check adjustment. Inspect for excessive stretch or wear (Tool P/N 950-350/CG)
Lift Chains
Lubricate.
Lubricate steer wheel assembly, steer wheel axle, steer chain, sideshift carriage,
Lubrication
and fork position pins.
Wipe old grease off mast uprights and apply new grease. Examine mast bearings.
Refer to Mast Service on page 7-74 or Quad Mast Service on page 7-87. Inspect
Mast
mast stops for tightness and wear. Inspect rails for abnormal wear, metal flakes,
or shavings.
AC - Check the cable lugs to make sure they are tight to the terminal studs. Both
the inside and outside nut should be torqued to the values listed on page 7-46.
Replace any cable that shows signs of excessive heat. Check sensor wires for
sound connection and condition. Blow out the 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 condition of commutator per photos starting on page 5-6. Find the
Motors shortest brush in the holder. Remove the brush and check the overall dimension
as per the chart on page 7-47. Inspect the brush for even wear over the full
surface of the brush. If the brush is not contacting the complete surface, replace
the brushes. Inspect the brush rigging for damage or loose brush holders. Make
sure the connections on the brush leads are tight. Check brush spring tension.
Blow out the inside of the motor with compressed air. Blow out impeller and
cooling fins. Check the cable lugs to make sure they are tight to the terminal
studs. Both the inside and outside nut should be torqued to the values listed on
page 7-46. Replace any cable that shows signs of excessive heat.
Overhead Guard Inspect guard for physical damage. If structurally damaged, replace the guard.

Component Task
Power Amplifiers Check torque on power amplifier connections.
Check for electrical shorts to frame. Refer to Shorts to Frame Test on page 5-3.
Shorts to Frame
Wipe compartments clean.
Make sure cap screws securing the lowering mounting hooks to the carriage bar
are tight. Inspect upper and lower bearing segments. If segments measure less
Sideshift
than 0.06 in. (1.5 mm), replace them. Replace segments as a set on the top or
bottom as required.
Make sure static straps are not worn or broken. Clean debris from straps. Check
Static Straps
resistance.
Check that steering system function is smooth and responsive. Inspect pivot
points and bearings in the steering assembly. Inspect the teeth on the steering
gear for wear. Lubricate the steer assembly.
Steering
Inspect the steer chain for correct adjustment. Chain should flex approx. 1/8 -
1/4 in. (1.6 to 3.2 mm). Inspect the wheel axle and bearings for excessive wear.
Check gap on steering prox switch. Inspect hoses and hydraulic motors for leaks.
Switches Check all switches for correct operation. Adjust as needed.
Make sure ventilation slots in the tractor frame/cover are clear of obstructions
Ventilation Slots
and debris.
Warning Decals Replace any illegible or damaged decals.
Wheels and Tires Examine for bond failure, chunking, and excessive or uneven wear.


Component What To Do
Drive Units Change fluid.
Hydraulic Reservoir Change fluid and filter.
Separate pump and motor. Apply Molybdenum Anti-Seize Compound (P/N 990-638)
Pump Couplings
to the splines. Refer to Lift Motor on page 7-53.

Contactor Tip Inspection
Contactor Tip Inspection

When inspecting contactor tips, follow these
guidelines:
• Darkened points do not indicate burning.
• Burning indicates a loss of contact point
material.
• Replace the contact points if there is not
enough contact point material to last until
the next regular inspection or severe
pitting is evident. See Figure 4-1.
• The silver alloy part of the point is usable
contact material; the copper backing is
not.
• Do not file contact points to remove
discoloration or minor irregularities. This
practice produces a surface more
susceptible to sticking.
• If a cone and crater appear, replace the
tips.
Figure 4-1. Severely Pitted Contactor

8A21032S.TIF

Lift Chains
Lift Chains Figure 4-2. Chain Gauge

Ma0634.eps
Inspection and Maintenance
A
A
Make sure chains are not damaged. Check the
chain for wear using a Chain Gauge Chain
(P/N 950-350/CG). See Figure 4-2. Wear
Scale
A
A
MA0634.
Chain Replace
OK Chain
Condition Cause Maintenance Procedure
Use a chain gauge or lay the chain on a flat

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

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

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

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

Fork Inspection
Fork Inspection 2. Multiply these numbers by 0.5%. The

smallest number is your maximum
deviation.
The following tools are required to perform fork
• Length of blade _____ x 0.5% = ______
inspection:
• Height of shank _____ x 0.5% = ______
• Fork Wear Caliper (P/N 922-369)
3. Place a 24 in. framing square on the blade
• Tape Measure or Ruler
of the fork, 2 in. away from the heel of the
• 24 in. Framing Square fork. See Figure 4-4.
• 4 ft. Level 4. At 21 in., measure the distance between
the face of the shank and the framing
Do the following when performing Scheduled square. See Figure 4-4.
Maintenance.
Figure 4-4. Fork Measurement with Framing Square
4forkstraight.svg
Surface Inspection 9
Remove the forks from the carriage. Visually

inspect all fork surfaces for signs of damage,
including, but not limited to:
• cracks
• excessive wear
• excessive heat
• deformation
v
• unauthorized modifications
Pay special attention to the heel and welds

attaching mounting components. If any damage
is found, remove the fork from service.
Straightness of Blade and v

Shank 5. Compare this measurement, minus 2 in.,
to the smallest maximum deviation
NOTE: This measurement can be done with the
number determined in step 2.
forks on or removed from the carriage.
6. If the maximum deviation number is
1. Measure the length of the blade and the exceeded, remove the fork from service.
height of the shank. See Figure 4-3.
Figure 4-3. Measuring Fork Blade and Shank Fork Angle

4forkFacts1.svg
NOTE: This measurement can be done with the

forks on or removed from the carriage.
1. Place the fork caliper on the blade. Make
sure that the two extruded points are
Shank touching the blade of the fork. See
Figure 4-5.
Blade 2. Now open and move the caliper so the two

extruded points are touching the shank.
See Figure 4-5.

Fork Tip Height

Figure 4-5. Fork Angle 4. Raise one end of the level to make it level.
4ForkArmWearCaliperGuide_2.svg
See Figure 4-6.
5. Measure the distance from the tip of the
Shank fork. See Figure 4-6.
Figure 4-6. Measuring Fork Tip Height

4Fork Inspection.jpg
Forks
Indicator
Lines
Distance
Blade
from tip
Level of fork
3. When all four extruded points are in

contact with the fork, gently remove the
caliper and note the reading on the Tips
indicator line, located right above the 6. Compare this measurement to the
hinge pin. See Figure 4-5. maximum deviation.
4. If the deviation is greater than 3° of the 7. If the maximum deviation number is
original angle, remove the fork from exceeded, remove the fork from service.
service.
NOTE: Most forks are manufactured with a 90° Wear
angle; therefore, a reading greater than
93° or less than 87° is unacceptable.
However, there are some forks that are Fork Blade and Shank
purposely manufactured to angles 1. Remove the forks from the carriage.
greater than or less than 90°.
2. Approx. half way up the shank, set the
front teeth of the jaws of the caliper on the
Fork Tip Height shank. Make sure the caliper is held
square across the shank to get an
1. With forks on the carriage, measure the
accurate reading. The caliper is now set to
length of the blade. See Figure 4-3.
measure fork blade wear. Carefully remove
• For forks 42 in. (106.7 cm) or less, max. the caliper from the shank. See Figure 4-7.
deviation is 0.25 in. (6.3 mm).
• If length of fork is >42 in. (106.7 cm),
multiply length of blade by 3%.
Blade length _____in. x 3% = _____in.
This is the maximum deviation.
2. Elevate forks approx. 4 ft. (1.2 m) off the
floor.
3. Place a 4 ft. level across the tips of the
forks. See Figure 4-6.

Wear
Figure 4-7. Measuring Fork Shank
If there is greater than 10% wear of the

fork arm, the fork has at least a 20%
reduction in capacity.
NOTE: The caliper is designed to measure forks

up to 4 in. (100 mm). It is not to be used
on full or lumber tapered forks. For
these forks, you must know the original
fork blade thickness and take a
measurement of the fork arm thickness.
If the difference in the measurement
exceeds 10% of the original thickness,
the fork must be removed from service.
Fork Hooks
3. Measure 2 in. (50 mm) out from the heel of
the fork. 1. Remove the forks from the carriage.
4. Place the caliper over the flanks of the fork 2. Determine the fork mounting class.
arm blade at this 2 in. (50 mm) point. See a. Measure the height of the carriage or
Figure 4-8. the distance between the hooks. See
Figure 4-9.
Figure 4-8. Measuring Fork Blade Wear
Figure 4-9. Determining Fork Mounting Class
Distance between hooks
Carriage Height
b. Compare this measurement to the table
below.
Fork Distance Carriage

Mounting Between Hooks Height
Class in. (mm) in. (mm)
5. If the inside teeth of the caliper hit the 1 12.05 (306) 13 (331)
fork, there is <10% wear. If the inside teeth
pass freely over the fork arm, there is 2 15.04 (382) 16 (407)
>10% wear and the fork must be removed
3 18.78 (477) 20 (508)
from service.

Wear
3. Locate the correct extruded edge on the

caliper for the fork mounting class. See
Figure 4-10.
4. Slide the extruded edge up into the hook
pocket. See Figure 4-10.
5. If the caliper’s extruded edge completely
slides up into the fork pocket, remove the
fork from service. See Figure 4-10.
Figure 4-10. Fork Hook Inspection

Fork Pocket
Fork Mounting Class

Designation
Markings
Make sure the fork’s marking (individual load

rating) is legible (typically located on side of
fork). If fork marking is not legible, remove the
fork from service.

Wear

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

Section 5. Troubleshooting Models 4100/4200 Maintenance Manual
Electrical Troubleshooting
Electrical • Printed circuit boards are conformal

coated. Make sure meter leads make a
Troubleshooting good electrical connection with test points.
• When measuring voltage, connect the
positive meter lead to the connector or
General probe point marked (+) in the test.
Connect the negative meter lead to the
connector or probe point marked (–).
• Whenever measuring resistance, turn the
Block the lift truck so that the drive tires key switch OFF and disconnect the battery
are off the floor whenever a connector. Battery current can damage an
troubleshooting procedure requires ohmmeter. Isolate the component from the
turning the key switch ON. This prevents circuit.
accidents caused by unexpected lift
truck travel. Shorts to Frame
Use extreme care when the truck is Shorts to frame is an industry term for
jacked up for any reason. Never block unintentional current leakage paths between
the lift truck between the carriage and normally isolated electrical circuits and their
the floor. Keep hands and feet clear metal enclosures.
while jacking the lift truck. After the lift
truck is jacked, place solid blocks or jack Shorts to frame may be metallic connections,
stands beneath it to support it. Do not such as a wire conductor contacting metal
rely on the jack alone. See Jacking through worn insulation. More often, shorts to
Safety on page 2-8. frame are resistive “leakage” paths caused by
contamination and/or moisture.
Unless otherwise directed, disconnect
the battery connector when you check These leakage paths can result in unwanted
electrical circuits or components with an electrical noise on the metallic lift truck
ohmmeter. Electrical current can damage structure and can cause incorrect operation.
an ohmmeter.
Shorts to frame are caused by:
Before removing a power amplifier,
• Accumulation of dirt
discharge the amplifier’s internal
capacitor by jumpering the + and – • Battery electrolyte leakage
terminals with a 100 ohm 25W resistor. • Motor brush dust
• Motor brush leads touching the housing
• Many problems can be caused by a dirty
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
• Batteries
cables are connected to the correct meter
jacks and that the correct function and • Motors
scale are selected. • Cables, wiring, and harnesses
• Heatsinks

• Bus bars the truck frame during the remaining

• Solenoids tests.
• Contactors 4. With the battery disconnected (or removed
and disconnected) from the truck, use a
• Terminal strips DMM to measure the resistance from lift
• Switches truck frame to truck B+, to truck B– (not
• Power panel insulation battery B+ and B–), and to all fuses and
motors. A reading of <1000 ohms indicates
• Circuit card mounts a serious short. Do not continue until this
condition is corrected. The meter may be
Shorts to Frame Test damaged if you proceed before correcting
this condition.
the battery connector. a. To identify the cause of the short to
frame, disconnect circuit components
2. To test the battery for shorts to case,
until the low resistance condition
connect a 12V test light to the battery case
disappears. Do not reconnect
from battery B+, and then to the battery
components one at a time, but leave
case from battery B–. If the light
them disconnected until the low
illuminates at all, even momentarily, there
resistance reading disappears. Prevent
is a serious problem with the battery,
disconnected terminals or connectors
either external contamination or internal
from touching the lift truck frame or
damage. Do not continue until this
other conductive surfaces.
condition is corrected. The meter may be
damaged if you proceed before correcting b. The most likely areas to check are:
this condition. • Motors
Install another battery in the truck and • Heatsinks

repeat this procedure from Step 1. • Power cables
• Power circuit components
If the test light does not illuminate,
continue to the next step. • Control circuit components
c. Repair or replace the component
3. Use a DMM set on the ampere function to
causing the low resistance condition.
measure the current leakage from the
battery case to battery B+ and from the Repeat Step 4.
battery case to battery B–. Begin d. Reconnect all other components
measuring at the highest ampere scale previously disconnected, one at a time,
and work toward the lowest. A reading of measuring resistance between steps. If
more than 0.001A (1mA) indicates a a reading is <1000 ohms when
serious short. Do not continue until this reconnecting a component, that
condition is corrected. The meter may be component or its wiring is faulty; repair
damaged if you proceed before correcting or replace as appropriate.
this condition.
e. When, after all components are
reconnected, you get readings
Install another battery in the lift truck and
>1000 ohms, continue with the next
repeat this procedure from Step 1.
step.
If the current is <0.0002A (0.2mA), go to 5. Reconnect the battery connector and turn
Step 4. If the current is >0.0002A (0.2mA) the key switch ON. If the battery was
and <0.001A (1mA), remove the battery previously removed, make sure the battery
from the truck, then continue with Step 4. case does not touch the lift truck frame.
Make sure the battery case does not touch

NOTE: The functions being checked must be c. Repair or replace the component(s)
energized. Example: to check for shorts causing the leakage current.
to frame in the travel circuit, travel must Repeat Step 6.
be requested.
d. Reconnect all other components
6. Use a DVM set to the current function to previously disconnected, measuring
measure current leakage to the truck current between steps. If a reading is
frame from B+, B–, and all fuses and more than 0.001A (1mA) when
motor terminals. Begin measuring at the reconnecting a component, that
highest ampere scale and work toward the component or its wiring is bad. Repair
lowest. If the current is <0.001A (1mA), go or replace as appropriate.
to step 7. If the current is more than 7. When, after all components are
0.001A (1mA), continue with the following reconnected, you get a reading <0.001A
steps. (1mA), there is no short to frame condition
a. To identify the cause of the short to with the truck or the battery. If you
frame, disconnect circuit components previously removed the battery from the
until the leakage current reads <0.001A truck, re-install the battery.
(1mA). Do not reconnect components
one at a time, but leave them
disconnected until the leakage current
Fuses
reads <0.001A (1mA). Prevent
disconnected terminals or connectors Test/Inspection
from touching the lift truck frame or
other conductive surfaces. Examine the fuse for signs of overheating,
discoloration, cracking, or other physical
b. The most likely areas to check are: damage. Replace as necessary.
• Motors
• Heatsinks To test a fuse, remove it from the lift truck. The
resistance should be <1 ohm.
• Power cables
• Power circuit components Table 5-1 lists the fuses for a lift truck with all
• Control circuit components available options. Not all trucks will have all of
the fuses listed.
Table 5-1. Fuse Chart

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

(See Figure 5-4 on
FU7 Control Fuse for Aux Power B+ page 5-14.) 15/5
FU8 Control Fuse for Aux Power B– 15/5
FU11 Control Fuse for Strobe and Warning Light (Optional) In-line Wiring 1.5
FU12 Control Fuse for Operator’s Cooling Fan (Optional) In-line Wiring 1.5

DC Motors the segments. This can lead to a short circuit in

the armature.
Types of DC Motors Good commutation is indicated by a dark
brown polished commutator and an evenly
There are two primary types of DC Motors:
polished brush wearing surface. See Table 5-2,
• A series-wound motor has only two “Commutator Surfaces.”
external connections because the
armature and field windings are connected If the commutator appears rough, pitted, or has
internally. signs of burning or heavy arcing between the
commutator bars, remove the motor for service.
Figure 5-1. Series-Wound Motor Circuit
5motor-series.eps
Service
S/D
If the commutator requires service, you must
remove the armature from the motor.
Do not use a stone to even out high and low

spots on the commutator.
MP
Servicing a motor for an abnormal commutator
surface condition and high mica or mica
A
undercutting requires special equipment at a
• A permanent magnet motor has two motor rebuilding facility.
external connections. The field is produced
by an internal magnet.
Figure 5-2. Permanent Magnet Motor Circuit

motor-pmagnet.eps
MS+
A2
MS
A1
MS–
NOTE: Field connections may be labeled A or S.

Series wound motor field connections
may be labeled D.
Inspection
Inspect commutator for surface condition and

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

provide maximum brush wear. When
commutators are not correctly maintained,
carbon dust can collect in the grooves between

Table 5-2. Commutator Surfaces
Condition Probable Cause Commutator Surface
Good Condition-Light Film Uniform coloring indicates satisfactory operation

of machine and brushes. Film color is largely an
effect of thickness; therefore, provided the film is
uniform, it is perfectly acceptable.
Satisfactory This is not a good condition, however, machines

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

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

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

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

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

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

Condition-Streaky Film example. Brush grade, machine applications,
with Commutator Wear and working environment are all suspect. Earlier
corrective action should have been taken.
Unsatisfactory Darkening of commutator in sequences two pole

Condition-Double Pole pitches apart is due to armature fault, bad coil,
Pitch riser bars, or equalizer connections.

Condition Probable Cause Commutator Surface
Unsatisfactory Storage of machines, for lengthy periods, with

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

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

Condition-Small Bright pressure. Due to sparking under brush, that
Spots gives rise to spots being of a random distribution.
If not corrected, results in scored commutator.
Open Circuit Motor Test 5. If you find an open circuit in a

series-wound motor, the motor must be
An open circuit is an electrical circuit within the disassembled by a motor rebuilding facility
motor that is broken. This can be caused by: to isolate the problem to the field or
armature circuit.
• bad brushes or brush springs
• a broken wire in the field or armature
Grounded Motor Test
winding
• loose or bad connections In a grounded motor, an electrical circuit exists
between the current-carrying conductors and
Refer to Figures 5-1 and 5-2 while performing the motor housing. This can be caused either by
the following procedure: direct contact or through conductive foreign
1. Isolate the motor from the lift truck circuit material.
by removing the power cables. Use two
wrenches to avoid twisting the terminal The ground may be caused by:
stud. • insulation breakdown
2. With the motor at room temperature, • brush leads touching the motor housing
connect the leads of a digital ohmmeter
• build-up of carbon dust or other materials
between the individual circuits in the
motor.
Isolate the motor from the lift truck circuit by
3. Observe the following measurements: removing the power cables. Use two wrenches
DC Motor Probe Points Resistance to avoid twisting the terminal studs.
A to S <1 ohm
Lift Attach one lead of a megohm meter or a digital
A to Frame >100,000 ohms ohmmeter to a motor terminal and the other
MS+ or MS– to lead to an unpainted surface of the motor
Steer >100,000 ohms housing. Set the ohmmeter to the highest scale.
Frame
4. If the meter indicates high resistance in If the ohmmeter reads resistance of

the armature, check the condition of the <100,000 ohms, the motor is grounded. Clean,
brushes before replacing the motor. repair, or replace the motor as necessary.

Short Circuited Armature or Field Figure 5-3. Traction Motor Circuits

5motor_AC3phaseA.eps
Winding
U
A short circuited winding is one that the
insulation on the field or armature has broken
down at two or more points. The breakdown
creates a low resistance path, allowing current
to flow from one turn of the coil to another
adjacent coil turn, without actually flowing AC
through the coil wire. The result is a decrease in
3φ
total resistance of the motor winding and an
increase in the current flow. The severity of the
short circuit depends on its location. V W
A shorted motor may be indicated by:
Open Winding
• Slow or sluggish operation
• Running faster than usual (suggests a If the AC motor fails with an open winding, the
short in the field) motor moves erratically, as if hunting, and
there is a ticking sound. Rotation is much
• Overheating
slower than usual.
• Blowing a power fuse
• Burning of brush wires Using a clamping ammeter, measure current in
each of the motor power cables. The open phase
• Severe burning or discoloration on
reads significantly lower than the other two
armature coil
phases.
• Severe burning or discoloration on one or
two commutator segments every 90° of
rotation.
Shorted Winding
If the AC motor fails with a shorted winding, the

These symptoms can be caused by problems
motor moves erratically, as if hunting, and
other than the motor itself, such as binding in a
there is a high-pitched sound.
related pump, hose, or solenoid valve.
Using a clamping ammeter, measure current in
Testing a motor for short circuited windings
each of the motor power cables. The shorted
requires special equipment at a motor
phase reads significantly higher than the other
rebuilding facility.
two phases.
AC Motors
AC motors used on this lift truck are brushless,
3-phase, internally delta-connected, variable
speed motors.
The AC motor has a rotor (in place of the DC

armature) and a stator (in place of the DC field).
There is no electrical connection to the rotor;
current is induced in the rotor. The stator has
three windings staggered 120° apart, and three
external connections labeled U, V, and W. See
Figure 5-3.

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

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

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

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

1. Run lift truck until lift cutout is activated.
2. Allow battery to set unused for two hours.
Check Specific Gravity (SG) and compare
to manufacturer’s recommendations.
3. Adjust cutout in Config until correct
discharge is obtained.
NOTE: Additional BSOC adjustment is available
using FlashWare. See BSOC Calibration
(Adjusts Time to 0%) on page 3-8.

Communication Error Code

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

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

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

least five seconds before turning it back to the
ON position. Test the key switch for high
resistance.
Test for shorts to frame. See Shorts to Frame

Test on page 5-3. If nothing is found, replace
the key switch.
Intermittent Codes During Travel and/or

Plugging
If lift truck is equipped with optional travel

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

Test on page 5-3.
Communication Code Every Time Key

Is Turned ON
Troubleshoot per code on display using Test I23

- CAN Communication Test (Page 6-38).

Electrical Connector Locations sockets have a single ridge on the short side at
pin number 1. Male plugs have 1, 2, and 3
raised ridges on the long side at pin numbers 1,
Terminology 2, and 3. See Figure 5-4. Refer to Table 5-3 for
electrical connector locations on the lift truck.
The term “connector JPx” means a mated
connector consisting of two connector (jack and Figure 5-4. Molex Jack and Pin Connector
pin) halves. One half contains male connectors, 8C04013S.TIF
or pins (P); the other half contains female

connectors, or jacks (J). For a list of connectors, Pin Identifier Lines
See Pinout Matrix on page 8-13.
When a technician disconnects a mated JP

connector, it becomes two connector halves.
The individual connector halves are designated
by “Jx” and “Px.” If you cannot locate a
connector designated “Jx” or “Px,” look for
Pins
“JPx,” and vice versa. Jacks
Molex-type connectors have ridges on the sides

to help locate pin number 1. Molex female
Table 5-3. Electrical Connector Locations and Functions
Connector Function or Routing Location

H2 Travel Alarm Forward of Battery Connector
JPA Ambient Temperature Sensor Forward of Fuse/Relay Card
JPB1 Power Amp Fans Near Power Amps
JPB3 Left Side Brake Near Left Traction Motor
JPB4 Right Side Brake Near Right Traction Motor
JPC3 USB
JPC4 Optional Lever #1 Connector
JPC6 Display Inputs and Outputs
JPC9 FlashWare
JPC10 CAN Digital Inputs/Outputs
JPC12 Handle
JPC12A Lever Option Harness Vehicle Manager
JPC12B Lever Option Harness
JPC14 Bus+ and Bus– CAN Communications
JPC18 Some Coils, Horn, and Travel Alarm
JPC20 Proportional Coils
JPC22 Digital Inputs
JPC24 Inputs from Display, Battery, and Temp Sensor

Connector Function or Routing Location

JPD1 Display
Operator Display
JPD2 Display
JPF1 B– Aux Power, B+ Power Amp
JPF2 B+ Connector (B+K1, B+K2, B+K4)
Fuse/Relay Card
JPF3 B– Connector on Fuse Relay Card
JPF4 Key Switch, EPO, Battery Sense
JPH1 Control Handle Control Handle
JPL1 Lift Power Amp Lift Power Amp
JPL2 Lift Encoder
Near Lift Motor
JPL3 Lift Motor Temperature Sensor
JPL4AC Lift Power Contactor Configuration (Model 4200)
Near Fuse/Relay Card
JPL4DC Lift Power Contactor Configuration (Model 4100)
JPS1 Contactor Panel Interface Near Contactor Panel
JPS2 Steering Position Sensor Near Steering Hub
JPS5 High Speed Limit Option
JPS6 Lift Limit Switch Option
Forward of Fuse/Relay Card
JPS13 Right Battery Gate Switch
JPS14 Left Battery Gate Switch
JPT1 Mast Tilt Sensing Option Near Lift Motor
JPTL1 Left Traction Amp Left Traction Amp
JPTL2 Left Traction Motor Encoder
Near Left Traction Motor
JPTL3 Left Traction Motor Temperature Sensor
JPTR1 Right Traction Amp Right Traction Amp
JPTR2 Right Traction Motor Encoder
Near Right Traction Motor
JPTR3 Right Traction Motor Temperature Sensor
JPW1 OCSS - Upper Left Emitter Near Steering Hub
JPW2 OCSS - Upper Right Detector Right side of Operator
JPW3 OCSS - Lower Right Emitter Compartment
JPW4 OCSS - Lower Left Detector Near Steering Hub

JPW5 Warning Light Near Warning Light
JPY1 Weight Pressure Sensor Option Near Hydraulic Manifold
TS1 Terminal Strip for Optional Equipment To Right of Control Handle

Vehicle Manager Connectors

1019283.cgm
22 12 10 6 6 4 24 13
11 1 5 1 3 1 12 1
P22 P10 P6 P24 J9 P3
1 7 1 9 1 10 1 6 1 2
8 14 10 18 11 20 7 12 3 4
P14 P18 P20 P12 P4

Fuse/Relay Card Connectors

R1022159_A.cgm
15A 15A
PF1
PF1
1 4
1 4
FU7
FU8
FU5
FU6
3 6
FU8 FU7 FU5 FU6
K3 K2 K4 K1
K3 K2 K4 K1
1 3 9 3 1 3
1 1 7 1 1 1
13 1 7 1 10 1
PF4 PF2 PF3

PF4 PF2 PF3

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

Symptom Tables: Hydraulic Functions
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.
Intermittent Lift/Lower
Possible Cause Action
Bad wiring Check wiring harnesses between valves and VM.
Hydraulic contamination (can Replace damaged component and flush, fill, and bleed the
cause binding proportional hydraulic system.
valve or load holding solenoid)
Lift Function
No Lift - Lift motor does not run
Bad battery Adjust lift cutout as necessary. Replace battery with fully-charged
battery. Test battery for bad cells. See Battery Procedures on
page 7-42.
Bad optional lift limit switch Run “Test I05 - Lift Limit (S12)”.
Slow Lift - Lift motor runs

Bad battery Adjust lift cutout as necessary. See Lift Cutout Adjustment on
page 5-9. Replace battery with fully-charged battery. Test battery
for bad cells.
Bad proportional lift/lower Inspect for binding. Run “Test O12 - Lift/Lower Solenoid (SOL2)”.
valve
Relief valve SOL3 stuck open Test system pressure. Check for contamination. If contamination is
present, replace valve. Flush, fill, and bleed the hydraulic system.
Run “Test O09 - Lift Relief Solenoid (SOL3)”.
Plugged or malfunctioning Check for contamination in hydraulic fluid. If contamination is
flow control valve in lift present, replace the flow control valves. Flush, fill, and bleed the
cylinder hydraulic system.
Bad lift pump Test system pressure.
Binding in the mast Inspect the mast and bearings for signs of binding.
Bad lift motor 4100 DC Lift Trucks: Test lift motor. See DC Motors on page 5-5.
Check amp draw.
4200 AC Lift Trucks: Run “Test O28 - Ramp Lift Motor (AC Lift)”
and/or “Test I20 - Lift RPM (AC Lift only)”.
Bad lift motor encoder Run “Test I20 - Lift RPM (AC Lift only)”.

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 7-42.
Incorrect lift pressure Check and adjust lift pressure setting.
adjustment
Bad lift pump Test system pressure.
Bad lift motor 4100 DC Lift Trucks: Test lift motor. See DC Motors on page 5-5.
Check amp draw.
4200 AC Lift Trucks: Run “Test O28 - Ramp Lift Motor (AC Lift)”
and/or “Test I20 - Lift RPM (AC Lift only)”.
Binding in the mast Inspect mast and bearings for signs of binding.
Lower Function
Slow Lower
Binding proportional valve Check valve operation. Run “Test O12 - Lift/Lower Solenoid
(SOL2)”.
Binding in the mast Inspect the mast and bearings for signs of binding.
Plugged or malfunctioning Check for contamination in hydraulic fluid. If contamination is
flow control valve present, flush, fill, and bleed the hydraulic system. If no
contamination is found, replace the flow control valves in the main
lift cylinders.
Intermittent Lower
Bad load hold solenoid Run “Test O11 - Load Hold Solenoid (SOL1)”.
Binding proportional valve Check valve operation. Run “Test O12 - Lift/Lower Solenoid
(SOL2)”.
Plugged or malfunctioning If still slow, remove and inspect. Check for contamination in
flow control valve hydraulic fluid. If contamination is present, flush, fill, and bleed
the hydraulic system. If no contamination is found, replace the flow
control valves in the main lift cylinders.
Load Drifting/Settling
Load holding solenoid Run “Test O11 - Load Hold Solenoid (SOL1)”. Check for
contamination in hydraulic fluid. If contamination is present,
inspect and clean the relief valve. Flush, fill, and bleed the
hydraulic system.

Auxiliary Functions
No Aux Functions
SOL4 not functioning Perform “Test O36 - Priority Bypass Solenoid (SOL4)”.
correctly
Aux Functions in One Direction Only

SOL6 not functioning Perform “Test O04 - Aux. Direction Solenoid (SOL6)”.
correctly
No Sideshift
No input Perform “Test A73 - Sideshift Right (S9)” and “Test A74 - Sideshift
Left (S8)” or “Test A74 - Sideshift Left/Right (SW4) (Optional
Handle)”.
SOL9L/9R not functioning Perform “Test O08 - Sideshift Solenoid (SOL9L, SOL9R)”.
correctly
Configuration Make sure Sideshift is enabled in FlashWare. Refer to FlashWare
on page 3-4. Check the selected percentage for Sideshift speed.
Refer to Maintenance Mode on page 3-16.
No Tilt
No input Perform “Test A71 - Tilt Down (S7)” and “Test A72 - Tilt Up (S6)”, or
“Test A72 - Tilt Up/Down (SW4) (Optional Handle)”.
SOL10 not functioning Perform “Test O07 - Tilt Solenoid (SOL10)”.
correctly
Unrequested Tilt
SOL10 stuck ON Perform “Test O07 - Tilt Solenoid (SOL10)”.

Symptom Tables: Drive Units
Symptom Tables: Drive

Units
See Drive Units on page 7-24 for standard drive
unit repair procedures.
Oil Leaks
Damaged sealing rings Replace sealing rings, bearing shims, and drive
shaft bearings, if needed.
Worn or damaged drive shaft Replace sealing rings, bearing shims, drive shaft
bearings, and drive shaft.
Housing/cover joint Reseal.
Worn or damaged housing Replace drive unit.
Drive Wheel Wobbles

Worn or damaged drive shaft bearings Replace sealing rings, bearing shims, and drive
shaft bearings.
Worn or damaged drive shaft Replace sealing rings, bearing shims, drive shaft
bearings, and drive shaft.
Loose wheel mounting hardware Inspect housing and drive shaft for damage;
re-torque mounting hardware.
Noise
Worn or damaged drive shaft bearings Replace sealing rings, bearing shims, and drive
shaft bearings.
Worn or damaged pinion bearings Replace pinion bearing and pinion shaft nut.
Worn or damaged gear set (drive shaft is in Replace sealing rings, bearing shims, drive shaft
good condition) bearings, pinion bearings, pinion shaft nut, and
gear set.
Worn or damaged gear set (drive shaft is worn Replace sealing rings, bearing shims, drive shaft
or damaged) bearings, pinion bearings, pinion shaft nut, gear
set, and drive shaft.
Worn or damaged helical gear and pinion Replace helical gear and pinion.
Incorrect oil level Add oil.

Symptom Tables: Travel Functions
Symptom Tables: Travel

Functions
Slow or Sluggish Acceleration
Dragging brake Replace brake or worn parts (see notes 1 and 2).
Worn wheel bearings Replace wheel bearings (see note 1).
Debris in wheel axle Remove debris (see notes 1 and 2).
Binding drive unit Remove motor and check movement (see notes 1 and 2).
Note 1: Perform “Test A11 - Left Traction Current” and “Test A67 - Right Traction Current” with the
drive tires off the floor and the truck correctly blocked. At full travel speed, readings should be
approx. 30A to 50A. If one test is significantly higher than the other, focus on the corresponding
drive unit.
Note 2: If truck operates in a dusty or dirty environment, install drive wheel fenders. Refer to parts
manual.
Slow Travel
Note: Determine if problem is mechanical or electrical.
Mechanical:
Dragging brake Replace brake or worn brake parts (see note).
Debris in wheel axle Remove debris (see note).
Binding drive unit Remove motor and check movement (see note).
Binding in control handle Run “Test A22 - Traction Request” to determine if the controller is
still seeing a 100% request.
Note: Perform “Test A11 - Left Traction Current” and “Test A67 - Right Traction Current” with the
drive tires off the floor and the truck correctly blocked. At full travel speed, readings should be
drive unit.
Electrical:
Bad mast speed limit switch Run “Test I02 - High Speed Limit SW (S11)” or “Test I89 - Steer
(S10 or S11) or associated Position Sensor”.
wiring
Incorrect reading from steer Run “Test I89 - Steer Position Sensor”.
position sensor
Speed limited due to traction Run “Test A08 - Left Traction Motor Temp”, “Test A10 - Left
motor or TPA temperature Traction Power Amp Temp”, “Test A65 - Right Traction Power Amp
(temperature icon Temp”, and “Test A68 - Right Traction Motor Temp”.
illuminated)
Bad encoder pulses from Run “Test I19 - Left Traction RPM” and/or “Test I82 - Right
traction motor encoder Traction RPM”.

Symptom Tables: Travel Functions
Sluggish or No Steering
Pump Check pressures (may have to obtain fittings to access and test
pressures). Approx. 1800 psi at bypass; working pressure - approx.
900 psi
Motor Check amperage, inspect brushes and holders, motor cables.
Mechanical Check steer chain, pump coupling, and steerable wheel bearings.

Symptom Tables: Electrical Symptoms
Symptom Tables:
Electrical Symptoms
Electrical Motors
Motor Arcing
Worn brushes or incorrect Replace brushes and brush springs.
brush tension
Partially shorted motor Replace motor.
armature or field
Rough or pitted motor Replace motor.
commutator
Motor Overheating
Dragging brake Replace brake or worn brake parts (see note). See Drive Units on
page 7-24.
Application exceeds designed Check with Dealer Service Manager to verify application.
workload -- short runs with
plugging/acceleration or
heavy-duty lifting cycles
Bad battery Check voltage, both open circuit and under load. Replace if
necessary with fully-charged good battery.
Incorrect BSOC Cutout value Check battery specific gravity at cutout, after battery has
stabilized. Compare to battery manufacturer specifications for
discharged battery. Adjust BSOC Cutout as needed.
Cable, terminal, or wiring Replace wiring or cables as necessary.
problems. Look for discolored Check cable connection torque.
terminals, loose or damaged
crimps
Worn, damaged, or bad Inspect motor brushes.
brushes or springs Check brush spring tension.
Binding gearbox or pump Check gearbox or pump for binding (see note for traction motors;
check amp draw for lift motor). Clean, repair, or replace as
necessary.
Hydraulic fluid viscosity too Replace hydraulic fluid with correct fluid. See Lubrication
high or too low Specification Chart on page A-2.
Pressure relief too high Adjust SOL3.
Note: Perform “Test A11 - Left Traction Current” and “Test A67 - Right Traction Current” with the
traction tires off the floor and the truck correctly blocked. At full travel speed, readings should be
drive unit.

