7600 Maintenance Manual PDF

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Maintenance Manual
Model 7600/7620/7640 Reach-Fork ® Truck
With The ACR System ™
Series: Serial Number

A 00001 and UP
Publication 1087967 Issued: 15 Apr 2009

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This publication, Publication 1087967 applies to the Model 7600/7620/7640 Reach-Fork ® Lift
Truck, S/N 00001 and above, and to all subsequent releases of this product until otherwise
indicated in new editions or bulletins. Changes occur periodically to the information in this
publication.
If you need assistance with your lift truck, or to order additional copies of this manual, contact your
local authorized Raymond dealer.
To locate your local authorized Raymond dealer, go to www.raymondcorp.com.
©2009 The Raymond Corporation.
The following terms are trademarks of The Raymond Corporation: Raymond, Auto Power Off,
Deep-Reach, Maintenance Minder, Reach-Fork, Vantage Point, iPort, and The ACR System. All other
brand and product names are trademarks or registered trademarks of their respective companies.
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Model 7600/7620/7640 Reach-Fork ® Truck Table of Contents
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Table of Contents
Page Revision Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
Service Bulletin List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Product Improvement Notice List . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
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
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Static Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Jacking Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Tie-Down for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Lift Truck Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Model 7600 Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
FlashWare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Maintenance Minder ™ Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Initial 90 Day/250 Deadman Hours (HD) Maintenance . . . . . . . . . . . 4-5
Every 180 Days or 500 HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Every 360 Days or 2000 HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Chain Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Hydraulic Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . 5-11
Symptom Tables: Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . 5-13
Symptom Tables: Travel Functions . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Symptom Tables: Electrical Symptoms . . . . . . . . . . . . . . . . . . . . . . 5-19
Symptom Tables: Vantage Point System . . . . . . . . . . . . . . . . . . . . . 5-21
Messages, Codes, and Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Power Amplifier LED Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Messages and Codes Summary List . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Messages and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Circuit Card Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Electrical Tests - Summary List . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Analog Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Digital Input Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
Digital Output Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-97
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Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Component Locator Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Special Tools, Decals, and Chassis . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Decals and Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Baselegs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Steering and Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Steering Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Steer Limit Switch (S11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Steerable Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Steering Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Drive and Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50
Inertial Dampener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55
Battery Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
Wiring and Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64
AC Motor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65
Steer Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69
Cold Storage Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
Hydraulic System Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75
Lift Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77
Manual Lowering of Fork Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . 7-78
Proportional Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
Auxiliary Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80
Manifold, Main, Model 7600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81
Manifold, Main, Model 7620/7640 . . . . . . . . . . . . . . . . . . . . . . . . . 7-82
Manifold, Auxiliary (Standard Reach) . . . . . . . . . . . . . . . . . . . . . . . 7-83
Manifold, Reach (Deep-Reach ®) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85
Manifold, Tilt/Sideshift (Deep-Reach ®) . . . . . . . . . . . . . . . . . . . . . . 7-87
Manifold Solenoids, Fittings, and Attachments . . . . . . . . . . . . . . . . 7-88
Hydraulic Components, Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 7-89
Lift Cylinder, Free Lift, Remove/Install . . . . . . . . . . . . . . . . . . . . . . 7-90
Lift Cylinder, Free Lift, Exploded Parts Drawing . . . . . . . . . . . . . . . 7-94
Lift Cylinder, Free Lift, Seal Repacking . . . . . . . . . . . . . . . . . . . . . . 7-96
Lift Cylinder, Main, Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . 7-99
Lift Cylinder, Main Lift, Exploded Parts Drawing . . . . . . . . . . . . . . 7-104
Lift Cylinder, Main, Seal Repacking . . . . . . . . . . . . . . . . . . . . . . . . 7-106
Lift Cylinder Lowering Cushion . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-108
Reach Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-110
Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-113
Flow Limiter, Main Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-115
Flow Limiter, Free Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-116
Mast, Chain, Hose, Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-119
Reach Carriage Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-120
Mast Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-121
Bow Pads - Model 7600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-123
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Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-124
Chain Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-127
Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-133
Height Encoder Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-138
Hose, Main Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-142
Hose and Cable, Over-the-Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-143
Cable, Over-the-Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-149
Hose/Tubing, Free Lift Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-153
Mast, Model 7600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-154
Mast, Model 7620 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-165
Mast, Model 7640 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-175
Carriage, Free Lift Cylinder, and Hose/Cable Installation . . . . . . . . 7-182
Mating Tractor to Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-185
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Traction System Functional Operation . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Cold Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Hydraulic System Functional Operation . . . . . . . . . . . . . . . . . . . . . . 8-7
Electric Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Pinout Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Lubrication Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Thread Adhesives, Sealants, and Lubricants . . . . . . . . . . . . . . . . . . . A-3
Component Specific Service/Torque Chart . . . . . . . . . . . . . . . . . . . . . A-4
Torque Chart - Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Torque Chart - Straight Thread Face Seal O-Rings . . . . . . . . . . . . . . . A-7
Torque Chart - Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Torque Chart - Metric (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Torque Chart - Standard (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11
Torque Chart - Metric (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13
Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-15
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-16
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
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Model 7600/7620/7640 Reach-Fork® Truck Page Revision Record
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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 identifed
with a change bar, however, affected pages are identifed with “Revised: Month Year” in the
footer.
Document Revision History

1087967A Original Issue . . . . . . . 15 Apr 2009
Publication 1087967, Issued: 15 Apr 2009 v

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Service Bulletin List
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
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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
Publication 1087967, Issued: 15 Apr 2009 vii

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Product Improvement Notice List
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Model 7600/7620/7640 Reach-Fork® Truck Section 1. How to Use This Manual
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Section 1. How to Use This Manual
Publication 1087967, Issued: 15 Apr 2009 1-1

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Section 1. How to Use This Manual Model 7600/7620/7640 Reach-Fork® Truck
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Map of the Manual
Map of the Manual

1MAP.WMF
T a b le o f
C o n te n ts M essages,
C odes, and
T e s ts
P a g e R e v is io n
R e c o rd
C om ponent
S e r v ic e B u lle tin s P ro c e d u re s
in c o r p o r a te d
S e r v ic e B u lle tin s L is t o f C o m p o n e n t
in c o r p o r a te d P ro c e d u re s
H o w to U s e C o m p o n e n t L o c a to r
T h is M a n u a l P h o to s
M a p o f th e M a n u a l T h e o ry o f
O p e r a tio n
M a n u a l D e s ig n
P in o u t M a tr ix
A b b r e v ia tio n s a n d
S y m b o ls
A p p e n d ix
S a fe ty
L u b r ic a tio n
S p e c ific a tio n C h a r t
S y s te m s T o rq u e C h a rts
O v e r v ie w
D e c im a l E q u iv a le n c y
C h a rts
S c h e d u le d S ta n d a r d /M e tr ic
M a in te n a n c e C o n v e r s io n s
E le c tr ic a l/H y d r a u lic
S c h e m a tic s
T r o u b le -
s h o o tin g
In d e x
1-2 Publication 1087967, Issued: 15 Apr 2009

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Manual Design
Manual Design • Component Procedures gives

step-by-step procedures for testing,
removing, replacing, and servicing
This manual is designed with the following individual lift truck components.
objectives in mind: Components are grouped by lift truck
• provide technical coverage for expected system. To find a component procedure,
levels of user expertise you may use one of three methods:
• anticipate your needs and reduce your • Look up the component name in the
decisions regarding maintenance List of Component Procedures.
• reduce page flipping through a “one-stop • Find the component in the Component
shopping” approach Locator Photos.
• Look up the component name in the
The two-line running page header at the top of Index.
each page tells you:
• Theory of Operations explains signal flow
• Name of the manual (Model within the electrical and hydraulic
7600/7620/7640 Reach-Fork® Truck) systems for various conditions of lift truck
• Current chapter title (for example, this operation. This section also contains a
page How to Use This Manual) detailed connection point table (Pinout
Matrix) designed to assist in testing and
• Current topic (for example, this page
troubleshooting the lift truck.
Manual Design)
• Appendix contains reference information
This manual consists of the following sections: such as torque values, lubricants,
standard/metric conversions, and system
• How to Use This Manual explains the
schematics.
manual format and design as well as
abbreviations and symbols used. • Index lists subjects alphabetically.
• Safety explains warning and caution notes
and general safety rules as well as safety
rules for batteries, static, jacking, and
welding.
• Systems Overview includes general lift
truck specifications, programming
instructions, and configuration menu.
• Scheduled Maintenance outlines the
recommended schedule of preventive
services to keep your lift truck working
most efficiently.
• Troubleshooting guides the user from
fault symptoms to a specific sequence of
tests in order to isolate a failing
component.
• Messages, Codes, and Tests lists the
electrical fault codes and procedures for
running firmware-based electrical tests.

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Abbreviations and Symbols
Abbreviations and
Symbols
These abbreviations, acronyms, and symbols are used in this manual.
Term/Symbol Definition
E UL Electric Truck Type
A Ampere Certification Rating with
AC Alternating Current safeguards against inherent
AGND Analog Ground fire and electrical shock
amp Ampere or amplifier hazards
ANSI American National
Standards Institute EE UL Electric Truck Type
API American Petroleum Certification Rating where
Institute electrical equipment is
approx approximately completely enclosed
aux auxiliary EPO Emergency Power Off
AWG American Wire Gauge ESD Electrostatic Discharge
ESDS Electrostatic Discharge
BSOC Battery State-of-Charge Sensitive
C Celsius or Centigrade F Fahrenheit
CAN Controller Area Network ft. foot or feet
CB Counterbalance valve ft. lb. foot pound(s)
CCW Counterclockwise FR Flow Regulator
CD Coil Driver FU Fuse
CE Compensating Element
(valve) GA gauge
cfg configuration gal. gallon or gallons
cm centimeter gm gram(s)
COP Computer Operating Gnd ground
Program
CS Cold Storage HTI Height-Tilt Indicator
CV Check Valve HTR Heater
CW Clockwise
in. inch or inches
DC Direct Current in. lb. inch pound(s)
DdManH Deadman Pedal Hours
JP jack and pin connector
DGND Digital Ground
diam. diameter
DOT US Department of
Transportation
DVM Digital Voltmeter or
Multimeter

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Term/Symbol Definition Term/Symbol Definition
K thousand OACH Overall Collapsed Height

KeyH hours with key switch ON OCSS Operator Compartment
kg kilogram(s) Sensor System
km/cm2 kilograms per square OD Operator Display
centimeter OSHA Occupational Safety and
km/hr kilometers per hour Health Association
kPa kiloPascal(s) otm over-the-mast
oz. ounce(s)
l liter(s)
lb. pound or pounds P pump or lift contactor
LPA Lift Power Amplifier PODS Priority On Demand Spool
LED Light Emitting Diode valve
LiftH Lift Hours pot potentiometer
L/H load holding psi pounds per square inch
L/L lift/lower PWM Pulse Width Modulation
LM Lift Motor P/N Part Number
LME Lift Motor speed Encoder
LMT Lift Motor Temperature qt. quart
sensor
RAM Random Access Memory
LPA Lift Power Amplifier
REL relief
LPC Lift Power Contactor
RF Radio Frequency
LR LPA precharge resistor
ROM Read Only Memory
LS load shuttle
RPIN Raymond Product
m meter(s) Improvement Notice
mA milliampere rpm revolutions per minute
mm millimeter R/R reach/retract
MM Maintenance Minder ™ RSB Raymond Service Bulletin
mph miles per hour
S Switch
MS steer motor
SA Steer Amplifier
N/A Not Applicable or Not SAE Society of Automotive
Available Engineers
N/C Normally Closed S/N Serial Number
NLGI National Lubricating Grease SOL Solenoid
Institute spec specification
Nm Newton Meter SPL Splice
N/O Normally Open s/s Sideshift
SSL Sideshift Left
SSR Sideshift Right
STR Steer Contactor
SWM Supplier Wireless Module

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temp temperature
TM Traction Motor
TME Traction Motor Encoder
TMT Traction Motor
Temperature sensor
TOTAL D Total Distance Traveled
TP Tie Point
TPA Traction Power Amplifier
TPC Traction Power Contactor
TS Terminal Strip
UL Underwriters Laboratories
UNC Unified Coarse thread
UNF Unified Fine thread
V Volts
VDC Volts Direct Current
ver. version
VM Vehicle Manager
VR variable resistor
WHLD Weight Height Limit Display

WMM Warehouse Management
Module
wrt with respect to
@ at
™ trademark
© copyright
+ plus or positive
– minus or negative
± plus or minus
° degrees
°F degrees Fahrenheit
°C degrees Celsius
< less than
> greater than
% percent
= equals

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Model 7600/7620/7640 Reach-Fork® Truck Section 2. Safety
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Section 2. Safety

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Section 2. Safety Model 7600/7620/7640 Reach-Fork® Truck
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Definitions
Definitions
Throughout this manual, you will see two kinds
of safety reminders:
Warning means a potentially hazardous

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

situation, which, if not avoided, may
result in minor or moderate injury or in
damage to the lift truck or nearby
objects. It may also be used to alert
against unsafe practices.

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General Safety
General Safety Operate this lift truck only from the operator’s
position.
6173_002.eps
Do not operate or work on this lift truck unless

you are trained, qualified, and authorized to do
so, and have read the Owner and Operator
Manuals.
8b15004d.eps
Before working on this lift truck, always turn

the key switch OFF and disconnect the lift
truck’s battery connector (unless this manual
tells you otherwise).
6173_005.eps
Know the lift truck’s controls and what they do.

6173_003.eps
Do not wear watches, rings, or jewelry when

working on this lift truck.
Do not operate this lift truck if it needs repair or jewelry.eps
if it is in any way unsafe.

6173_004.eps
Follow the scheduled lubrication, maintenance,

and inspection steps.
schedmnt.eps

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General Safety
Follow exactly the safety and repair instructions Always operate and park this lift truck indoors.
in this manual. Do not take “shortcuts.” 6173_008.eps
8b15008d.eps
Do not wash this lift truck with a hose.

Do not use an open flame near the lift truck. 6173_009.eps
6173_006.eps
Do not add to or modify this lift truck until you

Do not use gasoline or other flammable liquids contact your local Raymond dealer to receive
for cleaning parts. written manufacturer approval.
6173_007.eps 6173_010.eps
Clean up any hydraulic fluid, oil, or grease that Do not park this lift truck in a cold storage area
has leaked or spilled on the floor. overnight.
spills.eps 6173_010.eps

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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
Make sure a shower and eyewash station are
the charging area. An open flame or
nearby in case of an accident.
spark can ignite this gas, resulting in 04g6s059.eps
serious damage or injury.
Battery electrolyte is a solution of

sulfuric acid and water. Battery acid
causes burns. If any electrolyte comes in
contact with your clothing or skin, flush
the area immediately with cold water. If
the solution gets on your face or in your
eyes, flush the area with cold water and
get medical help immediately.
A battery gives off explosive gases. Never
Read, understand, and follow procedures, smoke, use an open flame, or use anything that
recommendations, and specifications in the gives off sparks near a battery.
battery and battery charger manufacturer’s 23l6s012.eps
manuals.
25l6s014.eps
Keep the charging area well-ventilated to avoid

hydrogen gas concentration.
Wear personal protective equipment to protect 04g6s058.eps
eyes, face, and skin when checking, handling,

or filling batteries. This equipment includes
Turn the key switch OFF before disconnecting

the battery from the lift truck at the battery

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Battery Safety
connector. Do not break live circuits at the Make sure the vent holes in the filler plugs are
battery terminals. A spark often occurs at the open to allow the gas to escape from the cells.
point where a live circuit is broken. 09g6s047.tif
6173_005.eps
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.
6173_011.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 lift truck’s

battery connector. Plug the battery charger only
into the battery connector from the battery.
6173_012.eps
Keep filler plugs firmly in place at all times

except when the electrolyte level is checked,
when water is added to the cells, or when the
specific gravity is checked.

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Static Precautions
Static Precautions surface (mat). Follow the instructions packaged

with the kit.
Electronic circuit boards can contain Figure 2-1. Anti-Static Kit with Wrist Strap and Mat
Electrostatic Discharge Sensitive (ESDS) 2mat2.tif
devices.
Static charges can accumulate from normal

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

discharged to a circuit board or component by
touching the parts. Electrostatic Discharge
(ESD) is also possible through the air when a
charged object is placed close to another
surface at a different electrical potential. Static
discharge can occur without seeing or feeling it.
Whenever working on or near ESDS devices, Wrist straps (P/N 1-187-058/001) are available
follow these precautions. in quantities of 25.
• Wear an ESD wrist strap. The wrist strap
A wrist strap tester (P/N 1-187-060/100) is also
should be equipped with a 1 megohm
available.
resistor to dissipate static charges slowly.
• Connect the wrist strap plug to the ground Contact your local Raymond dealer for
jack located tractor deck near the lift information.
motor. If you cannot use the ground jack,
connect the ground clip to an unpainted,
grounded surface on the lift truck frame.
• Handle circuit boards by the edges only.
Avoid touching the edge connectors.
• If you are removing or installing
static-sensitive components, place them
on a correctly grounded anti-static mat.
• To transport static sensitive components,
including failed components being
returned, place the components in an
anti-static bag or box (available from your
local authorized Raymond dealer).
Test the wrist strap and related accessories

before each use to make sure they are working
correctly.
Figure 2-1 shows the components of the

Raymond anti-static field service kit,
P/N 1-187-059. The kit includes a wrist strap,
ground cord, and static-dissipative work

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Jacking Safety
Jacking Safety
Some maintenance procedures require the lift Use extreme care when the lift truck is
truck to be jacked up. To safely jack the lift jacked up. Never block the lift truck
truck: between the telescopic and the floor.
1. Lower the forks completely. Remove any Attach a chain to the top of the mast and
load. an overhead hoist to stabilize the mast if
2. Place all controls in neutral. jacking more than described in this
procedure. Keep hands and feet clear
3. Block the wheels to prevent movement of while jacking the lift truck. After the lift
the vehicle. truck is jacked, place solid blocks or jack
4. Turn the key switch OFF and disconnect stands beneath it to support it. Do not
the battery connector. rely on the jack alone to support the lift
5. If possible, stabilize the top of the mast truck.
with an overhead chain hoist.
Figure 2-3. Correct Jacking Locations
6. Before jacking the lift truck, examine the toyrch_t.eps
A-frame down-travel adjustment bolt. See Jack only in

Figure 2-2. If the bolt is missing, or the these areas
hole that it passes through is excessively
worn, the A-frame will not be held in place
when the lift truck is jacked up; the
A-frame could pivot down and allow the
springs to fall out.
No Jack Area
Figure 2-2. A-frame Down-Travel Adjustment Bolt
13y7s001.tif
A-frame Springs
To elevate the rear of the lift

A-frame truck:
Down-Travel
1. Place the jack in the specified jacking
Adjustment Bolt
position. See Figure 2-3.
7. Place the jack under the designated 2. Jack the rear of the lift truck so that the
jacking points. See Figure 2-3. drive tire is off the floor no more than 2 in.
(50 mm). If you must elevate the drive tire
more than 2 in., attach a suitable capacity
hoist to the lift truck at the overhead
guard.
3. Block the lift truck in place.

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Jacking Safety
To elevate either side of the lift

truck:
1. Place the jack in the specified jacking
position. See Figure 2-3.
2. Jack the side of the lift truck so that the
load wheel is off the floor no more than
1/2 in. (13 mm).
3. Block the lift truck in place.
NOTE: After working on a vehicle, test all
controls and functions to make sure
they operate correctly.

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Tie-Down for Transport
Tie-Down for Transport

To transport your Raymond Model
7600/7620/7640 Reach-Fork lift truck in an
over-the-road vehicle or rail car, follow these
steps:
1. Lower the forks and locate the lift truck in
the center of the transport vehicle.
2. Using a suitable lifting device, remove the
battery. See “Battery Safety” on page 2-5.
3. Position the adjustable chain over and
through the battery compartment.
4. Position an additional adjustable chain
over and through the battery
compartment.
5. Position the chain ends of one chain
toward the front of the vehicle bed and the
chain ends of the other chain to the back
of the vehicle bed and draw taut.
NOTE: This secures the lift truck to the vehicle
bed and prevents tip-over and forward
or backward movement.
6. Secure the battery according to the battery
manufacturer’s instructions.

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Welding Safety
Welding Safety
Disconnect the battery before you
attempt to inspect, service, or repair the
lift truck.
Flame cutting or welding on painted 6173_005.eps
surfaces can produce potentially

harmful fumes, smoke, and vapors.
Before doing flame cutting or welding,
remove the coating in the area where
the operation(s) will occur.
Coating removal can occur by • Test for shorts to frame as described in

mechanical methods, chemical methods, “Shorts to Frame” on page 5-2. If you find
or a combination of methods. Do flame any shorts, correct them before you weld.
cutting and/or welding only in well
• Clean the area to be welded.
ventilated areas using local exhaust if
necessary. • Protect all lift truck components from
heat, weld spatter and debris.
04g6s059.eps
• Attach the ground cable as close to the

weld area as possible.
• Disconnect all electrical connectors from
circuit cards before doing any type of
electric resistance welding.
• Do not weld near electrical components.
• If you must weld near the battery
compartment, remove the battery from the
lift truck.
Before working on this lift truck, make sure
that: • When you are finished welding, re-install
connectors on circuit cards and do all
• Fire protection equipment is nearby. ground tests and electrical inspections
• You know where the nearest eyewash before operating the lift truck.
station is.

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Welding Safety

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Model 7600/7620/7640 Reach-Fork® Truck Section 3. Systems Overview
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Section 3. Systems Overview

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Section 3. Systems Overview Model 7600/7620/7640 Reach-Fork® Truck
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Introduction
Introduction
This manual provides information for
maintenance and repair of the Model
7600/7620/7640 Reach-Forkt® 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 nearest authorized
Raymond dealer.

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Lift Truck Specifications
Lift Truck Specifications

This lift truck is rated for performance by load
center and load weight.
Review the specification plate located in the

operator compartment of the tractor for detailed
load capacity and load center information.
Due to continuous product enhancement,

specifications are subject to change without
notice or obligation.
Figure 3-1. Lift Truck Specification Plate on Tractor

412-843_B.eps
Raymond model Serial number (see Note) Nominal battery voltage
THE RAYMOND CORP. GREENE NY
MODEL SERIAL NUMBER VOLTS BATTERY WIDTH
Approximate weight in. (mm)
Power rating of
of lift truck with TRUCK WEIGHT BATTERY WEIGHT BATTERY MAX. RATED CAPACITY
WITH MAXIMUM BATTERY MAXIMUM AMP HOURS

battery
heaviest battery lb. (kg) lb. (kg)
installed, minus load WITHOUT BATTERY MINIMUM HOUR RATE
and operator
lb. (kg) lb. (kg)
HORIZONTAL MOTION OF BATTERY NOT TO EXCEED 0.5" (13mm) ATTACH RESTRAINT AS REQUIRED
Maximum battery
WITH ATTACHMENT OR
weight for this lift
WITH FORKS
truck
ALTERNATE LOAD CENTER
Approximate weight HORIZONTAL LOAD CENTER A in. mm A in. mm
of lift truck minus VERTICAL LOAD CENTER B in. mm B in. mm
battery, load, and

LOAD CENTER SIDE TO SIDE C in. mm C in. mm
Minimum battery
operator
MAX.
CAPACITY
l b.
DIM. D
in.
MAX.
CAPACITY
l b.
DIM. D
in.
MAX.
CAPACITY
l b.
DIM. D
in.
MAX.
CAPACITY
l b.
DIM. D
in.
weight for this lift
C
truck
Load center B
Battery weight must
dimensions be between the
A D
FL
OO
R
minimum and
Maximum load ATTACHMENT TYPE MODEL SERIAL NUMBER
maximum weight
capacity for this lift MANUFACTURED TO COMPLY WITH THE MANDATORY REQUIREMENTS OF ASME B56.1 PART III EFFECTIVE ON THE DATE OF
truck MANUFACTURE FOR TYPE ___ INDUSTRIAL TRUCKS WHEN EQUIPPED WITH TYPE EO BATTERY
INCLUDE MODEL AND SERIAL NUMBER ON ALL CORRESPONDENCE
Attachment
MADE IN CANADA 412-843 information
NOTE: Lift truck serial number is also found:

• On the mast specification plate on the
lower right mast upright
• Stamped on the top edge of the rear
bumper, to the left of center
Load Capacity
Always refer to the specification plate on your
lift truck for the correct ratings for your lift
truck.

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Model 7600 Designation
Model 7600 Designation

Mast Series
The model number includes the model and the
mast series designation.
Table 3-1. Mast Series Designation
Max Load
Model(s) Mast Forks Carriage
Lowered
4500 lb. Standard

7600/ R45TT
(2041 kg)
7620/
7640 3200 lbs. Deep-Reach®
DR32TT
(1451 kg)
Tractor
The serial number consists of a three-digit
model abbreviation, two-digit year of
manufacture, tractor designator, and five-digit
serial number.
Table 3-2. Tractor Designation
Model Tractor Lift Lift

Stance
(abbrev.) Motor Pump
760/ Sit/Stand
762/ A AC Single Side
764 Stance

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Battery Specifications
Battery Specifications
Table 3-3. 36V Battery Specifications
Weight
Width (in.) lb. (kg) Hours Amps
Min Max
2300 2600
18.5 1085
(1044) (1180)
6
2600 2900
21.5 1240
(1180) (1315)
UL note 583 specifies that a battery should

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

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FlashWare
FlashWare self-extracting executable file. Read the

“Readme” file in the software package for the
latest detailed installation instructions.
Overview
Connecting PC to Truck
FlashWare allows you to update software, view
and configure options on the lift truck through 1. Turn the lift truck key switch OFF.
the following features: 2. Connect the surge protector to an
• Update Vehicle Manager software available com port on your computer.
• Clear Primary Memory 3. Connect a standard 9-pin serial cable to
the surge protector.
• Clear Vehicle Manager
4. Connect the cable to JPT-9 at the VM.
• Reset factory default settings
5. Turn the key switch ON.
• Update Display software
• Update Power Amplifier Software
Starting FlashWare
For more detailed FlashWare information, click 1. Make sure the lift truck key switch is ON.
on Help and select Help Topics from the menu
2. Double-click the FlashWare icon on the
bar.
main desktop screen or navigate via Start
> Programs > FlashWare. The lift truck
Requirements opening screen will appear. See Figure 3-2.
FlashWare can be installed on any Figure 3-2. Truck Opening Screen

none
IBM-compatible PC. The PC communicates with

the lift truck software via a 9-pin serial cable.
NOTE: A USB to 9-pin serial adapter
(P/N 610-809/USB) is available for
computers without a serial port.
To protect your PC from possible ESD or

voltage surge, use of a surge protector
(P/N 154-010-801) is recommended.
Installing FlashWare on PC
NOTE: When entering or using FlashWare, it is
If you are a customer service technician, obtain
normal for a 50 series code to display.
FlashWare from your Raymond dealer.
3. From the menu bar, click “Connect to
If you are a Raymond dealer technician, obtain Truck”, then select “All Other Trucks”. The
FlashWare from the iNet software download lift truck setup screen appears on your PC
site. If you do not have access to the download screen. See Figure 3-3.
page on iNet, contact the Parts Distribution
Center.
To install FlashWare on the PC, double-click the

installation file and follow the instructions on
the screen. The software package is a

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FlashWare
Configuration and Truck Setup

Options
The Truck Setup screen feature allows you to:
• enable options that were added to the lift
truck since shipment from the factory
• check the serial number, model number,
software model number, OACH, Elev Ht,
and Vehicle Manager version, and hour
meters of the lift truck. See Figure 3-3.
Figure 3-3. Typical Truck Setup Screen

37600 Flashware 1.jpg

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FlashWare
To Change an Option Setting: NOTE: Vertical Hold requires the Un-nested

Speed Switch and HTI options be
The pull down screen near the middle of the installed.
window lists the Truck Options.
HTI - enables digital fork height and tilt
Check the required option box. To disable an indicator.
option, remove the check mark. See Figure 3-3.
When the options are correctly configured, click HI - enables digital fork height indicator.
“SEND Changes to Truck” button.
Embedded Statistics - records lift truck
NOTE: Options displayed in red require utilization (lift and travel) is programmable in
authorization codes. When these options truck configuration.
are selected, a pop up window appears
requesting the authorization code. High Performance Traction - allows travel up
Contact your local Raymond dealer for to 8.0 mph.
the correct forms and procedure for
obtaining the authorization code. Reverse Steering - enables reverse steering for
models with electric steering.
Options include (but are not limited to):
Auxiliary Start Switch - enables additional
Electronic Key - requires the operator to enter switch that must be pressed to allow lift truck
a code before operation is allowed. to be turned ON.
Ambient Temperature Sensor - senses HS Travel Limit Switch - limits speed of lift
ambient air temperature required for cold truck when forks are above the switch height.
storage options.
Weight Height Limit Display - displays load
2nd Speed Limit Switch - limits the speed of capacity vs. height information.
the lift truck above a second programmable
height. Operator Compartment Sensor - enables
OCSS system.
Un-nested Speed Switch - limits the speed of
the lift truck to a programmable rate if the fork Ext Access Enable - enables additional switch
carriage is not fully retracted. Requires the that must be pressed to allow lift truck to be
installation of a switch S14. turned ON.
Travel Alarm - allows the alarm to sound when Vantage Point - enables Vantage Point ™
the lift truck is moving as configured. system.
Deadman Lockout - allows the operator to lift Lift Cutout SW (No Hgt encoder) - inhibits lift
and lower only when the deadman pedal is when the forks reaches the height of the
depressed. optional switch.
Lift Limit w/Bypass - limits lift height until iPort Basic - part of the iWarehouse package.
bypass switch is depressed.
iAlert - part of the iWarehouse package.
Vertical Hold - provides operator assistance in
storing and retrieving loads from frequently iControl - part of the iWarehouse package.
referenced rack heights. Once rack heights are
programmed into a lift truck, the information Sideshift - use to configure the sideshift on the
can be copied to other lift trucks. Refer to lift truck.
“Vertical Hold Data Copy” on page 3-11.

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FlashWare
Reviewing Vehicle Manager 4. Using the FlashWare application, load to

Software the PC the latest Software Model Table, if
one was provided in the package.
Vehicle Manager software information 5. Open the Software Model Table: Click on
management can be performed in the VM Help and select “View Software Model
Software window: Number Table” from the drop down menu.
• Identify current version of software 6. Compare the software versions listed in
installed in the lift truck the table with the versions in the lift truck.
• Update current version of software with a To display software versions in the lift
newer version truck, see “Version” under “Program Mode
Menu” on page 3-21.
• Upload currently installed version of
software 7. Load updates to FlashWare and install
software to the lift truck as needed to
1. Click Vehicle Manager Software button on
make sure a matching set of VM/DM
Truck Setup screen. See Figure 3-4.
software is installed.
2. Select Software version to load. See
8. When installation is complete, click Exit to
Figure 3-5.
return to the main Truck Setup screen.
3. Click the Load VM With Selected Software
Version button. See Figure 3-5. The new
software is then installed in the lift truck.
Figure 3-4. Truck Setup Screen

Click Here
Figure 3-5. VM Software Screen

Click Here
Select

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FlashWare
Clearing Primary Memory
The clear primary memory feature allows you to

clear a Display Card in a lift truck so it can be
used in another lift truck.
NOTE: The Display Card can be replaced
without losing truck identity. A copy of
the truck identity is stored in both the
VM and Traction Power Amplifier. If two
of the three memory storage locations
agree, the truck assumes that identity.
If all three memory locations disagree, a
code AV is displayed and a programmed
Display Card and VM must be installed.
1. Click on the Clear Primary Memory
button.
2. After selecting this feature, the clear
primary memory screen appears. See
Figure 3-6.
Figure 3-6. Clear Primary Memory Screen

clearcau.tif
3. If you select No, the action is cancelled.

4. If you select Yes, a new prompt appears.
See Figure 3-7. Click OK.
Figure 3-7. Remove Cleared Memory Screen

none
Do not cycle the key switch, or the

primary memory will be restored to the
current lift truck configuration.
5. Remove the Display Card.

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FlashWare
Reviewing Configuration Settings
Review the Configuration window on the Truck

Setup Screen, scrolling through the settings.
Click Configuration on the main Truck Setup

screen. See Figure 3-4. The Configuration
screen appears. See Figure 3-8.
Figure 3-8. Configuration Screen

3none
Reset Factory Defaults BSOC Calibration
Use this feature to reset vehicle configuration 5 is the factory default and specifies the average
including SuperWord and Password. See voltage that is considered as 0% BSOC.
Figure 3-9.
Making this number smaller (down to 1), lowers
NOTE: Record customer-specific
the average voltage considered as 0% BSOC,
configurations, for example; speed,
resulting in increasing the time to reach 0%
acceleration, lift, and coast from the
BSOC, by using more battery capacity.
Truck Config screens before resetting
defaults.
Making this number higher (up to 9) increases
Figure 3-9. Configuration Reset Screen the average voltage considered as 0% BSOC,
3none resulting in decreasing the time to reach 0%
BSOC, by using less battery capacity.
Vertical Hold Data Copy

1. From the Configuration screen, select
Vertical Hold Data Copy.
2. From the drop down menu, click on Read
From Truck. Click Save. Extracted data is
saved on the laptop with a filename of
[mast_type-serial_number.hsd] for
example, R45TTB-05546.hsd.

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FlashWare
NOTE: If the file already exists, you will be 3. If the software model number is incorrect,
asked if you want to overwrite the click “ERASE”. Memory is cleared and the
existing file. correct software model number can now
be selected and loaded.
3. Exit FlashWare when data copying is
complete.
Weight versus Height
4. Connect the computer to the next lift truck
and enter FlashWare.
This feature is used to specify weight versus
5. From the Configuration screen, click height information on lift trucks equipped with
Vertical Hold Data Copy. an optional Height Tilt Indicator (HTI). Refer to
6. From the drop down menu, select Write To WHLD Cfg in the “Program Mode Menu” on
Truck. page 3-21.
7. From the file browse window, browse to Figure 3-11. Weight vs. Height
the desired filename of Vertical Hold data. 37600 Flashware 5.jpg
For example: R45TTB-05546.hsd. Click

Open.
8. You are asked if you want to write data to
the lift truck. Click Yes.
9. Exit FlashWare when data copying is
complete.
Clear Vehicle Manager
The Clear Vehicle Manager feature provides the

ability to purge existing memory and software
from a Vehicle Manager so that it may be used
in a different model lift truck.
1. Click the “Clear Vehicle Manager” button
on the right side of the Truck Setup
window. See Figure 3-3.
2. The Erase Vehicle Manager Software
screen is displayed. Click the “View
Software Model Table” button. See
Figure 3-10.
Figure 3-10. Erase Vehicle Manager Software Screen

Displaying Manager/Power Amp

Software
NOTE: Refer to the Software Release Reference
Guide posted on iNet for current
software version information.
This feature is used to view and/or change the

Power Amplifier software.

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FlashWare
1. Click Display Manager/Power Amp

Software button in the main Truck Setup
screen.
2. When the Display Manager/Power
amplifiers screen appears, follow prompts
on the screen to Load/Upload software.
See Figure 3-12.
Figure 3-12. Display Manager/Power Amp Screen

none
Programming the Traction Power If these messages are displayed:

Amplifier 1. Disconnect the PC.
2. Turn the key switch to the OFF position,
Load the software into the Traction Power then to the ON position and wait 60
Amplifier. You may get the following messages seconds.
while attempting to load new software.
3. Repeat step 2, but do not wait 60 seconds.
Figure 3-13. Error Messages 4. Connect the PC and verify the software
none
version of the Traction Power Amplifier.

• If the requested software to be
downloaded is listed under (Current
Version) in the Display Manager
window, the download was a
success.
• If it shows Version ????, you must
attempt to load the software again.
NOTE: This procedure may have to be repeated
several times until it is completed
successfully.

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FlashWare
Programming the Lift Power

Amplifier
1. Connect the PC and open FlashWare.
2. Load the software into the Lift Power
Amplifier. You may get messages similar to
those shown in Figure 3-13 while
attempting to load new software. If you get
a similar message, disconnect the PC.
3. Turn the key switch OFF, then ON and
wait 60 seconds.
4. Repeat step 3, but do not wait 60 seconds.
5. Connect the PC and verify the software
version of the Lift Power Amplifier.
• If the requested software to be
downloaded is listed under (Current
Version) in Display Manager window,
the download was a success.
• If it shows Version ????, you must
attempt to load the software again.
RECONNECT (Re-read Truck)
This feature is used to re-establish

communication with the vehicle.
SAVE Settings to File
This feature is used to store the vehicle’s

current configuration for future reference.
SEND Changes to Truck
This feature is used to transmit desired option

and height-related changes to the vehicle.

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Operator Display
Operator Display
Figure 3-14. Operator Display
R1009195-A1.cgm
8
Up Button
4
Right Button
Enter Button
5
Left Down
1 6 7 Button Button
1. Battery Discharge Indicator

2. Lift Limit (optional)
3. Service Required
4. Traction/Lift Motor or Power Panel Overtemperature
5. Lift Truck Speed
6. SelfTest, Hour Meters, BSOC, Load Weight, Clock/Calendar, and
Status Messages
7. Display Dialog Buttons
8. Dashboard Selection and Optional Feature Buttons
Selecting Display Format • Lift H: Total hours spent lifting

• Total D: Total distance traveled (miles or
The Operator Display shows date, time, BSOC, kilometers, depending on Units specified
weight on forks, information/status messages, in Config)
and ambient temperature (optional). Use the
dashboard buttons 1 thru 8 to select the Graphic icons alert operator to other
desired layout of these items on the display. conditions:
• Battery State-of-Charge
Dashboard button 9 toggles display of up to 8
Active Service tests. See “Active Service Mode” • Lift Limit
on page 3-29. • Service Required
• Overtemperature
Use the display dialog buttons (up, down, left,
right, and enter) to navigate through display • Lift Truck Speed
menus and to select values for parameters.
Dashboard button 0 displays hour meters:

• KeyH: Total hours key switch is turned ON
• DdMan H: Total hours on deadman

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Modes of Operation
Modes of Operation Hour Meters and Distance Indicator
The Operator Display shows the following

Overview of Modes accumulated totals:
• KeyH: Total hours the key switch has been
This lift truck has two modes of operation: Run turned ON
Mode and Program Mode. Run Mode is the
• DdMan H: Total hours on deadman
normal operating mode. Program Mode permits
configuration, calibration, and diagnostic • Lift H: Total hours spent lifting
testing (service). • Total D: Total distance traveled (miles or
kilometers, depending on Units specified
Run Mode in Config)
At power on, on-board firmware performs a These accumulated totals cannot be changed
number of internal selftests and enters the from Program Mode.
default mode of operation, Run Mode. In Run
Mode, the Operator Display can show date, You can also display hour meters and distance
time, BSOC, weight on forks, and (optionally) indicator in Run Mode by pressing dashboard
ambient temperature. For information on the button 0 on the Operator Display panel.
Operator Display, see “Operator Display” on
page 3-15. Configure Mode
Run Mode is also entered when the lift truck Use Configure Mode to adjust various lift truck
exits Program Mode. performance parameters to specific customer
requirements. To enter Configure Mode, you
must enter either the Password or SuperWord
Program Mode for the lift truck.
Use Program Mode for configuration,
Some items in Configure Mode appear only if
calibration, and diagnostic testing of the lift
the SuperWord is entered.
truck. A password is required to enter Program
Mode. See “Passwords”.
For detailed description, see “Using Configure
Mode” on page 3-19.
Program Mode is divided into several categories:
• Serial Number
Service Mode
• Version
• WHLD (Weight Height Limit Display) Use Service Mode to calibrate, test, cycle, and
troubleshoot individual electrical circuits.
• Hour Meters
Service Mode tests are divided into two
• Configure Mode categories: static and active.
• Service Mode
Use the Learn Function to calibrate the lift
truck for correct operation. You can select the
Serial Number
following categories for calibration:
The serial number recorded in firmware must • Controls (travel, lift/lower)
match the serial number on the lift truck • Weight
tractor and mast specification plates. This field
cannot be changed from Program Mode.

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Modes of Operation
To enter Learn Function, you must enter Run Mode Tones

Service Mode. To enter Service Mode, you must
enter the SuperWord. The lift truck signals various situations by
using different tone patterns.
For a detailed description, see “Using Service
1. A single tone (chirp) occurs when the enter
button is used to enter a value in a
Program Mode.
Passwords 2. A double tone (high/low) means the
system has detected a fault condition. One
For detailed description of how to enter of the PC contactors may be de-energized
passwords, see “Entering an Electronic Key, (open). Travel, lift/lower, and auxiliary
Password, or SuperWord” on page 3-18. functions are disabled.
3. A triple tone (high/medium/low) means
Electronic Operator Key one of the following:
Electronic Operator Key is a configurable • Travel performance limitation: The lift

software feature that allows the customer to set truck is limited to a maximum travel
an operator electronic key or operator speed of 1 MPH (1.6 km/h). Lift, lower,
password. When the operator turns the key auxiliary functions, steering, and horn
switch ON, the software prompts the operator to all operate normally.
enter the electronic key. The lift truck will not • Traction system shutdown: The lift
enter Run Mode unless the correct electronic truck is disabled for travel. Lift, lower,
key is entered. Up to 20 different electronic auxiliary functions, steering, and horn
keys can be set. all operate normally.
• Lift system shutdown: The lift truck is
Password not permitted to lift. Lower, travel,
steering, and auxiliary functions all
Password permits access to Configure Mode operate normally.
only. It is intended for customer use in setting 4. A descending “arcade” tone means an
performance parameters within those features incorrect password or electronic key was
purchased with the lift truck. entered.
SuperWord
Entering Program Mode
SuperWord permits access to all Program
To enter Program Mode:
Modes. SuperWord is intended to limit service
access to qualified and trained service
From Run Mode, press the enter button on the
technicians.
Operator Display.
It is strongly recommended that, during
You will see an eight character password
installation, you change the SuperWord from
prompt field, displaying underscores:
the factory default to a code known only to the
dealer and/or owner so that access to Service
________
Mode is limited to approved personnel. Make
sure to record the new SuperWord in a safe
Enter the Password or SuperWord for the lift
place. If this code is lost or forgotten, a
truck. See “Entering a Password or SuperWord”.
technician must reset the lift truck to factory
default settings. This makes the reconfiguration
of all variable settings necessary.

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Modes of Operation
Entering an Electronic Key, 6. If you enter an invalid Password or

SuperWord, a descending “arcade” tone
Password, or SuperWord sounds and the following message appears
on the Operator Display:
An Electronic Key, Password, or SuperWord
may be from one to eight characters in length,
Invalid, Try Again
having any combination of letters, numbers,
and/or spaces (indicated by an underscore). A 7. If you make a mistake while entering a
password of all spaces is not permitted. character, repeat steps 2 thru 5.
NOTE: No two passwords (Electronic Key, When you have entered the correct Password or
Password, or SuperWord) may be set to SuperWord, the following is displayed:
the same value. If you try to do so, the
lift truck will treat the second password VSerial # °
as an invalid code and give an error
message. Each password must be set to Version
a unique value.
1. When the password prompt displays, an Hr Mtrs
eight character field of underscores
appears. Initially, the left-most character WConfig
position is flashing, showing it is the
currently selected position. To change Password or
2. Use the left/right buttons to select a SuperWord
different character position. The selected
position flashes. 1. Enter the Configure Mode using the
current Password or SuperWord. See
NOTE: After approximately 3 seconds, the “Using Configure Mode” on page 3-19. If
display prompt automatically Password is entered, Password is available
increments to the next position to the for change, but SuperWord is not.
right.
2. Use the up/down buttons to scroll to
3. Once you select the character position, Password. Press the right button.
use the up/down buttons to select the
3. Use the up/down buttons to scroll to the
number, letter, or space you want. The
Password or SuperWord item.
character set wraps between “0” and “-”
(space). In other words, to go quickly from 4. With Password or SuperWord selected,
the number “0” to the letter “z,” press the press the right button. (If Password was
up button twice. entered in step 1 above, Password is
available for change, but SuperWord is
0123456789 not.)
abcdefghijklmnopqrstuvwyz- 5. Enter the new password as specified under
NOTE: To enter numerical values, you can also “Entering an Electronic Key, Password, or
use the dashboard keys 1 thru 0 on the SuperWord”.
Operator Display panel. 6. With the new password displayed, press
the enter button.
4. Repeat steps 2 and 3 for the remaining
characters in the Password or SuperWord. 7. Save the new password as specified under
“To Save New Values” on page 3-19.
5. When you have completed entering all of
the characters in the Password or
SuperWord, press the enter button once.

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Modes of Operation
Using Configure Mode 2. Use the up/down buttons to move to the

item you want.
Use Configure Mode to adjust various lift truck 3. To configure the selected item, press the
performance parameters to specific customer right button. Follow the directions on the
requirements. To enter Configure Mode, you Operator Display. Use up/down buttons
must enter either the Password or SuperWord to select among specified values or to enter
for the lift truck. a numerical value. Use right/left buttons
to move to lower/higher menu levels.
Some items in Configure Mode appear only if
NOTE: To enter numerical values, you can also
the SuperWord is entered.
use the dashboard keys 1 thru 0 on the
Operator Display panel.
“Program Mode Menu” on page 3-21 lists all
possible lift truck configurations and options. If
When you have entered the values you want via
your lift truck does not have one or more of the
the up/down buttons, press the enter button.
listed options, those options do not appear in
The values are accepted and the Operator
the Operator Display.
Display shows the name of the item you last
selected.
To Place the Lift Truck in Configure
Mode NOTE: Changes are not saved until you exit
Configure Mode and reply Save to the
1. Enter Program Mode as described on Restore/Save prompt.
page 3-17.
2. Enter Password or SuperWord as To Configure Additional Items
described on page 3-18.
3. The Operator Display shows: After configuring the first item, press the left
button. Navigate to the next item as specified
VSerial # ° under “To configure an item.”
Version If You Make a Mistake
Hr Mtrs If you make a mistake in configuring an item,

simply navigate back to that item and configure
WConfig it again.
4. Press the down button until Config is
displayed. Press the right button. The To Save New Values
Operator Display shows:
Changes to configuration values are not saved
VDefault ° until you exit Configuration Mode. If you have
made changes to configured values:
Travel 1. Use the left button to back out of the
menus.
Lift
2. The Operator Display shows:
WBSOC
Restore
To Configure an Item Save
1. Use the up/down buttons to move to the 3. Use the down button to select Save. Press
item you want. An up (V) or down (W) the enter button. Your new values are
arrow in front of an item indicates there saved.
are more items above or below that item.

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Modes of Operation
NOTE: You will not be able to exit to the main 5. Press the left button to exit to Run Mode.
menu until you have selected either The lift truck enters the Run Mode.
Restore or Save and pressed the enter SelfTest is not re-run.
button.
4. Press the left button to back out to the To Reinstate Factory Default Settings
main menu. 1. Enter Configure Mode and use the down
button to select Default. Press the right
VSerial # ° button. The Operator Display shows:
Version Def No
Hr Mtrs Def Yes
WConfig 2. Use the up/down buttons to select Def
Yes. Press the enter button.
5. Press the left button to exit to Run Mode.
The lift truck enters the Run Mode.
SelfTest is not re-run. Factory default values are restored for all
items except:
If You Change Your Mind About • Password
Making Changes • SuperWord
• Electronic Key
Changes to configuration values are not saved
until you exit Configuration Mode. If you made • Error Log
configuration changes, but do not wish to keep • Emb Stats (VM Ver. 2.3+)
the changes:
• Switch 2H (VM Ver. 2.3+)
1. Use the left button to back out of the
• Lft Lmt (VM Ver. 2.3+)
menus.
• M Lwr Spd (VM Ver. 2.3+)
• Maximum Reach and Retract Speeds
Restore (VM Ver. 2.3+)
The following factory default values are
Save restored only if menu was entered from
3. With Restore selected, press the enter SuperWord:
button. Your new values are discarded. • BSOC
NOTE: You will not be able to exit to the main • Lift Cutout
menu until you have selected either • Travel Alarm
Restore or Save and pressed the enter
button. The following functions are disabled:
• Mnt Mind
4. Press the left button to back out to the
main menu. • Auto Off
3. Press the left button twice to select the
VSerial # ° main menu.
4. Press the left button to exit Program Mode
Version
and enter Run Mode.
Hr Mtrs
WConfig

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Modes of Operation
Program Mode Menu
Program Mode Menu
Note: Upper case value in Values column is the Factory Default.

Among values displayed on Operator Display, the item with an asterisk (*) is the currently
selected value.
Group Item Values Description
Lift Truck Identification
Serial # SN _ _ _ _ _ Lift truck serial number. Cannot be changed.
Version Lift truck firmware versions. Cannot be

changed.
VM xx.y Vehicle Manager
DM xx.y Display Manager
PAT xx.y Traction Power Amplifier
PAP xx.y Lift Power Amplifier
VMB xx.y VM Bootblock
WHLD Cfg Weight 1 xxxx lb Weight Height Limit Display configuration table.
Height 1 xxx in Values for weights and heights are
. factory-configured and not editable.
Weight 2 xxxx lb (Available with VM Ver 3.7+)
Height 2 xxx in
...
Weight 6 xxxx lb
Height 6 xxx in
Hr Mtrs Display hour meters. Cannot be changed.

Key H Key Switch Hours
DdMan H Deadman Hours
Lift H Lift Hours
Total D Traction Distance (mi./km)
Note: You can also display hour meters by
pressing the number 0 dashboard button on the
Operator Display.

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Modes of Operation
Program Mode Menu

selected value.
Config Mode Menu
Default Def No Do not restore factory default settings.