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

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


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

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

Summary List
Code 5A: CAN-Bus Error Overflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Code 5B: CAN Transmission Buffer Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Code 5F: No Communications Received by VM from Right TPA . . . . . . . . . . . . 6-15
Code 5G: No Communications Received by VM from Left TPA . . . . . . . . . . . . . 6-15
Code 5J: No Communications Received by VM from LPA . . . . . . . . . . . . . . . . . 6-15
Code 5M: Left TPA NMT Start Timeout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Code 5P: LPA NMT Start Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 5U: Right TPA NMT Start Timeout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 5Y: Left TPA Incorrect Ampacity for Application. . . . . . . . . . . . . . . . . . . . 6-16
Code 61: Mast Switch Not Sensed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 6D: Pressure Sensor Output Voltage Out-of-Range . . . . . . . . . . . . . . . . . 6-16
Code 7A: Lift Motor Overtemp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 7E: Lift Motor Temperature Sensor Out-of-Range . . . . . . . . . . . . . . . . . . 6-17
Code 7F: LPA Overtemp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 7G: LPA Motor Phase Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 7H: Lift Motor Feedback Encoder Failure Detected . . . . . . . . . . . . . . . . . 6-17
Code 7M: LPA Failed to Precharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 7T: LPA Current Sensor Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 7U: LPA Overcurrent or Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 7V: LPA High Voltage on DC Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 7W: LPA Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 7X: LPA Power Supply Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 7Y: Incorrect LPA Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 80: Throttle Potentiometer (VR1) Voltage Out-of-Range . . . . . . . . . . . . . . 6-19
Code 81: Lift/Lower Potentiometer (VR2) Voltage Out-of-Range . . . . . . . . . . . . 6-19
Code 83: Throttle Potentiometer (VR1) Out-of-Neutral . . . . . . . . . . . . . . . . . . . 6-19
Code 84: Brakes Inoperable - Not Applied . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 88: 5V Power Supply Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 8A: OCSS Photo Sensor Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 8F: Lift/Lower Potentiometer Out-of-Neutral . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 8J: Ambient Temperature Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . 6-20
Code 8L: Brake Feedback Current Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 8P: Tilt Potentiometer Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 8R: Tilt Out-of-Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 8S: Sideshift Potentiometer Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 8T: Sideshift Out-of-Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code 8U: Attachment Function 1 Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code 8V: Attachment Function 1 Out-of-Neutral . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code 8W: Attachment Function 2 Out-of-Range. . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code 8X: Attachment Function 2 Out-of-Neutral . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code 8Z: Drive Train Error Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code A0: Incorrect Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code A2: Software Compatibility Issue with VM and Left TPA . . . . . . . . . . . . . 6-22
Code A3: Software Compatibility Issue with VM and Right TPA . . . . . . . . . . . . 6-22
Code A4: Software Compatibility Issue with VM and LPA . . . . . . . . . . . . . . . . . 6-22
Code AG: Communications To/From Operator Display Failed . . . . . . . . . . . . . 6-23
Code AH: Bad Operator Display Checksum . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code AL: VM Battery Backed Up RAM Failed . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code AP: Left TPA Software Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code AT: LPA Software Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code EC: COP Not Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code FE: Internal VM Circuit for BSOC Not Calibrated . . . . . . . . . . . . . . . . . . 6-24

Summary List
Code FG: +5V Reference Voltage and +12V Power Supply Failure . . . .. .. . .. . 6-24
Code FH: Battery Voltage Out-of-Range. . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-24
Code FN: Relays Did Not Open at Power Off . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-24
Code FT: VM Internal Software Error. . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-24
Code G2: Bad Steer Position Reference Input . . . . . . . . . . . . . . . . . . .. .. . .. . 6-24
Code HA: Right Traction Motor Overtemp . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-25
Code HE: Right Traction Motor Temperature Sensor Out-of-Range . . .. .. . .. . 6-25
Code HF: Right TPA Overtemp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-25
Code HG: Right Traction Motor Phase Open . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-25
Code HH: Right Traction Motor Feedback Encoder Failure . . . . . . . . .. .. . .. . 6-25
Code HM: Right TPA Pre-Charge Failed . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-26
Code HT: Right TPA Current Sensor Fault . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-26
Code HU: Right TPA Overcurrent or Short Circuit . . . . . . . . . . . . . . . .. .. . .. . 6-26
Code HV: Right TPA High DC Bus Voltage . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-26
Code HW: Right TPA Software Error . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . 6-26
Code HX: Right TPA Power Supply Out-of-Range . . . . . . . . . . . . . . . . .. .. . .. . 6-27
Code T0: Aux Relief SOL5 Open Circuit or Constant Low. . . . . . . . . . .. .. . .. . 6-27
Code T3: Proportional Lower SOL2 Open Circuit or Constant Low . . . .. .. . .. . 6-27
Code T4: Priority Bypass SOL4 Open Circuit or Constant Low . . . . . . .. .. . .. . 6-27
Code VC: Internal Error in VM Communications . . . . . . . . . . . . . . . . .. .. . .. . 6-27
Input Tests
Test I00 - Deadman (S2) . . . . . . . . . . . . . . . . .......................... 6-30
Test I02 - High Speed Limit SW (S11) . . . . . . .......................... 6-31
Test I05 - Lift Limit (S12) . . . . . . . . . . . . . . . .......................... 6-32
Test I13 - Lift Contactor (DC Lift) . . . . . . . . . .......................... 6-33
Test I14 - Steer Contactor . . . . . . . . . . . . . . .......................... 6-34
Test I15 - Horn (S3, SW1) . . . . . . . . . . . . . . . .......................... 6-35
Test I19 - Left Traction RPM . . . . . . . . . . . . . .......................... 6-36
Test I20 - Lift RPM (AC Lift only) . . . . . . . . . .......................... 6-37
Test I23 - CAN Communication Test . . . . . . . .......................... 6-38
Test I65 - Tilt Position SW (S18) . . . . . . . . . . .......................... 6-40
Test I80 - OCSS - Low . . . . . . . . . . . . . . . . . .......................... 6-41
Test I81 - OCSS - High . . . . . . . . . . . . . . . . . .......................... 6-42
Test I82 - Right Traction RPM . . . . . . . . . . . .......................... 6-43
Test I87 - Battery Gatex . . . . . . . . . . . . . . . . .......................... 6-44
Test I88 - Battery Gate 2 . . . . . . . . . . . . . . . .......................... 6-45
Test I89 - Steer Position Sensor . . . . . . . . . . .......................... 6-46
Analog Tests
Test A04 - Travel Pot (VR1) . . . . . . . . . . . . . . . . .. . .. .. . .. . .. .. . .. .. . .. . 6-48
Test A05 - Lift/Lower Pot (VR2) . . . . . . . . . . . . .. . .. .. . .. . .. .. . .. .. . .. . 6-49
Test A08 - Left Traction Motor Temp . . . . . . . . .. . .. .. . .. . .. .. . .. .. . .. . 6-50
Test A09 - Lift Motor Temp (AC Lift only) . . . . . .. . .. .. . .. . .. .. . .. .. . .. . 6-51
Test A10 - Left Traction Power Amp Temp . . . . .. . .. .. . .. . .. .. . .. .. . .. . 6-52
Test A11 - Left Traction Current . . . . . . . . . . . . .. . .. .. . .. . .. .. . .. .. . .. . 6-53
Test A13 - Weight Sensor Voltage . . . . . . . . . . . .. . .. .. . .. . .. .. . .. .. . .. . 6-54
Test A14 - Ext. Supply Sense (12VDC) . . . . . . . .. . .. .. . .. . .. .. . .. .. . .. . 6-55
Test A15 - Battery Volts . . . . . . . . . . . . . . . . . . .. . .. .. . .. . .. .. . .. .. . .. . 6-56
Test A19 - Lift Power Amp Temp (AC Lift only) . .. . .. .. . .. . .. .. . .. .. . .. . 6-57

Summary List
Test A20 - Lift Current (AC Lift only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58

Test A22 - Traction Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
Test A23 - Lift Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
Test A26 - Pot Supply (5VDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
Test A34 - Lift/Lower Current (SOL2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
Test A36 - Ambient Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
Test A65 - Right Traction Power Amp Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Test A67 - Right Traction Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
Test A68 - Right Traction Motor Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66
Test A71 - Tilt Down (S7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
Test A72 - Tilt Up (S6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68
Test A72 - Tilt Up/Down (SW4) (Optional Handle) . . . . . . . . . . . . . . . . . . . . . . . 6-69
Test A73 - Sideshift Right (S9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70
Test A74 - Sideshift Left (S8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-71
Test A74 - Sideshift Left/Right (SW4) (Optional Handle) . . . . . . . . . . . . . . . . . . 6-72
Test A75 - Attach Fcn 1 (S4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73
Test A75 - Attach Fcn 1 (SW3) (Optional Handle) . . . . . . . . . . . . . . . . . . . . . . . 6-74
Test A76 - Attach Fcn 2 (S5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75
Test A76 - Attach Fcn 2 (SW2) (Optional Handle) . . . . . . . . . . . . . . . . . . . . . . . 6-76
Test A77 - EPO (S21) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
Test A80 - Lift Relief Current (SOL3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78
Test A81 - Priority Bypass Current (SOL4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79
Test A82 - Aux. Relief Current (SOL5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80
Output Tests
Test O00 - TPC Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . 6-82
Test O01 - Steer Contactor (STR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . 6-83
Test O02 - Lift Contactor (LPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . 6-84
Test O04 - Aux. Direction Solenoid (SOL6) . . . . . . . . . . . . . . . . . . . . . . ... . . . 6-85
Test O07 - Tilt Solenoid (SOL10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . 6-86
Test O08 - Sideshift Solenoid (SOL9L, SOL9R) . . . . . . . . . . . . . . . . . . . ... . . . 6-87
Test O09 - Lift Relief Solenoid (SOL3) . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . 6-88
Test O11 - Load Hold Solenoid (SOL1) . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . 6-89
Test O12 - Lift/Lower Solenoid (SOL2) . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . 6-90
Test O18 - Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . 6-91
Test O19 - Ramp Sounder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . 6-92
Test O20 - Travel Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . 6-93
Test O23 - Toggle Amplifier Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . 6-94
Test O28 - Ramp Lift Motor (AC Lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . 6-95
Test O29 - Ramp Traction Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . 6-96
Test O30 - Electric Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . 6-97
Test O32 - Toggle Relay Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . 6-98
Test O36 - Priority Bypass Solenoid (SOL4) . . . . . . . . . . . . . . . . . . . . . . ... . . . 6-99
Test O37 - Aux. Relief Solenoid (SOL5) . . . . . . . . . . . . . . . . . . . . . . . . . ... . . 6-100
Test O45 - HSA 1 Solenoid (SOL7C, SOL7R) . . . . . . . . . . . . . . . . . . . . . ... . . 6-101

Summary List

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

Section 6. Messages, Codes and Tests
Message Displayed: Step Off the Deadman

Icon Code Title/Reason Tests to Run Notes/Corrective Action
Step Off the Deadman “Test I00 - Deadman (S2)” Release deadman.
Deadman (S2) is activated while lift
truck is trying to perform SelfTest.
Message Displayed: Release Control Handle to Resume Operation

Release Control Handle to Resume “Test A04 - Travel Pot Release throttle, step on
Operation (VR1)” deadman, resume travel.
Control handle moved before deadman
pressed.
Message Displayed: Lift CutOut Pending...Low battery

Lift Cut-out Pending... Low Battery None Message is displayed for

Battery low. five minutes, then lift is
disabled. Change Battery.
Message Displayed: EPO Depressed

EPO Depressed “Test A77 - EPO (S21)” Lift EPO Button and cycle
VM senses the EPO switch is open (IN). key switch to clear.
Message Displayed: Scheduled Maintenance Due

Scheduled Maintenance Due None Reset Maintenance Minder

This message occurs when scheduled in Configure Mode.
maintenance is due and Maintenance
Minder is enabled in Configure Mode.
Message Displayed: Lift Cutout, Scheduled Maintenance Due

Lift Cutout, Scheduled Maintenance None Lift is disabled.

Due Reset Maintenance Minder
This message occurs when scheduled in Configure Mode.
maintenance is due and Maintenance
Minder is enabled in Configure Mode.

Section 6. Messages, Codes and Tests Models 4100/4200 Maintenance Manual
Messages and Codes
Message Displayed: Battery Low, No Lift

Battery Low, No Lift If charging or changing the Lift is disabled.

Lift interrupt has occurred due to the battery does not clear the Charge/change battery.
battery state-of-charge. message, run “Test A15 -
Battery Volts”
Message Displayed: Speed Limited

Speed Limited “Test A08 - Left Traction Traction or lift speed is

An overtemperature condition was Motor Temp” reduced when a traction
detected. “Test A09 - Lift Motor motor or the lift motor
Temp (AC Lift only)” becomes overheated. Allow
“Test A10 - Left Traction time for lift truck to cool.
Power Amp Temp”
“Test A19 - Lift Power Amp
Temp (AC Lift only)”
“Test A65 - Right Traction
Power Amp Temp”
“Test A68 - Right Traction
Motor Temp”
Message Displayed: Press Bypass Switch To Continue Lifting

Press Bypass Switch To Continue “Test I05 - Lift Limit (S12)” Lift is disabled unless
Lifting bypass switch (UP button)
Lift Inhibit Switch (S24) was crossed. is activated. Lower carriage
below lift inhibit switch.
Message Displayed: Stalled, Release Control Handle to Resume Operation

Stalled, Release Control Handle to “Test I19 - Left Traction Travel or lift speed is
Resume Operation RPM” limited when the
No encoder pulses are received by “Test I82 - Right Traction corresponding power amp
Power Amplifiers. RPM” is not receiving encoder
“Test I20 - Lift RPM pulses. Cycle key switch to
(AC Lift only)” clear.
Message Displayed: Release Handle Button to Resume Operation

Release Handle Button to Resume None This code appears prior to

Operation an out-of-range code being
Digital input from handle activated at displayed.
startup.

Messages and Codes
Message Displayed: Release Lift to Resume Operation

Release Lift to Resume Operation “Test A05 - Lift/Lower Pot Release lift, step on
Lift pot out of Learned neutral position (VR2)” deadman pedal.
at startup.
Message Displayed: Release Lift and Step on Deadman to Resume Operation

Release Lift and Step on Deadman to “Test I00 - Deadman (S2)” Release lift or lower request
Resume Operation and step on deadman.
Applies to trucks with "Lift/Lower
without deadman" enabled. Occurs
after the deadman switch has not been
activated for 30 seconds.
Message Displayed: Release Tilt to Resume Operation

Release Tilt to Resume Operation “Test A72 - Tilt Up/Down Release tilt control.
Applies to trucks equipped with (SW4) (Optional Handle)”
optional handle. Tilt control out of
Learned neutral at startup.
Message Displayed: Release Side Shift to Resume Operation

Release Side Shift to Resume Opera- “Test A74 - Sideshift Release sideshift control.
tion Left/Right (SW4) (Optional
Applies to trucks equipped with Handle)”
optional handle. Sideshift control out of
Learned neutral at startup.
Message Displayed: Release Horn Button

Release Horn Button “Test I15 - Horn (S3, SW1)” Release horn button.
Digital input from handle activated
longer than ten seconds.
Message Displayed: Press TILT BACK to Unclamp

Press TILT BACK to Unclamp “Test A72 - Tilt Up/Down N/A

Informational message to advise (SW4) (Optional Handle)”
operator to activate Tilt Back button
when the lift truck is equipped with a
clamp.

Messages and Codes
Message Displayed: Lower Mast or Tilt Back to Resume Travel and Lift
Lower Mast or Tilt Back to Resume “Test I02 - High Speed Follow instructions on
Travel and Lift Limit SW (S11)” display. If message still
Informational message for trucks “Test I65 - Tilt Position SW scrolls, perform tests.
equipped with bottler’s tilt. (S18)”
Message Displayed: Release Bypass Switch To Continue Lifting

Release Bypass Switch To Continue None Release UP button.

Lifting
Message Displayed: Lift Stalled, Re-key to Resume Operation

Lift Stalled, Re-key to Resume Oper- “Test I20 - Lift RPM Lift speed is limited. Cycle
ation (AC Lift only)” key switch to clear.
LPA is not receiving encoder pulses.
Message Displayed: Check Battery Gates/Travel Cutout

Check Battery Gates/Travel Cutout “Test I87 - Battery Gatex” Clear Condition.
Battery Gate Switch open or Travel “Test I88 - Battery Gate 2”
Cutout circuit activated.
Message Displayed: Entrance Beam Blocked

Entrance Beam Blocked “Test I80 - OCSS - Low” Clear Condition. Clean
Optional OCSS entrance beam blocked. “Test I81 - OCSS - High” photo eyes.
Message Displayed: Invalid Option Enabled

Invalid Option Enabled Use FlashWare to set a Cycle key switch to clear.
FlashWare options incorrectly valid configuration.
configured. Verify options are
configured correctly in FlashWare.
Some options are to be used for a
specific model. If selected when they
should not be selected, this message is
displayed.

Messages and Codes
Message Displayed: CODE 1H Overheated, Allow Time to Cool

Code 1H: Overheated, Allow Time to “Test A10 - Left Traction Cycle key switch to clear
Cool Power Amp Temp” after TPA has cooled.
The left TPA has reported its internal “Test I89 - Steer Position
temperature is less than –40°F (–40°C) Sensor”
or greater than +203°F (+95°C).
Message Displayed: CODE 2A Overheated, Allow Time to Cool

Code 2A: Left Traction Motor “Test A08 - Left Traction Travel speed is linearly
Approaching Overtemp Motor Temp” derated starting at 266°F
The TPA senses that the Traction Motor “Test I89 - Steer Position (130°C). Travel speed is
is approaching overtemperature. Sensor” limited to 1 mph
Traction performance is limited. (1.6 km/h) at 300°F
(149°C). Cycle key switch
to clear after Traction
Motor has cooled.
Message Displayed: CODE 2E Inform Service

Code 2E: Left Traction Motor Temp “Test A08 - Left Traction Travel is limited to 6.5 mph
Sensor Out-of-Range Motor Temp” (10.4 km/h). Clears when
The Traction Motor temperature sensor reason for fault is
is open or shorted. corrected.
Message Displayed: CODE 2G Inform Service

Code 2G: Phase Open on Left Trac- “Test O29 - Ramp Traction Travel is disabled. Cycle
tion Motor Motors” key switch to clear.
The TPA has detected no current draw
in one of the three phases of the motor.
Message Displayed: CODE 2H Inform Service

Code 2H: Failure Detected in Left “Test I19 - Left Traction Travel is limited to 1 mph
Traction Motor Speed Feedback RPM” (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 key
switch to clear.

Messages and Codes
Message Displayed: CODE 2M Inform Service

Code 2M: Left TPA Pre-Charge Failed None Travel is disabled. Check
Left TPA failed to precharge correctly. for B+ at the left TPA+
terminal. Cycle key switch
to clear. If code does not
clear, replace TPA. The VM
cannot cause this code.
Message Displayed: CODE 2T Inform Service

Code 2T: Left TPA Current Calibra- None Travel is limited to 2.5 mph
tion Error (4.0 km/h). Cycle key
The TPA has sensed a current switch to clear. If code does
calibration error. not clear, replace TPA. The
VM cannot cause this code.
Message Displayed: CODE 2U Inform Service

Code 2U: Left TPA Overcurrent or None Travel is disabled. Cycle

Short Circuit key switch to clear. Check
The TPA has sensed current in excess for shorted traction motor
of 400A. power cables. If code does
not clear, replace TPA. The
Message Displayed: CODE 2V Inform Service

Code 2V: Left TPA High DC Bus Volt- “Test A15 - Battery Volts” If voltage is OK, replace
age TPA. Cycle key switch to
The left TPA has detected an clear. The VM cannot cause
overvoltage condition at the + terminal. this code.
Message Displayed: CODE 2W Inform Service

Code 2W: Left TPA Internal Fault None Cycle key switch to clear. If
TPA internal circuitry has code does not clear, replace
malfunctioned. TPA.

Messages and Codes
Message Displayed: CODE 2X Inform Service

Code 2X: Left TPA Out-of-Range None Travel restricted to 1 mph

The power supply output in the left TPA (1.6 km/h). Cycle key
is less than 4.5V, greater than 5.5V, or switch to clear. Disconnect
too much current is being drawn by an (+) wire to temp and speed
external component. sensors. If code changes,
troubleshoot wires and
sensors. If not OK, replace
TPA. The VM cannot cause
this code.
Message Displayed: CODE 2Y Inform Service

Code 2Y: Incorrect TPA Installed None Replace with correct TPA.
Incorrect power amp installed. Should Travel is limited to 2.5 mph
be 500A, 400A was installed. (4.0 km/h).
Message Displayed: CODE 42 Inform Service

Code 42: LPC Detected Closed When “Test I13 - Lift Contactor Lift is disabled. Cycle key
Commanded Open (DC Lift)” switch to clear.
AC Lift - the LPA has detected an “Test O02 - Lift Contactor
incorrect voltage at the B+ terminal on (LPC)”
the amplifier.
DC Lift - the VM has detected an
incorrect voltage at JPC22-20.

Code 43: LPC Detected Open When “Test I13 - Lift Contactor Cycle key switch to clear.
Commanded Closed (DC Lift)”
AC Lift - the LPA has detected an “Test O02 - Lift Contactor
incorrect voltage at the B+ terminal on (LPC)”
the amplifier.
DC Lift - the VM has detected an
incorrect voltage at JPC22-20.
Message Displayed: CODE 4B Inform Service

Code 4B: Steer Contactor Detected “Test I14 - Steer Check for incorrect voltage
Closed When Commanded Open Contactor” at JPC22-19. Reference
The VM measured greater than “Test O01 - Steer “Pinout Matrix” on
+10VDC at JPC22-19 when the STR Contactor (STR)” page 8-13. Cycle key
coil was de-energized. switch to clear.

Messages and Codes
Message Displayed: CODE 4C Inform Service

Code 4C: Steer Contactor Detected “Test I14 - Steer Cycle key switch to clear.
Open When Commanded Closed Contactor”
The VM measured less than +10VDC at “Test O01 - Steer
JPC22-19 when the STR coil was Contactor (STR)”
commanded closed.
Message Displayed: CODE 4F Inform Service

Code 4F: TPC Detected Closed When “Test O00 - TPC Contactor” Travel is disabled.
Commanded Open Cycle key switch to clear.
The right TPA has detected an incorrect
voltage at the B+ terminal on the
amplifier.

Code 4G: TPC Detected Open When “Test O00 - TPC Contactor” Travel is disabled.
Commanded Closed Cycle key switch to clear.
The TPA has detected the TPC open
after power-up.
Message Displayed: CODE 4J Inform Service

Code 4J: TPC Contactor Coil Open or “Test O00 - TPC Contactor” Travel is disabled.
Shorted TPC Cycle key switch to clear.
TPC contactor coil is open or shorted.
Message Displayed: CODE 4K Inform Service

Code 4K: LPC Contactor Coil Open or “Test O02 - Lift Contactor Lift is disabled. Cycle key
Shorted (LPC)” switch to clear.
The LPC contactor coil is open or
shorted.

Code 59: CAN Transmission Buffer “Test I23 - CAN All functions disabled. See
Error Communication Test” Communication Error
The VM has detected a CAN Code Troubleshooting in
transmission buffer error. “Test I23 - CAN
Communication Test”.
Cycle key switch to clear.

Messages and Codes
Message Displayed: CODE 5A Inform Service

Code 5A: CAN-Bus Error Overflow “Test I23 - CAN All functions disabled. See
CAN-Bus error overflow detected by Communication Test” Communication Error
VM. Code Troubleshooting in
“Test I23 - CAN
Communication Test”.
Message Displayed: CODE 5B Inform Service

Code 5B: CAN Transmission Buffer “Test I23 - CAN Lift truck plugs to a stop if
Error Communication Test” traveling. Cycle key switch
CAN transmission buffer error. to clear.

Code 5F: No Communications “Test I23 - CAN Travel is disabled, lift truck
Received by VM from Right TPA Communication Test” plugs to a stop. Cycle key
The VM has not received CAN switch to clear.
communications from the right TPA.

Code 5G: No Communications “Test I23 - CAN Travel is disabled, lift truck
Received by VM from Left TPA Communication Test” plugs to a stop. Cycle key
The VM has not received CAN switch to clear.
communications from the left TPA.

Code 5J: No Communications “Test I23 - CAN Lift is disabled. Cycle key
Received by VM from LPA Communication Test” switch to clear.
AC lift only. The VM has not received
CAN communications from the LPA.

Code 5M: Left TPA NMT Start Time- None Check B+ and B– to left
out TPA. Check CAN-Bus
No communications received from left wiring. If code does not
TPA within one minute. clear, replace left TPA.

Messages and Codes
Message Displayed: CODE 5P Inform Service

Code 5P: LPA NMT Start Timeout None Check B+ and B– to LPA.
AC Lift only. No communications Check CAN-Bus wiring. If
received from LPA within one minute. code does not clear, replace
LPA.

Code 5U: Right TPA NMT Start Time- None Check B+ and B– to right
out TPA. Check CAN-Bus
No communications received from right wiring. If code does not
TPA within one minute. clear, replace the right TPA.

Code 5Y: Left TPA Incorrect Ampac- None Replace with correct power
ity for Application amp.
Left TPA incorrect ampacity for
application.

Code 61: Mast Switch Not Sensed “Test I02 - High Speed Travel is limited to 2.5 mph
Mast Switch change of state not Limit SW (S11)” (4.0 km/h). Clears when
detected within allotted lift request “Test O12 - Lift/Lower switch change of state is
time. Solenoid (SOL2)” detected.
Message Displayed: CODE 6D Inform Service

Code 6D: Pressure Sensor Output “Test A13 - Weight Sensor A high number is displayed
Voltage Out-of-Range Voltage” for weight.
The VM has determined that the
pressure sensor voltage has exceeded
the programmed limits.
Message Displayed: CODE 7A Overheated, Allow Time to Cool

Code 7A: Lift Motor Overtemp “Test A09 - Lift Motor Lift is disabled. Allow time
AC Lift only. Lift motor temperature has Temp (AC Lift only)” to cool. Cycle key switch to
exceeded 300°F (149°C). clear.

Messages and Codes
Message Displayed: CODE 7E Inform Service

Code 7E: Lift Motor Temperature “Test A09 - Lift Motor Lift performance is
Sensor Out-of-Range Temp (AC Lift only)” disabled by LPA. Cycle key
AC Lift only. Lift motor temperature switch to clear.
sensor voltage is out-of-range.
Message Displayed: CODE 7F Overheated, Allow Time to Cool

Code 7F: LPA Overtemp “Test A19 - Lift Power Amp Lift is disabled. Cycle key
AC Lift only. The LPA has reported its Temp (AC Lift only)” switch to clear.
internal temperature is less than –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 key
AC Lift only. The LPA has detected no Motor (AC Lift)” switch to clear.
current draw in one of the three phases
of the motor.
Message Displayed: CODE 7H Inform Service

Code 7H: Lift Motor Feedback “Test I20 - Lift RPM Lift is limited to approx.
Encoder Failure Detected (AC Lift only)” 10 fpm (3 m/min). Cycle
AC Lift only. The LPA 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

AC Lift only. The LPA failed to the key switch does not
precharge. clear this code, replace the
LPA. The VM cannot cause
this code.

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

Messages and Codes

Code 7U: LPA Overcurrent or Short None Lift is disabled. Cycle key
Circuit switch to clear. Check for
AC Lift only. The LPA has sensed shorted lift motor cables. If
current in excess of 500A. code does not clear, replace
LPA. The VM cannot cause
this code.

Code 7V: LPA High Voltage on DC Bus “Test A15 - Battery Volts” Lift is disabled. Test voltage
AC Lift only. The LPA has detected that at LPA+. If OK, replace LPA.
the voltage at the + terminal is Cycle key switch to clear.
overvoltage. The VM cannot cause this
code.

Code 7W: LPA Internal Fault None Cycle key switch to clear. If
AC Lift only. Internal circuitry has code does not clear, replace
malfunctioned. LPA. The VM cannot cause
this code.

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

Code 7Y: Incorrect LPA Installed None Replace with correct LPA.
AC Lift only. Incorrect LPA installed,
Incorrect ampacity for application.

Messages and Codes

Code 80: Throttle Potentiometer “Test A04 - Travel Pot Travel is disabled. Cycle
(VR1) Voltage Out-of-Range (VR1)” key switch to clear.

Code 81: Lift/Lower Potentiometer “Test A05 - Lift/Lower Pot Lift is disabled. Cycle key
(VR2) Voltage Out-of-Range (VR2)” switch to clear.

Code 83: Throttle Potentiometer “Test A04 - Travel Pot Travel is disabled. Return
(VR1) Out-of-Neutral (VR1)” control handle to neutral.
Throttle potentiometer (VR1) out of Cycle key switch to clear.
Learned neutral value.

Code 84: Brakes Inoperable - Not “Test O30 - Electric Travel disabled at startup.
Applied Brakes” Make sure brake release
The traction motor bearing encoder bolts are removed from
indicated movement during SelfTest. brake assembly. Cycle key
switch to clear.

Code 88: 5V Power Supply “Test A04 - Travel Pot Cycle key switch to clear.
Out-of-Range (VR1)”
Control handle 5V power supply located “Test A05 - Lift/Lower Pot
in VM out-of-range. (VR2)”
Message Displayed: CODE 8A Inform Service

Code 8A: OCSS Photo Sensor Fault “Test I80 - OCSS - Low” Clear obstruction. Clean
The VM senses the beams are ON with “Test I81 - OCSS - High” photoeyes. Cycle key
the deadman pedal up. switch to clear.

Messages and Codes

Code 8F: Lift/Lower Potentiometer “Test A05 - Lift/Lower Pot Lift and lower disabled.
Out-of-Neutral (VR2)” Return control handle to
Lift/Lower potentiometer (VR2) out of neutral. Cycle key switch to
Learned neutral value. clear.

Code 8J: Ambient Temperature Sen- “Test A36 - Ambient Cycle key switch to clear.
sor Out-of-Range Temperature”
Message Displayed: CODE 8L Inform Service

Code 8L: Brake Feedback Current “Test O30 - Electric Cycle key switch to clear.
Out-of-Range Brakes” Note: The brake is fully
The current measured in the brake engaged or fully disengaged
feedback circuit is zero, or outside the when this code is present.
reference range.
Message Displayed: CODE 8P Inform Service

Code 8P: Tilt Potentiometer “Test A72 - Tilt Up/Down Cycle key switch to clear.
Out-of-Range (SW4) (Optional Handle)” Check for correct handle
configuration in
FlashWare.
Message Displayed: CODE 8R Inform Service

Code 8R: Tilt Out-of-Neutral “Test A72 - Tilt Up (S6)” Return switch to neutral
Tilt potentiometer out-of-neutral or “Test A72 - Tilt Up/Down and cycle key switch to
switch detected closed at startup. (SW4) (Optional Handle)” clear.
Message Displayed: CODE 8S Inform Service

Code 8S: Sideshift Potentiometer “Test A74 - Sideshift Cycle key switch to clear.
Out-of-Range Left/Right (SW4) (Optional Check for correct handle
Handle)” configuration in
FlashWare.

Messages and Codes

Code 8T: Sideshift Out-of-Neutral “Test A74 - Sideshift Left Return switch to neutral
Sideshift potentiometer out-of-neutral (S8)” and cycle key switch to
or switch detected closed at startup. “Test A74 - Sideshift clear.
Left/Right (SW4) (Optional
Handle)”

Code 8U: Attachment Function 1 “Test A75 - Attach Fcn 1 Cycle key switch to clear.
Out-of-Range (S4)” Check for correct handle
configuration in
FlashWare.

Code 8V: Attachment Function 1 “Test A75 - Attach Fcn 1 Return switch to neutral
Out-of-Neutral (S4)” and cycle key switch to
Function 1 potentiometer “Test A75 - Attach Fcn 1 clear.
out-of-neutral or switch detected closed (SW3) (Optional Handle)”
at startup.

Code 8W: Attachment Function 2 “Test A76 - Attach Fcn 2 Cycle key switch to clear.
Out-of-Range (SW2) (Optional Handle)” Check for correct handle
configuration in
FlashWare.

Code 8X: Attachment Function 2 “Test A76 - Attach Fcn 2 Return switch to neutral
Out-of-Neutral (S5)” and cycle key switch to
Function 2 potentiometer “Test A76 - Attach Fcn 2 clear.
out-of-neutral or switch detected closed (SW2) (Optional Handle)”
at startup.

Messages and Codes
Message Displayed: CODE 8Z Inform Service

Code 8Z: Drive Train Error Detected None Jack up both traction tires
While traveling in a straight line at and request travel. If only
2.5 mph (4.0 km/h) or greater with a one traction tire turns
greater than 50% throttle request, high while both traction motors
current is detected in one traction are turning, repair the
motor and not the other. drive train as necessary.
Message Displayed: CODE A0 Inform Service

Code A0: Incorrect Software None Cycle key switch to clear. If

Incorrect VM installed in lift truck or this code appears, upgrade
Flashed with incorrect software. the software in the lift
truck using FlashWare.

Code A2: Software Compatibility None Travel disabled. Cycle key

Issue with VM and Left TPA switch to clear. If this code
appears, upgrade the
software in the lift truck
using FlashWare.

Code A3: Software Compatibility None Travel disabled. Cycle key

Issue with VM and Right TPA switch to clear. If this code
appears, upgrade the
using FlashWare.

Code A4: Software Compatibility None Lift disabled. Cycle key

Issue with VM and LPA switch to clear. If this code
AC lift only. appears, upgrade the
using FlashWare.

Messages and Codes
Message Displayed: CODE AG Inform Service

Code AG: Communications To/From None Cycle key switch to clear.

Operator Display Failed Check cable to display. If
Operator Display communications code does not clear, replace
failure detected by VM. OD.
Message Displayed: CODE AH Inform Service

Code AH: Bad Operator Display None Cycle key switch to clear. If
Checksum code does not clear, replace
OD.
Message Displayed: CODE AL Inform Service

Code AL: VM Battery Backed Up RAM None Cycle key switch to clear. If
Failed code does not clear, replace
VM.
Message Displayed: CODE AP Inform Service

Code AP: Left TPA Software Fault None Travel disabled. Cycle key
switch to clear. If code does
not clear, Flash TPA with
latest software.
Message Displayed: CODE AT Inform Service

Code AT: LPA Software Fault None Lift disabled. Cycle key
AC lift only. switch to clear. If code does
not clear, Flash LPA with
latest software.
Message Displayed: CODE EC Inform Service

Code EC: COP Not Enabled None Cycle key switch to clear. If
code does not clear, replace
VM.

Messages and Codes
Message Displayed: CODE FE Inform Service

Code FE: Internal VM Circuit for None Code is displayed for 30

BSOC Not Calibrated seconds. Cycle key switch
clear, replace VM.
Message Displayed: CODE FG Inform Service

Code FG: +5V Reference Voltage and “Test A14 - Ext. Supply Travel, lift, and lower
+12V Power Supply Failure Sense (12VDC)” disabled. Brake engages.
Message Displayed: CODE FH Inform Service

Code FH: Battery Voltage “Test A15 - Battery Volts” Brake remains engaged.
Out-of-Range Cycle key switch to clear.
Wrong voltage battery or voltage
out-of-range.
Message Displayed: CODE FN Inform Service

Code FN: Relays Did Not Open at “Test O32 - Toggle Relay Brake engages. Cycle key
Power Off Enable” switch to clear.
Message Displayed: CODE FT Inform Service

Code FT: VM Internal Software Error None Travel, lift, and lower
disabled. Brake remains
engaged. Cycle key switch
clear, Flash VM with latest
software.
Message Displayed: CODE G2 Inform Service

Code G2: Bad Steer Position Refer- “Test A14 - Ext. Supply Cycle key switch to clear.
ence Input Sense (12VDC)”
“Test I89 - Steer Position
Sensor”

Messages and Codes
Message Displayed: CODE HA Overheated, Allow Time to Cool

Code HA: Right Traction Motor Over- “Test A68 - Right Traction Travel speed is linearly
temp Motor Temp” derated starting at 266°F
“Test I89 - Steer Position (130°C). Travel speed is
Sensor” limited to 1 mph
(1.6 km/h) at 300°F
(149°C). Cycle key switch
to clear after traction motor
has cooled.
Message Displayed: CODE HE Inform Service

Code HE: Right Traction Motor Tem- “Test A68 - Right Traction Travel is limited to 6.5 mph
perature Sensor Out-of-Range Motor Temp” (10.4 km/h). Clears when
reason for fault is
corrected.
Message Displayed: CODE HF Overheated, Allow Time to Cool

Code HF: Right TPA Overtemp “Test A65 - Right Traction Cycle key switch to clear
The right TPA has reported its internal Power Amp Temp” after TPA has cooled.
temperature is less than –40°F (–40°C) “Test I89 - Steer Position
or greater than +203°F (+95°C). Sensor”
Message Displayed: CODE HG Inform Service

Code HG: Right Traction Motor “Test A67 - Right Traction Travel is disabled. Cycle
Phase Open Current” key switch to clear.
Message Displayed: CODE HH Inform Service

Code HH: Right Traction Motor Feed- “Test I82 - Right Traction Travel is limited to 1 mph
back Encoder Failure RPM” (1.6 km/h). If a single
Failure detected in traction motor channel is bad, this code is
speed feedback encoder. displayed during operation.
If one or both channels are
bad at SelfTest, STALLED
is displayed. Cycle key
switch to clear.

Messages and Codes
Message Displayed: CODE HM Inform Service

Code HM: Right TPA Pre-Charge “Test O32 - Toggle Relay Travel is disabled. Check
Failed Enable” for B+ at the right TPA+
TPA failed to precharge correctly. terminal. Cycle key switch
clear, replace TPA. The VM
Message Displayed: CODE HT Inform Service

Code HT: Right TPA Current Sensor “Test A67 - Right Traction Travel is limited to 2.5 mph
Fault Current” (4.0 km/h). Cycle key
The right TPA has sensed a current switch to clear. If code does
sensor fault. not clear, replace TPA. The
Message Displayed: CODE HU Inform Service

Code HU: Right TPA Overcurrent or None Travel is disabled. Cycle

Short Circuit key switch to clear. Check
The right TPA has sensed current in for shorted traction motor
excess of 400A. power cables. If code does
not clear, replace TPA. The
Message Displayed: CODE HV Inform Service

Code HV: Right TPA High DC Bus None If voltage is OK, replace
Voltage TPA. Cycle key switch to
The right TPA has detected an clear. The VM cannot cause
overvoltage condition at the + terminal. this code.
Message Displayed: CODE HW Inform Service

Code HW: Right TPA Software Error None Cycle key switch to clear. If
TPA internal software error (not code does not clear, replace
required for lift truck operation) has TPA.
malfunctioned.

Messages and Codes
Message Displayed: CODE HX Inform Service

Code HX: Right TPA Power Supply None Travel restricted to 1 mph
Out-of-Range (1.6 km/h). Cycle key
The power supply output in the right switch to clear. Disconnect
TPA is less than 4.5V, greater than (+) wire to temp and speed
5.5V, or too much current is being sensors. If code changes,
drawn by an external component. troubleshoot wires and
sensors. If not OK, replace
TPA. The VM cannot cause
this code.
Message Displayed: CODE T0 Inform Service

Code T0: Aux Relief SOL5 Open Cir- “Test A82 - Aux. Relief Cycle key switch to clear.
cuit or Constant Low Current (SOL5)”

Code T3: Proportional Lower SOL2 “Test A34 - Lift/Lower Cycle key switch to clear.
Open Circuit or Constant Low Current (SOL2)”

Code T4: Priority Bypass SOL4 Open “Test A81 - Priority Bypass Cycle key switch to clear.
Circuit or Constant Low Current (SOL4)”
Message Displayed: CODE VC Inform Service

Code VC: Internal Error in VM Com- None Cycle key switch to clear. If
munications code does not clear, replace
VM.

Messages and Codes

Digital Input Tests
Digital Input Tests

A Diagnosis and Repair table is provided for

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

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

Action/
Step (+) Lead (–) Lead Expected Results Step Passed Step Failed
Meter 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. Probe Probe The next
action to
Do the Note: If something point for point for action to
The reading perform if
testing was disconnected in the the perform if the
required to consider the
in this the prior step, positive negative Expected
the step a success. Expected
order. reconnect it before (+) meter (–) meter Results are
Results are
performing the next lead. lead. met.
not met.
step.
This column also

identifies the required
setting on the meter
for this step.

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

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

failed.
Diagnosis and Repair

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

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

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

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

Value Displayed
Sensor
Near Metal Belw
Away From Metal Abve

failed.

Action/
Setting
1 JPC20-8 JPC24-8 Perform step 2 Replace VM

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

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

This test monitors the state of the optional Lift
Limit switch (S12) and displays what the VM is
reading from the switch.
NOTE: This test only works on trucks equipped
with the lift limit option.
Run test:
results:
Mast Value Displayed
Below Switch (closed) Belw
Above Switch (open) Abve

failed.
(2.79 ±1 mm).

Action/
Setting
T/S wiring &

1 JPS6-4 JPS6-3 Approx. 12V Perform step 2 connections. If OK,
Perform step 3
DCV Switch Not Activated:
approx. 5V
2 JPS6-1 TP4 Perform step 4 Replace switch
Switch Activated:
approx. 0V
JPC20 & 24
3 Disconnected PC20-6 PC24-6 Approx. 12V Perform step 4 Replace VM
/DCV
Switch Not Activated:

approx. 5V T/S wiring &
Switch Activated: connections
approx. 0V

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

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

contactor in order to see the transition or
perform test in Active Maintenance mode.
Energizing the Lift Contactor causes the

Lift Motor to run.
Run test:
results:
LPC Contactor Value Displayed
Open Out
Closed In

failed. Check fuse FU3 and the LPC Contactor
tips.

Action/
Meter Setting
Remove FU3/
1 FU1+ FU1– 0 Ohms Perform step 2 Replace fuse
Ohms
T/S wiring &

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

Test I14 - Steer Contactor Digital Input Tests
Test I14 - Steer Contactor Check fuse FU1 and the STR Contactor tips.
This test reports the absence or presence of

voltage to the load side of the STR contactor.
Run test:
NOTE: Must be in Active Maintenance Mode to
perform this test.
For more information on how to use

Maintenance Mode, refer to page 3-16.

results:
STR Contactor Value Displayed
Open Out
Closed In

failed.

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

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

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

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

This test checks the input from the horn switch
(S3 on standard handle, SW1 on optional
control handle) to the VM.
Run test:
results:
Horn Switch Position Value Displayed
Out Off
Depressed On

failed.

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

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

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

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

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

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

Maintenance Mode.

Run test:
The Operator Display should show a linear
increase to maximum RPM.

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

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

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

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

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

obstructions with ample room for lifting.

Maintenance Mode.

Run test:

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

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

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

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

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

be a bad cable or connection. It could also be
caused by a static discharge. Check the static
straps, the terminating resistor, or wiring on
the Left Traction Amp JTL1-21 and JTL1-34.
Additionally, it can be caused by an optional
device or bad DC motor brushes.
Run test:
The Operator Display (OD) shows:
• V if VM is communicating with any
amplifier
• L if the left side TPA is communicating
with the VM
• R if the right side TPA is communicating
with the VM
• P (4200 Only) if the LPA is communicating
with the VM
If V, L, R, or P (4200 Only) are not displayed,

the test has failed.

Digital Input Tests Test I23 - CAN Communication Test

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

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

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

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

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

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

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

(S18) can be verified.
Run test:
results:
Tilt Position Switch (S18) Value Displayed
Depressed In
Released Out

failed.
Check that the tilt position switch has the

correct clearance; adjust the switch so that it
deactivates when the mast is tilted past 3°
forward. See “Adjusting the Mast Tilt Position
Switch” on page 7-100.

Action/
Meter Setting
T/S wiring &

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

approx. 5V T/S wiring &
Switch Activated: connections
approx. 0V

Digital Input Tests Test I80 - OCSS - Low
Test I80 - OCSS - Low Run test:

NOTE: The operator must be on the Deadman
This test displays the output from the optional pedal.
OCSS - Lower Beam.
Make sure the beam is not blocked. The
NOTE: This test shows best results in Active
Operator Display shows the state of the beam:
Maintenance mode.
For more information on how to use Deadman Pedal Value Displayed

Maintenance Mode, refer to page 3-16. Down On
Up Off

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

Receiver (3 Wires) Receiver is Receiving Light Beam
Down Yellow ON
(correctly aligned)
Emitter (2 Wires) Down Green ON +12V Present at Emitter
If an LED does not illuminate as described

above, troubleshoot according to the following
table:
Action/
Setting
1 JPW3-1 JPW3-2 Perform step 3 Perform step 2
Check wiring &

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

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

Test I81 - OCSS - High Digital Input Tests
Test I81 - OCSS - High Run test:

NOTE: The operator must be on the Deadman
This test displays the output from the optional pedal.
OCSS - Upper Beam.
Make sure the beam is not blocked. The
NOTE: This test shows best results in Active
Operator Display shows the state of the beam:
Maintenance mode.
For more information on how to use Deadman Pedal Value Displayed

Maintenance Mode, refer to page 3-16. Down On
Up Off

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

Receiver (3 Wires) Receiver is Receiving Light Beam
Down Yellow ON
(correctly aligned)
Emitter (2 Wires) Down Green ON +12V Present at Emitter
If an LED does not illuminate as described

above, troubleshoot according to the following
table:
Action/
Setting
Check wiring
2 PC20-1 PC10-3 Replace VM
& connections
Approx. 12V
Check wiring
4 DCV PC20-10 PC18-6 Replace VM
& connections
If 5V is missing, check wiring

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

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

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

maneuvering.

Maintenance Mode.

Run test:

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

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

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

Test I87 - Battery Gatex Digital Input Tests
Test I87 - Battery Gatex

This test checks the input from the left Battery
Gate switch (S22A) to the VM.
Run test:
failed.
Battery Gate Value Displayed
Removed Out
Installed In

(2.79 ±1.00 mm).

Action/
Setting

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

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

This test checks the input from the right
Battery Gate switch (S22B) to the VM.
Run test:
failed.
Battery Gate Value Displayed
Removed Out
Installed In

(2.79 ±1.00 mm).

Action/
Setting

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

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

Sensor
This test observes feedback from the Steer
Position Sensor.

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

steer tiller.
Run test:
As the steer tire rotates, the numbers listed in
the table appear on the display. If they do not
change or are erratic, the test has failed.
Make sure the steer position proximity switch is

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

Analog Tests
Analog Tests

and Repair table.

table below.

Action/
Meter Setting

the circuit. If no
The next
action to
Results are
not met.
step.
This column also

for this step.

Test A04 - Travel Pot (VR1) Analog Tests
Test A04 - Travel Pot Run test:

(VR1) The test is a success if the voltage displayed is
within these limits:
This test displays the voltage the VM produces
based on input from the control handle travel Throttle Position Value Displayed
potentiometer VR1. Full Tractor-First (TF) 0.16 to 0.90V
NOTE: Run Learn when the throttle (travel)
Neutral Position 0.9 to 1.4V
assembly is replaced, repaired, or
adjusted. See “Maintenance Mode” on Full Forks-First (FF) 1.25 to 2.00V
page 3-16.
NOTE: If vehicle is displaying code 83 (see If the voltage reading is outside these limits or
“Message Displayed: CODE 83 Inform does not change in a smooth (linear) fashion the
Service” on page 6-19), check the handle test has failed. Any voltage fluctuation indicates
spring for excessive movement. a bad cable or potentiometer VR1.
The voltage reading should decrease when the

throttle is moved from the Forks-First to the
Tractor-First position. If these results are not
observed, the test has failed.

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

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

Analog Tests Test A05 - Lift/Lower Pot (VR2)
Test A05 - Lift/Lower Pot Run test:

(VR2) The test is a success if the voltage displayed is
This test displays the voltage the VM produces
based on input from the control handle Lift/Lower
Value Displayed
lift/lower pot VR2. Control Position
NOTE: Run Learn when the lift/lower pot is Full Lift Position 0.21 to 0.95V
replaced, repaired, or adjusted. See Neutral Position 0.8 to 1.4V
“Maintenance Mode” on page 3-16.
Full Lower Position 1.35 to 2.19V
NOTE: If vehicle is displaying code 8F (see
“Message Displayed: CODE 8F Inform
Service” on page 6-20), check the handle If the voltage reading is outside these limits or
spring for excessive movement. does not change in a smooth, linear fashion, the
test has failed. Any voltage fluctuation indicates
a bad cable or potentiometer VR2.
The voltage reading should decrease when the

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

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

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

Test A08 - Left Traction Motor Temp Analog Tests
Test A08 - Left Traction Run test:

Motor Temp 1. With the lift truck at rest and at ambient
temperature, compare the temperatures
obtained from Maintenance Mode to the
This test displays the temperature of the left ambient temperature.
Traction Motor.
2. If the temperatures are not within several
degrees, the test has failed.
Limits 3. If the reading on the display is not at
• Normal operation: ambient to 258°F ambient temperature, refer to Diagnosis
(125°C) and Repair to isolate the cause.
• Between 266°F (130°C) and 300°F (149°C),
speed is linearly reduced to 1.0 mph
(1.6 km/h).
• Temperature icon blinks at 266°F (130°C)
• Fault Code 2A is displayed and travel is
disabled at 300°F (149°C)
While operating, the VM continually monitors

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
the lift truck up by driving it hard for approx.
30 minutes. As the motor heats, the
temperature increases.
NOTE: For more information on how to use
NOTE: Also check “Test I89 - Steer Position
Sensor” on page 6-46.

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

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

Temp (AC Lift only)
This test displays the temperature of the AC lift
motor.
Limits
• Normal operation: ambient to 294°F
(145°C)
• Temperature icon lights at 295°F (146°C)
• Fault Code 6F is displayed and lift is
Run test:
From ambient temperature, as lift is operated,
the readings should increase evenly over time. If
not, the test has failed.

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

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

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

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

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

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

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

Analog Tests Test A11 - Left Traction Current
Test A11 - Left Traction If readings are not within reference limits, the
test has failed.
Current 1. If any one phase differs significantly from
the other two, check power cable
This test displays the current in the left continuity. Replace cables as necessary.
Traction Motor power circuit. See “Power Cable Terminals” on
page 7-46.
• If power cable continuity is OK, T/S the
Limits: traction motor. See “AC Motors” on
• Above 266°F (130°C) current is reduced page 5-8.
linearly • If all phases give high readings, the
• Maximum current up to 540A when drive unit may be binding. Check drive
deadman pedal is released, unaffected and unit.
unreduced by temperature 2. The power amplifier may be bad. Run
NOTE: For best results, run this test in Active “Test O29 - Ramp Traction Motors” on
Maintenance Mode. page 6-96.

Run test:
The Operator Display shows the current that
the traction power amplifier reads from the
traction motor.
System Condition Value Displayed
Static at Rest <20A
Travel at Full Speed <150A
NOTE: Because Test A11 measures only one

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

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

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

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

Voltage
This test displays the voltage from the optional
pressure sensor used for load weight sensing.
Limits
The operator display shows the voltage present
with various load weights.
Load Weight Value Displayed
0 lbs. (no load) Approx. 1V
3000 lbs. (1361 kg.) Approx. 3V
If the weight sensor is disconnected at the VM,

the Operator Display shows 0V.
Run test:
The voltage shown on the Operator Display
should increase and decrease linearly as the
load weight is either increased or decreased.
If it does not, the test has failed. If the weight

display is inaccurate, the test has failed.

Action/
Meter Setting

DCV 10.5 to 13V
2 JPY1-1 JPY1-3 Perform step 3 T/S harness
Approx. 1V at 0 psi; Replace

3 Attach pressure JPY1-2 JPY1-3 increases approx. 1V Perform step 4 Pressure
gauge to G1/DCV per 1000 psi Transducer
4 JPC24-18 JPC24-10 (6895 kPa) Replace VM T/S harness

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

Sense (12VDC)
This test displays the output of the internal
+12VDC power supply of the Vehicle Manager.
Run test:
The display should read 10.8 to 13V. If the
voltage fluctuates more than 0.8V in 10
seconds, the test has failed.

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

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

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

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

reading BATTERY_SENSE_IN at JPC24-24.
NOTE: This voltage is used by the VM to
calculate the battery state-of-charge.
Run test:
The test is a success if the voltage displayed is
Nominal Battery
Value Displayed
Voltage
36V 33.0 to 39.0V
If the reading fluctuates by more than 0.8V in

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

Action/
Setting
Check battery water level

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

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

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

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

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

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

Test A20 - Lift Current (AC Lift only) Analog Tests
Test A20 - Lift Current 1. If any one phase differs significantly from
(AC Lift only) continuity. Replace cables as necessary.
• If power cable continuity is OK,
This test displays Lift Motor current through troubleshoot the traction motor. See
the Lift Power Amplifier. “AC Motors” on page 5-8.
• If all phases give high readings, the lift
pump may be binding.
Maintenance Mode.
2. The power amplifier may be bad. Run
For more information on how to use “Test O28 - Ramp Lift Motor (AC Lift)” on
Maintenance Mode, refer to page 3-16. page 6-95.
The lift carriage and forks will move

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

The ceiling clearance should allow for
the highest lift.
Limits
• 0 to 500A lifting
• Maximum current 675A
Run test:
the lift power amplifier reads from one phase of
the lift motor.
NOTE: Because only one phase is measured, a
current problem may not be revealed.


evenly as the lift accelerates and decelerates.
Phase currents must be approximately equal.
Gross differences indicate a problem.
If readings are not within reference limits, the

test has failed.

Analog Tests Test A22 - Traction Request
Test A22 - Traction

Request
This test displays the percentage of traction
throttle request from control handle travel pot
VR1 being read by the VM.
Run test:
NOTE: Run Learn after you replace, repair, or
adjust the throttle assembly. See
“Maintenance Mode” on page 3-16.
The Operator Display shows the percentage of

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

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

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

Action/
Meter Setting
Test should pass. Check traction

Run “Test A04 - Compare Test A04 system for speed
Travel Pot results with the limits due to motor
1 N/A N/A Replace TPA
(VR1)” on results from A22. temperature, limit
page 6-48 Max throw should switches, or
show max values. configured speed

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

This test displays the percentage of lift throttle
request from control handle lift/lower pot VR2
being read by the VM.
Run test:
NOTE: Run Learn after you replace, repair, or
adjust the lift/lower potentiometer VR2.
See “Maintenance Mode” on page 3-16.
The Operator Display shows the percentage of

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

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

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

Action/
Meter Setting
Compare Test A05

Run “Test A05 - Check lift system
results with the
Lift/Lower Pot for limits due to
1 N/A N/A results from A23. Replace the LPA
(VR2)” on motor temperature
Max throw should
page 6-49 or switches
show max values

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

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

voltage for power to control handle switches
and potentiometers.
Run test:
If the Operator Display does not read 5VDC
±0.25V, the test has failed.

Action/
Meter Setting
T/S the control

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

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

Current (SOL2)
This test displays the current the proportional
lift/lower solenoid coil (SOL2) is drawing.
Maintenance Mode.

Run test:
State Value Displayed
Neutral Approx. 0.0A
Full Lower Approx. 1.15A

failed.

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

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

Analog Tests Test A36 - Ambient Temperature
Test A36 - Ambient

Temperature
This test displays the ambient temperature of
the area around the lift truck.
Run test:
The Operator Display should display the room
temperature where the lift truck is located.
If not, the test has failed.

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

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

Test A65 - Right Traction Power Amp Temp Analog Tests
Test A65 - Right Traction

Power Amp Temp
This test displays the temperature of the right
Traction Power Amplifier.
Limits
reduced by the TPA to 0.0 mph at 239°F
(115°C), when traction is disabled
(85°C)
• Fault Code 1H is displayed at 203°F (95°C)
Run test:
temperature that the traction power amplifier
reads.
For ambient temperature, as drive is operated,

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

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

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

Analog Tests Test A67 - Right Traction Current
Test A67 - Right Traction • If any one phase differs significantly from
Current continuity. Replace cables as necessary.
See “Power Cable Terminals” on
page 7-46.
This test displays the current in the right
Traction Motor power circuits. • If power cable continuity is OK, T/S the
traction motor. See “AC Motors” on
page 5-8.
Limits: • If all phases give high readings, the drive
• Above 266°F (130°C) current is reduced unit may be binding. Check drive unit.
linearly
NOTE: The power amplifier may be bad. Run
• Maximum current up to 540A when “Test O29 - Ramp Traction Motors” on
deadman pedal is released, unaffected and page 6-96.
unreduced by temperature
Maintenance Mode.

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

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


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

test has failed.

Test A68 - Right Traction Motor Temp Analog Tests
Test A68 - Right Traction NOTE: Also run “Test I89 - Steer Position
Motor Temp
Run test:
This test displays the temperature of the right
1. With the lift truck at rest and at ambient
Traction Motor.
temperature, compare the temperatures
obtained using Maintenance Mode to the
Limits ambient temperature.
• Normal operation: ambient to 258°F 2. If the temperatures are not within several
(125°C) degrees, the test has failed.
• Between 266°F (130°C) and 300°F (149°C), 3. If the lift truck is not at ambient
speed is linearly reduced to 1.0 mph temperature, use the diagnosis and repair
(1.6 km/h) chart to isolate the cause.

(130°C)
• Fault Code 2A is displayed and travel is
While operating, the VM continually monitors

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

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

Action/
Meter Setting
Replace right
1 JTR1-8 JTR1-7 Perform step 2
JPTR1 <1200 ohms if traction TPA
Disconnected/ motor is cool; T/S Traction Replace
2 Ohms JTR3-2 JTR3-1 >1200 ohms if hot Motor temp Traction Motor
sensor wires temp sensor

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

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

failed.

Action/
Meter Setting
Repair or replace
S7 open: >4V control handle,
1 DCV JPC12-6 JPC12-12 Replace VM
S7 closed: <1V cable, or S7 (in
handle)

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

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

failed.

Action/
Meter Setting
S6 open: greater Repair or replace

than 4V control handle,
S6 closed: less than cable, or S6 (in
1V handle)

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

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

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

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

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

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

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

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

change, the test has failed.

Action/
Meter Setting
S9 open: greater Repair or replace

than 4V control handle,
S9 closed: less than cable, or S9 (in
1V handle)

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

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

Approx. 0.0V
Activated


Action/
Meter Setting
S8 open: greater than

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

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

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

change linearly, the test has failed.

Action/ Step
Step (+) Lead (–) Lead Expected Results Step Failed
Meter Setting Passed
Neutral: approx. 2.44V

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

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

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


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

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

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


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

Analog Tests Test A76 - Attach Fcn 2 (S5)

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


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

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

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


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

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

This test displays the voltage at the Emergency
Power Off Switch (S21).
Run test:
EPO Button Raised Approx. B+
EPO Button Depressed 0V

failed.

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

Open: less than 0.5V and connections

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

Current (SOL3)
This test displays the current at the Lift Relief
Solenoid (SOL3).
Run test:
Neutral Approx. 0A
Lift Request Approx. 0.80A

failed.

Action/
Setting
JPC20 T/S wiring,

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

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

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

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

Sideshift percentage.

failed.

Action/
Setting
JPC20
T/S wires &
1 Disconnected PC20-17 PC20-18 Approx. 20 ohms Perform step 2
coil
/Ohms
B+ when OFF;
Check valve for
Test ramps to approx. 26V tilting Replace VM
mechanical
3 Activated/ JPC20-18 B– forward;
binding/
DCV approx. 1V less tilting back;
contamination
approx. 25V sideshifting

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

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

Approx. 0.45A
Attachments

failed.

Action/
Setting
JPC20
T/S wires &
1 Disconnected PC20-19 PC20-20 Approx. 30 ohms Perform step 2
coil
/Ohms
B+ when OFF;
Approx. 24V when ON Check valve for Replace VM
Test
3 JPC20-20 B– (normal mast mechanical binding
ON/DCV
configuration, no /contamination
attachment)

Output Tests
Output Tests

and Repair table.

table below.

Action/
Meter Setting

the circuit. If no
The next
action to
Results are
not met.
step.
This column also

for this step.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Output Tests Test O04 - Aux. Direction Solenoid (SOL6)
Test O04 - Aux. Direction 4. Reconnect the battery connector and turn
the key switch ON. Start test.
Solenoid (SOL6) The percentage shown on the display starts at
0%. Use the UP button to increase the
This test ramps the Auxiliary Direction Solenoid percentage up to 90% in 15% increments.
(SOL6) from 0% to 90% in 15% increments.
Ammeter Reading Value Displayed
A successful test proves the wiring and the
0 to 1.3A Ramp (15% Increments)
related circuitry in the VM are all functioning
correctly. 0.000A 0%
It does not prove that the Auxiliary Direction If these results are not observed, the test has
solenoid itself is mechanically functional. failed.
Run test:
2. Disconnect wire from Aux Select SOL6-1.
3. Connect an ammeter in series with the
Aux Select solenoid as follows:
• (–) lead to terminal of SOL6-1
• (+) lead to wire removed from SOL6-1

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

Test O07 - Tilt Solenoid (SOL10) Output Tests
Test O07 - Tilt Solenoid 4. Reconnect the battery connector and turn
(SOL10) Ammeter Reading Value Displayed
This test toggles the Tilt Solenoid (SOL10) ON 0.500 to 1.000A ON

and OFF.
0.000 to 0.020A OFF
NOTE: This test does not prove that the
solenoid valve itself is mechanically If these results are not observed, the test has
functional. failed. Reconnect wire to the Tilt Solenoid at
SOL10-1.
Run test:
2. Disconnect wire from the Tilt Solenoid at
SOL10-1.
3. Connect an ammeter in series with the Tilt
Solenoid as follows:

Action/
Setting
JPF2 T/S wiring,

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

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

Output Tests Test O08 - Sideshift Solenoid (SOL9L, SOL9R)
Test O08 - Sideshift 5. Disconnect wire from the right Sideshift

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

has failed. Reconnect wire to SOL9L-1 and
proceed to the Diagnosis and Repair
section. If the test passes, proceed to step
5 for a similar procedure for SOL9R.

Action/
Setting
JPC18 Check wiring,

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

Test O09 - Lift Relief Solenoid (SOL3) Output Tests
Test O09 - Lift Relief 4. Reconnect the battery connector and turn
Solenoid (SOL3) Ammeter Reading Value Displayed
This test ramps the proportional Lift Relief 0.000 to 1.000A Ramp (15% increments)
(SOL3) Solenoid from 0% to 90% in 15%
0.000A 0%
increments.
A successful test proves the wiring and the The percentage shown on the display starts at
related circuitry in the VM are all functioning 0%. Use the UP button to increase the
correctly. percentage up to 90% in 15% increments.
It does not prove that the Lift Relief Solenoid If these results are not observed, the test has
itself is mechanically functional. failed. Reconnect wire to SOL3-1.
Run test:
2. Disconnect wire from SOL3-1.
3. Connect an ammeter in series with the Lift
Relief Solenoid as follows:

Action/
Setting
JPC20 &
JPF2
1 JC20-12 JPF2-8 Approx. 32 ohms Perform step 2 T/S wiring & coil
Disconnected
/Ohms
T/S wiring,
2 DCV SOL3-1 TP4 B+ Perform step 3 connections &
Fuse/Relay Card
Ramp from B+
Test Check valve for
when OFF to T/S B+K2. If OK,
3 Activated JC20-12 TP4 binding/
approx. 9V when replace VM
/DCV contamination
full lower

Output Tests Test O11 - Load Hold Solenoid (SOL1)
Test O11 - Load Hold 5. Reconnect the battery connector and turn
Solenoid (SOL1) Ammeter Reading Value Displayed
This test toggles the Load Holding (L/H) 0.500 to 1.000A ON

Solenoid ON and OFF.
0.000 to 0.020A OFF

Make sure the carriage is fully lowered failed. Reconnect wire to SOL1-1.
before performing this test.
NOTE: If there is a fault in the proportional

Lift/Lower circuit or in the proportional
Lift/Lower valve itself, the carriage may
lower. To guard against unexpected
motion of the carriage, fully lower the
carriage before entering this test.
Run test:
1. Lower the forks to the floor.
3. Disconnect wire from Load Holding
solenoid at SOL1-1.
L/H Solenoid as follows:

Action/
Meter Setting
JPC18 & JPF2 T/S wiring,

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

Test O12 - Lift/Lower Solenoid (SOL2) Output Tests
Test O12 - Lift/Lower 4. Reconnect the battery connector and turn

Solenoid (SOL2) Ammeter
Value Displayed
Reading
This test ramps the proportional Lift/Lower
(SOL2) Solenoid from 0% to 90% in 15% 0 to 1.300A Ramp (15% increments)
increments. 0 0%
A successful test proves the wiring and the

The percentage shown on the display starts at
related circuitry in the VM are all functioning
0%. Use the UP button to increase the
correctly. It does not prove the Lift/Lower
percentage up to 90% in 15% increments.
Solenoid itself is mechanically functional.
NOTE: Ramping the proportional Lift/Lower If these results are not observed, the test failed.
Solenoid should not allow the carriage to Reconnect wire to SOL2-1.
lower, since the Load Hold (SOL1) valve
should be closed. If there is a fault in the
Load Hold circuit or a fault in Load Hold
Solenoid itself, the carriage may lower.
To guard against unexpected motion of

the carriage, fully lower the carriage
before entering this test.
Run test:
2. Disconnect wire from SOL2-1.
Lift/Lower Solenoid as follows:
• (–) lead to terminal SOL2-1

Action/
Setting
JPC20
1 Disconnected JPC20-16 JPC20-15 Approx. 16 ohms Perform step 2 T/S wires & coil
/Ohms
2 DCV JPC20-15 B+ Perform step 3
Ramp from B+
Test TP4 Replace VM
when OFF to Check for binding/
3 Activated JPC20-16
approx. 21V when contamination
/DCV
full lower

Output Tests Test O18 - Horn
Test O18 - Horn

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

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

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

Test O19 - Ramp Sounder Output Tests
Test O19 - Ramp

Sounder
Using this test, the operation of the Sounder on
the Operator Display Card can be verified. A
successful test proves the Sounder is
functioning.
Run test:
This test sends a signal to the Sounder on the
Operator Display Card.
Press Enter. The sounder should emit a short,

warning tone. If this sound is not heard, the
test has failed.

Action/
Setting
Voltage ramps up to 24V and back

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

Output Tests Test O20 - Travel Alarm
Test O20 - Travel Alarm Run test:

Connect a voltmeter between JPF2-2 and
This test verifies the operation of the optional
JPC18-18.
Travel Alarm.
Voltage Output Value Displayed
A successful test proves the wiring and related
0.0 to 1.0V OFF
circuitry in the VM are functioning correctly.
NOTE: In order to test the output portion of the 22.0V ON
Vehicle Manager, a device is needed that
will load down the circuit. The Load When the display shows ON, the travel alarm
Holding Coil on the hydraulic manifold must be activated. If these results are not
can be used for that purpose. Remove observed, the test has failed.
the Load Holding Coil and carefully
connect its wires into the circuit.
Use extreme caution to prevent its wires

from shorting to any components.

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

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

Test O23 - Toggle Amplifier Fan Output Tests
Test O23 - Toggle Run test:

Amplifier Fan
Fan Value Displayed
On trucks equipped with an optional cooling
On PWM 100%
fan, this test toggles the power amplifier cooling
fan ON and OFF. Off PWM 0%
A successful test proves the fan, wiring, and If these results are not observed, the test has
related circuitry in the VM are working failed.
correctly.

Action/
Meter Setting
1 TP1 JPC18-17 PMW 0 and 100% Perform step 2 Replace VM

Test
Activated/DCV T/S wires and T/S K2
2 JPF2-1 TP4 B+
fan circuitry

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

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

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

of time can cause damage to the Lift
Motor, Lift Power Amplifier, or wiring.
Run test:
The requested percent of ON time is displayed.
Use the UP (s) button to increase RPM in
increments of 15%, from 0-90%.
Press DOWN (t) button to decrease the request

to 0 and exit the test.

Action/
Setting
If current does not ramp

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

Test O29 - Ramp Traction Motors Output Tests
Test O29 - Ramp Traction 2. Press ENTER once to run motors in

reverse. Press a second time to run motors
Motors in forward. The requested percent of ON
time is displayed.
This test ramps the Traction Motors by 3. Use the UP (s) button to increase RPM in
gradually increasing the command to the increments of 15%, from 0-90%.
Traction Power Amplifiers via the CAN Bus. 4. Press DOWN (t) button to decrease the
This test verifies that the TPAs can generate request to 0, and exit the test.
current and drive the Traction Motors. 5. Observe both traction motors; they both
should be moving close to the same rate of
speed.
Running this test for an extended period
of time can cause damage to the If one motor is faster than the other, refer to
Traction Motors, Traction Power Diagnosis and Repair below. Also, see “Test I89
Amplifiers, or wiring. - Steer Position Sensor” on page 6-46.
The Traction Motors will rotate during

this test. Jack the drive wheels off the
floor. Use extreme care whenever the lift
truck is jacked up for any reason. Never
block the lift truck between the
telescopic and the floor. Use a suitable
hoist to stabilize the mast. Keep hands
and feet clear from beneath vehicle
while jacking. Use jack stands or solid
blocks to support truck. DO NOT rely on
the jack alone. See “Jacking Safety” on
page 2-8.
Run test:
1. Step on the deadman pedal and run test.

Action/
Step
Step Meter (+) Lead (–) Lead Expected Results Step Failed
Passed
Setting
If current does not ramp on one or

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

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

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

test.

failed.

Action/
Setting
JPF2 & Right Side:

T/S wires,
JPC20 JF2-3
1 JC20-14 Approx. 17 ohms Perform step 2 Fuse/Relay
Disconnected Left Side:
Card, & coil
/Ohms JF2-5
If no B+, T/S
wiring &
Brake De-energized: B+ Inspect brake Fuse/Relay
2 DCV JPC20-14 TP4 Energized: approx. 0V assembly for Card. If voltage
then 15V binding does not drop
when energized,
replace VM

Test O32 - Toggle Relay Enable Output Tests
Test O32 - Toggle Relay Run test and observe the following results:
Enable Relays Value Displayed
Tips Closed ON
This test toggles Fuse/Relay Card relays K1, Tips Open OFF
K2, K3, and K4 ON and OFF.

Run test: failed.
NOTE: 50-Series error codes will be logged
while running this test.
NOTE: Must be off deadman when performing
this test.

Action/
Meter Setting
Check K1, K2, &

K3 relay coils. If
1 JF4-5 Approx. 180 K ohm Perform step 2
JPF4 OK, replace
Disconnected/ Fuse/Relay Card
Ohms Check K4 relay
JF4-13
2 JF4-10 Approx. 1.66 K ohm Perform step 3 coil. If OK, replace
Fuse/Relay Card
Check FU5. If OK,

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

4 JPC14-6 Replace VM
Fuse/Relay Card

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

Bypass Solenoid (SOL4) Ammeter Reading Value Displayed
This test ramps the Priority Bypass Solenoid 0.000 to 1.000A Ramp (15% increments)
(SOL4) from 0% to 90%.
0.00A 0%
The requested percent of ON time is displayed.

Use the UP (s) button to increase RPM If these results are not observed, the test has
percentage in increments of 15%, from 0 to failed. Reconnect wire to SOL4-1.
90%.

A successful test proves the wiring and related

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

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

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

Test O37 - Aux. Relief Solenoid (SOL5) Output Tests
Test O37 - Aux. Relief 3. Connect an ammeter in series with the

Proportional Auxiliary Relief (SOL5) as
Solenoid (SOL5) follows:
This test ramps the Proportional Auxiliary Relief • (+) lead to wire removed from SOL5-1
(SOL5) Solenoid (PROP RELIEF) from 0% to 4. Reconnect the battery connector and turn
90%. the key switch ON. Start test.
The requested percent of ON time is displayed. Ammeter Reading Value Displayed

Use the UP (s) button to increase RPM
percentage in increments of 15%, from 0-90%. 0.000 to 0.700A Ramp (15% increments)
0.00A 0%
A successful test proves the wiring and related failed. Reconnect wire to SOL5-1.
circuitry in the VM are all functioning correctly.
NOTE: This test does not prove the Proportional
Auxiliary Relief (SOL5) solenoid valve
itself is mechanically functional.
Run test:
2. Disconnect wire from Proportional
Auxiliary Relief (SOL5) at SOL5-1.

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

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

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

Action/
Meter Setting
JPT18 & JPF2

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

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

Test O45 - HSA 1 Solenoid (SOL7C, SOL7R) Output Tests

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

Section 7. Component Procedures Models 4100/4200 Maintenance Manual
List of Component Procedures
List of Component Motors . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . .
.
.
.
.
. 7-46
7-46
Procedures DC Motor Service . . . . . . . . . . . . .
AC Motor Service . . . . . . . . . . . . .
.
.
.
.
7-46
7-48
Traction Motors . . . . . . . . . . . . . . . . . . 7-51
Component Locator Photos . . . . . . . . . . 7-5 Removal . . . . . . . . . . . . . . . . . . . . . . 7-51
Installation. . . . . . . . . . . . . . . . . . . . 7-51
Steering and Controls. . . . . . . . . . . . .. 7-9 Lift Motor . . . . . . . . . . . . . . . . . . . . . . . 7-53
Steerable Wheel Assembly . . . . . . . . .. 7-10 Removal . . . . . . . . . . . . . . . . . . . . . . 7-53
Removal . . . . . . . . . . . . . . . . . . . . .. 7-10 Installation. . . . . . . . . . . . . . . . . . . . 7-53
Installation . . . . . . . . . . . . . . . . . . .. 7-12 Power Amplifiers . . . . . . . . . . . . . . . . . . 7-54
Disassembly . . . . . . . . . . . . . . . . . .. 7-13 Removal . . . . . . . . . . . . . . . . . . . . . . 7-54
Service . . . . . . . . . . . . . . . . . . . . . .. 7-14 Installation. . . . . . . . . . . . . . . . . . . . 7-54
Reassembly. . . . . . . . . . . . . . . . . . .. 7-14 Wiring and Harness Connectors . . . . . . 7-55
Control Handle - Standard . . . . . . . . .. 7-15 General Connector Repair
Removal . . . . . . . . . . . . . . . . . . . . .. 7-15 Procedures. . . . . . . . . . . . . . . . . . 7-55
Handle Disassembly . . . . . . . . . . . .. 7-15 Molex Connectors. . . . . . . . . . . . . . . 7-55
Handle Assembly . . . . . . . . . . . . . .. 7-15 AMP Water-Resistant Connectors . . . 7-56
Installation . . . . . . . . . . . . . . . . . . .. 7-16 AMP Harness/Traction Power
Inspection . . . . . . . . . . . . . . . . . . . .. 7-16 Amplifier Connector . . . . . . . . . . . 7-60
Hand Soldering Procedures . . . . . . .. 7-16
Control Handle - Optional . . . . . . . . .. 7-18 Hydraulic Components . . . . . . . . . . . . 7-63
Return Spring Replacement. . . . . . .. 7-18 Manifold Solenoids, Fittings, and
Handle Removal . . . . . . . . . . . . . . .. 7-18 Attachments . . . . . . . . . . . . . . . . . . . 7-64
Disassembly . . . . . . . . . . . . . . . . . .. 7-18 Hydraulic Fluid . . . . . . . . . . . . . . . . . . . 7-68
Lift/Lower Potentiometer (VR2) Fluid Level . . . . . . . . . . . . . . . . . . . . 7-68
Replacement. . . . . . . . . . . . . . . . . 7-18 Selecting Hydraulic Fluid Type . . . . . 7-68
Travel Potentiometer (VR1) Bleeding the Hydraulic System . . . . . 7-68
Replacement. . . . . . . . . . . . . . . . . 7-20 Pressure Relief Valve . . . . . . . . . . . . . . . 7-70
Sideshift/Tilt Switch Rubber Boot Measuring System Pressure . . . . . . . 7-70
Replacement. . . . . . . . . . . . . . . . . 7-20 Adjusting Pressure . . . . . . . . . . . . . . 7-70
Assembly . . . . . . . . . . . . . . . . . . . . . 7-20 Cylinder Service . . . . . . . . . . . . . . . . . . 7-71
Installation . . . . . . . . . . . . . . . . . . . . 7-21 Main or Free Lift Cylinders -
Model 4200 . . . . . . . . . . . . . . . . . 7-71
Drive and Brake . . . . ............ .. 7-23 Piston Removal. . . . . . . . . . . . . . . . . 7-71
Drive Units . . . . . . ............. .. 7-24 Quad Mast Check Valve Inspection. . 7-72
Removal . . . . . . . ............. .. 7-24
Installation . . . . . ............. .. 7-25 Mast . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
Adding Oil. . . . . . ............. .. 7-25 Mast Service . . . . . . . . . . . . . . . . . . . . . 7-74
Repair . . . . . . . . . ............. .. 7-26 Upright Inspection - Model 4200 . . . 7-74
Tire Replacement . . ............. .. 7-37 Mast Skewing - Model 4200 . . . . . . . 7-74
Brakes . . . . . . . . . . ............. .. 7-38 Mast Removal. . . . . . . . . . . . . . . . . . 7-74
Inspection . . . . . . ............. .. 7-38 Mast Installation . . . . . . . . . . . . . . . 7-75
Removal . . . . . . . ............. .. 7-38 TF and TT Mast Service - Model 4200 . . 7-77
Disassembly . . . . ............. .. 7-38 TF Mast Disassembly . . . . . . . . . . . . 7-77
Assembly . . . . . . ............. .. 7-38 TF Mast Reassembly. . . . . . . . . . . . . 7-77
Installation . . . . . ............. .. 7-39 TF Mast Main Lift Cylinder Removal . 7-77
TF Mast Main Lift Cylinder
Electrical Components . . . . . . . . . . . .. 7-41 Installation . . . . . . . . . . . . . . . . . 7-78
Battery Procedures . . . . . . . . . . . . . .. 7-42 TT Mast Disassembly . . . . . . . . . . . . 7-78
Battery Connector/Cables. . . . . . . .. 7-42 TT Mast Reassembly. . . . . . . . . . . . . 7-78
Power Cables . . . . . . . . . . . . . . . . . . .. 7-44 TT Mast Main Lift Cylinder Removal . 7-79
Power Cable Repair . . . . . . . . . . . . .. 7-44

TT Mast Main Lift Cylinder

Installation . . . . . . . . . . . . . . . . . . 7-79
TT Mast Free Lift Cylinder Removal . . 7-79
TT Mast Free Lift Cylinder Installation 7-80
TT Mast Free Lift Cylinder
Supply Hose . . . . . . . . . . . . . . . . . 7-80
Carriage - Model 4200 TF and
TT Masts . . . . . . . . . . . . . . . . . . . . . 7-81
Carriage Removal . . . . . . . . . . . . . . . 7-81
Carriage Installation . . . . . . . . . . . . . 7-81
Hose Reeving . . . . . . . . . . . . . . . . . . . . 7-82
Internal Reeving -
Model 4200 TF Mast . . . . . . . . . . . 7-82
Internal Reeving -
Model 4200 TT Mast . . . . . . . . . . . 7-84
Quad Mast Service . . . . . . . . . . . . . . . . 7-87
Mast Inspection . . . . . . . . . . . . . . . . . 7-87
Disassembly . . . . . . . . . . . . . . . . . . . 7-87
Reassembly . . . . . . . . . . . . . . . . . . . . 7-89
Carriage . . . . . . . . . . . . . . . . . . . . . . 7-92
Cylinder Removal and Installation . . . 7-92
Reeving . . . . . . . . . . . . . . . . . . . . . . . 7-93
Lift Chains . . . . . . . . . . . . . . . . . . . . . . 7-98
Adjusting Lift Chains - Model 4100 . . 7-98
Adjusting Lift Chains - Model 4200 . . 7-98
Model 4200 TT Mast - 2 in. to 3 in.
Lowered Height Conversion . . . . . . 7-99
Mast Tilt Adjustment . . . . . . . . . . . . . 7-100
Adjusting the Mast Tilt Position
Switch . . . . . . . . . . . . . . . . . . . . 7-100


Component Locator Photos

Figure 7-1. Models 4100/4200 Front View

1033170_D.cgm
Overhead Guard
Mast
Tilt Cylinder
Load Backrest
Carriage
Battery Gate
Forks
Left Traction Tire

Figure 7-2. Models 4100/4200 Rear View

1033170_D.cgm
Control Handle
Operator
Display
Steer Tiller
Deadman Pedal
Steerable Wheel

Figure 7-3. Major Components - Top View

1033350_1.cgm
Hydraulic
Horn Manifold
Vehicle Operator Fuse/Relay Contactor

Manager Display Card Panel
Right Traction
Power Amp
Lift Power Amp

(4200 Only)
Left Traction
Power Amp

Figure 7-4. Major Components - Front View

1033350_2.cgm
Steer Motor Brake Release

and Pump Bolts
Tilt Cylinder Tilt Cylinder
Right Traction Lift Motor Left Traction

Motor and Brake and Pump Motor and Brake

Steering and Controls
Steering and Controls


Steering and Controls Steerable Wheel Assembly
Steerable Wheel Figure 7-6. Removing Steering Position Sensor

137.TIF
Assembly Sensor Proximity

Ring Sensor
Removal
2. Remove the Steer Compartment Cover.
3. Take the steer chain off the steer plate by
removing the outer nut on the threaded
end of the chain anchor. See Figure 7-5.
Figure 7-5. Removing Steering Plate Chain Nut Steer

030.TIF
Plate
Steering
Motor 6. Remove the three flat head screws that
hold the steer sensing ring to the top of the
steer plate, then remove the ring. See
Chain Figure 7-7.
Figure 7-7. Removing Steering Sensor Ring

138.TIF
Flat Head Screws
Steering
Plate
Chain
Anchor Nut
4. Disengage the steer chain from the

steering motor assembly. Leave chain
attached to the other side of the steering
plate.
5. Remove the two screws that hold the steer
position proximity sensor bracket in place,
then remove the bracket. See Figure 7-6.
7. Scribe a mark from the top of the steer

hub onto the steer plate. (These marks will
be realigned later to help make sure the
steer plate is installed in its correct
position). See Figure 7-8.

Steerable Wheel Assembly Steering and Controls

Figure 7-8. Scribing a Mark from Hub to Steer Plate Figure 7-10. Steering Wheel Mounting Bolts
141.TIF DOCK67.TIF
Scribed Mark On Plate
Mounting Bolts
Scribed Mark On Hub
8. Remove the four bolts that hold the steer

plate in place, then remove the steer plate.
See Figure 7-9. 10. Place chocks in front of the drive wheels.
11. Reinstall one of the steer plate bolts. Wrap
Figure 7-9. Removing Steering Plate Bolts a piece of heavy wire around this screw to
use as a temporary support. You will use
139.TIF
this temporary support to lower the steer

assembly to the floor when the lift truck is
jacked up. See Figure 7-11.
Figure 7-11. Temporary Support for Steerable Wheel

DOCK64.TIF
Heavy Wire and

Steer Plate Bolt
9. Remove the six mounting bolts holding the

steerable wheel assembly to the lift truck
frame. See Figure 7-10.
Jack
Block
12. Remove the wheel from the steer assembly

to reduce jacking height and for ease of
removal.

17. Move the steerable wheel assembly down

and out from beneath the truck. See
Figure 7-13.
jacked up. Never block the truck Figure 7-13. Steerable Wheel Removed
DOCK60.TIF
between the telescopic and the floor.

Use a suitable hoist to stabilize the mast.
Keep hands and feet clear from vehicle
while jacking the truck. After the truck is
jacked, place solid blocks beneath it to
support it. Do not rely on the jack alone
to support the truck. See “Jacking
Safety” on page 2-8.
13. Jack the rear of the truck. As the lift truck

is jacked, the steerable wheel assembly
separates from the tractor frame.
14. Continue to jack the lift truck until the
upper hub on the steerable wheel is flush
with the tractor frame. Block the lift truck
in this position. See Figure 7-12.
Figure 7-12. Wheel Hub Shown Flush with Lift Truck Frame Installation
DOCK65.TIF
Position the steerable wheel assembly within

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

Steerable Wheel Assembly Steering and Controls
9. Reconnect the battery connector and turn Figure 7-14. Steerable Wheel Components
the key switch ON.
STRWHL.WMF
Lock Upper
10. Run Test I89 - Steer Position Sensor. This Nut Steer
verifies the steer position proximity sensor Hub
is adjusted correctly.
the battery connector. Key
12. Remove any blocks supporting the truck. Pivot

Hub
13. Lower the lift truck to the floor. Bearings
14. Install the steer compartment cover.
Steer
the key switch ON. Pivot
16. Test the steering function. If OK, return lift
truck to service.
Disassembly
1. Remove the nut that holds the upper steer
hub to the steer pivot. See Figure 7-14.
2. Use a three-arm puller to remove the

upper steer hub.
3. Pull the steer pivot out of the pivot hub.
See Figure 7-15.