Def Yes Restore factory values to all settings except:
Password and SuperWord
Electronic Key
Error Log, Emb Stats
Lft Lmt Height, M Lwr Spd
Max Reach & Retract Speeds
Switch 2H
Disable:
Mnt Mind and Auto Power Off
Restore factory values only if menu was entered
from SuperWord:
BSOC, Lift Cutout
Travel Alarm
Travel Speed 7.5 Maximum Travel Speed

(depends on model)
0.0 to 8.0 mph (0.0 to 12.8 km/h)
(8.0 mph with 7600 High Performance Option)
T Accel Soft Travel Acceleration

MEDIUM
Hard
Coast LONG Coast Distance after releasing directional/speed

Medium control
Short
Switch 1 3.5 [default] Travel Speed Limit at Height 1

0 to 3.5 mph (0 to 5.6 km/h)
Switch 2 (option) 1.8 [default] Travel Speed Limit at Height 2

0 to 1.8 mph (0 to 2.9 km/h)
Switch 2H OACH [default] Height at which speed is reduced to Switch 2

(Superword only) configured value.
Range - overall collapsed height to maximum
elevated height
Default = overall collapsed height
UnNested (option) 3.5 [default] Travel Speed Limit with Reach Extended
0 to 3.5 mph (0 to 5.6 km/h)
AlarmT (option) None Travel Alarm enabled for forks leading, forks
(Superword only) Fork Ld trailing, both directions, or not enabled.
Fork Trl
BOTH

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Modes of Operation
Program Mode Menu

selected value.
Lift L Accel Soft Lift Acceleration

Medium
HARD
L Decel Soft Lift Deceleration at end of lift

Medium
HARD
Lwr Accel Soft Lower Acceleration

Medium
HARD
Lwr Decel Soft Lower Deceleration at end of lower

Medium
HARD
M LwrSpd 70% to 80% Maximum Lower Speed. Factory-set to the

(Superword only) [typical] original proportional valve installed. 50%
(slowest) to 100% (fastest)
Lft Lmt STD BYP To bypass limit or continue past limit, press and
(Superword only) hold Up arrow on Operator Display.
Alt Byp To bypass or continue past limit, press and
release Up arrow on Operator Display.
No Byp No bypass even if Up arrow is pressed.
Lim Hgt Height at which limit cuts out. See Lft Lmt.
BSOC Reset by Config Default only when invoked from

(Superword SuperWord. Cannot be reset by FlashWare.
only)
BSOC 75% [default] The percentage of charge that a new battery
must exceed in order for the BSOC display to
reset to the new battery. For an explanation of
how BSOC is calculated, see “Battery
State-of-Charge” on page 5-10. 55% to 100%
Lift c/o 20% [default] Battery State-of-Charge value at which Lift

Cutout occurs (to permit lift truck to travel to
charging station). 0 to 50%
Units ENGLISH Measurement units used in display

Metric

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Modes of Operation
Program Mode Menu

selected value.
Carriage Reach 1-Spd Reach Speed

2-SPD
MaxHiRch 100% [default] Maximum High Reach Speed Value

(Superword only) 0% to 100%
MaxHiRtr 75% [default] Maximum High Retract Speed Value

MaxLoRch 40% [default] Maximum Low Reach Speed Value

MaxLoRtr 40% [default] Maximum Low Retract Speed Value

Rch Spd S High Reach Speed

. . . . . . . .High *
**
***
****
*****
F
Rch Spd S Low Reach Speed

. . . . . . . .Low *
**
***
****
*****
F
Rtr Spd S High Retract Speed

. . . . . . . .High *
**
***
****
*****
F
Rtr Spd S Low Retract Speed

. . . . . . . .Low *
**
***
****
*****
F

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Modes of Operation
Program Mode Menu

selected value.
Password Elec Key (option) ________ Electronic Key prompt. Up to 20 different keys
(Superword only) permitted.
Note: No two passwords (Electronic Key,
Password, SuperWord) may be set to the same
value. If you try to do so, the lift truck will treat
the second password as an invalid code and give
an error message. Each password must be set to
a unique value.
Password ________ Change Password. See note under Electronic

Key.
Superwrd ________ Change SuperWord. See note under Electronic

(Superword only) Key.
Embedded View ES Display embedded statistics.

Statistics
(option) Interval Daily Set interval
Weekly
Monthly
Clear ES NO Do not clear statistics.

Yes Clear statistics log.
Mnt Mind Status Maintenance Minder ™ tool

DISABLE Disables the feature (when enabled)
Enable Enables the feature, using last stored setup
Reset Resets internal timer to current deadman pedal

hours (restarts the countdown)
Action Action to be taken at specified interval
. . . . MSG ONLY . . .Display message but do not disable lift
. . . . L CutOut . . .Disable lift
Interval Set reminder interval from 50 to 500 hours on
. . . . 250 [default] deadman pedal, by one hour increments.
Default is initially 250.
Note: Action and Interval cannot be reset by
Config Default or by FlashWare.
See “Maintenance Minder ™ Tool” on page 4-3.
Auto Off 0 Auto Power Off device

1 0 (Disabled), 1, 2, 3, 4, 5, 10 minutes
.. Note: Auto Power Off shuts down a lift truck
10 only when the lift truck is in Run Mode.
Clock Set Time and Date

Time hh:mm a/p Note: Holding Up or Down button changes value
Date mm/dd/yy faster.
24 hr DISABLED 12-hour format (1 PM = 01:00)

Enabled 24-hour format (1 PM = 13:00)

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Modes of Operation
Program Mode Menu

selected value.
ES Mode DISABLE Energy Saving Mode is disabled.

Minimum Minimum Energy Saving Mode is achieved by
slightly reducing maximum lift speed.
Maximum Maximum Energy Saving Mode is achieved by
reducing maximum lift speed.
WHLD Weight Height Limit Display format

(VM Ver 3.7+)
Two Ln H Show height, use left and right buttons to
change to 2-line height and weight.
Two Ln W Show height and weight, use left and right
buttons to change to 1-line height.
Toggle Display toggles automatically between 1-line
height and 1-line weight.
Fixed Use left and right buttons to toggle between
1-line height and 1-line weight.
VH Cfg Vertical Hold Configuration

xxx nnn 1- to 3-character alphanumeric label, followed
by 3-character numeric height (minimum is
OACH plus 12 in. or 30 cm)
Quit Cfg Restore Quit Configuration Mode without saving

changes.
Save Quit Configuration Mode after saving changes.

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Modes of Operation
Program Mode Menu

selected value.
Service Mode (Superword only)
Learn
Controls Operator Display message scrolls:

“Learning”
“Return Handle Controls to Neutral, Press Horn
Button.”
“Lower Carriage to Floor, Press Horn Button
When Done.”
“Done”
Weight Operator Display message scrolls:

“Learning”
“Lower Carriage to Floor, Then Lift 4 Inches,
Press Horn Button When Done.”
“Raise Carriage Out of Free Lift, Press Horn
Button When Done”
Analog A04 Tra Pot 1.13 V Use Up and Down buttons to scroll through list
... ... of Analog Tests. Test shows real time value.
A41 EPO Sns
Input I00 Dman Sw Down/Up Use Up and Down buttons to scroll through list
... ... of Input Tests. Test shows real time value.
I60 Start Sw Open
Output O00 TPC Tgl Off/On Operator Display message scrolls:

... ... “WARNING...Jack Up the Drive Wheel, Press
O34 Htr En Off/On Enter When Ready.”
Use Up and Down buttons to scroll through list
of Output Tests. Test shows real time value.
Use Enter button to toggle test.
Clr Act This item appears only if tests have been

selected for active service.
Clr No Do not clear active service tests.
Clr Yes Clear active service tests.
Log “No errors in log”
“Date Time Code Log holds up to 20 errors in order of occurrence.

BSOC” BSOC is normalized to Lift Cutout = 0%.
Clr Log Clr No Retain error log entries.

Clr Yes Clear error log entries.
LB Test Analog See “Loop Back Tests” on page 6-117.

Input

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Modes of Operation
Using Service Mode 4. You can select the following from Service
Mode:
Service Mode is divided into two categories: Learn
static and active. Analog
Input
Static Service Mode
Output
Static Service Mode permits testing of Clr Act (only if tests are selected for Active
individual circuits while the lift truck is Service)
standing still. You can use Static Service Mode Log
for most analog and digital input and digital
Clr Log
output tests.
Use the up/down buttons to select the
test category desired, then press the right
button.
By entering Static Service Mode, you are 5. If you select Output tests, the Operator
disabling the safety circuits. Therefore, Display scrolls this warning:
you must take extra precautions while
in Static Service Mode. Follow all WARNING: Jack Up The Drive Wheel,
instructions in this manual for each test. Press Enter When Ready...
If you are unsure how to conduct a test
while in Service Mode, Stop: Do Not After you jack up and block the lift truck,
Proceed with the test. Contact an respond to the Ready prompt by pressing
authorized Raymond dealer. the enter button.
6. Within a test category, test numbers are
While in Static Service Mode elevate the displayed in numerical sequence. Use the
drive tire off the floor. See “Jacking up/down buttons to move to the test you
Safety” on page 2-8. want.
7. Analog and Input test results are
To Place the Lift Truck in Static Service displayed to the right of the test number
Mode as soon as you select the test. For
example, Test A04 might show:
1. Press the enter button to enter Program
Mode.
A04 Tra Pot 1.10 V
2. Enter the SuperWord and press enter.
8. You must explicitly start output tests.
3. Use the up/down buttons to select Select the test number you want by
Service, then press the right button. scrolling and highlighting the test.
O01 STR Tgl Off
Press the enter button. The Operator

Display shows the test results to the right
of the test number.
O01 STR Tgl On
Use the enter button to toggle the test.
O01 STR Tgl Off

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Modes of Operation
the current category and select the other

To exit output test, press the left button. category from the Service menu. Use the
9. The Error Log stores the last twenty error up/down buttons and remaining
codes recorded on the lift truck. Entries dashboard buttons to select more tests
are stored in order of occurrence, with the from that category.
most recent error first. 5. Quit Service Mode and Program Mode. Let
10. To access the Error Log, use the up/down the lift truck enter Run Mode.
buttons to select Log, then press the right 6. To display Active Service tests while in
button. Run Mode, press dashboard button 9.
11. If no errors are stored, the message “No Four tests will display at a time. Use the
Errors in Log” appears in the display. up/down buttons to scroll through the list
of selected tests.
12. If errors have been logged, use the
up/down buttons to scroll through the
list. To Clear All Active Maintenance Tests
At Once
13. To clear the log, use the up/down buttons
to scroll to Clr Log. Press the right button. 1. Go to Program Mode.
Scroll to Clr Yes and press the enter
2. Use the up/down buttons to select
button.
Service, then press the right button.
3. Use the up/down buttons to select
Active Service Mode Clr Act. This item only appears if you have
selected one or more tests for active
Active Service Mode permits testing circuits service.
while the lift truck is enabled for normal
4. Press the enter button. Active service tests
operation. You can use Active Service Mode for
are cleared. Exit Service Mode and
all analog and digital input tests.
Program Mode.
You can select up to eight tests at a time to run
in Active Service Mode. Tests can be displayed
whether you are on or off the deadman pedal.
Tests selected for Active Service are stored in

memory even if the key switch is turned OFF.
To Enable a Test For Active Service

Mode
1. Enter Static Service Mode.
2. Scroll to the test you want. Press one of
the dashboard buttons 1 thru 8 on the
Operator Display. The button number
appears to the left of the test number in
the test list to show that this test is
selected for Active Service Mode.
3. Assigning a test to a particular dashboard
button resets any previous assignment for
that button.
4. Use the up/down buttons to select more
tests from the same category. To select
more tests from a different category, exit

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Modes of Operation

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Model 7600/7620/7640 Reach-Fork® Truck Section 4. Scheduled Maintenance
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Section 4. Scheduled Maintenance

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Section 4. Scheduled Maintenance Model 7600/7620/7640 Reach-Fork® Truck
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Maintenance Guidelines
Maintenance Guidelines
Following a regularly scheduled maintenance
program:
• Promotes maximum lift truck performance
• Prolongs maximum lift truck life
• Reduces costly down time
• Prevents unnecessary repairs
Scheduled maintenance includes:

• Lubrication
• Cleaning
• Inspection
• Service
Perform all the scheduled inspections and

maintenance at the suggested intervals. The
time intervals given in this guide are based on
deadman hours under normal operating
conditions. When operating under severe or
extreme conditions, do these services more
often as specified in Table 4-1.
Table 4-1. Maintenance Frequency
Operating Service
Working Environment
Conditions Frequency
180 days or 500

Light to
An eight hour day of basic material handling hours, whichever
Moderate
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 100 hours
• High temperature areas such as in steel mills, foundries, enclosed
(Type EE) applications
• Corrosive atmosphere such as chlorine or salt-sea air environments
See “Lubrication Specification Chart” on

page A-2 in the Appendix for lubrication
specifications. Refer to the manufacturer’s
supplements for components not listed on the
following pages.

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Maintenance Minder ™ Tool
Maintenance Minder ™ NOTE: For instructions on selecting Modes of

Operation, see “Modes of Operation” on
Tool page 3-16.
With Configuration Mode selected, use the

Maintenance Minder Tool is a feature that down button to display the “Mnt Mind” item.
permits prompting of a customer when the lift Press the right button. With “Status”
truck is due for scheduled maintenance. highlighted, press the right button. Use the
down button to select “Enable.” Press the enter
Maintenance Minder, when configured and button. Maintenance Minder is enabled with the
enabled, monitors the Hours on Deadman (HD) last stored time interval and action option.
meter. When the time interval for scheduled
maintenance is exceeded, the operator is Exit program mode as described under “Exiting
informed in the following ways: Program Mode” on page 4-4.
• One of two messages appears on the
Operator Display following the “Daily
Checklist” message.
Setting or Changing Time
Interval and Action Option
• “Scheduled Maintenance Due”
• “Lift Cutout, Scheduled Maintenance With Configuration Mode selected, use the
Due” down button to display the “Mnt Mind” item.
• A wrench icon flashes Press the right button. Use the down button to
select “Setup.” Press the right button.
• The audible alarm sounds the high-low
tone for approximately 5 seconds.
Use the up/down buttons to scroll to “Interval.”
Press the right button. The first time you enter
Lift Cutout, when active, will not disable the lift
the time interval menu, the Operator Display
function until power to the control circuits is
shows the Factory Suggested setting. When the
cycled (key switch OFF or battery
time interval menu is entered, the Operator
disconnected). When control circuit power is
Display shows the last used setting. Values
cycled, lift is disabled until Maintenance Minder
from 50 to 500 deadman pedal hours are
is reset or disabled, or the lift cutout option is
available. Press the right button. Use the
turned OFF.
up/down buttons to scroll to the desired time
interval. With the selected value displayed,
Factory Configuration press the enter button. Press the left button to
return to the Setup menu.
For field installations, this feature must be
added to the configuration options via the Use the up/down buttons to select “Action.”
FlashWare program. The factory default is Then press the right button. The following
Disable. options are available:
• “Msg Only” causes the Operator Display to
Maintenance Minder settings are not changed show “Scheduled Maintenance Due” when
by resetting Defaults in the Config menu. the scheduled maintenance time interval
is exceeded.
Enabling • “L Cut Out” causes the Operator Display
to show “Lift Cut Out, Scheduled
Once installed, Maintenance Minder appears in Maintenance Due” when the scheduled
the Configure Mode menu. The initial factory maintenance time interval is exceeded. Lift
setting is “Disable.” To enable the feature, enter is disabled the next time the power circuits
Configure Mode. are cycled.

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Maintenance Minder ™ Tool
Use the up/down buttons to select the option 3. Use the down button to select Save. Press
you want, then press the enter button. the enter button. Your new values are
saved.
Exit Program Mode as described under “Exiting
NOTE: You will not be able to exit to the main
Program Mode”.
menu until you have selected either
Restore or Save and pressed the enter
Resetting Maintenance button.
Minder ™ 4. Press the left button to back out to the
main menu.
If you want to reset the reminder prompt when
▲Serial # ➠
Maintenance Minder is active and you have
completed scheduled maintenance, enter Version
Configure Mode. Hr Mtrs
▼Config
down button to display the “Mnt Mind” item. Press the left button to exit to Run Mode.
Press the right button. Use the down button to The lift truck enters the Run Mode.
select “Setup.” Press the right button.
With “Reset” highlighted, press the right

button. Use the down button to scroll to “Yes.”
Press the enter button.

Program Mode”.
Disabling
When Maintenance Minder is active and you
want to disable it, enter Configure Mode.

down button to display the “Mnt Mind” item.
Press the right button. With “Status”
highlighted, press the right button. Use the up
button to select “Disable.” Press the enter
button.

Program Mode”.
Exiting Program Mode

1. Use the left button to back out of the
menus.
Restore
Save

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Initial 90 Day/250 Deadman Hours (HD) Maintenance
Initial 90 Day/250
Deadman Hours (HD)
Maintenance
4
Perform the following maintenance tasks 90 days after the lift truck was put into service or at
250 HD, whichever comes first.
Component Task
Break free, reapply thread-locking compound (P/N 990-544), and retorque mounting
Drive Unit
bolts to 150 ft. lb. (204 Nm). Change fluid.
Hydraulic
Change fluid and filter(s). See “Hydraulic Filter” on page 7-75 and “Lubrication
Reservoir and
Specification Chart” on page A-2.
Manifold
Break mast to tractor mounting bolts free. Clean threads, reapply primer (P/N 990-666)
Mast and thread-locking compound (P/N 990-544). Re-torque mounting bolts to 165 ft. lb.
(224 Nm).
Power
Retorque power cable terminal nuts to 11 ft. lb. (15 Nm).
Amplifiers

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Every 180 Days or 500 HD
Every 180 Days or

500 HD
4
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 allowable weight.
Battery
Inspect all battery connectors and leads for damage and cuts in protective coatings. Make
sure the 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 a open area, measure stopping distance. Traveling at 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 conditions.
Brake Examine for signs of oil on the pads or rotor. If oil is present, disassemble brake, clean
rotor, and replace pads.
Measure for correct air gap between armature and armature plate: 0.040 in. (1 mm) max.
See “Brake” on page 7-50.
Failure to keep brakes adjusted causes premature pad and rotor wear and excessive
motor heat.
Examine for bond failure, chunking, and excessive or uneven wear. Inspect bearings for
Caster Wheel
binding or excessive play. Check adjustment of caster wheel.
Inspect contactor tips for burnt or pitted surfaces. Failure to replace the tips can cause
surfaces to weld together, causing unscheduled down time. With the key switch OFF and
Contactors
the battery disconnected, examine the plunger for smooth operation with no binding. If
binding occurs, the lift truck could malfunction or display intermittent fault codes.
Verify lift/lower function is smooth and controllable. Verify travel function is smooth and
Control responsive through full range of motion. Check for play in the center position of lift or
Handle(s) 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.
Check free lift cylinder piston position. With forks completely lowered, make sure one
Cylinders
piston is not higher than the other.
The deadman pedals must operate smoothly with no binding. Check for correct activation
Deadman Pedal
and deactivation of the deadman switch under the pedal.
Drain Holes Make sure the drain holes in the battery compartment are free of any debris.
Check oil level. Inspect for leaks. Make sure O-ring is present on the dipstick. Check
Drive Unit drive axle for play. Examine for drive unit radial ring wear (7600/7620). See “Radial Ring
Inspection” on page 7-37.

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Component Task
Inspect all power cables for nicks or cuts. Give special attention to those cables that are
not stationary, for example, cables to the Traction Motor. Replace any cable that is
damaged or shows signs of excessive heat. Failure to do so causes intermittent system
Electrical
shutdowns and/or electronic failures. Check the tension of the over-the-mast cables. Set
Cables
the tension on the spring at the carriage by sliding the cable grip to produce a length of
1.75 ±0.12 in. (44.5 ±3.0 mm) across the coils. Do not over tension. Tighten the cable tie
on the cable grip.
Fans Check for correct operation. Run “Test O23 - Toggle Fans” on page 6-112.
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
Forks
unauthorized modifications. Replace if found. Measure fork thickness
(Tool P/N 922-369). See “Fork Inspection” on page 4-17.
Frame and Perform a visual inspection of structural members for cracks, including but not limited to
Baselegs baselegs, main frame, and tractor.
Check bolt torque of major components (motors, pumps, brake, drive unit,
Hardware mast-to-tractor mounting bolts, overhead guard).
Tighten any loose hardware. Replace any broken or missing hardware. See “Appendix”.
Horn Make sure horn sounds correctly when activated.
Inspect all hydraulic hoses for leaks, nicks, cut, chafing, and bulges. Replace damaged
Hydraulic hoses as soon as possible. Inspect all fittings for leaks. Repair any leaks immediately.
Hoses Inspect over-the-mast hoses for correct tension. Make sure over-the-mast hose pulleys
spin freely and show no signs of wear.
Hydraulic
Check fluid level.
Reservoir
Check adjustment. Inspect for excessive stretch or wear (tool P/N 950-350/CG).
Lift Chains
Lubricate. See “Chain Maintenance” on page 4-16.
Lubrication Lubricate all grease points. See “Lubrication Points” on page 4-10.
Wipe old grease off mast uprights and apply new grease.
Inspect anti-rattle pads and anti-bow pads (7600 only). Anti-bow pad minimum thickness
is 0.187 in. (4.75 mm) and correct gap is 0.03 to 0.09 in. (0.8 to 2.3 mm).
Examine mast bearings.
Mast Inspect carriage stops for tightness and wear.
Inspect the outside of the main frame for wear, especially if the lift truck is used in
drive-in racks.
Inspect rails for abnormal wear, metal flakes, or shavings.
Repair any grooves worn in the mast deeper than 1/8 in. (3 mm).

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Component Task
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. 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 - Inspect commutator. Inspect brushes for excessive heat (discoloration of the

pigtails). If excessive heat is evident, inspect the armature circuit for loose connections.
Motors Check condition of commutator per photos on page 5-6. 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 that 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. Torque both the
inside and outside nut to the values listed. Replace any cable that shows signs of
excessive heat. Check sensor wires for sound connection and condition.
Overhead
Inspect guard for physical damage. If structurally damaged, replace the guard.
Guard
Power Make sure power amplifier heatsink fins are free of debris and that air flows freely
Amplifiers through them. Check torque of power cable hardware.
Check for electrical shorts to frame. See “Shorts to Frame” on page 5-2. Wipe
Shorts to Frame
compartments clean.
Make sure static straps are not worn or broken. Clean debris from straps. Check
Static Straps resistance of resistor in standoff. EE trucks require a phosphor bronze static strap; do
not use steel braided cable on EE trucks.
Check that steering system function is smooth and responsive. Inspect pivot points and
bearings in the steering linkage. Inspect teeth on the steering gear and drive unit for
wear.
Check adjustment of the steerable caster. See “Steerable Caster” on page 7-22.
Steering Lubricate the steer axle assembly.
Make sure steering is smooth and responsive, without binding or excess play. Refer to
“Steering Encoder” on page 7-20.
Check the gap on the steer limit switch (S11). See “Steer Limit Switch (S11)” on
page 7-21.
Check all switches for correct operation and adjust as needed. See “Component Specific
Switches
Service/Torque Chart” on page A-4.
Ventilation
Make sure ventilation slots in the tractor frame are open, with no obstructions or debris.
Slots
Warning Decals Replace any illegible or damaged decals.
Warning Lights Check for correct operation.
Examine for bond failure, chunking, and excessive or uneven wear.

Wheels/Tires Inspect load wheel bearings for binding or excessive play.
Inspect drive axle and idler axle for excessive play.

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Every 360 Days or

2000 HD
4
Component Task
Drive Unit Change fluid.
Hydraulic
Reservoir and Change hydraulic fluid and filter. Filter is located in main manifold.
Manifold
Lift Pump Separate pump and motor. Apply molybdenum anti-seize compound (P/N 990-638) to the
Coupling splines.

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Lubrication Points
Lubrication Points
NOTE: Locate items by numbers on the photos
that follow this list:
1. Steering linkage arm, pivot point
2. Steering linkage, steerable idler arm
3. Steering linkage, drive wheel arm
4. A-frame pivot bolts
5. Idler wheel bearing
6. Idler wheel axle
7. Drive unit radial rings and steer gear
8. Scissors mechanism
9. Reach cylinder
10. Inner telescopic channels (left and right,
both sides)
11. Lift chains (spray)
12. Sideshift carriage
13. Load Wheels
Lubrication Point Locator Photos

Figure 4-1. Lubrication Points, Steering Linkage and A-frame (underside view)
4P5180009.tif
1 (access in battery
compartment)
4 (access on
top side)

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Lubrication Points
Figure 4-2. Lubrication Points, Steering Linkage and A-frame (top views)
4QAP289_b.jpg,p5180011.tif
Battery Compartment
Figure 4-3. Lubrication Points, Idler Wheel bearing and axle

46353_005.jpg,p5180019.tif
Figure 4-4. Lubrication Points, Drive Unit

46353_103g.jpg
7 (behind pedal assy.)

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Lubrication Points
Figure 4-5. Lubrication Points, Scissor Mechanism R45TT
4R1020670_A1.cgm,R1020670_A.cgm
8 (Both Sides)
8 (Both Sides)
8
8
8 (also
other side)

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Lubrication Points
Figure 4-6. Lubrication Points, Scissor Mechanism DR32TT
4R1021624_A1.cgm,R1021575_A1.cgm
8 (Inside Surface Both Sides)

8 (Both Sides)

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Lubrication Points
Figure 4-7. Lubrication Points, Reach Cylinder
4DSC_0873a.jpg
Figure 4-8. Lubrication Points, Sideshift Carriage

4R1020739_A.cgm
12
12
12

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Lubrication Points
Figure 4-9. Lubrication Points, Mast and Carriage
46353_117g.jpg
10
11
13

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Chain Maintenance
Chain Maintenance Figure 4-10. Chain Gauge

4Ma0634.eps
Lift Chain Inspection
A
A
Chain
Wear
Make sure chains are not damaged. Check the Scale
chain for wear using a Chain Gauge
(P/N 950-350/CG). See Figure 4-10.
A
A
MA0634.ill
Chain OK Replace Chain
Replace chains with genuine Raymond spare

parts. See “Lift Chains” on page 7-70.
Condition-Cause Chart
4
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
Chain Elongation Wear mm) length that has operated over the pulley sheave.
Stretch the chain; if more than 1/3 in. (8.5 mm) play
is detected, replace the chain.
Steam cleaning or
Rust and corrosion degreasing new lift truck Lubricate chain frequently.
chains
Infrequent Oiling
Rust
Cracked Plates Replace the chain.
Corrosion
Chain Fatigue
Bent pins or plates Replace the chain.

Tight Joints Rusty joints or peened plate
Replace the chain.
edges
Chain side wear Chain misalignment Replace the chain.

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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 4-12.
• 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 4-12.
Maintenance.
Figure 4-12. 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 to the
smallest maximum deviation number
NOTE: This measurement can be done with the
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 4-11.
Figure 4-11. 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 4-13.
Blade 2. Now open and move the caliper so the two

extruded points are touching the shank.
See Figure 4-13.

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Fork Inspection
Figure 4-13. Fork Angle 4. Raise one end of the level to make it level.
4ForkArmWearCaliperGuide_2.svg
See Figure 4-14.
5. Measure the distance from the tip of the
Shank fork. See Figure 4-14.
Figure 4-14. 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 4-13. 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° Positioning Locks (if applicable)
angle; therefore, a reading greater than
93° or less than 87° is unacceptable. 1. With the forks on the carriage, visually
However, there are some forks that are inspect the positioning locks for damage.
purposely manufactured to angles 2. Test the positioning locks to verify they
greater than or less than 90°. work correctly.
3. If the positioning locks are damaged or do
Fork Tip Height not work correctly, remove the fork from
service.
1. With forks on the carriage, measure the
length of the blade. See Figure 4-11.
• For forks 42 in. (106.7 cm) or less, max. Wear
deviation is 0.25 in. (6.3 mm).
• If length of fork is >42 in. (106.7 cm), Fork Blade and Shank
multiply length of blade by 3%. 1. Remove the forks from the carriage.
Blade length _____in. x 3% = _____in.
2. Approx. half way up the shank, set the
This is the maximum deviation.
front teeth of the jaws of the caliper on the
2. Elevate forks approx. 4 ft. (1.2 m) off the shank. Make sure the caliper is held
floor. square across the shank to get an
3. Place a 4 ft. level across the tips of the accurate reading. The caliper is now set to
forks. See Figure 4-14. measure fork blade wear. Carefully remove

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Fork Inspection
the caliper from the shank. See

Figure 4-15.
Figure 4-15. Measuring Fork Shank If there is greater than 10% wear of the
4Fork Inspection.jpg 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
1. Remove the forks from the carriage.
3. Measure 2 in. (50 mm) out from the heel of 2. Determine the fork mounting class.
the fork.
a. Measure the height of the carriage or
4. Place the caliper over the flanks of the fork the distance between the hooks. See
arm blade at this 2 in. (50 mm) point. See Figure 4-17.
Figure 4-16.
Figure 4-17. Determining Fork Mounting Class
Figure 4-16. Measuring Fork Blade Wear 4Fork Inspection.jpg
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)
1 12.05 (306) 13 (331)

5. If the inside teeth of the caliper hit the
fork, there is <10% wear. If the inside teeth 2 15.04 (382) 16 (407)
pass freely over the fork arm, there is
>10% wear and the fork must be removed 3 18.78 (477) 20 (508)
from service.

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Fork Inspection
3. Locate the correct extruded edge on the

caliper for the fork mounting class. See
Figure 4-18.
4. Slide the extruded edge up into the hook
pocket. See Figure 4-18.
5. If the caliper’s extruded edge completely
slides up into the fork pocket, remove the
fork from service. See Figure 4-18.
Figure 4-18. 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.

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Model 7600/7620/7640 Reach-Fork® Truck Section 5. Troubleshooting
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Section 5. Troubleshooting

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Section 5. Troubleshooting Model 7600/7620/7640 Reach-Fork® Truck
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Electrical Troubleshooting
Electrical • Whenever measuring resistance, turn the

key switch OFF and disconnect the battery
Troubleshooting connector. Battery current can damage an
ohmmeter. Isolate the component from the
circuit.
General
Shorts to Frame
“Shorts to frame” is an industry term for
unintentional current leakage paths between
Block the lift truck so that the drive tires normally isolated electrical circuits and their
are off the floor whenever a metal enclosures.
troubleshooting procedure requires
turning the key switch ON. This prevents Shorts to frame may be metallic connections,
accidents caused by unexpected lift such as a wire conductor contacting metal
truck travel. through worn insulation. More often, shorts to
frame are resistive “leakage” paths caused by
Unless otherwise directed, disconnect contamination and/or moisture.
the battery connector when you check
electrical ciruits or components with an These leakage paths can result in unwanted
ohmmeter. Electrical current can damage electrical noise on the metallic lift truck
an ohmmeter. structure and can cause incorrect operation.
Before removing a power amplifier, Shorts to frame are caused by:

discharge the amplifier’s internal
• Accumulation of dirt
capacitor by jumpering the + and –
terminals with a 100 ohm 25W resistor. • Battery electrolyte leakage
• Motor brush dust
• Many problems can be caused by a dirty
• Motor brush leads touching the housing
battery. Make sure the battery is clean.
• Breakdown in insulation
• Save time and trouble by looking for
simple causes first. • Bare wires
• Use a Digital MultiMeter (DMM) such as a • Pinched wiring harness
Fluke meter for all measurements. Analog • Incorrect mounting of circuit cards
meters can give inaccurate readings and
load down sensitive electronic circuits Shorts to frame can occur at numerous
enough to cause failure. Make sure meter locations on a lift truck, including:
cables are connected to the correct meter
• Batteries
jacks and that the correct function and
scale are selected. • Motors
• Printed circuit boards are conformal • Cables, wiring, and harnesses
coated. Make sure meter leads make a • Heatsinks
good electrical connection with test points.
• Bus bars
• When measuring voltage, connect the
• Solenoids
positive meter lead to the connector or
probe point marked (+) in the test. • Contactors
Connect the negative meter lead to the • Terminal strips
connector or probe point marked (–).
• Switches
• Power panel insulation
• Circuit card mounts

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Shorts to Frame Test: damaged if you proceed before correcting

this condition.
1. Turn the key switch OFF and disconnect
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
• Heatsinks
Install another battery in the lift truck and
repeat this procedure from Step 1. • Power cables
• Power circuit components
If the test light does not illuminate,
• Control circuit components
continue to the next step.
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
Repeat Step 4.
battery case to battery B+ and from the
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 lift truck, then continue with case does not touch the lift truck frame.
Step 4. Make sure the battery case does NOTE: The functions being checked must be
not touch the lift truck frame during the energized. Example: to check for shorts
remaining tests. to frame in the travel circuit, travel must
4. With the battery disconnected (or removed be requested.
and disconnected) from the lift truck, use 6. Use a DVM set to the current function to
a DMM to measure the resistance from lift measure current leakage to the truck
truck frame to truck B+, to truck B– (not frame from B+, B–, and all fuses and
battery B+ and B–), and to all fuses and motor terminals. Begin measuring at the
motors. A reading of <1000 ohms indicates highest ampere scale and work toward the
a serious short. Do not continue until this lowest. If the current is <0.001A (1mA), go
condition is corrected. The meter may be to step 7. If the current is more than

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0.001A (1mA), continue with the following d. Reconnect all other components
steps: previously disconnected, measuring
a. To identify the cause of the short to current between steps. If a reading is
frame, disconnect circuit components more than 0.001A (1mA) when
until the leakage current reads <0.001A reconnecting a component, that
(1mA). Do not reconnect components component or its wiring is faulty.
one at a time, but leave them Repair or replace as appropriate.
disconnected until the leakage current 7. When, after all components are
reads <0.001A (1mA). Prevent reconnected, you get a reading <0.001A
disconnected terminals or connectors (1mA) there is no short to frame condition
from touching the lift truck frame or with the lift truck or the battery. If you
other conductive surfaces. previously removed the battery from the
b. The most likely areas to check are: lift truck, re-install the battery.
• Motors Fuses
• Heatsinks
• Power cables Test/Inspection
• Power circuit components Examine the fuse for signs of overheating,
• Control circuit components discoloration, cracking, or other physical
c. Repair or replace the component(s) damage. Replace as necessary.
causing the leakage current.
Repeat Step 6. To test a fuse, remove it from the lift truck. The
resistance should be <1 ohm.
Table 5-1. Fuse Chart
Fuse Amps Location Function
FU1 150 Contactor/Fuse Panel Power fuse for steering
FU2 350 Contactor/Fuse Panel Power fuse for travel
FU3 500 Contactor/Fuse Panel Power fuse for lift
FU5 15 Fuse/Relay Card Control fuse for Vehicle Manager B+
FU6 15 Fuse/Relay Card Control fuse for Vehicle Manager B–
FU7 15/5 Fuse/Relay Card Control fuse for aux power B+
FU8 15/5 Fuse/Relay Card Control fuse for aux power B–
FU9 10 Travel alarm Control fuse for travel alarm
FU11 10 In-line harness Control fuse for warning light and strobe
FU12 10 In-line harness Control fuse for working lights and fan
FU13 n/a Control Handle Thermal fuse for control handle external heater
FU14 10 ThermaKit Control Module Control Fuse for ThermaKit handle
FU15 2 TS2 Control Fuse for Fork-Laser Module B+
FU16 2 In-line harness near TP4 Control Fuse for Fork-Laser Module B–

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

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

5motor-series.eps,motor-pmagnet.eps
Series-Wound Motor
Permanent Magnet
S/D
Motor
MS+
A2
MS
MP
MS–
A1
A
Inspection
Inspect the 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
the segments. This can lead to a short circuit in
the armature.
Good commutation is indicated by a dark

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

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

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

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

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

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

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

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

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

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

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Condition Probable Cause Commutator Surface
Unsatisfactory Darkening of commutator in sequences two pole

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

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

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

Unsatisfactory
pressure. Due to sparking under brush, that
Condition-Small Bright
gives rise to spots being of a random distribution.
Spots
If not corrected, will result in scored commutator.
Open Circuit Motor Test 3. Observe the following measurements:
An open circuit is an electrical circuit within the

DC Motor Probe Points Resistance
motor that is broken. This can be caused by:
A to S <1 ohm
• bad brushes or brush springs Lift
A to Frame
• a broken wire in the field or armature
winding Auxiliary A1 or A2 to
Frame >100,000 ohms
• loose or bad connections
MS+ or MS– to
Steer
Frame
Refer to Figure 5-1 on page 5-5 while
performing the following procedure:
1. Isolate the motor from the lift truck circuit 4. If the meter indicates high resistance in
by removing the power cables. Use two the armature, check the condition of the
wrenches to avoid twisting the terminal brushes before replacing the motor.
stud. 5. If you find an open circuit in a
2. With the motor at room temperature, series-wound motor, the motor must be
connect the leads of a digital ohmmeter disassembled by a motor rebuilding facility
between the individual circuits in the to isolate the problem to the field or
motor. armature circuit.
Grounded Motor Test
In a grounded motor, an electrical circuit exists

between the current-carrying conductors and
the motor housing. This can be caused either by
direct contact or through conductive foreign
material.

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The ground may be caused by: Testing a motor for short circuited windings
• insulation breakdown requires special equipment at a motor
rebuilding facility.
• brush leads touching the motor housing
• build-up of carbon dust or other materials
Isolate the motor from the lift truck circuit by

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

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

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

Winding
A short circuited winding is one that the

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

• Slow or sluggish operation
• Running faster than usual (suggests a
short in the field)
• Overheating
• Blowing a power fuse
• Burning of brush wires
• Severe burning or discoloration on
armature coil
• Severe burning or discoloration on one or
two commutator segments every 90° of
rotation.
These symptoms can be caused by problems

other than the motor itself, such as binding in a
related pump, hose, or solenoid valve.

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AC Motors Using a clamping ammeter, measure current in

each of the motor power cables. The shorted
AC motors used on this lift truck are brushless, phase will read significantly higher than the
3-phase, internally delta-connected, variable other two phases.
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 5-2.
Figure 5-2. Traction Motor Circuits

motor_AC3phaseA.eps motor_AC3phaseB.eps
AC
3φ
V W
U
AC
V
3φ
W
Open Winding
If the AC motor fails with an open winding, the

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

each of the motor power cables. The open phase
will read significantly lower than the other two
phases.
Shorted Winding
If the AC motor fails with a shorted winding, the

motor moves erratically, as if hunting, and
there is a high-pitched sound.

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Battery State-of-Charge 95%. Plugging in a battery at anything

below 95% charge will not change the
Battery State-of-Charge (BSOC) is a feature that Operator Display. Older batteries or
monitors and remembers the charge level of the applications providing inadequate
battery connected to the lift truck and helps to charging time could require a lower
prevent excessive discharging of that battery. configured value for BSOC since older
Operating a lift truck using a discharged batteries might be unable to reach a
battery can damage both the battery and the higher percent charge. Therefore, some
electrical components of the lift truck. batteries could require BSOC configured
as low as 55% before lift cutout resets and
At power-up, BSOC tests the battery voltage to the Operator Display shows the charge of
determine if it is the same as it was at the replacement battery.
power-down. If the voltage is the same, BSOC
assumes it is the same battery and continues to Setting Battery State-of-Charge
monitor the battery for discharge and updates Cutout
the Operator Display as required.
1. Fill, charge, and install a battery that is
If a different battery voltage is detected, BSOC typical of the batteries normally used in
assumes a different battery is installed and this application.
tests to determine the state-of-charge of the 2. Have a customer operator use the lift
replacement battery. The replacement battery truck in normal application until cutout
must meet one of the following criteria before occurs.
the display resets and lift is restored.
3. Allow the battery to cool and stabilize for
• The replacement battery must have a at least two hours.
charge level at least 50% different from the
4. Before filling the battery, either take
previously installed battery.
specific gravity readings or measure open
• The charge value of the replacement circuit voltage of the battery cells.
battery must be greater than the
5. Compare the measurements with the
configured BSOC setting.
battery manufacturer’s recommendations
for maximum discharge.
The criteria are determined in this way:
6. Adjust the cutout value as needed and
• BSOC compares the charge of the battery
repeat the previous steps until battery
that was connected to the lift truck with
cutout occurs at the desired discharge
the replacement battery’s charge. A charge
level.
difference of at least 50% between the two
batteries resets BSOC to show the
state-of-charge of the replacement battery,
that is, the measured state-of-charge of
the replacement battery minus the
remembered state-of-charge of the old
battery must equal or exceed 50%. This
reset can be higher or lower than the old
battery.
• BSOC looks at the configured reset point.
BSOC reset is programmable from 55% to
100% of total battery charge and can be
changed by entering the Configure Mode
using the SuperWord. The replacement
battery must be greater than the
configured percent of charge before BSOC
changes. Example - BSOC configured at

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Hydraulic Troubleshooting Guidelines
Hydraulic
Troubleshooting
Guidelines
NOTE: After elevating or reaching the carriage
for troubleshooting, make sure to use
blocks to secure the carriage.
NOTE: Use extreme care when blocking the
mast for any reason. Never remove a
block when it is supporting the mast.
Lower the carriage fully and retract the reach

mechanism fully.
Stabilize the top of the mast with an overhead

chain hoist.
When you measure voltage at solenoids, make

sure hydraulic lines and components are fully
installed.
Whenever possible, keep the key switch OFF

and the battery connector disconnected.
Cap open hydraulic lines to prevent

contamination.

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Hydraulic Troubleshooting Guidelines

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Symptom Tables: Hydraulic Functions
Symptom Tables:
Section 5. Troubleshooting
Hydraulic Functions
NOTE: If a component fails due to hydraulic
fluid contamination, replace the failed
component, flush, fill, and bleed the
hydraulic system. Refer to “Hydraulic
System Bleeding” on page 7-74.
NOTE: Reference electrical schematics
beginning on page A-17 and hydraulic
schematics beginning on page A-22.
Auxiliary Functions
No Auxiliary Functions Work (Reach/Retract, Tilt, Sideshift)
Possible Cause Action
Bad K2 relay circuit Troubleshoot K2 relay circuit.
Bad LS1 shuttle Replace LS1.
Bad aux directional solenoid 5B or 5T (valve or Run Tests O04 and O05. Follow test
wiring) recommendations.
All Auxiliary Functions are Slow
Incorrect hydraulic fluid for application Replace hydraulic fluid with correct fluid. See
“Lubrication Specification Chart” on page A-2.
Bad POD-1 valve Replace POD-1 valve.
Aux system relief pressure too low Adjust aux pressure. See “Auxiliary Pressure
Adjustment” on page 7-80.
Bad LS1 shuttle Replace LS1.

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No Tilt or Tilt One Direction Only; Other Aux Functions OK
Bad tilt switch (S6 and/or S7) Run Test I08 and/or I09. Follow
recommendations in test.
Bad tilt solenoid valve or coil, or wiring. Check Run Test O07. Follow recommendations in
for contamination. test. If contamination is found, flush, refill,
and bleed hydraulic system. Swap hoses with
sideshift to check valve and cylinder.
Broken tilt cylinder pin Replace tilt cylinder pin.
Mechanical binding in tilt cylinder or carriage Measure pressure; normal operation should
be below bypass pressure. See “Auxiliary
Pressure Adjustment” on page 7-80. Binding
produces higher pressures. Repair/replace
cylinder or other binding components.
Slow Tilt; Other Aux Functions OK
Mechanical binding in tilt cylinder or carriage Measure pressure; normal operation should
be below bypass pressure. See “Auxiliary
Bad tilt solenoid Examine for binding or contamination. Swap

hoses with sideshift to check valve and
cylinder.
No Sideshift or One Direction Only; Other Aux Functions OK
Bad sideshift switch (S8 and/or S9) Run Test I10 and/or I11. Follow
recommendations in test.
Bad sideshift solenoid, or wiring Run Test O08. Follow recommendations in

test. Swap hoses with tilt to check valve and
cylinder.
Mechanical binding in sideshift cylinder or Measure pressure; normal operation should

carriage be below bypass pressure. See “Auxiliary

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Slow Sideshift; Other Aux Functions OK
Mechanical binding in sideshift cylinder or Measure pressure; normal operation should

carriage be below bypass pressure. See “Auxiliary
Bad sideshift solenoid valve Repair/replace sideshift solenoid valve.
Reach and Retract Do Not Work or are Slow; Other Functions OK
Bad reach solenoid (valve or wiring) Run Test I06. Check wiring. Check valve for
binding.
Damaged or worn reach cylinders Inspect cylinder. Measure pressure; normal

operation should be below bypass pressure.
See “Auxiliary Pressure Adjustment” on
page 7-80. Binding produces higher
pressures. Repair/replace cylinder or other
binding components.
Damaged or worn scissors assembly Inspect for damage. Measure pressure;

normal operation should be below bypass
pressure. See “Auxiliary Pressure Adjustment”
on page 7-80. Binding produces higher
pressures. Repair/replace cylinder or other
binding components.
Switches S4 and S5 both bad (or wiring) Run tests I06 and I07. Follow
recommendations in tests.
Reach Does Not Work; Other Functions OK
Bad reach switch (S4) Run Test I06. Follow recommendations in test.
Retract Does Not Work; Other Functions OK
Bad retract switch (S5) Run Test I07. Follow recommendations in test.

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Lift/Lower System
No Lift - Motor Runs
Bad POD-1 valve Replace POD-1 valve.
SOL3 main relief dump valve pressure too low Run Test O09. Replace SOL3.
SOL2 lift/lower valve open Run Test O12. Follow recommendations in

test.
No Lift - Motor Does Not Run
Battery below BSOC cutout setting Check battery voltage and BSOC settings.
Maintenance Minder ™ interval exceeded with Display config settings for Maintenance
LCutout specified Minder.
Slow Lift with No Load
Plugged or malfunctioning flow limiter in lift Replace flow limiter. If contamination is

cylinder present, flush, fill, and bleed the hydraulic
system.
Binding in the mast Check for binding.
Bad SOL3 Run Test O09. Follow recommendations in

test.
Unable to Pick Up a Load
Bad SOL3 Run Test O09. Follow recommendations in

test.
Bad lift pump Check pressures. Replace pump.

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Slow Lower
Clogged hydraulic filter Replace hydraulic filter.
Mechanical binding in bearings or telescopics Adjust or replace bearings. Check shimming.
Bad lift/lower proportional solenoid valve Run Test O12. Follow recommendations in
SOL2 test.
Maximum Lower Speed not matching SOL2 In Configure Mode, adjust Lift M LwrSpd.
Contamination in load holding solenoid valve Inspect load holding solenoid SOL1 for
SOL1 contamination.
Plugged or malfunctioning flow limiter valves Replace flow limiters.
Intermittent Lower
Bad SOL2 solenoid (valve or wiring) Run Test O12. Check wiring. Replace SOL2.
Bad SOL1 load holding solenoid (valve or Run Test O11. Check wiring. Replace SOL1.
wiring)
Plugged or malfunctioning flow limiter valves Replace flow limiters.
Load Drifting/Settling
Load too large for lift truck capacity Check load weight.
DC Only: Incorrect lift pressure adjustment Check and adjust lift pressure setting.
DC Only: Contaminated or bad relief valve Replace relief valve REL1. If contamination is
REL1 present, flush, fill, and bleed the hydraulic
system.
AC Only: Leaking or contaminated Replace SOL3.

proportional relief solenoid SOL3
Leaking or contaminated load holding Replace SOL1.

solenoid SOL1

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Symptom Tables: Travel Functions
Symptom Tables: Travel

Functions
Slow or Sluggish Acceleration
Configuration:
Accel set to “soft” Set accel to “medium” or “hard.” See

“Configuration and Truck Setup Options” on
page 3-7.
Mechanical: Measure current draw.
Worn load wheel or idler assembly Replace load wheel/idler assembly as

required.
Debris in load wheel axle or idler Remove debris.
Dragging brake Check brake. See “Brake” on page 7-50.
Binding drive unit Inspect for wear.
Electrical:
Current is limited due to high temperature Check temperature and temperature sensors
for Traction Motor and power amplifier. Run
tests A08, A10, and A24.
Slow Travel
Mechanical:
Binding drive unit Check for excessive current draw in Traction

Motor.
Dragging brake Check brake. See “Brake” on page 7-50.
Electrical:
Incorrect configuration of speed Reconfigure the lift truck. See “Using

Configure Mode” on page 3-19.
If equipped with nested switch option, bad Run Test I01.

S14 switch
Speed limited due to high temperature Run Tests A08, A10, A24. Follow
recommendations in tests.
Bad height encoder (causing false speed Run Test I26. Follow recommendations in test.
limiting)

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Symptom Tables: Electrical Symptoms
Symptom Tables:
Electrical Symptoms
NOTE: Reference electrical schematics
beginning on page A-17 and hydraulic
schematics beginning on page A-22.
Motor Overheating
Application exceeds designed workload -- Contact Dealer Service Manager to make sure
short runs with plugging/acceleration or of application.
heavy-duty lifting cycles
Incorrect BSOC Cutout value Measure battery specific gravity at cutout,

after battery has stabilized. Compare to
battery manufacturer specifications for
discharged battery. Adjust BSOC Cutout as
needed.
Clogged motor vents Examine and clear motor vent openings.
DC Motors: worn, damaged, or bad brushes or Check motor brushes.

springs (lift and aux motor only) Check brush spring tension.
Cable, terminal, or wiring problems. Look for Replace wiring or cables as needed. Make sure
loose or discolored terminals, loose or motor cables are torqued correctly.
damaged crimps.
High motor current due to binding gearbox, Inspect gearbox or pump for binding. Check
pump, or dragging brake brake. See “Brake” on page 7-50.
Note: See also “DC Motors” on page 5-5 and “AC Motors” on page 5-9.

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Symptom Tables: Electrical Symptoms
Scrambled or Intermittent Display
Electrostatic discharge resulting from dirty, Clean or replace static straps as needed.
worn, or wrong type static straps
Loose display harness or card connectors; Reseat cards and harness connections. Test
intermittent wires or connectors in harness for continuity while flexing harness. If no
continuity is found, replace wiring harness.
See “Wiring and Harness Connectors” on
page 7-59.
Short to frame See “Shorts to Frame” on page 5-2.
Unmatched Vehicle Manager and Display Install matching Vehicle Manager and Display
Manager software Manager software. VM and DM versions may
not have the same version number. See
“Reviewing Vehicle Manager Software” on
page 3-9.
Incorrect installation of options or Verify correct installation of options.

unauthorized parts
Bad Operator Display card Replace Operator Display card.
Display is Dark; Lift Truck is Not Operational
Fuse FU5 or FU6 could be blown Remove fuses and test fuse continuity. If
continuity is missing, replace fuse.
Problem in key switch circuit or with B+ to Troubleshoot B+ to B+KEY circuits from

Vehicle Manager or bad Vehicle Manager battery to VM.
Problem with +12V power supply Troubleshoot +12V supply at VM.

Run Test A14.
Bad Operator Display Replace Operator Display.
Bad battery cables or connector Repair or replace as necessary.