Figure 7-15. Steerable Wheel Shown Unassembled
119.TIF
Pivot Hub
Steer Hub
Steer Pivot and Lock Nut
and Wheel
Service
1. Clean the inside of the pivot hub.
2. Clean and inspect the bearings. Replace
any worn components.
3. Remove, clean, and inspect the keys.
Clean and inspect the keyways.
4. Pack the bearings with grease, see
Appendix for lubrication specifications.
Add additional grease to the pivot spindle
and hub so that when the unit is
assembled, it is 50-75% full of grease.
5. Slide the steer pivot into the pivot hub.
6. Coat the keys and keyways with
thread-locking compound (P/N 990-536).
Reassembly
1. Install the upper steer hub.
2. Install the nut.
3. Tighten the nut while rotating the pivot
hub that mounts to the tractor frame.
4. Continue to tighten the nut until the pivot
hub just starts to resist rotation.

Control Handle - Standard Steering and Controls
Control Handle - 2. Replace the seven screws on the control

handle, making sure that they are located
Standard correctly.
3. Position the thumb control return spring
onto the control handle. Make sure that
Removal the ears of the spring are positioned
1. Turn the key switch OFF and disconnect correctly. See Figure 7-16.
Figure 7-16. Correct Positioning of Spring Ears
2. Remove the console cover. SPRNG1_1.TIF
Use correct ESD precautions. See “Static

Precautions” on page 2-7.
3. Unplug the control handle wiring harness

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

Steering and Controls Control Handle - Standard
Lift Knob Assembly 4. Route the control handle wiring harness

and plug into the VM at JPC12.
1. Rotate the lift potentiometer shaft fully
5. Make sure cable extends out of the handle
CCW.
as straight as possible to avoid kinking.
2. Install the lift knob on the potentiometer
shaft. Do not tighten the set screws yet.
the key switch ON.
3. Rotate the lift knob fully CCW and tighten
7. Enter Maintenance Mode and perform
the set screws.
Learn. See “Maintenance Mode” on
4. Verify the lift potentiometer voltages. page 3-16.
5. Install the nylon plugs over the set screws. 8. Reinstall the console cover.
Inspection
The solid state potentiometers used in
this handle are ESD sensitive. Whenever the control handle is disassembled,
perform the checks defined in the following
6. When installing the wire harness, a service table.
loop is required.
Part Check for:
7. Install the handle and route the harness
last, after all the other wires are routed Horn button Cracks or deformation
through this area. Routing should occur assembly
toward the left side of the truck, then
Lift/lower pot Cracks, deformation, loose dowel
forward and around the front of the VM.
bracket pin, over-round or oversized
Connect the handle from the right side of
shaft hole
the VM.
Travel pot Cracks, loose spirol pin, stripped
enclosure threads, deformation or indents
on external stops
Make sure all other wires are tied back
and away from the handle harness Handle halves Cracks, damage or
deformation/indents on external
service loop. Do not route through any
stops
components.
Lift/lower Cracks, deformation, stripped
8. Test the motion of the service loop by knob threads, loose dowel pin
cycling the handle. The entire length of the
Other Stripped threads. All screw
loop should absorb the twist. Make sure
hardware threads must be cleaned.
that the loop does not hang up on adjacent
wires, cable ties, or structures.
Hand Soldering Procedures
Installation
When hand soldering is performed on solid
1. Insert the shaft of the control handle state potentiometers, the following is
assembly into the support bracket. recommended:
2. Apply thread-locking compound • Flux - rosin base
(P/N 990-536) to threads of socket head
securing screw. • Solder - 60/40 rosin core or equivalent
3. Hold the control handle in place, aligning • Solder Iron - 55 watt max.
the hole in the shaft with the securing • Tip Size - 0.118 in. (3 mm) dia. x 1.182 in.
screw hole. Torque the securing screw to (30 mm) long screwdriver
30 ft. lb. (42 Nm). • Tip Temperature - 500°F (260°C) max.

Control Handle - Standard Steering and Controls
• Terminal Contact Time - 6 seconds max.

NOTE: Apply light soldering iron pressure on
the terminal. Make sure the tip is clean.
A dirty tip does not transfer heat well,
therefore requiring longer dwell time
and greater tip pressure.
Contact contamination can occur if

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

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

are not covered under warranty.

Steering and Controls Control Handle - Optional
Control Handle - 3. Install double-sided tape to back of new

pot.
Optional 4. Slide the lift/lower potentiometer bracket
over the potentiometer shaft, engaging the
metal tab of potentiometer in the slot in
Return Spring Replacement the side of the bracket. See Figure 7-17.
The lift/lower knob return spring can be Figure 7-17. Lift/Lower Pot Bracket Installation
replaced without removing and disassembling DSC_4848_sm.jpg
the control handle.

Metal Tab
When replacing a return spring, coat the inside
of the spring lightly with lithium grease
(P/N 990-635). Bracket
Handle Removal
2. Remove the console cover.
3. Disconnect cable from the control handle.
5. Insert the lift/lower pot assembly into the
4. Loosen control handle set screw and
right control handle shell.
remove handle from pivot.
6. Connect PCH2.
Disassembly 7. Adhere heater pad section of flexible
circuit to back of pot.
NOTE: A fixture (P/N 828-009-213) is available
8. Reassemble and reinstall the control
to hold the handle in position while
handle. See Assembly and “Installation” on
disassembled. Note the orientation of
page 7-21.
switches, potentiometers, routing of
cables and wires for reassembly. 9. Reconnect the battery connector and turn
the key switch ON.
1. Remove nylon plug from the lift/lower
knob to expose set screw underneath. 10. Enter Maintenance Mode and perform
Loosen set screw and remove lift/lower Learn. See “Maintenance Mode” on
knob. page 3-16.
2. Remove six socket head screws securing 11. In Run Mode, test the lift/lower function
the handle shell halves together. for correct operation.
3. Carefully remove the left half of the handle

shell.
Lift/Lower Potentiometer (VR2)

Replacement
1. Remove the lift/lower potentiometer
bracket and potentiometer from the
handle shell. Slide the bracket off the
potentiometer. See Figure 7-18 on
page 7-19.
2. Disconnect PCH2.

Control Handle - Optional Steering and Controls

Figure 7-18. Optional Control Handle
1033396_G4.cgm
Sideshift/Tilt Switch Rubber Boot
Lift/Lower Pot Bracket

PCH2
Lift/Lower Pot (VR2)
Flexible Circuit
Travel Pot Return Spring PCH1
Travel Pot (VR1) Positioner Pin Composite Bushings Pivot Shaft Assembly

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

replacement boot inside out, install the
Replacement replacement boot and verify that the tabs
1. Lift up gently on the pivot shaft to free the are aligned and that the boot is seated
travel pot assembly from the handle. See correctly. Stretch the boot over the joystick
Figure 7-18 on page 7-19. housing. See Figure 7-19.
2. Slide the travel pot out of the pivot shaft
Figure 7-19. Boot Installation
assembly. DSC_4873_sm.jpg
3. Disconnect PCH1.
4. Install double-sided tape to back of new
pot.
5. Install pot in the pivot shaft assembly,
aligning the flat on the pot shaft with the
flat inside the positioner.
6. Install the travel pot assembly in the
handle shell. The tab of the throttle pot
must engage the slot in the handle shell
(straight down). Align the composite Boot (turned inside out)
bushings with the molded holders in the
handle.
5. Reassemble and re-install the control
7. Connect PCH1. handle.
8. Adhere heater pad section of flexible
circuit to back of pot.
Assembly
9. Reassemble and reinstall the control
handle. See Assembly and Installation. 1. Check flexible circuit and wires for correct
routing.
the key switch ON. 2. Orient the VR1 return spring ears straight
up in the right half of the handle.
11. Enter Maintenance Mode and perform
Learn. See “Maintenance Mode” on 3. Install the left half of the handle shell. The
page 3-16. pin in the left side handle shell must fit
between the ears of the VR1 throttle
12. In Run Mode, test the travel function for
potentiometer return spring. The wires
correct operation.
from the VR2 lift/lower potentiometer
must fit between the tabs in the handle
Sideshift/Tilt Switch Rubber shell. Make sure the tabs do not crush any
Boot Replacement of these wires.
4. If using a fixture, loosen the thumb screw
1. Move the lift lower potentiometer and
and remove the handle from the fixture.
bracket out of the way in order to access
the tilt and sideshift joystick boot. 5. Install the two socket head screws to hold
the handle halves together.
2. While activating the switch in the tilt
position, tilt back and rotate the assembly 6. Insert a screwdriver in the handle shaft
out of the handle half. mounting hole to hold the shaft in place.
3. Remove the boot assembly. 7. Rotate the control handle from neutral to
maximum forward, then maximum
NOTE: The joystick assembly has locating backward, then to neutral. The handle
indentations and the replacement boot should move freely with no binding.
has corresponding tabs. Correct any binding before proceeding
further.

Control Handle - Optional Steering and Controls
8. Install the five remaining socket head

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


Drive and Brake
Drive and Brake


Drive and Brake Drive Units
Drive Units Figure 7-21. Lifting Drive Unit

DU-PINS.WMF
Lifting Eye Hook

Locating Pins
Removal
Drive unit weighs approximately 175 lb.

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

2. Remove the mast from the lift truck. See 7. Loosen, but do not remove, the eight bolts
“Mast Service” on page 7-74. that secure the wheel and tire assembly to
3. Drain all the lubricant out of the drive the drive unit.
unit. Use a drain pan that is
approximately 1.5 gal. (5.7 liters). See
Figure 7-20.
Figure 7-20. Draining Drive Unit Use extreme caution whenever the lift
8d14066s.tif
truck is jacked up. Never block the lift
truck between the telescopic and the
floor. Use a suitable hoist to stabilize the
mast. Keep hands and feet clear from
beneath vehicle while jacking the lift
truck. After the lift truck is jacked up,
place solid blocks or jack stands
beneath it to support it. DO NOT rely on
the jack alone to support the lift truck.
See “Jacking Safety” on page 2-8.
8. Jack the side of the lift truck to remove the

drive unit. Place blocks beneath the lift
truck to support it. See Figure 7-22.
Figure 7-22. Drive Wheel Removal
8d14044s.tif
4. Remove the brake assembly.

5. Remove the traction motor.
6. Install a lifting eye hook into one of the
traction motor mounting holes. See
Figure 7-21.

Drive Units Drive and Brake
9. Remove the eight bolts that secure the Adding Oil

wheel and tire assembly to the drive unit.
NOTE: The drive unit must be installed before
10. Remove the six bolts securing the drive
filling the drive unit with oil.
unit to the lift truck frame. See
Figure 7-23. 1. Remove the oil level check screw.
Figure 7-23. Drive Unit Mounting Bolts 2. Remove the fill screw.
8d14072s.tif
3. Refer to “Lubrication Specification Chart”

on page A-2 to determine the correct type
of gear lubricant (or oil for cold storage lift
trucks).
4. Slowly pour the lubricant in the fill hole.
Watch the oil level check screw hole. When
the lubricant is level with the bottom of the
screw hole, stop pouring. Allow all excess
oil to drain out.
5. Reinstall the oil level check screw and fill
screw.
Installation
1. Make sure the drain plug is installed in
the drive unit.
(P/N 990-536) to the two locating pins.
Install the locating pins into the drive unit
casting. See Figure 7-21.
3. Position the drive unit in place. Align the
bolt holes in the mounting flange with the
bolt holes in the tractor frame.
4. Install the six bolts that hold the drive unit
to the tractor frame. Torque bolts to
120 ft. lb. (168 Nm).
5. Install the drive wheel and tire assembly.
Install the wheel mounting bolts.
6. Lower the lift truck to the floor. Torque
wheel mounting bolts to 110 ft. lb.
(151 Nm).
7. Reinstall the traction motor.
8. Reinstall the brake assembly. Make sure
to remove the brake release bolts from the
brakes.
9. Refill the drive unit with gear oil until the
fluid is even with the bottom of the fluid
check hole located on the side of the drive
unit.
10. Install the mast.

Repair
Refer to Figure 7-23 for all item references in
this procedure.
Figure 7-24. Drive Unit Exploded View

P31151.cgm
17 15
Legend:
1. Housing
2. Upper Pinion Bearing Cup and Cone Set
3. Helical Gear and Pinion Set
4. Spiral Pinion and Ring Gear Set
5. Axle Seal
6. Axle Shaft 16 13
7. Lower Pinion Bearing Cup and Cone Set
8. Outer Axle Bearing Cup and Cone Set
10
9. Inner Axle Bearing Cup and Cone Set
10. Thrust Washer
11. Shim Stack
12. Spacer 4
13. Axle Shaft Clamp Nut
14. Helical Gear Clamp Nut 10
15. Screw
16. Main Cover 11
17. Drain Plug
18. Filler Plug (Not Shown) 4
12
7
2 3
1
14
8
5

Troubleshooting Drive Unit
Symptom Probable Cause Required Action

Oil leaks Damaged lip seal Replace lip seal, main cover and bearing shims,
output shaft bearings.
Worn or damaged axle shaft Replace lip seal, main cover and bearing shims,
output shaft bearings, and output shaft.
Plugged vent Unclog vent and clean motor.
Overfilled Drain some oil and clean motor.
Motor to housing flange joint or main Reseal
cover joint
Worn or damaged housing Replace drive unit.
Drive wheel Worn or damaged axle shaft bearings Replace lip seal, main cover and bearing shims,
wobbles output shaft bearings.
Worn or damaged axle shaft Replace lip seal, main cover and bearing shims,
output shaft bearings, and output shaft.
Loose wheel mounting hardware Inspect housing and main cover for damage.
Re-torque mounting hardware.
Noise Worn or damaged axle shaft bearings Replace lip seal, main cover and bearing shims,
output shaft bearings.
Worn or damaged pinion bearings Replace pinion bearings and clamp nut.
Worn or damaged gear set - axle shaft Replace lip seal, main cover and bearing shims,
is in good condition output shaft bearings, pinion bearings, gear set, and
clamp nut.
Worn or damaged gear set - axle shaft Replace lip seal, main cover and bearing shims,
is worn or damaged output shaft bearings, pinion bearings, gear set,
clamp nut, and output shaft.
Worn or damaged helical gear and Replace helical gear and pinion.
pinion

Disassembly Figure 7-27. Fill Level Plug Removal

2610_068.tif
Refer to Figure 7-23 on page 7-26 for all item

references in this procedure.
Clean the outside of the drive unit thoroughly

and drain any remaining oil from the drive unit.
Visually inspect the outside of the housing

(item 1) for damage, wear, or cracks. Pay
particular attention to the area where hub wear
may be evident, the mast pivot area, motor
area, and around all bolts. 3. Remove the Main Cover screws (item 15).
Figure 7-25. Hub Wear Inspection 4. Pry the cover (item 16) or tap with a mallet
1826_006.tif
to loosen the cover’s seal to the housing.

5. Remove the cover from the housing.
6. Inspect inside cover for damage or wear.
Axle Shaft and Ring Gear Removal

1. Loosen the set screw locking the axle shaft
clamp nut (item 13).
Figure 7-28. Axle Shaft Clamp Nut Set Screw
1826_027.tif
Main Cover Removal

1. Remove the drain plug (item 17).
Figure 7-26. Drain Plug Removal
2610_067.tif
2. Use a screwdriver in the clamp nut slot to

turn the clamp nut off.
Figure 7-29. Clamp Nut Removal
2610_072.tif
2. Remove the fill level plug.

3. Remove thrust washer (item 10). Figure 7-32. Spiral Pinion Removal
2610_079.tif
4. Lift the ring gear from the housing.

5. Remove thrust washer, shim, and spacer
(items 10, 11, and 12).
6. Drive the axle from the housing using a
rubber mallet.
Spiral Gear and Helical Gear Removal

1. Remove the set screw locking the helical
gear clamp nut (item 14).
Figure 7-30. Clamp Nut Set Screw Removal
2610_077.tif
4. Lift the helical gear (item 3), spacer, and

bearing (item 2) from the housing.
5. Inspect the helical gear and the spiral gear
for damage or wear.
NOTE: The spiral pinion and ring gear are a
matched set. Their alignment is critical.
Do not replace them separately.
Bearing Cup, Shim, and Seal Removal

NOTE: The bearing cups and cones are usually
damaged during removal. They must be
2. Use a screwdriver in the clamp nut slot to
replaced as sets.
turn the clamp nut off. (The gear may need
to be wedged to keep it from turning.) 1. Use a mallet and a long punch to drive the
Inspect the clamp nut for damage. lower pinion bearing cup (item 7) from the
Figure 7-31. Remove Clamp Nut
housing.
2610_078.tif
NOTE: If axle and pinion bearing seat

dimensions are not recorded (stamped)
on the inside of the drive unit housing,
save the shims to use for reference at
reassembly.
Figure 7-33. Lower Pinion Bearing Cup Removal
2610_081.tif
3. Use a rubber mallet to drive the spiral

pinion (item 4) from the housing.
NOTE: If axle and pinion bearing seat
reassembly. 2. Use a mallet and punch to drive the upper
pinion bearing cup (item 2) from housing.


Figure 7-34. Upper Pinion Bearing Cup Removal Figure 7-36. Inner Axle Bearing Cup Removal
2610_082.tif 2610_076.tif
3. Remove the outer axle bearing cup (item 8)

(toward the axle) and axle seal (item 5) 5. Visually inspect the housing bores and
from the housing using the punch and sealing surfaces for damage or wear.
mallet.
Figure 7-35. Axle Shaft Bearing Cup Removal
Housing Cleaning and Inspection
2610_075.tif
Thoroughly degrease the housing. Visually

inspect the entire housing again for excessive
damage, cracks, or wear.
Axle Shaft Disassembly
Always watch for pinch points when

using a press or pressing tools.
1. Place a bearing puller clamp beneath the

4. Use a mallet and punch to drive the inner outer axle bearing cone (item 8).
axle bearing cup (item 9) (toward the ring 2. Press the bearing from the axle using a
gear) from the housing. bearing press and a 6 in. tube.
NOTE: If axle and pinion bearing seat Figure 7-37. Press Bearing from Axle
2610_084.tif

reassembly.
3. Inspect the axle for damage or wear.
Pinion Gear Shaft Disassembly

1. Place a bearing puller clamp beneath the
bearing cone (item 7) on the spiral gear.


Figure 7-38. Lower Pinion Bearing Removal
2610_087.tif
2. Press the bearing from the pinion gear

shaft.

Assembly Example Ring Gear Shim Calculation

Bearing seat dim. from housing 3.7175 in.
Mounting distance from ring gear –1.8120 in.
Minimum bearing height –1.1875 in.
Safety glasses are required.
Minimum thickness of spacer –0.4630 in.
Minimum thickness of washer –0.2175 in.
Prepare the housing for assembly by running a
tap through all bolt and screw holes. Starting Shim Thickness Req’d 0.0375 in.
Shim Calculation Actual Ring Gear Shim Calculation

Bearing seat dim. from housing _______ in.
NOTE: Drive Units built after November 2009
have the axle and pinion bearing seat Mounting distance from ring gear –_______ in.
dimensions recorded (stamped) on the Minimum bearing height –1.1875 in.
inside of the drive unit housing. Minimum thickness of spacer –0.4630 in.
1. Determine pinion shim starting thickness. Minimum thickness of washer –0.2175 in.
Starting Shim Thickness Req’d ______ in.
a. Record pinion bearing seat dimension
from housing.
Bearing Cup Installation
b. Record mounting distance etched on
pinion shaft. 1. Press upper pinion bearing cup (item 2)
into housing. Place the spiral gear shims
c. Determine shim thickness required for (0.015 in. [0.38 mm] thickness) in the
pinion. housing, then place the bearing cup
(item 7) in the housing.
Example Pinion Shim Calculation
Figure 7-39. Upper Pinion Bearing Cup Installation
Bearing seat dim. from housing 5.9020 in. 2610_093.tif
Mounting distance from pinion –4.9380 in.

Shim Thickness Required 0.0265 in.
Actual Pinion Shim Calculation

Bearing seat dim. from housing _______ in.
Mounting distance from pinion –_______ in.
Shim Thickness Required _______ in.
2. Determine ring gear shim thickness. 2. Turn the drive unit housing over. Insert
a. Record axle bearing seat dimension correct shim thickness (calculated - refer
from housing. to “Shim Calculation”) into lower pinion
bearing seat.
b. Record mounting distance etched on
3. Press the lower pinion bearing cup (item 7)
ring gear.
in the housing.
c. Determine shim thickness required for
ring gear. NOTE: A setup bearing can be made by having
the outside of the cup turned down to
2.6130 in. so pressing and pulling it is
not required during the setup process.


Figure 7-40. Lower Pinion Bearing Cup Installation
2610_092.tif
Bearing can become extremely hot. Use

gloves to protect hands from burns.
1. Use a bearing heater to preheat pinion

shaft bearing cones (items 2 and 7) to
300ºF (150ºC) maximum.
Figure 7-43. Preheating Bearing Cone
1826_087.tif
4. Install the inner axle bearing cup (item 9)

in the housing bore using a press or
mallet.
Figure 7-41. Inner Axle Bearing Cup Installation
2610_095.tif
NOTE: Steps 2 thru 5 must be completed before

the bearing cools for correct installation.
2. Slide a preheated pinion shaft bearing
cone (item 7) onto the spiral pinion gear
shaft.
NOTE: Wipe away any chips or excess metal 3. Gather helical gear and pinion clamp nut.
pieces resulting from installation.
NOTE: Handle helical gear with care during the
5. Install the outer axle bearing cup (item 8) entire assembly process. Do not allow
in the housing using a mallet or press. the gear teeth to be nicked or damaged.
Figure 7-42. Outer Axle Bearing Cup Installation 4. Place second preheated pinion bearing
2610_094.tif
cone into the top bearing cup (item 2)

(traction motor flange on housing must be
facing up).
Figure 7-44. Upper Pinion Bearing Cone Installation
2610_098.tif
Spiral Pinion and Helical Gear Installation

NOTE: The Spiral Pinion and Ring gears are a
matched set (item 4). Their alignment is
critical. Do not replace them separately.

5. Place helical gear (item 3) onto top pinion ends of the pinion clamp nut do not touch
bearing cone (item 2). after the locking screw is torqued down.
NOTE: Install helical gear with the word “UP” 11. Check the rolling torque. The rolling
stamped on the gear facing up. The gear torque must be 5 to 8 in. lb.
hub face that is flush with the outside (0.6 to 0.9 Nm)
surface of the gear should face down 12. Tighten or loosen the pinion nut, as
and touch the bearing. necessary, to attain the correct rolling
6. Insert pinion gear up from bottom of torque.
housing, through pinion bearing cone and NOTE: Less than 1/16 of a turn on the pinion
helical gear. nut will have an effect on the rolling
7. Install helical gear clamp nut onto spiral torque.
pinion shaft. Rotate the helical gear
incrementally, bringing the clamp nut Axle Assembly/Installation
torque to approx. 35 ft. lb. (47.5 Nm) to 1. Use a bearing heater to preheat axle
seat the pinion bearings and the helical bearing cones (items 8 and 9) to 300ºF
gear. (150ºC) maximum.
Figure 7-45. Install Clamp Nut 2. Apply thread-locking compound
2610_099.tif
(P/N 990-543) to the OD of the axle seal

(item 5) and install into housing.
Bearing can become extremely hot. Use

gloves to protect hands from burns.
NOTE: Steps 3 thru 7 must be completed before

the bearing cools for correct installation.
3. Press outer axle bearing cup (item 8) onto
axle shaft (item 6).
8. Check rolling torque of pinion gear. Rolling
torque must be 5 to 8 in. lb. (0.6 to 4. Gather axle bearing cone (item 9), spacer
0.9 Nm). Tighten or loosen the clamp nut, (item 12), shim stack (item 11) (calculated
as necessary, to attain the correct rolling - refer to “Shim Calculation” on
torque. page 7-32), thrust washer (item 10), ring
gear (item 4), thrust washer (item 10), and
NOTE: If necessary, loosen the pinion nut and axle shaft clamp nut (item 13).
strike the pinion gear with a punch in
the drill center to slide the bearing cone 5. Rotate unit so ring gear cavity is facing up.
on the pinion gear to loosen the rolling Lightly oil axle bearing cone (item 9) and
torque. Retighten the pinion nut as set into cup that is already pressed into
required. the housing. Place spacer (item 12) on axle
bearing, then shim stack (item 11), and
9. Apply thread-locking compound thrust washer (item 10), in that order.
(P/N 990-669) to clamp nut and locking Insert ring gear (item 4) under pinion gear.
screw threads after shimming is correct Make sure tooth marked “X” on pinion gear
and final assembly is being completed. is between two teeth marked “X-X” on ring
10. Tighten the nut onto the spiral pinion gear.
shaft to approx. 22 to 23 ft. lb. (30 to 6. Insert axle shaft (item 6) up through
31.2 Nm) and tighten the locking screw to bottom of housing, through spacer, shims,
140 in. lb. (15.8 Nm). Make sure the open thrust washer, and ring gear. Install

second thrust washer (item 10) and axle Figure 7-46. Ring Gear Contact Patterns
Ds10.tif
shaft clamp nut (item 13) onto axle.

NOTE: Do not use thread-locking compound on
clamp nut until shimming is correct.
7. Clamp helical gear to keep gear assembly
from rotating. Torque clamp nut (item 13)
to 125 ft. lb. (170 Nm). Additional torque
may be required to pull axle up through
heated bearing. Re-adjust to correct torque
setting. Remove clamp, then using torque
wrench on axle shaft clamp nut, rotate
gear assembly 11 times to re-align “X” on
pinion gear with “X-X” on ring gear (to seat
bearings). Replace clamp and re-torque
axle shaft clamp nut. Ideal
Contact
8. Make sure “X” on pinion gear is aligned to Pattern
“X-X” on ring gear. Using a dial indicator,
check backlash at the large spiral bevel
ring gear, by firmly rotating the large spiral
bevel ring gear back and forth, making
certain that the pinion gear is held
motionless. Rotate gear to the tightest
backlash location as determined by the
assembler and check backlash again.
NOTE: Clamp helical gear to achieve a more
accurate backlash reading.
9. If the lowest backlash reading is within
tolerance [0.004 to 0.010 in. (0.1 to
0.25 mm)], proceed to Step 10. If backlash
is not within tolerance, disassemble axle
ring gear assembly. Check for errors in 11. Disassemble the components and return
assembly of components or to Step 2 of “Bearing Cup Installation” on
contamination. If backlash is still not page 7-32. Follow procedures for
within tolerance, repeat steps 8 thru 11, reassembly.
adding or subtracting shims as necessary
until backlash is within tolerance.
(P/N 990-669) to clamp nut and locking
NOTE: Backlash may increase up to 0.003 in. screw threads. Install clamp nut onto axle
(0.076 mm) after the heated bearings and torque to 125 ft. lb. (170 Nm). Torque
cool. locking screw to 140 in. lb. (15.8 Nm).
Make sure the open ends of the axle clamp
10. Apply marking compound to the ring gear
nut do not touch after the locking screw is
and check the contact pattern. See
torqued down. Check the axle gap
Figure 7-46. Add or remove shims as
(distance between axle and housing). This
required. After shimming is corrected,
is an indication that the bearings are
verify backlash is still within tolerance per
correctly seated and should measure
Step 9.
approx. 0.195 in. (4.95 mm).
13. Check that the mounting surface of the
cover plate and housing are free of paint,
dirt, and debris. Clean both surfaces with

isopropyl alcohol and allow surfaces to

dry. Apply RTV silicone gasket-forming
compound (P/N 990-659) to housing
surface. Install cover plate onto housing,
making sure drain hole in cover is on the
opposite side of the pinion gear. Install
screws (qty. 10) and torque to 6 to 8 ft. lb.
(8 to 10.8 Nm).
14. Install magnetic drain plug into cover plate
using gasket sealant compound
(P/N 990-520). Install “Check Level” plug
into housing finger tight and without
sealant.
15. Install dowel pins using thread-locking
compound (P/N 990-536).

Tire Replacement Drive and Brake
Tire Replacement measure how far hub is recessed inside

tire. The new tire must be placed in the
same position the old tire was installed on
hub. You can use a spacer (slightly smaller
in diameter than inside diameter of tire
Any misalignment of the tire and hub insert and same thickness as depth of
while the tire is being pressed onto the recess) to obtain correct amount of
hub can damage the hub. For this recession.
reason, chamfers are provided on the 4. Position hub assembly with old tire on top
outside edge of the hub and on the end of circular ram so outside of wheel is
of the inside diameter of the tire’s metal positioned upward. The outside edge of
insert. The chamfers help to center the hub has a chamfer to help guide new tire
hub and tire during the pressing onto wheel. The chamfered edge must
operations and reduce the possibility of always be leading edge when a tire is
misalignment. To prevent damage, the pressed onto hub.
hub must be installed on the circular
ram with its chamfered side up. 5. Center hub assembly on top of ram and
make sure that they mate squarely.
1. Check inside surface of metal insert on 6. Position new tire with its chamfered insert
new tire. Use sandpaper to remove any facing hub. Align new tire and hub so that
scaling or rust. Clean inside of metal they are concentric.
insert and lubricate it with a soap 7. Begin pressing new tire onto hub and old
solution. tire off wheel. Run press slowly for the first
2. Place a circular ram on the press table. few inches of travel, because this is the
See Figure 7-47. To allow complete critical stage of the operation. If tire begins
removal of the old tire, the ram must be to cock to one side, stop press and realign
longer than the width of the old tire. The tire. A sharp jar with soft-headed mallet
outside diameter of the ram must be small usually realigns tire on hub.
enough to fit loosely in the insert of the
NOTE: If new tire does not press on with a
tire, but must be large enough to rest
minimum of 5 tons (68,947 kPa)
squarely on a flat surface on the outer
pressure, replace hub.
edge of the hub.
8. Release press. Remove wheel, tire
Figure 7-47. Drive Tire Installation
2453_200.eps assembly, and old tire from press table.
Outside of Hub Inspect wheel and tire assembly.
and Tire Assembly
New Tire
Worn Tire
Circular Ram
Press Table
3. If outside edge of hub is not flush with
edge of metal insert in the old tire,

Drive and Brake Brakes
Brakes 6. Remove nut and washer from motor shaft.

7. Remove the three bolts that hold the brake
assembly to the motor. Lift the brake
Inspection assembly off the traction motor.
Check the gap between the brake coil and

armature disk. The gap should measure 0.004
Disassembly
to 0.020 in. (0.1 to 0.5 mm). If gap exceeds 1. Remove the three bolts that hold the lower
0.020 in. (0.5 mm), remove and disassemble the friction plate to the brake coil.
brake assembly to check components. 2. Remove and inspect the brake friction
disc.
Removal 3. Clamp brake assembly in vise or use “C”
1. Lower the forks all the way and tilt clamps.
forward. 4. Remove the brake release bolts and top
2. Turn the key switch OFF and disconnect friction plate from the brake coil.
the battery connector. NOTE: When removing the top friction plate
3. Remove the front covers. from the brake coil, hold the coil
inverted so the brake springs remain in
4. Cut the cable ties joining the brake coil
the coil assembly.
harness and the speed feedback sensor
harness and temperature sensors. 5. Check the thickness of the friction disk. If
Disconnect the brake coil assembly the thickness is less than 0.235 in.
electrical connector JPB4 or JPB3 from (6 mm), replace the friction disk.
the lift truck’s harness. 6. Check the top and bottom friction plates.
5. Install the brake release bolts. Tighten to Replace them if worn more than 0.003 in.
release the brake. (0.08 mm).
Figure 7-48. Brake Release Bolt Installation
2453_200.eps
Assembly
1. Place the springs evenly in the holes in the
brake coil. (There may be fewer springs
used than there are holes.)
2. Place the top friction plate over springs.
3. Carefully clamp assembly together.
4. Install the two brake release bolts and
tighten.
5. Center the friction disc on the upper
friction plate.
(P/N 990-536) to the three bolts previously
removed and place them through the
brake coil assembly.
7. Secure the brake coil assembly to the
lower friction plate assembly. Torque to
9 ft. lb. (12 Nm).

Brakes Drive and Brake
Installation
1. Install the brake assembly onto the
traction motor. Make sure the friction disc
fits over the splined hub.
2. Tighten the three mounting bolts to
13 ft. lb. (18 Nm).
3. Install nut and washer on motor shaft.
Torque to 120 ft. lb. (163 Nm).
4. Remove the brake release bolts and store
for future use.
Make sure that all the brake release

bolts are removed before using the lift
truck. The brake will not work if the
brake release bolts are not removed.
5. Plug the wiring harness connector from

the brake coil into the connector from the
VM (JPB4 for the right brake coil; JPB3 for
the left brake coil).
6. Re-install the front covers.
the key switch ON.
8. Check the operation of the brake. Travel
with a rated load traveling forks-first at
full speed, depress the EPO button. The
lift truck should stop within one and one
half truck lengths. This distance varies
depending on floor and tire conditions.

Drive and Brake Brakes

Electrical Components
Electrical Components

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 7-49 and
to 1475 kg). Use extreme care during
Figure 7-50.
replacement. Use a suitable battery
moving device or hoist for lifting. Do not Figure 7-49. Battery Cable and Connector
extend a battery more than 1/3 of its Battcon2.tif
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 battery cables are pulling
Figure 7-50. Battery Cable Removal from Connector
out of the connector. Battcon1.tif
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 2. Do not attempt to repair battery cables by

Installation crimping new terminals. Replace the
cable.
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
connector.
NOTE: When replacing battery cable ends,
remove only one end at a time from the
connector, to avoid the cable ends

Battery Procedures Electrical Components
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
25l6s014.eps
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
4. Inspect the battery cables to make sure maintaining your lift truck battery, consult the
they are not frayed or loose. Inspect the battery manufacturer’s specifications and
battery connector to make sure there is no instruction manual.
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
Figure 7-51. Battery Cable and Filler Plug battery.
09g6s047.tif
Battery Cable
6173_012.eps
Filler Plug
Vent Hole
Battery State-of-Charge
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 5-10 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.

Electrical Components Power Cables
Power Cables Table 7-1. 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
• damaged or overheated terminal lugs 4/0 1002215/013-015 1-1/16 in. (27 mm)
• damaged mounting hardware or brackets

Table 7-2. 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
marking is missing or is not readable, remark 3/0 1002217/007-009
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 cable into terminal.
tools. Crimping tool, lugs, and 6. Place cable and terminal into tool die and
heat-shrink are available through the crimp. Refer to pictures below for what
Parts Distribution Center. Failure to use completed crimps should look like.
correct cables, terminal hardware, and
torque values can result in overheating Figure 7-52. Short Barrel Terminal
and damage to components. 7FIG1_LUGS.jpg
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.
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 7-1 and
Table 7-2.

Power Cables Electrical Components

Figure 7-53. Long Barrel Terminals
7FIG2_LUGS.jpg
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.

Electrical Components Motors
Motors DC Motor Service

Motor Brushes
General
Inspection
Power Cable Terminals
Figure 7-54. Motor Brush Location
Mtrbrush.tif
Table 7-3. 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 Bottom Nut: 10.7 to 11 ft. lb.
(14.5 to 15 Nm)
Steer Motor Top Nut: 7.5 to 9.2 ft. lb.

(10.2 to 12.5 Nm)
Bottom Nut: 9.2 to 11.7 ft. lb.
(12.5 to 15.9 Nm)
85 to 94 in. lb.
Power Amplifiers
(9.6 to 10.6 Nm)
Contactor - M6 50 in. lb. (5.6 Nm)

steel
Contactor - M8 180 in. lb. (20.3 Nm)

steel Conduct a partial inspection of the motor
Contactor - M8 70 in. lb. (7.8 Nm) during scheduled maintenance. If the truck is
brass/copper operated in a severe or caustic environment or
is used in an extended duty cycle application,
inspect the motor more frequently.
DC Motor Troubleshooting
Set up and rigidly adhere to a strict inspection
See “DC Motors” on page 5-5. schedule to obtain the maximum efficiency
from the electrical equipment.
AC Motor Troubleshooting
Each partial inspection of the motor must
include:
See “AC Motors” on page 5-8.
1. Inspect the brushes for wear and for
correct contact with the commutator.
Record the level of wear on the brushes.
This history provides an indication of
whether a brush must be changed or if it
can wait until the next inspection. Refer to
Table 7-4 on page 7-48 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.

Motors Electrical Components
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 operator compartment 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 Figure 7-55.
insulating parts. See “Power Cable
Figure 7-55. Motor Brush Spring Tension Inspection
Terminals” on page 7-46. 8b16032s.eps
7. Check all the cap screws around the frame Spring

for tightness. Scale
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.
If the end of the brush is not already contoured Paper

to fit the commutator, seat the brush to the
commutator:
NOTE: If the motor commutator is not
accessible, form the brush contour
using a brush seating stone. Rotation
1. Move the motor brush springs out of your Pull paper in direction of rotation
way. 5. Place a small leather loop around the coil
2. Wrap a piece of 00 sandpaper around the spring for the brush. If the brush spring
commutator. Do not use emery cloth to has a loop at the brush, hook the spring
seat brushes. scale directly to the spring.
3. Move the brushes back down into their 6. Attach a 5 lb. (2.27 kilogram) spring scale
holders. Rotate the armature until the face to the leather loop.
of the brushes are contoured to match the
curve of the commutator.

7. While gently pulling the scale outward, 4. Disconnect power cables. Note locations
slowly pull the paper strip in the direction for reassembly later.
that the commutator normally rotates. 5. Remove the terminal board.
8. When the paper strip begins to move
freely, the spring scale will read the spring
brush tension.
Use correct electrostatic discharge
9. Refer to Table 7-4 for correct spring
precautions. See “Static Precautions” on
tension.
page 2-7.
Table 7-4. Minimum Brush Length and Spring Tension
6. Mark the position of the top end bell and
Min. bottom end bell relative to the stator, then
Motor Brush Spring Tension remove the snap ring.
Length
7. Remove the brake mounting motor flange.
Lift 0.62 in. 40 to 65 oz.
NOTE: Use new flange mounting bolts when
(4100 only) (15.7 mm) (1134 to 1842 grams)
reassembling.
0.50 in. 12 to 30 oz.
Steer 8. Remove the four bolts that secure the top
(13 mm) (907 to 1134 grams)
end bell to the bottom end bell.
Note: Brush holder assemblies on Steer Motors 9. Remove the top end bell using a puller.
S/N K0853258 and lower can cause
Use care that the encoder bearing remains
brush/commutator related failures. A replacement
in the bottom end bell to reduce the
brush holder assembly is available through the
Raymond Parts Distribution Center. chance of damaging the bearing.
10. Install a new temperature sensor using the
10. Repeat steps 3 thru 9 for the remaining high temperature silicone (neutral curing)
brushes. supplied with the temperature sensor.
Mount the sensor close to the location of
the original. Secure the cable with a cable
AC Motor Service tie to one of the power leads for stress
relief.
AC traction and lift motor service is limited to
Encoder Bearing Assembly and Temperature 11. Install the top end bell in the position that
Sensor replacement. was previously marked. Verify correct
stator installation and install snap ring.
AC Motor Temperature Sensor 12. Secure the top end bell to the bottom end
bell using the four bolts previously
Temperature sensors in the AC traction and lift removed.
motors are integral to the motor. When a motor 13. Install the brake mounting motor flange
temperature sensor fails, it can be replaced with new mounting bolts.
using the procedures below. 14. Re-install the brake assembly including
the rotor hub mount and rotor hub.
Traction Motor Temp Sensor Replacement
15. Install the terminal board, reconnect
1. Turn the key switch OFF and disconnect JPTA3 and power cables. Torque motor
the battery connector. cable securing nuts to 18 ft. lb. (24 Nm).
2. Remove the brake assembly including the 16. Reconnect the battery connector and turn
rotor hub nut and rotor hub. Note the the key switch ON.
number of spacers used.
3. Disconnect the temperature sensor Lift Motor Temp Sensor Replacement
connector JPTA3. 1. Turn the key switch OFF and disconnect

Motors Electrical Components
2. Disconnect the temperature sensor 6. Remove the terminal board.

connector JPLA3.
3. Disconnect cables and motor harness
connections, making sure that you note
locations for reassembly later.
4. Separate the pump assembly from the lift page 2-7.
pump motor and remove lift pump motor.
5. Remove the four bolts that secure the top 7. Remove the steering position reference
end bell to the bottom end bell. bracket.
6. Remove the top end bell. Use care that the 8. Remove the traction motor. See “Removal”
bearing remains in the bottom end bell to on page 7-51.
reduce the chance of damaging the 9. Remove the nut that secures the pinion
bearing. gear. Remove the gear and key using a
7. Install a new temperature sensor using the suitable puller.
high temperature silicone (neutral curing) 10. Mark the position of the top end bell and
supplied with the temperature sensor. bottom end bell relative to the stator, then
Mount the sensor close to the location of remove the snap ring.
the original. Secure the cable with a cable
11. Remove the brake mounting motor flange.
tie to one of the power leads for stress
relief. NOTE: Use new flange mounting bolts when
8. Carefully press the top end bell to the reassembling.
stator. Do not pinch the cables or allow 12. Remove the four bolts that secure the top
contact with the rotor. Verify correct stator end bell to the bottom end bell.
installation.
13. Remove the top end bell and bottom end
9. Secure the top end bell to the bottom end bell using a puller.
bell using the four bolts previously
14. Remove the clamps that secure the
removed.
encoder bearing cable.
10. Reinstall lift motor to the lift pump
15. Remove the encoder bearing from the rotor
assembly.
using a suitable puller, pulling on the
11. Reconnect JPLA3 and power cables. outer race only.
12. Reconnect the battery connector and turn 16. Remove the oil seal to allow pressing of the
the key switch ON. bottom end bell to the stator for later
reassembly.
AC Motor Bearing Encoder 17. Make sure that the O-ring and wave
washer are correctly positioned in the
Traction Motor Encoder Replacement bottom bell bearing pocket.
1. Turn the key switch OFF and disconnect 18. Position the new encoder bearing in the
the battery connector. 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. 19. Use an assembly bushing on the outer
3. Disconnect the temperature sensor race and press the bearing into place. Do
connector JPTA3. not press on the encoder part of the
bearing.
4. Disconnect the bearing encoder connector
JPTA2. 20. Re-install encoder bearing cable clamps.
5. Disconnect power cables. Note locations
for reassembly later.

21. Install the top end bell in the position that 6. Remove the top end bell using a suitable
was previously marked. Verify correct puller.
stator installation and install snap ring. 7. Remove the encoder bearing from the
22. Carefully press the bottom end bell to the rotor, pulling on the outer race only.
stator. 8. Install the new encoder bearing by
23. Secure the top end bell to the bottom end applying steady pressure to the inner ring.
bell using the four bolts previously 9. Carefully press the top end bell to the
removed. Re-install oil seal. stator. Do not pinch the cables or allow
24. Install key, pinion gear, and nut to the contact with the rotor. Verify correct stator
bottom of the traction motor. Re-install installation.
traction motor. See “Installation” on 10. Secure the top end bell to the bottom end
page 7-51. bell using the four bolts previously
25. Install the brake mounting motor flange removed.
with new mounting bolts. 11. Install lift motor and reconnect lift pump
26. Re-install the brake assembly including assembly. See “Lift Motor” on page 7-53.
the rotor hub mount and rotor hub. See 12. Reconnect JPLA2, JPLA3, and power
“Brakes” on page 7-29. cables.
27. Install the terminal board, reconnect 13. Reconnect the battery connector and turn
JPTA2, JPTA3, and power cables. Torque the key switch ON.
motor cable securing nuts to 18 ft. lb.
(24 Nm).
28. Re-install steering position reference
bracket and filler tube if previously
removed.
the key switch ON.
Lift Motor Encoder Replacement


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 lift pump motor.
5. Remove the four bolts that secure the top
end bell to the bottom end bell.

Traction Motors Electrical Components
Traction Motors c. As you turn the bolts, the traction

motor pushes upward, breaking its seal
to the drive unit. See Figure 7-57.
Removal Figure 7-57. Traction Motor Removal, Breaking Seal
8D14068S.TIF

the battery connector. Traction Motor
2. Remove the three front covers.
3. Remove the mast.
4. Remove the brake assembly.
5. Remove the friction plate retaining nut.
6. Remove the friction plate.
7. Disconnect the three power cables from
the terminals on the traction motor and Bolt in “Blind” Hole
label for later installation. Use two Drive Unit
wrenches to avoid twisting the terminal
studs.
8. Disconnect JPTL2 (left) or JPTR2 (right)
and JPTL3 (left) or JPTR3 (right). The traction motor is heavy. Use a
9. Place a drain pan beneath the drive unit. suitable lifting device to move it if
Remove the drain plug and drain approx. necessary.
two pints (one liter) of drive unit oil. This
prevents oil from spilling when the traction 12. Lift the traction motor off the drive unit.
motor is removed. See Figure 7-56. 13. If you are not reinstalling a traction motor,
use plastic film and masking tape to seal
Figure 7-56. Drive Unit Drain Plug the opening for the traction motor so that
8D14066S.TIF
no debris can fall into the drive unit.

14. Remove the pinion gear from the traction
motor shaft.
Installation
1. Thoroughly clean the mating areas on the
traction motor shaft and pinion gear.
2. Correctly install the pinion gear on the
traction motor shaft (taper correctly
oriented). Apply thread-locking compound
(P/N 990-536) and install nut. Torque to
10. Remove the four bolts that attach the 45 ft. lb. (61 Nm).
traction motor to the top of the drive unit. 3. Thoroughly clean the mating areas on the
11. To break the seal between the traction top of the drive unit and the bottom of the
motor and drive unit: traction motor mounting flange.
a. Install two of the bolts you removed in 4. Apply a coat of gasket cement
step 10 into the two “blind” holes on the (P/N 990 556) to the mating surface on
traction motor mounting flange. the top of the drive unit. A gasket
(P/N 828 013-978) may be used instead of
b. Evenly turn each bolt clockwise. the gasket cement.

Electrical Components Traction Motors
5. Position the traction motor on top of the

drive unit and align the mounting holes.
(P/N 990-536) to the four motor mounting
bolts and install the bolts. Torque to
13 ft. lb. (17.6 Nm).
7. Install the brake assembly.
8. Reconnect the cables to the terminals on
the traction motor. Use two wrenches to
avoid twisting the terminal studs. Torque
cable securing nuts to 205 to 220 in. lb.
(23 to 25 Nm).
9. Reconnect the harnesses to the traction
speed feedback sensors and temperature
sensors.
10. Add gear oil to the drive unit through the
filler plug hole.
12. Install the front covers.
the key switch ON.

Lift Motor Electrical Components
Lift Motor Installation

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

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

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

terminal lugs 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 7-44. Failure to use correct
cables, flanged nuts, and torque values
can result in overheating and damage to
components.
4. Reinstall the bus bar and reconnect the

power cables to the correct terminals.
Torque to 85 to 94 in. lb. (9.6 to 10.6 Nm).
NOTE: When correctly torqued, the cable and
terminal can rotate up to 5° in either
direction.
5. Reconnect JT1.
the key switch ON.

Wiring and Harness Connectors Electrical Components
Wiring and Harness When replacing wires, follow these guidelines:

• Use the appropriate tools to remove and
Connectors 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.
Molex Connectors
Repair
Molex connectors have pins with locking ears
that engage ridges in the plastic connector
body. See Figure 7-58.
precautions. See “Static Precautions” on Figure 7-58. Molex Connectors - End View
page 2-7.
MOLEX.WMF
When pulling a wire out through a bundle, cut Pin

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

Locking Ears
new wire. In other cases, it is easier to secure a
new wire to the outside of the existing wire
bundle with cable ties of an appropriate size. To remove a pin from a Molex connector, these
locking ears must be depressed far enough to
The failed wire can be left in the bundle, or can clear the ridge in the connector.
be pulled by one end to remove it from the
bundle.

Electrical Components Wiring and Harness Connectors
Pin Extraction Pin Insertion

1. To insert a pin into a Molex connector,
To remove a pin from a Molex connector, use
insert the pin into the back side of the
pin extraction tool P/N 950-026. See
connector and push the wire all the way in
Figure 7-59.
until it clicks.
1. Insert the extraction tool over the pin and
2. The locking ears have now engaged the
push all the way into the connector. This
connector.
releases the locking ears on the pin.
2. Pull the wire and pin from the connector.
Figure 7-59. Pin Extraction Tool

MOLEX1.WMF
Tool Inserted Over Pin

Top View
Locking Ears
Extraction Tool
Side View
AMP Water-Resistant
Connectors
AMP connectors provide water-resistant
connection by the use of seals between wires
and connectors and between the mating
connector halves.
To maintain the integrity of water-resistant

seals, use the following procedures when
working with AMP connectors. See Figure 7-60.


Figure 7-60. AMP Water Resistive Connectors
4570_001.tif
Wire Seal
Interface Seal
Contact Cavity
Wire Seal
Jack Housing
Pin Contact
Pin Housing
Sealing Plug
Pin Extraction Figure 7-61. AMP Pin Extraction Tool

4570_009.tif
Extraction Tool
To aid in separating AMP connectors, use
unlatching tool P/N 950-042. To remove a pin
from an AMP connector, use pin extraction tool
P/N 950-009.
1. While holding the wire seal, push the
selected wire forward, then insert the
extraction tool into the contact socket.
2. Pull the wire gently until you feel the
contact locking lances disengage.
3. Holding the wire seal and connector
housing together, rotate the wire while
pulling it through the wire seal. See
Figure 7-61. This prevents damage to the
seal.
Locking Lance

Pin Insertion Figure 7-64. Sealing Plug

4570_005.tif
1. Make sure the connector has a wire seal

attached to the connector back. See
Figure 7-62.
Figure 7-62. Wire Seal

4570_002.tif
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.
2. If re-inserting a wire previously removed, 4. Sealing plugs can be removed by pulling

check the pin contact locking lances to with needle-nose pliers while grasping the
make sure they are extended to their wire seal and connector.
original position. See Figure 7-63. 5. Use an interface seal between pin and jack
halves of the connector. To prevent
Figure 7-63. Wire Insertion damage to the seal, use the matching
4570_004.tif
connector cap to slide the interface seal

over the contact silos on the pin housing.
See Figure 7-65.
Figure 7-65. Interface Seal

4570_003.tif
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. 6. When mating connectors, make sure
polarized silos are correctly oriented. Push
pin and jack halves of the connector
Seals together until locking latches engage. See
1. Use a wire seal at the back (wire end) of Figure 7-66.
each connector half. See Figure 7-64.
2. Plug unused pin positions with sealing
plugs.


Figure 7-66. Latching Amp Connector
4570_006.tif

AMP Harness/Traction Power

Amplifier Connector
Connector Components
Figure 7-67. Power Amp Connector Components

amp006.tif
(PT-1 on Traction Power

Amplifier)
(JT-1)
Disassembly (Contact Removal) Contact Insertion

1. Insert a 4.8 mm screwdriver blade between
The axial concentricity of the crimped contact
the mating seal and one of the red wedge
must fall into an area defined by a 2 mm
lock tabs. See Figure 7-67.
diameter cylinder whose center is the centerline
2. Pry the wedge lock to the open position. of the contact front end. See Figure 7-69.
3. While rotating the wire back and forth over
a half turn (1/4 turn in each direction), Assembly
gently pull the wire until the contact is
removed. See Figure 7-68. Make sure the wedge lock is open.
1. To insert a contact, push it straight into
Figure 7-68. AMP JPT1 Connector
amp001.tif the appropriate circuit cavity as far as it
goes. See Figure 7-69. (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 7-69. (c).


Figure 7-69. Contact Insertion
amp005.tif,amp004.tif
3. After all contacts are inserted, the wedge

lock must be closed to its locked position.
Release the locking latches by squeezing
Be very careful when putting the wedge
them inward. See Figure 7-70.
lock in the locked position. Forcing the
Figure 7-70. Wedge Lock Latches
wedge lock can cause damage to the
amp003.tif
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 7-71.


Figure 7-71. Wedge Lock Flush With Housing
amp002.tif
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
Hydraulic Components

Hydraulic Components Manifold Solenoids, Fittings, and Attachments
Manifold Solenoids,
Fittings, and
Attachments
Table 7-5 provides torque specifications for
manifold components.
Table 7-5. Main Manifold Torque Specifications
Valve/Fitting Torque Coil Nut Torque

Component Function
ft. lb. (Nm) ft. lb. (Nm)
SOL1 Load Hold 60 (80) 5 (6.8)
SOL2 Lift/Lower 100 (135) Finger Tight
SOL3 Lift Relief 37 (50) Finger Tight
SOL4 Priority Bypass 37 (50) 12 (16)
SOL5 Aux Proportional Relief 25 (35) 5 (6.8)
SOL6 Aux Select 60 (80) 10 (14)
SOL7C/7R HSA (4200 Only) 27 (35) 7 (9.0)
SOL9L/9R L/R Sideshift 27 (35) 7 (9.0)
SOL10 Tilt 25 (35) 5 (6.8)
CV1 Check Valve 35 (47) N/A
N/A Filter Plug 30 (40) N/A
CB1, CB2 Counterbalanced Check Valve 35 (47) N/A

Manifold Solenoids, Fittings, and Attachments Hydraulic Components

Figure 7-72. Hydraulic Manifold (1 of 3)
1071691_1A.cgm
SOL7R SOL9L SOL9R SSR Hydraulic Filter and Plug
SOL6
G2
SOL10 SOL7C AC CB1 CB2 SOL2
Expansion
Plugs
Bottom
View
CV1

Hydraulic Components Manifold Solenoids, Fittings, and Attachments

1071691_1C.cgm
SOL9L SOL9R
SOL7R SOL10 SOL7C
P1 SSL SSR
AA
G1
CYL
AUX-P TC TR AR

Manifold Solenoids, Fittings, and Attachments Hydraulic Components

1071691_1E.cgm
SOL5
SOL4
SOL1
SOL3
TANK CYL-P

Hydraulic Components Hydraulic Fluid
Hydraulic Fluid Model 4100

the key switch ON. Step on the deadman
Fluid Level pedal and lift the forks 6 to 12 in. (150 to
300 mm) off the ground.
To check the level of the hydraulic fluid in the
system: 2. Loosen (do not remove) the bleed screw on
the lift cylinder to let any air escape. See
1. Lower the forks to the floor.
Figure 7-76. Hold a shop rag close to and
2. Unscrew the fill cap from the hydraulic beneath the bleed screw to keep any
reservoir. hydraulic fluid from spraying out.
3. The hydraulic fluid should be 1/2 to 1 in.
Figure 7-76. Cylinder Bleed Screw
(13 to 25.4 mm) above filler screen. See 8D14012S.TIF
Figure 7-75. Reservoir capacity is approx.

5.0 gal (22 liters).
Figure 7-75. Hydraulic Fluid Filler Screen

8D14083S.TIF
Bleed Screw
Selecting Hydraulic Fluid Type

3. When all of the air has escaped and
See Lubrication Specification Chart on hydraulic fluid starts coming out of the
page A-2. bleed screw hole, securely tighten the
bleed screw.
4. Lower the forks all the way to the floor.
Bleeding the Hydraulic System
NOTE: When bleeding the hydraulic system,
You must bleed the hydraulic system whenever bleed all cylinders.
you:
5. Bleed the auxiliary system:
• Change the hydraulic fluid and filter a. Tilt the mast all the way forward and
• Change a hydraulic hose backward several times.
• Disconnect a hydraulic fitting b. If the lift truck has sideshift, shift the
• Notice that the load is bouncing carriage all the way to the left and right
several times.
• Remove a hydraulic cylinder
• Remove a hydraulic pump 6. Check the hydraulic fluid level.
• Remove the hydraulic reservoir 7. Add hydraulic fluid as needed.

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

Hydraulic Components Pressure Relief Valve
Pressure Relief Valve Figure 7-77. Uninstalled Circlip

D20013345-2.jpg
Measuring System Pressure

NOTE: To measure the system pressure, you
need a calibrated pressure gauge
capable of measuring 3000 psi (20684
kPa) at mid-range and the coupler to
attach to the manifold.
2. Remove the front covers.
3. Connect the pressure gauge to the test
port (G1) on the main hydraulic manifold.
the key switch ON. 2. Elevate the forks until the upper limit is
5. Place a maximum rated load (or heaviest reached.
load available) on the forks. 3. Continue to try and elevate. Using a 5/64
6. Elevate the forks. Record the pressure hex key, push in and turn the lift pressure
required to lift the load. Make sure the adjusting screw to obtain a pressure
load is elevated near the maximum rated reading 10% greater than that previously
height for that load when taking the recorded, ±50 psi (344 kPa).
pressure reading. NOTE: A 5K lift truck may need +50 psi
7. Lower the forks and remove the load. (344 kPa) over the 10% value.
NOTE: Make sure to push the adjuster in when
Adjusting Pressure turning.
NOTE: The adjuster is very sensitive, and
changes pressure very quickly with very
little movement.
Be very careful not to lose the retaining
circlip on SOL3. 4. Turn the adjusting screw clockwise to
increase pressure; counterclockwise to
1. Use a jeweler’s screwdriver or other small decrease pressure.
tool to remove the retaining circlip on 5. Reinstall the circlip.
SOL3. See Figure 7-77. Save the clip to 6. Check the pressure again. If the value has
reinstall after pressure is set. changed, repeat this procedure until the
correct pressure reading is obtained.
8. Remove the pressure gauge.
9. Reinstall the front covers.

Cylinder Service Hydraulic Components
Cylinder Service Free Lift Cylinder - Install the plunger

retainer on the plunger. Install the
plunger/piston assembly into the cylinder
Main or Free Lift Cylinders - shell.
Model 4200 • TF/TT Masts - Pour 25 to 30 cc
hydraulic oil into the cylinder cavity
1. Remove the cylinder from the mast. See TF between the shell and rod. Tighten the
and TT Mast Service - Model 4200 on retainer to 280 to 300 ft. lb. (380 to
page 7-77. 407 Nm) using the claw spanner
2. Use a spanner wrench to remove the wrench and a strap wrench.
retainer. • Quad Masts - Pour 120 cc hydraulic oil
3. Remove the plunger/piston assembly from into the cylinder cavity between the
the shell. To remove the piston, refer to shell and rod. Tighten the retainer to 95
Piston Removal. to 125 ft. lb. (129 to 169 Nm) using the
claw spanner wrench and a strap
4. Remove the Hydraulic Fuse or fitting as
wrench.
equipped.
5. Inspect all components for nicks or burrs.
Minor nicks or burrs can be removed with Piston Removal
400-grit emery cloth.
1. Remove the plunger/piston assembly from
NOTE: Minor nicks are those that do not the cylinder shell.
bypass oil when under pressure. If they
cannot be removed with emery cloth, 2. Use a strap wrench and 400-grit emery
replace the part. cloth to secure the plunger while turning
the piston with a pin type spanner wrench.
6. Replace the retainer and piston seals, See Figure 7-78.
back-up rings, O-rings, and bearing.
Lubricate the new seals with petroleum Figure 7-78. Piston Removal
jelly prior to installation. MA0677.eps
NOTE: Observe correct seal direction. The

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

Hydraulic Components Cylinder Service
Quad Mast Check Valve

Inspection
Some Quad masts may experience drift if the
check valve(s) in the right side main lift cylinder
become loose.
1. Remove the right side main lift cylinder.
2. Remove piston.
3. Remove check valve. See Figure 7-79.
Figure 7-79. Quad Mast Check Valves

MA0677.eps
4. Inspect check valve. If the O-ring is

missing or damaged, replace the check
valve. Refer to Parts Manual.
5. Clean check valve and apply
thread-locking compound (P/N 990-403)
to circumference of check valve.
6. Re-install check valve and torque to 50 in.
lb. (5.65 Nm).
7. Repeat steps 3 thru 6 for remaining two
check valves.
8. Reassemble cylinder and install in mast.

Mast
Mast

Mast Mast Service
Mast Service down past the cylinder mount to install

the shim. See Figure 7-81.
Figure 7-81. Shim Installation

Upright Inspection - MA2004.eps
Model 4200
Inspect the thrust plugs. See Figure 7-80.
Bolt
Figure 7-80. Upright Inspection

MA1192.eps Shim
4
Thrust Plug Main Lift Cylinder
1
MA1192.eps
MA2004.eps
4. Carefully activate lift to raise the main lift

cylinder back into the cylinder mount.
Reinstall the bolt.
5. Repeat steps 3 and 4 until skewing is
If the wear surface is worn to less than 0.06 in. removed.
(1.5 mm), replace them.
Mast Removal
Inspect the lift chains. See Lift Chains on
page 4-11.
Mast Skewing - Model 4200 A hoist or lift truck of suitable capacity is

required for this procedure.
1. Extend the mast to the full lift height.
a. If the mast kicks to the right at full 1. Turn the key switch OFF and disconnect
extension, a shim must be installed to the battery connector.
the right hand main lift cylinder rod. 2. Remove the console, front covers, and
b. If the mast kicks to the left at full forks.
extension, a shim must be installed to 3. Reconnect the battery connector and turn
the left hand main lift cylinder rod. the key switch ON.
2. Place a 4 x 4 x 20 in. (10 x 10 x 50 cm) 4. Elevate the fork carriage approx. 18 in.
wood block between the upper (450 mm). Place blocks under the fork
intermediate and the upper outer cross carriage. Lower the fork carriage onto the
member. Lower the mast onto the block. blocks.
3. Remove the bolt from the cylinder to be 5. Turn the key switch OFF and disconnect
adjusted. Activate the lower control to the battery connector.
allow the center (free lift) cylinders to fully
retract. Tap the main lift cylinder rod

Mast Service Mast
6. Remove the lower mounting bolt only from 17. Remove the upper mounting bolt securing
each mast bearing cap. Do not remove the the mast pivot bearing cap on each drive
upper bolt. See Figure 7-82. unit. Remove the mast pivot bearing cap.
18. Use the hoist or other lift truck to lift the
Figure 7-82. Mast Pivot Bearing Caps
8D14030S.TIF mast just enough to allow it to be moved
away from the tractor.
19. Have wood blocks positioned to support
the mast off the floor.
20. Carefully lower the mast onto the support
blocks with the fork carriage facing down.
21. Note the number of shims between the
Oilite bearings and mast. See Figure 7-83.
Figure 7-83. Mast Pivot Bearing Parts

8D14035S.TIF
Drive Unit
Shims
Lower Mounting Bolts
Drive Wheel
7. Reconnect the battery connector and turn Mast
the key switch ON.
8. Elevate the fork carriage, remove the
blocking, and lower the fork carriage all
the way to the floor. Verify that the mast is
in a vertical position. Pivot
9. Position the lift truck beneath the hoist. Bearing Cap
Oilite Bearing
11. Wrap a chain or lifting strap around the
Mast Installation
top of the mast. Attach the chains or
straps to a hoist.
12. Lift the hoist just enough to take the slack A hoist or lift truck of suitable capacity is
out the chain or strap. required for this procedure.
13. Count the number of threads visible in
back of the tilt cylinder jam nut for 1. Make sure the pivot bearings are shimmed
reference in re-assembly. Loosen tilt as they were when the mast was removed.
cylinder jam nuts. Remove the piston from 2. Wrap a chain or lifting strap around the
the tilt cylinder pivot block. top of the mast. Attach the chains or
14. Reconnect the battery connector and turn straps to the lifting device.
the key switch ON. Actuate the tilt control 3. Slowly lift the mast up and off the wooden
and retract the tilt rams. blocks.
15. Turn the key switch OFF and disconnect 4. Slowly move the mast towards the truck.
5. Position the lower pivot bearings on the
16. Carefully lay the tilt cylinder down on the mast at the same height as the pivot yokes
brake assembly. Remove cable ties. on the drive units.
Disconnect the main feed hose.
Disconnect both auxiliary function hoses. 6. Carefully engage the mast pivot bearings
Cap all hoses. with the yokes on the drive unit.

Mast Mast Service
7. Place the mast pivot bearing caps over

both mast pivot bearings. Apply
thread-locking compound (P/N 990-536)
to the mast mounting bolts and install.
8. Reconnect the hydraulic hoses and cable
tie the auxiliary hoses.
the key switch ON.
10. Slowly extend the tilt rams until you are
able to thread the piston into the tilt
cylinder pivot block. Screw the jam nut
snug against the pivot block. Adjust so the
number of threads showing behind the
jam nut is the same as before removal.
11. Remove the lifting device and any
chains/straps used to lift the mast.
12. Slowly elevate and tilt the mast. Check for
any hydraulic leaks.
13. Elevate the fork carriage approx. 18 in.
(450 mm). Place blocks under the fork
carriage. Lower the fork carriage onto the
blocks.
15. Torque pivot bearing cap bolts to 43 ft. lb.
(60 Nm).
the key switch ON.
17. Elevate the fork carriage and remove any
blocking.
18. Install the forks.
19. Bleed the hydraulic system. See Bleeding
the Hydraulic System on page 7-68.
20. Install the covers.

TF and TT Mast Service - Model 4200 Mast
TF and TT Mast Service - NOTE: Roll the inner upright past the thrust
plugs before checking roller clearances.
Model 4200 4. Install the free lift chains to the inner
upright cross member chain anchors.
TF Mast Disassembly 5. Install the free lift cylinder.
6. Install the carriage. Refer to Carriage
1. Remove the mast assembly from the truck. Installation on page 7-81.
Refer to Mast Removal on page 7-74.
7. Turn the mast over.
2. Remove the main lift cylinders from the
mast. Refer to TF Mast Main Lift Cylinder 8. Install the main lift cylinders. Refer to TF
Removal on page 7-77. Mast Main Lift Cylinder Installation on
page 7-78.
3. Turn the mast over.
9. Install the mast to the truck. Refer to Mast
4. Remove internal reeving hoses. Installation on page 7-75.
5. Remove the free lift cylinders from the 10. Install the internal hose reeving hoses (if
mast. equipped). Refer to Internal Reeving -
6. Remove the carriage from the mast. Refer Model 4200 TF Mast on page 7-82.
to Carriage Removal on page 7-81.
11. Adjust the free lift chains. Refer to
7. Remove the cotter pins and pins fastening Adjusting Lift Chains - Model 4200 on
the free lift chains to the inner upright page 7-98.
chain anchors. 12. Check for mast skewing. Refer to Mast
8. Attach an overhead hoist to the inner Skewing - Model 4200 on page 7-74.
upright cross member.
9. Roll the inner upright downward to expose TF Mast Main Lift Cylinder
the upper and lower load rollers. Remove
the load rollers. Note the number of shims
Removal
behind each load roller. 1. Remove the mast from the truck. See Mast
10. Slide the inner upright out of the top of the Service on page 7-74.
outer upright. 2. Lay the mast down on wooden blocks as
11. Inspect upright. Refer to Upright shown. Block under the outer upright so
Inspection - Model 4200 on page 7-74. the inner upright is free to move. The
carriage must be positioned between the
blocks and free to move.
TF Mast Reassembly
3. Disconnect the cylinder supply hoses from
1. Lubricate the outer upright rails. See the cylinder inlet ports. Remove the special
Lubrication Specification Chart on long fittings from the cylinder ports and
page A-2. install plugs.
2. Attach an overhead hoist to the inner 4. Disconnect the hose and tube from the
upright. Install the inner upright through cylinder plungers.
the top of the outer upright. 5. Remove the snap rings fastening the
3. Assemble the load rollers on the stub cylinder rods to the inner upright.
shafts using the correct number of shims. 6. Pull the inner upright outward 2 ft.
The shims should be installed to provide a (50 cm).
total side to side clearance no looser than
0.06 in. (1.5 mm) at the tightest point 7. Lift the cylinder from the base mount and
throughout the travel in the upright. Use angle inward to remove through the gap at
an equal amount of shims on each side. the top of the uprights.

Mast TF and TT Mast Service - Model 4200
8. Note the number of shims (if equipped) on upright cross member. Tag the anchors for
each cylinder rod. reassembly.
12. Roll the inner upright downward to expose
TF Mast Main Lift Cylinder the intermediate and outer upright load
Installation rollers. Remove the load rollers. Note the
number of shims behind each load roller.
For installation, reverse the Removal procedure. 13. Attach an overhead hoist to the
Bleed the system. See Bleeding the Hydraulic intermediate upright. Remove the
System on page 7-68. intermediate upright through the top of
the outer upright.
TT Mast Disassembly
TT Mast Reassembly
1. Remove the internal hose reeving sheaves
and hoses from the mast. 1. Lubricate the outer upright rails. See
2. Remove the mast assembly from the truck. Lubrication Specification Chart on
Refer to Mast Removal on page 7-74. page A-2.
3. Remove the main lift cylinders from the 2. Attach an overhead hoist to the
mast. Refer to TT Mast Main Lift Cylinder intermediate upright. Install the
Removal on page 7-79. intermediate upright through the top of
the outer upright.
4. Remove the free lift cylinders from the
3. Install the thrust plugs.
mast.
5. Remove the carriage from the mast. Refer 4. Assemble shims and load rollers to the
to Carriage Removal on page 7-81. outer upright and lower intermediate
upright stub shafts. The shims should be
6. Remove the pins fastening the main lift installed to provide a total side to side
chains to the inner upright chain anchors. clearance no looser than 0.06 in. (1.5 mm)
Pull the main lift chains back through the at the tightest point throughout the travel
chain sheaves. in the upright. Use an equal amount of
shims on each side.
NOTE: Roll the upright past the thrust plugs
The chain anchor nuts should be used before checking roller clearances.
one time only and be replaced after
5. Lubricate the intermediate upright rails.
removal.
See Lubrication Specification Chart on
page A-2.
7. Remove the main lift chain anchors (long
anchors) from the inner upright lower 6. Attach an overhead hoist to the inner
back side. Tag the anchors for reassembly. upright. Install the inner upright through
the top of the intermediate upright. Adjust
8. Remove the free lift cylinder supply hose
thrust plugs with shims as required.
and sheave. Remove the main lift chain
sheaves. 7. Assemble shims and load rollers to the
intermediate upright top and inner upright
9. Roll the inner upright downward to expose
lower stub shafts. The shims should be
the inner and intermediate upright load
installed to provide a total side clearance
rollers. Remove the load rollers. Note the
no looser than 0.06 in. (1.5 mm) at the
number of shims behind each load roller.
tightest point throughout the travel in the
10. Attach an overhead hoist to the inner upright. Use an equal amount of shims on
upright. Remove the inner upright through each side.
the top of the intermediate upright.
NOTE: Roll the upright past the thrust plugs
11. Remove the main lift chain anchors (long before checking roller clearances.
anchors) and chains from the outer

TF and TT Mast Service - Model 4200 Mast
8. Install the chain sheaves and free lift hose 4. Remove bolts fastening the cylinder rods
sheave to the intermediate upright. Torque to the intermediate upright. Remove the
the cap screw to 26 to 30 ft. lb. (35 to bolts at the base of the cylinders that
40 Nm). attach the cylinders to the lower outer
9. Install the main lift chain anchors (long cross member.
anchors) and chains to the outer upright 5. Remove nuts from chain mounts. Remove
cross member using new nuts. mount from cylinder and lay over carriage.
10. Install the chain anchors (long anchors) to 6. Pull the inner and intermediate upright
the back side of the inner upright lower outward as required to allow the main lift
cross member using new nuts. cylinders to be removed.
11. Pull the main lift chains over the chain 7. Lift the cylinder from the base mount and
sheaves and attach to the lower inner angle inward to remove.
upright chain anchors. 8. Note the number of shims on each cylinder
12. Install the free lift cylinder supply hose rod.
clamp on the outer upright and route hose
over the sheave on the intermediate top
upright.
TT Mast Main Lift Cylinder
Installation
13. Install the carriage. Refer to Carriage
Installation on page 7-81.
For installation, reverse the Removal procedure.
14. Install the free lift cylinders. Bleed the system. See Bleeding the Hydraulic
15. Install the main lift cylinders. Refer to TT System on page 7-68.
Mast Main Lift Cylinder Installation.
16. Install the mast to the truck. Refer to Mast TT Mast Free Lift Cylinder
Installation on page 7-75. Removal
17. Adjust the main lift and free lift chains.
1. Lower the carriage completely. Remove
See Adjusting Lift Chains - Model 4200 on
forks or attachment if equipped. Make
page 7-98.
sure the free lift cylinder is completely
18. Check for mast skewing. Refer to Mast retracted. Attach an overhead hoist to the
Skewing - Model 4200 on page 7-74. top carriage bar.
19. Install the internal reeving sheave and
hoses (if equipped). Refer to Internal
Reeving - Model 4200 TT Mast on page
7-84. The carriage must be supported by a
block while removing the cylinder to
TT Mast Main Lift Cylinder avoid possible injury.
Removal 2. Raise the carriage to the center of the
1. Remove the mast from the truck. See Mast cylinder to slacken the chains and internal
Service on page 7-74. reeving hoses (if equipped). Block the
2. Lay the mast down on wooden blocks. carriage in place using a 4 x 4 x 24 in.
Extend inner and intermediate rails to (10 x 10 x 60 cm) wood block between the
expose the lower fittings on the main lift lower carriage bar and the floor.
cylinders. 3. Remove the chain guards from the
3. Disconnect the cylinder supply hoses from crosshead.
the cylinder inlet ports. Remove the 4. Remove the snap ring fastening the
fittings from the cylinder ports and install crosshead to the cylinder rod.
plug fittings.

Mast TF and TT Mast Service - Model 4200
5. Pull the crosshead with chains and hoses Figure 7-84. Free Lift Cylinder Supply Hose Adjustment
MA1157.eps
(if equipped) off the cylinder rod and lay

over the upper carriage bar.
6. Remove cylinder mounting bolts, keeping
the shims for reassembly.
7. Pry the cylinder up out of the support
casting to gain access to the cylinder hose
fitting. Remove the hose from the 45°
fitting. Cap the fitting and plug the hose.
8. Remove the cylinder from the mast from Free Lift
Hose Clamp
the top.

Installation
Torque the chain guard cap screws to 48 to MA1157.eps
52 ft. lb. (65 to 70 Nm).

4. Tighten the clamp while holding the hose
Bleed the system. See Bleeding the Hydraulic in place.
System on page 7-68. 5. Adjust tension on the hose by sliding the
hose through the loosened clamp as
required.
Supply Hose NOTE: The hose and the clamp must be dry of
oil and water before inserting the hose
into the clamp.
Tracking and Tension Adjustment
6. After inserting the hose through the loose
1. Make sure the cylinder supply hose is not clamp and tensioning the hose, snugly
twisted, and that it travels evenly in the tighten the two clamp bolts, then tighten
hose sheave. to 5.9 ft. lb. (8 Nm) with a torque wrench.
2. Check the hose to make sure it is not
scuffing.
3. Adjust the hose by loosening the hose
clamp on the outer upright as shown in
Figure 7-84 and twisting the hose.

Carriage - Model 4200 TF and TT Masts Mast
Carriage - Model 4200 NOTE: On TT Mast carriages, make sure the

retainer bolts are torqued to at least 84
TF and TT Masts in. lb. (9.5 Nm). If retainer bolts or plate
are damaged, replace them.
Carriage Removal Figure 7-85. Carriage Side Thrust Rollers

MA0927.eps
1. Remove mast from truck. See Mast Service Left Right

on page 7-74. Roller
Carriage Side Roller
2. Remove chain anchor nuts.
NOTE: Install new self-locking chain anchor
Thrust Rollers
nuts during reassembly. Important:
3. Remove the chain anchors. Adjust roller
4. Disconnect the internal reeving hoses for toward rail in
the carriage fittings. Plug the hose ends. Direction shown.
5. Roll the carriage to the bottom of the mast.
6. Attach an overhead hoist to the carriage
fork bars. Remove the carriage through
the bottom of the mast.
7. Note the number of shims located behind
each load roller for reassembly.
Carriage Installation
Reverse the removal procedure and do the
following:
• Inspect the carriage.
• Lubricate the inner upright rails. Refer to
Lubrication Specification Chart on page
A-2.
• Assemble shims and load rollers on the
carriage stub shafts. The shims should be
installed to provide a total side to side
clearance no looser than 0.06 in. (1.5 mm)
at the tightest point throughout the travel
of the carriage. Use an equal amount of
shims on each side.
• TT Masts - Adjust the carriage side thrust
rollers for unrestricted clearance along the
travel of the carriage. Turn the eccentric
mount base of each roller toward the
upright rail to decrease clearance. See
Figure 7-85. Torque the cap screws to 63
to 70 ft. lb. (85 to 95 Nm).
• Check and adjust the free lift chains. See
Lift Chains on page 7-98.

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

Check and adjust hose clearances.
10. Install the bulkhead fittings to the bracket
Internal Reeving - Model 4200 with the securing nuts located on the top
TF Mast side. Install the hose ends to the fittings.
11. Move the lowering control valve and
NOTE: For double function or left hand internal
bracket to the back side of the center cross
reeving, a spacer is added on the left
member. Torque the cap screws to 25 to
hand rear guide.
30 ft. lb. (35 to 40 Nm). Check and adjust
hose clearances.
Refer to Figure 7-86.
12. Raise and lower the mast several times to
1. Install the fittings on the carriage bracket.
make sure the hoses are tracking correctly
2. Install the front hose guide bracket to the in the guide brackets. Use the white line
back side of the inner upright cross on the hoses to detect twisting. Adjusting
member. Torque the cap screws to 48 to the hose ends with a slight amount of twist
52 ft. lb. (65 to 70 Nm). may improve hose tracking in the guides.
3. Install the rear hose bracket to the outer
upright by inserting the round bar at the
end of the bracket into the hole in the
upper outer upright.
4. Attach the lower end of the bracket to the
inside of the outer upright chain anchor
mounting leaving a gap between the top of
the bracket and the chain anchor mount.
The bracket should be parallel with the
upright. Torque the cap screw to 48 to
52 ft. lb. (65 to 70 Nm).
5. Remove the existing cap screw and guard
from one side of the cylinder crosshead.
Install the hose sheave and guard with the
hardware supplied. Tighten the cap screw
to a torque of 48 to 52 ft. lb. (65 to 70 Nm).
6. Install the hoses to the carriage fittings
with the white line facing outward.
7. Feed the hoses between the crosshead
guard and sheave. Raise the carriage just
above free lift. Route the hoses under the
front hose guide bracket. Install the hose
clamp. Pull on the hoses to remove slack.
Torque the cap screw to 25 to 30 ft. lb. (35
to 40 Nm). Completely lower the carriage.
8. Route the hoses to the rear guide bracket.
The loop in the hoses should be 4 ±1 in.
(101 ±25 mm) below the bottom of the rear
bracket.
9. Install the hose clamps at the top of the
rear guide bracket. Make sure the loop is
the same for both hoses. Torque the cap

Hose Reeving Mast

Figure 7-86. Internal Reeving - TF Mast (Model 4200)
MA2146.eps
4
Hoses must not
contact bottom of
chain anchor mount.
Rear Hose
Guide Bracket
7
10
4
5 2 8 11
1 6
MA2146.eps
11
Left Hand
DETAIL A Guide Spacer
DETAIL C

Mast Hose Reeving
Internal Reeving - Model 4200

TT Mast
Bracket Installation
NOTE: For single function internal reeving,
perform the following procedure for the
left side only.
Refer to Figure 7-87.