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Symptom Tables: Vantage Point System
Symptom Tables:
Vantage Point System
NOTE: Reference Electrical Schematic -
Optional Equipment on page A-18.
Monitor is Blank
Indication and Possible Cause Action
Button 3 LED lit - monitor in standby mode, Normal condition: To activate display, elevate
Monitor Standby disabled, Carriage below free above free lift transition.
lift transition
Button 3 LED lit - monitor in standby mode, Normal condition: To activate display, elevate
Monitor Standby enabled, Carriage below free above free lift transition.
lift transition Or unlock keypad. Press Button 3. Lock
keypad.
Button 8 LED off - monitor turned off, Unlock keypad. Press Button 8.
Powersave Mode is enabled
Or unlock keypad. Press and hold Buttons 4
and 5 for 60 seconds to disable Powersave
Mode. Lock keypad.
Button 1 LED and camera LED both blinking - Return lift truck to operating temperature
Ambient temperature out of operating range range of unit.
(–13°F/–25°C to +167°F/+75°C)
Button 8 LED off - one or both power fuses Replace fuse(s) in Aux Power circuit.
blown
Keypad Inoperative
Monitor is OK- keypad locked Press and hold Buttons 1 and 5 for 15
seconds to unlock the keypad.
Do not leave keypad unlocked.

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Symptom Tables: Vantage Point System
Video Problems
Black horizontal bar in picture: Wrong Unlock keypad. Press and hold Button 4 for
monitor frequency 15 seconds. Lock keypad.
Picture is reversed (mirror-image): Image Unlock keypad. Press and hold Buttons 1 and
reversed 3 for 5 seconds. Lock keypad.
Picture is inverted (upside-down): Image Unlock keypad. Press and hold Buttons 1 and
inverted 2 for 35 seconds. Lock keypad.
Picture too light or too dark, Button 2 LED is Unlock keypad. Press Button 2 to turn
OFF automatic brightness ON. Button 2 LED turns
ON. Lock keypad.
If picture is still too light or too dark, go to
next action.
Picture too light or too dark, Button 2 LED is Unlock keypad, press Button 2 to turn
ON automatic brightness OFF.
To adjust brightness, press Button 5, then
Button 6 to decrease, Button 7 to increase.
To adjust contract, press Button 4, then
Button 6 to decrease, Button 7 to increase.
Press Button 2 to turn automatic brightness
ON. Lock keypad.

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Model 7600/7620/7640 Reach-Fork® Truck Section 6. Messages, Codes, and Tests
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Section 6. Messages, Codes, and Tests

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Section 6. Messages, Codes, and Tests Model 7600/7620/7640 Reach-Fork® Truck
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Power Amplifier LED Diagnostics
Power Amplifier LED

Diagnostics
Most error conditions are displayed as a
message or fault code on the Operator Display.
The power amps also contain a Light Emitting

Diode (LED) status indicator, which provides
basic diagnostic information.
• When the LED is illuminated (steady or
blinking), the amplifier is receiving power.
• A steady LED indicates the amplifier is
operating normally.
• A blinking LED indicates a malfunction.

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Messages and Codes Summary List

Deadman? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Code 1H - TPA Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Code 1T - Battery Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Code 1V - LPA Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Code 2A - Traction Motor Approaching Overtemp . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Code 2C - TPA Temp Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Code 2E - Traction Motor Temp Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Code 2H - Traction Motor Speed Sensor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Code 2M - TPA Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Code 2P - TPA Reverted to Default Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Code 2T - TPA Current Calibration Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Code 2U - TPA Overcurrent or Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Code 2V - TPA High DC Bus Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Code 42 - LPC Detected Closed When Commanded Open . . . . . . . . . . . . . . . . . . . . . 6-7
Code 43 - LPC Detected Open When Commanded Closed . . . . . . . . . . . . . . . . . . . . . 6-7
Code 44 - TPC Detected Closed When Commanded Open . . . . . . . . . . . . . . . . . . . . . 6-8
Code 45 - TPC Detected Open When Commanded Closed . . . . . . . . . . . . . . . . . . . . . 6-8
Code 4B - Steer Contactor Detected Closed When Commanded Open . . . . . . . . . . . . 6-8
Code 4C - Steer Contactor Detected Open When Commanded Closed . . . . . . . . . . . . 6-8
Code 4D - No Pre-Charge Traction DC Input Voltage During Start-Up . . . . . . . . . . . 6-9
Code 4E - No Pre-Charge Lift DC Input Voltage During Start-Up . . . . . . . . . . . . . . . 6-9
Code 57- VM Not Responding to Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Code 58 - OCSS CAN Communication Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Code 59 - CAN Transmission Buffer Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Code 5A - CAN Bus Error/VM for BUS_I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Code 5B - CAN Receive Bus Error/VM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Code 5G - No Communications Received from TPA . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Code 5J - No Communications Received from LPA . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Code 5M - TPA CAN Watchdog Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Code 5P - LPA CAN Watchdog Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Code 5Q - Display Manager Not Responding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Code 5R - Secondary CAN Bus Error for BUS_E . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Code 5T - No CAN Message from any Node . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Code 61 - Mast Switch #1 Not Crossed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Code 62 - LPA Reverted to Default Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Code 63 - HS Travel and First Speed Limiting Switches Do Not Agree . . . . . . . . . . . 6-12
Code 64 - No Pulses Seen from Height Indicator Encoder . . . . . . . . . . . . . . . . . . . . 6-13
Code 66 - Calculated Height Greater Than Configured Height . . . . . . . . . . . . . . . . 6-13
Code 67 - Calculated Height Does Not Match First Speed Limiting Switch (S12) . . . 6-13
Code 6D - Pressure Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Code 6F - Lift Motor Overtemp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Code 6G - Lift Motor Temp Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 6S - LPA Temp Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 6T - LPA Current Calibration Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 6V - LPA Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 6W - Failure Detected in Lift Motor Speed Sensor . . . . . . . . . . . . . . . . . . . . . 6-14
Code 6X - LPA Fault: Overcurrent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Code 6Y - LPA Fault: High DC Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Code 6Z - FlashWare Parameters Do Not Match Stored Values . . . . . . . . . . . . . . . . 6-15
Code 80 - Primary Throttle Pot Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

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Code 81 - Lift/Lower Pot Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Code 83 - Primary Throttle Pot Out-of-Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 84 - Brake Not Applied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 88 - +5VDC Power Supply Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 8A - OCSS Photo Sensor Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 8F - Lift/Lower Pot Out-of-Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 8J - Ambient Air Temp Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 8L - Brake Feedback Current Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 8M - Internal Handle Heater Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 8N - Optional Start Switch Closed at Start-Up . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code A0 - Mismatched Software Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code AH - Bad Operator Display Checksum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code AJ - Bad VM Flash Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code AK - Bad VM RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code AL - Bad VM Battery Backed-Up RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code AM - Bad Operator Display Flash Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code AN - Bad Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code AV - Primary Memory Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code EH - Invalid Interrupt - Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code F4 - VM COP Time-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code F5 - Bad Op Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code F8 - VM COP Not Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code FE - VM Not Calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code FG - 5 and/or 12V Power Supply Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code FH - Battery Voltage Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code FN - Relays Did Not Open at Power Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code FP - VM Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code FR - VM Config Item Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code FT - VM Internal Software Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code FV - Display Internal Software Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code G0 - Steer Tiller 1 Channel A/B Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code G3 - Steer Feedback Prox Sensor Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code G4 - Open Detected in Steer Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code G5 - Short Detected in Steer Motor Encoder Circuit . . . . . . . . . . . . . . . . . . . 6-23
Code G7 - Steer Tiller 2 Channel A/B Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code GD - Open Detected in Steer Motor Encoder Circuit . . . . . . . . . . . . . . . . . . . 6-23
Code GE - Steer Tiller Encoder Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Code T0 - SOL5T Current Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Code T1 - SOL5B Current Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Code T2 - SOL3 Current Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Code T3 - SOL2 Current Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Code X4 - Switch Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

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Messages and Codes
Messages and Codes

Deadman?
Icon Code Title/Reason Test to Run Notes/Corrective Action
Deadman? Test I00 - Deadman Open one of the deadman

Both deadman switches closed at Switch (DS1) switches.
the same time. (Page 6-60)
Test I32 - Deadman
Switch (DS2)
(Page 6-79)
Code 1H Overheated. Allow Time to Cool

Code 1H - TPA Overheated Test A10 - TPA Travel is disabled. Cycle key
The TPA has reported its internal Temperature switch to clear after TPA has
temperature is >239°F (115°C). (Page 6-38) cooled.
Test O23 - Toggle Fans Note: The VM cannot cause this
(Page 6-112) code.
Lift Cut-Out Pending...Low Battery

Code 1T - Battery Low None Change battery. Self resetting.

Lift cutout point configured for
BSOC has been reached.
Code 1V Overheated, Allow Time to Cool

Code 1V - LPA Overheated Test A19 - LPA Temp Lift is disabled. Cycle key switch
LPA has reported its internal (Page 6-43) to clear after LPA has cooled.
temperature is >239°F (115°C). Test O23 - Toggle Fans Note: The VM cannot cause this
(Page 6-112) code.
Code 2A Overheated, Allow Time to Cool

Code 2A - Traction Motor Test A08 - Traction Traction performance is limited.

Approaching Overtemp Motor Temperature Self resetting after motor has
TPA senses the Traction Motor is (Page 6-36) cooled.
approaching overtemperature. Note: The VM cannot cause this
code.

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Messages and Codes
Code 2C Inform Service

Code 2C - TPA Temp Sensor Test A10 - TPA Traction performance is limited.
Out-of-Range Temperature Cycle key switch to clear.
TPA temperature sensor is open or (Page 6-38) Note: The VM cannot cause this
shorted. code.
Code 2E Inform Service

Code 2E - Traction Motor Temp Test A08 - Traction Traction performance is limited.
Sensor Out-of-Range Motor Temperature Self resetting.
Traction Motor temperature sensor (Page 6-36) Note: The VM cannot cause this
is open or shorted. code.
Code 2H Inform Service

Code 2H - Traction Motor Speed Test I19 - Traction Traction performance is limited.
Sensor Failure Motor Speed Sensor Self resetting.
Traction Motor speed sensor (Page 6-71) Note: The VM cannot cause this
circuit is inoperative. code.
Code 2M Inform Service

Code 2M - TPA Failed None Traction is disabled. Check for B+

TPA failed to precharge correctly. at the TPA+ terminal. Cycle key
switch to clear. If code will not
clear, replace TPA.
Note: The VM cannot cause this
code.
Code 2P Inform Service

Code 2P - TPA Reverted to None Should clear automatically after

Default Parameters 30 seconds; if not, cycle key
TPA has detected an internal switch.
malfunction with the amplifier This code may appear when first
software. turning key switch ON after
installing a new VM, TPA, or after
updating software.
If code appears infrequently, keep
running. If code appears often,
reload FlashWare; if problem
continues, replace TPA.

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Messages and Codes
Code 2T Inform Service

Code 2T - TPA Current None Traction performance is limited.

Calibration Error Cycle key switch to clear. If code
TPA has detected a current does not clear, replace TPA.
calibration error. Note: The VM cannot cause this
code.
Code 2U Inform Service

Code 2U - TPA Overcurrent or Test A11 - Traction Traction is disabled. Cycle key
Short Circuit Motor Current switch to clear.
TPA has sensed current in excess (Page 6-39) Note: This code may be caused by
of 540A. a shorted TPC diode.
code.
Code 2V Inform Service

Code 2V - TPA High DC Bus None Traction is disabled. Cycle key

Voltage switch to clear. If code occurs
TPA has detected >50VDC at TPA+. during plugging, replace all
battery cables and connections
that show signs of heat or
corrosion. Install a battery that is
in good condition. If code persists,
replace the TPA.
code.
Code 42 Inform Service

Code 42 - LPC Detected Closed Test O02 - Toggle the Cycle key switch to clear.
When Commanded Open LPC Contactor Note: Low battery voltage can
LPA detected an incorrect voltage (Page 6-100) contribute to burnt tips. If
at LPA+ during SelfTest. contactor tips are welded or
burnt, check the BSOC setting in
Config Mode menu.

Code 43 - LPC Detected Open Test O02 - Toggle the Cycle key switch to clear.
When Commanded Closed LPC Contactor Note: The VM cannot cause this
LPA detected <12VDC at LPA+ after (Page 6-100) code.
the LPC coil was energized.

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Messages and Codes

Code 44 - TPC Detected Closed Test O00 - Toggle the Cycle key switch to clear.
When Commanded Open TPC Contactor Note: Low battery voltage can
TPA detected an incorrect voltage (Page 6-98) contribute to burnt tips. If
at TPA+ during SelfTest. contactor tips are welded or
burnt, check the BSOC setting in
Config Mode menu.
code.

Code 45 - TPC Detected Open Test O00 - Toggle the Cycle key switch to clear.
When Commanded Closed TPC Contactor Note: The VM cannot cause this
The TPA detected <12VDC at TPA+ (Page 6-98) code.
after the TPC coil was energized. In Active Service, run
Test A15 - Battery
Voltage (Page 6-42) to
verify battery voltage
Code 4B Inform Service

Code 4B - Steer Contactor Test O01 - Toggle the Cycle key switch to clear.
Detected Closed When STR Contactor
Commanded Open (Page 6-99)
The VM detected >10VDC at If open, run Test
JPC22-19 when the STR coil was I14 - Steering Fuse
de-energized. (FU1) (Page 6-69)
Code 4C Inform Service

Code 4C - Steer Contactor If contactor closes, run Cycle key switch to clear.
Detected Open When Test I14 - Steering Fuse
Commanded Closed (FU1) (Page 6-69), if
The VM detected <10VDC at contactor does not
JPC22-19 when the STR coil was close, run Test
energized. O01 - Toggle the STR
Contactor (Page 6-99)

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Messages and Codes
Code 4D Inform Service

Code 4D - No Pre-Charge None Cycle key switch to clear.

Traction DC Input Voltage Check components, connections,
During Start-Up and wiring between JPF1-5 and
The TPA detected an incorrect TPA+ for correct resistance and
pre-charge voltage (<25VDC) at continuity.
TPA+. TPA Pre-Charge Resistor (TR) =
12 ohms
Thermistor on Fuse/Relay Card =
6 to 12 ohms at room temp
(70°F/21°C).
Code 4E Inform Service

Code 4E - No Pre-Charge Lift DC None Cycle key switch to clear.

Input Voltage During Start-Up Check components, connections,
The LPA detected an incorrect and wiring between JPF1-3 and
pre-charge voltage (<25VDC) at LPA+ for correct resistance and
LPA+. continuity.
LPA Pre-Charge Resistor (LR) =
12 ohms.
Thermistor on Fuse/Relay Card =
6 to 12 ohms at room temp
(70°F/21°C).

Code 57- VM Not Responding to Test I23 - CAN Bus Self resetting.
Operator Display Test (Page 6-74) Note: This code will not normally
The Operator Display has lost be recorded in the error log since
communication with the VM over the log resides in the VM.
the CAN bus. This code is initiated A code 5Q is often recorded in the
by the Operator Display. error log when a code 57 is on the
Operator Display.

Code 58 - OCSS CAN None. Cycle key switch to clear.

Communication Error Check for +12V at JPX1-1 and 0V
No communication received from at JPX1-4 on the OCSS CAN I/O
the OCSS controller. Expander Module.

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Messages and Codes

Code 59 - CAN Transmission Test I23 - CAN Bus Cycle key switch to clear.
Buffer Error Test (Page 6-74) Check for shorts to frame, static,
The VM has detected a CAN and electrical leakage from
transmission buffer error. battery.
Code 5A Inform Service

Code 5A - CAN Bus Error/VM for Test I23 - CAN Bus Cycle key switch to clear.
BUS_I Test (Page 6-74) Check for shorts to frame, static,
The VM detected an error in the and electrical leakage from
CAN Bus. battery.
Note: This code cannot be caused
by an error on the secondary bus
BUS_E.
Code 5B Inform Service

Code 5B - CAN Receive Bus Test I23 - CAN Bus Cycle key switch to clear.
Error/VM Test (Page 6-74) Check for shorts to frame, static,
CAN Receive Bus error in VM for and electrical leakage from
BUS_I. battery.
Note: This code cannot be caused
by an error on the secondary bus
BUS_E.
Code 5G Inform Service

Code 5G - No Communications Test I23 - CAN Bus Cycle key switch to clear.
Received from TPA Test (Page 6-74) Check for shorts to frame, static,
The VM has received no and electrical leakage from
communication from the TPA. battery.
Note: This code can be caused by
bad K3 relay tips. Check LEDs on
both power amplifiers. If both are
not illuminated, check the K3
relay.
Code 5J Inform Service

Code 5J - No Communications Test I23 - CAN Bus Cycle key switch to clear.
Received from LPA Test (Page 6-74) Check for shorts to frame, static,
The VM has received no and electrical leakage from
communication from the LPA. battery.

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Messages and Codes

Code 5M - TPA CAN Watchdog Test I23 - CAN Bus Cycle key switch to clear.
Timeout Test (Page 6-74) This code is generated by the TPA.
CAN watchdog circuit timeout This fault can be caused by a
detected by TPA. source external to the amplifier.
Check for shorts to frame, static,
electrical leakage from battery,
bad power amp cables or wiring,
and CAN Bus.
Code 5P Inform Service

Code 5P - LPA CAN Watchdog Test I23 - CAN Bus Cycle key switch to clear.
Timeout Test (Page 6-74) This code is generated by the LPA.
The CAN watchdog circuit has not This fault can be caused by a
received communication from other source external to the amplifier.
amplifier circuits. Check for shorts to frame, static,
electrical leakage from battery,
bad power amp cables or wiring,
and CAN Bus.
Code 5Q Inform Service

Code 5Q - Display Manager Not Test I23 - CAN Bus Self resetting.
Responding Test (Page 6-74) Note: Code 5Q is recorded in the
The VM is not receiving error log. The Operator Display
communication from the Display will most likely display Code 57.
Manager. This code appears in the
error log but not usually on the
Operator Display.
Code 5R Inform Service

Code 5R - Secondary CAN Bus Test I23 - CAN Bus Cycle key switch to clear.
Error for BUS_E Test (Page 6-74) This code could be caused by
There is a transmission error system noise, static discharge, or
between the VM and the secondary shorts to frame.
CAN BUS_E to which external Note: Primary BUS_I and
equipment is connected. secondary BUS_E are totally
independent. Therefore, this code
cannot be caused by devices
connected to BUS_I.

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Messages and Codes

Code 5T - No CAN Message from Test I23 - CAN Bus Cycle key switch to clear.
any Node Test (Page 6-74)
The VM is not receiving CAN
message from any node.

Code 61 - Mast Switch #1 Not Test I02 - First Speed Cross mast switch #1.
Crossed Limiting Switch (S12)
Too many height encoder pulses (Page 6-62)
were seen without detecting mast
switch #1 opening.

Code 62 - LPA Reverted to None Resets after 30 seconds; if not,

Default Parameters cycle key switch.
The LPA has detected a change in If code continues to appear
internal software. infrequently, keep running.
If code continues to appear often,
reload FlashWare; if problem
continues, replace LPA.
Note: This code may appear when
first turning key switch ON after
installing a new VM or LPA.

Code 63 - HS Travel and First Test I02 - First Speed [VM ver. < 2.1] Cycle key switch to
Speed Limiting Switches Do Limiting Switch (S12) clear.
Not Agree (Page 6-62) [VM ver. 2.1+] Cross the first
The VM reads the 1st speed Test I61 - High Speed speed limiting switch several
limiting switch as closed when the Travel Switch (S25) times.
HS travel switch or Switch 2 reads (Page 6-86) Note: Check the error log to see if
open. Code 64 or 67 preceded the Code
63. If so, troubleshoot per that
code.
Note: Switch 2 must be on for
trucks with an elevated height
above 331 in.

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Messages and Codes

Code 64 - No Pulses Seen from Test I02 - First Speed Lower the carriage, then lift past
Height Indicator Encoder Limiting Switch (S12) the first mast switch.
With the lift pump running or (Page 6-62) Troubleshoot HTI system. Code
SOL2 energized, the first mast limit Test I86 - Lift Height clears when pulses are detected.
switch is open, but the VM (Page 6-91) Cycle key switch.
detected no pulses from the Height If code is intermittent, cause
Indicator encoder. could be proportional valve.
Adjust valve - see “Proportional
Valve Adjustment” on page 7-79.

Code 66 - Calculated Height Test I86 - Lift Height Lower the carriage below the
Greater Than Configured (Page 6-91) configured maximum height to
Height clear.
The carriage height calculated by Check actual mast height against
the VM from information from the configured height.
Height Indicator is more than 6 in. Check actual fork height against
(15 cm) greater than the configured indicated fork height when HTI
height of the lift truck. counting begins.

Code 67 - Calculated Height Does Test I02 - First Speed Lift the carriage through the first
Not Match First Speed Limiting Switch (S12) speed limiting switch height or
Limiting Switch (S12) (Page 6-62) cycle the key switch to clear.
The VM detected S12 closed at an
incorrect calculated height when
lowering.
Code 6D Inform Service

Code 6D - Pressure Sensor Test A13 - Pressure Cycle key switch to clear.
Out-of-Range Sensor Voltage
Voltage is <0.7V (indicating (Page 6-40)
<300 psi) or >5.0V (indicating
>3999 psi).
Code 6F Inform Service

Code 6F - Lift Motor Overtemp Test A09 - Lift Motor Allow time to cool. Self resetting.
The LPA has detected Lift Motor is Temperature
overheated (>300°F/149°C). (Page 6-37)

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Messages and Codes
Code 6G Inform Service

Code 6G - Lift Motor Temp Test A09 - Lift Motor Self resetting.
Sensor Out-of-Range Temperature Note: The VM cannot cause this
Lift motor temperature sensor is (Page 6-37) code.
out-of-range.
Code 6S Inform Service

Code 6S - LPA Temp Sensor None Cycle key switch to clear.

Out-of-Range Replace the LPA.
The LPA reported to the VM that its Note: The VM cannot cause this
internal temperature is not within code.
acceptable limits.

Code 6T - LPA Current None Cycle key switch to clear.

Calibration Error Replace the LPA.
The LPA has detected an internal Note: The VM cannot cause this
fault. code.
Code 6V Inform Service

Code 6V - LPA Failure None Cycle key switch to clear.

The LPA has detected an internal Replace the LPA.
fault. Note: The VM cannot cause this
code.
Code 6W Inform Service

Code 6W - Failure Detected in Test I20 - Lift Motor Self resetting.

Lift Motor Speed Sensor Speed Sensor Note: The VM cannot cause this
The lift feedback circuit, as seen by (Page 6-72) code.
the LPA, is not functioning.

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Messages and Codes
Code 6X Inform Service

Code 6X - LPA Fault: Overcurrent Test A20 - Lift Motor Cycle key switch to clear.
The LPA has detected >675A or a Current (Page 6-44) Note: The VM cannot cause this
shorted output. code.
Code 6Y Inform Service

Code 6Y - LPA Fault: High DC None Cycle key switch to clear.

Voltage Install battery that is in good
The LPA has detected a DC input condition.
voltage exceeding 50V at LPA (+). Replace TPA.
Code 6Z Inform Service

Code 6Z - FlashWare Parameters None Cycle key switch to clear.

Do Not Match Stored Values Verify programmed height is
Fork height, as calculated by the correct in FlashWare.
display, is at least 6 in. higher than
the maximum elevated height
programmed in the truck’s
memory.

Code 80 - Primary Throttle Pot Test A04 - Primary Cycle key switch to clear.
Out-of-Range Throttle Pot (VR1)
The VM detects <0.15V or >2.1V at Voltage (Page 6-34)
JPC12-3. Test A26 - +5VDC
Power Supply
(Page 6-47)

Code 81 - Lift/Lower Pot Test A05 - Lift/Lower Lift is disabled. Cycle key switch
Out-of-Range Pot Voltage (Page 6-35) to clear.
The VM detected <0.15V or >2.1V Test A26 - +5VDC
at JPC12-2. Power Supply
(Page 6-47)

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Messages and Codes

Code 83 - Primary Throttle Pot Test A04 - Primary Travel is disabled.

Out-of-Neutral Throttle Pot (VR1) Return control handle to neutral.
Primary throttle pot (VR1) out of Voltage (Page 6-34) Cycle key switch to clear.
learned neutral value. Test A26 - +5VDC
Power Supply
(Page 6-47)

Code 84 - Brake Not Applied Test I19 - Traction Cycle key switch to clear.
The Traction Motor speed sensor Motor Speed Sensor Check brake. See “Brake” on
indicated movement during (Page 6-71) page 7-50.
SelfTest.

Code 88 - +5VDC Power Supply Test A26 - +5VDC Cycle key switch to clear.
Out-of-Range Power Supply
Control Handle +5VDC power (Page 6-47)
supply (located on the VM) is
out-of-range.
Code 8A Inform Service

Code 8A - OCSS Photo Sensor Test I80 - OCSS Upper Cycle key switch to clear.
Fault Beam (Page 6-87)
The VM senses the beams are ON Test I81 - OCSS Lower
with the deadman pedal UP. Beam (Page 6-89)
Code 8F Inform Service

Code 8F - Lift/Lower Pot Test A05 - Lift/Lower Lift/lower disabled. Return

Out-of-Neutral Pot Voltage (Page 6-35) control handle to neutral.
Lift/Lower pot (VR2) out of learned Cycle key switch to clear.
neutral value.

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Messages and Codes
Code 8J Inform Service (temperature display is “- -”)

Code 8J - Ambient Air Temp Test A36 - Ambient Air Cycle key switch to clear.
Sensor Out-of-Range Temp Sensor Note: Control handle heaters are
The voltage measured from the (Page 6-53) off when this code is present.
ambient air temp sensor is outside
the reference range.
Code 8L Inform Service

Code 8L - Brake Feedback Test A35 - Brake Cycle key switch to clear.
Current Out-of-Range Armature (Page 6-52) Note: The brake is either fully
The current measured in the brake engaged or fully disengaged when
feedback circuit is zero, or outside this code is present.
the reference range.

Code 8M - Internal Handle Test A40 - Handle Self resetting.

Heater Failure Heater Reference
The internal heater in the control Voltage (optional)
handle has malfunctioned. (Page 6-56)
Code 8N Inform Service

Code 8N - Optional Start Switch Test I60 - Security Open, then close the optional
Closed at Start-Up Start Switch (S23) start switch.
The VM senses switch closed. (optional) (Page 6-85)
Code A0 Inform Service

Code A0 - Mismatched Software None Cycle key switch to clear. Re-flash

Versions the VM with correct software. See
The Display Card and VM software “FlashWare” on page 3-6.
versions incompatible.

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Messages and Codes
Code AH Inform Service

Code AH - Bad Operator Display None Cycle key switch to clear.

Checksum 1. If the problem is
The Operator Display and VM intermittent, check for
software checksums do not match. shorts to frame. See “Shorts
to Frame” on page 5-2.
2. Re-flash the software. See
“FlashWare” on page 3-6.
3. Replace the VM.
4. If the correct software
version appears on the
Operator Display, replace the
Operator Display.
Code AJ Inform Service

Code AJ - Bad VM Flash Memory None Cycle key switch to clear.

The VM flash memory test failed 1. If the problem is
during SelfTest. intermittent, check for
shorts to frame. See “Shorts
3. Replace the VM.
Code AK Inform Service

Code AK - Bad VM RAM None Cycle key switch to clear.

The VM RAM test failed during 1. If the problem is
SelfTest. intermittent, check for
3. Replace the VM.

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Messages and Codes
Code AL Inform Service

Code AL - Bad VM Battery None Cycle key switch to clear.

Backed-Up RAM 1. If the problem is
The non-volatile RAM memory test intermittent, check for
failed during SelfTest. shorts to frame. See “Shorts
3. Replace the VM.
Code AM Inform Service

Code AM - Bad Operator Display None Cycle key switch to clear.

Flash Memory Re-flash the software. See
The Operator Display flash memory “FlashWare” on page 3-6.
test failed during SelfTest. The Replace Operator Display.
Operator Display and VM software
versions do not match.
Code AN Inform Service

Code AN - Bad Operator Display None Cycle key switch to clear.

The Operator Display is bad. Replace Operator Display.
Code AV Inform Service

Code AV - Primary Memory None Cycle key switch to clear.

Mismatch Install a preprogrammed Operator
The three primary memory Display and a preprogrammed
locations do not agree. VM.
Table 6-1. Code EH Inform Service

Code EH - Invalid Interrupt - None Cycle key switch to clear.

Operator Display 1. If the problem is
There was a software malfunction intermittent, check for
on the Operator Display card. shorts to frame. See “Shorts
3. Replace Operator Display.

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Messages and Codes
Code F4 Inform Service

Code F4 - VM COP Time-out None Cycle key switch to clear.

The COP circuit has timed out 1. If the problem is
before a reset was generated. intermittent, check for
3. Replace the VM.

Code F5 - Bad Op Code None Cycle key switch to clear.

Bad code was detected during 1. If the problem is
SelfTest. Results in total intermittent, check for
shutdown. shorts to frame. See “Shorts
3. Replace the VM.

Code F8 - VM COP Not Enabled None Cycle key switch to clear.

1. If the problem is
intermittent, check for
3. Replace the VM.
Code FE Inform Service

Code FE - VM Not Calibrated None Message clears in 30 seconds.

The VM detected an internal Cycle key switch.
calibration error. BSOC Make sure lift truck firmware at
information could be inaccurate. VM version 3.3/Display Manager
version 2.4 or higher is installed.
If code continues, replace VM.

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Messages and Codes
Code FG Inform Service

Code FG - 5 and/or 12V Power Test A14 - +12VDC Cycle key switch.
Supply Out-of-Range Power Supply Make sure lift truck firmware at
The +5 and/or +12V power supply (Page 6-41) VM version 3.3/Display Manager
voltage is out-of-range. version 2.4 or higher is installed.
Code FH Inform Service

Code FH - Battery Voltage Test A15 - Battery Cycle key switch.

Out-of-Range Voltage (Page 6-42) Check Fuse FU10.
Battery voltage is <28V or >45V at
SelfTest. Results in total
shutdown.
Code FN Inform Service

Code FN - Relays Did Not Open at Test O32 - Toggle Brake engages.
Power Off Relays K1, K2, K3, and Disconnect, then re-connect
K4 (Page 6-116) battery connector.
Check other relays and circuits
associated with the K4 relay tips.
Code FP Inform Service

Code FP - VM Internal Fault None Brake engages.

Cycle key switch.
Replace VM.
Code FR Inform Service (displays for 5 seconds)

Code FR - VM Config Item None Out-of-range parameter is reset

Out-of-Range after 5 seconds to the default
The value of a configurable value.
parameter is out of the reference
range.

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Messages and Codes
Code FT Inform Service

Code FT - VM Internal Software None Brake engages.

Error Cycle key switch.
Document the sequence of events
that occurred just before the code
displayed. Have the dealer service
technician supply them to
Raymond Field Service.
Code FV Inform Service

Code FV - Display Internal None Cycle key switch.

Software Error Document the sequence of events
that occurred just before the code
displayed. Have the dealer service
technician supply them to
Raymond Field Service.
Code G0 Inform Service

Code G0 - Steer Tiller 1 Channel Test I33 - Steer Tiller Cycle key switch.
A/B Fault Encoder 1 Connect
Steer tiller 1 is missing pulses Detect (Page 6-80)
compared to steer tiller 2, or Test I35 - Steer Tiller
intermittent connection detected at Encoder 1 - Channels A
JPC10-6 or JPC18-5. & B (Page 6-82)

Code G3 - Steer Feedback Prox Test I24 - Steer Cycle key switch.
Sensor Fault Feedback Prox Sensor
A steer motor encoder count (Page 6-76)
should have put the steer feedback
prox sensor past the steer limit
flag, but the flag was not sensed.
The steer prox sensor is either low
or high all the time.

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Messages and Codes

Code G4 - Open Detected in Test I39 - Neutral Cycle key switch.

Steer Control Circuit Pulses (Page 6-84)
The VM did not detect either
neutral pulses at JPC6-1 or tiller
encoder inputs at JPC22-5,
JPC22-12, JPC22-13, and
JPC22-14.

Code G5 - Short Detected in Test I25 - Steer Motor Cycle key switch.
Steer Motor Encoder Circuit Encoder (Page 6-77)
A steer command or steer motor
encoder pulses were detected
without steer tiller encoder pulses
detected.

Code G7 - Steer Tiller 2 Channel Test I34 - Steer Tiller Cycle key switch.
A/B Fault Encoder 2 Connect
Steer tiller 2 is missing pulses Detect (Page 6-81)
compared to steer tiller 1, or Test I36 - Steer Tiller
intermittent connection detected at Encoder 2 - Channels A
JPC10-7 or JPC18-6. & B (Page 6-83)
Code GD Inform Service

Code GD - Open Detected in Test I25 - Steer Motor Cycle key switch. Verify correct
Steer Motor Encoder Circuit Encoder (Page 6-77) steer flag is installed.
A steer command was issued while Test I90 - Degrees
traveling >1 mph but no steer Turned Past Steer Flag
position feedback encoder pulses (Page 6-92)
were detected.

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Messages and Codes
Code GE Inform Service

Code GE - Steer Tiller Encoder Test I33 - Steer Tiller Cycle key switch.
Failure Encoder 1 Connect
The VM detected connect-detect Detect (Page 6-80)
failures or abnormal inputs on Test I34 - Steer Tiller
both channels of the steer tiller Encoder 2 Connect
encoder. Detect (Page 6-81)
Test I35 - Steer Tiller
Encoder 1 - Channels A
& B (Page 6-82)
Encoder 2 - Channels A
& B (Page 6-83)
Code T0 Inform Service

Code T0 - SOL5T Current Test A31 - Solenoid 5T Cycle key switch.

Incorrect (AUX1) Current
Current being drawn by SOL5T, as (Page 6-48)
seen by the VM, is not at the
expected level.

Code T1 - SOL5B Current Test A32 - Solenoid 5B Cycle key switch.

Incorrect (AUX2) Current
Current being drawn by SOL5B, as (Page 6-49)
expected level.

Code T2 - SOL3 Current Test A33 - Aux Dump Cycle key to clear. Dump valve
Incorrect (SOL3) (Page 6-50) fault causes shut down of aux
Current being drawn by SOL3, as functions.
expected level.

Code T3 - SOL2 Current Test O12 - Ramp the Cycle key switch.
Incorrect Proportional Lower
Current being drawn by soleniod 2 (SOL2) Solenoid
as seen by the VM is not at the (Page 6-108)
expected level.

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Messages and Codes
Code X4 Inform Service

Code X4 - Switch Mismatch Test I02 - First Speed Cycle key switch. Cross First
System detects both S12 (First Limiting Switch (S12) Speed Limit Switch (S12) and/or
Speed Limit Switch) and S27 (Lift (Page 6-62) Lift Cutout Switch (S27).
Cutout Switch) ON at the same Test I22 - Lift Cutout
time. Switch (S27)
(Page 6-73)

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Messages and Codes

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Electrical Connections
Electrical Connections
Terminology
The term “connector JPx” means a mated
connector having two connector halves. One
half has male connectors, or pins (P); the other
half has female connectors, or jacks (J).
When you disconnect a mated JP connector,

you have two connector halves. The individual
connector halves are specified by “Jx” and “Px.”
If you cannot find a connector designated “Jx”
or “Px,” look for “JPx,” and vice versa.
For example, connector JP1 is the mated main

Operator Display connector. J1 represents the
jack connections (in the harness). P1 represents
the pin connections (on the Operator Display).
Molex connectors have ridges on the sides to

help locate pin number 1. The short side has a
single ridge at pin number 1. The long side has
1, 2, and 3 raised ridges at pin numbers 1, 2,
and 3. See Figure 6-1.
Figure 6-1. Molex Jack and Pin Connector

8c04013s.tif
Pin Identifier Lines

(black lines added for clarity)
Jack Pins
Electrical Connector Locator

Chart
See legend on electrical schematic beginning on
page A-17.

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Circuit Card Connectors

Vehicle Manager
Figure 6-2. Vehicle Manager Connectors
R1019283_B.cgm
PC22 PC10 PC6 PC24 JC9 PC3
PC14 PC18 PC20 PC12 PC4
PC22 PC10 PC6 PC24 JC9 PC3
PC14 PC18 PC20 PC12 PC4

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Fuse/Relay Card
Figure 6-3. Fuse/Relay Card Connectors
R1022159_A.cgm
PF1 FU8 FU7 FU5 FU6
15A 15A
PF1
1 4
FU7
FU8
FU5
FU6
K3 K2 K4 K1
K3 K2 K4 K1
13 1 7 1 10 1
PF4 PF2 PF3
PF4 PF2 PF3

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Electrical Tests - Summary List

Analog Tests
Test A04 - Primary Throttle Pot (VR1) Voltage . . . . . . .. .. . .. . .. . 6-34
Test A05 - Lift/Lower Pot Voltage . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-35
Test A08 - Traction Motor Temperature . . . . . . . . . . . .. .. . .. . .. . 6-36
Test A09 - Lift Motor Temperature . . . . . . . . . . . . . . .. .. . .. . .. . 6-37
Test A10 - TPA Temperature . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-38
Test A11 - Traction Motor Current . . . . . . . . . . . . . . . .. .. . .. . .. . 6-39
Test A13 - Pressure Sensor Voltage . . . . . . . . . . . . . . .. .. . .. . .. . 6-40
Test A14 - +12VDC Power Supply . . . . . . . . . . . . . . . .. .. . .. . .. . 6-41
Test A15 - Battery Voltage . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-42
Test A19 - LPA Temp . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-43
Test A20 - Lift Motor Current . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-44
Test A22 - Traction Throttle (VR1) Request . . . . . . . . .. .. . .. . .. . 6-45
Test A23 - Lift Throttle (VR2) Request . . . . . . . . . . . . .. .. . .. . .. . 6-46
Test A26 - +5VDC Power Supply . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-47
Test A31 - Solenoid 5T (AUX1) Current . . . . . . . . . . . .. .. . .. . .. . 6-48
Test A32 - Solenoid 5B (AUX2) Current . . . . . . . . . . . .. .. . .. . .. . 6-49
Test A33 - Aux Dump (SOL3) . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-50
Test A34 - Lift/Lower Current (SOL2) . . . . . . . . . . . . .. .. . .. . .. . 6-51
Test A35 - Brake Armature . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-52
Test A36 - Ambient Air Temp Sensor . . . . . . . . . . . . . .. .. . .. . .. . 6-53
Test A37 - Steer Power Amp Current . . . . . . . . . . . . . .. .. . .. . .. . 6-54
Test A39 - Analog Reference Voltage . . . . . . . . . . . . . .. .. . .. . .. . 6-55
Test A40 - Handle Heater Reference Voltage (optional) .. .. . .. . .. . 6-56
Test A41 - Emergency Power Off (EPO) Switch . . . . . . .. .. . .. . .. . 6-57
Input Tests
Test I00 - Deadman Switch (DS1) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
Test I01 - Nested Switch (S14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
Test I02 - First Speed Limiting Switch (S12) . . . . . . . . . . . . . . . . . . . 6-62
Test I06 - Reach Switch (S4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
Test I07 - Retract Switch (S5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Test I08 - Tilt Up Switch (S6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
Test I09 - Tilt Down Switch (S7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66
Test I10 - Sideshift Right Switch (S9) . . . . . . . . . . . . . . . . . . . . . . . . 6-67
Test I11 - Sideshift Left Switch (S8) . . . . . . . . . . . . . . . . . . . . . . . . . 6-68
Test I14 - Steering Fuse (FU1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69
Test I15 - Horn Switch (S3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70
Test I19 - Traction Motor Speed Sensor . . . . . . . . . . . . . . . . . . . . . . 6-71
Test I20 - Lift Motor Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72
Test I22 - Lift Cutout Switch (S27) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73
Test I23 - CAN Bus Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
Test I24 - Steer Feedback Prox Sensor . . . . . . . . . . . . . . . . . . . . . . . 6-76
Test I25 - Steer Motor Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
Test I26 - Height Indicator Encoder . . . . . . . . . . . . . . . . . . . . . . . . . 6-78
Test I32 - Deadman Switch (DS2) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79
Test I33 - Steer Tiller Encoder 1 Connect Detect . . . . . . . . . . . . . . . 6-80

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Test I34 - Steer Tiller Encoder 2 Connect Detect . . . . . . . . . . . . . . . 6-81

Test I35 - Steer Tiller Encoder 1 - Channels A & B . . . . . . . . . . . . . 6-82
Test I36 - Steer Tiller Encoder 2 - Channels A & B . . . . . . . . . . . . . 6-83
Test I39 - Neutral Pulses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84
Test I60 - Security Start Switch (S23) (optional) . . . . . . . . . . . . . . . . 6-85
Test I61 - High Speed Travel Switch (S25) . . . . . . . . . . . . . . . . . . . . 6-86
Test I80 - OCSS Upper Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87
Test I81 - OCSS Lower Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89
Test I86 - Lift Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91
Test I90 - Degrees Turned Past Steer Flag . . . . . . . . . . . . . . . . . . . . 6-92
Test I91 - iPort ™ Communication Test . . . . . . . . . . . . . . . . . . . . . . 6-93
Test I92 - iPort ™ Error Bitmap Test . . . . . . . . . . . . . . . . . . . . . . . . 6-95
Output Tests
Test O00 - Toggle the TPC Contactor . . . . . . . . . . . . . . . . . . . . . . . . 6-98
Test O01 - Toggle the STR Contactor . . . . . . . . . . . . . . . . . . . . . . . . 6-99
Test O02 - Toggle the LPC Contactor . . . . . . . . . . . . . . . . . . . . . . . 6-100
Test O04 - Toggle Aux1 Directional (SOL5T) Solenoid . . . . . . . . . . 6-101
Test O05 - Toggle Aux2 Directional (SOL5B) Solenoid . . . . . . . . . . 6-102
Test O06 - Toggle the Reach Solenoid . . . . . . . . . . . . . . . . . . . . . . 6-103
Test O07 - Toggle the Tilt Solenoid . . . . . . . . . . . . . . . . . . . . . . . . 6-104
Test O08 - Toggle the Sideshift Solenoid . . . . . . . . . . . . . . . . . . . . 6-105
Test O09 - Aux Dump (SOL3)/ Main Relief Dump (SOL8) Current . 6-106
Test O11 - Toggle the Load Hold (SOL1) Solenoid . . . . . . . . . . . . . . 6-107
Test O12 - Ramp the Proportional Lower (SOL2) Solenoid . . . . . . . 6-108
Test O18 - Toggle the Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-109
Test O19 - Audible Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-110
Test O20 - Travel Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-111
Test O23 - Toggle Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-112
Test O28 - Ramp Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-113
Test O29 - Ramp Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 6-114
Test O30 - Toggle the Brake Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 6-115
Test O32 - Toggle Relays K1, K2, K3, and K4 . . . . . . . . . . . . . . . . . 6-116
Loop Back Tests

Loop Back Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-117

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Analog Tests
Analog 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 a step-by-step approach to diagnosing a
problem and the necessary corrective action.
See the example below.
Table 6-1. Example Diagnosis and Repair Table
Action/
Step (+) Lead (–) Lead Expected Results Step Passed Step Failed
Meter Scale
This column identifies

any actions required
before testing the
circuit, such as
disconnecting certain
connectors. If no
instructions are given,
The next
all circuits must be Probe Probe The next
action to
Do the connected. point for point for action to
The reading perform if
testing Note: If something the the perform if
required to consider the
in this was disconnected in positive negative the Expected
the step a success. Expected
order. the prior step, (+) meter (–) meter Results are
Results are
reconnect it before lead. lead. met.
not met.
performing the next
step.
This column also

identifies the required
setting on the meter
for this step.

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Test A04 - Primary Throttle Pot (VR1) Voltage Analog Tests
Test A04 - Primary 2. The test is a success if the voltage

displayed is within these limits:
Throttle Pot (VR1)
Throttle Position Value Displayed
Voltage Full Tractor-First 0.45 to 0.8
This test displays the voltage the Vehicle Neutral 0.9 to 1.3
Manager reads from the control handle throttle
Full Forks-First 1.4 to 1.8
potentiometer (VR1).
NOTE: Run Learn after you replace, repair, or
adjust the throttle assembly. • The values should change smoothly
and evenly as the handle is moved from
NOTE: For information on how to use Service full tractor-first to full forks-first
Mode, see “Using Service Mode” on direction.
page 3-28.
• If voltages are not within reference
ranges, the test has failed.
Run Test 3. In Active Service Mode, if the voltage
NOTE: This test can be run in Loop Back mode. fluctuates erratically as you move the
See Loop Back Tests (Page 6-117). handle back and forth, replace the control
handle cable.
1. The Operator Display shows the voltage
4. If there is a problem after reconnecting the
the Vehicle Manager reads from the
control handle cable, inspect the pins in
primary throttle potentiometer (VR1).
the DB15 connector.
Diagnosis and Repair

Action/
Meter Scale
JPC12-1 JPH1-1
Disconnect
1 JPC12-12 JPH1-12 0 Ohms Perform step 2 Replace cable
JPC12/Ohms
JPC12-3 JPH1-3
Run Test
Replace control
Disconnect A26 - +5VDC
2 JC12-1 JC12-12 4.75 to 5.25V handle or pot
JPC12/DCV Power Supply
VR1
(Page 6-47)

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Analog Tests Test A05 - Lift/Lower Pot Voltage
Test A05 - Lift/Lower Pot 2. The test is a success if the voltage

Voltage
This test displays the voltage the Vehicle Full Lift 0.45 to 0.8
Manager reads from the lift/lower
potentiometer (VR2). Neutral 0.9 to 1.3
NOTE: Run Learn after you replace, repair, or Full Lower 1.4 to 1.8
adjust the lift/lower potentiometer.
NOTE: For information on how to use Service • The values should change smoothly
Mode, see “Using Service Mode” on and evenly as the handle is moved from
page 3-28. full lower to full lift.
• If voltages are not within reference
Run Test ranges, the test has failed.
NOTE: This test can be run in Loop Back mode. 3. In Active Service Mode, run the test while
See Loop Back Tests (Page 6-117). moving the travel pot back and forth. If the
voltage fluctuates erratically, replace the
1. The Operator Display shows the voltage control handle cable.
the Vehicle Manager reads from the
lift/lower potentiometer (VR2).
the DB15 connector.

Action/
Meter Scale
JPC12-1 JPH1-1
Disconnect
1 JPC12-12 JPH1-12 0 Ohms Perform step 2 Replace cable
JPC12/Ohms
JPC12-2 JPH1-2
Run Test
Replace control
2 JC12-1 JC12-12 4.75 to 5.25V handle or pot
VR1
(Page 6-47)

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Test A08 - Traction Motor Temperature Analog Tests
Test A08 - Traction Motor Run Test

Temperature NOTE: For information on how to use Service
Mode, see “Using Service Mode” on
page 3-28.
This test displays Traction Motor temperature.
If the temperature displayed matches the lift
Limits truck operation to the limits listed, allow the lift
truck to cool and investigate the operation of
• Normal operation: ambient to 258°F the brake and drive unit. If the brake and drive
(125°C) unit are functioning correctly, look at the lift
• Speed is linearly reduced to 1.0 mph at: truck application for over use. If the
temperature displayed does not match the
• Danaher Motor: 266°F (130°C) to 300°F
limits listed, proceed to Diagnosis and Repair.
(149°C)
• Sauer Danfoss Motor: 278°F (137°C) to
311°F (155°C)
• Temperature icon illuminates at 275°F
(135°C)
• Fault Code 2A and travel disabled at:
• Danaher Motor: 300°F (149°C)
• Sauer Danfoss Motor: 311°F (155°C)

Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
Temperature Icon is illuminated or Fault Code 2A is present and Traction Motor is hot to touch
Disconnect
1 JPT1-16 JPT1-17 >1200 ohms Perform step 2 Replace TPA
JPT1/Ohms
Less than See section on

Repeat step 1 after
2 measurement in motor Perform step 3
cooling for one hour.
step 1 overheating
Less than Troubleshoot Replace Traction

Disconnect
3 JPT3-2 JPT3-1 measurement in Traction Motor Motor temp
JPT1/Ohms
step 1 sensor wires sensor
Temperature Icon is illuminated or Fault Code 2A is present and Traction Motor is NOT hot to touch
Disconnect
1 JPT1-16 JPT1-17 Replace TPA Perform step 2
JPT1/Ohms
<800 ohms Troubleshoot Replace Traction
Disconnect
2 JPT3-2 JPT3-1 Traction Motor Motor temp
JPT3/Ohms
sensor wires sensor

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Analog Tests Test A09 - Lift Motor Temperature
Test A09 - Lift Motor Run Test

page 3-28.
This test measures the temperature of the Lift
Motor. If the temperature displayed matches the lift
truck operation to the limits listed, allow the lift
Limits truck to cool. Check the mast for binding and
investigate the operation of the pump. If the
• Normal operation: ambient to 294°F mast and pump are functioning correctly, look
(145°C) at the lift truck application for over use. If the
• Temperature icon illuminates at 295°F temperature displayed does not match the
(146°C) limits listed, proceed to Diagnosis and Repair.
• Fault Code 6F and lift shutdown at 300°F
(149°C)

Action/ Expected
Meter Scale Results
Temperature Icon is illuminated or Fault Code 6F is present and Lift Motor is hot to touch
Disconnect
1 >1200 ohms Perform step 2 Replace LPA
JPL1/Ohms
JPL1-16 JPL1-17 Less than See section on
Repeat step 1 after
2 measurement in motor Perform step 3
cooling for one hour.
step 1 overheating
Less than Replace Lift

Disconnect T/S Lift Motor
3 JPL3-2 JPL3-1 measurement in Motor temp
JPL3/Ohms sensor wires
step 1 sensor
Temperature Icon is illuminated or Fault Code 6F is present and Lift Motor is NOT hot to touch
Disconnect
1 JPL1-16 JPL1-17 Replace LPA Perform step 2
JPL1/Ohms
<800 ohms Replace Lift
Disconnect T/S Lift Motor
2 JPL3-2 JPL3-1 Motor temp
JPL3/Ohms sensor wires
sensor

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Test A10 - TPA Temperature Analog Tests
Test A10 - TPA Run Test

page 3-28.
This test measures the temperature of the TPA.
The TPA heatsink temperature is displayed.
Limits
As lift truck is operated, the readings should
• Normal operation: ambient to 175°F (79°C) increase evenly over time. If not, the test has
• Fans toggle on/off at 113°F (45°C) failed.
• Starting at 176°F (80°C), speed is linearly
reduced by the TPA to 0 mph at 239°F
(115°C), when traction is disabled.
(90°C)
• Fault Code 1H at 239°F (115°C)

Action/ Expected
Meter Scale Results
Heatsink should
Run Test
Operate lift truck for heat up and
O23 - Toggle
1 15 to 20 minutes of N/A N/A fans turn on at Replace TPA
Fans
hard operation. approx 113°F
(Page 6-112)
(45°C)

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Analog Tests Test A11 - Traction Motor Current
Test A11 - Traction Motor Check individual phase currents with a

clamp-on ammeter.
Current • The current should ramp evenly as the lift
truck accelerates and decelerates.
This test displays the current in the Traction • Phase currents should be approximately
Motor power circuits. equal. Gross differences indicate a
problem.
Limits If readings are not within reference limits, the
• 0 to 450A while driving or plugging test has failed.
• Above 266°F (130°C) current is reduced 1. If any one phase differs significantly from
linearly the other two, check power cable
• Maximum current up to 540A when continuity. Replace cables as necessary.
deadman pedal is released, unaffected and See “Terminal Nuts” on page 7-64.
unreduced by temperature • If power cable continuity is OK,
troubleshoot the Traction Motor. See
“AC Motors” on page 5-9.
Run Test
• If all phases give high readings, the
NOTE: For information on how to use Service drive unit may be binding. Check drive
Mode, see “Using Service Mode” on unit.
page 3-28.
2. The TPA may be bad. Run “Test
O29 - Ramp Traction Motor” on
This test shows better results in Active Service.
page 6-114.
The Operator Display shows the current the NOTE: For instructions on selecting Modes of
TPA reads from one phase of the Traction Operation, see “Modes of Operation” on
Motor. page 3-16.
NOTE: Set speed to 3.0 mph (4.8 km/hr) in
Configure Mode. See “Using Configure
System Condition Value Displayed (amps)
Static at Rest <20
240 at 0 mph
Travel 0 to 3.0 mph
80 at 3.0 mph
(4.8 km/hr)
(4.8 km/hr)
Plugging
(from 3.0 mph) 275 Max
(4.8 km/hr)
Because Test A11 measures only one phase, the

test might not always reveal a current problem.