1. Install fittings and caps to the carriage
termination bracket and install brackets
on carriage.
2. Install two tube assemblies on lower inner
cross member.
3. Install guard and sheave onto existing left
hand upper intermediate chain guard.
4. Install bracket (with sheave) to tapped
block located on upper intermediate cross
member.
5. Install bracket and one clamp piece on
outer tab (on both sides of mast, left and
right).
Figure 7-87. Bracket Installation - TT Mast (Model 4200)

MA2971.eps
Step 3
Step 5 Step 4
MA2971.eps
Step 2
Step 1

Hose Reeving Mast
Hose Tension Figure 7-89. Hose Tension - Rear Termination

NoFile
Rear Termination
1. Route hoses over upper intermediate
sheave and down to clamp mounted on
outer weldment. See Figure 7-88.
Figure 7-88. Rear Hose Termination

NoFlie
Between
2.0 and 3.1 in.
(50 and 80 mm)
movement
Clamp
Carriage Termination
1. Make sure carriage is correctly adjusted
for desired fork settings.
2. Mount carriage termination bracket (with
fittings installed) to carriage in the desired
hole (based on fork height setting). See
Figure 7-90.
2. Loosely clamp hoses so that tension is Figure 7-90. Bracket Installation

MA2935.eps
held when hoses are pulled through the

clamp.
3. Pull hoses tight so that when 4 to 6 lbs. 3” Fork Height
(1.8 to 2.7 kg) of horizontal force is applied
to the hoses at 24 in. (0.6 m) above the 2” Fork Height
clamp, the hoses move between 2.0 and
3.1 in. (50 and 80 mm). See Figure 7-89.
MA
Termination
Bracket
3. Route hoses over free lift crosshead sheave

and attach to fittings on carriage bracket.
4. Install hoses with 7 to 10 lbs. (3.2 to
4.5 kg) of horizontal force at a point

Mast Hose Reeving
midway between the upper integral

sideshift cylinder block and crosshead.
Determine movement of the hoses (refer to
Figure 7-91):
• If movement is more than 2.3 in.
(60 mm), remove hoses from bracket
and move down one hole to increase
tension.
• If the movement is less than 1.2 in.
(30 mm), remove the hoses from the
bracket and move up one hole to
decrease tension.
• If correct tension cannot be obtained,
hoses are incorrect length and must be
replaced.
Figure 7-91. Hose Tension - Carriage Termination

MA2972.eps
Hose
Hose movement
movement as
described in Step 4.
as described in
Section 4a or 4b
MA2972.eps

Quad Mast Service Mast
Quad Mast Service Refer to Figure 7-93.

1. Remove the internal hose reeving from the
mast while it is on the truck.
Bubbled items in figures correspond to steps in
associated procedure. 2. Remove the mast assembly from the truck.
Refer to Mast Removal on page 7-74.
Mast Inspection 3. Remove the main lift cylinders from the
mast. Refer to Cylinder Removal and
During normal Scheduled maintenance checks, Installation on page 7-92.
pry between the upright and load roller so the 4. Using an overhead chain hoist, turn the
opposite load roller is tight against the upright. mast over (face up).
Measure the clearance for the pair of rollers at 5. Remove the free lift cylinder from the
XXX shown in Figure 7-92. mast. Refer to Free Lift Cylinder Removal -
Mast on Floor on page 7-93.
Figure 7-92. Load Roller Clearances
MA1174.eps
6. Remove the carriage from the mast. Refer
Pry Here
Load Roller to Removal - Mast on Floor on page 7-92.
7. Remove the free lift chain anchors and
chains from the inner upright center cross
member and tag for reassembly.
X
8. Disconnect the free lift cylinder hose from
X
X
the tube and remove the stop/hose
bracket/tube assembly.
9. Disconnect the inner main chain anchors
from the lower end of the inner upright
and the upper end of the outer
intermediate upright.
.06 in.
(1.5 mm) 10. Move the inner upright downward. Remove
Max.
the free lift hose sheave, hose, and main
chain sheaves at the top of the inner
NOTE: The lower end of the inner upright must
be raised slightly to clear the inner
intermediate upright lower cross
member.
11. Remove the inner main lift chains and tag
MA1174.eps for reassembly.
12. Remove the load rollers from the lower end
Each pair of load rollers on the uprights and
of the inner upright. Remove the load
carriage should be shimmed so that a total side
rollers and thrust plugs from the upper
to side clearance no greater than 0.06 in.
end of the inner intermediate upright. Note
(1.5 mm) occurs at the tightest point
the number of shims behind each for
throughout the travel of the member.
reassembly.
13. Attach an overhead hoist to the inner
Disassembly upright and remove it through the top end
NOTE: Quad Mast uprights require complete of the inner intermediate upright.
disassembly in order to service load NOTE: The stub shafts on the lower end of the
rollers, thrust plugs/blocks, and inner upright come out of the inner
chain/hose sheaves.

Mast Quad Mast Service
intermediate upright between the rail the number of shims behind each roller for
cutout and the stub shaft. reassembly.
14. Remove the outer main lift chain anchors 18. Attach an overhead hoist to the inner
from the lower end of the inner intermediate upright and remove it
intermediate upright and the top end of through the top end of the outer
the outer upright. Set the chains aside and intermediate upright.
tag for reassembly. 19. Roll the outer intermediate upright
15. Remove the lower stop from the outer downward and remove the lower rollers.
intermediate upright. Remove the upper rollers and thrust
blocks from the outer upright. Note the
16. Remove the chain sheaves from the outer
number of shims behind each roller and
thrust block for reassembly.
17. Roll the inner intermediate upright
20. Attach an overhead hoist to the outer
downward and remove the lower rollers.
intermediate upright and remove it
Remove the upper rollers and thrust plugs
through the top end of the outer upright.
from the outer intermediate upright. Note
Figure 7-93. Quad Mast Disassembly

MA0078.eps
8
Inner 12 12
Intermediate
9 Upright
10 Thrust
Plug
7 10 Thrust
Plug
Inner Shim
Main Lift
Chains
11
10
10
MA0244.eps
12 9
7 12
Free Lift
Chains
MA0078.eps

Reassembly NOTE: Roll the uprights past installed thrust

plugs/blocks before checking load roller
1. Lubricate the full length of the outer clearance.
upright rails. See Lubrication Specification
Chart on page A-2. • Thrust Plug/Block Replacement - Install
thrust plugs/blocks to provide a
2. Attach an overhead hoist to the outer clearance of 0.06 in. (1.5 mm) max.
intermediate upright and install it through between an upright and its
the top of the outer upright. Position it out corresponding thrust plug/block. See
the lower end of the outer upright approx. Figure 7-95. Pry between the upright
6 in. (15 cm). upper cross members. Measure the
3. Assemble shims, load rollers, and thrust clearance at the XXX shown to
blocks to the upper end of the outer determine the thickness of thrust
upright. Assemble shims and load rollers plug/block to use. Thrust plugs/blocks
to the lower end of the outer intermediate may be shimmed as required.
upright. 4. Lubricate the full length of the outer
• Roller Shimming - Install shims to intermediate upright rails. See Lubrication
provide a total side-to-side clearance of Specification Chart on page A-2 and
0.06 in. (1.5 mm) max. at the tightest Figure 7-94.
point throughout the travel of the 5. Attach an overhead hoist to the inner
upright. See Figure 7-94. Pry between intermediate upright and install it through
the upright and the load roller so that the top end of the outer intermediate
the opposite load roller is tight against upright. Position it out the lower end of the
the upright. Measure the clearance for outer intermediate upright approx. 6 in.
the pair of rollers at the XXX shown in (15 cm).
Figure 7-94. Use an equal number of
shims on each side. 6. Install shims and load rollers to the lower
end of the inner intermediate upright.
Figure 7-94. Load Roller Clearance/Channel Lubrication Install shims, load rollers, and thrust
MA0259.eps
plugs to the upper end of the outer
1 4 Lube intermediate upright. Refer to step 3 for
roller shimming and thrust plug clearance
Upright measurement.
Rails 7. Install the chain sheaves to the upper end
of the outer intermediate upright. Install
the outer main lift chain anchors and
chains over the outer intermediate upright
chain sheaves.
8. Install the outer main lift chain anchors
(long anchors) to the lower end of the inner
Upright 9. Install the lower stop on the outer
Rail intermediate upright. Torque the cap
Shim screw to 81 to 88 ft. lb. (110 to 120 Nm).
Load 10. Install the main chain sheaves, free lift
Rollers sheaves, and hose in the inner
intermediate upright. Torque the retainer
cap screws to 26 to 30 ft. lb. (35 to 40 Nm).
3 11. Install the upper inner main chain
.06 in. anchors to the outer intermediate upright.
(1.5 mm)
Max. Install the free lift hose bracket and tube.
MA0259.eps


Figure 7-95. Outer Intermediate Upright Installation
MA2046.eps
3
Thrust Thrust
Plugs Block
2
.06 in.
(1.5 mm)
Max.
2 Thrust
Block
Inside
of Rail
Outer
3 Upright
MA0246.eps
Outer
Intermediate
Upright
12. Lubricate the inner intermediate upright

rails. See Lubrication Specification Chart
on page A-2.
13. Attach an overhead hoist to the inner
upright and install through the top of the
inner intermediate upright. Position it out
the lower end of the inner intermediate
upright approx. 6 in. (25 cm).
14. Assemble shims and load roller to the
lower end of the inner upright. Assemble
shims, load rollers, and thrust plugs to the
upper end of the inner intermediate
upright. Refer to step 3 for roller shimming
and thrust plug clearance measurement.
15. Install the inner main lift chain anchors
(long anchors) on the back side, lower end
of the inner upright. Connect the inner
main lift chains.
16. Install the stop/hose bracket/tube
assembly on the lower end of the inner
upright. Torque the cap screws to 81 to
88 ft. lb. (110 to 120 Nm).


Figure 7-96. Inner Upright Installation
MA0251.eps
14
13
Thrust
Plug
15 Thrust
13 Plug
Shim
MA0269.eps
14
14
Inner
Upright
16
MA0251.eps
17. Install the free lift chain anchors (short re-blocked in a level position. See
anchors) and chains to the inner upright Figure 7-97.
center cross member.
Figure 7-97. Blocking Uprights Before Turning Mast Over
18. Install the free lift cylinder supply hose to MA0254.eps
the free lift cylinder tube. Leave the tubing

clamp loose.
19. Install the carriage. See Installation - Mast 21
22
on Floor on page 7-92.
20. Install the free lift cylinder. See Free Lift
Cylinder Installation - Mast on Floor on
page 7-93. Connect the tube to the
cylinder fitting and tighten the tubing MA0254.eps
clamp.
23. Install main lift cylinders. See Main Lift
21. Place a 2 x 4 in. (5 x 10 cm) wood block Cylinder Installation - Mast on Floor on
between the outer and outer intermediate page 7-93.
lower cross members to prevent upright
movement. 24. Install the Mast. Refer to Mast Installation
on page 7-75.
22. Turn the mast over (face down), rotating it
on its lower end. Make sure the mast is

25. Install the internal hose reeving. See • Adjust the carriage side thrust rollers for
Reeving on page 7-93. unrestricted clearance along the travel of
26. Adjust the main and free lift chains. the carriage. Turn the eccentric mount
base of each roller toward the upright rail
27. Check the mast for skewing. to decrease clearance. See Figure 7-98.
Torque the cap screws to 79 to 80 ft. lb.
Carriage (95 to 110 Nm).
Figure 7-98. Carriage Side Thrust Roller Adjustment

Removal - Mast on Floor MA0927.EPS
1. Remove mast from truck. See Mast

Removal on page 7-74.
2. Remove the pins fastening the free lift
chains to the carriage chain anchors.
3. Disconnect the internal reeving hoses from
the carriage fittings (if equipped). Plug the
hose ends.
• Check and adjust the free lift chains.
4. Remove the socket head stops on the inner
upright lower cross member. For • Adjust mast tilt. See Mast Tilt Adjustment
reassembly, tighten to 80 ft. lb. (110 Nm). on page 7-100.
5. Roll the carriage to the bottom end of the
mast. Cylinder Removal and
6. Attach an overhead hoist to the carriage Installation
side bars and remove the carriage through
the bottom end of the mast. Main Lift Cylinder Removal - Mast on
7. Remove the load rollers, noting the Floor
number of shims behind each roller for
1. Remove the mast from the truck. See Mast
reassembly.
Installation - Mast on Floor 2. Insert a 2 x 4 in. (5 x 10 cm) wood block

between the lower cross members of the
outer upright and outer intermediate
Reverse the removal procedure and do the
upright to prevent uprights from moving
following:
out the bottom of the mast.
• Inspect the carriage.
3. Lay the mast face-down on wood blocks.
• Lubricate the inner upright rails. Refer to Block under each end of the outer upright
Lubrication Specification Chart on page so the mast is level and the inner uprights
A-2. and carriage are free to move.
• Assemble shims and load rollers on the 4. Using a 1 in. wrench, disconnect the
carriage. Install load roller shims to cylinder supply hoses from the cylinder
provide a total side to side clearance of inlet ports. Using a 1 in. socket, remove
0.06 in. (1.5 mm) at the tightest point the special long fittings from the cylinder
throughout the travel of the carriage. Use ports and install plugs.
equal numbers of shims on each side.
5. Remove the snap ring from the top of the
left hand cylinder rod. Remove the tube
and fitting from the top of the right hand
cylinder rod. Plug the cylinder port.
6. Roll the uprights through the top of the
mast 1 to 2 ft. (30 to 60 cm) and disengage

the cylinder rods from the outer Reeving

7. Lift the cylinder from its base mounting Internal Reeving Installation
boss in the outer upright and angle it
inward. Remove the cylinders through the 1. Install the shaft, sheave, and hose guards
sides of the uprights. to the crosshead center plate. See
Figure 7-99. Leave the cap screw and nut
8. Note the number of shims (if equipped) on
finger tight to allow for hose installation.
each cylinder rod.
Figure 7-99. Crosshead Center Plate Assembly
Main Lift Cylinder Installation - Mast MA0222.eps
on Floor 1
Bleed the system. See Bleeding the Hydraulic
System on page 7-44.
Free Lift Cylinder Removal - Mast on

Floor
1. Remove the mast from the truck. See Mast
2. Lay the mast face-up, blocking under the 2. Install the carriage hose bracket to the
lower mounts so the mast is level. center tab on the lower carriage bar. See
3. Roll the carriage upward to allow slack in Figure 7-100.
the free lift chains and internal reeving.
Figure 7-100. Carriage Hose Bracket Installation
4. Remove the snap ring fastening the MA0255.eps
crosshead to the cylinder rod.

5. Pull the crosshead with chains and hoses
off the cylinder rod.
6. Roll the carriage above the free lift
cylinder.
7. Using a 1 in. wrench, disconnect the tube
from the cylinder fitting. Cap the cylinder
fitting and plug the tube.
8. Using a 5 mm hex head wrench, remove
the cylinder strap. 3
9. Remove the cylinder from the mast.
2
Free Lift Cylinder Installation - Mast
on Floor
3. Install the fittings on the bracket. See
For installation, reverse the Removal procedure. Figure 7-101.
Bleed the system. See Bleeding the Hydraulic
• Single Function - Install the fittings to
System on page 7-44.
the left or right side location. Tighten
the fittings finger tight.

• Double Function - Install the fittings to the bottom of the inner upright weldment.
the left and right side location. Tighten See Figure 7-102. Torque the cap screw to
the fittings finger tight. 52 ft. lb. (71 Nm).
5. Install the shaft and hardware to the inner
Figure 7-101. Fitting Installation
MA0256.eps intermediate upright chain sheave shaft.
See Figure 7-102. Torque the cap screw to
OR
3 52 ft. lb. (71 Nm).
6. Install the lower hose guide to the outer
intermediate upright. Torque the cap
screw to 30 ft. lb. (41 Nm).
SINGLE DOUBLE 7. Install hose clamps to lower guide. Leave
FUNCTION FUNCTION cap screws finger tight.
MA0256.eps
Figure 7-102. Hose Reeving Hardware Installation on
4. Install the lower internal hose reeving
Uprights
bracket and plastic inserts to the block at MA0225.eps
2XWHU
8SSHU+RVH*XLGH 8SULJKW
2XWHU
,QWHUPHGLDWH
8SULJKW

,QQHU
,QWHUPHGLDWH
8SULJKW

,QQHU
8SULJKW
&URVVKHDG
0$HSV &RPSRQHQWV
/RZHU*XLGHV

/RZHU,QQHU

&RPSRQHQWV &DUULDJH
&RPSRQHQWV

8. Completely lower the carriage. Route the and route upward into the upper hose
short hoses down behind the carriage bar guide.
to the carriage bracket fittings. Connect 19. Install the hose clamps to the upper hose
the hose ends to the fittings, leaving the guide. Leave cap screws finger tight.
hose ends finger tight.
20. Route the hoses under the hose clamps at
NOTE: For Double Function, the No. 4 hoses the top of the upper hose guide. Tighten
connect to the two right fittings (viewed the cap screws finger tight.
from the operator’s seat).
21. Route the hoses under the hose clamps at
9. Route the hoses over the crosshead the bottom of the upper hose guide. Do not
sheaves. tighten the clamp cap screws.
10. Route the hoses down between the free lift 22. Torque the crosshead cover plate cap
cylinder and cross member. Position the screw to 52 ft. lb. (71 Nm).
hoses in their natural curve over the
crosshead sheaves. Tighten the hose ends
at the carriage bracket.
11. Connect the long hoses to the short hoses
behind the free lift cylinder. The outside
hose(s) is approx. 4 in. (102 mm) shorter
than the inside hose(s). See Figure 7-103.
12. Pull down on the hoses with approx.
30 lbs. of force. Clamp the hoses to the
lower bracket attached to the inner
upright cross member. Torque the cap
screws to 7 to 11 ft. lb. (10 to 15 Nm).
13. Position the hoses with the tabs on the
inner upright bracket as shown in
Figure 7-103.
14. Install the lower internal hose reeving
cover plate and hardware. Tighten the cap
screws to 30 ft. lb. (41 Nm).
15. Route the hoses up toward the top of the
mast following the inner lift chains. Bend
the hoses over the inner intermediate
upright sheave and install the sheave on
the shaft bolted to the intermediate
upright. Install washer and retaining ring
to shaft.
16. Route hoses down to the lower hose guide.
Place hoses under the hose clamp at the
top of the lower hose guide. Pull downward
on the hoses with 20 lbs. force. Tighten
clamp cap screws enough to stop hose
movement.
17. Install the upper hose guide to the outer
upright. Tighten the cap screw to 30 ft. lb.
(41 Nm).
18. Loop the hoses approx. 5 in. (125 mm)
below the bottom of the lower hose clamp


Figure 7-103. Hose Reeving Installation
MA0257.eps

,QQHU
,QWHUPHGLDWH
8SULJKW6KHDYH 6,1*/( '28%/(
/RQJ )81&7,21 )81&7,21
+RVH

6KRUW
+RVH
/RQJ 6KRUW 6KRUW

+RVH +RVH +RVHV
/RQJ /RZHU
/RQJ
+RVH +RVH
+RVH
*XLGH
0$HSV
6,1*/( '28%/(
)81&7,21 )81&7,21 &RQQHFW
%$&.9,(:
KRVHV
,QQHU
8SULJKW
%UDFNHW

&DUULDJH
%UDFNHW
)LWWLQJV
6,1*/( '28%/(
)81&7,21 )81&7,21
0$HSV
6,1*/( '28%/(
)81&7,21 )81&7,21
%$&.9,(:

23. Align the hoses by twisting the hose ends Figure 7-104. Hose Reeving Installation - continued
MA0258.eps
to travel centered in the crosshead on the

natural curve of the hose. The hoses
should travel parallel to each other. Hold
the hoses while tightening the fittings to
keep the hoses from twisting.
24. Loosen the hose clamps at the top of the
lower hose guide. Pull down on the hoses
with 40 lbs. of force. Tighten the hose
clamp cap screws to 7 to 11 ft. lb. (10 to
15 Nm).
25. Loosen the hose clamps on the upper hose
guide. Adjust the hoses to the natural
hose bend and align evenly spaced in the 8SSHU
guide rails. Tighten the hose clamp cap +RVH
screws to 7 to 11 ft. lb. (10 to 15 Nm). *XLGH
26. Raise and lower the mast slowly through

several cycles and check for correct hose
alignment, clearances, and hose tracking
in the guides.
&URVVKHDG

/RZHU
+RVH
*XLGH


Mast Lift Chains
Lift Chains • Adjust each pair to achieve equal chain

tension. Tighten the nuts together to a
torque of 50 to 70 ft. lb. (98 to 96 Nm).
Adjusting Lift Chains - Model Make sure cotter pins are installed in
the hole at the bottom of each chain
4100 anchor.
1. Loosen the locking nut on the chain • Raise and lower the mast several times
anchor. See Figure 7-105. to confirm the adjustment is correct.
Figure 7-105. Lift Chain Locking Nut Figure 7-106. Main Lift Chains - Model 4200
5534-017a.tif
MA1156.eps
Main Lift
Chain Anchors
Main Lift
Locking Nut Adjusting Nuts
Adjusting Free Lift Chains - TF Mast

2. Tighten the adjusting nut until the chain
is free of any twist and tension is correct. The free lift chains should be adjusted so that
Lift chain tension is correct if the lift chain when the unloaded mast is fully lowered, the
can be forced sideways approx. 0.5 in. to upright channels and carriage are positioned as
1 in. (12.7 to 25.4 mm) before the lift shown in Figure 7-107.
frame raises slightly.
3. Retighten the locking nut on the chain Figure 7-107. Upright and Carriage Position
MA2778.eps
anchor and install a cotter pin. *3 in. *5 in.

Underclearance Underclearance
Adjusting Lift Chains - Model

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

when the unloaded mast is fully lowered, the Carriage 2 in.
Below Outer
uprights are positioned as shown in Upright
Figure 7-106.
1. Locate the threaded chain anchors on the
1. Adjust one chain to achieve the correct front side of the inner upright cross
upright position when fully lowered. member on each side of the cylinder.

Lift Chains Mast
Adjust one chain to achieve the correct 6. Relocate the hose bracket down two holes
upright position when fully lowered. See [approx. 1 in. (25.4 mm)]. Torque hose
Figure 7-108. bracket mounting bolt to 30 ft. lb. (40 Nm).
If two sets of hoses are present, repeat for
Figure 7-108. Free Lift Chains the second set of hoses. See Figure 7-109.
MA0387.eps
Figure 7-109. Hose Bracket Relocation

MA0387.eps
Bracket
and hoses
removed
Refer to
for clarity
Step 6
2 in. fork
height
Free Lift location
Cylinder
3 in. fork
height
location
Cylinder
Strap
Shown in 2 in. fork
height location
Free Lift
Adjusting
Nuts
MA0387.ill
2. Adjust the other chain to achieve equal
chain tension. Tighten the nuts together to
a torque of 50 to 70 ft. lb. (68 to 95 Nm).
3. Raise and lower the mast several times to
confirm the adjustments.
Model 4200 TT Mast -

2 in. to 3 in. Lowered Height
Conversion
1. With the mast vertical, readjust one free
lift chain until a 3 in. (76 mm) fork height
is obtained.
2. Lift the carriage until the free lift cylinders
are fully extended.
3. Adjust the second free lift chain until there
is equal tension on both chains.
4. Torque the chain anchor jam nuts to
50-70 ft. lb. (68-95 Nm).
5. Fully lower the carriage and verify the fork
height.

Mast Mast Tilt Adjustment
Mast Tilt Adjustment 3. Place a square on the mast 39.4 in.

(1 meter) below where the plumb line is
attached and measure the distance
Perform the following procedure when adjusting between the face of the mast and the
mast tilt. plumb line.
1. Attach a plumb line to the mast. See 4. Repeat steps 1 thru 3 using the back of
Figure 7-110. the mast main frame for backward tilt.
Figure 7-110. Measuring Mast Tilt 5. Adjust the stroke of the tilt cylinders as
KL-25.TIF
necessary to achieve the correct mast tilt.
Refer to Figure 7-110 and Table 7-6.
Table 7-6. Mast Tilt Parameters
Tilt Fwd Tilt Back Tilt

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

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

adjusted so that it opens when the mast is tilted
beyond 3° forward.
Mast
Face 1. Attach a plumb line to the mast. See
Figure 7-110.
39.4 in. (1 meter) Plumb
from plumb line 2. Place a square on the mast 39.4 in.
attach point Line (1 meter) below where the plumb line is
attached and tilt the mast forward 3°
(2.05 in./52 mm at Dim. A in
Figure 7-110).
3. Adjust Mast Tilt Position Switch (S18)
bracket so that the switch opens when the
mast is tilted further forward.
Dim. A
2. Tilt the mast forward completely.

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

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

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

Systems Overview
Systems Overview operator requests. The VM calculates the

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

Systems Overview
encoder and temperature sensor. Motor speed TPC Contactor

may be fixed or vary based on different types of
requests (such as tilt versus sideshift versus The TPC Contactor provides B+ to the power
high speed clamp). It determines from the side of both traction amplifiers. It is controlled
encoder feedback if the motor has achieved the by the Right Traction Power Amplifier (RTPA).
requested speed request. The LPA is solely
responsible for controlling lift motor current. It
STR Contactor
sends the lift motor temperature status to the
VM. The VM then determines if the motor must
The STR Contactor provides B+ to the power
be shut-down due to motor temperature. The
side of the Steer Motor (SM). It is controlled by
LPA monitors its internal temperature and
the VM.
limits current or lift speed as required by its
internal programming. The LPA also checks the
operation of the LPC, the charging of the Steer Position Sensor
amplifiers, and various internal operating
parameters. It also sends fault codes to the VM Consists of three independent Steer Feedback
if anything is operating incorrectly. Proximity Sensors located in one potted
assembly. The steering hub has a plate
mounted on it that changes the activation
Non-intelligent Devices sequence of the sensors when the steering hub
is rotated. The VM uses this to determine the
Operator Display Card steering position for correct control of the
traction motors.
The Operator Display Card is connected to the
VM. Messages and codes are displayed on it.
The Display contains the Primary Memory,
Hydraulic Devices
which includes Model Number, Serial Number,
The lift system consists of single acting
Date of Manufacture, Hour Meters, and a list of
hydraulic cylinders. During a lift from floor
enabled Options. The keypad that contains the
level, the free lift cylinders elevate the carriage
data entry push buttons connects to the
before the telescopic is extended by the lift
Operator Display.
action of the main cylinders.
Fuse/Relay Card Lift/Aux Pump (P1)

The Fuse/Relay Card is the control power
Pump P1 is a positive displacement gear pump
distribution board. It contains the B+ and B–
that rotates clockwise from the shaft end. P1 is
control fuses and the K1 thru K4 relays. It
used for all lift and aux functions.
provides B+ and B– to the VM, TPC, LPC, and
STR. It also supplies B+ and B– to optional
equipment. Sideshift Cylinders
The sideshift cylinder is a double-acting

LPC Contactor
hydraulic cylinder used to shift the load left and
right with respect to the mast. It is an integral
In the Model 4200, this contactor is used to
part of the sideshift carriage.
supply B+ to the power side of the Lift Power
Amplifier.
Tilt Cylinders
In the Model 4100, this contactor is used to
supply B+ to the DC Lift Motor. The tilt cylinders are double-acting hydraulic
cylinders used to tilt the mast forward and
back.

Systems Overview
Load Hold Valve (SOL1) Attachment Solenoids (SOL7C/R)
The load hold valve is a normally closed SOL7C/R are normally closed solenoid valves
solenoid valve used to hold the carriage in an used to block (de-energized) or allow (energized)
elevated position. fluid flow to and from the attachment cylinders.
Lift/Lower Valve (SOL2) Sideshift Solenoids (SOL9R/L)
The proportional lower valve is a pressure SOL9R/L are normally closed solenoid valves
compensated flow control solenoid valve used to used to block (de-energized) or allow (energized)
lower the carriage. As the voltage to the valve fluid flow to and from the sideshift cylinders.
increases, the flow through the valve increases,
regardless of the pressure. The Model 4100 Tilt Solenoid (SOL10)
uses SOL2 for feathering lift as well.
SOL10 is a normally closed solenoid valve used
Dump Valve (SOL3) to block (de-energized) or allow (energized) fluid
flow to and from the tilt cylinders.
SOL3 is a solenoid used as a lift system relief.
In addition, SOL3 is used to divert oil from P1 Steer Valve
back to the reservoir after a lift is stopped and
the pump is still spinning. It also acts as a valve The steer valve is an orbitrol type rotary flow
to port excess oil back to the reservoir when valve with an auxiliary port. When no steering
performing auxiliary functions. is requested, fluid flows through the auxiliary
port (E). When steering is requested, fluid flows
Priority Bypass (SOL4) first through the steer valve, hydraulic motor,
and the steer return port (T). Any excess flow
SOL4 is a normally open proportional pressure exits out the auxiliary port.
compensated priority flow valve. It regulates
flow to the auxiliary system by the voltage to the Counterbalance Check Valves (CB1,
coil, regardless of the system working pressure.
CB2)
Increasing the voltage decreases the flow to the
auxiliary system.
Counterbalanced check valves are used to hold
the tilt cylinders in place when a tilt request is
Prop Relief (SOL5) no longer present.
SOL5 is a proportional solenoid used as an

Check Valve (CV1)
auxiliary system relief. Voltage is used to adjust
the relief pressure [24V = 3000 psi (20684 kPa);
Check valve is used to make sure the fluid
0V = 100 psi (689 kPa)]. The voltage to this
exiting the lift cylinders during a lower
valve varies when different pressure settings
command is routed through SOL2.
are chosen on the display for auxiliary
attachments.
Hydraulic Filter
Aux Select (SOL6)
The hydraulic system has a filter in the main
manifold. Its purpose is to filter impurities from
SOL6 is a directional solenoid valve providing
the hydraulic system. It filters oil on the return
directional control to the tilt, sideshift, or
to the reservoir from the lift system. It has no
auxiliary functions. When SOL6 is energized,
internal bypass.
flow direction is reversed for tilt, sideshift, or
auxiliary functions.

Traction System Theory
Traction System Theory page 3-12. For Travel or Lift/Lower, the VM

compares the pot position information to the
values that it stored when it learned the pots.
Key ON
When the control handle is moved from neutral,
When the key is turned ON, the Vehicle the VM detects a different voltage at JPC12-3
Manager powers up and proceeds with SelfTest. from VR1. To release the brake, the VM must
If the Battery_Sense_In (JPC24-24) voltage is know the deadman switch is operational and
between 28 and 45V, a circuit is turned ON in that the control handle has moved. The VM
the VM that provides B– to the RELAY_ENABLE then provides B– to JPC20-14 (Brake) that
(JPC14-6) in order to energize the relays. After energizes the brake coils and releases the
this, the Battery_Sense_In voltage is used to brakes. The lift truck is equipped with two
determine BSOC. When K1, K2, K3, and K4 are traction motors, each with its own brake. Both
energized, K3 provides B+ to the control side of brakes are controlled by the same circuit from
the power amplifiers as well as the precharge the VM.
circuit internal to the amplifiers.
When the VM receives a request to travel by
The VM establishes communication to the seeing the VR1 voltage change (control handle
amplifiers and after successful communications moved), it compares that voltage to the learned
has been established, the VM requests the value for VR1 to determine the direction and
RTPA to activate the TPC contactor and check magnitude of the travel request. The VM then
its status. For the 4200, the VM requests the looks at all speed limiting inputs such as motor
LPA to activate the LPC contactor and check its temperature, height, weight, steering angle, and
status. For the 4100, the VM activates the LPC fault codes to determine if the requested speed
contactor via pin LPC_CTRL (JPC18-9) and is allowable. The VM then initiates a request for
verifies by LPC_SENSE (JPC22-20). the appropriate direction and speed to the TPAs
over the communications BUS. The VM
constantly updates the travel request to the
Deadman Pedal Depressed TPAs.
When the Deadman Pedal is depressed, S2 When the TPA receives a travel request from the
(Deadman Switch) is closed. The switch is an VM, it produces a control output to the traction
input at JPC22-8 to the VM. When S2 closes, it motor. All operational parameters that affect
switches Deadman Switch voltage from a high traction motor torque and speed are controlled
state (greater than 4.5VDC) to a low state (less exclusively by the TPA. It monitors motor
than 0.7VDC). current, voltage, and RPM, and from them, can
determine motor performance. The TPA alters
When the VM receives that voltage, it activates its control output to the traction motor to
a circuit in the VM that provides B– to match the motor performance to the travel
JPC18-11, energizing the STR contactor coil request from the VM. As the travel request from
and the steer motor is powered up. the control handle changes, so does the travel
request from the VM to the TPA. That in turn,
Travel Theory alters motor operation. To track the travel
request from the operator, the TPA monitors the
During Learn, the VM learns the neutral speed sensor. The TPA also monitors traction
position for the travel (VR1) and lift (VR2) motor temperature and the internal
potentiometers and stores those values in temperature of the amplifier and can alter travel
memory. See “Maintenance Mode” on based on the TPA temperature. The TPA sends
page 3-16. During normal use, the VM learns motor temperature to the VM, and the VM
the extreme values for full forward/reverse and alters the travel request based on traction
full lift/lower. These values are also stored in motor temperature.
memory in the VM. See “Configure Mode” on

Traction System Theory
When the lift truck is moving and the travel or a regeneration control output to the traction
control handle is moved to request the opposite motor.
direction, the same sequence of events takes
place. The VM constantly monitors the steering
position sensor for reduction in speed to a
The VM does not request plugging or particular traction motor, cut power to a
regeneration; it just requests travel in the particular traction motor, or cause the motor to
opposite direction. reverse the direction of travel even if the travel
control direction request did not change.
The TPA calculates both direction and speed,
then determines whether the travel request This allows the vehicle to corner correctly with
from the VM must be met with a travel, a plug, the dual drive system.
Table 8-3. Steering Parameters
Operator
Steer Tiller
Steer Tire Position Effect On System Display
Position
Message
90° (full CW) to 67° Reverse direction in 1 motor Left 101
67° to 41° One motor power cut Left 100
41° to 18° Reduced throttle percentage Left 000
18° to –18° (wheels centered) Full Speed Centered 001
–18° to –41° Reduced throttle percentage Right 011
–41° to –67° One motor power cut Right 010
–90° (full CCW) to –67° Reverse direction in 1 motor Right 110

Steering System Theory
Steering System Theory

With the key switch ON, the deadman pedal
depressed, and the EPO switch closed, Relay K2
is energized, sending B+K2 from the Fuse/Relay
Card at JPF2-1 to SPL9.
From SPL9, the voltage goes to the STR

contactor X terminal. The VM supplies a
negative (JPC18-11) to energize the steering
contactor coil. When the coil is energized, the
steer contactor tips close, supplying battery
voltage to the steer motor.
With the steer motor running, oil is sent

through the steering orbitrol and back to the
hydraulic reservoir. When steering is requested,
oil is sent through the orbitrol to the hydraulic
steer motor to rotate (steer) the drive unit.

Lift/Lower System Theory
Lift/Lower System motor to determine that the lift motor has

stopped spinning. As long as the VM senses
Theory voltage on the P Sense line, it provides voltage
to the Priority Bypass (SOL4) and lift/lower
proportional (SOL2) coil, keeping the valve(s)
Model 4100 open to allow the fluid from the pump to return
to tank. This ensures the cylinders do not
continue lifting after the request has ended.
Lift System
Once the lift motor has completely stopped
spinning, the VM removes voltage to the Priority
The VM constantly monitors the output voltage
Bypass (SOL4) and lift/lower proportional
of VR2. The VM compares this voltage to the
(SOL2) coil, closing the Priority Bypass (SOL4)
voltages stored during the Learn process. The
and lift/lower proportional valve.
VM checks the battery voltage (for lift cutout),
and all enabled options and switches that could
prevent the activation of the lift system. When Lower System
satisfied that no criteria are present to prevent
lift, it then determines the requested percentage The following description is based on a lower
of full speed lift. It then activates Priority request from a full speed lift situation.
Bypass (SOL4). The lift/lower proportional valve
(SOL2) fully opens and closes the lift pump VR2 passes through neutral to a full speed
contactor (LPC) by taking the coils to B–. lower request. The VM recognizes the change
and realizes full speed lower is required. All
Opening the lift/lower valve fully prevents enabled options and switches that can prohibit
sudden movement when the lift pump is first lower are checked.
activated by allowing the fluid to return to the
tank. As soon as the command to close the P Once the VM is satisfied that lower is allowed, it
contactor is activated, the VM looks at the monitors the LPC_Sense line to determine the
LPC_Sense input, verifying the contactor closed condition of the P contactor (open or closed) and
as commanded. It then slowly reduces the PWM verifies the lift motor is not still spinning by
(Pulse Width Modulation) output to the coil for checking for back ElectroMotive Force (EMF).
the lift/lower proportional valve to match the As long as the VM senses voltage on the
percentage of full speed lift requested. As the LPC_Sense line, it provides voltage to the
lift/lower proportional valve closes, hydraulic Priority Bypass (SOL4) and lift/lower
fluid passes through the CV1 check valve, the proportional coil, keeping the valve(s) open to
normally closed check valve in the load holding allow the fluid from the pump to return to tank.
valve, to the flow limiter on the crosstie, to the This ensures the cylinders do not continue
flow limiters at the bottom of the lift cylinders. lifting after the request has ended.
The flow limiter in the cylinder allows
unrestricted fluid flow to the center lift ram. The Once the lift motor has completely stopped
free lift cylinder elevates first because less spinning, the VM removes voltage to the
pressure is required. Once the carriage hits the lift/lower coil, closing the lift/lower
stops on the inner telescopic, the pressure proportional valve. The Load Holding solenoid
increases enough to start elevating the main (SOL1) is activated by the VM, opening the
cylinder(s). valve. The VM then gradually opens the
lift/lower solenoid (SOL2) to the percentage of
The VM monitors the LPC_Sense line to requested lower. This allows the oil to flow from
determine the condition of the LPC contactor the cylinders, the load holding valve, the
and verify the lift motor is spinning. When a lift lift/lower proportional valve, the filter, and back
request has finished (VR2 has either returned to the reservoir. The telescopics lower first due
to neutral or through neutral to a lower to the greater weight of the telescopics. Once
request), the VM monitors the LPC_Sense line the telescopics are fully lowered, the center
for back ElectroMotive Force (EMF) from the cylinder begins to lower.

Model 4200 When the lift knob is returned to neutral, the

lift motor is ramped down. SOL3 is opened to
relieve any pressure spikes in the system.
Lift System
All inputs and outputs related to the lift/lower Lower System

system are controlled by the Vehicle Manager
(VM). The VM determines what actions are With the key switch ON and the deadman
required based on inputs from the operator and depressed, rotating the lift/lower control VR2 to
from system feedback. the lower position sends a change in voltage to
the VM on JPC12-2 (the voltage is an increasing
The VM sends voltage through lift/lower voltage).
potentiometer VR2. When VR2 is moved to
request lift, a voltage is sent to the VM at The VM senses the request for lower and sends
JPC12-2. The VM sees a voltage different from the negative to the load holding solenoid (SOL1)
the “learned” neutral voltage, and sends a at JPC18-10 to energize its coil.
request to the lift power amplifier via BUS+/–
(JPC14-11 and JPC14-4 on the VM to JPL1-23 After the load holding solenoid opens, the
and JPL1-35 on the Lift Amp). To lift, voltage proportional lower solenoid (SOL3) opens to
from VR2 decreases; when it is moved to lower, allow fluid to flow back to the reservoir by
the voltage from VR2 increases. controlling the negative to the coil. This
negative comes from the VM at JPC20-16. SOL3
Lift speed varies directly with lift motor RPM. opens proportionally to the amount that VR2 is
The voltage supplied to the lift motor is moved from neutral during lower.
proportional to the amount of lift request from
VR2, faster lift = higher motor voltage. Voltage across the proportional lower solenoid
Frequency is also manipulated to perform the varies, depending on the position of the
operator’s request. lift/lower control (VR2):
• Low voltage = slow lowering
The lift power amplifier internally supplies B+ • High voltage = fast lowering
and B– to the lift contactor coil (LPC coil) at
JPL1-13 and JPL1-6 respectively. B– is
controlled to close the normally open contactor Auxiliary Functions
tips. When the lift contactor coil is energized,
the contactor tips close, allowing B+ to the Sideshift
power side of the LPA. The LPA supplies voltage
to the lift motor. With the key switch ON and the deadman pedal
depressed, the following occurs to activate the
Prior to requesting a lift, all valves are in the sideshift function.
de-energized state.
Moving the sideshift control to one side varies
SOL4 receives oil flow at port 1 placing pressure the output voltage of the sideshift pot (optional
on the pilot line of the valve. This pressure handle). This voltage goes to the VM at
moves the spool in the valve to allow flow out of JPC12-5. The VM sees a voltage change and
port 2 and down to CV-1. Then the oil flows sends a request to the lift amplifier via BUS+/–
through the de-energized load holding solenoid (JPC14-11 and JPC14-4 to JPL1-23 and
(SOL1), through the mast mounted flow limiter JPL1-35).
to the flow limiters in the base of the lift
cylinders, and into the lift cylinders producing The lift power amplifier internally supplies B– to
lift. the lift contactor coil (LPC) at JPL1-6, closing
the normally open contactor tips.