NOTE: Check all motor and power amplifier
connections for tightness and corrosion.

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Test A13 - Pressure Sensor Voltage Analog Tests
Test A13 - Pressure The voltage shown on the Operator Display

should increase and decrease linearly as the
Sensor Voltage load weight is increased or decreased. If it does
not, the test has failed. If the weight display is
inaccurate, the test has failed.
This test measures the voltage from the
pressure sensor used for load weight sensing. Carriage Position Value Displayed (Volts)
Fully Lowered approx. 1.0
Use extreme caution when working Lifted in Free Lift approx. 1.5
near the elevated forks. Lifted in Second Stage approx. 2.0
Run Test
NOTE: This test can be run in Loop Back mode.
See Loop Back Tests (Page 6-117).
NOTE: For information on how to use Service
page 3-28.

Action/ Expected
Meter Scale Results
1 JPY1-2 JPY1-3 1.0V lowered Perform step 2 Perform step 3

1.5V Lifted in
free lift
2 JPC24-18 JPC24-6 2.0V Lifted in Replace VM
DCV second stage Troubleshoot
pressure sensor
Replace harness
3 JPY1-1 JPY1-3 10.5 to 13V pressure
transducer

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Analog Tests Test A14 - +12VDC Power Supply
Test A14 - +12VDC

Power Supply
This test displays the VM +12V Power Supply
voltage.
Run Test
page 3-28.
1. The Operator Display shows the voltage
measured from the +12V power supply.
2. The test is a success if the voltage
System Condition Value Displayed
Lift truck at rest 10.1 to 13.0V
If the reading fluctuates by more than

0.8V in 10 seconds, the test has failed.

Disconnect everything powered by +12V except
JPC14 (includes Operator Display and Power
Amps). Monitor the +12V and reconnect each
connector. Troubleshoot the circuit that causes
the +12V supply to go out-of-range. Otherwise,
replace VM.

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Test A15 - Battery Voltage Analog Tests
Test A15 - Battery

Voltage
This test displays the voltage used to calculate
Battery State-of-Charge (BSOC).
Run Test
page 3-28.
1. The battery voltage as shown on the
Operator Display should be 28 to 45VDC.
2. If the numbers displayed are not in this
range, the test has failed.

Action/ Expected
Meter Scale Results
Check battery voltage/

specific gravity.
1 TP1 Perform step 2 Replace battery.
Troubleshoot or replace
battery cables
Troubleshoot harness
2 DCV JPF4-1 TP4 B+ Perform step 3
TP1 to JPF4-1
Replace Fuse/Relay
3 JPF4-7 Perform step 4
Card
Troubleshoot harness
4 JPC24-24 Replace VM from Fuse/Relay Card
to VM

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Analog Tests Test A19 - LPA Temp
Test A19 - LPA Temp

This test displays the temperature of the Lift
Power Amplifier.
Limits
• Normal operation: ambient to 175°F (79°C)
• Fans toggle on/off at 113°F (45°C)
• Starting at 176°F (80°C), speed is linearly
reduced to 0 fpm at 239°F (115°C), when
lift is disabled.
(87°C)
• Fault Code 1V at 239°F (115°C)
Run Test
page 3-28.
The Operator Display shows the heatsink

temperature the LPA reads.
As the lift is operated, the readings should

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

1. Check for dirt and debris in the LPA
cooling fins.
2. Run lift truck hard for 15 to 20 minutes.
Check operation of the LPA cooling fans.
Run Test O23 - Toggle Fans (Page 6-112).
3. The LPA may be bad. Replace the LPA.

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Test A20 - Lift Motor Current Analog Tests
Test A20 - Lift Motor • The current should ramp evenly as the lift
truck accelerates and decelerates.
Current • Phase currents should be approximately
equal. Gross differences indicate a
This test measures the Lift Motor current problem.
through the Lift Power Amplifier. • If readings are not within reference limits,
the test has failed.
If any one phase differs significantly from the

The lift carriage and forks will move other two, check power cable continuity.
during this test. Replace cables as necessary. See “Terminal
Nuts” on page 7-64.
• If power cable continuity is OK,
troubleshoot the Lift Motor. See “AC
Motors” on page 5-9.
The area around the forks should be
clear. The ceiling clearance should allow • If all phases give high readings, the mast
for the highest lift. may be binding. Check mast.
NOTE: For instructions on selecting Modes of
Limits Operation, see “Modes of Operation” on
page 3-16.
• 0 to 550A lifting
• Maximum current 675A
Run Test
page 3-28.
NOTE: This test shows better results in Active
Service.
The Operator Display shows the current the

LPA reads from one phase of the Lift Motor.
Because Test A20 measures only one phase, the

test might not always reveal a current problem.
Lifting an empty carriage in free lift gives

readings of 280 to 320 amps. Readings are
approximately the same if a clamp-on ammeter
is used.

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

clamp-on ammeter.

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Analog Tests Test A22 - Traction Throttle (VR1) Request
Test A22 - Traction The Operator Display shows the percentage of

throttle request the VM reads from VR1.
Throttle (VR1) Request Throttle Position Value Displayed
This test displays the percentage of primary Full Tractor-First 0 to +100

control handle traction throttle request from
Neutral 0
VR1 being read by the VM.
Full Forks-First 0 to –100
Run Test
NOTE: Run Learn after you replace, repair, or The values must change smoothly and evenly
adjust the throttle assembly. as the handle moves from full tractor-first to
full forks-first.
Mode, see “Using Service Mode” on If percentages are not within reference limits,
page 3-28. the test has failed.

Action/
Meter Scale
Disconnect JPC12-1 JPH1-1

1 JPC12 JPC12-12 JPH1-12 0 Ohms Perform step 2 Replace cable
/Ohms JPC12-3 JPH1-3
Run Test
2 JC12-1 JC12-12 4.75 to 5.25V Perform step 3
(Page 6-47)
Neutral: 0.9 to 1.3V

Full tractor-first: 0.45 to
3 DCV JPC12-3 JPC12-12 0.8V Replace VM Replace VR1
Full forks-first: 1.4 to
1.8V

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Test A23 - Lift Throttle (VR2) Request Analog Tests
Test A23 - Lift Throttle

(VR2) Request
This test displays the percentage of lift throttle
request from VR2 being read by the VM.
Run Test
NOTE: Run Learn after you replace, repair, or
adjust the lift/lower potentiometer.
page 3-28.
The Operator Display shows the percentage of

lift request the VM reads from VR2.
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,


Action/
Meter Scale
Disconnect JPC12-1 JPH1-1

1 JPC12 JPC12-12 JPH1-12 0 Ohms Perform step 2 Replace cable
/Ohms JPC12-2 JPH1-2
Run Test
Disconnect
A26 - +5VDC
2 JPC12 JC12-1 JC12-12 4.75 to 5.25V Perform step 3
Power Supply
/DCV
(Page 6-47)
Neutral: 0.9 to 1.3V

3 DCV JPC12-2 JPC12-12 Full lift: 0.45 to 0.8V Replace VM Replace VR2
Full lower: 1.4 to 1.8V

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Analog Tests Test A26 - +5VDC Power Supply
Test A26 - +5VDC Power

Supply
This test measures the +5V Power Supply
voltage used for the control handle switches
and potentiometers.
Run Test
page 3-28.
If the Operator Display does not read

+5 ±0.25V, the test has failed.

Action/ Expected
Meter Scale Results
Troubleshoot
Disconnect JPC12
1 PC12-1 PC12-12 4.75 to 5.25V wires and Replace VM
and JCP4/DCV
control handle

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Test A31 - Solenoid 5T (AUX1) Current Analog Tests
Test A31 - Solenoid 5T The test is a success if the current displayed is:
(AUX1) Current Function Value Displayed (amps)
Retract - Slow approx. 0.3

This test displays the current the Aux1
Retract - High approx. 0.6
directional solenoid coil is drawing.
Tilt Down/Sideshift
approx. 0.6
It does not prove the Aux1 directional solenoid Left
valve is functioning correctly mechanically. It
does not prove the condition of the wiring or the
VM itself. Because the directional coil is proportional,
current for tilt/sideshift can be different from
the current for reach/retract. If any one
Run Test function passes, run input test for failed
NOTE: For information on how to use Service functions (I07, I09, or I11).
page 3-28. If results do not match the preceding table, the
test has failed.

Action/ Expected
Meter Scale Results
Disconnect approx. Troubleshoot

1 JC20-18 Perform step 2
JPC20/Ohms 40 Ohms wires and coil
JC20-17 Troubleshoot
2 DCV TP4 B+ Replace VM B+K2 from
Fuse/Relay Card

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Analog Tests Test A32 - Solenoid 5B (AUX2) Current
Test A32 - Solenoid 5B The test is a success if the current displayed is:
(AUX2) Current Function Value Displayed (amps)
Retract - Slow approx. 0.2

This test displays the current the Aux2
Retract - High approx. 0.6
directional solenoid coil is drawing.
Tilt Down/Sideshift
approx. 0.6
It does not prove the Aux2 directional solenoid Left
valve is functioning correctly mechanically. It
does not prove the condition of the wiring or the
VM itself. Because the directional coil is proportional,
current for tilt/sideshift can be different from
the current for reach/retract. If any one
Run Test function passes, run input test for failed
NOTE: For information on how to use Service functions (I06, I08, or I10).
page 3-28. If results do not match the preceding table, the
test has failed.

Action/ Expected
Meter Scale Results

B+K2 from
2 DCV TP4 B+ Replace VM
Fuse/Relay
Card

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Test A33 - Aux Dump (SOL3) Analog Tests
Test A33 - Aux Dump

(SOL3)
This test displays the current the dump
solenoid coil is drawing.
Run Test
page 3-28.
The test is a success if the current displayed is:
Function Value Displayed (amps)
Any Aux Function

approx. 0.8
Activated
If results do not match the preceding table, the

test has failed.

Action/ Expected
Meter Scale Results

B+K2 from
Fuse/Relay
Card

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

Current (SOL2)
This test displays the current the proportional
lift/lower solenoid coil is drawing.
Run Test
page 3-28.
State Value Displayed (amps)
Neutral approx. 0
Full Lower approx. 1.5

test has failed.

Action/ Expected
Meter Scale Results
Disconnect Troubleshoot
1 JC20-15 JC20-16 approx. 13 Ohms Perform step 2
JPC20/Ohms wires and coil
Troubleshoot
B+K2 from
2 DCV PC20-15 TP4 B+ Replace VM
Fuse/Relay
Card

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Test A35 - Brake Armature Analog Tests
Test A35 - Brake

Armature
The brake coil is activated by a coil driver
located inside the Vehicle Manager. This test
displays the voltage measured across that coil
driver.
Run Test
page 3-28.
The test is a success if the voltage displayed is

within these limits:
Value Displayed
State of Brake
(Volts)
approx. 0.25 for

Brake Pulling In
2 seconds
Deadman Pedal Depressed/

approx. 9.0
Travel Requested

test has failed.

Action/ Expected
Meter Scale Results
Disconnect Troubleshoot
1 JF2-2 JC20-14 approx. 9 Ohms Perform step 2
JPC20/Ohms wires and coil
Troubleshoot
B+K2 from
2 DCV PF2-2 TP4 B+ Replace VM
Fuse/Relay
Card

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Analog Tests Test A36 - Ambient Air Temp Sensor
Test A36 - Ambient Air

Temp Sensor
This test displays the ambient air temperature
of the area around the lift truck.
Run Test
page 3-28.
The Operator Display should display the

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

Action/ Expected
Meter Scale Results
Disconnect
1 JPC24-23 JPC24-11 approx. 5V Perform step 2 Replace VM
JPA/DCV
Troubleshoot
JPC24-23 JPA-1 Replace temp
2 Ohms 0 Ohms wires as
JPC24-11 JPA-2 sensor
indicated by test

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Test A37 - Steer Power Amp Current Analog Tests
Test A37 - Steer Power

Amp Current
This test displays the current the steer motor is
drawing.
Run Test
page 3-28.
Steer Direction Value Displayed (amps)
At rest <3
Clockwise (CW) –30 to –50
Counterclockwise
30 to 50
(CCW)
Note: CW and CCW is drive unit direction.

test has failed.

Action/
Meter Scale
At rest: approx. 2.5V

Steering CCW: less
Replace Steer
1 DCV JPC6-3 TP4 than voltage at rest Replace VM
Amp
Steering CW: more
than voltage at rest

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Analog Tests Test A39 - Analog Reference Voltage
Test A39 - Analog

Reference Voltage
This test displays the voltage used by the
Vehicle Manager to verify all analog voltages.
Run Test
page 3-28.
You should see 2.4 to 2.6V. If not, the test has

failed.

Replace Vehicle Manager.

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Test A40 - Handle Heater Reference Voltage (optional) Analog Tests
Test A40 - Handle If results do not match the preceding table, the
test has failed. Verify option is turned on.
Heater Reference
Voltage (optional)
This test displays the voltage the Vehicle
Manager sees going through the internal
primary control handle heater (HTR6).
NOTE: Heater operation requires ambient
temperature sensor to be activated.
Heaters then turn on at 40°F (4.4°C).
Run Test
page 3-28.

Heater OFF Heater ON
0V approx. 8V

Action/ Expected
Meter Scale Results
Check cable
wiring. If OK,
Disconnect
1 JPC12-7 JPC12-12 9 to 10 Ohms Perform step 2 replace handle
JPC12/Ohms
or internal
heater
Heater ON:
Disconnect JPC12-7 JPC12-12
2 approx. 8V Perform step 1 Replace VM
JPC12/DCV on VM on VM
Test OFF: 0V

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Analog Tests Test A41 - Emergency Power Off (EPO) Switch
Test A41 - Emergency

Power Off (EPO) Switch
This test shows the Vehicle Manager reading
from the EPO switch.
Run Test
page 3-28.

Displayed Value
State of Switch
(Volts)
Up (closed) B+
Down (open) 0

test has failed.

Action/ Expected
Meter Scale Results
Clean pin connection then

replace Fuse/Relay Card
Repair/replace wiring or
switch
DCV TP4 (B–) B+
Clean pin connection then
replace Fuse/Relay Card
Repair/replace wiring or
4 JPC22-21 Replace VM
switch

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Test A41 - Emergency Power Off (EPO) Switch Analog Tests

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Digital Input Tests
Digital Input Tests


and Repair table.

Action/
Meter Scale

before testing the
circuit, such as
connectors. If no
The next
all circuits should be Probe Probe The next
action to
Results are
not met.
performing the next
step.
This column also

scale on the meter for
this step.

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Test I00 - Deadman Switch (DS1) Digital Input Tests
Test I00 - Deadman

Switch (DS1)
from the deadman switch (DS1).
DO NOT perform this test on a ramp.
Run Test
NOTE: For information on how to use
maintenance mode, see “Using Service
The Operator Display shows the state of the

switch.
Operator Action Message Displayed
Off deadman Up
On deadman Down
If the display does not change when you step on

the pedal, the test has failed.

Action/ Expected
Meter Scale Results
DS1 closed:
Disconnect JPC22 0 Ohms Troubleshoot
1 JC22-8 JC18-7 Perform step 2
and JPC18/Ohms DS1 open: wires and switch
open circuit
Disconnect
2 JPS12-2 JPS12-3 4.5V Recheck step 1 Replace VM
JPS12/DCV

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Digital Input Tests Test I01 - Nested Switch (S14)
Test I01 - Nested Switch Run Test

(S14) NOTE: This test can be run in Loop Back mode.
NOTE: This test applies only to lift trucks with NOTE: For information on how to use
the nested switch option. maintenance mode, see “Using Service
from the nested switch (S14). The Operator Display shows the state of the
switch:
Mast Position Message Displayed

Use extreme caution when working
around an elevated mast. Nested In
Unnested Out
If these results are not observed, the test has

Lift only in an area with a ceiling height failed.
greater than the lift truck’s maximum
elevated height.

Action/
Meter Scale
Disconnect S14 open: open circuit Troubleshoot

1 JPF2-8 JPC22-18 Perform step 2
JPF2/Ohms S14 closed: 0 Ohms wires and switch
Verify options
Disconnect Troubleshoot K2
2 JPC22-18 TP4 S14 closed: B+ are on, then
JPC22/DCV circuit
replace VM

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Test I02 - First Speed Limiting Switch (S12) Digital Input Tests
Test I02 - First Speed Run this test in Active Service Mode.
Limiting Switch (S12) maintenance mode, see “Using Service
from the first speed limiting mast switch (S12). The Operator Display should show the
following:

around an elevated mast. Lowered Below
Raised Above
Run Test
NOTE: This test can be run in Loop Back mode. If these results are not observed, the test has
See Loop Back Tests (Page 6-117). failed.

Action/
Meter Scale
Proximity Sensor Switch
Disconnect
1 JS4-3 10.5 to 13V Perform step 4 Perform step 2
JPS4/DCV
Disconnect JS4-1
Repair or
2 JPS4 and JC20-1 Perform step 3
replace wire
JPC20/Ohms
0 Ohms
Inspect pin
Disconnect JPS4 Repair or
3 JS4-3 JF3-8 connection to
and JPF3/Ohms replace wire
FRC
4 JPS4-1 JPS4-2 Mast lowered: Perform step 5 Replace S12

DCV 10.5 to 13V Repair or
5 JC20-1 JC22-1 Mast elevated: 0V Replace VM
replace wire

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Digital Input Tests Test I06 - Reach Switch (S4)
Test I06 - Reach Switch The Operator Display shows the state of the
switch:
(S4) State of Switch Message Displayed
Use this test to monitor the state of reach Depressed In

switch (S4). This test shows what the Vehicle
Released Out
Manager is reading from the switch.
Run Test 1. If results do not match the preceding

table, the test has failed. Perform
NOTE: This test can be run in Loop Back mode. diagnosis.
2. In Active Service Mode, run the test while
NOTE: For information on how to use moving the travel pot back and forth. If the
maintenance mode, see “Using Service voltage fluctuates erratically as you move
Mode” on page 3-28. the handle back and forth, replace the
control handle cable.
the DB15 connector.

Action/ Expected
Meter Scale Results
Disconnect
1 JPC12-4 JPC12-12 Perform step 2 Replace VM
JPC12/DCV
>4V Repair or
Disconnect
2 JPH1-4 JPH1-12 Perform step 3 replace cable to
JPH1/DCV
VM
S4 open: >4V Replace control

3 DCV JPH1-4 JPH1-12 Replace VM
S4 closed: <1V handle
Note: Voltage to switch being tested may drop when any other control handle switch is depressed.

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Test I07 - Retract Switch (S5) Digital Input Tests
Test I07 - Retract Switch The Operator Display shows the state of the
switch:
Use this test to monitor the state of retract Depressed In

Released Out

the DB15 connector.

Action/ Expected
Meter Scale Results
Disconnect
JPC12/DCV
>4V Repair or
Disconnect
2 Perform step 3 replace cable to
JPH1/DCV
JPH1-11 JPH1-12 VM

3 DCV Replace VM

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Digital Input Tests Test I08 - Tilt Up Switch (S6)
Test I08 - Tilt Up Switch The Operator Display shows the state of the
switch:
Use this test to monitor the state of tilt up Depressed In

Released Out

the DB15 connector.

Action/ Expected
Meter Scale Results
Disconnect
JPC12/DCV
>4V Repair or
Disconnect
JPH1/DCV
JPH1-5 JPH1-12 VM

3 DCV Replace VM

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Test I09 - Tilt Down Switch (S7) Digital Input Tests
Test I09 - Tilt Down The Operator Display shows the state of the
switch:
Switch (S7) State of Switch Message Displayed
Use this test to monitor the state of tilt down Depressed In

Released Out

the DB15 connector.

Action/ Expected
Meter Scale Results
Disconnect
JPC12/DCV
>4V Repair or
Disconnect
JPH1/DCV
JPH1-6 JPH1-12 VM

3 DCV Replace VM

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Digital Input Tests Test I10 - Sideshift Right Switch (S9)
Test I10 - Sideshift Right The Operator Display shows the state of the
switch:
Use this test to monitor the state of sideshift Depressed In

right switch (S9). This test shows what the
Released Out
Vehicle Manager is reading from the switch.

the DB15 connector.

Action/ Expected
Meter Scale Results
Disconnect
JPC12/DCV
>4V Repair or
Disconnect
JPH1/DCV
JPH1-9 JPH1-12 VM

3 DCV Replace VM

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Test I11 - Sideshift Left Switch (S8) Digital Input Tests
Test I11 - Sideshift Left The Operator Display shows the state of the
switch:
Use this test to monitor the state of sideshift left Depressed In

switch (S8). This test shows the Vehicle
Released Out
Manager reading from the switch.

the DB15 connector.

Action/ Expected
Meter Scale Results
Disconnect
JPC12/DCV
>4V Repair or
Disconnect
JPH1/DCV
JPH1-8 JPH1-12 VM

3 DCV Replace VM

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Digital Input Tests Test I14 - Steering Fuse (FU1)
Test I14 - Steering Fuse Use the following table as a guideline.
(FU1) Deadman Pedal

Position
Message Displayed
This test reports the absence or presence of B+ Down Clsd (closed)

voltage at the load side of the steer motor (STR) Up Open
contactor.
NOTE: The display shows CLSD until the TPC

and LPC timeout. The contactor opens
When this test is activated and the
but capacitors in the steer amplifier take
deadman pedal is depressed, the steer
some time to bleed off.
motor/pump activates.
If the STR contactor tips do not close, run Test
Run Test O01 - Toggle the STR Contactor (Page 6-99).
NOTE: This test can be run in Loop Back mode. If the display message does not change when
See Loop Back Tests (Page 6-117). the test is activated, the test has failed.

Action/
Meter Scale
Remove FU1/ Replace fuse

1 Fuse Fuse 0 Ohms Perform step 2
Ohms FU1
STR Tips open: 0V Replace STR

2 STR-1 STR-2 Perform step 3
STR Tips closed: B+ contactor tips
DCV Troubleshoot
STR Tips open: 0V
3 JPC22-19 TP4 Replace VM wiring from VM
STR Tips closed: B+
to contactor

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Test I15 - Horn Switch (S3) Digital Input Tests
Test I15 - Horn Switch The Operator Display shows the state of the
switch:
(S3) Message
State of Switch
Displayed
Use this test to monitor the state of the horn
switch (S3). This test shows the Vehicle Depressed In
Manager reading from the switch. Released Out
Run Test
NOTE: This test can be run in Loop Back mode. test has failed. Perform diagnosis.

Action/ Expected
Meter Scale Results
Disconnect
JPC12/DCV
>4V Repair or
Disconnect
JPH1/DCV
JPH1-10 JPH1-12 VM

3 DCV Replace VM

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Digital Input Tests Test I19 - Traction Motor Speed Sensor
Test I19 - Traction Motor

Speed Sensor
This test displays the Traction Motor speed
sensor output as seen by the TPA.
Do this test in an area free of

obstructions with ample room for
maneuvering.
Run Test
“0000 to ±3200 rpm” should be displayed.

NOTE: The Operator Display shows rpm as
measured by the TPA.

Action/ Expected
Meter Scale Results
1 DCV JPT1-3 JPT1-4 Perform step 2 Replace TPA
10.5 to 13V Troubleshoot

Disconnect
2 JPT2-1 Perform step 3 wiring TPA to
JPT2/DCV
Traction Motor
JPT2-4
Reconnect Replace Traction
3 JPT2-2 Perform step 4
JPT2/DCV Motor speed
At rest: 0V or
4 JPT2-3 10.5 to 13V Perform step 5 sensor
Traveling:
5 DCV JPT1-5 approx. 5V Perform step 6 Troubleshoot
JPT1-4 wiring TPA to
6 JPT1-6 Replace TPA Traction Motor

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Test I20 - Lift Motor Speed Sensor Digital Input Tests
Test I20 - Lift Motor

Speed Sensor
This test displays the input from the speed
sensor on the Lift Motor as seen by the lift
power amplifier.
Do this test in an area free of

obstructions with ample room for lifting.
Run Test
This test shows best results in Active Service.
“0000 to ±2450 rpm” should be displayed.

NOTE: The Operator Display shows rpm as
measured by the LPA.

Action/ Expected
Meter Scale Results
1 JPL1-3 JPL1-4 Perform step 2 Replace LPA
10.5 to 13V Troubleshoot

2 JPL2-1 Perform step 3 wiring from LPA
to Lift Motor
JPL2-4
3 DCV JPL2-2 Perform step 4 Replace
At rest: 0V or Lift Motor
4 JPL2-3 Perform step 5 speed sensor
10.5 to 13V
5 JPL1-5 Lifting: Perform step 6 Troubleshoot
JPL1-4 approx. 5V wiring LPA to
6 JPL1-6 Replace LPA Lift Motor

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Digital Input Tests Test I22 - Lift Cutout Switch (S27)
Test I22 - Lift Cutout

Switch (S27)
This test displays what the VM is reading from
the Lift Cutout switch (S27).
Run Test

switch:
Message Dis-
Mast Position
played
Over Flag ON
Not Over Flag OFF

Action/ Expected
Meter Scale Results
Disconnect
1 JS5-3 10.5 to 13V Perform step 4 Perform step 2
JPS5/DCV
JS5-1
Disconnect JPS5
and JPC20/Ohms
Repair or
0 Ohms Check wiring to
Disconnect JPS5 replace wiring
3 JS5-3 JF3-12 Fuse/Relay
and JPF3/Ohms
Card
4 JPS5-1 JPS5-2 Mast lowered: Perform step 5 Replace S27

10.5 to 13V
DCV Repair or
5 JC20-6 JC22-6 Mast elevated: Replace VM
6V replace wiring

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Test I23 - CAN Bus Test Digital Input Tests
Test I23 - CAN Bus Test

This test verifies the VM is communicating with
the TPA, LPA, and Operator Display.
Run Test
The Operator Display shows:

• T if the TPA is communicating with the VM
• L if the LPA is communicating with the VM
• V if the Operator Display is
communicating with the VM
If T, L, or V is not present, the test has failed.

Action/ Expected
Meter Scale Results
Unable to enter the test and see letters
Remove JPD1-2 and

1 JPD1-3 from V visible in test Perform step 2 Perform step 5
connector
L and V visible
2 Disconnect JPT1 Replace TPA Perform step 3
in test
n/a n/a
Disconnect JPL1 and
jumpers between
JPL1-14 and T and V visible
3 Replace LPA Perform step 4
JPL1-15; and in test
between JPL1-22
and JPL1-23
Test wires for

continuity.
Disconnect JPT1 approx.
4 JPD1-2 JPD1-3 Perform step 1 Make sure they
and JPD1/Ohms 38 Ohms
are not shorted
together.
Test wires for

continuity.
Disconnect approx. Make sure they
5 JPD1-6 JPD1-7 Replace display
JPD1/Ohms 120 Ohms are not shorted
together. If OK,
replace VM.

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Digital Input Tests Test I23 - CAN Bus Test
Action/ Expected
Meter Scale Results
T Missing
Verify LED's on
TPA are lit. If
not, test
Troubleshoot B+
Traction Motor
from K3 Relay
1 DCV JPT1-1 JPT1-7 B+ temp sensor and
and DGND from
speed encoder
LPA.
circuits. Replace
TPA. If OK,
perform step 2.
Disconnect JPT1
2 JPT1-22 JPL1-23 0 Ohms Perform step 3 Repair wiring
and JPL1/Ohms
Disconnect JPT1
3 JPT1-14 JPL1-15 0 Ohms Replace TPA Repair wiring
and JPL1/Ohms
L Missing
Verify LED's on
LPA are lit. If
not, test Lift
Troubleshoot B+
Motor temp
from K3 Relay
1 DCV JPL1-1 JPL1-7 B+ sensor and
and DGND from
speed encoder
Display.
circuits. Replace
LPA. If OK,
perform step 2.
2 Disconnect JPD1 JPL1-22 JPD1-2 0 Ohms Perform step 3 Repair wiring
3 and JPL1/Ohms JPL1-14 JPD1-3 0 Ohms Replace TPA Repair wiring

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Test I24 - Steer Feedback Prox Sensor Digital Input Tests
Test I24 - Steer Feedback

Prox Sensor
This test reads the input to the Vehicle Manager
from the Steer Feedback Proximity Sensor.
Run Test

sensor:
Sensor Position Message Displayed
Over Metal On
Not Over Metal Off

test has failed.

Action/ Expected
Meter Scale Results
Disconnect
1 PC20-9 PC20-11 Perform step 2 Replace VM
JPC20/DCV
12V
Repair or
2 JPST-1 JPST-3 Perform step 3
replace wiring
3 DCV JPST-2 JPST-3 Sensor over Perform step 4 Replace sensor

metal: 5V
Sensor not over Repair or
4 JPC22-22 JPC22-11 Replace VM
metal: <1V replace wiring

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Digital Input Tests Test I25 - Steer Motor Encoder
Test I25 - Steer Motor

Encoder
This test displays the encoder counts from the
steer motor encoder.
Run Test
You should see “0 to 255” while steering. If not,


Action/
Meter Scale

12V Troubleshoot
2 JPE4-1 Perform step 3
wiring to VM
JPE4-4
3 JPE4-3 Perform step 4 Replace Steer
DCV
4 JPE4-2 Perform step 5 Motor encoder
Steering: approx. 1.8V
5 JPC22-10 Not steering: 0 or 4.5V Perform step 6 Troubleshoot
JPC10-9 wiring to
6 JPC22-9 Replace VM. encoder

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Test I26 - Height Indicator Encoder Digital Input Tests
Test I26 - Height

Indicator Encoder
This test reads the input from the height
encoder to the Operator’s Display.
Run Test
Above free lift: counts increase “0 to 255” lifting

counts decrease “255 to 0” lowering

Action/
Meter Scale
Replace
1 JPD2-1 JPD2-2 Perform step 2 Operator
10.5 to 13V Display
Repair or
replace wiring
JPE3-4
JPE3-3
3 Perform step 4
(Channel A) Replace height
DCV
JPE3-2 encoder
4 JPE3-4 Not lifting: Perform step 5
(Channel B) approx. 5 or 0V
JPD2-3
5 Lifting above free lift: Perform step 6
(Channel A)
approx. 2.3V Repair or
JPD2-2 Replace
JPD2-4 replace wiring
6 Operator
(Channel B)
Display

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Digital Input Tests Test I32 - Deadman Switch (DS2)
Test I32 - Deadman

Switch (DS2)
This test shows what the Vehicle Manager is
reading from the deadman switch (DS2).
DO NOT perform this test on a ramp.
Run Test

switch.
Operator Action Message Displayed
Off deadman Up
On deadman Down
If the display does not change when you step on

the pedal, the test has failed.

Action/ Expected
Meter Scale Results
DS2 closed:
Disconnect JPC22 0 Ohms T/S wires and
1 JC22-8 JC10-8 Perform step 2
and JPC10/Ohms DS2 open: switch
open circuit
Disconnect
2 JPS12-1 JPS12-3 4.5V Recheck step 1 Replace VM
JPS12/DCV

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Test I33 - Steer Tiller Encoder 1 Connect Detect Digital Input Tests

Encoder 1 Connect Detect
This test verifies the Vehicle Manager sees the
12V circuit connected to the Steer Tiller
Encoder Channel 1.
Run Test
The Operator Display should show the

following:
Connection Status Message Displayed
Connected Yes
Not Connected No

test has failed.

Action/ Expected
Meter Scale Results

DCV 10.5 to 13V Replace Steer Repair wiring
2 JPE1-1 JPE1-4
Tiller Encoder from VM

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Digital Input Tests Test I34 - Steer Tiller Encoder 2 Connect Detect

Encoder 2 Connect Detect The Operator Display should show the
following:
This test verifies the Vehicle Manager sees the Connection Status Message Displayed
12V circuit connected to the Steer Tiller
Encoder Channel 2. Connected Yes
Not Connected No
Run Test
NOTE: This test can be run in Loop Back mode. If results do not match the preceding table, the
See Loop Back Tests (Page 6-117). test has failed.

Action/ Expected
Meter Scale Results

DCV 10.5 to 13V Replace Steer
2 JPE2-1 JPE2-4 Repair wiring from VM
Tiller Encoder

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Test I35 - Steer Tiller Encoder 1 - Channels A & B Digital Input Tests

Encoder 1 - Channels
A&B
This test monitors input to Vehicle Manager
from Channel 1.
Run Test
Count should increase CW; decrease CCW. If

not, the test has failed.

Action/ Expected
Meter Scale Results

10.5 to 13V
2 JPE1-1 Perform step 3 Repair wiring from VM
3 JPE1-3 JPE1-4 Perform step 4 Replace Steer Tiller

DCV
4 JPE1-2 Perform step 5 Encoder
Turning tiller:
5 JPC22-5 approx. 2.5V Perform step 6
JPC18-5 Repair or replace wiring

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Digital Input Tests Test I36 - Steer Tiller Encoder 2 - Channels A & B

Encoder 2 - Channels
A&B
This test monitors input to Vehicle Manager
from Channel 2.
Run Test
Count should increase CW; decrease CCW. If

not, the test has failed.

Action/ Expected
Meter Scale Results

10.5 to 13V
2 JPE2-1 Perform step 3 Repair wiring from VM
3 JPE2-3 JPE2-4 Perform step 4 Replace Steer Tiller

DCV
4 JPE2-2 Perform step 5 Encoder
Turning tiller:
JPC18-6 Repair or replace wiring

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Test I39 - Neutral Pulses Digital Input Tests
Test I39 - Neutral Pulses

This test displays the neutral pulses seen by
the Vehicle Manager from the Steer Power
Amplifier.
Run Test
The Operator Display should show the

following:
Deadman Pedal Message Displayed
Toggles between On
Depressed
and Off
Released >15 sec = On or Off

test has failed.

Action/ Expected
Meter Scale Results
1 JPC6-6 10.5 to 13V Perform step 2 Replace VM
Deadman Pedal
DCV JPC6-4 Repair wiring or
Up: >4V
2 JPC6-1 Replace VM replace Steer
Down: 1.7 to
Power Amp
3.4V

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Digital Input Tests Test I60 - Security Start Switch (S23) (optional)
Test I60 - Security Start

Switch (S23) (optional)
from S23.
Run Test

switch:
State of Switch Message Displayed
Depressed In
Released Out

test has failed.

Action/
Meter Scale
Disconnect Verify option is

1 >4.0V Perform step 2
JPC10/DCV ON
JPC10-2 JPC10-4
S23 open: >4.0V Troubleshoot
2 DCV Replace VM
S23 closed: 0V switch and wires

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Test I61 - High Speed Travel Switch (S25) Digital Input Tests
Test I61 - High Speed Run this test in Active Service Mode.
Travel Switch (S25) maintenance mode, see “Using Service
from the High Speed Travel Switch (S25). The Operator Display should show the
following:

around an elevated mast. Lowered Below
Raised Above
Run Test
NOTE: This test can be run in Loop Back mode. If these results are not observed, the test has
See Loop Back Tests (Page 6-117). failed.

Action/
Meter Scale
Proximity Sensor Switch
Disconnect
1 JPC20-3 10.5 to 13.0V Perform step 2
JPC20/DCV
TP4 Replace VM
Disconnect
JPC22/DCV
Troubleshoot
wire to
3 TP1 JPS6-3 B+ Perform step 4
Fuse/Relay
Disconnect Card
JPS6/DCV
4 JPS6-2 approx. 5.0 Watts Perform step 5 Troubleshoot
5 JPS6-1 10.5 to 13.0V Perform step 6 wire to VM
TP4 Switch not over

metal: approx. 5.0V
6 DCV JPS6-1 Replace VM Replace switch
Switch over metal:
approx. 5.0V

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Digital Input Tests Test I80 - OCSS Upper Beam
Test I80 - OCSS Upper Run Test

Beam Make sure the beam is not blocked by objects,
debris, or dirt. The Operator Display shows the
This test verifies the upper beam is working state of the beam:
correctly.
Deadman Pedal Message Displayed
Down On
Mode” on page 3-28. Up Off

test has failed. Perform Diagnosis and Repair.

Remove sensor housing covers. Turn key switch ON and verify LEDs are illuminated as follows:
Deadman
Component LED Status
Pedal Position
Up or Down Green ON +12V present at RCVR_1

Receiver (3 wires)
Down Yellow ON Receiver is receiving light beam (correctly aligned)
Emitter (2 wires) Down Green ON +12V present at EMTR_1
If the LEDs do not illuminate as described above, troubleshoot per the following table:
Action/ Expected
Meter Scale Results
Fault: All LEDS not illuminated
Replace Expander
1 JX1-1 JX1-4 Perform step 2
Module
Deadman pedal
10.7 to Replace harness
down, disconnect
13V between Expander
2 JPX1/DCV PD1-1 PT1-8 Troubleshoot VM
Module and OD/PA
JX1 to JD1-1/JT1
Fault: EMITTER - Green LED not illuminated
Deadman pedal
Replace Emitter
1 down, disconnect JCS1-1 JCS1-2 Perform step 2
harness PCS1
JPCS1/DCV
10.7 to
13V Replace harness
Deadman pedal
between Expander Replace Expander
2 down, disconnect PX2-4 PX2-9
Module and Emitter Module
JPX2/DCV
harness JX2 to JCS1

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Test I80 - OCSS Upper Beam Digital Input Tests
Action/ Expected
Meter Scale Results
Fault: RECEIVER - Green LED not illuminated
Deadman pedal up,

Replace Receiver
1 disconnect JCS2-1 JCS2-4 Perform step 2
harness PCS2
JPCS2/DCV
10.7 to
13V Replace harness
Deadman pedal up,
2 disconnect PX2-1 PX2-6
Module and Receiver Module
JPX2/DCV
harness JX2 to JCS2
Fault: RECEIVER - Yellow LED not illuminated
Replace harness
between Expander
Disconnect JPCS2
1 JCS2-2 PX2-2 0 Ohms Perform step 2 Module and
and JPX2/Ohms
Receiver harness
JX2 to JPCS2
Clean Emitter eye

Make sure Emitter is not obscured (dirty) and is aligned
2 Perform step 3 and/or align
correctly
correctly
Disconnect Replace Receiver Replace Expander

3 PX2-2 PX2-6 approx. 5V
JPX2/DCV harness PCS2 Module
Fault Code 58 - Previous Tests Pass
1 JX1-5 JT1-15 Perform step 2

Disconnect JPX1 Repair/Replace
0 Ohms Replace Expander
2 and JPT1/Ohms JX1-2 JT1-23 harness JX1-JT1
Module

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Digital Input Tests Test I81 - OCSS Lower Beam
Test I81 - OCSS Lower Run Test

Beam Make sure the beam is not blocked by objects,
debris, or dirt. The Operator Display shows the
This test verifies the lower beam is working state of the beam:
correctly.
NOTE: For information on how to use Deadman Pedal Message Displayed
Mode” on page 3-28. Down On
Up Off

test has failed. Perform Diagnosis and Repair.

Remove sensor housing covers. Turn key switch ON and verify LEDs are illuminated as follows:
Deadman
Component LED Status
Pedal Position
Receiver Up or Down Green ON +12V present at RCVR_2

(3 wires) Down Yellow ON Receiver is receiving light beam (correctly aligned)
Emitter
Down Green ON +12V present at EMTR_2
(2 wires)
If the LEDs do not illuminate as described above, troubleshoot as follows:
Action/ Step
Step (+) Lead (–) Lead Expected Results Step Failed
Meter Scale Passed
Fault: All LEDS not illuminated
Replace Expander
1 JX1-1 JX1-4 Perform step 2
Module
Deadman pedal
down, disconnect
13V between Expander
2 JPX1/DCV PD1-1 PT1-8 Troubleshoot VM
Module and OD/TPA
JX1 to JD1-1/JT1

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Test I81 - OCSS Lower Beam Digital Input Tests
Action/ Step
Step (+) Lead (–) Lead Expected Results Step Failed
Meter Scale Passed
Fault: EMITTER - Green LED not illuminated
Deadman pedal
Replace Emitter
1 down, disconnect JCS3-1 JCS3-2 Perform step 2
harness PCS3
JPCS3/DCV
10.7 to
13V Replace harness
Deadman pedal
2 down, disconnect PX2-5 PX2-10
Module and Emitter Module.
JPX2/DCV
harness PX2 to JCS1
Fault: RECEIVER - Green LED not illuminated
Deadman pedal
Replace Receiver
1 up, disconnect JCS4-1 JCS4-4 Perform step 2
harness PCS4
JPCS4/DCV
Deadman pedal 13V between Expander
Replace Expander
2 up, disconnect PX2-3 PX2-8 Module and Receiver
Module
JPX2/DCV harness JX2 to
JPCS4
Fault: RECEIVER - Yellow LED not illuminated
Replace harness
Disconnect JPCS4 between Expander
1 JCS4-3 PX2-7 0 Ohms Perform step 2
and JPX2/Ohms Module and Receiver
harness JX2 to JCS4
Make sure Emitter is not obscured (dirty) and is Clean Emitter eye
2 Perform step 3
aligned correctly and/or align correctly
Disconnect approx. Replace Receiver Replace Expander

3 PX2-7 PX2-8
JPX2/DCV 5V harness PCS4 Module
Fault Code 58 - Previous Tests Pass
Disconnect
1 harness at JPX1 JX1-5 JT1-15 0 Ohms Perform step 2
and JPT1/ Ohms Repair/replace
Disconnect harness JX1-JT1
Replace Expander
2 harness at JPX1 JX1-2 JT1-23 0 Ohms
Module
and JPT1/ Ohms

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Digital Input Tests Test I86 - Lift Height
Test I86 - Lift Height

NOTE: This test applies to lift trucks with VM
versions 3.7 and above.
This test displays fork height above free lift.
Run Test
NOTE: This test cannot be run in Active Service
Mode. For information on how to use
You should see: below free lift = 0; height

increase going up; height decrease going down.

Action/ Expected
Meter Scale Results
JPD-2 disconnected
1 JPD2-1 JPD2-2 Perform step 2 Replace display
/DCV
10.5 to 13V
Troubleshoot
JPE3-4 wiring

DCV Replace encoder
4 JPE3-2 JPE3-4 Lifting: approx. Perform step 5
5 JPD2-3 2.4V Perform step 6 Troubleshoot

JPD2-2
6 JPD2-4 Replace display wiring

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Test I90 - Degrees Turned Past Steer Flag Digital Input Tests
Test I90 - Degrees

Turned Past Steer Flag
This test shows the number of degrees the drive
unit has turned after the steer flag is no longer
under the steer proximity switch.
Use this test to adjust the switch so the drive

unit does not contact the hard stop on either
side during normal operation.
NOTE: To verify a 10° steering rail is installed,
enter Test I90. Steer until the steering is
at the stop. 7 to 10 is displayed for a 10°
rail; 2 or 3 is displayed for older rails.
Run Test
Turn the steering wheel all the way in one
direction until the drive unit is against the
mechanical stop. Record the steering degrees
displayed. Turn the steering wheel all the way
in the opposite direction against the mechanical
stop. Compare this reading to the reading from
the opposite side.
Both sides should be approx. 10°.

Adjust the Steer Limit Switch (S11) mounting
bracket so the reading on both ends is as close
to 10° as possible.

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Digital Input Tests Test I91 - iPort ™ Communication Test
Test I91 - iPort ™

Communication Test
This test shows the status of communication
between the VM and Supplier Wireless Module
(SWM).
Run Test
When running the test, the numbers may

alternate:
• between 2 and 3, indicating correct
operation of SWM and VM
• between 1 and 2, indicating a
communication error; perform Diagnosis
and Repair
Action/ Expected
Meter Scale Results
Connect FlashWare to
another truck to make
sure the cable and
Connect
FlashWare program are
FlashWare to
can functioning correctly. If
1 VM and N/A N/A Perform step 2
communicate OK, reconnect to the
attempt to
with the VM original truck. If still
communicate
unable to
communicate, replace
VM.

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Test I91 - iPort ™ Communication Test Digital Input Tests
Action/ Expected
Meter Scale Results
Check connection at
2 JRDP1-6 B– Perform step 3 TP1, in-line fuse, and
wire continuity.
B+
3 JRDP1-5 Perform step 4 Check connection at
B+ TP4 and wire
4 JRDP1-3 Perform step 5 continuity.
DCV Check connection at

5 JRDP1-2 B– Perform Step 6
VM and wire continuity.
Make sure VM
–5 to –10V and SWM are Check connection at
loaded with SWM and wire
6 JRDP1-1 B–
latest software continuity. Refer to
and option is SWM documentation.
enabled

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Digital Input Tests Test I92 - iPort ™ Error Bitmap Test
Test I92 - iPort ™

Error Bitmap Test
This test is for factory use only.

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Test I92 - iPort ™ Error Bitmap Test Digital Input Tests

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Digital Output Tests
Digital Output Tests


and Repair table.

Action/
Meter Scale

before testing the
circuit, such as
connectors. If no
The next
all circuits should be Probe Probe The next
action to
Results are
not met.
performing the next
step.
This column also

scale on the meter for
this step.

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Test O00 - Toggle the TPC Contactor Digital Output Tests
Test O00 - Toggle the If the contactor does not cycle in/out when the
test is toggled, the test has failed.
TPC Contactor
This test turns the TPC contactor ON and OFF.
Jack the drive wheels off the floor for

this test.
Run Test
Use the ENTER button to toggle the test ON and

OFF. The Operator Display shows ON or OFF.

Action/ Expected
Meter Scale Results
Disconnect JPS1
approx. 38 Troubleshoot
1 from contactor JPS1-8 Perform step 2
ohms wires and coil
panel/Ohms
JPS1-10 Troubleshoot K2
relay and
2 TP4 B+ Perform step 3
Fuse/Relay
DCV Card
Test wire to TPA.

Test ON: 18V Test contactor
3 B+ JPS1-8 If OK, replace
Test OFF: 0V for binding
TPA

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Digital Output Tests Test O01 - Toggle the STR Contactor
STR Contactor
This test turns the STR contactor ON and OFF.
DO NOT attempt to drive the lift truck

while conducting this test.
Run Test


Action/ Expected
Meter Scale Results

1 JPS1-11 Perform step 2
JPS1/Ohms JPS1-10 40 Ohms wires and coil
2 Perform step 4 Perform step 3
TP4 B+ Replace
Troubleshoot
3 JPF2-1 Fuse/Relay
wire to JPS1-10
Card
DCV
Test contactor
4 JPS1-11 Test OFF: 0V Perform step 5
for binding
B+ Test ON:
approx. 24V Troubleshoot
wire to JPS1-11

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Test O02 - Toggle the LPC Contactor Digital Output Tests
LPC Contactor
This test turns the LPC contactor ON and OFF.
Ceiling height must be higher than the

maximum elevated height of the lift
truck under test.
The lift system on a truck with DC lift

might not act as expected during this
test. If the STR contactor is shorted, the
carriage lifts when the LPC contactor is
toggled ON.
This does not happen on a truck with AC
lift, because the AC Lift Motor does not
turn without power from the LPA.
Run Test


Action/ Expected
Meter Scale Results
Disconnect JPS1
approx. Troubleshoot
1 from contactor JPS1-9 Perform step 2
38 Ohms wires and coil
panel/Ohms
JPS1-10
Troubleshoot K2
2 TP4 B+ Perform step 3 relay and
Fuse/Relay Card
DCV Test wire to LPA
Test ON: 18V
Test contactor or VM. If OK,
3 B+ JPS1-9
for binding replace LPA
Test OFF: 0V
or VM.

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Digital Output Tests Test O04 - Toggle Aux1 Directional (SOL5T) Solenoid
Test O04 - Toggle Aux1

Directional (SOL5T)
Solenoid
Refer to Test A31 - Solenoid 5T (AUX1) Current
(Page 6-48).

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Test O05 - Toggle Aux2 Directional (SOL5B) Solenoid Digital Output Tests
Test O05 - Toggle Aux2

Directional (SOL5B)
Solenoid
Refer to Test A32 - Solenoid 5B (AUX2) Current
(Page 6-49).

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Digital Output Tests Test O06 - Toggle the Reach Solenoid
Test O06 - Toggle the 2. Disconnect wire REACH-1 from the reach
solenoid.
Reach Solenoid 3. Connect a digital ammeter in series with
the reach solenoid coil, positive lead (+) to
This test turns the reach solenoid ON and OFF, the wire removed and the negative lead (–)
verifying its correct operation electrically. to terminal REACH-1 on the solenoid.
4. Reconnect the battery connector and turn
A successful test proves the reach solenoid coil, the key switch ON.
wiring, and related circuitry in the Vehicle 5. Run Test O06 and toggle the solenoid coil
Manager are functioning correctly. ON. Use the ENTER button to toggle the
test ON and OFF. The Operator Display
It does not prove the reach solenoid valve is shows ON or OFF. The ammeter must read
functioning mechanically. approx 560 mA.
a. If the ammeter reading is correct, the
Run Test solenoid coil is functioning electrically.
NOTE: For information on how to use b. If the solenoid is not working correctly,
maintenance mode, see “Using Service check for a mechanical problem in the
Mode” on page 3-28. valve, such as binding or
contamination.
the battery connector.

Action/ Expected
Meter Scale Results
Disconnect JPC18 approx. Troubleshoot

1 JPC18-12 Perform step 2
and JPF2/Ohms 41 Ohms coil and wires
JPF2-8
Troubleshoot K2
circuit

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Test O07 - Toggle the Tilt Solenoid Digital Output Tests
Test O07 - Toggle the Tilt 1. Turn the key switch OFF and disconnect
Solenoid 2. Disconnect wire TILT-1 from the tilt
solenoid.
This test turns the tilt solenoid ON and OFF, 3. Connect a digital ammeter in series with
verifying its correct operation electrically. the tilt solenoid coil, positive lead (+) to the
wire removed, and the negative lead (–) to
A successful test proves the tilt solenoid coil, terminal TILT-1 on the solenoid.
wiring, and related circuitry in the Vehicle 4. Reconnect the battery connector and turn
Manager are functioning correctly. the key switch ON.
It does not prove the tilt solenoid valve is 5. Run Test O07 and toggle the solenoid coil
functioning mechanically. ON. Use the ENTER button to toggle the
shows ON or OFF. The ammeter must read
Run Test approx 560 mA.
NOTE: For information on how to use a. If the ammeter reading is correct, the
maintenance mode, see “Using Service solenoid coil is functioning electrically.
Mode” on page 3-28. b. If the solenoid is not working correctly,
NOTE: This test is available only if the tilt check for a mechanical problem in the
option is configured for the lift truck. valve, such as binding or
contamination.

Action/ Expected
Meter Scale Results

JPF2-8
Troubleshoot K2
circuit

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Digital Output Tests Test O08 - Toggle the Sideshift Solenoid
Test O08 - Toggle the 1. Turn the key switch OFF and disconnect
Sideshift Solenoid 2. Disconnect wire SIDESHIFT-1 from the
sideshift solenoid.
This test turns the sideshift solenoid ON and 3. Connect a digital ammeter in series with
OFF, verifying its correct operation electrically. the sideshift solenoid coil, positive lead (+)
to the wire removed and the negative lead
A successful test proves the sideshift solenoid (–) to terminal SIDESHIFT-1 on the
coil, wiring, and related circuitry in the Vehicle solenoid.
Manager are functioning correctly. 4. Reconnect the battery connector and turn
the key switch ON.
It does not prove the sideshift solenoid valve is
functioning mechanically. 5. Run Test O08 and toggle the solenoid coil
ON. Use the ENTER button to toggle the
Run Test shows ON or OFF. The ammeter must read
NOTE: For information on how to use approx 560 mA.
maintenance mode, see “Using Service a. If the ammeter reading is correct, the
Mode” on page 3-28. solenoid coil is functioning electrically.
NOTE: This test is available only if the sideshift b. If the solenoid is not working correctly,
option is configured for the lift truck. check for a mechanical problem in the
valve, such as binding or
contamination.

Action/ Expected
Meter Scale Results

JPF2-8
Troubleshoot K2
circuit

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Test O09 - Aux Dump (SOL3)/ Main Relief Dump (SOL8) Current Digital Output Tests
Test O09 - Aux Dump

(SOL3)/ Main Relief
Dump (SOL8) Current
Refer to Test A33 - Aux Dump (SOL3)
(Page 6-50).

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Digital Output Tests Test O11 - Toggle the Load Hold (SOL1) Solenoid
Test O11 - Toggle the 2. Disconnect wire SOL1-1 from the load
hold solenoid.
Load Hold (SOL1) 3. Connect a digital ammeter in series with
the load hold solenoid coil, positive lead (+)
Solenoid to the wire removed, and the negative
lead (–) to terminal SOL1-1 on the
This test turns the load hold solenoid ON and solenoid.
OFF, verifying its correct operation electrically. 4. Reconnect the battery connector and turn
the key switch ON.
A successful test proves the load hold solenoid
5. Run Test O11 and toggle the solenoid coil
coil, wiring, and related circuitry in the Vehicle
ON. Use the ENTER button to toggle the
Manager are functioning correctly.
shows ON or OFF. The ammeter must read
It does not prove the load hold solenoid valve is
approx 800 mA.
functioning mechanically.
a. If the ammeter reading is correct, the
solenoid coil is functioning electrically.
Run Test
b. If the solenoid is not working correctly,
NOTE: For information on how to use check for a mechanical problem in the
maintenance mode, see “Using Service valve, such as binding or
Mode” on page 3-28. contamination.

Action/ Expected
Meter Scale Results

1 JPF2-5 JPC18-10 Perform step 2
Troubleshoot K2
2 DCV JPC18-10 TP4 B+ Replace VM
circuit

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Test O12 - Ramp the Proportional Lower (SOL2) Solenoid Digital Output Tests
Test O12 - Ramp the

Proportional Lower
(SOL2) Solenoid
Refer to Test A34 - Lift/Lower Current (SOL2)
(Page 6-51).

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Digital Output Tests Test O18 - Toggle the Horn
Test O18 - Toggle the 3. When the ENTER key is pressed, the horn
must sound. If it does not sound, the test
Horn has failed.
This test turns the lift truck’s horn ON and

OFF.
Run Test
1. Run this test in Active Service Mode while
taking readings,
2. Use the ENTER button to toggle the test
ON and OFF. The Operator Display shows
ON or OFF.

Action/ Expected
Meter Scale Results
Troubleshoot wires and

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

Test ON: B+
TP1
3 JPC18-16 Test OFF: 0V Troubleshoot Replace VM
wires to horn

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Test O19 - Audible Alarm Digital Output Tests
Test O19 - Audible Run Test

Alarm NOTE: For information on how to use
This test turns on the Operator Display alarm
by gradually increasing the PWM voltage. If the alarm does not sound when you depress
the ENTER button, the test has failed.

Action/
Meter Scale
Button Up: 0V Replace Operator

1 JPD3-1 JPD3-2 Perform step 2
Hold the Up Button Display card
DCV
Sounder Sounder ON for 6 seconds: Troubleshoot wiring
2 approx. 4.0V Replace sounder
B1 B2 to sounder

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

NOTE: This test only applies to lift trucks with
Travel Alarm option.
This test toggles the travel alarm ON and OFF.
Run Test


Action/ Expected
Meter Scale Results
1 H2– Replace travel alarm Perform step 2

H2+ Troubleshoot FU9 and
2 TP4 Test ON: B+ Perform step 3
DCV wiring
Test OFF: 0V
Troubleshoot wiring
3 TP1 JPC18-18 Replace VM
to horn

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Test O23 - Toggle Fans Digital Output Tests
Test O23 - Toggle Fans

This test toggles the power amplifier fans and
motor compartment cooling fans ON and OFF.
Run Test
Use the TILT UP/DOWN buttons to toggle the

test ON and OFF. The Operator Display shows
ON or OFF.
NOTE: Upon exiting this test, the power
amplifier fans remains in the state last
chosen (ON or OFF), until the technician
exits Program Mode. This permits
running Test O23 in conjunction with
other tests.

Action/ Expected
Meter Scale Results
Test OFF: 0V
1 TP1 JPC18-17 Perform step 2 Replace VM
Test ON: B+
DCV
Troubleshoot wires Troubleshoot K2
2 JPF2-3 TP4 B+
and fans circuitry

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Digital Output Tests Test O28 - Ramp Lift Motor
Test O28 - Ramp Lift The Operator Display first shows the current
RPM request.
Motor Use the tilt down button to increase the RPM
request by 25 RPM increments, from a
This test ramps the Lift Motor by gradually minimum of 775 RPM to a maximum of
increasing the command to the Lift Power 1500 RPM.
Amplifier via the CAN Bus. This test verifies the
Lift Power Amplifier can drive the Lift Motor. Once the maximum RPM request is reached,
pressing tilt down again resets the request to
775. To prevent lift pump damage due to very
low RPM, the minimum Lift Motor speed
The Lift Motor may rotate during this request is 775 RPM. Tilt up resets the request
test. Make sure lift truck is in an area to 0.
with sufficient overhead clearance for
lifting the mast. Use the horn button to stop the motor, reset the
RPM request to 0, de-energize the lift contactor,
and exit the test. If instead, you press tilt up,
tilt down, sideshift left, or sideshift right, the
test is still active with the request set to 0.
Running this test for an extended period
of time can cause damage to the Lift
Motor, Lift Power Amplifier, or wiring.
Run Test

Action/ Expected
Meter Scale Results
If current does not ramp

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

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Test O29 - Ramp Traction Motor Digital Output Tests
Test O29 - Ramp Run Test

Traction Motor NOTE: For information on how to use
This test ramps the Traction Motor by gradually
increasing the command to the Traction Power NOTE: The deadman pedal must be depressed
Amplifier via the CAN Bus. This test verifies the for the brake to release.
Traction Power Amplifier can drive the Traction
Motor. The Operator Display first shows the current
RPM request.
Use the tilt down button to increase the RPM

request by 25 RPM increments, from a
The Traction Motor will rotate during this minimum of 25 RPM to a maximum of 750
test. Jack the drive wheels off the floor. RPM.
Use extreme caution whenever the lift
truck is jacked up. Never block the lift Once the maximum RPM request is reached,
truck between the telescopic and the pressing tilt down again resets the request to 0.
floor. Use a suitable hoist to stabilize the Tilt up also resets the request to 0.
mast. Keep hands and feet clear from
vehicle while jacking the lift truck. After Use the horn button to stop the motor, reset the
the lift truck is jacked, place solid blocks RPM request to 0, and exit the test. If instead,
or jack stands beneath it to support it. you press tilt up, tilt down, sideshift left, or
DO NOT rely on the jack alone to sideshift right, the test is still active with the
support the lift truck. See “Jacking request set to 0.
Safety” on page 2-8.
Running this test for an extended period

of time can cause damage to the
Traction Motor, Traction Power Amplifier,
or wiring.

Action/ Expected
Meter Scale Results
If current does not ramp

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

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Digital Output Tests Test O30 - Toggle the Brake Coil
Test O30 - Toggle the

Brake Coil
See “Test A35 - Brake Armature” on page 6-52.

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Test O32 - Toggle Relays K1, K2, K3, and K4 Digital Output Tests
Test O32 - Toggle Relays

K1, K2, K3, and K4
This test toggles the relays ON and OFF.
Run Test
NOTE: OFF is displayed when entering the test
even if the relays are closed.
Press the ENTER button to toggle the test.
The Operator Display shows:
Test Status Relay Status
ON Tips closed
OFF Tips open
The test will cause codes to be written to the

error log. Clear the error log after test is
complete.
NOTE: Codes are written to the Error Log when
this test is run. Clear the Error Log
when done.

Action/ Expected
Meter Scale Results
Check K1, K2, and K3

approx. 1.6 relay coils. If OK,
Megohms replace Fuse/Relay
Disconnect JPF4 Card.
/Ohms
JPF4-13 Check K4 relay coil. If
approx. 1.7K
2 JPF4-10 Perform step 3 OK, replace
Ohms
Fuse/Relay Card.
Replace Fuse/Relay
3 Perforn step 4
Card
DCV TP4 B+ Troubleshoot wiring
4 JPC14-6 Replace VM from Fuse/Relay
Card

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Digital Output Tests Loop Back Tests
Loop Back Tests to enabling the LBT function. Then observe the
reading indicated in Table 6-4 under “Disabled
Value”. Next, apply the LBT voltage by pressing
The Loop Back Test (LBT) feature is standard on the Enter key on the display keypad. The status
the Model 7400/7420/7440 Reach-Fork ® Lift of the LBT will read “LOOP BACK ENABLED”.
Truck. This feature allows you to toggle inputs Observe the reading in Table 6-4 column
and monitor their respective values on the “Enabled Value” for the particular test.
Operator Display.
NOTE: When testing any of the entries where
Access this feature via the SuperWord level. It is JPC-22 is disconnected, the lift truck
nested inside the Service submenu. restarts after LBT is toggled from
Enabled to Disabled. The reason for this
Upon entering the Loop Back Test, the display is the EPO is wired to JPC-22. Toggling
shows the status of the LBT (defaults to the input simulates the EPO engaged
Disabled) and the first three entries. You can then disengaged, thus restarting the
scroll through the list, locating the test of vehicle.
interest.
If any loop back test fails, replace the Vehicle
The layout for the tests is very similar to the Manager.
standard Analog and Digital Input tests. The
major difference is the LBT references a When exiting LBT, the lift truck will restart
connector on the Vehicle Manager. Disconnect when the Service submenu is exited.
this connector from the Vehicle Manager prior
Table 6-4. Loop Back Tests

Test Connector Disabled Value Enabled Value
Test A04 - Primary Throttle Pot (VR1) Voltage (Page 6-34) JPC-12 0.00 5.0V ±0.2V
Test A05 - Lift/Lower Pot Voltage (Page 6-35) JPC-12 0.00 5.00V ±0.2V
Test A13 - Pressure Sensor Voltage (Page 6-40) JPC-24 0.00 5.00V ±0.2V
Test A15 - Battery Voltage (Page 6-42) JPC-24 0.00 35.00 V ±2V
400 to 460°F/ 44°F/6°C

Test A36 - Ambient Air Temp Sensor (Page 6-53) JPC-24
204 to 238°C ±10°F/6°C
Test A37 - Steer Power Amp Current (Page 6-54) JPC-6 650A ±20A 2A ±10A
Test A41 - Emergency Power Off (EPO) Switch

JPC-22 Down Up
(Page 6-57)
Test I00 - Deadman Switch (DS1) (Page 6-60) JPC-22 Up Down
Test I01 - Nested Switch (S14) (Page 6-61) JPC-22 Out In
Test I02 - First Speed Limiting Switch (S12) (Page 6-62) JPC-22 Above Below
Test I06 - Reach Switch (S4) (Page 6-63) JPC-12 Out In
Test I07 - Retract Switch (S5) (Page 6-64) JPC-12 Out In
Test I08 - Tilt Up Switch (S6) (Page 6-65) JPC-12 Out In
Test I09 - Tilt Down Switch (S7) (Page 6-66) JPC-12 Out In
Test I10 - Sideshift Right Switch (S9) (Page 6-67) JPC-12 Out In

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Loop Back Tests Digital Output Tests
Test Connector Disabled Value Enabled Value
Test I11 - Sideshift Left Switch (S8) (Page 6-68) JPC-12 Out In
Test I14 - Steering Fuse (FU1) (Page 6-69) JPC-22 Blown OK
Test I15 - Horn Switch (S3) (Page 6-70) JPC-12 Out In
Test I24 - Steer Feedback Prox Sensor (Page 6-76) JPC-22 Off On
Test I32 - Deadman Switch (DS2) (Page 6-79) JPC-10 Up Down
Test I33 - Steer Tiller Encoder 1 Connect Detect

JPC-10 No Yes
(Page 6-80)
Test I34 - Steer Tiller Encoder 2 Connect Detect

JPC-10 No Yes
(Page 6-81)
Test I35 - Steer Tiller Encoder 1 - Channels A & B

JPC-22 High Low
(Page 6-82) (35A and 35B displayed separately)
Test I36 - Steer Tiller Encoder 2 - Channels A & B

JPC-22 High Low
(Page 6-83) (36A and 36B displayed separately)
Test I39 - Neutral Pulses (Page 6-84) JPC-6 On Off
Test I60 - Security Start Switch (S23) (optional)

JPC-10 Out In
(Page 6-85)

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Model 7600/7620/7640 Reach-Fork ® Truck Section 7. Component Procedures
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Section 7. Component Procedures

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Section 7. Component Procedures Model 7600/7620/7640 Reach-Fork ® Truck
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List of Component Procedures
List of Component Procedures

Component Locator Photos . . . . . . . . . 7-3 Lift Cylinder, Main, Remove/Install . . 7-99
Special Tools, Decals, and Chassis . . . . 7-9 Left Side Main Lift Cylinder . . . . . 7-99
Special Tools . . . . . . . . . . . . . . . . . . . 7-10 Right Side Main Lift Cylinder . . . 7-100
Decals and Plates . . . . . . . . . . . . . . . 7-11 Lift Cylinder, Main Lift,
Baselegs . . . . . . . . . . . . . . . . . . . . . . 7-16 Exploded Parts Drawing . . . . . . . . . 7-104
Steering and Controls . . . . . . . . . . . . . 7-19 Lift Cylinder, Main, Seal Repacking . 7-106
Steering Encoder . . . . . . . . . . . . . . . . 7-20 Lift Cylinder Lowering Cushion . . . . . 7-108
Steer Limit Switch (S11) . . . . . . . . . . 7-21 Reach Cylinder . . . . . . . . . . . . . . . . . 7-110
Steerable Caster . . . . . . . . . . . . . . . . 7-22 Tilt Cylinder . . . . . . . . . . . . . . . . . . . 7-113
Steering Linkage . . . . . . . . . . . . . . . . 7-25 Flow Limiter, Main Lift . . . . . . . . . . . 7-115
Control Handle . . . . . . . . . . . . . . . . . 7-26 Flow Limiter, Free Lift . . . . . . . . . . . . 7-116
Drive and Brake . . . . . . . . . . . . . . . . . 7-31 Mast, Chain, Hose, Cable . . . . . . . . . . 7-119
Drive Unit . . . . . . . . . . . . . . . . . . . . . 7-32 Reach Carriage Bearings . . . . . . . . . 7-120
Brake . . . . . . . . . . . . . . . . . . . . . . . . 7-50 Mast Shimming . . . . . . . . . . . . . . . . 7-121
Inertial Dampener . . . . . . . . . . . . . . . 7-52 Bow Pads - Model 7600 . . . . . . . . . . 7-123
Electrical Components . . . . . . . . . . . . 7-55 Carriage . . . . . . . . . . . . . . . . . . . . . . 7-124
Battery Procedures . . . . . . . . . . . . . . 7-56 Chain Anchors . . . . . . . . . . . . . . . . . 7-127
Wiring and Harness Connectors . . . . 7-59 Main Lift Chain Anchors . . . . . . 7-127
General Repair Procedures . . . . . . 7-59 Free Lift Chain Anchors . . . . . . . 7-130
Molex Connectors . . . . . . . . . . . . . 7-60 Lift Chains . . . . . . . . . . . . . . . . . . . . 7-133
AMP Water-Resistant Connectors . 7-61 Chains, Main Lift . . . . . . . . . . . . 7-133
Motors . . . . . . . . . . . . . . . . . . . . . . . 7-64 Chains, Free Lift . . . . . . . . . . . . 7-136
AC Motor Service . . . . . . . . . . . . . . . . 7-65 Height Encoder Belt . . . . . . . . . . . . . 7-138
Steer Amplifier . . . . . . . . . . . . . . . . . 7-69 Model 7620 . . . . . . . . . . . . . . . . 7-138
Cold Storage Conditioning . . . . . . . . . 7-70 Model 7640 . . . . . . . . . . . . . . . . 7-140
Hydraulic Components . . . . . . . . . . . . 7-73 Hose, Main Lift . . . . . . . . . . . . . . . . . 7-142
Hydraulic System Bleeding . . . . . . . . 7-74 Hose and Cable, Over-the-Mast . . . . 7-143
Hydraulic Filter . . . . . . . . . . . . . . . . . 7-75 Cable, Over-the-Mast . . . . . . . . . . . . 7-149
Lift Pressure . . . . . . . . . . . . . . . . . . . 7-77 Hose/Tubing, Free Lift Feed . . . . . . . 7-153
Manual Lowering of Fork Carriage . . . 7-78 Mast, Model 7600 . . . . . . . . . . . . . . 7-154
Proportional Valve Adjustment . . . . . 7-79 Mast, Model 7620 . . . . . . . . . . . . . . . 7-165
Auxiliary Pressure Adjustment . . . . . 7-80 Mast, Model 7640 . . . . . . . . . . . . . . . 7-175
Manifold, Main, Model 7600 . . . . . . . 7-81 Carriage, Free Lift Cylinder,
Manifold, Main, Model 7620/7640 . . 7-82 and Hose/Cable Installation . . . . . . 7-182
Manifold, Auxiliary (Standard Reach) . 7-83 Mating Tractor to Mast . . . . . . . . . . . 7-185
Manifold, Reach (Deep-Reach ®) . . . . . 7-85
Reducing Carriage Drift . . . . . . . . 7-86
Manifold, Tilt/Sideshift (Deep-Reach ®) 7-87
Manifold Solenoids, Fittings,
and Attachments . . . . . . . . . . . . . . 7-88
Hydraulic Components, Cylinder . . . . 7-89
Lift Cylinder, Free Lift, Remove/Install 7-90
Model 7600 . . . . . . . . . . . . . . . . . 7-90
Model 7620/7640 . . . . . . . . . . . . . 7-92
Lift Cylinder, Free Lift,
Exploded Parts Drawing . . . . . . . . . 7-94
Model 7600, Staging . . . . . . . . . . . 7-94
Model 7620/7640, Staging . . . . . . 7-95
Lift Cylinder, Free Lift, Seal Repacking 7-96

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Component Locator Photos

Figure 7-1. Mast and Tractor

6353_117g.jpg
Carriage
Load
Backrest
Battery
Fork
Carriage
(integral
Battery
sideshift)
Gate
Reach Baseleg Load Wheel Forks

Mechanism
Publication: 1087967, Issued: 15 Apr 2009 7-3

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Figure 7-2. Tractor
DSC_854a.jpg
Overhead
Guard
Mast Guard
(mesh or glass)
Tiller
Operator Emergency
Manual Power Off
Pocket
Vehicle
Manager
Operator
Display Seat
Hydraulic Seat
Seat
Reservoir Adjustment
Adjustment
Filler Cap Handle
Handle
Hydraulic Fluid Specification

Level Indicator Plate
Traction Power
Horn Amplifier
(Behind Cover)
Brake See Figure 7-7.
Traction Traction Power

Motor Amplifier Fan
(Behind Cover)
See Figure 7-7.
Drive Unit
Motor
Compartment
Fan
Deadman
Steer Motor
Pedal
Drive Wheel Steer Idler

(not visible)
7-4 Publication: 1087967, Issued: 15 Apr 2009

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Figure 7-3. Tractor Deck
DSC_0866a.jpg
Lift Power Key Switch Lift Motor Emergency Contactor Panel

Amplifier Power Off See Figure 7-4.
Operator Lift Motor Steer Amplifier Vehicle

Display Cooling Fan Manager
Hydraulic Main Lift Pump Tiller Control

Reservoir Filler Manifold Handle
Cap

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Figure 7-4. Contactor Panel Figure 7-6. TP4
DSC_920a.jpg DSC_920a.jpg
Emergency TP4
Contactor Power Off
Panel
LPC
STR
TPC
Vehicle
Manager
Figure 7-7. Traction Power Amplifier
DSC_920a.jpg
Figure 7-5. Fuse/Relay Card

DSC_920a.jpg
Contactor Fuse/Relay Card

Panel
Traction
Power
Amplifier
Traction
Power
Amplifier
Fan
ESD Ground
Jack

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Figure 7-8. Reach Carriage, Operator View
DSC_0873a.jpg
Hose
Ambient Tensioning
Temperature Spring
Sensor
Aux
Hose
Manifold
Retainer/
Guide
Reach
Cylinder
Tilt
Cylinder

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Figure 7-9. Underside Components
P5180009.tif
Steering
Linkage Static Strap
Steer Idler A-frame Deadman Pedal Drive Wheel

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Special Tools, Decals, and Chassis
Special Tools, Decals, and Chassis

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Special Tools Special Tools, Decals, and Chassis
Special Tools
The following tools are available from your local
authorized Raymond dealer.
Table 7-1. Special Tools
Tool Used On Part Number Purpose
Connector
All 950-042 Separate AMP connectors
Unlatching
End Cap 7620/7640 1090761/004 Free Lift Cylinder end cap removal/installation
Free Lift Cylinder w/staging end cap

End Cap 7600 1090761/005
removal/installation
End Cap 7620/7640 1090761/005 Main Lift Cylinder end cap removal/installation
Main Lift and Free Lift Cylinder w/o staging end cap
End Cap 7600 1090761/007
removal/installation
Pin Extraction All 950-009 AMP connector pin extraction
Pin Extraction All 950-026 MOLEX connector pin extraction
Seal Driver All 401-000-051 Free Lift Cylinder seal installation

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Special Tools, Decals, and Chassis Decals and Plates
Decals and Plates

Table 7-2. Decal and Plate Location Chart
Decal and Specification Plate Locations
Identifier Description Location
Tractor frame, aft of battery compartment

1 Raymond
(both sides)
Tractor frame, with respect to battery

compartment opening, 1.0 in. from front edge,
2 ACR
bottom of decal 5.8 in. (147 mm) above
opening (both sides)
Tractor frame, centered 5.0 in. (127 mm)

3 EE Compliance (optional) above battery opening (both sides), above
battery warning decal
Tractor frame, centered 0.25 in. (6.35 mm)

4 Battery Warning Decal above battery compartment opening (both
sides)
Battery connector mounted on right side of

tractor frame – centered over battery
connector opening. Negative sign towards
front of tractor, positive sign toward rear of
5 Battery Connector Polarity tractor
Battery connector mounted on left side of
tractor frame – centered over battery
connector opening. Negative sign towards rear
of tractor, positive sign toward front of tractor
6 EPO Function On surface below EPO knob towards operator
7 Primary Control Handle Functions In recess provided in top cover
Mast guard, bottom edge of decal 1.5 in.

8 General Safety Decal (38 mm) above bottom of guard, left edge of
decal 2.88 in. (292 mm) from left edge of guard
9 Specification Plate Front of operator compartment
Front of operator compartment, below spec

10 Aux Specification Plate
plate
Front of operator compartment, below aux

11 Type E Specification Plate
specification plate
Front of operator compartment, below aux

12 Type EE Specification Plate
specification plate
Front of operator compartment, under top

13 Torque Specs cover, centered on sloping deck
of toe plate
Inside of Traction Motor compartment door,

14 Lubrication Decal
above and centered with ventilation slots

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Decals and Plates Special Tools, Decals, and Chassis
Decal and Specification Plate Locations
Identifier Description Location
Inside of Traction Motor compartment door,

15 Traction Motor Warning Decal centered with ventilation slots, above
lubrication decal
16 Hydraulic Filter Locator On reservoir, forward of filler cap
17 Cold Storage Oil Installed (Optional) Top of filler cap
Right side of mast, 2 in. (50.8 mm) above top

18 Mast Specification Plate
of baseleg
Centered on mast main frame (both sides),

19 ISO 9001 Decal
61.7 in. (156.7 cm) above floor
Centered on left mast upright under ISO9001

20 Operating Instructions
decal
21 Manual Replacement Centered at top of operator manual pocket
22 No Riding Centered on load backrest
Overhead Guard ANSI/ITSDF

23 Inside left side of overhead guard
conformance
NOTE: Items in italics are safety decals.

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Figure 7-10. Decal and Specification Plate Location,
Tractor
3
3
2 2
5
4
4
1
17 16
15
14
13
10
11
12

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Decals and Plates Special Tools, Decals, and Chassis
Figure 7-11. Decal and Specification Plate Locations, Mast
R1017504_A1.cgm
23 (inside surface) 22
19
20
21
18

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Figure 7-12. Warning/Safety Decals
1024303_02Mar04.eps,R1017269.eps,R1017233.eps,R1017232.eps,R1017362.eps,R411_587.eps
10
17
23

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Baselegs Special Tools, Decals, and Chassis
Baselegs 7. Remove the bolts holding the baseleg to

the main frame.
Removal
1. Lower the mast and retract the carriage Baseleg weighs over 100 pounds
completely. (45 kg). Use a suitable lifting device to
assist in removing baseleg.
8. Slide the baseleg off the locating pins. See
3. Remove the right or left front cover. Figure 7-14. If added force is needed to
4. Remove the battery gate on the side being separate the baseleg from the mast,
repaired. protect the casting from direct blows.
Figure 7-14. Baseleg Removal, Model 7600 shown

R1015167_Ax.cgm

truck is jacked up. Never block the lift
truck between the telescopic and the
floor. Use a suitable hoist to stabilize the
vehicle while jacking the lift truck. After
the lift truck is jacked, 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 Locating
Safety” on page 2-8. Pins
5. Jack and block the lift truck under the

side of the tractor.
6. Remove the bolts holding the load wheel Installation
plates to the baseleg. Slide the load wheel
assembly forward off the baseleg. See 1. Apply anti-seize compound (P/N 990-452)
Figure 7-13. to the baseleg alignment pins and mating
surfaces of main frame, baseleg, and
Figure 7-13. Load Wheel Assembly and Baseleg baseleg shim, if used. Insert locating pins
(closed toe version shown) into the mast.
1040765_B.cgm
2. Using a suitable lifting device to assist,

mount the baseleg over the alignment
pins.
3. Apply thread-locking compound
(P/N 990-669) to the baseleg mounting
bolts.
4. Install baseleg mounting bolts and
washers. Torque as shown in Table 7-3.
Table 7-3. Baseleg mounting bolt torque values
Model 7600 Model 7620/7640
165 ft. lb. (223 Nm) 295 ft. lb. (434 Nm)

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Special Tools, Decals, and Chassis Baselegs
5. Slide load wheel assembly over baseleg.

6. Apply Solvent (P/N 990-589), primer
(P/N 990-533), and retaining compound
(P/N 990-575) to the outside of the
mounting bolt sleeve and the inside of the
baseleg hole.
(P/N 1013829) to the load wheel plate
mounting bolts. Install mounting bolts,
washers and nuts. Torque as shown in
Table 7-4.
Table 7-4. Wheel plate torque values
Bolt Torque
Wheel Plate, Mounting,

50 ft. lb. (68 Nm)
7600
Wheel Plate, Mounting,

150 ft. lb. (203 Nm)
7620/7640
Wheel Plate, Top 21 ft. lb. (28 Nm)
Nose, Closed Toe 55 ft. lb. (74.5 Nm)
8. Remove blocking and lower the baseleg to

the floor.
9. Install right or left front cover.
10. Install battery gate.

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Baselegs Special Tools, Decals, and Chassis

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Steering and Controls
Steering and Controls


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Steering Encoder Steering and Controls
Steering Encoder
Removal
NOTE: Use correct electrostatic discharge
precautions. See “Static Precautions” on
page 2-7.
2. Remove the center tiller cap.
3. Remove the 2 cap screws holding the
steering tiller to the steering encoder.
Remove the tiller.
4. Disconnect encoder harness connectors
JPE1 and JPE2. Cut cable ties as needed.
5. Remove three screws, washers, and nuts
holding the steering encoder to the
steering tiller stem.
Installation
1. Install steering encoder to steering tiller
stem with three screws, washers, and nuts
previously removed. Torque to 9 ft. lb.
(12 Nm).
2. Route encoder harness and install cable
ties where previously removed. Connect
harness connectors JPE1 and JPE2.
(P/N 990-536) to the steering wheel cap
screws.
4. Position the steering tiller over the steering
encoder. Apply medium strength adhesive
(P/N 1013829) to two cap screws
previously removed. Install cap screws and
washers. Torque to 21 ft. lb. (29 Nm).
5. Apply sealant (P/N 990-542) to the tiller
cap seat area in the steering tiller. Install
tiller cap.

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Steering and Controls Steer Limit Switch (S11)
Steer Limit Switch (S11)

Figure 7-15. Steer Limit Switch
R1016524_A.cgm
Steer Limit Steer Motor

Switch
Sensing Rail (Steer Flag)
View is toward
Mounting
motor compartment
Bracket
door, Traction Motor
removed for clarity
Vertical Gap Adjustment

2. Open the Traction Motor compartment
door.
3. Loosen the nuts securing the switch to the
bracket.
4. Adjust the vertical gap between the switch
and the sensing rail to 0.12 to 0.25 in. (3.0
to 6.4 mm). Tighten the nuts.
Lateral Adjustment
1. Run Test I90 - Degrees Turned Past Steer
Flag (Page 6-97).
2. Adjust the mounting bracket so the
reading on both ends is as close to 10° as
possible.

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Steerable Caster Steering and Controls
Steerable Caster truck to provide access to adjustment

bolts underneath.
b. Loosen the center steering link locking
Correct caster adjustment is critical for correct
bolts. See Figure 7-17.
performance. A misadjusted caster can cause
excessive braking distances, poor stability, or
Figure 7-17. Steering Adjustments
damage to inertial dampener components. R86758a.eps
Drive
C Caster
Initial Adjustment Wheel Wheel
B
1. The drive and caster wheels should be
parallel.
2. Place a straightedge along the tractor
frame. Measure the distance from the B
straightedge to the front edge of the drive C
tire and to the back edge. Adjust steering
until the measurements are equal. The
drive wheel is now parallel to the tractor
frame. See Figure 7-16. A
Figure 7-16. Setting Drive Wheel Parallel Steering Steering

Link Link
R86758a.eps
Straightedge Drive Tire Locking Adjusting

Bolts (4) Bolts (2)
E E
c. Loosen jam nuts on center steering link
C adjusting bolts and adjust the bolts to
get both wheels parallel to the tractor
frame.
d. Apply thread-locking compound
(P/N 1013829) to steering link
adjusting bolts and locking bolts.
e. Tighten the jam nuts on the adjusting
C bolts.
f. Tighten locking bolts and torque to
70 ft. lb. (95 Nm).
g. Re-install the battery rollers. Using a
A suitable battery removing device,
3. Place a straightedge along the opposite re-install the lift truck battery.
side tractor frame. Measure the distance Re-install battery gates.
from the straightedge to the front edge of
the caster wheel and to the back edge. If Caster height adjustment varies, depending
the dimensions are not equal, adjust as upon the type of mast. See “Caster Height
follows: Adjustment” on page 7-23.
a. Turn the key switch OFF and
disconnect the battery connector.
Remove battery gates. Using a suitable
battery removal device, remove the
battery and battery rollers from the lift

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Steering and Controls Steerable Caster
Caster Height Adjustment

NOTE: Make sure a correctly rated battery is
installed in the lift truck prior to making Use extreme caution whenever the lift
this adjustment. truck is jacked up. Never block the lift
1. Remove the inertial dampener cover plate. truck between the telescopic and the
See Figure 7-18. floor. Use a suitable hoist to stabilize the
Figure 7-18. Inertial Dampener Cover Plate vehicle while jacking the lift truck. See
7074_004.tif
“Jacking Safety” on page 2-8.
Figure 7-20. A-frame Spring Adjustments

R86758b.eps
Cover Plate
Initially Initially
1 in. 6 in.
(25 (152
mm) mm)
2. Check the A-frame down-travel

adjustment bolt in Figure 7-19. Make sure
it is installed correctly. If the bolt is
missing, the A-frame could drop and allow 3. Jack the lift truck until the caster is clear
the springs to escape when the truck is of the floor.
jacked up. 4. Turn the A-frame down-travel adjustment
bolt to obtain an initial gap of 1.0 in.
Figure 7-19. A-frame Down-Travel Adjustment Bolt
13y7s001.tif
(25 mm) between the arm and frame.
Adjust the A-frame spring nuts to obtain
an initial spring length of 6.0 in.
A-frame Spring (152 mm). See Figure 7-19 and
Nuts Figure 7-20.
5. Lower the lift truck back onto the floor.
Make sure the lift truck is sitting on a flat
floor surface.
6. Adjust the A-frame spring nuts to obtain
the spring length shown in Table 7-5. The
A-frame dimension is measured from the top of the
Down-Travel spring to the top of the caster, not the
Adjustment Bolt frame.

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Steerable Caster Steering and Controls
Table 7-5. A-frame spring length 10. Apply thread-locking compound
(P/N 990-536) to the A-frame up-travel
Elevated Height Spring Length stop bolt. Tighten the jam nut.
11. Test the lift truck for correct braking
Below 330 in. (8328 mm) 5.75 in. (146 mm)
action.
Above 331 in. (8407 mm) 5.50 in. (140 mm) 12. Reinstall the inertial dampener cover
plate.

(P/N 990-536) and turn the A-frame
down-travel adjustment bolt to set the
correct gap between the bottom of the bolt
head and the top of the flat washer. See
Figure 7-19 and Table 7-6.
Table 7-6. A-frame down-travel gap
Elevated Height Gap
All 0.12 in. (3.05 mm)
Note: DO NOT overtighten the bolt. The bolt head

should apply slight pressure on the flat washer.
8. Loosen the jam nut on the A-frame

up-travel stop bolt. See Figure 7-21.
Figure 7-21. A-frame Up-Travel Stop Adjustment

13y7s001.tif
A-frame
Up-Travel
Stop Bolt
9. Turn the A-frame up-travel stop bolt to

adjust the gap between the bolt head and
the top of the A-frame. See Figure 7-21
and Table 7-7.
Table 7-7. A-frame up-travel stop bolt gap
Elevated Height Gap
Below 330 in. (8328 mm) 0.38 in. (9.65 mm)
Above 331 in. (8407 mm) 0.25 in. (6.35 mm)

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Steering and Controls Steering Linkage
Steering Linkage
Use Figure 7-22 as a reference when
removing/replacing steering linkage
components. After replacing any components,
make sure the steering is adjusted correctly.
Figure 7-22. Steering Linkage

R86758a.eps,R86758c.eps,R86758d.eps,R86758e.eps,R86758f.eps
Section BB
and
Section CC
D
C
B
B
C D
A A
Detail of
Section AA
E E
Section EE
Section AA

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Control Handle Steering and Controls
Control Handle 3. Press the latch on the travel pot connector

and disconnect the travel pot from the flex
circuit. See Figure 7-23.
If a ThermaKit component has failed in the
4. Lift the travel pot shaft out of the lower
control handle; replace both handle shells. In
handle shell.
this case, it is more cost effective to replace the
entire handle than to rebuild it. 5. Slide the travel pot out of the pivot shaft
assembly. See Figure 7-23.
Disassembly NOTE: Do not lose the D-shaped clip inside the
pivot shaft.
1. Remove the lift knob.
6. Remove the external snap ring.
NOTE: The outer spring paddle may fall off
when the lift knob is removed. Figure 7-24. Pivot Shaft Assembly
HNDL_FA3.jpg
D-Clip
Use correct electrostatic discharge Snap Ring

Spring
page 2-7.
Pin
2. Remove the socket head cap screws from

the handle shell. Paddle
3. Lift off the upper handle shell. If
ThermaKit equipped, the upper shell can NOTE: Observe orientation of the spring and
be removed but wiring will connect the two paddles on the pivot shaft.
halves. 7. Remove the spring and paddles from the
pivot shaft. See Figure 7-24.
Travel Pot Repair/Replacement 8. Apply a thin coat of lubricant
(P/N 990-635) to the inside surface of the
1. Carefully peel the flex heater from the spring. Assemble spring between the
travel pot. It is attached to the pot with spring paddles. See Figure 7-25.
double-sided tape.
2. Remove harness connector and travel pot Figure 7-25. Travel Pot Spring Assembly
HNDL_FA4.jpg
heater from lower shell. See Figure 7-23.
Figure 7-23. Pivot Shaft Components

HNDL_SS1.jpg
Travel Pot Spring
Travel Pot Connector

Travel Pot
9. Slide the spring and paddles part way

down the pivot shaft to engage the lower
spring tang.
Travel Pot Heater Pivot Shaft

Harness Connector

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Steering and Controls Control Handle
10. Using the upper paddle, press the upper Figure 7-27. Handle Shell
HNDL_SS5.jpg
spring tang over the pin on the pivot shaft.

With one paddle and one spring tang on
Flex Circuit Reach/Retract Buttons Lift Pot
each side of the pin, slide all parts down to
expose the snap ring groove. See Horn Button
Figure 7-25.
11. Install the external snap ring. See Lift Pot Connector
Figure 7-24.
12. Slide the travel pot shaft into the pivot
shaft assembly (make sure D-clip is in
pivot shaft).
13. Insert the pivot shaft assembly into the
lower handle shell. Make sure the tang on ThermaKit Connector
the travel pot enters the center slot in the Lift Pot Heater Tilt/Sideshift Button
shell. See Figure 7-26.
2. Slide the inner spring paddle off the lift pot
Figure 7-26. Travel Pot Tang Alignment shaft.
HNDL_SS4.jpg
3. Press the latch on the lift pot connector

Tang and disconnect the lift pot from the flex
circuit. See Figure 7-27.
4. Carefully peel the flex heater from the lift
pot. It is attached to the pot with
double-sided tape.
5. Pull the lift pot/bracket assembly out of
the handle shell.
6. Slide the lift pot out of the lift pot bracket.
7. Slide a new lift pot into the lift pot bracket.
The lift pot tang must slide into the slot on
the lift pot bracket. See Figure 7-28.
Slot
Figure 7-28. Lift Pot Tang and Bracket Slot
HNDL_SS8.jpg
14. Re-tape the flex heater to the travel pot

Tang and Slot
body. Replace the double-sided tape if
necessary. See Figure 7-23.
15. Re-seat the travel pot flex connector in the
handle shell. Re-connect the travel pot to
the flex circuit. See Figure 7-23.
Lift Pot Repair/Replacement 8. Slide the inner spring paddle onto the lift
1. Slide the outer paddle and lift pot spring pot bracket.
off the lift pot shaft. See Figure 7-27. 9. Apply a thin coat of lubricant
(P/N 990-635) to the inside surface of the
NOTE: Observe orientation of the lift pot spring,
spring. Install the spring with one tang
paddles, and dowel pin.
resting on the inner spring paddle (not the
dowel pin).
10. Slide the outer spring paddle part way
onto the lift pot shaft to engage the outer
spring tang.

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11. Using the outer paddle, press the outer 5. Carefully remove the ThermaKit and travel
spring tang over the dowel. Slide parts pot connectors from the slots in the handle
together until the outer paddle is flush shell. See Figure 7-27.
with the lift pot bracket. See Figure 7-28. 6. Lift the flex circuit out of the handle shell.
12. Make sure the tilt/sideshift card is 7. Remove the tilt/sideshift button and
correctly positioned. Slide the lift spring from the flex circuit by removing
pot/bracket assembly into the handle one screw from the back of the
shell. See Figure 7-29. tilt/sideshift card.
Figure 7-29. Lift Pot/Bracket Assembly Insertion 8. To install the tilt/sideshift button and
H
N
D
spring on the tilt/sideshift card, place the
spring over the post on the back of the
L
_
Bracket Sits on Card Notch Fits in Slot

S
S
tilt/sideshift button. Align the “A” on the

0
6
.
J
back of the button with the “A” on the

P
G
card. See Figure 7-30. Press the button

N
D
L
_
against the card so the post protrudes

S
S
7
.
through the back of the card. Thread the

J
P
G
H
screw into the post until it just bottoms,

N
D
L
_
then tighten an additional 1/8 turn. Do

S
S
0
6
not overtighten.
.
J
P
G
H
N
D
L
_
S
Figure 7-30. Tilt/Sideshift Card and Button
S
7 HNDL_FA8.jpg
.
JPG
13. Re-tape the flex heater to the lift pot body. Orientation Letter ”A”
Replace the double-sided tape if
necessary. Use a screwdriver blade to
press the heater against the pot body.
14. Route lift pot wires under the
reach/retract buttons. Re-connect the lift
pot to the flex circuit at the connector.
15. Re-connect the ThermaKit (if so equipped) Tilt/Sideshift
to the flex circuit. Button Circuit Card
9. Press the ThermaKit and travel pot

Flex Circuit Repair/Replacement connectors into the slots in the handle
shell. See Figure 7-27.
1. Press the latch on the ThermaKit
connector and disconnect the ThermaKit 10. Place the gasket over the tilt/sideshift
(if so equipped) from the flex circuit. See button. Gently position the tilt/sideshift
Figure 7-27. card in the handle shell. The bottom of the
card sits forward of a ridge in the handle;
2. Hold the tilt/sideshift button and card the card edge nearest the lift knob sits
between thumb and forefinger. Tip the behind a ridge in the handle. Confirm that
card back and remove from the handle the gasket is in place on the tilt/sideshift
shell (the gasket on the tilt/sideshift button. See Figure 7-31.
button may fall off as the tilt/sideshift
card is removed from the lower handle
shell).
3. Lift the horn button off the positioning
pin.
4. Carefully remove the lift pot connector
from the slot in the handle shell.

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Steering and Controls Control Handle
Figure 7-31. Tilt/Sideshift Card Insertion as this can cause damage. You should feel
spring tension immediately and there
HNDL_SS10.jpg
Horn Button Hole Card Sits should be no free play in the pivot shaft. If
Forward of you do not feel spring tension, lift off the
Ridge upper handle shell, and repeat step 2.
5. Fasten the harness connector to the upper
handle shell. Tighten each screw until it
bottoms, plus an additional 1/16 turn. Do
not overtighten.
Card Sits
6. Install the socket head cap screws.
Behind Tighten each screw until it bottoms, plus
Ridge an additional 1/4 turn. Do not
overtighten.
11. Correctly position the reach/retract
7. Confirm the two spring paddles and spring
buttons and re-connect the ThermaKit (if
are in place. The outer paddle must be
so equipped) to the flex circuit.
flush with the end of the lift pot bracket.
8. Set the flat on the lift pot shaft parallel to
Assembly the top spring paddle. See Figure 7-33.
1. Confirm the flex circuit is routed correctly
Figure 7-33. Lift Pot Shaft Alignment
through the locating slots. HNDL_SS12.jpg
2. Position the upper handle shell over the

lower shell and ease it into position. See
Figure 7-32. Make sure:
• A - travel pot tang is entering the slot in
the shell
• B - travel shaft rib on upper shell is
passing between the paddles of the
pivot shaft assembly
Figure 7-32. Handle Assembly

HNDL_SS11.jpg
9. Install the lift knob with the dowel pin in

between the paddles.
10. Tighten the steel set screw until it
bottoms, plus an additional 1/4 turn.
11. Install the nylon set screw. Run the nylon
set screw down flush or below the surface
B
of the knob.
3. Squeeze the handle halves together.

4. Place the tip of a screwdriver into the pivot
shaft set screw hole. Gently rotate the
shaft in both directions to confirm that the
pin in the upper handle shell is between
the paddles. Do not over-rotate the shaft,

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Drive and Brake
Drive and Brake


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Drive Unit Drive and Brake
Drive Unit
Figure 7-34. Drive Unit Exploded View
R1008858_C.cgm
21 22 20 19 18 24 25
23
4
26
3
2
17
6
12 16
28
13
5
9
7
27 8 10 11 7 14 15 29

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Drive and Brake Drive Unit
Table 7-7. Legend for Figure 7-1 Required Tools

Item Description Before performing any maintenance on the
drive unit, note the tools required. Also, make
1 Housing, Drive Unit
sure that any maintenance performed does not
2 Gear, Pinion, Drive Unit void warranty.
3 Gear, Helical, Drive Unit

Standard Tools
4 Nut, Clamp
The tools listed in Table 7-8 are required for
5 Bearing Set, Drive Unit
performing maintenance tasks on the drive
6 Bearing Set, Drive Unit unit.
7 Gear and Pinion Set, Drive Unit Table 7-8. Standard Hand Tools for Servicing Drive Unit
Bearing puller
9 Shaft, Flanged Output, Drive
Bearing press
10 Shim, Drive Unit Output Bearing
Micrometer
11 Ring, Retaining
Hammer or mallet
12 Plug, Pipe
Brass punch
13 Screw
Pinion gauge
Bearing heater
15 Seal, Lip
Screwdriver
16 Cover
Magnetic dial indicator
17 Ring, Pivot
Pry bars
18 Pin, Spiral
Tube 12 in. diam. x 6 in. long
19 Plug, Bearing Filler
Tube 8 in. diam. x 6 in. long
20 Fitting, Grease
Torque wrench, 150 ft. lb. (210 Nm) capacity
21 Screw
22 Washer, Flat
23 Kit, Ring Set
24 Bearing, Ball
25 Gear, Spur, Drive Unit
26 Fitting, Grease
27 Shim
28 Shim
29 Cover, Shim

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Special Tools
The tool shown in Figure 7-35 is recommended

for removal/installation of the drive unit.
Figure 7-35. Drive Unit Removal/Installation Tool

3323_002.eps
Top View Edge View
35°
Typical
“Eye” welded
to plate
Four 0.342 to 0.350 in. (8.7 to 5/16-18 UNC-2B equally

8.9 mm) holes spaced as spaced on a 10.5 in. 5/16 in. (8 mm) steel
shown on a 10.5 in. (266.7 mm) bolt circle (used to plate 11.25 in.
(266.7 mm) bolt circle separate tool from drive unit) (286 mm) in diameter

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Troubleshooting
Table 7-9. Troubleshooting Drive Unit Symptoms
Symptom Probable Cause Required Action Available Kits
Oil leaks Damaged lip seal Replace lip seal, main cover and Seal Kit
bearing shims, and output shaft P/N 410-029/50
bearings
Worn or damaged output Replace lip seal, main cover and Axle Shaft Kit
shaft bearing shims, output shaft P/N 410-029/51
bearings, and output shaft
Housing/main cover joint Reseal N/A
Worn or damaged housing Replace drive unit N/A
Drive wheel Worn or damaged output Replace lip seal, main cover and Seal Kit
wobbles shaft bearings bearing shims, and output shaft P/N 410-029/50
bearings
Worn or damaged output Replace lip seal, main cover and Axle Shaft Kit
shaft bearing shims, output shaft P/N 410-029/51
bearings, and output shaft
Loose wheel mounting Inspect housing and main cover for N/A
hardware damage, retorque mounting
hardware
Noise Worn or damaged output Replace lip seal, main cover and Seal Kit
shaft bearings bearing shims, and output shaft P/N 410-029/50
bearings
Worn or damaged pinion Replace pinion bearings and clamp N/A

bearings nut
Worn or damaged gear set - Replace lip seal, main cover and Seal Kit
Output shaft is in good bearing shims, output shaft P/N 410-029/50
condition bearings, pinion bearings, gear set, Drive Gear Kit
and clamp nut P/N 410-029/52
Worn or damaged gear set - Replace lip seal, main cover and Axle Shaft Kit
Output shaft is worn or bearing shims, output shaft P/N 410-029/51
damaged bearings, pinion bearings, gear set, Drive Gear Kit
clamp nut, and output shaft P/N 410-029/52
Worn or damaged helical Replace helical gear and pinion N/A

gear and pinion
Steering Inadequate bearing Grease pivot bearing and spherical N/A

binds lubrication bearing
Worn or damaged pivot Replace radial ring set, steel balls, Steer Kit
bearing bearing filler plug, and spherical P/N 410-029/53
bearing

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Symptom Probable Cause Required Action Available Kits
Steering Worn or damaged spur Replace spur gear and spherical N/A
binds gear bearing
Worn or damaged spherical Replace spherical bearing and N/A

bearing grease fittings
Worn or damaged pivot Replace pivot ring, radial ring set, Steer Kit
ring steel balls, bearing filler plug, and P/N 410-029/53
spherical bearing

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Radial Ring Inspection Figure 7-36.