When the lift contactor coil is energized, the rotate. The motor turns at a speed
contactor tips close, allowing B+ to the power predetermined by software.
side of the LPA. The LPA supplies voltage to the
lift motor. The motor turns at a speed SOL4 receives oil flow at port 1, that flows
predetermined by software. through the valve and out port 3 to SOL6, the
directional solenoid. When energized, SOL6
SOL4 receives oil flow at port 1 that flows reverses the direction of the Aux functions.
through the valve and out port 3 to SOL6, the
directional solenoid. When energized, SOL6 Oil flow then goes to SOL10. SOL10 must be
reverses the direction of the Aux functions. energized for Tilt to work in either direction.
Oil flow then goes to solenoid 9R or 9L. Solenoid From SOL10, the oil flows through CB-1 or 2,
9R and 9L must be energized for Sideshift to depending on the requested tilt direction. The
work in either direction. From SOL9, the oil oil then flows through the hoses to the Tilt
flows through the over-the-mast hoses to the cylinders.
Sideshift cylinders.
During a lift and aux function at the same time,
From the Maintenance Menu, the user can SOL4 becomes energized to allow the correct oil
establish sideshift speed. See Table 3-3, flow to the Aux functions.
“Maintenance Mode Menu,” on page 3-17.
Bottler’s Tilt (Optional)
This is used to adjust sideshift speed between 3
and 4.5 seconds. It is also used to set the Bottler’s Tilt allows additional forward mast tilt
correct speed of an attachment that has a while in free lift, and may limit the lift height
second AUX function. Changing this setting depending on the tilt position.
affects tilt speed as well. The VM varies the
voltage to SOL4 in order to create the differing To accomplish this, there are modifications to
sideshift speeds. the lift truck and the option must be enabled in
FlashWare. See Table 3-1, “Configure Mode
Tilt Menu,” on page 3-14.
With the key switch ON and the deadman pedal When the mast is fully lowered and vertical, the
depressed, the following occurs to activate the High Speed Limit Switch (SW11) and Mast Tilt
Tilt function. Switch (SW18) are normally closed.
Moving the Tilt control forward or back varies When tilt is requested, greater than 3° tilt
the output voltage of the Tilt pot (optional forward is possible.
handle). This voltage goes to the VM at
JPC12-8. The VM sees a voltage change and When the lift truck is elevated above free lift,
sends a request to the lift amplifier via BUS+/– SW11 opens, causing a change in state to be
(JPC14-11 and JPC14-4 to JPL1-23 and seen at the VM.
JPL1-35).
The VM does not allow tilt forward to go more
The lift power amplifier internally supplies B– to than 3° as seen by SW18.
the lift contactor coil (LPC) at JPL1-6, closing
the normally open contactor tips. When the mast is tilted more than 3° while in
free lift, and lift is requested, lift stops when
When the lift contactor coil is energized, the switch SW11 is deactivated.
contactor tips close, allowing B+ to be supplied
to the power side of the lift power amplifier. This
supplies voltage to the lift motor to make it


Pinout Matrix
Pinout Matrix
Section 8. Theory of Operation
The pinout matrix chart lists functions and • Normal Level: the approximate voltage that
normal voltages of terminals and harness must be seen on that wire for the state
connector pins. The matrix columns have the indicated. Unless otherwise indicated,
following meanings: voltages are measured with respect to (wrt)
• Item: sequential number to aid in B– at TP4.
reference. • Signal Source: the device or connection
• Connection: the actual wire numbers or that supplies the signal directly to the
component abbreviations on the electrical wire.
schematic. • Signal User: the device or connection
• Function Description: brief definition of where the wire directly delivers the signal.
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.
Functional Signal Signal

Item Connector Theory of Operation Normal Level
Description Source User
1 JPC3-1 VBUS Voltage Supply for USB.
2 JPC3-2 D– Used for USB Communication.
3 JPC3-3 D+ Used for USB Communication.
4 JPC3-4 DGND B– for USB. <0.5V
5 JPC6-2 DATA_OUT No usable data can be obtained.
6 JPC6-4 DGND This is the negative path for the <0.5V VM OD

operator display circuits.
7 JPC6-5 SHIFT_CLOCK No usable data can be obtained.
8 JPC6-6 +12V This is the positive path for the 12V 10.8 to 13V VM OD
supply to the Operator Display.
9 JPC9-2 TXD Connector for FlashWare.
10 JPC9-3 RXD Connector for FlashWare.
11 JPC9-5 DGND Connector for FlashWare.
12 JPC10-3 ENABLE Connection for VM to enable Key ON: 12V VM OCSS

Emitters for OCSS after the Deadman down: Emitters
Deadman pedal is depressed. <1V
13 JPC12-1 +5VP 5V supply from VM used for VR1 5V VM VR1, VR2

std. handle (Travel) and VR2 (Lift/Lower) pots.
14 JPC12-1 +5VP 5V supply from VM used for switches 5V VM Optional

opt. handle in optional handle. handle
switches

Pinout Matrix

15 JPC12-2 LIFT Input to VM from VR2. Neutral: 1.17V VR2 VM

Full Lift: 0.62V
Full Lwr: 1.68V
16 JPC12-3 TRAVEL Input to VM from VR1. Neutral: 1.0V VR1 VM

Full TF: 0.52V
Full FF: 1.60V
17 JPC12-4 FUNCTION 1 Input to VM from SW3. De-activated: SW3 VM

opt. handle 4.32V
Variable down to
0.597V fully
activated
18 JPC12-4 FUNCTION 1 Input to VM from S4. De-activated: 5V S4 VM

std. handle Activated: <1V
19 JPC12-5 SSHIFT Input to VM from SW4. Neutral: 2.44V SW4 VM

opt. handle Full Tilt Dn: 0.6V
Full Tilt Up: 4.36V
20 JPC12-5 TILT_UP Input to VM from S6. De-activated: 5V S6 VM

21 JPC12-6 TILT_Down Input to VM from S7. De-activated: 5V S7 VM

22 JPC12-7 H_HTR 8V to the heater in the optional Linear based on VM HTR6

opt. handle control handle. ambient temp.
0V @ 97°F,
8V @ 50°F
23 JPC12-8 TILT Input to VM from SW4. Neutral: 2.44V SW4 VM

opt. handle Full SS Right: 0.6V
Full SS Left: 4.36V
24 JPC12-8 SSHIFT_LEFT Input to VM from S8. De-activated: 5V S8 VM

25 JPC12-9 SSHIFT_RIGHT Input to VM from S9. De-activated: 5V S9 VM

26 JPC12-10 HORN Input to VM from SW1. De-activated: 5V SW1 VM

opt. handle Activated: <1V
27 JPC12-10 HORN Input to VM from S3. De-activated: 5V S3 VM

28 JPC12-11 FUNCTION 2 Input to VM from SW2. De-activated: SW2 VM

opt. handle 4.32V
Variable down to
0.597V fully
activated
29 JPC12-11 FUNCTION 2 Input to VM from S5. De-activated: 5V S5 VM

30 JPC12-12 DGND B– to control handle. <0.5V VM Handle

switches

Pinout Matrix

31 JPC14-1 B–F B–F for the VM. <0.5V TP4 VM
32 JPC14-2 DGND B–F for DGND on the VM. <0.5V TP4 VM
34 JPC14-4 BUS– The wire that carries the negative 2.185V VM VM,
component of the digital Power
communications between the VM Amps
and power amplifiers.
35 JPC14-6 RELAY_ENABLE Control path for K1, K2, K3, & K4 B+ w/Key Switch VM K1, K2,
on the Fuse/Relay Card. After S1 is ON and all relays K3, & K4
closed, all relays are energized de-energized;
simultaneously during SelfTest if the <0.5V w/Key
voltage at Battery_Sense_In is Switch OFF or ON
between 28 and 45V. If the vehicle and any relay
is equipped with optional heaters, energized
the VM may keep this circuit active
at B– even with the Key Switch OFF
(JPC14-7) to allow the heaters to run
based on the ambient temperature
sensor reading.
36 JPC14-7 B+K4 This is used for a circuit in the VM. If B+ w/Key Switch VM K4
the lift truck is equipped with the ON (B+ w/Key
optional heater assembly, the VM Switch OFF if truck
looks at the Ambient Temperature is equipped with
Sensor (JPC24-23) input to Cold Storage and
determine if the Relay Enable circuit ambient temp.
should remain activated in order to requires heaters to
have power remaining to the VM remain ON.
power supply.
40 JPC14-11 BUS+ The wire that carries the positive 2.8V VM VM,
component of the digital Power
communications between the VM Amps
and power amplifiers.
41 JPC14-12 B+KEY B+ that is switched by the Key Switch B+ S1 VM

(S1) to power functions on the VM
that are initiated after S1 is closed
and are not affected by the EPO.
This includes the VM power supplies,
the operation of the microprocessor,
and execution of the firmware.
42 JPC14-13 B+K2 B+ provided to the VM when the K2 B+ K2 VM

relay tips are closed. They are
de-energized when the EPO is open.

Pinout Matrix

43 JPC14-14 B+K2 B+ provided to the VM when the K2 B+ K2 VM

relay tips are closed. They are
de-energized when the EPO is open.
44 JPC18-1 AUX SELECT Control path for SOL6. Voltage Neutral: B+ VM SOL6
varies with different functions and SS Left: 23.7V
also depends on selection of SS Rt: 23.7V
sideshift percentage in Configure Tilt Up: 9.0V
Mode. Tilt Dn: 33.5V
45 JPC18-5 DGND DGND for OCSS lower left detector. <0.5V VM Lower Left
Detector
46 JPC18-6 DGND DGND for OCSS upper right <0.5V VM Upper

detector. Right
Detector
47 JPC18-9 LPC_CTRL Control path for LPC Contactor De-energized: B+ VM LPC Coil
(4100 only). Energized: 12.7V
48 JPC18-10 LOAD HOLD Control path for SOL1. De-energized: B+ VM SOL1

Energized: 13V
49 JPC18-11 STR_CONTACTOR Control path for Steering Contactor. De-energized: B+ VM Steering

Energized: 11.3V Contactor
Coil
50 JPC18-12 HSA1 Control path for SOL7R and SOL7C. De-energized: B+ VM SOL7R,
Energized: 12.7V SOL7C
51 JPC18-14 SIDESHIFT Control path for SOL9R and SOL9L. De-energized: B+ VM SOL9R,
Energized: 11.9V SOL9L
52 JPC18-15 TILT Control path for SOL10. De-energized: B+ VM SOL10

Energized: 10.6V
53 JPC18-16 HORN Control path for Horn. De-energized: B+ VM Horn

Energized: 0.1V
54 JPC18-18 TRAV/LIFT ALARM Control path for Trav/Lift Alarm. De-energized: B+ VM Trav/Lift
Energized: 0.09V Alarm
55 JPC20-1 +12VP 12V supply to optional OCSS Upper 10.8 to 13V VM Upper Left
Left Emitter. Emitter
56 JPC20-2 +12VP 12V supply to optional OCSS Lower 10.8 to 13V VM Lower Left
Left Detector. Detector
57 JPC20-3 +12VP 12V supply to optional Left Battery 10.8 to 13V VM S22A
Gate (S22A).
58 JPC20-4 +12VP 12V supply to optional Right Battery 10.8 to 13V VM S22B
Gate (S22B).
59 JPC20-5 +12VP 12V supply to optional Mast Tilt 10.8 to 13V VM S18
(Bottler’s Tilt) Switch (S18).
60 JPC20-6 +12VP 12V supply to optional Lift Limit 10.8 to 13V VM S12
Switch (S12).

Pinout Matrix

61 JPC20-8 +12VP 12V supply to optional (Bottler’s Tilt) 10.8 to 13V VM S11
Hi-Speed Limit Switch (S11).
62 JPC20-9 +12VP 12V supply to optional OCSS Lower 10.8 to 13V VM Lower
Right Emitter. Right
Emitter
63 JPC20-10 +12VP 12V supply to optional OCSS Upper 10.8 to 13V VM Upper
Right Detector. Right
Detector
64 JPC20-12 DUMP Control path for SOL3. No request: B+ VM SOL3

Feather Lift: 9.0V
Full Lift: 8.1V
Full Lift & Aux
Request: 7.0V
65 JPC20-13 ISENSE5(K2) B+ from the K2 relay to the SOL6 B+ VM SOL6

coil. This is also used to sense the
current drawn by SOL6.
66 JPC20-14 BRAKES Control path for the Brake coils. B+ without request VM Brakes
Brakes are released after a throttle and Key Switch
command has been initiated, and ON; Initial brake
are applied when travel has stopped release: 0.4V, then
or EPO is depressed. 16V
67 JPC20-15 ISENSE2(K2) B+ Supply from the K2 relay to the B+ VM SOL2

SOL2 coil. This is also used to sense
the current drawn by SOL2.
68 JPC20-16 LIFT/LOWER Control path for proportional SOL2. De-energized: B+ VR2 VM

(4100) Voltage should vary depending on Lift: 21 to 34V
the position of Lift pot (VR2). Lower: 35 to 19V
69 JPC20-16 LIFT/LOWER Control path for proportional SOL2. De-energized: B+ VR2 VM

(4200) Voltage should vary depending on Lower: 35 to 19V
the position of Lift pot (VR2).
70 JPC20-17 ISENSE3(K2) B+ from the K2 relay to SOL4 coil. B+ VM SOL4

This is also used to sense the current
drawn by SOL4.
71 JPC20-18 PRIORITY BYPASS Control path for SOL4. (Normal Key ON: B+ VM SOL4
std. handle Model 4100 voltages are approximate Sideshift: 22.75V
depending on sideshift setting in Tilt: 23.9V
Maintenance Mode.)
72 JPC20-18 PRIORITY BYPASS Control path for SOL4. (Normal Key Switch ON: VM SOL4
opt. handle Model 4200 voltages are approximate B+
depending on sideshift setting in Feather Lift: 12.4V
Maintenance Mode.) Full Lift: 11.4V
Tilt: 26V
Tilt & Lift: 20V
73 JPC20-19 ISENSE4(K2) B+ from the K2 relay to the SOL5 B+ VM SOL5

coil. This is also used to sense the
current drawn by SOL5.

Pinout Matrix

74 JPC20-20 PROP RELIEF Control path for SOL5. Lift: 9V VM SOL5

std. handle Aux: 34V
75 JPC20-20 PROP RELIEF Control path for SOL5. Full Lift: 33V VM SOL5
opt. handle Feather Lift: 12.4V
Full Lift: 11.4V
Tilt: 26V
Tilt & Lift: 20V
76 JPC22-3 GATE_L Input to the VM from the optional left Activated: approx. S22A VM
Battery Gate Switch (S22A). 0V
Not activated: 5V
77 JPC22-4 GATE_R Input to the VM from the optional Activated: approx. S22B VM
right Battery Gate Switch (S22B). 0V
Not activated: 5V
78 JPC22-5 TILT_DN Input to the VM from the optional Activated: approx. S18 VM
Mast Tilt Switch (S18) (Bottler’s Tilt). 0V
Not activated: 5V
79 JPC22-6 LIFT_LIM Input to the VM from the optional Lift Activated: approx. S12 VM
Limit Switch (S12). 0V
Not activated: 5V
80 JPC22-8 ON DEADMAN Input to the VM from the Deadman S2 open: approx. S2 VM

Switch (S2). 5V;
S2 closed: 0V
81 JPC22-9 POS C POS C input to the VM from the Activated: 1.36V Steer VM
Steer Position Sensor. Not activated: Position
8.12V Sensor
82 JPC22-10 DISP_MISO No usable data can be obtained.
83 JPC22-11 DGND DGND for Deadman Switch (S2). B– VM S2
84 JPC22-13 BEAM_L Input to the VM from the optional Clear: <1V Lower Left VM
Lower Left OCSS Detector (Deadman Blocked: 5V Detector
depressed).
85 JPC22-14 BEAM_R Input to the VM from the optional Clear: <1V Upper VM
Upper Right OCSS Detector Blocked: 5V Right
(Deadman depressed). Detector
86 JPC22-19 STR_SENSE Sense wire used by the VM to Contactor STR VM

determine the state of the Steer de-energized: Contactor
Contactor and FU1. <0.5V
Energized: B+
87 JPC22-20 LPC_SENSE Sense wire used by the VM to Contactor LPC VM

(4100) determine the state of the LPC de-energized: Contactor
Contactor and FU3 (4100 only). <0.5V
Energized: B+
88 JPC22-21 EPO_SENSE Sense wire used by the VM to EPO Closed: B+ S21 VM

determine when the EPO (S21) is Open: <0.5V
open. This is used to initiate braking
and display a message.

Pinout Matrix

89 JPC22-22 HIGH_SPD Input to the VM from the optional Activated: approx. S11 VM
Hi-Speed Limit Switch (S11) (Bottler’s 0V
Tilt). Not activated: 5V
90 JPC24-1 +12VP 12V supply to the Steer Position 10.8 to 13V VM Steer
Sensor from the VM. Position
Sensor
91 JPC24-3 DGND DGND for left Battery Gate Switch <0.5V VM S22A
(S22A).
92 JPC24-4 DGND DGND for right Battery Gate Switch <0.5V VM S22B
(S22B).
93 JPC24-5 DGND DGND for Mast Tilt Switch (S18). <0.5V VM S18
94 JPC24-6 DGND DGND for Lift Limit Switch (S12). <0.5V VM S12
95 JPC24-6 DGND DGND for Mast Tilt Speed Reduction <0.5V VM S12
Quad Mast Switch (S12).
96 JPC24-7 DGND DGND for Ambient Temperature <0.5V VM Ambient

Sensor. Temp
Sensor
97 JPC24-8 DGND DGND for Hi-Speed Limit Switch <0.5V VM S11

(S11).
98 JPC24-10 DGND DGND for Pressure (Weight) Sensor. <0.5V VM Pressure

Sensor
99 JPC24-12 DATA_LATCH No usable data can be obtained.
100 JPC24-13 +12VP 12V supply to the optional Pressure 10.8 to 13V VM Pressure
Sensor from the VM. Sensor
101 JPC24-14 ADDR_LATCH No usable data can be obtained.
102 JPC24-17 POS A POS A input to the VM from the Activated: 1.36V Steer VM
Steer Position Sensor. Not activated: Position
8.12V Sensor
103 JPC24-18 PRESSURE_AIN Input to the VM from the optional 0 to 5V Based on Pressure VM
Pressure Sensor. weight on forks Sensor
104 JPC24-20 POS B POS B input to the VM from the Steer Activated: 1.36V Steer VM
Position Sensor. Not activated: Position
8.12V Sensor
105 JPC24-22 TILT_AIN Not Used.
106 JPC24-23 AMBIENT Input to the VM from the optional 0 to 5V Based on Ambient VM
Ambient Temperature Sensor. ambient temp. Temp
Sensor

Pinout Matrix

107 JPC24-24 BATTERY_SENSE_IN B+ present when the battery is B+ (there should TP1 VM
plugged in. It is supplied through a be no voltage
thermistor on the Fuse/Relay Panel. drop)
This is used by the VM to determine
that the correct battery is connected.
It accepts between 28 and 45V. If
the correct battery is sensed, Relay
Enable is energized during start-up.
After startup, this voltage is used to
determine BSOC.
108 JPF1-1 B– B– for FU8 (15A/5A) Fuse for <0.5V TP4 Accessory
optional Accessory Power. Power
109 JPF1-2 B– B– for FU8 (15A/5A) for optional <0.5V TP4 Accessory
Accessory Power. Power
110 JPF1-3 ID0 Provides either B+F or B–F to B+ID0 K3 de-energized: K3 LPA
on the LPA. At Startup, the K3 coil is B– energized:
energized and this is used to identify Energized: B+ FU5
amplifiers. K3 de-
energized:
FU6
111 JPF1-4 B–F B– from FU8 (15A/5A) for optional <0.5V TP4 TS1-1 & 2
Accessory Power.
112 JPF1-5 ID0, ID1 Provides either B+F or B–F to B+ID’s K3 de-energized: K3 TPAs
on the TPAs. At startup, the K3 coil is B– energized:
energized and this is used to identify Energized: B+ FU5
amplifiers. K3 de-
energized:
FU6
113 JPF1-6 B+F or B–F Provides either B+F or B–F to B+K3 K3 de-energized: K3 Power
on the Power Amplifiers. At Startup, B– energized: Amplifiers
the K3 coil is energized, providing Energized: B+ FU5
B+ to the pre-charge circuit and logic K3 de-
circuits in the power amplifiers. With energized:
the K3 coil de-energized, JPF1-6 is at FU6
B– to discharge the amplifier
pre-charge circuits.
114 JPF2-1 B+K2 B+ supplied to the Steer Contactor, K2 energized: B+ K2 tips STR, LPC
LPC Contactor, and optional Power CNTR and
Amp Fan. optional
power
amp fan
115 JPF2-2 B+K2 B+K2 to power the Horn and K2 energized: B+ K2 tips Horn and
Travel/Lift Alarm. Travel/Lift
Alarm
116 JPF2-3 B+K2 B+ Supply from the K2 relay to the K2 energized: B+ K2 tips Right
Right Brake Coil. Brake Coil

Pinout Matrix

117 JPF2-4 B+K4 Supply input to the VM that allows K4 energized: B+ K4 tips VM
the VM to remain powered up with
the Key Switch OFF. This is used in
cold storage applications to allow
the handle heater circuit to work
based on input from the ambient
temperature sensor.
118 JPF2-5 B+K2 B+ from the K2 relay to the Left K2 energized: B+ K2 tips Left Brake
Brake Coil. Coil
119 JPF2-6 B+K2 B+ from the K2 relay to VM. K2 energized: B+ K2 tips VM
120 JPF2-7 B+K2 B+ from the K2 relay to VM. K2 energized: B+ K2 tips VM
121 JPF2-8 B+K2 B+ Supply from the K2 relay to K2 energized: B+ K2 tips SOL1, 3,
SOL1, 3, 7R, 7C, 9R, 9L, and 7R, 7C,
optional SOL11. 9R, 9L, &
SOL11
122 JPF2-9 B+Key B+ from the K1 relay to be used for K1 energized: B+ K1 tips TS1-5 & 6
accessory power after the Key
Switch is activated.
123 JPF3-1 B– B– for FU6 that provides B– to the <0.5V TP4 VM

VM.
124 JPF3-2 B– B– for FU6 that provides B– to the <0.5V TP4 VM

VM.
125 JPF3-3 DGND B–F for DGND on the VM. <0.5V FU6 VM
126 JPF3-4 DGND B–F for DGND on the VM. <0.5V FU6 VM
127 JPF3-5 B–F B–F for the VM. <0.5V FU6 VM
130 JPF4-1 B+ B+ from TP1 to FU5 to supply K4 coil B+ TP1 VM

and the K2, K4 relay tips. Also
supplies Battery_Sense_In to the VM.
131 JPF4-2 B+ B+ from TP1 to FU5 to supply the K4 B+ TP1 VM

coil and the K2, K4 relay tips. Also
supplies Battery_Sense_In to the VM.
132 JPF4-3 B+ B+ from TP1 to FU7 and K1 tips to B+ TP1 FU7 &
supply Accessory Power option. Accessory
Power
Option
133 JPF4-4 B+ B+ from TP1 to FU7 and K1 tips to B+ TP1 FU7 and
supply Accessory Power option. Accessory
Power
Option

Pinout Matrix

134 JPF4-5 B+EPO B+ supply from EPO to K1, K2, and EPO closed: B+ EPO K1, K2,
K3. All functions associated with Open: 0.05V K3
these relays are inoperable when the
EPO is open.
135 JPF4-7 BATTERY_SENSE_IN B+ present when the battery is B+ (there should TP1 VM
plugged in. It is supplied through a be no voltage
thermistor on the Fuse/Relay Panel. drop)
This is used by the VM to determine
that the correct battery is connected.
It accepts between 28 and 45V. If
the correct battery is sensed, Relay
Enable is energized during start-up.
After start-up, this voltage is used to
determine BSOC.
136 JPF4-8 BRAKES Control path for the Brake coils. B+ without request VM Brakes
Brakes are released after a throttle and Key Switch
command is initiated, and are ON;
applied when travel is stopped or Initial brake
EPO is depressed. release: 0.4V, then
16V
137 JPF4-10 B+F B+ to the Key Switch. B+ FU5 S1
138 JPF4-11 BRAKES (Left) Control path for the left brake coil. B+ without request VM Brakes
Brake is released after a throttle and Key Switch
command is initiated, and is applied ON;
when travel is stopped or EPO is Initial brake
depressed. release: 0.4V, then
16V
139 JPF4-12 BRAKES (Right) Control path for the right brake coil. B+ without request VM Brakes
Brake is released after a throttle and Key Switch
command is initiated, and is applied ON;
when travel is stopped or EPO is Initial brake
depressed. release: 0.4V, then
16V
140 JPF4-13 RELAY_ENABLE Control path for K1, K2, K3, and K4 B+ w/Key Switch VM K1, K2,
on the Fuse/Relay Card. After S1 is ON and all relays K3 & K4
closed, all relays are energized de-energized;
simultaneously during SelfTest if the <0.5 w/Key
voltage at BATTERY_SENSE_IN is Switch OFF or ON
between 28 and 45V. If the vehicle and any relay
is equipped with optional heaters, energized
the VM may keep this circuit active
at B– even with the Key Switch OFF
(JPC14-7) to allow the heaters to run
based on the ambient temperature
sensor input.
141 JPL1-1 B+K3 B+ to the LPA. Present when K3 is K3 energized: B+ K3 LPA

energized.

Pinout Matrix

142 JPL1-6 LPC Control path for the LPC. The Lift LPC de-energized: LPA LPC
Power Amplifier supplies a path for B+
B– for the contactor by the way of Energized:14.7V
the B– terminal.
143 JPL1-7 L VEL SENSOR– Return path for the encoder in the Lift <0.5V LPA Lift
Motor. Encoder
144 JPL1-8 T TEMP+ Temp Sensor input to the LPA. Approx. 1V @ Lift Motor LPA
Analog voltage that varies with the 75ºF (24ºC) Temp
Lift Motor temperature. Sensor
145 JPL1-11 ID0 B+ present at the amp with the K3 K3 energized: K3 LPA
tips activated. It is used as an approx. B+
identifier.
146 JPL1-12 ID1 Not Used
147 JPL1-13 B+K3 B+ for the LPC (4200 only). The Lift Key Switch ON: LPA LPC Coil
Power Amplifier supplies B+ for the B+
LPC.
148 JPL1-23 BUS+ Positive component of the digital 2.8V VM VM,

communications (CAN Bus) between Power
the VM and Power Amplifiers. Amps
149 JPL1-26 L VEL SENSOR+ 5V to the encoder on the Lift Motor. 4.95V LPA Lift
Encoder
150 JPL1-31 L VEL PHASE A Input to LPA from Lift Motor Encoder. Motor Stationary: Lift LPA
It is a square wave that is either high 4.06 or 0.03V Encoder
(>3V) or low (<1V). The frequency Turning: 2.3V
varies directly with motor speed.
Identical to L VEL Phase B except for
phase. The LPA uses the relationship
between phases to determine lift
speed.
151 JPL1-32 L VEL PHASE B Input to LPA from Lift Motor Encoder. Motor Stationary: Lift LPA
Identical to L VEL Phase A except for
phase. The LPA uses the relationship
between phases to determine lift
speed.
152 JPL1-33 BUS– Negative component of the digital 2.185V VM VM,

153 JPTL1-1 B+K3 B+ to Left TPA. Present when K3 is K3 energized: B+ K3 Left TPA
energized.
154 JPTL1-7 T VEL SENSOR– Return path for the encoder in the <0.5V Left TPA TML
Left Traction Motor (TML). Encoder

Pinout Matrix

155 JPTL1-8 T TEMP+ TML Temp Sensor input to the left Approx. 1V @ TML Temp Left TPA
TPA. Analog voltage that varies with 75ºF (24ºC) Sensor
motor temperature.
156 JPTL1-11 NOT USED
157 JPTL1-12 ID1 B+ present at the amp with the K3 K3 energized: B+ K3

tips activated. It is used as an –1V
identifier.
158 JPTL1-21 CAN TERM H Connection used to terminate the K3 energized: Left TPA Left TPA
BUS+, BUS– communication. 2.96V
159 JPTL1-23 BUS+ Positive component of the digital 2.8V VM VM,

160 JPTL1-26 T VEL SENSOR+ 5V supply to the TML Encoder. This 4.95V Left TPA TML
voltage is produced by the left TPA Encoder
from B+K3.
161 JPTL1-31 T VEL PHASE A Input from TML Encoder to left TPA. It Motor Stationary: TML Left TPA
is a square wave that is either high 4.06V or 0.03V Encoder
Identical to T VEL Phase B except for
phase. The left TPA uses the
relationship between phase A and B
to determine travel speed and
direction.
162 JPTL1-32 T VEL PHASE B Input from TML Encoder to left TPA. It Motor Stationary: TML Left TPA
is a square wave that is either high 4.06 or 0.03V Encoder
Identical to T VEL Phase A except for
phase. The TPA uses the relationship
between phase A and B to determine
travel speed and direction.
163 JPTL1-33 BUS– Negative component of the digital 2.185V VM VM,

164 JPTL1-34 CAN TERM L Connection used to terminate the K3 energized: Left TPA Left TPA
BUS+, BUS– communication. 2.96V
165 JPTR1-1 B+K3 B+ to Right TPA. Present when K3 is K3 energized: B+ K3 Right TPA
energized.
166 JPTR1-6 TPC Control path for the TPC. The right TPC de-energized: Right TPA TPC
TPA supplies a path for B– for the B+
contactor. Energized: 14.7V
167 JPTR1-7 T VEL SENSOR– Return path for the encoder in the <0.5V Right TPA TMR
Right Traction Motor (TMR). Encoder

Pinout Matrix

168 JPTR1-8 T TEMP+ TMR Temp Sensor input to the right Approx. 1V @ TMR Temp Right TPA
TPA. Analog voltage that varies with 75ºF (24ºC) Sensor
motor temperature.
169 JPTR1-11 ID0 B+ present at the amp with the K3 K3 energized: K3 VM

identifier.
170 JPTR1-12 ID1 B+ present at the amp with the K3 K3 energized: K3 VM

identifier.
171 JPTR1-13 B+K3 B+ to the TPC from the right TPA. B+ w/Key Switch TPA TPC Coil
ON
172 JPTR1-23 BUS+ Positive component of the digital 2.8V VM VM,

communications between the VM Power
and Power Amps. Amps
173 JPTR1-26 T VEL SENSOR+ 5V supply to the TMR Encoder. This 4.95V Right TPA TMR
voltage is produced by the Right TPA Encoder
from B+K3.
174 JPTR1-31 T VEL PHASE A Input from TMR Encoder to right TPA. Motor Stationary: TMR Right TPA
Identical to T VEL Phase B except for
phase. The right TPA uses the
direction.
175 JPTR1-32 T VEL PHASE B Input from TMR Encoder to right TPA. Motor Stationary: TMR Right TPA
Identical to T VEL Phase A except for
phase. The right TPA uses the
direction.
176 JPTR1-33 BUS– Negative component of the digital 2.185V VM VM,


Pinout Matrix

Models 4100/4200 Maintenance Manual Section A. Appendix
Section A. Appendix
Publication: 1060345, Re-issued: 01 Jul 2010 A-1

Section A. Appendix Models 4100/4200 Maintenance Manual
Lubrication Specification Chart
Lubrication Specification
Chart
Approved Raymond Lubricants
Where Used Type Specification Raymond Part Number
75W-90 Synthetic Gear

Drive Unit Gear Case Gear 990-655/001 (1 qt./0.9 liter)
Oil
(all applications) Lubricant 990-655/003 (1 gal/3.8 liters)
API Service GL-5
Hydraulic Reservoir
ISO 46 990-616/04 (1 qt./0.9 liter)
(Non-CS trucks) Hydraulic
Anti-Wear Hydraulic 990-616/01 (1 gal/3.8 liters)
(+50°F to +120°F) Fluid
Fluid 990-616/03 (5 gal/18.9 liters)
(+10°C to +49°C)
Hydraulic Reservoir
(CS trucks - in and out of
Hydraulic 1017238
freezer) ISO VG32
Fluid Note: Do not add any additives.
0°F to +50°F
(–18°C to +10°C)
Hydraulic Reservoir
(CS trucks - confined to
Hydraulic 990-618/TX1 (1 gal/3.8 liters)
freezer) MIL-H-5606E
Fluid 990-618/01 (1 gal/3.8 liters)
–20°F to 0°F
(–29°C to –18°C)
Mast Uprights, Bearings, 1012992/01 (10 cartridges/case)

Grease NLGI Grade 2
etc. 1012992/02 (5 gal/18.9 liters)
Teflon
Chains Aerosol 990-652/001 (spray)
Grease
A-2 Publication: 1060345, Re-issued: 01 Jul 2010

Thread Adhesives, Sealants, and Lubricants
Thread Adhesives,
Sealants, and Lubricants
Loctite*
Application Raymond P/N
Number/Color
Thread-locking 1/4 in. and below 990-403 222/Purple
Thread-locking 1/4 to 3/4 in. contamination tolerant 990-536 243/Blue
Thread-locking 1 in. and under 990-544 271/Red
Thread-locking 1 in. and under, contamination tolerant 990-463 603/Green
Thread-locking 1 in. and over 990-571 277/Red
Thread-locking Cleaner/Primer 990-538 7075
Thread-locking Primer 990-533 T7471
Hydraulic Sealant, fittings up to 2 in. 990-552 569
Molybdenum Anti-Seize Compound (Molykote) 990-638 Silver
Gasket Cement 990-556 Permatex 300
Cover Plate Sealant 990-443 587/UltraBlue
Corrosion Inhibitor Coating 990-456/001
Silicone Sealant (cold storage) 990-445 Dow Corning III
*Loctite is a registered trademark of the Loctite Corporation. Brand endorsement is not implied here, but
listed only as a commonly identified product.

Component Specific Torque Chart
Component Specific
Torque Chart
Thread-Locking
Component Sub-Component(s) Torque to:
Compound
Brake mounting to traction motor 13 ft. lb. (18.2 Nm)
coil mtg. to lower friction 9 ft. lb. (12 Nm)
plate
Drive Axle clamp nut 125 ft. lb. (170 Nm)
clamp nut screw P/N 990-536 140 in. lb. (8 Nm)
Drive Unit cover screws 6 ft. lb. (8.6 Nm)
tractor frame mtg. bolts 120 ft. lb. (168 Nm)
Drive Wheels mounting bolts 108 ft. lb. (146 Nm)
Hydraulic Steer Motor sprocket set screws P/N 990-536 N/A
Lift Cylinders end caps P/N 990-571 200 ft. lb. (271 Nm)
Lift Motor cable securing nut (top) 12.5 to 18.4 ft. lb. (23 to 25 Nm)
cable securing nut (bottom) 10.7 to 11 ft. lb. (14.5 to 15 Nm)
Mast lower and upper mtg. bolts 43 ft. lb. (60 Nm)
Mast, Quad cover cap screw 63 ft. lb. (18.2 Nm)
clamp cap screw 11 ft. lb. (15 Nm)
Power Amplifiers mounting bolts 7.4 ft. lb. (10 Nm)
Power Amplifiers power cables 100 in. lb. (11.3 Nm)
Free lift cylinder supply hose 5.9 ft. lb. (8 Nm)
clamp
Solenoid Coils securing nut 5 ft. lb. (7 Nm)
Solenoid Valves N/A 60 ft. lb. (81 Nm)
Speed Feedback Sensor mounting bolts P/N 990-536 N/A
Steer Motor impeller shroud mtg. screws P/N 990-536 N/A
cable securing nut (top) 7.5 -9.5 ft. lb. (10.2 - 12.5 Nm)
cable securing nut (bottom) 9.2 -11.7 ft. lb. (12.5 - 15.9 Nm)
mtg. bolts (qty. 4) P/N 990-536 Reference “Torque Chart -
Standard (Ferrous)” on page A-5
Steer Reference (Home) sensor mtg. screws (qty. 4) P/N 990-536 N/A
Proximity Sensor bracket mtg. bolts (qty. 2) P/N 990-536 N/A
Tire Replacement A minimum pressure of 5 tons (4536 kg) is required to press on a new tire. If the
minimum pressure is not met, replace the hub.
Traction Motors mtg. bolts 13 ft. lb. (18.2 Nm)
cable securing nuts (top) 12.5 to 18.4 ft. lb. (23 to 25 Nm)
cable securing nuts (bottom) 10.7 to 11 ft. lb. (14.5 to 15 Nm)
pinion shaft 45 ft. lb. (63 Nm)

Torque Chart - Standard (Ferrous)
Torque Chart - Standard

(Ferrous)
Grade
Identification None
Marking
SAE Grade 2 Bolts SAE Grade 5 Bolts SAE Grade 8 Bolts
Tightening Torque Tightening Torque Tightening Torque
Size
Dry Oiled Dry Oiled Dry Oiled
in. lb. in. lb. in. lb. in. lb. in. lb. in. lb.
4-40 5 4 8 6 12 9
4-48 6 5 9 7 13 10
6-32 10 8 16 12 23 17
8-32 19 14 30 22 41 31
8-36 20 15 31 23 43 32
10-24 27 21 43 32 60 45
10-32 31 23 49 36 68 51
1/4-20 66 49 96 75 144 108
1/4-28 78 56 120 86 168 120
ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb.
5/16-18 11 8 17 13 25 18
5/16-24 12 9 19 14 25 20
3/8-16 20 15 30 23 45 35
3/8-24 23 17 35 25 50 35
7/16-14 30 24 50 35 70 55
7/16-20 35 25 55 40 80 60
1/2-13 50 35 75 55 110 80
1/2-20 55 40 90 65 120 90
9/16-12 65 50 110 80 150 110
9/16-18 75 55 120 90 170 130
5/8-11 90 70 150 110 220 170
5/8-18 110 85 180 130 240 180
3/4-10 160 120 260 200 380 280
3/4-16 180 140 300 220 420 320
7/8-9 140 110 400 300 600 460
7/8-14 155 120 440 320 660 500
1-8 220 160 580 440 900 680
1-12 240 170 640 480 1000 740
1 1/8-7 300 220 800 600 1280 960
1 1/8-12 340 260 880 660 1440 1080
1 1/4-7 420 320 1120 840 1820 1360
1 1/4-12 460 360 1240 920 2000 1500
1 3/8-6 560 420 1460 1100 2380 1780
1 3/8-12 640 460 1680 1260 2720 2040
1 1/2-6 740 560 1940 1460 3160 2360
1 1/2-12 840 620 2200 1640 3560 2660
Note: Use “oiled” values for bolts with thread-locking compound.