7600_radialRing1.jpg
Dial Indicator Placement
NOTE: This inspection applies to Model 7600

and 7620 trucks only.
If worn radial rings are suspected as the cause

of play in the drive unit, perform the following
steps to determine if the rings should be
replaced.

vehicle while jacking the lift truck. See
1. Jack the rear of the truck up until the

drive tire is clear of the floor.
2. Place a magnetic base dial indicator on the
tractor bumper. Place the indicator pin on
top of the ring gear. See Figure 7-36.
NOTE: When positioning the indicator, align it
with a feature on the truck (such as a
grease fitting). This will help maintain
consistent results between trucks.
Drive Unit Removal
3. Zero the indicator and lower the truck to 1. Turn the key switch OFF and disconnect
the floor. Observe the new indicator the battery connector.
reading. 2. Drain the oil from the drive unit.
4. If the reading exceeds 0.090 in. (2.3 mm), 3. Loosen the drive tire lug nuts.
the radial rings should be replaced. 4. Remove the horn assembly.
NOTE: Any looseness that results in the pivot 5. Disconnect the power cables from the
ring casting contacting the drive unit Traction Motor, labeling the cables if
housing as the unit turns during necessary for later installation. Use two
steering requires the radial rings to be wrenches to avoid twisting the motor
changed immediately. studs.
6. Disconnect remainder of wires and brake
hose.
7. Remove mounting bolts for cable bracket.
8. Remove Traction Motor mounting bolts.
Lift brake assembly and motor off drive
unit.
9. Remove the steering shaft.
10. To facilitate the removal of the drive unit,
construct the tool shown in Figure 7-35.

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Attach the tool to the top of the drive unit Drive Unit Disassembly
using the screws that held the Traction
Motor. All item numbers refer to exploded view,
11. Remove the dust shield between the ring Figure 7-34 on page 7-32.
gear and the tractor frame.
Clean the outside of the drive unit thoroughly
and drain any remaining oil from the drive unit
by removing the drain plug [Item 12].
Visually inspect the outside of the housing

Use extreme caution whenever the lift [Item 1] for damage, wear, or cracks.
floor. Use a suitable hoist to stabilize the Pivot Ring Disassembly
mast. Keep hands and feet clear from 1. On the pivot ring [Item 17], remove the
vehicle while jacking the lift truck. See grease fitting [Item 20] and the bearing
“Jacking Safety” on page 2-8. filler plug [Item 19]. Inspect the bearing
filler plug hole for uneven wear. See
12. Secure the lift truck with a suitable Figure 7-37.
capacity hoist attached to the overhead
guard. Jack the rear of tractor so that the Figure 7-37. Remove Grease Fitting and Filler Plug
bottom edge of the bumper is approx 1018_003.tif
6.5 in. (16.5 cm) off the floor. Filler Plug

13. Remove the drive wheel.
14. Disconnect the steer linkage from the drive
unit; swing the linkage clear (if the lift
truck has a steered idler).
15. Place a temporary support under the drive
unit or attach a hoist to the tool installed
in Step 10.
Pivot Ring
Drive unit weighs approx 175 lb. 2. Turn the pivot ring [Item 17] to remove the
(80 kg.) steel balls [Item 24] through the bearing
filler plug hole. See Figure 7-38.
16. Loosen, then remove the four mounting NOTE: If the pivot ring does not spin or even
screws holding the drive unit to the tractor turn, it is an indication of damaged
frame. The steering stop also becomes radial rings and/or excessive wear to the
unattached at this stage. channel in housing. If this is the case,
17. Lower the drive unit to the floor. Tip the replace the entire drive unit. No further
drive unit over on its side and remove the disassembly is necessary.
hoist.
18. If you have trouble separating the tool
from the drive unit, thread mounting
screws in the threaded holes in the tool to
push the tool off the drive unit.

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Figure 7-38. Remove Steel Ball Bearings Figure 7-40. Remove Radial Rings
1018_002.tif 1018_001.tif
Radial Rings
3. After removing all the steel balls, remove Main Cover and Output Shaft
the pivot ring [Item 17] by working it off Disassembly
toward drive end of the housing. See
Figure 7-39. 1. Visually inspect the housing around the
main cover [Item 16] for wear outside the
Figure 7-39. Remove Pivot Ring cover bolts [Item 13]. See Figure 7-41.
1018_004.tif
NOTE: Excessive housing wear outside the

cover bolts can make them difficult to
remove. If this occurs, replace the entire
Pivot Ring drive unit. No further disassembly is
necessary.
Figure 7-41. Remove Cover and Output Shaft

1018_005.tif
Main Cover
4. Remove the radial rings [Item 23] from the
channel in the housing and inside the
pivot ring.
Due to normal wear, the edges of the

radial rings could be very sharp.
2. Remove the main cover bolts [Item 13].
5. Clean the grease from the radial ring 3. Using a mallet, knock the flanged output
channel in the housing. Inspect the shaft [Item 9] to break the seal on the
channel for uneven wear. Also clean and main cover [Item 16].
inspect the inside of the pivot ring. See
4. Remove the main cover and output shaft
Figure 7-40.
5. You need a press and 8 x 6 in. tube to
remove the bearing cup [Item 14] on the
end of the output shaft.

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clamp is resting on the tube. Press the

flanged output shaft [Item 9] and the
output bearing spacer [Item 10] out.
Always watch for pinch points when
using a press or pressing tools. 9. Remove the exterior retaining ring
[Item 11]. See Figure 7-43.
10. To remove the bevel gear [Item 7], support
the main cover assembly on 8 x 6 in. tube
Safety glasses are required after this under press. Press the output shaft [Item
point in disassembly. 9] down through the bevel gear. The
bearing cone [Item 14] will be removed at
6. Place the main cover assembly, gear side the same time. See Figure 7-44.
down, on the tube under press. Press the
Figure 7-44. Remove Bevel Gear
output shaft [Item 9] down slightly to 1018_012.tif
create a space between the bevel gear

[Item 7] and the output bearing spacer
Figure 7-42. Press Down Output Shaft

1018_010.tif
Output Shaft
Output Shaft
11. Remove the bearing cup [Item 8] from the

main cover with a race driver and pry bars.
12. Remove the lip seal [Item 15] from the
Bevel Gear main cover. See Figure 7-45.
7. Tighten a bearing puller clamp under the Figure 7-45. Remove Bearing Cup and Lip Seal
1018_013.tif
lip of the output bearing spacer, being

careful not to catch the exterior retaining
ring [Item 11]. See Figure 7-43. Lip Seal
Figure 7-43. Press Out Output Shaft

1018_011.tif
13. Remove the output shaft bearing cone

[Item 8] in the base of the housing using
two pry bars. Insert the pry bars under
bottom edge of the cone on opposite sides.
Apply even pressure on both tools to lift
8. Place the main cover assembly, gear side the cone out. See Figure 7-46.
up, on 12 x 6 in. tube so the bearing puller

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Figure 7-46. Remove Output Shaft Bearing Cone Figure 7-48. Remove Spiral Pinion
1018_009.tif 1018_007.tif
Helical Gear
Output Shaft
Bearing Cone
14. Remove the shims [Item 27] from the 3. Remove the helical gear [Item 3] and the
housing bore. Save shims for reference bearing cone [Item 5] from the housing.
only, as they are usually damaged when See Figure 7-48.
removing the bearing cone. New shims are
4. Drive out the bearing cup [Item 6]. Inspect
provided with Kits #1 and #2.
the bearing cup and housing bores for
15. Remove the cover shims [Item 29]. Save wear. See Figure 7-49.
the shims for reference only. Replacement
shims are provided with Kits #1 and #2. NOTE: The bearing cups and cones are usually
damaged during removal. Replace them
as sets; they are included with Kits #1
Spiral Pinion Disassembly and #2.
NOTE: The spiral pinion and bevel gear are a
Figure 7-49. Remove Bearing Cup
matched set. Their alignment is critical. 1018_008.tif
Do not replace them separately.

1. Loosen the set screw on the clamp nut
[Item 4] on the spiral pinion [Item 7].
Remove the clamp nut. See Figure 7-47.
Figure 7-47. Remove Clamp Nut

1018_006.tif
Bearing Cup
Thoroughly wash the housing and visually

inspect entire housing again for excessive
damage, wear, or cracks.
Clamp Nut
Drive Unit Assembly
2. Using a brass punch and hammer, drive
the spiral pinion [Item 7] out of the
housing. See Figure 7-48.
NOTE: You may need to remove the spiral Safety glasses are required.
pinion with a press or pressing device
equivalent. Prepare the housing for assembly by running a
tap through all bolt and screw holes. Cleaning

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the threads also makes sure that there is no Main Cover and Output Shaft
damage. Assembly
Spiral Pinion Assembly 1. Prior to installing the output shaft lip seal
[Item 15], apply a thin layer of sealing
1. Using a press or mallet, install the bearing adhesive around the seal surface of the
cup into the housing bore. See main housing, to prevent leaking. Install
Figure 7-50. the lip seal, spring side down, in the
housing.
Figure 7-50. Drive In Bearing Cup
1018_014.tif
2. Press the lip seal [Item 15] into the
housing until it is just below flush with
housing surface. See Figure 7-52.
Figure 7-52. Press Lip Seal

1018_016.tif
Bearing Cup
2. Install the second bearing cup [Item 6] into

the housing bore on the opposite side. Lip Seal
3. Press the output bearing cup [Item 14]

Always watch for pinch points when
into main cover until it is seated. Place the
using a press or pressing tools.
bearing cone into the bearing cup. See
Figure 7-53.
3. Press the bearing cone [Item 5] onto the
spiral pinion [Item 7] until it is seated. See Figure 7-53. Press Output Bearing Cup
Figure 7-51. 1018_017.tif
Output
Figure 7-51. Press Bearing onto Spiral Pinion
1018_015.tif Bearing Cup
Bearing Cone
Spiral Pinion
4. Push down on the bearing and turn to seat

bearing into the bearing cup.
5. Take a measurement from the edge of the
bearing cone [Item 14] to the flange
surface of main cover [Item 16]. Make sure
that dial indicator tips come into contact
with flange surface. See Figure 7-54.

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Figure 7-54. Bearing Cone to Flange Measurement Figure 7-56. Press on Bearing Cone
1826_127.tif 1018_020.tif
6. The reading on the two dial indicators 11. Place the bevel gear [Item 7] down over the
should be the same. If they are different, output shaft, teeth side up. Press the bevel
repeat steps 4 and 5 until the readings are gear down, seating the bearing cone [Item
identical. Record final reading as 14] into the bearing cup. See Figure 7-57.
Measurement D on flange surface. This is
required during final assembly. Figure 7-57. Press on Bevel Gear
1018_022.tif
7. Remove the bearing cone [Item 14] in

preparation for installing the flanged Bevel Gear
output bearing shaft [Item 9].
8. Use a light oil on the surface of the lip seal
[Item 15] and inside the bearing cup
[Item 14].
9. Place the main cover down over the output
shaft, flange side up. Place the bearing
cone [Item 14] down over the output shaft
Bearing Cone
Figure 7-55. Install Main Cover and Bearing Cone
1018_021.tif 12. Install the external retaining ring [Item 11]
on the output shaft [Item 9]. Pull up on the
Bearing Cone
bevel gear [Item 7] to make sure the
external retaining ring is installed
securely.
13. Place the output bearing spacer [Item 10],
with the recessed area down, over the
output shaft. Place the bearing cone
[Item 8] on top of the output shaft.
14. Press the bearing cone [Item 8] down until
Output Shaft
it is fully seated against the spacer and
snap ring. See Figure 7-58.
10. Press the bearing cone onto the output
shaft. See Figure 7-56.

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Figure 7-58. Press Down Bearing Cone Figure 7-60. Bearing Cup to Flange Measurement
1018_023.tif 1826_130.tif
Bearing Cone
Output
Bearing
Spacer
15. Place the main cover assembly, flange side 18. Record final readings as Measurement E.
up. Press the bearing cone [Item 8] into This is required during final assembly.
place. At the same time, pull the gear
sideways to eliminate any backlash in the Helical Gear Assembly
spline area. See Figure 7-59.
NOTE: The pinion shaft and bevel gear are a
Figure 7-59. Eliminate Backlash matched set. Their alignment is critical.
Do not replace them separately.
1018_024.tif
Bearing Cup
Bearing can become extremely hot. Use

gloves to protect hands from burns.
1. Preheat the bearing cone with a bearing

heater. Install the heated bearing cone in
the bearing cup [Item 6] in the housing.
NOTE: Complete steps 2 through 4 before the
16. Place bearing cup [Item 8] onto bearing bearing cools.
and rotate cup while applying downward 2. Place the helical gear [Item 3] into the
pressure to seat bearing. housing.
17. Position dial indicator onto the main cover 3. Install the spiral pinion [Item 7] up
so that the tips rest on the bearing cup. through the helical gear [Item 3].
The readings on the two dial indicators
4. Put the clamp nut [Item 4] on the end of
should be the same. If they are different,
the spiral pinion [Item 7] and hand tighten
repeat steps 15 and 16 until the readings
until the bearing cools. See Figure 7-61.
are identical. See Figure 7-60.

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Figure 7-61. Install Helical Gear and Pinion S2 = Shim amount between cover plate face to
set preload of bearings for output shaft.
1018_027.tif
Clamp Nut
S3 = J – F – G
S3 = Shim amount between drive unit housing

and lower bearing on spiral pinion.
Figure 7-62. Bearing Cone to Flange Measurement

1826_127.tif
Helical Gear
5. Remove clamp nut [Item 4]. Apply

thread-locking compound (P/N 990-669)
to the threads of the spiral pinion.
Re-assemble clamp nut on spiral pinion
and hand tighten.
6. While the bearing cone [Item 6] is cooling,
calculate the formula for determining the
required shim thickness.
Figure 7-63. Bearing Cup to Flange Measurement
Calculate Shim Formulas 1826_130.tif
• A = Dimension A stamped on housing

(2.102/2.108)
• B = Dimension B stamped on housing
(3.409/3.412)
• C = Number etched on back of gear
(nominal 1.812)
• D = Distance from bearing cone to flange
surface (see Figure 7-62)
• E = Distance from bearing cup to flange
surface (see Figure 7-63)
• F = Mounting distance etched on spiral Installing and Testing Shims
pinion
1. Remove any end play in the bearings
• G = Distance from top of teeth on spiral
between the helical gear [Item 3] and the
pinion to top of lower bearing cup on spiral
spiral gear [Item 7] using lock nut wrench.
pinon
Wedge the helical gear, and tighten the
• J = Distance from centerline of output clamp nut [Item 4] until there is no end
shaft to top of lower bearing cup on spiral play between the gears. See Figure 7-64.
pinion
S1 = (B - A - E + D + C)
S1 = Shim amount behind bearing cup in main

housing to position gear for correct backlash.
S2 = E + S1 - B - 0.006 preload

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Figure 7-64. Remove End Play marked. Mark that tooth surface also. See
Figure 7-65.
1018_028.tif
Figure 7-65. Mark Spiral and Bevel Gears

1018_029.tif
Spiral Gear
2. Preload the helical gear [Item 3] for 0.000

to 0.002.
3. Remove any oil from the clamp nut
7. Place the predetermined shims [Item 27]
[Item 4]. Apply thread-locking compound
into the housing bore for the bearing cup
(P/N 1013829) to the threads in the clamp
[Item 8]. Install the bearing cup into the
nut. Tighten the set screw in the clamp
housing bore over the shims.
nut to 140 in. lb. (15.8 Nm).
4. Spin the helical gear [Item 3] to make sure 8. Install the cover shims [Item 29]. See
that the bearings are not too tight. The Figure 7-66.
helical gear must spin freely for at least
Figure 7-66. Install Cover Shims
one full rotation. 1018_030.tif
5. Only perform the following procedure if

the helical gear assembly is too tight.
a. Unscrew the clamp nut [Item 4] the
width of one spanner slot (0.188 in.
[4.77 mm]).
b. Tap the spiral bevel gear [Item 7] to
unseat the bearing cone. Cover Shim
c. Place the predetermined shims
[Item 28] in the housing bore for the 9. Place the main cover assembly over the
bearing cup [Item 5]. shims, making sure to line up the marked
teeth on both the spiral and bevel gears
d. Install the spiral pinion gear and helical
gear. See “Helical Gear Assembly” on
page 7-44.
e. Repeat steps 1 thru 4 until the helical
gear spins at least one full rotation.
6. One tooth on the spiral gear [Item 7] is
etched or marked with an X. With a
marker, mark that tooth surface for the
purpose of lining up the spiral and bevel
gears [Item 7] to check backlash. One
tooth on the matching bevel gear is also

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Figure 7-67.
1018_031.tif
Line Up Spiral and Bevel Gears Main Cover Installation
1. Clean the cover mating surface on the
Spiral gear housing, then apply thread-locking
compound (P/N 990-411) sparingly.
2. Install the cover shims [Item 29] and the
main cover assembly. Install the main
cover bolts [Item 13], and torque to
40 ft. lb. (54 Nm).
Pivot Ring Assembly

Bevel Gear
10. Put in four housing cover bolts [Item 13],

evenly spaced, and tighten to 40 ft. lb. Safety glasses are required.
(54 Nm).
1. On the inside of the pivot ring [Item 17],
Measuring Backlash make sure the roll pins [Item 18] are
installed and in good condition on either
NOTE: Backlash tolerance is critical to the side of the bearing filler plug hole. If they
performance of the drive unit. Incorrectly are missing or damaged, install new roll
adjusted units will experience premature pins. See Figure 7-69.
failure.
Figure 7-69. Install Roll Pins
1. Wedge the helical gear [Item 3], then 1018_035.tif
slightly turn the output shaft to determine Pivot Ring

backlash. Backlash reading on the dial
indicator should be between 0.004 and
0.006. See Figure 7-68.
Figure 7-68. Backlash Measurement

1826_131.tif
Roll Pin
2. Install the grease fitting [Item 26] on the

outside of the pivot ring.
3. Screw the grease fitting [Item 20] in the
bearing filler plug.
4. Install radial rings [Item 23]. Install the
flat radial ring on the inside flat surface of
2. Calculate any necessary adjustments to the pivot ring. Place the ends of the
the shims. Remove the main cover chamfered radial rings against the roll
assembly and the bearing cup, and adjust pins [Item 18] to install them in the pivot
the shims. Repeat Steps 6 through 9 ring. See Figure 7-70.
“Installing and Testing Shims” until
backlash is between 0.004 and 0.006.
3. When backlash is within acceptable range,
remove the main cover assembly and the
cover shims.

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Figure 7-70. Install Radial Rings Figure 7-72. Install Ball Bearings
1018_036.tif 1018_038.tif
Radial Rings Steel Ball
Roll Pins
5. Install the outer radial rings [Item 23] on 9. Intall the bearing filler plug [Item 19] with
the housing. See Figure 7-71. the grease fitting [Item 20] pointing toward
the spur gear [Item 25]. See Figure 7-73.
Figure 7-71. Install Outer Radial Rings
Figure 7-73. Install Bearing Filler Plug
1018_037.tif
Outer
1018_040.tif
Radial Ring Filler Plug and Filler Plug

Grease Fitting Bolt
Washer
6. Lift the drive end of the housing and slide
the pivot ring over the housing. Be careful
not to jar the radial rings out of place.
Slide the pivot ring into place just behind
Excessive thread-locking compound will
the spur gear [Item 25].
damage the ball bearings and pivot
7. Make sure the pivot ring bearing filler plug ring. Use thread-locking compound
hole is on top, in preparation for installing sparingly.
the steel balls [Item 24].
8. Put one ball at a time into the pivot ring 10. Apply thread-locking compound
filler hole. Use a screwdriver to direct the (P/N 990-536) sparingly to the filler plug
steel balls first to one side then the other. bolts [Item 21]. Install the bolts [Item 21]
Continue until all 70 balls are installed. and washers [Item 22] on either side of the
See Figure 7-72. bearing filler plug [Item19] and tighten to
20 ft. lb. (27 Nm).
11. Grease and then test the pivot ring,
checking to see that it spins freely.
Drive Unit Installation

1. Place the new drive unit in position.

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(P/N 990-544) to the drive unit mounting
bolts. Install and torque the drive unit
mounting bolts to 130 ft. lb. (176 Nm).
(P/N 990-536) to the steer linkage bolt
threads. Reconnect the steering linkage.
Torque bolts to 150 ft. lb. (204 Nm).
4. Reinstall the steering shaft and hydraulic
motor.
5. Refill the drive unit with the correct type
fluid. Add fluid until level reaches the
bottom of the helical gear.
6. Install the Traction Motor and brake. Use
a fiber gasket between Traction Motor and
drive unit.
7. Install mounting bolts for Traction Motor
and drive unit and torque to 13 ft. lb.
(17.6 Nm).
8. Connect cables, wires, and brake line.
Torque motor cables to 18 ft. lb. (24.4 Nm).
9. Install the drive unit dust shield.
10. Install the drive wheel. Torque the drive
tire lug bolts to 170 ft. lb. (230 Nm).
11. Install the horn assembly.
12. Check the drive unit fluid level.
13. Test the brake for correct operation.

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Brake Drive and Brake
Brake measured total air gap (non-energized).

Insert spacer between the armature plate
and the coil body. Tighten the locking bolt
Inspection just enough to prevent rotation of the
motor shaft.
7. Remove the retaining nut and washer from
the motor shaft. See Figure 7-74.
2. Open the motor compartment door. 8. Remove the three brake mounting bolts.
3. Check air gap between the armature and 9. Use a brake puller to remove the brake
armature plate near all three spacers. See assembly from the motor.
Figure 7-74. If air gap exceeds 0.040 in. (1
mm), replace the brake pads. See “Pad
Replacement”. Pad Replacement
Figure 7-74. Checking Brake Air Gap 1. Install the brake release bolts.
NOTE: Do not overtighten the brake release
brake3.JPG
bolts.
Motor 2. Turn the brake assembly over and remove
Shaft the three bolts securing the adapter plate.
See Figure 7-75.
Brake Figure 7-75. Adapter Plate Removal
Mounting brake1.JPG
Bolt (qty 3)
Armature
Armature
Plate
Spacer
Adapter
Plate
Brake Removal
the battery connector. Adapter
2. Block the drive tire to prevent movement. Plate Bolts
3. Open the motor compartment door.
4. Note the location of cable ties securing the 3. Remove adapter plate. Inspect spacers and
motor cable bundle to the cable bracket. replace if damaged.
Cut cable ties to free the cables from the
bracket. Remove the cable bracket. 4. Remove old pads from carrier and install
new pads. See Figure 7-76.
5. Disconnect brake armature lead
connection.
6. Loosen one of the locking bolts and obtain
a spacer approx. 0.005 to 0.015 in.
(0.12 to 0.38 mm) thicker than the

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Drive and Brake Brake
Figure 7-76.
brake1.JPG
Pad Replacement Brake Installation
Adapter Flange Carrier 1. Correctly position brake assembly on
(large flange motor, making sure the keyways on the
opposite side) motor shaft and carrier are correctly
aligned.
2. Gently tap the carrier flange onto motor
shaft until seated.
(P/N 990-536) and install the three brake
mounting bolts. Torque to 16 ft. lb.
(21.7 Nm).
4. Remove brake release bolts and install in
Pad (qty 6) their storage locations.
5. Loosen one of the retainer bolts and insert
5. Install adapter plate. Torque adapter plate a 0.030 to 0.040 in. (0.76 to 1 mm) spacer
bolts to 6 ft. lb. (8.6 Nm). between the armature plate and coil body.
NOTE: Leave the brake release bolts installed Tighten the retainer bolt just enough to
for reassembly to motor. prevent rotation of the motor shaft as the
retaining nut is being torqued.
Coil Replacement 6. Install retaining nut and a new washer to

motor shaft. Torque retaining nut to 150
1. If installed, carefully remove the brake ft. lb. (203 Nm).
release bolts. Separate the coil from the 7. Loosen the retainer bolt and remove the
armature plate. spacer.
NOTE: The brake release bolts are under 8. Attach the motor cable bracket. Apply
tension from the springs inside the coil thread-locking compound (P/N 990-536)
body. to the bolts and torque to 6 ft. lb. (8.6 Nm).
2. With the coil inverted, make sure all eight 9. Attach the cable bundle to the cable
springs are inserted into the cavities. bracket with cable ties and connect the
brake armature lead connector.
NOTE: On coils with ten spring cavities, the two
empty cavities must be 180° apart. 10. Unblock the drive tire. Reconnect the
battery connector and turn the key switch
3. Place the thin washer shaped spacer over ON.
the springs.
11. Make sure brake operates correctly and
4. Note the orientation and place the inverted traction motor rotates without interference
armature plate on the coil directly over the to motor cables.
spacer.
NOTE: When the truck is stationary, depressing
5. Assemble the armature and coil:
and releasing the deadman pedal should
a. Using a clamp, mate the armature plate cause the brake to release and engage.
to the coil, make sure the thin washer When the truck is traveling, the brake
is correctly aligned. should remain released (coil energized)
b. Install the brake release bolts through until the truck speed reaches 0.5 mph
the coil and armature plate and tighten. (0.8 km/hr).
6. Install carrier, pads, and adapter plate.
Torque adapter plate bolts to 6 ft. lb.
(8.6 Nm).

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Inertial Dampener Drive and Brake
Inertial Dampener
Figure 7-77. Inertial Dampener Assembly
R1014725_B.cgm
Mounting
Bracket
Slide Plate
Friction
Plate
Friction
Plate
Dampener
Spring
Spring
Retainer
Lock Nut
NOTE: The A-frame up-travel stop bolt Figure 7-78. Inertial Dampener (unrelated parts removed
adjustment is critical. Incorrect for clarity)
13y7s001.tif
adjustment will result in damage to the

inertial dampener. See “Steerable Dampener
Dampener Spring
Spring
Caster” on page 7-22. If extra A-frame (1 (1
9/16
9/16
in.in.
oror
4040
mm)
travel is required such that stop bolt
adjustment cannot be maintained,
remove the inertial dampener. Spring
Retainer Friction
Plate
Removal
2. Remove the right side cover.
Lock Nut
3. Remove the inertial dampener cover plate.
4. Loosen and remove the inertial dampener 5. If necessary, turn the A-frame down-travel
lock nuts, spring retainer, two springs, adjustment bolt clockwise until there is
and friction plate. See Figure 7-78. clearance between the dampener bolts and
the bottom of the slot in the slide plate.
See Figure 7-79.

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Drive and Brake Inertial Dampener
Figure 7-79. Inertial Dampener (nuts, retainer, springs, Figure 7-80. Inertial Dampener (A-frame springs, slide
friction plate removed) plate removed)
13Y7S002.TIF 13y7s004.tif
Cap Screws Friction Plate
A-frame
Spring Slide
Plate
Bolt
A-frame Down-Travel
Adjustment Bolt
10. Remove the bolt holding the friction plate
6. Remove the cap screws holding the slide to the A-frame yoke. See Figure 7-80 and
plate mounting bracket to the frame. Figure 7-81.
Remove the bracket. See Figure 7-79.
7. Loosen the A-frame down-travel Figure 7-81. Inertial Dampener (jacked up for shoulder
bolt removal)
adjustment bolt and remove the bolt and 13y7s005.tif
washers. A-frame Friction Plate

Down-Travel
Adjustment
Bolt Hole
vehicle while jacking the lift truck. See
Bolt Thread-Locking
Compound
8. Jack the tractor up approx 2 in. (5 cm) at
the tractor frame and block.
9. Remove the A-frame springs. See Installation and Adjustment
Figure 7-79 and Figure 7-80.
1. Attach the friction plate to the A-frame
yoke with the bolt and nylon lock nut.
2. Install the A-frame springs. Lower the lift
truck slightly on the jack to seat the
springs in their retainer holes. See
Figure 7-82.
3. Install the A-frame down-travel
adjustment bolt with the plastic washer
between the metal washer and the frame.
Tighten until the distance between the top
of the A-frame and the bottom of the
A-frame spring upper weldment is 7 in.
(17.7 cm).

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Inertial Dampener Drive and Brake
Figure 7-82. Inertial Dampener parts 8. Install the inertial dampener cover plate.
6906_001.JPG
9. Reattach the right side cover.

Dampener Slide Plate
Spring
Spring
Retainer
Lock Nuts
Friction Plates
4. Attach the slide plate over the dampener

bolts. Apply thread-locking compound
(P/N 1013829) to the threads in the frame.
Attach the slide plate mounting bracket to
the frame with the two cap screws. Pivot
joint on mounting bracket should be free
to flex. Torque the slide plate mounting
cap screws to 18 ft. lb. (24.4 Nm). See
Figure 7-80.
Figure 7-83. Inertial Dampener adjustment

6906_002.JPG
Pivot Joint Slide Plate
Clearance Here Friction Plate
5. Unblock and lower the lift truck to the

floor.
6. Attach the friction plate, two springs,
spring retainer, and two lock nuts. See
Figure 7-82 for orientation of parts.
Tighten the lock nuts until the distance
between the top of the spring retainer and
the friction plate is 1 9/16 in. (40 mm) at
both bolts. See Figure 7-78 on page 7-52.
7. Adjust the idler. See “Steerable Caster” on
page 7-22.

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Electrical Components
Electrical Components

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Battery Procedures Electrical Components
Battery Procedures 3. Check to see if battery cables are pulling

out of the connector.
4. Check the cables at the battery terminals.
Connections should be tight, with no
corrosion.
Before working on the battery, review
Battery Safety, beginning on page 2-5. 5. Look inside the connector. Check all
Batteries for this lift truck weigh internal contacts for damage, dirt, or
between 2000 and 2900 lb. (908 to corrosion. Do not use a metal object to
1316 kg). Use extreme care during clean the connector.
replacement. Use a suitable battery
moving device or hoist for lifting. DO
NOT extend a battery more than 1/3 of Some degreasers and parts cleaners will
its length outside the battery cause the connector shell to disintegrate.
compartment without being attached to Avoid contacting battery connectors with
a battery-moving device. solvents.
Battery Connector/Cables Removal, Replacement, and

Installation
Location
The cables to either half of the connector have a
The battery connector is located at the front lip on their forward end. This lip snaps over a
right of the tractor, above the battery. spring-loaded retainer that is part of the
NOTE: An optional kit is available to allow the connector.
battery connector to be relocated to the
front left of the tractor. Refer to Parts
Manual.
When replacing battery cable ends,
Figure 7-84. Battery Connector location remove only one end at a time from the
connector, to avoid the cable ends
6353_118g.jpg
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.
Battery
Connector 1. To remove a cable from the connector,
push the retainer down while pulling the
battery cable towards the rear and out of
the connector. See Figure 7-85 and
Figure 7-86.
Inspection
2. Check the battery connector for damaged
cables.

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Electrical Components Battery Procedures
Figure 7-85.
Battcon2.tif
Battery Cable and Connector Battery Exterior Cleaning
1. Read, understand, and follow procedures,
recommendations and specifications in the
battery and battery charger
manufacturer’s manuals.
25l6s014.eps
Figure 7-86. Battery Cable Removal from Connector 2. Wear personal protective equipment. See
Battcon1.tif
“Battery Safety” on page 2-5.

the battery connector. Remove the battery
from the lift truck.
4. Inspect the battery cables to make sure
they are not frayed or loose. Inspect the
battery connector to make sure there is no
foreign material inside the connector.
Make sure the filler plugs are tight and the
vent holes in the filler plugs are open.
Figure 7-87. Battery Cable and Filler Plug

09g6s047.tif
2. Do not attempt to repair battery cables by Battery Cable

crimping new terminals. Replace the
cable.
Disconnect Blocks
Model 7600/7620/7640 lift trucks use an

electrical EPO system. Battery connectors do
not need to have battery disconnect blocks
installed.
Filler Plug
Vent Hole
5. Keep the top of the battery clean and dry.

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

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Battery Procedures Electrical Components
Battery State-of-Charge
DO NOT clean the top of the battery Battery State-of-Charge (BSOC) is a feature that
with the soda solution while it is monitors and remembers the charge level of the
installed in the lift truck. Water can seep battery connected to the lift truck and prevents
into the electrical components and cause excessive discharging of that battery. Operating
serious damage. a lift truck using a discharged battery can
damage both the battery and the electrical
6. Wash dirty batteries (or any that have had components of the lift truck. See page 5-10 for a
electrolyte spilled on them) with a solution detailed description of how BSOC works. See
of 1 lb. (0.45 kg) of baking soda added to page 5-10 for the procedure for setting BSOC
0.5 gal. (1.9 liters) of hot water. Cutout.
7. Use a brush with flexible bristles to clean
the entire top of the battery with the soda
solution. Wait until all foaming stops,
indicating that the battery exterior is
neutralized.
8. Rinse the battery with clean water.
9. Dry the battery completely before
reinstalling it.
10. Reinstall the battery in the lift truck, using
a suitable battery moving device.
Reconnect the battery connector.
Testing, Charging, and

Maintenance
For information on testing, charging, and
maintaining your lift truck battery, consult the
battery manufacturer’s specifications and
instruction manual.
Never plug the battery charger into the

lift truck. This will severely damage the
lift truck’s electrical system. Plug the
charger only into the connector from the
battery.
6173_012.eps

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Electrical Components Wiring and Harness Connectors
Wiring and Harness • Remove damaged terminations and

discard. Never reuse a termination from a
Connectors wire.
• Do not cut away a terminal lug and reuse
the wire strands that were crimped into
General Repair Procedures the original lug.
• When stripping wire, use new wire strands
See “Electrical Troubleshooting” on page 5-2.
for new terminations. Make sure to use a
new wire with extra length to allow for
Whenever working on the lift truck, use care
cutting and stripping of the ends to install
around wiring harnesses.
new terminations.
• Carefully connect and disconnect all
• Use a new wire that is the same gauge
connections.
(typically gauge 18 AWG), size, type, and
• Do not pry connectors apart with color as the wire it is replacing.
unspecified tools.
• Use a hand stripper capable of stripping
by wire gauge number. Use care not to
There should be a wire marker at each
nick or cut any of the wire strands.
termination. If the marker is missing or
Discard and replace a wire with damaged
unreadable, remark the wire to allow easier
strands. Insert the wire strands the
identification.
correct length into termination before
NOTE: It is normal to find unused connectors crimping.
for uninstalled options that have had
heat shrink applied over them and have Soldering Procedures
been strapped to the harness.
To prevent damage from excessive heat when
Repair soldering small components in assemblies,
follow these guidelines:
• Make sure the soldering tip is clean. A
dirty tip does not transfer heat well and
Use correct electrostatic discharge encourages long dwell time and greater
precautions. See “Static Precautions” on pressure. Apply light pressure on the
page 2-7. terminal.
When pulling a wire out through a bundle, cut • Flux: rosin base
off the pin or socket so it does not snag. When • Solder: 60/40 rosin core or equivalent
replacing wires, tape or solder one end of a new • Solder Iron: 15-25 watt “pencil-type”
wire to one end of the failed wire. Pull the new maximum
wire into the bundle. Make sure to disconnect
the old wire from the new wire. • Tip Size: 3 mm (0.118 in.) diameter x
30 mm (1.182 in.) long screwdriver tip.
In other cases, it is easier to secure a new wire Make sure the tip is clean.
to the outside of the existing wire bundle with • After soldering, clean the terminals with a
straps of an appropriate size. Leave the failed brush dampened with an alcohol-based
wire in the bundle, or pull it by one end to cleaner (P/N 990-600/FOF). Do not allow
remove it from the bundle. any cleaner to seep into the switches or
potentiometers, or contact contamination
When replacing wires, follow these guidelines: may occur.
• Use the appropriate tools to remove and
insert terminations at each connector.

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Wiring and Harness Connectors Electrical Components
Molex Connectors Pin Extraction
For pin orientation of Molex connectors, see To remove a pin from a Molex connector, use
Figure 6-1 on page 6-27. Molex connectors have pin extraction tool P/N 950-026.
pins with locking ears that engage ridges in the 1. Insert the extraction tool over the pin and
plastic connector body. To remove a pin from a push all the way into the connector. This
Molex connector, depress these locking ears far releases the locking ears on the pin.
enough to clear the ridge in the connector. See
2. Pull the wire and pin from the connector.
Figure 7-88.
Figure 7-88. Molex Connector, end view Pin Insertion

Molex.wmf
To insert a pin into a Molex connector, insert

Socket the pin into the back side of the connector and
push the wire all the way in until it clicks. The
locking ears have now engaged the connector.
Pin See Figure 7-89.
Locking
Ears
Figure 7-89. Pin Extraction

Molex1.wmf
Top view of
connector Tool inserted over
pin
Extraction
Locking Tool
ears
Side view of
connector

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AMP Water-Resistant
Connectors
AMP connectors provide water-resistant
connection by the use of seals between wires
and connectors and between the mating
connector halves. See Figure 7-90.
Figure 7-90. AMP Water-Resistant Connector

4570_001.tif
Wire Seal
Interface
Seal
Contact
Cavity
Wire Seal Jack

Housing
Pin Contact
Pin Housing
Sealing Plug
To maintain the integrity of water-resistant Figure 7-91. AMP Pin Extraction

seals, use the following procedures when
4570_009.tif
working with AMP connectors. Extraction Tool
Pin Extraction
To aid in separating AMP connectors, use

unlatching tool Raymond P/N 950-042. To
remove a pin from an AMP connector, use pin
extraction tool Raymond P/N 950-009.
1. While holding the wire seal, push the
selected wire forward, then insert the
extraction tool into the contact socket. See Locking
Figure 7-91. Lance
2. Pull the wire gently until you feel the
contact locking lances disengage.
3. Holding the wire seal and connector
housing together, rotate the wire while
pulling it through the wire seal. This
prevents damage to the seal. See
Figure 7-92.

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Wiring and Harness Connectors Electrical Components
Figure 7-92. Removing Wire Figure 7-94. Wire Insertion
4570_008.tif 4570_004.tif
Rotate and Pull

Pin Contact
Pin Insertion Seals

1. Make sure the connector has a wire seal 1. Use a wire seal at the back (wire end) of
attached to the connector back. See each connector half. See Figure 7-93.
Figure 7-93. 2. Plug unused pin positions with sealing
plugs. See Figure 7-95.
Figure 7-93. Wire Seal
4570_002.tif
Figure 7-95. Sealing Plug

Wire Seal 4570_005.tif
Sealing Plug
Pin Housing
2. If re-inserting a wire previously removed,

check the pin contact locking lances to
make sure they are extended to their
original position. 3. Align the split tapered end of the sealing
3. Grasp the wire close behind the contact plug with the unused opening in the wire
insulation barrel and push the wire seal. Push the plug through the wire seal
straight through the wire seal into the into the connector until it snaps into
socket until it clicks. Pull back gently to position.
make sure the contact is locked in place. 4. Remove sealing plugs by pulling with
See Figure 7-94. needle-nose pliers while grasping the wire
seal and connector.
5. Use an interface seal between pin and jack
halves of the connector. To prevent
damage to the seal, use the matching
connector cap to slide the interface seal
over the contact silos on the pin housing.
See Figure 7-96.

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Figure 7-96. Interface Seal
4570_003.tif
Interface
Seal
Pin Housing
6. When mating connectors, make sure

polarized silos are correctly oriented. Push
pin and jack halves of the connector
together until locking latches engage. See
Figure 7-97.
Figure 7-97. Latching AMP Connector

4570_006.tif
Locking
Latches

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Motors Electrical Components
Motors
Terminal Nuts
Table 7-10. Power Cable Terminal Torques
Stud Size/Type Torque
Motors
M8 top nut 18 ft. lb. (24.4 Nm)
Power Amplifiers and Contactors
Aluminum 132 in. lb. (15 Nm)
M6 steel 50 in. lb. (5.6 Nm)
M8 steel 180 in. lb. (20.3 Nm)
M8 brass/copper 70 in. lb. (7.8 Nm)
DC Motor Troubleshooting
See “DC Motors” on page 5-5.
AC Motor Troubleshooting
See “AC Motors” on page 5-9.

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Electrical Components AC Motor Service
AC Motor Service 3. Remove the four bolts that secure the top
end bell to the bottom end bell.
4. Remove the top end bell.
Temperature Sensor 5. Cut the bad temperature sensor cable.
Replacement 6. Install a new temperature sensor using the
high temperature silicone (neutral curing)
Traction Motor supplied with the temperature sensor.
Mount the sensor close to the location of
the original.
7. Re-install the top end bell.
2. Remove the brake assembly.
8. Re-install the four bolts that secure the
3. Disconnect the temperature sensor
top end bell to the bottom end bell.
connector.
9. Connect the new temperature sensor
4. Disconnect motor power cables. Note
cable.
locations for reassembly later.
5. Remove the terminal board.
the key switch ON.
6. Remove the four bolts that secure the top
end bell to the bottom end bell.
Speed Sensor Replacement -
7. Remove the top end bell using a puller.
Internal Bearing Type
8. Cut the bad temperature sensor cable.
9. Install a new temperature sensor using the Traction Motor
high temperature silicone (neutral curing)
supplied with the temperature sensor. 1. Turn the key switch OFF and disconnect
Mount the sensor close to the location of the battery connector.
the original. Secure the cable with a cable 2. Remove the brake assembly.
tie to one of the power leads for stress
relief.
connector.
10. Re-install the top end bell.
4. Disconnect motor power cables. Note
11. Re-install the four bolts that secure the locations for reassembly later.
top end bell to the bottom end bell.
5. Remove the traction motor.
12. Re-install the brake assembly.
6. Place the motor on a suitable work surface
13. Connect the new temperature sensor and remove the nut that secures the
cable. pinion gear. Remove the gear and key
14. Install the terminal board and reconnect using a suitable puller.
power cables. Torque motor cable securing 7. Remove the clamps that secure the
nuts to 18 ft. lb. (24 Nm). encoder bearing cable. See Figure 7-98.
15. Reconnect the battery connector and turn (Pry the inner clamp up to release the
the key switch ON. cable.)
Lift Motor
connector.

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AC Motor Service Electrical Components
Figure 7-98. Sensor Bearing Cable Clamps Figure 7-100. Brake Flange Bolts
rch_06_R011A_1.tif rch_06_R011A_3.tif
Clamps
8. Mark the position of the top end bell and

bottom end bell relative to the stator. See 10. Remove the four bolts that secure the top
Figure 7-99. end bell to the bottom end bell. See
Figure 7-101.
Figure 7-99. Component Orientation Marking
Figure 7-101. Motor Disassembly
rch_06_R011A_2.tif
rch_06_R011A_4.tif
Bottom End Bell
End Bell Bolts (qty. 4)
11. Remove the bottom end bell using a puller.

12. Remove the encoder bearing from the rotor
using a suitable puller, pulling on the
outer race only. See Figure 7-102.
9. Unscrew the four bolts securing the brake

end flange and remove. See Figure 7-100.

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Electrical Components AC Motor Service
Figure 7-102. Sensor Bearing Removal Figure 7-104. Sensor Bearing Alignment and Insertion
rch_06_R011A_5.tif rch_06_R011A_7.tif
13. Remove the oil seal. See Figure 7-103. Notch

14. Make sure the O-ring and wavey washer
are correctly positioned in the bottom bell
bearing pocket. See Figure 7-103.
Clamps
Figure 7-103. Bearing Pocket Components
rch_06_R011A_6.tif
18. Carefully press the bottom end bell to the

O-Ring Wavey Washer stator. See Figure 7-105.
NOTE: Press on inner race of bearing only.
Figure 7-105. Pressing Bottom End Bell onto Rotor

rch_06_R011A_8.tif
Oil Seal
15. Position the new encoder bearing in the

bottom end bell with the cable oriented in
the middle of the notch in the side of the
bearing pocket. See Figure 7-104.
16. Use an assembly bushing on the outer
race and press the bearing into place. Do
not press on the encoder part of the
bearing.
17. Reinstall encoder bearing cable clamps.
See Figure 7-104.

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AC Motor Service Electrical Components
19. Align top and bottom end bells to stator

using marks from step 8. Secure the top
end bell to the bottom end bell using the
four bolts previously removed. Torque to
8 ft. lb. (11 Nm).
20. Reinstall brake end flange using the
previously removed bolts. Torque to
20 ft. lb. (28 Nm).
21. Install new oil seal. See Figure 7-106.
Figure 7-106. Oil Seal

rch_06_R011A_9.tif
22. Install key, pinion gear, and nut to the

bottom of the traction motor. Make sure all
oil is removed from the threads of shaft
and nut. Apply thread-locking compound
P/N 1013829 and torque to 85 ft. lb.
(115 Nm). Reinstall traction motor.

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Electrical Components Steer Amplifier
Steer Amplifier Figure 7-108. Contactor Panel

R1020143_A.cgm
Removal
2. Remove the top cover, right side cover,
control handle cover, and right front cover.
Use correct electrostatic discharge

page 2-7.
6. Open the Traction Motor compartment.
3. Disconnect wire from TP4. See 7. Disconnect the steer motor primary power
Figure 7-107. wires at A1 and A2 on the motor. Cut cable
ties as needed.
Figure 7-107. Steer Amplifier Removal
6353_116g.jpg
8. Remove bolts holding steer amplifier to
frame.
Steer
Amplifier Installation
1. Install steer amplifier to frame with bolts.
TP4
2. Route steer motor wires to steer motor and
Vehicle connect. Install cable ties where previously
Manager removed.
3. Route wire STR-1 to the contactor panel
and connect to STR-2 on the steer
contactor. Install cable ties where
previously removed. Make sure cable is
not pinched behind traction power
amplifier.
4. Connect the remaining wire to TP4.
4. Remove the contactor panel cover.
5. Install the contactor cover, right front
5. Disconnect wire STR-1 from the contactor,
cover, primary control handle cover, right
removing cable ties as necessary. See
side cover, and front cover. Close the
Figure 7-108.
Traction Motor compartment door.

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Cold Storage Conditioning Electrical Components
Cold Storage Treat the following parts with sealing

compound (P/N 990-564) to prevent moisture
Conditioning from entering:
• EPO button
NOTE: Conversion of Model 7400/7420/7440 lift • Key switch terminals
trucks for cold storage operation
• Light and fan switch terminals, if not
requires prior Raymond approval via
sealed
Form S207.
• Deadman switch terminals
New Model 7400/7420/7440 lift trucks to be • Proportional valve (SOL2) terminals
operated in a cold storage environment require
• Operator display interface card: coat both
the following:
sides completely
• All control wire (18 GA) terminals and
Components terminal strip posts (TS1, TS2)
• All-weather hydraulic fluid (P/N 1017238) • Any unsealed connectors not located in a
NOTE: Do not add any additve to this hydraulic heated compartment.
fluid.
• Ambient temperature sensor Corrosion Inhibitor Coating
• Special cold storage control handle Coat or spray bare metal surfaces listed below
assemblies with heaters with Corrosion Inhibitor Coating (P/N 990-644):
• Wire mesh mast guard • Reach cylinder cotter pins
• Main and free lift chain pulleys and shafts
Lubricants • Main and free lift chain anchors and
threaded pins
See the “Lubrication Specification Chart” on
page A-2 for special hydraulic fluid and drive • Drive unit dipstick
unit lubricants for cold storage operation.
Condensation Drip Guard
Coat battery roller shafts with all-weather
grease (P/N 1012992). To add the control handle condensation drip
guard (P/N 1036240) to the overhead guard, do
Grease carriage fittings with all-weather grease the following:
(P/N 1012992).
1. Remove the right-hand lower hex head cap
screw located almost directly above the
Sealing Treatment control handle on the overhead guard.
2. Install an M16 flat washer onto the cap
Fill sockets and the front and back of both
screw.
halves of unsealed connectors with cold storage
sealing compound (P/N 990-445). Connect 3. Reinstall the cap screw with flat washer
wires and connectors. Coat the outside and and drip guard. See Figure 7-109.
where connectors attach to the circuit board.
Coat terminals and terminal strips.
NOTE: Self-sealing AMP connectors (reference
page 7-61) do not need sealing
treatment.

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Electrical Components Cold Storage Conditioning
Figure 7-109. Condensation Drip Guard
RCH_05_002.tif

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Cold Storage Conditioning Electrical Components

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Hydraulic Components
Hydraulic Components

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Hydraulic System Bleeding Hydraulic Components
Hydraulic System 6. Repeat steps 4 and 5 for the other main lift
cylinder.
Bleeding 7. Repeat steps 4 and 5 for each of the two
free lift cylinders. See Figure 7-111.
You must bleed the hydraulic system to remove
Figure 7-111. Bleed Screw, Free Lift Cylinder
any trapped air whenever you: bleederfree.JPG
• Change a hydraulic hose

• Disconnect a hydraulic fitting
• Remove a hydraulic cylinder
• Remove the hydraulic pump Bleed Screw
• Remove the hydraulic reservoir
• Notice that the load is bouncing
Procedure
1. Elevate the fork carriage past free lift and
lower it to the floor. Repeat several times.
This tends to encourage any trapped air
bubbles to migrate to the top of the
cylinders.
2. With no load on the forks, elevate the forks
2 to 3 in. (5 to 7.5 cm) off the floor. 8. Reconnect the battery connector and turn
the key switch ON.
the battery connector. 9. Lower the forks all the way down to the
floor.
4. Loosen (do not remove) the bleed screw at
the top of the main lift cylinder. Hold a rag 10. Fully extend and retract the reach
close to and beneath the bleed screw to mechanism several times.
keep hydraulic fluid from spraying out. 11. If the truck is equipped with tilt, tilt the
See Figure 7-110. carriage all the way forward and backward
several times.
Figure 7-110. Bleed Screw, Main Lift Cylinder
bleedermain.JPG
12. If the truck is equipped with sideshift,
shift the carriage all the way to the left and
right several times.
13. Thoroughly clean up any spilled hydraulic
fluid.
14. Check the hydraulic reservoir level and
refill as necessary. Do not overfill the
reservoir.
Bleed Screw
5. Securely tighten the bleed screw when

hydraulic fluid starts flowing from the
bleed screw hole.