Torque Chart - Metric
Torque Chart - Metric

Ferrous Metric Bolts, Coarse Thread
(The grade rating is stamped on the head of the bolt)
Grade 8.8 Grade 10.9
Diameter
Torque (with bolts oiled) Torque (with bolts oiled)
(in millimeters)
Nm ft. lb. Nm ft. lb.
6 8.6 6 12 9
8 21 15 29 21
10 42 30 68 43
12 72 55 101 75
16 174 130 245 181
20 340 255 475 350
24 580 435 820 605
Brass MS63 Metric Bolts, Coarse Thread

Diameter Torque (with bolts oiled)
(in millimeters) Nm in. lb.
3 0.5 4.4
3.5 0.79 7.0
4 1.2 10
5 2.2 19
6 3.9 34
8 9 79
10 17 150

Torque Chart - Standard (Brass)
Torque Chart - Standard

(Brass)
Brass MS63 Standard Bolts, Coarse Thread
Torque (with bolts oiled)
Size
Nm in. lb.
4-40 0.37 3.3
4-48 0.40 3.6
6-32 0.69 6.1
6-40 0.77 6.8
8-32 1.24 11
8-36 1.24 11
10-24 1.58 14
10-32 1.92 17
1/4-20 3.96 35
1/4-28 4.52 40
5/16-18 8.25 73
5/16-24 9.15 81
3/8-16 14.69 130
3/8-24 16.61 147

Decimal Equivalent Chart

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
1/64 .016 .02 0.397
1/32 .031 .03 0.794
3/64 .047 .05 1.191
1/16 .062 .06 1.587
5/64 .078 .08 1.984
3/32 .094 .09 2.381
7/64 .109 .11 2.778
1/8 .125 .12 3.175
9/64 .141 .14 3.572
5/32 .156 .16 3.969
11/64 .172 .17 4.366
3/16 .188 .19 4.762
13/64 .203 .20 5.159
7/32 .219 .22 5.556
15/64 .234 .23 5.593
1/4 .250 .25 6.350
17/64 .266 .27 6.747
9/32 .281 .28 7.144
19/64 .297 .30 7.540
5/16 .312 .31 7.937
21/64 .328 .33 8.334
11/32 .344 .34 8.731
23/64 .359 .36 9.128
3/8 .375 .38 9.525
25/64 .391 .39 9.922
13/32 .406 .41 10.319
27/64 .422 .42 10.716
7/16 .438 .44 11.112
29/64 .453 .45 11.509
15/32 .469 .47 11.906
31/64 .484 .48 12.303
1/2 .500 .50 12.700

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
33/64 .516 .52 13.097
17/32 .531 .53 13.494
35/64 .547 .55 13.891
9/16 .562 .56 14.288
37/64 .578 .58 14.684
19/32 .594 .59 15.081
39/64 .609 .61 15.478
5/8 .625 .62 15.875
41/64 .641 .64 16.272
21/32 .665 .66 16.669
43/64 .672 .67 17.065
11/16 .688 .69 17.462
45/64 .703 .70 17.859
23/32 .719 .72 18.256
47/64 .734 .73 18.653
3/4 .750 .75 19.050
49/64 .766 .77 19.447
25/32 .781 .78 19.844
51/64 .797 .80 20.241
13/16 .812 .81 20.637
53/64 .828 .83 21.034
27/32 .844 .84 21.431
55/64 .859 .86 21.828
7/8 .875 .88 22.225
57/64 .891 .89 22.622
29/32 .906 .91 23.019
59/64 .922 .92 23.416
15/16 .938 .94 23.812
61/64 .953 .95 24.209
31/32 .969 .97 24.606
63/64 .984 .98 25.003
1.000 1.00 25.400

Standard/Metric Conversions
Standard/Metric
Conversions
To Convert... Multiply, Add, or Subtract...
Area
Square Inches to Square Centimeters Square Inches x 6.452
Square Centimeters to Square Inches Square Centimeters x 0.155
Square Feet to Square Meters Square Feet x 0.093
Square Meters to Square Feet Square Meters x 10.753
Square Yards to Square Meters Square Yards x 0.836
Square Meters to Square Yards Square Meters x 1.196
Distance
Inches to Millimeters Inches x 25.4
Millimeters to Inches Millimeters x 0.039
Inches to Centimeters Inches x 2.54
Centimeters to Inches Centimeters x 0.394
Feet to Meters Feet x 0.305
Meters to Feet Meters x 3.281
Yards to Meters Yards x 0.914
Meters to Yards Meters x 1.094
Miles to Kilometers Miles x 1.609
Kilometers to Miles Kilometers x 0.621
Mass
Ounces to Grams Ounces x 28.35
Grams to Ounces Ounces x 0.035
Ounces to Kilograms Ounces x 0.028
Kilograms to Ounces Kilograms x 35.27
Pounds to Kilograms Pounds x 0.454
Kilograms to Pounds Kilograms x 2.2
Pressure
Pounds per Square Inch (PSI) to kiloPascals PSI x 6.894
kiloPascals to Pounds per Square Inch (PSI) kiloPascals x 0.145
Speed
Miles per hour to Kilometers per hour Miles per hour x 1.609
Kilometers per hour to Miles per hour Kilometers per hour x 0.6214
Temperature
Fahrenheit to Celsius (°F minus 32) x 0.555
Celsius to Fahrenheit (°C x 1.8) plus 32
Torque
Inch Pounds (in. lbs.) to Newton Meters (Nm) Inch Pounds x 0.113
Newton Meters (Nm) to Inch Pounds (in. lbs.) Newton Meters x 8.85
Foot Pounds (ft. lbs.) to Newton Meters (Nm) Foot Pounds x 1.3568
Newton Meters (Nm) to Foot Pounds (ft. lbs.) Newton Meters x 0.737
Volume
Pints to Liters Pints x 0.473
Liters to Pints Liters x 2.113
Quarts to Liters Quarts x 0.946
Liters to Quarts Liters x 1.057
Gallons to Liters Gallons x 3.785
Liters to Gallons Liters x 0.26

Models 4100/4200 Maintenance Manual Section I. Index
Section I. Index
A Storage Preparation . . . . . . . . . . . 3-24
Charts
AC Motors . . . . . . . . . . . . . . . . . . . . . . 5-8 Decimal Equivalent . . . . . . . . . . . . . A-8
Adjustment Torque
Attachment Pressure . . . . . . . . . . 3-22 Component Specific . . . . . . . . . . A-4
Free Lift Cylinder Supply Hose Metric . . . . . . . . . . . . . . . . . . . . A-6
Model 4200 . . . . . . . . . . . . . . 7-80 Standard (Brass) . . . . . . . . . . . . A-7
Lift Chain . . . . . . . . . . . . . . . . . . 7-98 Standard (Ferrous) . . . . . . . . . . A-5
Mast Tilt . . . . . . . . . . . . . . . . . . .7-100 Check Valve
System Pressure . . . . . . . . . . . . . 7-70 CV1 . . . . . . . . . . . . . . . . . . . . . . . 7-64
Attachment Control . . . . . . . . . . . . . . 3-20 Check Valve (CV1) . . . . . . . . . . . . . . . . 8-5
Attachment Solenoids (SOL7C/R) . . . . 8-5 Checking Hydraulic Oil Level, see Oil . 7-68
Attachments Codes . . . . . . . . . . . . . . . . . . . 6-11 to 6-27
Setup and Operation . . . . . . . . . . 3-21 Cold Storage . . . . . . . . . . . . . . . . . . . . 3-23
Aux Prop Valve SOL5 . . . . . . . . . . . . . 7-64 Conditioning . . . . . . . . . . . . . . . . . 3-23
Aux Select (SOL6) . . . . . . . . . . . . . . . . 8-5 Communication Error Code
Troubleshooting . . . . . . . . . . . . . . 5-10
Commutator . . . . . . . . . . . . . . . . . . . . . 5-5
B Configure Mode . . . . . . . . . . . . . . . . . 3-12
Configure Mode Menu . . . . . . . . . . . . 3-14
Battery Connector
BSOC . . . . . . . . . . . . . . . . . . . . . . 5-9 Battery . . . . . . . . . . . . . . . . . . . . . 7-42
Cables . . . . . . . . . . . . . . . . . . . . . 7-42 Connectors
Charging . . . . . . . . . . . . . . . . . . . 7-43 AMP . . . . . . . . . . . . . . . . . . . . . . . 7-55
Cleaning Exterior . . . . . . . . . . . . . 7-43 General . . . . . . . . . . . . . . . . . . . . . 7-55
Maintenance . . . . . . . . . . . . . . . . 7-43 Molex . . . . . . . . . . . . . . . . . . . . . . 7-55
Safety . . . . . . . . . . . . . . . . . . . . . . 2-5 Power Amp . . . . . . . . . . . . . . . . . . 7-60
State-of-Charge (BSOC) . . . . . . . . 7-43 Repair . . . . . . . . . . . . . . . . . . . . . . 7-55
Testing . . . . . . . . . . . . . . . . . . . . 7-43 Contactors . . . . . . . . . . . . . . . . . . . . . 4-10
Bleeding Hydraulic System . . . . . . . . 7-68 LPC . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Model 4100 . . . . . . . . . . . . . . . . . 7-68 STR . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Model 4200 . . . . . . . . . . . . . . . . . 7-69 Tests
Brakes . . . . . . . . . . . . . . . . . . . . . . . 7-38 LPC . . . . . . . . . . . . . . . . . . . . . 6-84
Disassembly . . . . . . . . . . . . . . . . 7-38 Steer . . . . . . . . . . . . . . . . . . . . 6-83
Installation . . . . . . . . . . . . . . . . . 7-39 TPC . . . . . . . . . . . . . . . . . . . . . 6-82
Brushes . . . . . . . . . . . . . . . . . . . . . . 7-46 TPC . . . . . . . . . . . . . . . . . . . . . . . . 8-4
BSOC (Battery State-of-Charge) . . . . . 7-43 Control Handle
Bulletins, Service . . . . . . . . . . . . . . . . . . iv Optional . . . . . . . . . . . . . . . . . . . . 7-18
Soldering Procedures . . . . . . . . . . 7-16
C Standard . . . . . . . . . . . . . . . . . . . 7-15
Conversions, Standard/Metric . . . . . . A-10
Cables, Power . . . . . . . . . . . . . . . . . . 7-44 Counterbalance Check Valves
CAN Bus (CB-1, CB-2) . . . . . . . . . . . . . . . . . . 8-5
Test . . . . . . . . . . . . . . . . . . . . . . . 6-38 CV1 Check Valve . . . . . . . . . . . . . . . . 7-64
Theory of Ops . . . . . . . . . . . . . . . . 8-3 Cylinder
Carriage Piston Removal . . . . . . . . . . . . . . . 7-71
Installation - Model 4200 . . . . . . . 7-81 Quad Mast
Removal - Model 4200 . . . . . . . . . 7-81 Free Lift
Chain, Lift . . . . . . . . . . . . . . . . . . . . . 7-98 Installation . . . . . . . . . . . . 7-93
Publication: 1060345, Re-issued: 01 Jul 2010 I-1

Section I. Index Models 4100/4200 Maintenance Manual
Removal . . . . . . . . . . . . . . . 7-93 E
Main
Installation . . . . . . . . . . . . 7-93 Electrostatic Discharge . . . . . . . . . . . . 2-7
Removal . . . . . . . . . . . . . . . 7-92 ESD
Service . . . . . . . . . . . . . . . . . . . . . 7-71 Antistatic Kit . . . . . . . . . . . . . . . . . 2-7
Storage Preparation . . . . . . . . . . . . 3-24 Precautions . . . . . . . . . . . . . . . . . . 2-7
Cylinder, Free Lift
Installation
TT Mast/Model 4200 . . . . . . . . 7-80 F
Removal
TT Mast/Model 4200 . . . . . . . . 7-79 Filter, Hydraulic . . . . . . . . . . . . . . . . . 7-64
Supply Hose/Model 4200 FlashWare
Tracking and Tension Changing Options . . . . . . . . . . . . . . 3-7
Adjustment . . . . . . . . . . . . 7-80 Starting . . . . . . . . . . . . . . . . . . . . . 3-4
Cylinder, Main FlashWare Program . . . . . . . . . . . . . . . 3-4
Installation Fluids, see Oil . . . . . . . . . . . . . . . . . . 7-68
TF Mast/Model 4200 . . . . . . . . 7-78 Forks
TT Mast/Model 4200 . . . . . . . . 7-79 Inspection . . . . . . . . . . . . . . . . . . 4-12
Removal Fraction to Decimal Conversion . . . . . . A-8
TF Mast/Model 4200 . . . . . . . . 7-77 Fuse/Relay Card
TT Mast/Model 4200 . . . . . . . . 7-79 Theory of Ops . . . . . . . . . . . . . . . . . 8-4
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
D
H
DC Motor
Brushes . . . . . . . . . . . . . . . . . . . . 7-46 Harness Connectors . . . . . . . . . . . . . . 7-55
Test . . . . . . . . . . . . . . . . . . . . . . . . .5-7 Hose Reeving
Troubleshooting . . . . . . . . . . . . . . .5-5 Quad Mast . . . . . . . . . . . . . . . . . . 7-93
Decimal to Fraction Conversion . . . . . .A-8 TF Mast/Model 4200 . . . . . . . . . . 7-82
Default Passwords, see Passwords . . . 3-18 TT Mast/Model 4200 . . . . . . . . . . 7-84
Display Messages . . . . . . . . . . . . . . . . 3-11 Hose, Supply
Drive Motor, see Motors . . . . . . . . . . . 7-51 Free Lift Cylinder/Model 4200
Drive Unit Adjustment . . . . . . . . . . . . . . . 7-80
Adding Oil . . . . . . . . . . . . . . . . . . . 7-25 Hydraulic
Assembly Procedures . . . . . . . . . . 7-32 Components . . . . . . . . . . . . . . . . . 7-64
Axle Shaft Cylinder Service . . . . . . . . . . . . . . 7-71
Assembly . . . . . . . . . . . . . . . . . 7-34 Filter . . . . . . . . . . . . . . . . . . . . . . 7-64
Bearing Installation System Storage Preparation . . . . . 3-24
Shim Calculation . . . . . . . . . . . 7-32 Hydraulic Filter . . . . . . . . . . . . . .7-64, 8-5
Disassembly Hydraulic Fluid, see Oil . . . . . . . . . . . 7-68
Bearings . . . . . . . . . . . . . . . . . 7-29 Hydraulic Oil, Selecting, see Oil . . . . . 7-68
Disassembly Procedure . . . . . . . . . 7-28 Hydraulic System
Exploded View . . . . . . . . . . . . . . . . 7-26 Bleeding . . . . . . . . . . . . . . . . . . . . 7-68
Housing Disassembly Bleeding - Model 4100 . . . . . . . . . 7-68
Helical Gear . . . . . . . . . . . . . . . 7-29 Bleeding - Model 4200 . . . . . . . . . 7-69
Spiral Gear . . . . . . . . . . . . . . . 7-29
Troubleshooting . . . . . . . . . . . . . . 7-27 I
Drive Units . . . . . . . . . . . . . . . . . . . . . 7-24
Dump Valve (SOL3) . . . . . . . . . . . . . . . .8-5 Improvement Notices, Product . . . . . . . . . v
Input Tests . . . . . . . . . . . . . . . . . . . . 6-29
Inspection
I-2 Publication: 1060345, Re-issued: 01 Jul 2010

Battery Connector . . . . . . . . . . . . 7-42 M

Brakes . . . . . . . . . . . . . . . . . . . . . 7-38
Commutator . . . . . . . . . . . . . . . . . 5-5 Maintenance
Contactors . . . . . . . . . . . . . . . . . . 4-10 180 Day/500 HD . . . . . . . . . . . . . . 4-6
Control Handle . . . . . . . . . . . . . . 7-16 360 Days/1500 HD . . . . . . . . . . . . . 4-9
Forks . . . . . . . . . . . . . . . . . . . . . . 4-12 90 Day . . . . . . . . . . . . . . . . . . . . . . 4-5
Fuses . . . . . . . . . . . . . . . . . . . . . . 5-4 Maintenance Minder . . . . . . . . . . . . . . . 4-3
Lift Chain . . . . . . . . . . . . . . . . . . 4-11 Disabling . . . . . . . . . . . . . . . . . . . . 4-4
Motor Brushes . . . . . . . . . . . . . . . 7-46 Enabling . . . . . . . . . . . . . . . . . . . . . 4-3
Quad Mast . . . . . . . . . . . . . . . . . 7-87 Menu . . . . . . . . . . . . . . . . . . . . . . 3-15
Quad Mast Check Valve . . . . . . . . 7-72 Maintenance Mode . . . . . . . . . . . . . . . 3-16
Upright - Model 4200 . . . . . . . . . . 7-74 Maintenance Mode Menu . . . . . . . . . . 3-17
Wiring/Harness . . . . . . . . . . . . . . 7-55 Maintenance, Scheduled . . . . . . 4-2 to 4-15
Manual Design . . . . . . . . . . . . . . . . . . . 1-3
K Map, Navigating the Manual . . . . . . . . . 1-2
Mast
Kit, Antistatic . . . . . . . . . . . . . . . . . . . 2-7 Disassembly
TF Mast/Model 4200 . . . . . . . . 7-77
TT Mast/Model 4200 . . . . . . . . 7-78
L
Installation . . . . . . . . . . . . . . . . . . 7-75
Quad
L/L Pot Test . . . . . . . . . . . . . . . . . .. 6-49 Check Valve . . . . . . . . . . . . . . 7-72
Learn Mode Menu . . . . . . . . . . . . . .. 3-17 Hose Reeving . . . . . . . . . . . . . . 7-93
Lift Chain . . . . . . . . . . . . . . . . . . . .. 7-98 Hose Replacement . . . . . . . . . . 7-93
Adjustment . . . . . . . . . . . . . . . .. 7-98 Reassembly
Inspection and Maintenance . . .. 4-11 Quad Mast . . . . . . . . . . . . . . . 7-89
Maintenance . . . . . . . . . . . . . . .. 4-11 TF Mast/Model 4200 . . . . . . . . 7-77
Storage Preparation . . . . . . . . . .. 3-24 TT Mast/Model 4200 . . . . . . . . 7-78
Lift Cylinder Skewing - Model 4200 . . . . . . . . . . 7-74
Piston Removal . . . . . . . . . . . . . . 7-71 TF Hose Reeving/Model 4200 . . . . 7-82
Service . . . . . . . . . . . . . . . . . . . . 7-71 Tilt Adjustment . . . . . . . . . . . . . . 7-100
Lift Motor, see Motors . . . . . . . . . . . . 7-53 TT Hose Reeving/Model 4200 . . . . 7-84
Lift Power Amp Upright Inspection - Model 4200 . . 7-74
Theory of Ops . . . . . . . . . . . . . . . . 8-3 Mast Service . . . . . . . . . . . . . . . . . . . . 7-74
Lift Power Amplifier . . . . . . . . . . . . . . 7-54 Mast, Main
Lift/Aux Pump (P1) . . . . . . . . . . . . . . . 8-4 Lift Chain . . . . . . . . . . . . . . . . . . . 7-98
Lift/Lower Memory Location . . . . . . . . . . . . . . . . . 8-2
Potentiometer . . . . . . . . . . . . . . . 7-18 Menu
Theory of Ops . . . . . . . . . . . . 8-9, 8-11 Attachment . . . . . . . . . . . . . . . . . . 3-20
Valve (SOL2) . . . . . . . . . . . . . . . . . 8-5 Configure Mode . . . . . . . . . . . . . . 3-14
Lights Learn Mode . . . . . . . . . . . . . . . . . . 3-17
Steering Indicator . . . . . . . . . . . . 3-11 Maintenance Minder . . . . . . . . . . . 3-15
Load Holding Valve (SOL1) . . . . . . 7-64, 8-5 Maintenance Mode . . . . . . . . . . . . 3-17
LPC Contactor . . . . . . . . . . . . . . . . . . . 8-4 Messages . . . . . . . . . . . . . . . . . 6-7 to 6-10
Lubricants . . . . . . . . . . . . . . . . . . . . . A-3 Modes of Operation . . . . . . . . . . . . . . 3-12
Lubrication Configure . . . . . . . . . . . . . . . . . . . 3-12
Specification Chart . . . . . . . . . . . . A-2 Maintenance . . . . . . . . . . . . . . . . . 3-16
Lubrication Equivalency Chart . . . . . . A-2 Run . . . . . . . . . . . . . . . . . . . . . . . 3-12
See also Passwords . . . . . . . . . . . . 3-12

Motors Travel (VR1) . . . . . . . . . . . . . . . . . 7-20

AC . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 Power Amplifier
Bearing Encoder . . . . . . . . . . . 7-49 Connectors . . . . . . . . . . . . . .7-56, 7-60
Open Winding . . . . . . . . . . . . . .5-8 Discharging Internal Capacitor . . . . 5-2
Shorted Winding . . . . . . . . . . . .5-8 Replacement . . . . . . . . . . . . . . . . . 7-54
Temperature Sensor . . . . . . . . 7-48 Power Cables . . . . . . . . . . . . . . . . . . . 7-44
Armature . . . . . . . . . . . . . . . . . . . .5-8 Power Cables, Motor . . . . . . . . . . . . . . 7-46
DC . . . . . . . . . . . . . . . . . . . . . . . . .5-5 Pressure
Field Winding Test . . . . . . . . . . .5-8 Attachment Adjustment . . . . . . . . 3-22
Grounded Motor Test . . . . . . . . .5-7 Relief Valve . . . . . . . . . . . . . . . . . . 7-70
Open Circuit Test . . . . . . . . . . .5-7 System, Adjustment . . . . . . . . . . . 7-70
Short Circuited Armature . . . . .5-8 System, Measuring . . . . . . . . . . . . 7-70
Drive . . . . . . . . . . . . . . . . . . . . . . . 7-51 Priority Bypass (SOL4) . . . . . . . . . . . . . 8-5
Lift . . . . . . . . . . . . . . . . . . . . . . . . 7-53 Product Improvement Notices . . . . . . . . . . v
Power Cable Terminals . . . . . . . . . 7-46 Prop Relief (SOL5) . . . . . . . . . . . . . . . . 8-5
Steer . . . . . . . . . . . . . . . . . . . . . . . 7-10
Storage Preparation . . . . . . . . . . . . 3-24 Q
Troubleshooting
AC . . . . . . . . . . . . . . . . . . . . . . .5-8
Quad Mast
DC . . . . . . . . . . . . . . . . . . . . . . .5-5
Check Valve . . . . . . . . . . . . . . . . . 7-72
Inspection . . . . . . . . . . . . . . . . 7-72
N Free Lift Cylinder
Installation . . . . . . . . . . . . . . . 7-93
Notices, Product Improvement . . . . . . . . v Removal . . . . . . . . . . . . . . . . . 7-93
Hose Replacement . . . . . . . . . . . . 7-93
O Inspection . . . . . . . . . . . . . . . . . . 7-87
Main Cylinder
Installation . . . . . . . . . . . . . . . 7-93
Oil
Removal . . . . . . . . . . . . . . . . . 7-92
Checking Hydraulic Oil Level . . . . . 7-68
Selecting Hydraulic Oil . . . . . . . . . 7-68
Open Circuit DC Motor Test . . . . . . . . .5-7 R
Open Winding AC Motor . . . . . . . . . . . .5-8
Operator Display . . . . . . . . . . . . . . . . . 3-11 Run Mode . . . . . . . . . . . . . . . . . . . . . 3-12
Steering Indicator Lights . . . . . . . . 3-11
Operator Display Card S
Theory of Ops . . . . . . . . . . . . . . . . .8-4
Options
Safety
Changing . . . . . . . . . . . . . . . . . . . .3-7
Battery . . . . . . . . . . . . . . . . . . . . . . 2-5
Output Tests . . . . . . . . . . . . . . . . . . . . 6-81
Definitions . . . . . . . . . . . . . . . . . . . 2-2
General . . . . . . . . . . . . . . . . . . . . . 2-3
P Towing . . . . . . . . . . . . . . . . . . . . . . 2-9
Welding . . . . . . . . . . . . . . . . . . . . 2-10
Passwords . . . . . . . . . . . .. . . . . . . . . 3-18 Scheduled Maintenance . . . . . . 4-2 to 4-15
Changing a Password .. . . . . . . . . 3-19 180 Day/500 HD . . . . . . . . . . . . . . 4-6
Config Mode . . . . . . . .. . . . . . . . . 3-18 360 Day/1500 HD . . . . . . . . . . . . . 4-9
Default . . . . . . . . . . . .. . . . . . . . . 3-18 90 Day . . . . . . . . . . . . . . . . . . . . . . 4-5
Entering a Password . .. . . . . . . . . 3-18 Guidelines . . . . . . . . . . . . . . . . . . . 4-2
Maintenance Mode . . .. . . . . . . . . 3-18 Sealants . . . . . . . . . . . . . . . . . . . . . . . . A-3
Pin-Out Matrix . . . . . . . . .. . . . . . . . . 8-13 Service Bulletins . . . . . . . . . . . . . . . . . . iv
Potentiometer Settings
Lift/Lower (VR2) . . . . . . . . . . . . . . 7-18 Changing Truck . . . . . . . . . . . . . . . 3-7

Shorted Winding on AC Motor . . . . . . . 5-8 Standard/Metric Conversions . . . . . . . A-10

Shorts to Frame Test . . . . . . . . . . . . . . 5-2 Steer Motor . . . . . . . . . . . . . . . . . . . . 7-10
Sideshift Cylinders . . . . . . . . . . . . . . . 8-4 Steer Position Sensor Theory . . . . . . . . 8-4
Sideshift Solenoids (SOL9L/R) . . . . . . . 8-5 Steer Valve Theory . . . . . . . . . . . . . . . . 8-5
SOL1 Steerable Wheel
Test . . . . . . . . . . . . . . . . . . . . . . . 6-89 Assembly . . . . . . . . . . . . . . . . . . . 7-10
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5 Disassembly . . . . . . . . . . . . . . . . . 7-13
Torque Specs . . . . . . . . . . . . . . . . 7-64 Steering
SOL10 Indicator Lights . . . . . . . . . . . . . . 3-11
Test . . . . . . . . . . . . . . . . . . . . . . . 6-86 Steering System Theory . . . . . . . . . . . . 8-8
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5 Storage
Torque Specs . . . . . . . . . . . . . . . . 7-64 Hydraulic Cylinders . . . . . . . . . . . 3-24
SOL2 Hydraulic System . . . . . . . . . . . . . 3-24
Test . . . . . . . . . . . . . . . . . . . . . . . 6-90 Lift Chains . . . . . . . . . . . . . . . . . . 3-24
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5 Motors . . . . . . . . . . . . . . . . . . . . . 3-24
Torque Specs . . . . . . . . . . . . . . . . 7-64 Warranty Issues . . . . . . . . . . . . . . 3-24
SOL3 STR Contactor . . . . . . . . . . . . . . . . . . . 8-4
Test . . . . . . . . . . . . . . . . . . . . . . . 6-88 Switches
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5 Tests
Torque Specs . . . . . . . . . . . . . . . . 7-64 S11 . . . . . . . . . . . . . . . . . . . . . 6-31
SOL4 S12 . . . . . . . . . . . . . . . . . . . . . 6-32
Test . . . . . . . . . . . . . . . . . . . . . . . 6-99 S18 . . . . . . . . . . . . . . . . . . . . . 6-40
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5 S21 . . . . . . . . . . . . . . . . . . . . . 6-77
Torque Specs . . . . . . . . . . . . . . . . 7-64 S22B . . . . . . . . . . . . . . . 6-44, 6-45
SOL5 S3 . . . . . . . . . . . . . . . . . . . . . . 6-35
Test . . . . . . . . . . . . . . . . . . . . . . .6-100 S6 . . . . . . . . . . . . . . . . . . . . . . 6-68
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5 S7 . . . . . . . . . . . . . . . . . . . . . . 6-67
Torque Specs . . . . . . . . . . . . . . . . 7-64 S9 . . . . . . . . . . . . . . . . . . . . . . 6-70
SOL6 SW1 . . . . . . . . . . . . . . . . . . . . 6-35
Test . . . . . . . . . . . . . . . . . . . . . . . 6-85 SW2 . . . . . . . . . . . . . . . . . . . . 6-76
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5 SW3 . . . . . . . . . . . . . . . . . . . . 6-74
Torque Specs . . . . . . . . . . . . . . . . 7-64 SW4 . . . . . . . . . . . . . . . 6-69, 6-72
SOL7C/R System Architecture . . . . . . . . . . . . . . . 8-2
Test . . . . . . . . . . . . . . . . . . . . . . .6-101
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5 T
Torque Specs . . . . . . . . . . . . . . . . 7-64
SOL9L/R
Terminals, Motor Power Cable . . . . . . 7-46
Test . . . . . . . . . . . . . . . . . . . . . . . 6-87
Tests
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5
A04 - Travel Pot . . . . . . . . . . . . . . 6-48
Torque Specs . . . . . . . . . . . . . . . . 7-64
A05 - L/L Pot . . . . . . . . . . . . . . . . 6-49
Solenoid Tests
A08 - Left Trac Motor Temp . . . . . 6-50
Aux. Direction . . . . . . . . . . . . . . . 6-85
A09 - Lift Motor Temp . . . . . . . . . . 6-51
Aux. Relief . . . . . . . . . . . . . . . . . .6-100
A10 - Left TPA Temp . . . . . . . . . . . 6-52
HSA 1 . . . . . . . . . . . . . . . . . . . . .6-101
A11 - Left Traction Current . . . . . . 6-53
Lift Relief . . . . . . . . . . . . . . . . . . . 6-88
A13 - Press Sensor Voltage . . . . . . 6-54
Lift/Lower . . . . . . . . . . . . . . . . . . 6-90
A14 - Ext. Supply Sense (12VDC) . 6-55
Load Hold . . . . . . . . . . . . . . . . . . 6-89
A15 - Battery Voltage . . . . . . . . . . 6-56
Priority Bypass . . . . . . . . . . . . . . 6-99
A19 - LPA Temp . . . . . . . . . . . . . . 6-57
Sideshift . . . . . . . . . . . . . . . . . . . 6-87
A20 - Lift Motor Current . . . . . . . . 6-58
Tilt . . . . . . . . . . . . . . . . . . . . . . . 6-86
A22 - Traction Throttle Request . . 6-59
Specification Plate . . . . . . . . . . . . . . . . 3-3
A23 - Lift Request . . . . . . . . . . . . . 6-60
Specifications, Vehicle . . . . . . . . . . . . . 3-3
A26 - Pot Supply (5VDC) . . . . . . . . 6-61

A34 - Lift/Lower Current (SOL2) . . 6-62 O18 - Horn . . . . . . . . . . . . . . . . . . 6-91

A36 - Ambient Temperature . . . . . 6-63 O20 - Travel Alarm . . . . . . . . . . . . 6-93
A65 - Right TPA Temp . . . . . . . . . . 6-64 O23 - Toggle Amplifier Fan . . . . . . 6-94
A67 - Right Trac Motor Current . . . 6-65 O28 - Ramp Lift Motor (AC Lift) . . 6-95
A68 - Right Trac Motor Temp . . . . 6-66 O29 - Ramp Traction Motors . . . . 6-96
A71 - Tilt Down (S7) . . . . . . . . . . . 6-67 O30 - Electric Brakes . . . . . . . . . . 6-97
A72 - Tilt Up (S6) . . . . . . . . . . . . . 6-68 O32 - Toggle Relay Enable . . . . . . 6-98
A72 - Tilt Up/Down (SW4) O36 - Priority Bypass Solenoid
(Optional Handle) . . . . . . . . . . 6-69 (SOL4) . . . . . . . . . . . . . . . . . . 6-99
A73 - Sideshift Right (S9) . . . . . . . 6-70 O37 - Aux. Relief Solenoid
A74 - Sideshift Left . . . . . . . . . . . . 6-71 (SOL5) . . . . . . . . . . . . . . . . . 6-100
A74 - Sideshift Switch O45 - HSA 1 Solenoid
(SW4) (Optional Handle) . . . . . . 6-72 (SOL7C, SOL7R) . . . . . . . . . . 6-101
A75 - Attach Func 1 . . . . . . . . . . . 6-73 Output . . . . . . . . . . . . . . . . . . . . . 6-81
A75 - Attach Func 1 Shorts to Frame . . . . . . . . . . . . . . . 5-2
(Optional Handle) . . . . . . . . . . 6-74 Theory of Operation
A76 - Attach Fcn 2 (SW2) Pin-Out Matrix . . . . . . . . . . . . . . . 8-13
(Optional Handle) . . . . . . . . . . 6-76 Theory of Ops
A76 - Attach Func 2 . . . . . . . . . . . 6-75 CAN Bus . . . . . . . . . . . . . . . . . . . . 8-3
A76 - Attach Func 2 Fuse/Relay Card . . . . . . . . . . . . . . 8-4
(Optional Handle) . . . . . . . . . . 6-76 Lift Power Amp . . . . . . . . . . . . . . . . 8-3
A77 - EPO (S21) . . . . . . . . . . . . . . 6-77 Lift/Lower . . . . . . . . . . . . . . .8-9, 8-11
A80 - Lift Relief Solenoid . . . . . . . . 6-78 Operator Display Card . . . . . . . . . . 8-4
A81 - Priority Bypass Current Steer Position Sensor . . . . . . . . . . . 8-4
(SOL4) . . . . . . . . . . . . . . . . . . . 6-79 Steer Valve . . . . . . . . . . . . . . . . . . . 8-5
A82 - Aux. Relief Current Steering System . . . . . . . . . . . . . . . 8-8
(SOL5) . . . . . . . . . . . . . . . . . . . 6-80 Traction Power Amps . . . . . . . . . . . 8-3
I02 - High Speed Limit SW (S11) . . 6-31 Traction System . . . . . . . . . . . . . . . 8-6
I05 - Lift Limit (S12) . . . . . . . . . . . 6-32 VM . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
I13 - Lift Contactor (DC Lift) . . . . . 6-33 Thread Adhesives . . . . . . . . . . . . . . . . . A-3
I14 - Steer Contactor . . . . . . . . . . . 6-34 Tilt Solenoid (SOL10) . . . . . . . . . . . . . . 8-5
I15 - Horn (S3) . . . . . . . . . . . . . . . 6-35 Tilt, Mast
I15 - Horn (SW1) . . . . . . . . . . . . . . 6-35 Adjustment . . . . . . . . . . . . . . . . 7-100
I19 - Left Traction RPM . . . . . . . . . 6-36 Tire Replacement . . . . . . . . . . . . . . . . 7-37
I20 - Lift Motor RPM . . . . . . . . . . . 6-37 Torque Chart
I23 - CAN Communication Test . . . 6-38 Component Specific . . . . . . . . . . . . A-4
I65 - Tilt Position SW (S18) . . . . . . 6-40 Metric . . . . . . . . . . . . . . . . . . . . . . . A-6
I82 - Right Traction RPM . . . . . . . . 6-43 Standard (Brass) . . . . . . . . . . . . . . A-7
I88 - Battery Gate 2 . . . . . . . 6-44, 6-45 Standard (Ferrous) . . . . . . . . . . . . . A-5
I89 - Steer Position Sensor . . . . . . 6-46 Towing Safety . . . . . . . . . . . . . . . . . . . . 2-9
Input . . . . . . . . . . . . . . . . . . . . . . . 6-29 TPC Contactor . . . . . . . . . . . . . . . . . . . 8-4
O00 - TPC Contactor . . . . . . . . . . . 6-82 Traction Motor
O01 - Steer Contactor (STR) . . . . . 6-83 Power Cable Terminal Nuts . . . . . 7-46
O02 - Lift Contactor (LPC) . . . . . . . 6-84 Traction Motor, see Motors, Drive . . . . 7-51
O04 - Aux. Direction Solenoid Traction Power Amplifiers . . . . . . . . . 7-54
(SOL6) . . . . . . . . . . . . . . . . . . . 6-85 Theory of Ops . . . . . . . . . . . . . . . . . 8-3
O07 - Tilt Solenoid (SOL10) . . . . . . 6-86 Traction System
O08 - Sideshift Solenoid Theory of Ops . . . . . . . . . . . . . . . . . 8-6
(SOL9L, SOL9R) . . . . . . . . . . . . 6-87 Travel Potentiometer . . . . . . . . . . . . . 7-20
O09 - Lift Relief Solenoid (SOL3) . . 6-88 Troubleshooting
O11 - Load Hold Solenoid (SOL1) . . 6-89 BSOC . . . . . . . . . . . . . . . . . . . . . . . 5-9
O12 - Lift/Lower Solenoid (SOL2) . 6-90 Communication Error Codes . . . . 5-10

Drive Units . . . . . . . . . . . . . . . . . 5-19 VM, Theory of Ops . . . . . . . . . . . . . . . . 8-3

Electrical . . . . . . . . . . . . . . . . . . . . 5-2 VR1 Test . . . . . . . . . . . . . . . . . . . . . . 6-48
Electrical Symptoms . . . . . . . . . . 5-22 VR2 Test . . . . . . . . . . . . . . . . . . . . . . 6-49
Fuses . . . . . . . . . . . . . . . . . . . . . . 5-4
Hydraulic Functions . . . . . . . . . . 5-16 W
Motors . . . . . . . . . . . . . . . . . 5-5 to 5-8
AC . . . . . . . . . . . . . . . . . . . . . . 5-8
Warranty
DC . . . . . . . . . . . . . . . . . . . . . . 5-5
Storage Issues . . . . . . . . . . . . . . . 3-24
Pin-Out Matrix . . . . . . . . . . . . . . 8-13
Welding Safety . . . . . . . . . . . . . . . . . . 2-10
Shorts to Frame Test . . . . . . . . . . . 5-2
Wheel
Travel Functions . . . . . . . . . . . . . 5-20
Steerable . . . . . . . . . . . . . . . . . . . 7-10
Disassembly . . . . . . . . . . . . . . 7-13
V Removal . . . . . . . . . . . . . . . . . 7-10
Wiring Connectors . . . . . . . . . . . . . . . 7-55
Valve
Check
Quad Mast . . . . . . . . . . . . . . . 7-72
CV1 Check Valve . . . . . . . . . . . . . 7-64
Pressure Relief . . . . . . . . . . . . . . . 7-70
SOL1
Test . . . . . . . . . . . . . . . . . . . . 6-89
Torque Spec . . . . . . . . . . . . . . 7-64
SOL10
Test . . . . . . . . . . . . . . . . . . . . 6-86
Torque Spec . . . . . . . . . . . . . . 7-64
SOL2
Test . . . . . . . . . . . . . . . . . . . . 6-90
Torque Spec . . . . . . . . . . . . . . 7-64
SOL3
Test . . . . . . . . . . . . . . . . . . . . 6-88
Torque Spec . . . . . . . . . . . . . . 7-64
SOL4
Test . . . . . . . . . . . . . . . . . . . . 6-99
Torque Spec . . . . . . . . . . . . . . 7-64
SOL5
Test . . . . . . . . . . . . . . . . . . . .6-100
Torque Spec . . . . . . . . . . . . . . 7-64
SOL6
Test . . . . . . . . . . . . . . . . . . . . 6-85
Torque Spec . . . . . . . . . . . . . . 7-64
SOL7C/R
Test . . . . . . . . . . . . . . . . . . . .6-101
Torque Spec . . . . . . . . . . . . . . 7-64
SOL9L/R
Test . . . . . . . . . . . . . . . . . . . . 6-87
Torque Spec . . . . . . . . . . . . . . 7-64
Valve, Check
Quad Mast . . . . . . . . . . . . . . . . . 7-72
Valves
CB1, CB2 . . . . . . . . . . . . . . . . . . . 8-5
CV1 . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Vehicle Specifications . . . . . . . . . . . . . 3-3


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Maintenance Manual

Model 4100 and 4200

Models Serial Numbers

1060345B Re-issued: 01 Jul 2010

©2010 The Raymond Corporation.

Publication: 1060345, Re-issued: 01 Jul 2010 i

Drive and Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

ii Publication: 1060345, Re-issued: 01 Jul 2010

Document Revision History

Page Revision Record

Document Revision History

Publication: 1060345, Re-issued: 01 Jul 2010 iii

Document Revision History

Service Bulletin List

Document Number Subject Date

CTB-08-001 VM Firmware Version 2.5 28 Feb 2008

CTB-08-003 Wrench Icon is Lit All of the Time 06 Jun 2008

CTB-08-008 VM Firmware Version 3.0 21 Jul 2008

CTB-08-005 Drive Motor Pinion Nut 21 May 2008

CTB-08-011 Mast Drifting on Quad Masts 02 Dec 2008

CTB-09-001 Aux/Steer Motor Improvements 11 Jun 2009

CTB-09-002 VM Firmware Update to 3.6 11 Aug 2009

CTB-10-001 Sideshift Carriage Lower Hooks 26 Jan 2010

iv Publication: 1060345, Re-issued: 01 Jul 2010

Document Revision History

Product Improvement Notice List

Document Number Subject Date

CTB-08-R004 Drive Wheel Fenders 08 Aug 08

Publication: 1060345, Re-issued: 01 Jul 2010 v

Document Revision History

vi Publication: 1060345, Re-issued: 01 Jul 2010

Section 1. How to Use This Manual

Publication: 1060345, Re-issued: 01 Jul 2010 1-1

Map of the Manual

Map of the Manual

1-2 Publication: 1060345, Re-issued: 01 Jul 2010

Manual Design • Section 7. Component Procedures gives

Publication: 1060345, Re-issued: 01 Jul 2010 1-3

Abbreviations and Symbols

BSOC Battery State-of-Charge kg kilogram(s)

OACH Overall Collapsed

1-4 Publication: 1060345, Re-issued: 01 Jul 2010

Abbreviations and Symbols

Term/Symbol Definition Term/Symbol Definition

SAE Society of Automotive

Publication: 1060345, Re-issued: 01 Jul 2010 1-5

Abbreviations and Symbols

1-6 Publication: 1060345, Re-issued: 01 Jul 2010

Publication: 1060345, Re-issued: 01 Jul 2010 2-1

Indicates a potentially hazardous

Indicates a potentially hazardous

2-2 Publication: 1060345, Re-issued: 01 Jul 2010

Do not operate or work on this lift truck unless

Before working on this truck, turn the key

Do not operate or work on this lift truck unless

Always use and park this lift truck indoors.

Do not operate this lift truck if it needs repair or

Do not park in a cold storage area overnight

Publication: 1060345, Re-issued: 01 Jul 2010 2-3

contact your local authorized Raymond dealer

2-4 Publication: 1060345, Re-issued: 01 Jul 2010

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

As a battery is being charged, an

serious damage or injury.