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Hydraulic Components Hydraulic Filter
Hydraulic Filter Figure 7-113. Filter Extraction

oldfilter2.jpg
One of two types of hydraulic filters is installed

in the main manifold, herein referred to as
Type 1 and Type 2.
Filter Type 1
Removal
1. Remove the top cover.
2. If you are not draining the reservoir,
elevate the mast to lower the hydraulic oil
level in the reservoir to minimize oil
leakage.
3. Turn the key switch OFF and disconnect Installation
1. Check the cavity for contamination and
4. Remove the plug retaining the oil filter
clean as required.
using a 3/4 in. socket. See Figure 7-112.
2. Install the new filter, making sure it seats
Figure 7-112. Filter Plug into the cavity correctly.
oldfilter1.jpg
3. Install the spring on top of the filter.

Extraction Bolt 4. Install and torque the hex plug to 30 ft. lb.
(40 Nm).
5. Reinstall the extraction bolt into the
manifold.
the key switch ON.
7. Lower the mast and check for leaks.
8. Install the top cover.
Filter Type 2
Plug
5. Remove the spring on top of the filter. Removal

6. Using the extraction bolt installed in the NOTE: Model 7620/7640 use two filter
manifold, remove the filter. See cartridges in the main manifold.
Figure 7-113. 1. Remove the top cover.
2. If you have not drained the reservoir,
elevate the mast to lower the hydraulic
fluid level to minimize hydraulic fluid
leakage.

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Hydraulic Filter Hydraulic Components
4. Remove the plug retaining the hydraulic 2. Install the new filter cartridge on the
fluid filter, using a 3/4 in. socket. See cartridge core. See Figure 7-116.
Figure 7-114.
Figure 7-116. Filter Cartridge (without shield)
Figure 7-114. Filter Plug
newfilter3.jpg
newfilter1.jpg
3. Install and torque the hex plug to 30 ft. lb.

5. Remove the filter cartridge. (40 Nm).
6. If contamination is evident, remove the 4. Reconnect the battery connector and turn
cartridge core and clean as required. the key switch ON.
7. Inspect the O-ring on the core and replace 5. Lower the mast and check for leaks.
if necessary. 6. Install the top cover.
Installation
1. Install the cartridge core into the manifold
making sure the core seats correctly into
the nose of the cavity. See Figure 7-115.
Figure 7-115. Cartridge Core

newfilter2.jpg

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Hydraulic Components Lift Pressure
Lift Pressure
Lift pressure is set by software in trucks. See
Table 7-11 for maximum lift pressure.
Table 7-11. Maximum LIft Pressures
Model/Mast Maximum Lift Pressure
7600/R45TT mast 3300 psi (22,753 kPa)
7600/DR32TT mast 3600 psi (24,821 kPa)
7620 and
2950 psi (20,339 kPa)
7640/R45TT mast
7620 and
2600 psi (17,926 kPa)
7640/DR32TT mast

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Manual Lowering of Fork Carriage Hydraulic Components
Manual Lowering of
Fork Carriage
If the fork carriage is hung up and unable to
lower normally, use the following procedure to
lower the carriage.
NOTE: Make sure the forks and carriage are
free from racks and other obstructions
before lowering.
1. Manually open the load holding valve
SOL1. See “Manifold, Main, Model 7600”
on page 7-81. On the top of SOL1 is a
small knurled knob. Depress the knob and
turn counterclockwise until the knob pops
up.
2. If there is power on the lift truck, try to
lower by using the lift/lower knob.
a. If this is successful, go to step 4.
b. If this is unsuccessful, continue to the
next step.
3. Manually adjust the proportional lift/lower
valve SOL2 to cause the carriage to lower.
a. Loosen the lock nut on top of SOL2.
b. Using a hex-key wrench, adjust the
brass adjustment screw clockwise until
the carriage begins to move.
c. Turning the screw clockwise increases
lowering speed. Turning the screw
counterclockwise slows the lowering
speed.
4. After making necessary repairs to the lift
truck, return SOL1 and SOL2 to their
original positions.
a. Depress the knob on top of SOL1 and
turn the knob clockwise until it locks in
the depressed position.
b. Adjust the proportional lift/lower valve
as described under “Proportional Valve
Adjustment” on page 7-79.

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Hydraulic Components Proportional Valve Adjustment
Proportional Valve
Adjustment
If the carriage hesitates when being lowered, or
cannot be feathered, adjust the proportional
valve as follows:
1. Raise the fork carriage to eye level.
4. Remove one of the coil wires from SOL2.
See “Manifold, Main, Model 7600” on
page 7-81. Loosen the jam nut and lock
nut holding the adjusting screw on the
proportional valve.
the key switch ON.
6. Energize the load holding solenoid by
requesting “lower” with the lift/lower
potentiometer.
7. Slowly rotate the adjusting screw
clockwise until the carriage just starts to
creep downward. Turn the screw
counterclockwise until the carriage stops.
Repeat several times in order to refine the
adjustment point. When adjustment is
complete, tighten the lock nut and jam
nut.
9. Reconnect the coil wire previously
removed.
the key switch ON.
11. Check for correct lowering operation
empty and loaded, using “Test A23 - Lift
Throttle (VR2) Request” on page 6-46 in
Active Service Mode. Carriage movement
should start at approximately 9 to 10%
request.
12. Reinstall the top cover.

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Auxiliary Pressure Adjustment Hydraulic Components
Auxiliary Pressure
Adjustment
3. Loosen the lock nut on the aux pressure
relief valve (REL2) on the main manifold.
See Figure 7-117 on page 7-81.
4. Remove the cap from the G2 auxiliary test
port on the main manifold. Connect a
pressure gauge capable of measuring
5000 psi (34,470 kPa).
the key switch ON.
6. Tilt the carriage all the way back against
the stops.
7. While continuing to try tilting the carriage
backward, use a hex key to turn the
auxiliary pressure adjusting screw to
obtain a pressure of 2000 psi
(13,790 kPa).
9. Tighten the lock nut on the aux pressure
relief valve. Remove the pressure gauge
from the auxiliary pressure test port and
replace the cap.
10. Reinstall the top cover.

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Hydraulic Components Manifold, Main, Model 7600
Manifold, Main,
Model 7600
Figure 7-117. Main Manifold, Model 7600
R1015351_B1a.cgm,R1015351_B1b.cgm
Hydraulic G2 port CYL-P SOL 1 POD-1 A1 A2

Filter Valve
S-RET
SOL 3
SOL 5
SOL 2 HTI G1 port P1 or CYL-1 CV-1 REL-2 LS-1

PMP-1

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Manifold, Main, Model 7620/7640 Hydraulic Components
Manifold, Main,
Model 7620/7640
Figure 7-118. Main Manifold, Model 7620/7640
44947_B1.cgm,1044947_B2.cgm
Hydraulic G2 port POD-1 CYL-P SOL 1 POD-1 A1 A2

Filter Valve Valve
Hydraulic
Filter
S-RET
TANK
SOL 5
SOL 2 SOL 3 HTI G1 port P1 or CYL-1 CV-1 REL-2 LS-1

PMP-1

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Hydraulic Components Manifold, Auxiliary (Standard Reach)
Manifold, Auxiliary
(Standard Reach)
Figure 7-119. Manifold, Aux (Standard Reach), with Reach, Tilt, Sideshift
R1015154_A1.cgm,R1015154_A2.cgm
Sideshift
Solenoid
Tilt
Solenoid
RV1
Reach
Solenoid
Tilt
Sideshift Solenoid
Solenoid
A1
A2
SSL TR

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Manifold, Auxiliary (Standard Reach) Hydraulic Components
Removal 5. Connect reach cylinder to inner scissor.

Apply thread-locking compound
1. Reach (extend) the fork carriage fully. (P/N 1013829) to threads of cylinder pin
2. Block the scissor assembly so that the screws.
scissors cannot retract. 6. Install mast guard.
3. Turn the key switch OFF and disconnect 7. Reconnect the battery connector and turn
the battery connector. the key switch ON. Remove the carriage
4. Remove auxiliary carriage cover. blocking.
Disconnect solenoid wires. Label as 8. Lower the carriage completely.
needed for correct re-connection.
5. Reconnect the battery connector and turn the battery connector.
the key switch ON.
10. Connect the solenoid coil wires and attach
6. Elevate the carriage approximately 2.5 ft. the manifold cover to the carriage.
(0.75 m).
7. Block the carriage so it cannot lower. the key switch ON.
8. Tilt forks completely down. 12. Bleed the hydraulic system as necessary.
9. Turn the key switch OFF and disconnect See “Hydraulic System Bleeding” on
the battery connector. page 7-74.
10. Remove mast guard. 13. Test auxiliary functions for correct
operation. Check the manifold connections
11. Disconnect the reach cylinder at the inner
for leaks.
scissor to permit removal of the manifold.
12. Remove auxiliary manifold mounting
screws.
13. Disconnect and cap the auxiliary hoses
from the manifold. Label as needed for
correct re-connection.
14. Place manifold in a vice and remove the
solenoid coils and valves from the
manifold. Note the position of all the
fittings and remove them.
Installation
NOTE: For torque values, see Table 7-13 on
page 7-88.
1. Install all fittings in the new manifold in
the same orientation as they were in the
manifold removed.
2. Install and torque all valves and solenoid
coils.
3. Position the manifold and connect all
auxiliary hoses.
4. Mount auxiliary manifold to carriage.
(P/N 990-536) to mounting bolt threads.
Torque to 21 ft. lb. (29 Nm).

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®
Hydraulic Components Manifold, Reach (Deep-Reach )
Manifold, Reach
(Deep-Reach ®)
Figure 7-120. Manifold, Reach (Deep-Reach Carriage)
7R1020906_B1.cgm,R1020906_B2.cgm,R1020906_B3.cgm
Reach CB-1 CB-2 REL-3

Solenoid
RR
RC
CV-3
REL-3
Reach
Solenoid
RR
RC
CV-3

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®
Manifold, Reach (Deep-Reach ) Hydraulic Components
Removal 3. Clean the surface of the reach manifold to

avoid contamination.
1. Reach the carriage out and lower to the
4. Remove relief valve REL-3.
floor. Block the reach mechanism so that
the scissors cannot retract. 5. Remove counterbalance valve CB-1.
2. Turn the key switch OFF and disconnect 6. Removed the reach solenoid coil.
the battery connector. 7. Remove counterbalance valve CB-2, using
3. Remove the two manifold mounting bolts an offset 15/16 in. open-end wrench.
to gain access to all hydraulic fittings. 8. Install the new relief valve REL-3.
4. Label as required all the solenoid wires 9. Reinstall counterbalance valve CB-2.
and remove.
10. Install the new counterbalance valve CB-1.
5. Disconnect and cap all hydraulic hoses.
11. Reinstall the reach solenoid coil.
Note the location of each of the hoses.
12. Remove the blocking from the scissor
6. Remove the manifold from the truck.
mechanism.
Installation the key switch ON.
NOTE: For torque values, see Table 7-13 on 14. Bleed the auxiliary system by fully
page 7-88. extending the reach mechanism several
times. Hold over the relief until the system
times out if air remains present.
the same orientation that they were in the
manifold removed. 15. Test reach and retract functions for
correct operation.
2. Install and torque all valves and solenoid
coils.
3. Position the manifold and connect all the
hydraulic hoses.
4. Reconnect the solenoid wires.
5. Mount the manifold to the scissors.
the key switch ON.
7. Remove the blocking.
8. Bleed the hydraulic system. See
“Hydraulic System Bleeding” on page 7-74.
9. Test the auxiliary functions for correct
operation and check connections for leaks.
Reducing Carriage Drift

If carriage drifts, replace Counterbalance Valve
(CB-1) P/N 1020951/001 with 1020951/004,
and Relief Valve (REL-3) P/N 1007104/001 with
1009281/013.
1. Fully extend and block the scissor
mechanism.

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Hydraulic Components Manifold, Tilt/Sideshift (Deep-Reach )
Manifold, Tilt/Sideshift
(Deep-Reach ®)
Figure 7-121. Manifold, Tilt/Sideshift (Deep-Reach
Carriage)
R1014583_A1.cgm
Sideshift Tilt
Solenoid Solenoid
Refer to Parts Manual for “Tilt Only” Manifold
Removal 2. Install and torque all valves and solenoid

coils.
1. Reach the fork carriage out and fully lower
3. Mount the manifold to the carriage.
to the floor.
4. Connect the hydraulic hoses.
2. Tilt the forks fully down.
5. Connect the wiring to the solenoids.
the battery connector. 6. Reconnect the battery connector and turn
the key switch ON.
4. Disconnect the wiring for the solenoids.
7. Bleed the hydraulic system.
5. Disconnect and cap the hydraulic hoses.
Note the location of the hoses. 8. Test the auxiliary functions for correct
operation and the connections for leaks.
6. Remove the manifold from the truck.
7. Remove the solenoid valves from the
manifold.
8. Note the position of all fittings and remove
them from the manifold.
Installation
NOTE: For torque values, see Table 7-13 on
page 7-88.
the same orientation that they were in the
manifold removed.

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Manifold Solenoids, Fittings, and Attachments Hydraulic Components
Manifold Solenoids, Table 7-13.

Torques
Aux Manifold and Cylinder Attachment
Fittings, and
Solenoid/ Torque
Attachments Attachment/Fitting ft. lb. (Nm)
A1 & A2 (Standard Reach) 15 (20)

Table 7-12. Main Manifold Attachment Torques
20 (27) standard
Reach Valve 25 (34) Deep-Reach
Solenoid/ Torque coil nut: 5 (6.8)
Attachment/Fitting ft. lb. (Nm)
RC & RR 15 (20)
SOL1 Load Holding w/locking 50 (68)
tab coil nut: 5 (6.8) 20 (27)
Tilt Valve
coil nut: 5 (6.8)
95 (129)
SOL2 Lift/Lower
coil nut: 0.5 (0.7) TC & TR 15 (20)
SOL3 Proportional Main 25 (34) 20 (27)

Sideshift Valve
Relief/Dump coil nut: 5 (6.8) coil nut: 5 (6.8)
20 (27) SSR & SSL 15 (20)

SOL5B/5T Aux
coil nut: 5 (6.8)
Flow Limiter (7620/7640
85 (115)
A1 & A2 21 (28) Free Lift Cylinder)
CV-1 Check Valve 30 (41) Pump & Tank 15 (20)
CYL-1 55 (75) A1 & A2 (Deep-Reach) 15
CYL-P Pressure Transducer 12 (16) A1 & A2 (Deep-Reach Tilt or

15
Tilt/Sideshift)
Filter Plug 30 (41)
REL-3 Deep-Reach Relief n/a
G1 & G2 21 (28)
CV-3 Deep-Reach Check
HTI Pressure Switch 12 (16) 25 (34)
valve
LS-1 Load Shuttle 20 (27) CB-1 & CB-2 Deep-Reach
35 (47)
P1 55 (75) Counterbalance
POD-1 Priority on Demand 35 (47)
REL-2 Aux Relief 25 (34)
Return (Suction) to Pump 55 (75)
S-RET 21 (28)
TANK 55 (75)

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Hydraulic Components, Cylinder
Hydraulic Components, Cylinder


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Lift Cylinder, Free Lift, Remove/Install Hydraulic Components, Cylinder
Lift Cylinder, Free Lift, 12. Disconnect the hydraulic line at the
bottom of the cylinder. Plug and cap the
Remove/Install fittings to prevent contamination from
entering the system.
NOTE: Place a pan below the main frame to
Model 7600 catch any hydraulic fluid when the line
is disconnected.
Left Side Free Lift Cylinder
13. Position the carriage at an appropriate
height to allow removal of the cylinder.
Removal
1. Remove mast guard.
cylinder.
2. Elevate telescopics to access the
over-the-mast (OTM) hoses/cable clamp at Installation
the bottom of the free lift cylinder.
NOTE: The left side free lift cylinder contains a
3. Remove the clamp and the free lift cylinder flow limiter located in the manifold block
set screw at the bottom of the cylinder at the bottom of the cylinder. See “Flow
mounting bracket. Remove any cable ties Limiter, Free Lift” on page 7-116.
securing the hoses/cable to the cylinder.
1. Install the flow control, fitting, and feed
4. Fully lower the telescopics carefully so as
hose at the bottom of the cylinder.
not to damage the hoses and cable.
2. Position the cylinder into the truck.
5. Using a suitable lifting device, lift the
carriage to relieve the tension on the lift 3. Connect the hydraulic line at the bottom of
chains and hoses. the cylinder.
6. Turn the key switch OFF and disconnect 4. Lift the carriage assembly to provide slack
the battery connector. in the lift chains and hoses for assembly.
7. Remove the master link from the free lift 5. Apply thread-locking compound
chain at the free lift cylinder anchor bolt. (P/N 1013829) to the threads of the
mounting bolt and install the pulley
8. Drape the chain over the carriage
bracket assembly.
assembly.
6. Install the chain pulley and the free lift
9. Remove the chain pulley to access the
chain.
pulley bracket assembly mounting bolt.
Remove the pulley bracket assembly from 7. Install the OTM upper free lift cylinder
the piston and set to the side with the retainer, noting the marks made on the
hoses and cable in place. hoses/cable when removed.
10. Mark the OTM hoses and cable at the 8. Lower the carriage and remove the lifting
upper free lift cylinder retainer for the device.
correct stretch when re-assembled. 9. Reconnect the battery connector and turn
Remove the retainer. the key switch ON.
11. Using the lifting device, lift and block the 10. Carefully lift the telescopics to access the
carriage assembly to a height that permits bottom of the free lift cylinder.
access to the tubing at the bottom of the
11. Install the OTM hoses/cable clamp at the
cylinder.
bottom of the free lift cylinder. Make sure
NOTE: As the carriage is being lifted, feed the there is correct clearance between the
right side free lift chain towards the bracket, hoses/cable, and the front plate
operator compartment to avoid jamming of the tractor.
of the chain. 12. Bleed the hydraulic system. See

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Hydraulic Components, Cylinder Lift Cylinder, Free Lift, Remove/Install
13. Check the truck for leaks and correct Installation

operation. 1. Position the cylinder into the truck.
14. Install the mast guard. 2. Position and block carriage to permit
access to bottom of the cylinder.
Right Side Free Lift Cylinder 3. Install the set screw at the bottom of the
cylinder.
Removal
4. Connect the hydraulic line at the bottom of
1. Fully lower the forks to the floor. the cylinder.
2. Turn the key switch OFF and disconnect 5. Lift the carriage assembly to provide slack
the battery connector. to install the free lift chain.
3. Remove the mast guard. 6. Install the ring adapter. Apply
4. Using a suitable lifting device, lift the thread-locking compound (P/N 1013829)
carriage to relieve the tension on the lift to the mounting bolt threads and install
chain. the pulley bracket assembly to the piston.
5. Remove the master link from the free lift 7. Install the chain pulley and the free lift
chain at the free lift anchor bolt. chain.
6. Remove and drape the chain over the 8. Lower the carriage and remove the lifting
carriage assembly. device.
NOTE: Twist the pulley assembly to permit the 9. Reconnect the battery connector and turn
removal of the chain. the key switch ON.
7. Remove the chain pulley to access the 10. Bleed the hydraulic system. See
pulley bracket assembly mounting bolt. “Hydraulic System Bleeding” on page 7-74.
8. Remove the pulley bracket assembly and 11. Check the truck for leaks and correct
ring adapter. operation.
9. Using the lifting device, lift and block the 12. Install the mast guard.
carriage assembly to a height that permits
access to the bottom of the cylinder.
NOTE: As the carriage is being lifted, feed the
left side free lift chain toward the
operator compartment to avoid jamming
the chain.
10. Disconnect the hydraulic line at the
bottom of the cylinder. Plug and cap the
fitting to avoid contamination from
entering the system.
NOTE: Place a pan below the main frame to
catch any hydraulic fluid when the line
is disconnected.
11. Remove the set screw at the bottom of the
cylinder.
12. Position the carriage at an appropriate
height to permit removal of the cylinder.
cylinder.

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Lift Cylinder, Free Lift, Remove/Install Hydraulic Components, Cylinder
Model 7620/7640 4. Attach the cylinder retaining nylon nut

snug to the shoulder.
Left Side Free Lift Cylinder 5. Reattach the pulley bracket to the
cylinder.
Removal 6. Install the pulley, pin, and securing screw.
1. Elevate the fork carriage approx 4 in. 7. Using a new master link, install the free
(10 cm) above the floor. lift chain to the upper chain anchor.
2. Place hardwood blocks under the carriage. 8. Secure the hoses to the hose clamps with
3. Lower the carriage to slacken the chains. cable ties.
4. Request lower and collapse the free lift 9. Reattach the mast guard.
cylinder. This minimizes the amount of 10. Reconnect the battery connector and turn
hydraulic fluid in the cylinder. the key switch ON.
5. Turn the key switch OFF and disconnect 11. Elevate the fork carriage.
the battery connector. 12. Remove blocking.
6. Remove the mast guard. 13. Test lift and lower function for correct
7. Cut the cable ties on the hose clamps. operation. Check for hydraulic leaks.
8. Place a chalk witness mark on the hoses to
aid in reassembly. Right Side Free Lift Cylinder
9. Remove the hose retainer brackets near
the top of the cylinder. Removal
10. Disconnect the free lift chain at the 1. Remove the auxiliary manifold top cover
adjusting chain anchor and feed the chain on the carriage.
over the pulley. 2. Disconnect the over-the-mast (OTM) cable
11. Remove the pulley shaft securing screw, at terminal strip TS-2.
pin, and the pulley. 3. Elevate the fork carriage approximately
12. Remove the pulley bracket from the 4 in. (10 cm) above the floor.
cylinder. 4. Place hardwood blocks under the carriage.
13. Disconnect and cap/plug the hydraulic 5. Lower the carriage to slacken the chains.
line at the bottom of the cylinder.
6. Request lower and collapse the free lift
14. Remove the nut from the cylinder cylinder. This minimizes the amount of
retaining anchor at the inner telescopic hydraulic fluid in the cylinder.
crosstie.
15. Wrap a hoist strap securely around the the battery connector.
cylinder at the retaining bracket.
8. Loosen the U-clamp and feed the OTM
16. Using a hoist or other suitable lifting cable through.
device, carefully lift the cylinder out.
9. Cut the cable ties on the cable clamps.
Installation 10. Feed the OTM cable over the pulley.
1. Wrap a hoist strap securely around the 11. Disconnect the free lift chain at the
cylinder at the retaining bracket. adjusting chain anchor and feed the chain
over the pulley.
2. Using a hoist or other suitable lifting
device, carefully lower the cylinder onto 12. Remove the pulley shaft securing screw,
the two locating pins on the inner pin, and the pulley.
telescopic lower crosstie. 13. Remove the pulley bracket from the
3. Connect the hydraulic line. cylinder.

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Hydraulic Components, Cylinder Lift Cylinder, Free Lift, Remove/Install
14. Disconnect and cap/plug the hydraulic

line at the bottom of the cylinder.
15. Remove the nut from the cylinder
retaining anchor at the inner telescopic
crosstie.
16. Wrap a hoist strap securely around the
device, carefully lift the cylinder out.
Installation
1. Wrap a hoist strap securely around the
device, carefully lower the cylinder onto
the two locating pins on the inner
telescopic lower crosstie.
3. Connect the hydraulic line.
4. Attach the cylinder retaining nylon nut
snug to the shoulder.
5. Reattach the pulley bracket to the
cylinder.
6. Install the pulley, pin, and securing screw.
7. Using a new master link, install the free
lift chain to the upper chain anchor.
8. Route the OTM cable through the spring
tension bracket, over the pulley, and
through the U-clamp to terminal strip TS2
in the auxiliary manifold cover.
9. Hook the cable tensioner to the bracket.
10. Tighten the U-clamp.
11. Connect the OTM cable wires at terminal
strip TS2.
12. Reattach the auxiliary manifold top cover
on the carriage.
13. Secure the cable to the cable brackets with
cable ties.
14. Reattach the mast guard.
the key switch ON.
16. Elevate the fork carriage.
17. Remove blocking.
18. Test lift and lower function for correct
operation. Check for hydraulic leaks.

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Lift Cylinder, Free Lift, Exploded Parts Drawing Hydraulic Components, Cylinder
Lift Cylinder, Free Lift,

Exploded Parts Drawing
Model 7600, Staging
Figure 7-122. Free Lift Cylinder, Staging, Model 7600
1023208_G.cgm
Cap
O-Ring
Wiper
Spacer Ring
Seal
Spring
Ring Sleeve
Retaining Screw
Pressure Piston and Backup
Ring
Piston Rod
Retaining Screw
and Backup
Tube Ring
O-Ring
Piston Plug
Spring
Seal
Lowering Cushion Piston

Screw
Retainer Ring
Snap Ring
Cylinder Plug

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Hydraulic Components, Cylinder Lift Cylinder, Free Lift, Exploded Parts Drawing
Model 7620/7640, Staging

Figure 7-123. Free Lift Cylinder, Staging, Model 7620/7640
1048548_C.cgm
Tube
O-Ring
Seal Piston Plug
Piston Spring
Retainer Ring
Wiper
Snap Ring
Screw
O-Ring
Cap
Packing
Cap
Rod
Spring Retaining
Screw and
Sleeve
Backup
Ring
Pressure
Piston
Retaining
Screw and
Backup Ring

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Lift Cylinder, Free Lift, Seal Repacking Hydraulic Components, Cylinder
Lift Cylinder, Free Lift, zone stop screws and the bleeder screw
and lifting the cylinder with the use of a
Seal Repacking hoist.
10. On a clean work surface, remove the wiper
seal, packing seal, O-rings, and backup
Model 7600 ring from the gland. Note the position and
orientation of each when removing.
Refer to Figure 7-122.
11. Inspect the surfaces of the gland for any
scratches or damage. Remove minor
Disassembly imperfections using fine emery cloth.
There is a staging zone mechanism in the free 12. Clean the gland.
lift cylinders in addition to a cushion at the 13. Inspect the inside of the housing for
bottom of the cylinder. damage and clean as required.
1. Remove the mast guard.
2. Lower the carriage onto a suitable block Reassembly
and fully lower cylinder to relieve the 1. If the piston was removed, install the
tension on the hoses, cable, and free lift piston and the three staging zone
chains. mechanism stop screws that were removed
3. Turn the key switch OFF and disconnect in step 8 of the disassembly procedure.
the battery connector. 2. Lubricate the wiper seal, packing seal,
4. Remove the free lift chain master link at O-rings, and backup ring with new
the free lift cylinder anchor bolt and lay hydraulic fluid and install into their
the chain over the carriage. respective grooves on the gland. Make sure
that they are correctly positioned.
NOTE: Twist the right side pulley to remove the
chain from the pulley. 3. Install the pressure ring with the seal
towards the open end of the housing. See
5. Remove the chain pulley to access the Figure 7-124.
pulley bracket mounting bolt.
6. Remove the pulley bracket assembly. Set Figure 7-124. Pressure Ring Orientation
RPIN06005.jpg
the left side to one side keeping the hoses

and cable in place.
7. For 3 in. lowered height option, remove the
adapter ring.
8. If you are removing the piston, remove the
three staging zone mechanism stop screws
and the bleeder screw. It may be necessary
to loosen the upper OTM retainer to allow
the removal of the three stop screws.
NOTE: Mark the hoses and cable to make sure
the correct stretch when re-assembled.
9. Remove the snap ring and gland.
NOTE: When the snap ring is removed, a spring
behind the packing plug should push 4. Apply lubricant (P/N 990-652) to the
the gland out of the housing. outside surface of gland.
NOTE: If necessary, use the piston to extract
the gland by removing the three staging

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Hydraulic Components, Cylinder Lift Cylinder, Free Lift, Seal Repacking
5. Lubricate the piston rod with new 4. Disconnect the lift chain master link from
hydraulic fluid. Carefully slide the gland the chain anchor.
over it. 5. Secure the lift chain to the crosstie with a
6. Using the seal installation driver welding or sheet metal locking clamp. This
(P/N 401-000-051), push the gland into minimizes rethreading of chain later.
the housing and compress the spring. 6. Remove the nut from the tractor side of
7. Apply a film of lubricant (P/N 990-652) to the free lift cylinder mounting bracket.
the top of the gland and housing to 7. Remove the locking screw from the pulley
prevent moisture entry. shaft.
8. Install the snap ring inside the housing. 8. Drive out the pulley shaft.
Make sure that the snap ring is fully
seated in the groove. 9. Remove the pulley bracket.
9. Wipe away any excess hydraulic fluid. NOTE: With slack in hoses and cable, it is not
necessary to remove the hoses or cable.
10. Tighten the upper OTM retainer, if
previously loosened. 10. Using a 2 in. spanner wrench, remove the
11. For 3 in. lowered height option, install the end cap (gland).
adapter ring. 11. On a clean work surface, remove the wiper
12. Apply thread-locking compound seal, packing seal, and O-ring from the
(P/N 1013829) to the threads of the gland.
mounting bolt and install the pulley 12. Inspect the surfaces of the gland for any
bracket assembly. scratches or damage. Remove minor
13. Install the chain pulley and the free lift imperfections using fine emery cloth.
chain.
14. Reconnect the battery connector and turn Reassembly
the key switch ON. 1. Lubricate with new hydraulic fluid the
15. Remove the block from beneath the packing seal, wiper seal, and O-ring and
carriage. install into their respective grooves on the
16. Bleed the hydraulic system. See gland. Make sure that they are correctly
“Hydraulic System Bleeding”. seated within the grooves.
17. Check the truck for leaks and correct 2. Apply thread-locking compound
operation. (P/N 990-571) to the threads of the gland.
Do not apply compound to the first
18. Install the mast guard. threads to engage.
3. Lubricate the piston rod with new
Model 7620/7640 hydraulic fluid. Carefully slide the gland
over the piston rod.
4. Torque the gland to 200 ft. lb. (271 Nm).
Disassembly (P/N 990-571) to the threads of the
1. Elevate the carriage about 4 in. (10 cm) mounting bolt and install the pulley
and lower the carriage onto blocks to bracket assembly.
slacken the chains. 6. Install the pulley and pulley shaft on the
2. Turn the key switch OFF and disconnect bracket.
the battery connector. 7. Install the pulley shaft locking screw.
3. Collapse the cylinder. 8. Route the free lift chain over the pulley
and attach to the chain anchor with a
master link.

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Lift Cylinder, Free Lift, Seal Repacking Hydraulic Components, Cylinder

the key switch ON.
10. Slowly request lift, lift the carriage, remove
the blocking, and lower the carriage.
11. Bleed the cylinder as required. See
“Hydraulic System Bleeding”.
12. Test lift and lower functions. Check for
leaks.

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Hydraulic Components, Cylinder Lift Cylinder, Main, Remove/Install
Lift Cylinder, Main, 12. Place a jack beneath the tractor to slightly
spread the tractor and the attachment to
Remove/Install allow the removal of the connector.
13. Remove the connector.
Model 7600 cylinder from the truck.
Left Side Main Lift Cylinder Installation

Removal 1. Install the fitting and feed hose at the
bottom of the cylinder.
1. Remove mast guard, top cover, and left 2. Attach the mast guard bracket onto the
front cover. cylinder.
2. Remove the retainer bolt at the bottom of 3. Position the cylinder into the truck.
the cylinder.
4. Apply thread-locking primer
3. Place a block approx 18 in. long between (P/N 990-666) to both the right and left
the inner telescopic crosstie and the outer mast mounting bolt threads and the hole
telescopic crosstie. Place a block approx threads. Permit to dry for several minutes.
12 in. (305 mm) in length between the Apply thread-locking compound
outer telescopic crosstie and the main (P/N 990-544) to the threads of the mast
frame crosstie. mounting bolts. Install the mast connector
NOTE: This provides the necessary hose/cable and torque the bolts to 160/170 ft. lb.
slack and clearance to remove the (217/230 Nm).
cylinder. 5. Install the mast connector snap ring.
4. Fully lower the carriage. 6. Remove the jack.
5. Turn the key switch OFF and disconnect 7. Connect the feed hose at the bulkhead
the battery connector. fitting.
6. Remove the bolt, washer, and spacer at the 8. Attach the OTM hose/cable retainer
top of the piston. bracket to the cylinder.
7. Remove the cylinder mounting 9. Install the cylinder mounting L-bracket(s)
L-bracket(s). with sleeves and bolts. Do not tighten at
this time.
NOTE: Models with an OACH of 131 in.
(333 cm) and above have two brackets. 10. Reconnect the battery connector and turn
the key switch ON.
8. Remove the OTM hose/cable retainer
bracket from the cylinder. 11. Carefully rotate the lift knob to raise the
piston to the telescopic crosstie.
9. Place a pan below the tractor and
disconnect the cylinder feed hose at the 12. Install the bolt, washer, and spacer at the
tractor bulkhead fitting. crosstie to the top of the piston.
NOTE: The feed hose can remain connected to
(P/N 1013829) to the threads and tighten,
the bottom of the cylinder to assist in
leaving a 0.12 in. (3 mm) gap between the
removal.
head of the bolt and the washer.
10. From inside the battery compartment, 14. Tighten the cylinder mounting L-bracket
loosen the right side mast connector bolts to 55 ft. lb. (75 Nm).
mounting bolts.
15. Remove the blocks from the telescopics
11. Remove the left side mast bolts and the and the main frame.
mast connector snap ring.

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Lift Cylinder, Main, Remove/Install Hydraulic Components, Cylinder
16. Install the retainer bolt at the bottom of 11. Place a jack beneath the tractor to slightly
the cylinder. spread the tractor and attachment to allow
17. Bleed the hydraulic system. See the removal of the connector.
“Hydraulic System Bleeding” on page 7-74. 12. Remove the connector.
18. Check for leaks and correct operation. 13. Using a suitable lifting device, remove the
19. Install the mast guard, top cover, and left cylinder from the truck.
front cover.
Installation
Right Side Main Lift Cylinder NOTE: The right side main lift cylinder houses
a flow limiter located in the manifold
Removal block at the bottom of the cylinder. See
“Flow Limiter, Main Lift” on page 7-115.
1. Remove mast guard, top cover, and right
front cover. 1. Install the flow control, fitting, and feed
hose at the bottom of the cylinder.
2. Elevate telescopics and remove the
retainer bolt at bottom of cylinder. 2. Attach mast guard bracket to cylinder.
3. Place a block at least 12 in. (305 mm) in 3. Position the cylinder into the truck.
length between the main frame and the 4. Apply thread-locking primer
outer telescopic crosstie and fully lower (P/N 990-666) to mast mounting bolt
the carriage. threads and the hole threads. Permit to
dry for several minutes. Apply
NOTE: This length provides the clearance
required to remove the cylinder.
to the threads of the mast mounting bolts.
4. Fully lower the carriage. Install the mast connector and torque the
5. Turn the key switch OFF and disconnect bolts to 160/170 ft. lb. (217/230 Nm).
the battery connector. 5. Install the mast connector snap ring.
6. Remove the bolt, washer, and spacer at the 6. Remove the jack from the truck.
top of the piston and outer telescopic 7. Connect the feed hose at the tractor
crosstie. bulkhead fitting.
7. Remove the cylinder mounting 8. Install the cylinder mounting L-bracket(s)
L-bracket(s). with sleeves and bolts. Do not tighten at
NOTE: Models with an OACH of 131 in. this time.
(333 cm) and above have two upper 9. Install the retainer bolt at the bottom of
brackets. the cylinder.
8. Place a pan below the tractor. Disconnect 10. Reconnect the battery connector and turn
the cylinder feed hose at the tractor the key switch ON.
bulkhead. Plug and cap the fittings to 11. Carefully rotate the lift knob to raise the
prevent contamination from entering the piston to the telescopic crosstie.
system.
12. Install the bolt, washer, and spacer at the
NOTE: The feed hose can remain connected to crosstie to the top of the piston.
the cylinder to assist in removal of the
cylinder. NOTE: Install thread-locking compound
(P/N 1013829) to bolt threads and
9. From inside the battery compartment, tighten, leaving a 0.12 in. (3 mm) gap
loosen the left side mast bolts. between head of the bolt and washer.
10. Remove the right side mast bolts and the 13. Tighten the cylinder mounting L-bracket
mast connector snap ring. bolts to 55 ft. lb. (75 Nm).

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14. Remove the block from between the 10. Attach a hoist strap under the top crosstie
telescopic and the main frame. of the main frame and support the mast
15. Bleed the hydraulic system. See with a 3-ton hoist or other suitable lifting
“Hydraulic System Bleeding” on page 7-74. device.
16. Check the truck for leaks and correct 11. Place blocks snugly under the tractor near
operation. the mast. These blocks take the weight of
the tractor when the tractor is unbolted
17. Install the mast guard, top cover, and right from the mast.
front cover.
12. Working inside the battery compartment,
remove eight mast mounting bolts from
Model 7620/7640 the bottom of the tractor frame.
13. Working from the top of the tractor,
Left and Right Side Main Lift Cylinder remove two mast mounting bolts from
each side.
Removal
14. Remove the tractor to provide working
1. Turn the key switch OFF and disconnect space at the mast.
15. Wrap hoist straps around each baseleg
2. Remove the top cover. where they join the mast. Extend the hoist
3. Remove the mast guard. straps in the direction of the tractor and
attach to a 3-ton hoist or other suitable
4. Disconnect the auxiliary hydraulic hoses
lifting device.
at the main manifold. Cap hoses and plug
ports. 16. Keeping tension on the top of the mast,
carefully begin lifting at the baseleg straps.
5. Disconnect the over-the-mast electrical
The mast will tip forward toward the
cable at connector JPS3 near the main
carriage.
manifold.
17. Continue lowering the mast into jack
6. Remove the battery gate. Using a suitable
stands.
battery moving device, remove the battery.
18. Remove the main lift hose at the cylinder
7. Remove the battery connector mounting
manifold. Plug the fitting.
bracket (for access to the mast mounting
bolts). See Figure 7-125. 19. Remove the upper and lower cylinder
mounting bolts and sleeves at the main
Figure 7-125. Battery Connector and Mast Mounting Block frame crossties.
R1008505_B1.cgm
Figure 7-126. Cylinder Mounting Bolts, Model 7620/7640

DSCF1672BW.JPG
Battery
Connector
Mounting
Bracket
8. Remove the forks from the fork carriage.

9. Disconnect the main lift hoses at the
tractor bulkhead. Cap the hoses and plug
the fittings.

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Lift Cylinder, Main, Remove/Install Hydraulic Components, Cylinder
20. Extend the outer telescopic about 6 in. Attach a hoist strap under the top crosstie
(15 cm) to access the cylinder top of the main frame.
mounting bolt. 2. Wrap several turns of a hoist strap around
21. Remove the cylinder top mounting bolt. the lift cylinder at its midpoint.
22. Left-side only: Remove the two hose/cable 3. Using a hoist or other suitable lifting
retaining block assemblies. Do not device, carefully guide the cylinder into
disassemble the retainers, but remove the position via the bottom of the mast,
entire assembly by removing two engaging the cylinder mounting studs on
countersunk Allen head screws. the main frame crossties.
See Figure 7-127. 4. Install the cylinder top mounting bolt.
Figure 7-127. Hose/Cable Retainer Block Assemblies 5. Left-side only: Attach the two hose/cable
1066854_B2.cgm
retaining block assemblies, using two
countersunk Allen head screws for each.
6. Attach the main lift hose at the cylinder
manifold.
7. Install the upper and lower cylinder
mounting bolts and sleeves at the main
frame crossties. Torque bolts to 55 ft. lb.
(75 Nm).
8. Using a hoist of other suitable lifting
Hose/Cable device, carefully lift the mast by the hoist
Retaining strap at the top until the mast is erect.
Blocks
9. Move the tractor into location with the
mast. Support the tractor frame near the
mast with blocks to align the mast
mounting bolt holes.
10. Working inside the battery compartment,
install eight mast mounting bolts at the
bottom of the tractor frame. Apply
threading-locking compound
(P/N 990-669) and torque to 170 ft. lb.
(230 Nm).
23. Remove the set screw at the bottom of the 11. Working from the top of the tractor, install
cylinder. two mast mounting bolts on each side.
24. Wrap several turns of a hoist strap around Apply threading-locking compound
the lift cylinder at its midpoint. (P/N 990-669) and torque to 170 ft. lb.
(230 Nm).
device, carefully remove the cylinder via 12. Connect the main lift hoses at the tractor
the bottom of the mast. bulkhead.
13. Connect the auxiliary hydraulic hoses at
Installation the main manifold.
1. Support the mast securely on jack stands, 14. Connect the over-the-mast electrical cable
carriage side down. Wrap hoist straps at connector JPS3 near the main manifold.
around each baseleg where they join the 15. Attach the forks onto the fork carriage.
mast. Extend the hoist straps in the
direction of the tractor and attach to a 16. Attach the battery connector mounting
3-ton hoist or other suitable lifting device. bracket near the mast mounting bolts on
the right side.

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17. Using a suitable battery moving device,

install the battery. Install the battery gate.
18. Install the mast guard.
19. Install the top cover.
the key switch ON.
21. Test lift and lower functions for correct
operation. Check for hydraulic fluid leaks.

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Lift Cylinder, Main Lift, Exploded Parts Drawing Hydraulic Components, Cylinder
Lift Cylinder, Main Lift,

Exploded Parts Drawing
Model 7600
Figure 7-128. Main Lift Cylinder, Model 7600
1024919_E1.CGM
Snap Ring
Cap Screw
Retaining
Ring

Spring
Seal
Piston Rod
Square Seal
Wiper Seal
Gland
Piston Seal

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Hydraulic Components, Cylinder Lift Cylinder, Main Lift, Exploded Parts Drawing
Model 7620/7640
Figure 7-129. Main Lift Cylinder, Model 7620/7640
1054090_B.CGM
Snap Ring
Cap Screw
Seal Retaining
Ring
Piston Rod
Spring
Square Seal
Wiper Seal
Piston Seal
Gland

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Lift Cylinder, Main, Seal Repacking Hydraulic Components, Cylinder
Lift Cylinder, Main, Seal 3. Lubricate the piston rod with new
hydraulic fluid and carefully install the
Repacking gland.
Model 7600 the key switch ON.
Refer to Figure 7-128. 6. Carefully rotate the lift knob to raise the
Disassembly 7. Install the bolt, washer, and spacer at the
crosstie to the top of the piston.
1. Slightly elevate the mast and place a block
between the outer telescopic crosstie and NOTE: Apply thread-locking compound
the main frame. (P/N 1013829) to the threads of the bolt
and tighten, leaving a 0.12 in. (3 mm)
2. Fully lower the carriage.
gap between the head of the bolt and the
3. Turn the key switch OFF and disconnect washer.
8. Remove the block from between the outer
4. Remove the bolt, washer, and spacer at the telescopic crosstie and the main frame.
top of the piston and the outer telescopic
crosstie.
5. Retract the piston into the housing enough 10. Check the truck for leaks and correct
to allow the removal of the end cap (gland). operation.
6. Using cylinder end cap tool

(P/N 1090761/007), remove the end cap Model 7620/7640
(gland).
7. On a clean working surface, remove the
packing seal, wiper seal, and square seal
from the end cap. Note position and Disassembly
orientation of each when removing. 1. Elevate the mast to produce a 6 to 8 in. (15
8. Inspect the surfaces of the gland for any to 20 cm) gap between the outer telescopic
scratches or damage. Remove minor crosstie and the main frame.
imperfections using fine emery cloth. 2. Block the mast between the inner and
9. Inspect the inside of the housing for outer telescopics and between the outer
damage and clean as required. telescopic and the main frame.
10. Clean the threads on the gland and the 3. Remove the cylinder mounting bolt at the
cylinder. top of the cylinder.
4. Collapse the cylinder (push on cylinder
Reassembly while requesting lower).
1. Lubricate with new hydraulic fluid, the 5. Turn the key switch OFF and disconnect
packing seal, wiper seal, and square seal the battery connector.
and install into their respective grooves on 6. Using a 2 in. spanner wrench, remove the
the gland. Make sure they are correctly end cap (gland).
seated within the grooves and are not
7. On a clean working surface, remove the
twisted.
packing seal, wiper seal, and O-ring from
2. Apply thread-locking compound the gland. Note position and orientation of
(P/N 990-571) to the last three threads of each when removing.
the gland.

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Hydraulic Components, Cylinder Lift Cylinder, Main, Seal Repacking
8. Inspect the surfaces of the gland for any

scratches or damage. Remove minor
imperfections using fine emery cloth.
9. Clean the threads on the gland and the
cylinder.
Reassembly
1. Lubricate with new hydraulic fluid, the
packing seal, wiper seal, and square seal,
and install into their respective grooves on
the end cap. Make sure they are correctly
seated within the grooves and are not
twisted.
(P/N 990-571) to the last three threads of
the gland.
3. Lubricate the piston rod with new
hydraulic fluid and carefully install the
gland.
the key switch ON.
6. Carefully rotate the lift knob to raise the
7. Install the bolt, washer, and spacer at the
crosstie to the top of the piston.
NOTE: Apply thread-locking compound
(P/N 1013829) to the threads of the bolt
and tighten, leaving a 0.12 in. (3 mm)
gap between the head of the bolt and the
washer.
8. Remove the blocking from between the
inner and outer telescopics and between
the outer telescopic and the main frame.
10. Check the lift truck for leaks and correct
operation.

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Lift Cylinder Lowering Cushion Hydraulic Components, Cylinder
Lift Cylinder Lowering 2. Lubricate the seal with clean hydraulic

fluid and install on the cushion. Install the
Cushion retainer ring on the cushion.
3. Insert and seat the cushion spring in the
center of the piston. Insert and seat the
Main Lift Cylinders cushion on the end of the cushion spring.
4. Compress the spring and hold it in place
For Model 7600, refer to Figure 7-128. For
with a drill bit or drift pin inserted in one
Models 7620/7640, refer to Figure 7-129.
of the hydraulic fluid ports in the cushion
housing.
Removal
5. Install the snap ring.
1. Remove the main lift cylinder. 6. Carefully release cushion pressure.
a. For Model 7600, refer to “Lift Cylinder, 7. Reassemble the cylinder. See “Lift
Main, Remove/Install”, “Model 7600”. Cylinder, Main, Seal Repacking”.
b. For Model 7620/7640, refer to “Lift 8. Install the cylinder.
Cylinder, Main, Remove/Install”,
a. For Model 7600, refer to “Lift Cylinder,
“Model 7620/7640”.
Main, Remove/Install”, “Model 7600”.
2. Remove the piston rod from the cylinder.
b. For Model 7620/7640, refer to “Lift
See “Lift Cylinder, Main, Seal Repacking”.
Cylinder, Main, Remove/Install”,
3. Place the piston rod on a clean padded “Model 7620/7640”.
working surface.
4. Compress the spring and hold it in place Free Lift Cylinders
of the hydraulic fluid ports in the cushion NOTE: For Model 7600, refer to Figure 7-122.
housing. For Model 7620/7640, refer to
Figure 7-123.
Removal
When the snap ring is removed, the
cushion spring ejects the cushion from
There is a staging zone mechanism in the free
the piston. Keep body away from the
lift cylinders in addition to a cushion at the
piston end when performing this
procedure.
1. Using an eye bolt and hoist, remove the
5. Remove the snap ring from inside of the piston rod from the cylinder.
cylinder. a. For Model 7600, perform steps 1 thru 9
6. Release the cushion slowly. of “Lift Cylinder, Free Lift, Seal
Repacking”, “Model 7600”,
7. Remove the ring retainer and seal from the
“Disassembly”.
cushion.
b. For Model 7620/7640, perform steps 1
8. Replace the cushion, spring, seal, and/or
thru 10 of “Lift Cylinder, Free Lift, Seal
retainer components as necessary. If
Repacking”, “Model 7620/7640”,
replacing the cushion, install the cap
“Disassembly”,
screw in the end of the cushion.
2. Place the piston rod on a clean padded
Reassembly working surface.
1. Lubricate the inside of the piston surface

with clean hydraulic fluid.

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Hydraulic Components, Cylinder Lift Cylinder Lowering Cushion
3. Compress the spring and hold it in place of the hydraulic fluid ports in the cushion
with a drill bit or drift pin inserted in one housing.
of the hydraulic fluid ports in the cushion 10. Install the snap ring in the cushion
housing. housing.
11. Release the cushion slowly.
12. Reassemble the cylinder.
When the snap ring is removed, the
a. For Model 7600, perform steps 2 thru
cushion spring ejects the cushion from
14 of “Lift Cylinder, Free Lift, Seal
the piston. Keep body away from the
Repacking”, “Model 7600”,
piston end when performing this
“Reassembly”.
procedure.
b. For Model 7620/7640, perform steps 3
4. Remove the snap ring from inside of the thru 12 of “Lift Cylinder, Free Lift, Seal
cylinder. Repacking”, “Model 7620/7640”,
5. Release the cushion slowly. “Reassembly”.
6. Remove the retaining ring and the two

O-rings on the inside and outside of the
ring.
7. Remove the spring and decel piston.
8. Remove the decel bearing and piston ring
from the decel piston.
9. Remove the spring and plug from the
cushion housing (piston plug).
10. Remove the O-ring from the plug.
Reassembly
1. Lubricate new O-rings, piston ring, and
decel bearing with clean hydraulic fluid.
2. Install the new piston ring and decel
bearing in the decel piston.
3. Lubricate the inside of the piston surface
with clean hydraulic fluid.
4. Install the new O-ring in the groove in the
plug and install the plug in the cushion
housing.
5. Seat the plug in the housing by inserting
the spring and the decel piston in the
cushion housing.
6. Install the other spring.
7. Install new O-rings on the inside and
outside of the retaining ring.
8. Install the retaining ring on the shaft of
the decel piston.
9. Compress the spring and hold it in place

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Reach Cylinder Hydraulic Components, Cylinder
Reach Cylinder 9. Clamp the rod at the wrench flats or clevis

in a soft-jawed vise. Loosen the retaining
nut on the piston assembly.
Reach Cylinder, Standard and 10. Slide the piston assembly off the end of the
Deep-Reach rod.
11. Slide the cushion sleeve off the rod. Note
Removal the direction of the taper.
12. Remove the head assembly.
13. Remove the head static seal O-rings,
2. Raise the carriage until the reach cylinder backup washers, rod inside diameter
is accessible from the operator’s dynamic seal, and the rod wiper. Use care
compartment. to avoid scratching the groove.
3. Fully retract the carriage. 14. Remove the O-ring and backup washers
4. Turn the key switch OFF and disconnect from the piston assembly.
5. Place a pan below the reach cylinder. Reassembly
6. Remove and cap the reach hoses at the
1. Remove any burrs or sharp edges caused
reach cylinder.
from disassembly before installing the new
7. Remove the screw and cotter pin holding seals.
the piston yoke in place.
2. Clean all parts with solvent. Lubricate
8. Remove the clevis pin and spacers. parts with petroleum jelly or clean
9. Remove the screw and cotter pin at the hydraulic fluid as indicated.
housing end. 3. Lubricate and install the new rod,
10. While supporting the cylinder, remove the dynamic seal, and rod wiper in their
clevis pin and spacers holding the cylinder respective inside grooves of the head
in place. assembly.
4. Lubricate and install the new head static
Disassembly seal O-rings and head static seal backup
washers on the outside grooves of the head
1. With the cylinder removed, drain all assembly.
hydraulic fluid from the cylinder assembly. 5. Lubricate the head assembly inside seals
2. Clamp the cylinder base end in a bench and carefully slide the head assembly onto
vise. Cover the ports with a clean rag. the rod assembly.
3. Remove the external lock ring.
4. Push the head assembly into the tube
assembly approximately 3/4 in. (19 mm).
5. Remove the spacer.
6. Remove the internal lock ring.
7. Important: Look for and remove any sharp
edges from the back corner of the internal
lock ring groove, if present.
8. Grip the rod firmly and pull the rod
assembly out of the tube assembly. (Oil
can spray out of the cylinder ports).

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Hydraulic Components, Cylinder Reach Cylinder
Figure 7-130. Reach Cylinder Installation
1. Place the spacers on the cylinder (hold
them in place with grease) and position the
cylinder housing into the yoke on the
carriage. Insert the clevis pin and secure
with the cotter pin and screw.
2. Place the spacers on the carriage bracket
(hold them in place with grease). Position
the piston yoke and insert the clevis pin.
Secure with the cotter pin and screw.
3. Reconnect the hydraulic hoses.
the key switch ON.
6. Adjust the reach cylinder. See
“Adjustment”.
7. Check the truck for leaks and correct
operation.
Adjustment
The top of the scissor roller must not protrude
6. Install the piston O-ring and backup more than 0.90 in. (22.8 mm) from the top of
washers in the outside groove of the piston the roller channel on the fork carriage. This
assembly. takes precedence over the extended dimension.
7. Slide the cushion sleeve onto the rod. Figure 7-131. Scissor Roller Dimension
rchadj1.jpg
NOTE: The taper on the cushion faces the head

assembly.
8. Carefully slide the piston assembly onto
the rod assembly. Install a new prevailing
torque nut and tighten.
9. Lubricate the piston and head assembly
and carefully slide it into the tube
assembly.
11. Install a new internal lock ring in the When the reach is fully extended, the
groove in the tube assembly bore. dimension from the front of the main frame to
12. Grip the rod firmly and pull outward until the face of the forks when level should be as
the head assembly is tight against the lock listed in Table 7-14.
ring.
13. Install the spacer and external lock ring in
the head assembly.

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Reach Cylinder Hydraulic Components, Cylinder
Table 7-14. Reach Dimension Table 7-15. Gap Dimension
Carriage Dimension Carriage Gap
R45TT 28.38 in. (720.00 mm) Standard Reach 0.125 to 0.250 in.
(3.2 to 6.4 mm)
DR32TT 53.40 in. (1356.4 mm)
Deep-Reach 0.125 to 0.375 in.
(3.2 to 9.5 mm)
Figure 7-132. Reach Fully Extended Dimension
rchadj2.jpg
Reach Scissor Roller Shimming
Make sure at least half of the thickness of the

scissor roller is running on the roll plate wear
bar. Shim as needed between the shoulder of
the scissor arm stud and the bearing inner
race. See Figure 7-133.
Figure 7-133. Reach Scissor Roller Bearing Shimming

RSB05013.jpg
NOTE: The face of the fork to the front of the

load wheel (or wheel box) should be a
minimum of 0.50 in. (13 mm). If not,
perform the adjustment procedure.
Adjustment Procedure Shim Here
1. Loosen the jam nut that holds the piston

to the yoke.
2. Turn the piston to obtain the correct
dimension.
(P/N 1013829) to the threads on the
piston and torque the jam nut to 175 ft. lb.
(237 Nm).
Retract Adjustment
Model 7600/7620/7640 lift trucks are designed

with reach and retract stops inside the reach
cylinder at both ends of the stroke. When the
scissors mechanism is fully retracted, there
should be a gap between the plastic block and
the metal block (Deep-Reach) or fixed carriage
(Standard Reach). This is a backup stop only.
Shim the plastic block to produce the gap listed
in Table 7-15.

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Hydraulic Components, Cylinder Tilt Cylinder
Tilt Cylinder Figure 7-134. Tilt Cylinder, Disassembly

cylassy.wmf
Head Static Seal

Backup Washer
Removal Internal Lock
Head Static Ring
1. Extend and block the scissor assembly so Seal O-ring
it cannot retract. Spacer
2. Position and block the carriage at a External Lock
comfortable working height. Ring
3. Spread the forks on the carriage to gain
complete access to the tilt cylinder. Rod Wiper
4. Tilt the forks completely up. Rod Wear
5. Turn the key switch OFF and disconnect Ring
the battery connector. Rod Dynamic
Tube Seal
6. Remove the snap rings from the tilt pin. Assembly
7. Place a block between the fork carriage Piston
and the carriage frame. Assembly
Head Assembly
8. Remove the tilt pin.
9. Place a pan below the tilt cylinder and
disconnect and cap the hydraulic hoses.
Note the orientation of the fittings and
position of the hoses.
10. Support the tilt cylinder and remove the
mounting bolts from the mounting blocks. Pin Hole
Base
End
Disassembly
Rod
With the cylinder removed, drain all hydraulic
fluid from the cylinder assembly. Clamp the
cylinder at the base end in a bench vise. Cover
the ports with a clean rag. Refer to Figure 7-134 Piston
Wear
for the following steps.
Ring
1. Remove the external lock ring.
2. Remove the spacer. Piston
3. Push the head assembly into the tube Seal
4. Remove the internal lock ring.
5. Important: Remove the sharp edge from the Rod Piston
O-ring
back corner of the internal lock ring
groove.
6. Grip the rod through the hole in the pin
and pull the rod assembly out of the tube 8. Loosen the piston assembly with a
assembly. spanner wrench. Unthread the piston
7. Clamp the rod in a bench vise at the pin assembly from the rod.
hole end. 9. Slide the head assembly off the rod from
the piston end.

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Tilt Cylinder Hydraulic Components, Cylinder
10. Clean the male threads of the rod. Remove 12. Grip the rod through the pin hole and pull
the rod piston O-ring. outward until the head assembly is tight
11. Remove the head static seal O-ring, against the lock ring.
backup washer, wear ring, rod dynamic 13. Install the spacer and external lock ring on
seal, and rod wiper. Use care to avoid the head assembly.
scratching grooves. 14. Stroke the cylinder rod back and forth by
12. Remove the wear ring and piston dynamic hand. It should move smoothly, without
seal from the piston assembly. Use care to binding or heavy drag.
avoid scratching grooves. 15. Install the cylinder assembly in the lift
13. Clean all parts in solvent. truck.
Reassembly Installation
1. Remove any burrs or sharp edges caused 1. Make sure the hydraulic fittings are in the
from disassembly before installing new same orientation on the cylinder as when
seals. removed.
2. Lubricate parts as indicated below with 2. Install the yokes on the cylinder and
petroleum jelly or clean hydraulic fluid. position the cylinder in place. Bolt the
3. Lubricate and install a new rod wear ring, yokes to the carriage.
rod dynamic seal, and rod wiper in their 3. Connect the hydraulic hoses noting their
respective inside grooves of the head correct orientation and position.
assembly. 4. Coat the tilt cylinder pin with all weather
4. Lubricate and install a new head static grease (P/N 1012992). Install the tilt
seal, O-ring, and head static seal backup cylinder pin and snap rings.
washer on the outside grooves of the head 5. Reconnect the battery connector and turn
assembly. the key switch ON.
5. Lubricate the head assembly inside seals 6. Remove the blocks.
with hydraulic fluid and carefully slide the
head assembly onto the rod assembly. 7. Check for clearance between the free lift
feed hose assembly, tilt hoses, and fittings
6. Install the piston wear ring and piston seal when the carriage is fully lowered and
in their respective outside grooves of the retracted.
piston assembly.
8. Check the tilt function for correct
7. Install the rod piston O-ring in the groove operation and leaks.
of the rod.
8. Apply red thread-locking compound “Hydraulic System Bleeding” on page 7-74.
(P/N 990-571) to the male threads of the
piston. Carefully thread the piston
assembly onto the rod assembly. Torque to
200 ft. lbs. (271 Nm).
9. Lubricate the piston and head assembly
with hydraulic fluid and carefully slide it
into the tube assembly.
11. Install a new internal lock ring in the
groove in the tube assembly bore.

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Hydraulic Components, Cylinder Flow Limiter, Main Lift
Flow Limiter, Main Lift Installation

1. Install the flow limiter. Make sure the
The main lift cylinder flow limiter restricts arrow points in the up direction.
lowering flow to 15 gpm (57 l per minute). These 2. Install the fitting in the manifold block.
flow limiters can be replaced without removing
the cylinder. 3. Reconnect the hose to the cylinder.
On Model 7600, a single main lift cylinder flow the key switch ON.
limiter is located in the manifold block at the 5. Bleed the hydraulic system. See
bottom of the right side main lift cylinder. “Hydraulic System Bleeding” on page 7-74.
On Models 7620 and 7640, there are two main 6. Check the truck for leaks and correct
lift cylinder flow limiters, one in the manifold operation.
block at the bottom of each main lift cylinder. 7. Install the top and front covers.
Removal
1. Fully lower the carriage to the floor.
3. Remove the top cover and front cover(s).
4. Place a pan below the baseleg at the
cylinder.
5. Disconnect and cap the hose at the bottom
of the cylinder.
6. Remove the fitting from the manifold
block.
7. Remove the flow limiter noting the
direction of the arrow.
Figure 7-135. Flow Limiter

mainlimiter.jpg

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Flow Limiter, Free Lift Hydraulic Components, Cylinder
Flow Limiter, Free Lift Figure 7-136. Free Lift Flow Limiter, Model 7600
Flow Limiter
On Model 7600, the free lift flow limiter is
located in the manifold block at the bottom of
the left side free lift cylinder.
On Models 7620 and 7640, the free lift flow

limiter is located inline between the free lift
cylinder and hydraulic line. The number and
location of flow limiter(s) may vary among
trucks.
Model 7600
Removal Installation
1. Install the flow limiter. Make sure the
2. Raise the telescopics until the bottom of arrow points in the down direction.
the left free lift cylinder is accessible from
2. Install the fitting in the manifold block.
the operator’s compartment.
3. Install the set screw at the bottom of the
3. Place a block of sufficient length
cylinder.
(approximately 24 in./610 mm) between
the outer telescopic crosstie and the main 4. Reconnect the hydraulic line at the bottom
frame to hold the position in step 2. of the cylinder.
4. Fully lower the carriage. 5. Reconnect the battery connector and turn
the key switch ON.
5. Extend the reach mechanism to allow
easier removal of the free lift lines and 6. Remove the block between the outer
fittings. telescopic and main frame.
6. Turn the key switch OFF and disconnect 7. Bleed the hydraulic system. See
the battery connector. “Hydraulic System Bleeding” on page 7-74.
7. Place a pan below the baseleg at the left 8. Check the truck for leaks and correct
free lift cylinder. operation.
8. From the operator’s compartment, remove 9. Install the mast guard.
and cap the hydraulic line at the bottom of
the free lift cylinder. See Figure 7-136. Model 7620/7640
9. Remove the set screw at the bottom of the
NOTE: The number and location of flow
free lift cylinder to permit the cylinder to
limiter(s) may vary among trucks.
rotate for the removal of the fitting.
10. Remove the fitting from the manifold
Removal
block.
11. Remove the flow limiter, noting the 1. Fully lower the mast.
direction of the arrow. 2. Turn the key switch OFF and disconnect
3. Using a suitable hoist, raise the carriage at
least 4 feet (1.2 m) and secure.
4. Place a shallow pan below the flow limiter.

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Hydraulic Components, Cylinder Flow Limiter, Free Lift
5. Disconnect and cap the hydraulic hose at

the bottom of the cylinder.
6. Remove the flow limiter from the cylinder,
noting the direction of the arrow.
Installation
1. Install the flow limiter in the cylinder.
Make sure the arrow points toward the
outside of the truck.
2. Reconnect the hydraulic hose at the
the key switch ON.
4. Using the hoist, lower the carriage
completely.
operation.
Figure 7-137. Free Lift Flow Limiter, Model 7620/7640

1067160_C1.cgm
Flow
Limiter

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Flow Limiter, Free Lift Hydraulic Components, Cylinder

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Mast, Chain, Hose, Cable
Mast, Chain, Hose, Cable


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Reach Carriage Bearings Mast, Chain, Hose, Cable
Reach Carriage Bearings 4. If the inner race of the bearing does not
protrude past the end of the shaft when
the bearing is fully seated, bend the flat
The upper reach carriage roller bearing is washer to contact the bearing so the
accessible when the carriage is elevated. The bearing does not walk on the shaft.
reach carriage must be removed to access the
5. Repeat steps 1 thru 4 for the five
middle and lower bearings. The bearings are
remaining bearings.
shimmed at the factory to a 0.00 ±0.010 overall
interference between the bearings and the inner 6. Clean and re-grease the telescopic
telescopic after the inner telescopic is shimmed channels.
and inserted in the outer telescopic. Inspect 7. Re-install the carriage. See “Carriage” on
bearings for damage or wear and replace as page 7-124.
required.
8. Test the reach/retract functions of the
carriage.
Removal
1. Remove the carriage. See “Carriage” on Adjustment
page 7-124.
2. Remove the socket head cap screw and Test reach carriage operation. If there is any
washer on the end of the bearing. kick or forks are not level, adjust eccentric pins
as necessary. Start with lower carriage roller
3. The bearing should slide off the shaft with bearing pins.
hand pressure. A suitable bearing puller
can be used if required.
Installation
Shim the top and middle bearings to obtain an
overall width equal to the minimum inner
telescopic dimension (±0.010 in. [.25 mm])
taken from the inside to inside of the I-beam
webs at the front flange of the inner telescopic.
Shim the bottom bearings to obtain an overall

width equal to the minimum inner telescopic
dimension (±0.010 in./0.25 mm) taken from the
inside to inside of the I-beam webs at the rear of
the inner telescopic.
If possible, maintain an equal amount of shim

thickness on each side of the carriage when
shimming the bearings.
1. Install or remove the required amount of
shims.
2. Install the bearing on the shaft.
(P/N 990-536) to the socket head cap
screw and fasten the screw and washer in
place.

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Mast, Chain, Hose, Cable Mast Shimming
Mast Shimming 8. Shim the outer telescopic upper bearing

set to 0.000 ±0.010 in. overall
interference with the inner telescopic after
Shimming a mast makes a smooth running unit the top main frame bearings have been
that is not too tight or too loose. If you find any correctly shimmed.
marks within the telescopics or main frame
9. Shim the inner telescopic lower bearing set
where the rollers have been running, remove
to 0.030 ±0.010 in. overall interference
them, using a sanding disc and 80 grit paper.
with the outer telescopic after the outer
Do not attempt to remove all marks, only the
telescopic lower bearings have been set.
ridges. Shim the bearings to the tightest spot on
the assembly (as the rollers run up and down 10. Install or remove the required amount of
the rail). Buff small areas that are slightly shims.
higher than the rest of the web to avoid 11. Install the bearing on the shaft.
shimming the major portion of the rail too loose.
The shims used under each roller bearing come
(P/N 990-536) to the socket head cap
in the following sizes: thin, medium and thick.
screw and fasten the screw and washer in
Although you can use different combinations of
place.
shims to obtain the correct adjustment, you
should try to maintain equal shim thickness on 13. If the inner race of the bearing does not
each side of the mast. protrude past the end of the bearing stud
when the bearing is fully seated, bend the
flat washer to contact the bearing to
Shimming Procedure prevent the bearing from walking on the
1. Elevate the mast to gain access to the stud shaft.
bearings.
Figure 7-138. Inner Race
2. Place a block between the outer telescopic mastbearshim1.jpg
crosstie and the main frame.

NOTE: When removing the upper bearings, use
caution not to let the bearing fall down
into the mast assembly. If the bearings
are worn or damaged, replace them.
5. Remove the bolt and roller stud sleeve
securing the roller bearing to the
respective mast or telescopic.
6. Remove the bearing.
NOTE: It may be necessary to drive a wedge 14. Install the bearing assembly into its
between the respective telescopics to respective mast or telescopic. Make sure
provide clearance for removal and that the flat spot of the bearing stud aligns
installation. with the welded stop on the mast or
telescopic.
7. Remove the socket head cap screw and
washer retaining the bearing on the stud. 15. Install the roller stud sleeve.
NOTE: Shim the main frame top bearing and 16. Apply thread-locking compound
the outer telescopic lower bearing set to (P/N 1013829) to the threads of the
a 0.030 ±0.010 in. overall interference. mounting bolt and torque to 260 ft. lb.
(352.5 Nm).

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Mast Shimming Mast, Chain, Hose, Cable

the key switch ON.
18. Remove the block from between the outer
telescopic and the main frame.
19. Test the operation of the elevating
assembly.

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Mast, Chain, Hose, Cable Bow Pads - Model 7600
Bow Pads - Model 7600 2. Examine each bow pad and measure its
thickness. If the thickness is <0.187 in.
(4.75 mm), replace the pad. Lower the
Inspection and Adjustment mast. Using a suitable feeler gauge, check
the clearance gap of the bow pads between
R45TT and DR32TT the inner telescopic and the outer
1. Elevate the mast to expose the bow pads telescopic. See Figure 7-140 and
mounted on the outside of the inner Figure 7-141.
telescopic. Pads are on the leading (forks
side) edge of the rail. See Figure 7-139. Figure 7-140. Inner Telescopic Bow Pads Model 7600
R45TT/DR32TT Mast
RPINRCH06R008_img002.jpg
Figure 7-139. Bow Pad Locations

1043120_C12.cgm,1043120_C13.cgm,1043786_A5.cgm
R45TT/DR32TT
Mast
Figure 7-141. Inner Telescopic Bow Pads

RPINRCH06R008_img006.jpg
3. Shim as required to obtain a gap of 0.03 to

0.09 in. (0.8 to 2.3 mm).
3 Bow Pads on each leading edge of

inner telescopic — total of 6 pads

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Carriage Mast, Chain, Hose, Cable
Carriage 14. Carefully lift the carriage assembly out of

the mast assembly.
NOTE: Twist the left side free lift pulley to allow
Model 7600 the carriage stop mounting block to
clear.
The carriage is removed through the top of the
mast.
Installation
1. Lower the carriage assembly into
telescopic.
A standard carriage without forks 2. Continue lowering carriage to an
weighs approximately 880 lbs. appropriate height and reconnect free lift
(363 kg). A Deep-Reach ® carriage chains to the anchors.
without forks weighs approximately 3. Connect the OTM hoses to the auxiliary
1100 lbs. (500 kg). manifold.
4. Remove the lifting device.
Removal
5. Connect the cable to TS2 at carriage and
1. Remove mast guard and top cover. JPS3 in tractor.
2. Remove forks. 6. Attach the manifold cover to the carriage.
3. Remove the mounting bolts from the Apply thread-locking compound
hose/cable guide and retainer at the back (P/N 1013829) to the mounting bolts and
of the carriage. torque to 30 ft. lb. (42 Nm).
4. Retract scissor assembly. 7. Mount the auxiliary manifold to the
carriage. Apply thread-locking compound
5. Disconnect the OTM cable at JPS3 in the
(P/N 990-536) to the mounting bolts and
tractor.
torque to 21 ft. lb. (29 Nm).
6. Remove the auxiliary manifold cover and
8. Extend the reach. Block the carriage at an
disconnect the over-the-mast (OTM) cable
appropriate height to relieve the tension
at TS2. Remove the auxiliary manifold
on the OTM hoses and cable to install the
mounting screws.
hose/cable guide retainer at the back of
7. Elevate the carriage to gain access from the carriage.
the operator’s compartment to the carriage
stops and the OTM hose fittings at the
(P/N 1013829) to the mounting bolts and
auxiliary manifold.
install the hose/cable guide retainer at the
8. Turn the key switch OFF and disconnect back of the carriage.
the battery.
10. Install the carriage stops.
9. Remove the OTM hoses from the carriage
11. Install the forks.
manifold. Cap hoses and plug the fittings.
12. Check the tension of the hoses, cable, and
10. Remove the carriage stops.
free lift chains. Adjust as required.
11. Using a suitable lifting device, lift the
carriage assembly to relieve the tension
from the free lift chains.
14. Check for leaks and test the truck for
12. Remove the master link from the free lift
correct operation.
chains at the free lift cylinder anchor
bolts. Twist the right side pulley to allow 15. Install the top cover and mast guard.
the removal of the chain.
13. Drape the chains over the carriage
assembly.

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Mast, Chain, Hose, Cable Carriage
Model 7620/7640 Figure 7-142. Model 7640 Auxiliary Hose CLamp

1051959_B3.cgm,1051959_B10.cgm
The carriage is removed from the top of the

mast.
A standard carriage without forks

weighs approximately 880 lbs.
(363 kg). A Deep-Reach ® carriage
without forks weighs approximately
1100 lbs. (500 kg).
Removal
1. Using a suitable work platform, remove
the carriage stops at the top of the inner
telescopic.
2. Remove the mast guard and top cover.
3. Remove the forks.
4. Elevate the carriage approximately 3 ft.
(1 m) for access to the auxiliary manifold.
5. Slightly extend the carriage. Attach hoist
straps at three points to keep the carriage
level.
Remove
6. Using a hoist or other suitable lifting these
device, lift the carriage slightly to slacken screws
the chains.
7. Remove the auxiliary manifold cover.
8. Disconnect the over-the-mast (OTM) cable
at terminal strip TS2, marking wires as
needed to aid in reconnection.
9. Loosen the auxiliary manifold mounting
bolts.
10. Remove the auxiliary hoses at the
auxiliary manifold, marking them if Do not
necessary for re-assembly. remove
these
11. Loosen and remove the auxiliary hose screws
clamp on the carriage. See Figure 7-142.
12. Loosen the U-clamp and feed the OTM
cable through.
13. Disconnect the OTM tensioning spring and
feed the cable through the bracket on the
free lift cylinder.
14. Remove the button head screw from both
chain anchor pin retainers. Remove the
pins to free the chains from the anchors.

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Carriage Mast, Chain, Hose, Cable
15. Using a hoist or other suitable lifting 8. Feed the over-the-mast cable through the
device, carefully lift the carriage out the U-clamp and tighten the U-clamp snug.
top of the mast. Do not overtighten.
NOTE: Observe the four kickback pads and 9. Connect the over-the-mast cable wires at
shims located between the carriage and terminal strip TS2.
the inner telescopic. They may fall out 10. Reinstall the auxiliary manifold cover.
as the carriage emerges from the mast.
11. Release hoist tension on the carriage.
Figure 7-143. Carriage Kickback Pads Remove hoist straps.
1036594_A.cgm
12. Reinstall the forks.

13. Reinstall the mast guard and top cover.
the key switch ON.
15. Test all carriage functions for correct
operation. Check for hydraulic leaks.
Kickback Pad and Shims

(both sides)
Installation
1. Make sure the free lift cylinder pulleys are
pivoted 90°.
2. Make sure the top carriage bearing
keepers are in place.
device, carefully lower the carriage into the
mast.
NOTE: Make sure the four kickback pads are in
place and shimmed snug to the mast as
the carriage is lowered into the mast. A
dab of grease will hold the pads and
shims in place while lowering.
4. Pivot the free lift cylinder pulleys fore-aft.
5. Reattach the auxiliary hose bracket.
6. Reconnect the auxiliary hoses to the
auxiliary manifold.
7. Tighten the auxiliary manifold mounting
bolts.

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Mast, Chain, Hose, Cable Chain Anchors
Chain Anchors Figure 7-145. Upper Main Lift Chain Anchor Removal,
Model 7600/7620
chain2.jpg
Main Lift Chain Anchors

Preparation for Removal - 7600 and
7620
1. Place a block between the outer telescopic
crosstie and the main frame crosstie and a
slightly longer block between the inner
telescopic crosstie and the outer telescopic
crosstie. This provides the required slack
in the chains. See Figure 7-144.
Figure 7-144. Blocking Telescopics

DSCF1361.JPG
2. Grasp the chain and remove the anchor

pin.
NOTE: You can remove the pin by using a slide
hammer or by using a large socket
(1 1/16 in.), a M8 x 50 mm bolt, and
washers to act as a pulling device.
See Figure 7-146.
Figure 7-146. Anchor Pin Removal, Model 7600/7620

chain3.jpg
Blocking
2. Lower the carriage and block at a height

that allows access to the lower chain
anchors at the bottom of the inner
telescopic. If only the upper anchors are
being removed, fully lower the carriage.
Upper Chain Anchor Removal - 7600

and 7620
1. Remove the chain anchor bolt and the
3. To hold the chain in position, attach a pair
anchor pin retainer. See Figure 7-145.
of locking pliers to the chain nearest the
chain sheave.
4. Remove the chain anchor from the lift
chain.
Upper Chain Anchor Removal - 7640


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Chain Anchors Mast, Chain, Hose, Cable
slightly longer block between the inner 5. Reconnect the battery connector and turn
telescopic crosstie and the outer telescopic the key switch ON.
crosstie. This provides the required slack 6. Remove the blocks from between the
in the chains. See Figure 7-144 on telescopic crossties.
page 7-127.
7. Adjust the lift chains until there is a
2. Turn the key switch OFF and disconnect 0.25 in. (6.4 mm) - Model 7600
the battery connector. 0.375 in. (9.5 mm) - Model 7620
3. Disconnect the lift chain master link from gap at the narrowest point between the
the chain anchor. inner and outer telescopics when the
4. Note the distance of the adjusting nut. carriage is fully lowered. Make sure there
This distance is used as a preliminary is equal tension on the lift chains after the
adjustment when re-installing. adjustment.
5. Remove the adjusting nut from the anchor. 8. Test the truck for correct operation.
6. Remove the chain anchor from the

telescopic. Upper Chain Anchor Installation -
7640
Figure 7-147. Upper Main Lift Chain Anchor, Model 7640
1051602_C2a.cgm 1. Install a new master link to the lift chain
anchor and secure with a new cotter pin.
2. Install the chain anchor into the chain
anchor block and thread the adjusting nut
on to the distance recorded earlier.
Master Link 3. Reconnect the battery connector and turn
Cotter Pin the key switch ON.
Chain Anchor
4. Remove the blocks from between the
Chain Anchor
telescopic crossties.
Block 5. Adjust the lift chains until there is a
0.5 in. (13 mm) gap at the narrowest point
Adjusting Nut between the inner and outer telescopics
when the carriage is fully lowered. Make
sure there is equal tension on the lift
Upper Chain Anchor Installation - chains after the adjustment.
7600 and 7620 6. Test the truck for correct operation.
1. Install the mast stop to the chain anchor.

Lower Chain Anchor Removal - 7600
2. Attach the chain anchor to the lift chain,
making sure that the two holes in the 1. Disconnect the lift chain master link from
anchor are facing towards the outside. the chain anchor at the bottom of the
3. Remove the locking pliers, position the inner telescopic.
chain anchor and install the anchor pin. 2. Note the distance of the adjusting nut.
You can install the chain anchor bolt This distance is used as a preliminary
temporarily to assist in the installation of adjustment when re-installing.
the pin. 3. Remove the cotter pin and chain anchor
4. Install the chain anchor pin retainer. adjusting nut.
Apply thread-locking compound 4. Remove the chain anchor from the
(P/N 1013829) to the threads of the telescopic.
anchor bolt and torque to 130 ft. lb.
(174 Nm).

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Figure 7-148. Lower Main Lift Chain Anchor, Model 7600 3. Remove the nut from the chain anchor
bolt.
chain1.jpg
4. Remove the chain anchor from the

telescopic by pulling the chain out at the
main lift pulley.
Master Link
5. Disconnect the lift chain master link from
Cotter the chain anchor.
Pin
Chain
Anchor
Lower Chain Anchor Removal - 7640
1. Attach a hoist strap around the top plate
Chain Anchor
of the inner telescopic.
Block 2. Using a suitable hoist, lift the inner
telescopic to slacken the chains.
Adjusting 3. Remove the lower bearings in the inner
Nut telescopic by removing the mounting bolts
for the bosses. See Figure 7-150.
Cotter Pin
4. Use a pry bar to increase the access space
between the inner and outer telescopics.
5. Disconnect the lift chain master link from
Lower Chain Anchor Removal - 7620 the chain anchor. Twist the chain if
necessary to reveal the master link.
1. Remove the anti-kickback pad and block
6. Unscrew the chain anchor from the chain
from the bottom of the inner telescopic.
anchor block.
See Figure 7-149.
Figure 7-150. Lower Main Lift Chain Anchor, Model 7460
Figure 7-149. Anti-Kickback Pad and Block, Model 7620 1051602_C8.cgm
Master Link
1051418_E8.cgm
Chain Anchor
Chain Anchor
Block
Bearing Boss
Bearing
Boss
Mounting
Bolt
Lower Chain Anchor Installation -

7600
Anti-Kickback Anti-Kickback
Pad Block 1. Reinstall the master link to the lift chain
and chain anchor.
2. Note the distance of the adjusting nut 2. Install the chain anchor into the chain
threads. This distance is used as a anchor block and thread the adjusting nut
preliminary adjustment when on to the distance recorded earlier. Install
re-installing.

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the cotter pin at the end of the chain thread-locking compound (P/N 1013829)
anchor. to the bosses and torque to 260 ft. lb.
3. Reconnect the battery connector and turn (353 Nm).
the key switch ON. 4. Lower the inner telescopic to slacken the
4. Remove the blocks from between the hoist strap. Remove the strap.
telescopic crossties. 5. Adjust the lift chains until there is a
5. Adjust the lift chains until there is a 0.5 in. (13 mm) gap at the narrowest point
0.25 in. (6.4 mm) gap at the narrowest between the inner and outer telescopics
point between the inner and outer when the carriage is fully lowered. Make
telescopics when the carriage is fully sure there is equal tension on the lift
lowered. Make sure there is equal tension chains after the adjustment.
on the lift chains after the adjustment. 6. Test the truck for correct operation.
6. Test the truck for correct operation.
Free Lift Chain Anchors
7620 Upper Chain Anchor Removal - 7600
1. Reinstall the master link to the lift chain 1. Elevate and block the carriage at a
and chain anchor. convenient working height.
2. Feed the lift chain over the main lift chain 2. Lower the carriage to relieve tension on the
pulley and down the telescopic. chains.
3. Install the chain anchor into the chain 3. Turn the key switch OFF and disconnect
anchor block and thread the adjusting nut the battery connector.
on to the distance recorded earlier. 4. Remove the mast guard.
4. Reinstall the anti-kickback pad and block 5. Left side only: Remove the hose/cable
at the bottom of the inner telescopic. retaining block.
5. Reconnect the battery connector and turn 6. Disconnect the lift chain master link from
the key switch ON. the chain anchor.
6. Remove the blocks from between the 7. Note the distance of the adjusting nut.
telescopic crossties. This distance is used as a preliminary
7. Adjust the lift chains until there is a adjustment when re-installing.
0.375 in. (9.5 mm) gap at the narrowest 8. Remove the nut from the chain anchor
point between the inner and outer bolt. Remove anchor from anchor block.
telescopics when the carriage is fully
lowered. Make sure there is equal tension Figure 7-151. Upper Free Lift Chain Anchor, Model 7600
on the lift chains after the adjustment. R1022604_A4.cgm
8. Test the truck for correct operation.
Lower Chain Anchor Installation - Master Link

7640
Chain Anchor
1. Thread the chain anchor into the chain
anchor block. Chain Anchor
2. Install a new master link to the lift chain Block
and chain anchor and secure with a new
cotter pin. Adjusting Nut
3. Reattach the lower bearing bosses and

bearings in the inner telescopic. Apply

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Upper Chain Anchor Removal - 7620 5. Test the truck for correct operation.
and 7640
Figure 7-152. Upper Free Lift Chain Anchor,
1. Elevate the carriage to a convenient Model 7620/7640
1067328_A.cgm
working height.
2. Lower the carriage onto blocks to slacken
the chains.
3. Turn the key switch OFF and disconnect Master Link
Chain Anchor
4. Disconnect the master link from the chain
anchor. Chain Anchor
5. Note the distance of the adjusting nut. Block
This distance is used as a preliminary
adjustment when re-installing. Adjusting Nut
6. Remove the chain anchor from the free lift
cylinder.
Upper Chain Anchor Installation - Lower Chain Anchor Removal - 7600

7600 NOTE: Model 7600 right side lower free lift
1. Insert the chain anchor in the chain chain anchors are welded to the
anchor block. carriage. Use the following procedure to
remove the left side chain anchor.
2. Install a new master link to the lift chain
anchor and secure with a new cotter pin. 1. Elevate and block the carriage at a
3. Thread the adjusting nut on the chain convenient working height.
anchor bolt to the distance recorded 2. Lower the carriage to relieve tension on the
earlier. chains.
4. Left side only: Reattach the hose/cable 3. Turn the key switch OFF and disconnect
retaining block. the battery connector.
5. Reinstall the mast guard. 4. Remove the mast guard.
6. Reconnect the battery connector and turn 5. Disconnect the lift chain master link from
the key switch ON. the chain anchor.
7. Remove blocking from carriage. 6. Unscrew the anchor from the anchor
8. Test the truck for correct operation. block.
Upper Chain Anchor Installation -

7620 and 7640
1. Install a new master link to the lift chain
anchor and secure with a new cotter pin.
2. Install the chain anchor into the chain
anchor block and thread the adjusting nut
the key switch ON.
4. Elevate the carriage, remove blocks, and
lower carriage completely.

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Figure 7-153. Lower Free Lift Chain Anchor, Model 7600
R1022604_A1.cgm
Master Link
Chain Anchor
Chain Anchor
Block

7600
1. Screw the chain anchor into the chain
anchor block.
2. Attach a new master link to the chain
anchor block and secure with a new cotter
pin.
3. Reinstall the mast guard.
the key switch ON.
5. Remove blocking from the carriage.
6. Test truck for correct operation.
Lower Chain Anchors - 7620 and

7640
Model 7620/7640 lower free lift chain anchors

are welded to the carriage.

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Mast, Chain, Hose, Cable Lift Chains
Lift Chains 3. Position the upper chain anchor and

install the anchor pin. You can install the
chain anchor bolt temporarily to assist in
Chains, Main Lift the installation of the pin.
4. Install the anchor pin retainer. Apply
Model 7600 thread-locking compound (P/N 1013829)
to the threads of the anchor bolt and
Removal torque to 130 ft. lb. (174 Nm).
1. Place a block between the outer telescopic 5. Attach the chain and the lower chain
crosstie and the main frame crosstie and a anchor, using a new master link and cotter
slightly longer block between the inner pin.
telescopic crosstie and the outer telescopic 6. Remove the blocks between the telescopics
crosstie. This provides the required slack and the main frame and fully lower the
in the chains for their removal. See forks to the floor.
Figure 7-144 on page 7-127. 7. Adjust the lift chains until there is a
2. Lower the carriage and block at a height 0.25 in. (6.4 mm) gap at the narrowest
that allows access to the chain anchor at point between the inner and outer
the bottom of the inner telescopic. telescopics when the carriage is fully
3. Turn the key switch OFF and disconnect lowered. Make sure there is equal tension
the battery connector. on the lift chains after the adjustment.
4. Disconnect the lift chain master link from 8. Lubricate the chains and test the truck
the lower chain anchor at bottom of inner operation.
telescopic.
5. Remove the chain anchor bolt and the Chain Sheave Alignment
anchor pin retainer. See Figure 7-146 on
page 7-127. If the main lift chain sheave becomes
misaligned so that the chain scrubs one side
6. Grasp the chain and remove the anchor wall of the sheave, install a new shaft with an
pin. eccentric bushing to correct the alignment.
NOTE: You can remove the pin by using a slide 1. Elevate and block the mast to provide
hammer or by using a large socket slack in the main lift chain.
(1 1/16 in.), an M8 x 50 mm bolt, and
1. Remove the chain anchor and chain from 3. Disconnect the main lift chain from the
the telescopic. inner telescopic chain anchor bolt.
2. Remove the master link between chain 4. Loosen the set screw and remove the
and chain anchor. pulley shaft.
Installation 5. Insert the new pulley shaft into position.

6. Insert the eccentric bushing. (Two
NOTE: Replace both chains when either is bad.
different bushings are available,
1. Attach the upper chain anchor to the new depending on the amount of eccentricity.)
chain using a new master link and cotter
pin.
2. Make sure the two holes in the upper
chain anchor are facing towards the
outside. Feed the chain from the outside to
the inside over the chain sheave.

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Lift Chains Mast, Chain, Hose, Cable
Figure 7-154. Eccentric Bushing for Main Lift Chain Sheave 3. Turn the key switch OFF and disconnect
RSBRCH07004A.jpg
4. Remove the anti-kickback pad and block

Eccentric
Bushing
See Figure 7-155.
Figure 7-155. Anti-Kickback Pad and Block, Model 7620

1051418_E8.CGM
Chain
Sheave
Shaft
7. Reconnect the lift chain to the chain

anchor block.
8. Remove the blocks to permit normal
operation of the mast.
9. Adjust the eccentric bushing with a
spanner wrench until the lift chain is
tracking parallel with the telescopic
profile.
10. Reconnect the battery connector and turn Anti-Kickback Anti-Kickback
the key switch ON. Pad Block
11. Cycle the telescopic several times to make
sure the lift chain is tracking correctly. 5. Note the distance of the adjusting nut
12. Prick punch the eccentric bushing threads. This distance is used as a
through the existing set screw hole. preliminary adjustment when
re-installing.
13. Drill a hole 0.13 in. deep on the prick
punch mark, using a 7/32 in. drill bit. 6. Remove the nut from the chain anchor
bolt.
14. Apply thread-locking compound to the
threads of the set screw and install the set 7. Remove the upper chain anchor bolt and
screw to lock the eccentric bushing in the anchor pin retainer. See Figure 7-156.
place.
Model 7620
Removal
slightly longer block between the inner
telescopic crosstie and the outer telescopic
crosstie. This provides the required slack
in the chains for their removal. See
Figure 7-144 on page 7-127.
2. Lower the carriage and block at a height
that allows access to the chain anchor at
the bottom of the inner telescopic.

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Figure 7-156. Upper Main Lift Chain Anchor Removal, 6. Install the chain anchor into the chain
Model 7620 anchor block and thread the adjusting nut
1051418_E5.cgm

7. Reinstall the anti-kickback pad and block
at the bottom of the inner telescopic.
8. Remove the blocks between the telescopics
and the main frame and fully lower the
forks to the floor.
9. Adjust the lift chains until there is a
0.375 in. (9.5 mm) gap at the narrowest
point between the inner and outer
telescopics when the carriage is fully
Pin lowered. Make sure there is equal tension
on the lift chains after the adjustment.
Anchor
Pin 10. Lubricate the chains and test the truck
Block
Retainer operation.
Bolt
Model 7640
8. Grasp the chain and remove the anchor
pin. See Figure 7-146. Removal
NOTE: You can remove the pin by using a slide 1. Attach a hoist strap around the top plate
hammer or by using a large socket of the inner telescopic.
(1 1/16 in.), an M8 x 50 mm bolt, and 2. Using a suitable hoist, lift the inner
washers to act as a pulling device. telescopic to slacken the chains.
9. Remove the chain anchors and chain from 3. Remove the lower bearings in the inner
the telescopic. telescopic by removing the mounting bolts
10. Disconnect the master links between for the bosses.
chain and chain anchors. 4. Use a pry bar to increase the access space
between the inner and outer telescopics.
Installation 5. Remove the cotter pin and disconnect the
NOTE: Replace both chains when either is bad. lift chain master link from the lower chain
anchor. Twist the chain if necessary to
1. Attach the chain anchors to the new chain reveal the master link.
using new master links and cotter pins.
6. Remove the cotter pin and disconnect the
2. Make sure the two holes in the upper lift chain master link from the upper chain
chain anchor are facing towards the anchor.
outside. Feed the chain from the outside to
the inside over the chain sheave. Installation
3. Position the upper chain anchor and 1. Connect the chain to the upper chain
install the anchor pin. You can install the anchor with a new master link and new
chain anchor bolt temporarily to assist in cotter pin.
the installation of the pin.
2. Route the chain over the main lift chain
4. Install the anchor pin retainer. Apply pulley and between the inner and outer
thread-locking compound (P/N 1013829) telescopics.
to the threads of the anchor bolt and
torque to 130 ft. lb. (174 Nm). 3. Connect the chain to the lower chain
anchor with a new master link and new
5. Feed the lift chain over the main lift chain cotter pin.
pulley and down the telescopic.

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Lift Chains Mast, Chain, Hose, Cable
4. Reattach the lower bearing bosses and 6. Remove the master links at the carriage
bearings in the inner telescopic. Torque to chain anchors.
130 ft. lb. (176 Nm). a. Model 7600: The right side requires the
5. Lower the inner telescopic to slacken the removal of a retainer tab and pin rather
hoist strap. Remove the strap. than a cotter pin. See Figure 7-157.
6. Adjust the lift chains until there is a b. Model 7620/7640: Both sides require
0.5 in. (12.7 mm) gap at the narrowest the removal of a retainer tab and pin
point between the inner and outer rather than a cotter pin. See
telescopics when the carriage is fully Figure 7-157.
lowered. Make sure there is equal tension
on the lift chains after the adjustment. Figure 7-158. Retainer Tab (right side)
flchain2.jpg
7. Lubricate the chains and test the truck

operation.
Chains, Free Lift

Removal
1. For easy access to the lift chain master
links at the carriage anchor blocks, elevate
the carriage to a convenient working
height. Using a suitable hoist or stand,
secure the carriage at this height. See
Figure 7-157.
Figure 7-157. Carriage Chain Anchor

flchain1.jpg
7. Remove the chains.
Installation
1. Position the chain over the pulley and
fasten the chain to the carriage anchor
with a new master link.
a. Model 7600: Secure the left side with a
cotter pin and the right side with the
pin and retainer tab, applying
thread-locking compound
(P/N 1013829) to the threads of the
retainer screw.
b. Model 7620/7640: Secure both sides
with the pin and retainer tab, applying
2. Activate “lower” to relieve the tension on thread-locking compound
the free lift chains. (P/N 1013829) to the threads of the
3. Turn the key switch OFF and disconnect retainer screw.
the battery connector. 2. Fasten the chain to the adjustable chain
4. Remove the mast guard. anchor with a new master link and secure
with a new cotter pin.
5. Remove the master links at the adjustable
chain anchors. NOTE: Bend the ends of the cotter pins over 90°
after installation.

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3. Reinstall the mast guard.

the key switch ON.
5. Slowly raise the carriage, using the lift
button to place the weight of the carriage
on the free lift chains.
6. Remove the hoist.
8. With the reach mechanism retracted, forks
level with the floor and the key switch
OFF, adjust the anchor nuts equally until
the forks are approx 3 in. (76 mm) off the
floor (or just touching the floor with the
floor lower height option). Make sure there
is equal pressure on the chains when the
carriage is fully lowered.

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Height Encoder Belt Mast, Chain, Hose, Cable
Height Encoder Belt Figure 7-160. Height Encoder Assembly, 7620

7620HTEncoderAssy.jpg
Do
DoNot
NotRemove
RemoveThese
These Screws
Screws
Model 7620
Removal
1. Lift and block the mast high enough to
access the belt and its mounting eye.
NOTE: The tensioning spring is at the bottom of
the belt, hooked to a bracket.
the battery connector. Remove These Screws
3. Access the height encoder assembly.
4. Remove the old belt. Make sure you
a. If there is an access plate secured by retrieve the tension spring through the
diagonally opposed nuts, remove the access hole at the bottom of the outer
nuts. Do not remove the bottom telescopic.
button-head screws. See Figure 7-159.
Installation
Figure 7-159. Height Encoder Assembly, 7620
1. Using cable ties, make a 1 in. (25 mm) loop

Remove These Nuts in the bottom of the new encoder belt and
attach it to the tension spring.
2. Attach a small weight on the tension
Access spring. Drop the weighted spring down the
Plate mast channel. Clamp the belt at the top so
it does not fall completely down into the
channel.
3. Access the spring through the hole at the
bottom of the mast channel, attach the
spring to the bracket. See Figure 7-161.
Do Not Remove These Screws
Figure 7-161. Height Encoder Belt Tension Spring, 7620
1051604_D5.cgm
b. If there is no access plate, remove the

bottom two button-head screws. Do not
remove the diagonally opposed screws,
as they hold the encoder assembly
together. See Figure 7-160.

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Mast, Chain, Hose, Cable Height Encoder Belt
4. Thread the belt through the encoder Figure 7-163. Height Encoder Belt and Mast Bearing, 7620
assembly, making sure it is routed
7620HTEncodeMastBearing.jpg
correctly around the toothed gear and Belt

idler. See Figure 7-162.
Figure 7-162. Height Encoder Belt Routing, 7620

1051604_D4.cgm
Mast Bearing
Belt
Idler
9. With the belt snug around the hook eye,

trim the belt 1 in. (25 mm) longer. Attach
two cable ties loosely to form a loop of the
belt around the hook eye. With the belt
snug, pull the belt approx. 0.5 in. (13 mm)
Toothed Gear tighter to apply tension to the spring, and
tighten the cable ties. Trim any excess belt
at the loop. See Figure 7-164.
Encoder Assembly
Mounting Screws Figure 7-164. Height Encoder Belt, Top, 7620
1051604_D6.cgm
5. Attach the top end of the belt to a stiff wire

and feed the belt up through the encoder
assembly hole.
6. Loop the belt around the eye at the top of
the mast and clamp it temporarily in Hook Eye
place.
7. Secure the height encoder assembly.
a. If there is an access plate, install the Add Cable
access plate with the nylon locking Ties Here
nuts. See Figure 7-159.
b. If there is no access plate, fit the
encoder assembly back into the mast
channel. Keep slight tension on the belt Belt
and make sure the belt wraps correctly
around the gear and idler. Secure the
encoder assembly with mounting
screws. See Figure 7-160.
8. Make sure the belt feeds past the mast 10. Reconnect the battery connector and turn
bearing without becoming entangled in the the key switch ON.
bearing. See Figure 7-163.
11. Elevate the mast, remove the blocking. Lift
and lower the carriage to test correct
operation.

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Height Encoder Belt Mast, Chain, Hose, Cable
Model 7640 Figure 7-166. Height Encoder Assembly, 7640

Remove These Screws

Removal
1. Lift and block the mast high enough to
access the belt and its mounting eye.
NOTE: The tensioning spring is at the top of the
belt, hooked to a bracket.
3. Access the height encoder assembly.
a. If there is an access plate secured by Do Not Remove These Screws
diagonally opposed nuts, remove the
nuts. Do not remove the top 4. Remove the old belt. Make sure you
button-head screws. See Figure 7-165. retrieve all the broken pieces. There is an
access hole at the bottom of the outer
Figure 7-165. Height Encoder Assembly, 7640 telescopic.
Do Not Remove These Screws

Installation
1. Attach a small weight to the belt. Drop the
weighted belt down the mast channel.
Clamp the belt at the top so it does not fall
Access
Plate completely down into the channel.
2. Accessing the bracket through the hole at
the bottom of the mast channel, loop the
belt through the bracket to form a 1 in. (25
mm) loop. Secure the loop with cable ties.
See Figure 7-167.
Remove These Nuts
Figure 7-167. Height Encoder Belt Tension Spring, 7640
b. If there is no access plate, remove the 1051610_C4.cgm
top two button-head screws. Do not

Belt Access Hole
remove the diagonally opposed screws,
as they hold the encoder assembly
together. See Figure 7-166. Add Cable
Ties Here
Bracket

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Mast, Chain, Hose, Cable Height Encoder Belt
3. Thread the belt through the encoder 7. With the belt snug around the hook eye,
assembly, making sure it is routed trim the belt 1 in. (25 mm) longer. Attach
correctly around the toothed gear and two cable ties loosely to form a loop of the
idler. See Figure 7-168. belt around the hook eye. With the belt
snug, pull the belt approx 0.5 in. (12 mm)
Figure 7-168. Height Encoder Belt Routing, 7640 tighter to apply tension to the spring, and
1051610_C2.cgm
tighten the cable ties. Trim any excess belt

Encoder Assembly at the loop. See Figure 7-169.
Mounting Screws
Figure 7-169. Height Encoder Belt, Top, 7620
1051604_D6.cgm
Idler
Hook Eye
Add Cable
Belt Ties Here
Toothed Gear
Belt
4. Attach the top end of the belt to a stiff wire
and feed the belt up through the encoder
assembly hole.
5. Loop the belt around the eye at the top of
the mast and clamp it temporarily in 8. Reconnect the battery connector and turn
place. the key switch ON.
6. Secure the height encoder assembly. 9. Elevate the mast, remove the blocking. Lift
and lower the carriage to test correct
a. If there is an access plate, install the operation.
access plate with the nylon locking
nuts. See Figure 7-165.
b. If there is no access plate, fit the
encoder assembly back into the mast
channel. Keep slight tension on the belt
and make sure the belt wraps correctly
around the gear and idler. Secure the
encoder assembly with mounting
screws. See Figure 7-166.

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Hose, Main Lift Mast, Chain, Hose, Cable
Hose, Main Lift 8. Install the top cover and the right and left
front cover.
Removal
1. Fully lower forks to the floor.
3. Remove the battery from the truck to
access the display and Lift Motor
mounting bracket bolts.
4. Remove the top cover and the front left
and right covers.
5. Remove the 4 mounting bolts from both
the display bracket and the Lift Motor
mounting bracket to gain access to the lift
hose.
6. If applicable, remove the lift amp/shroud
assembly as one unit. It is retained by four
bolts on the mast side of the front tractor
plate.
7. Disconnect and cap the main lift cylinder
feed hoses at the front tractor plate.
NOTE: Place a small container below the
fittings to allow the main lift hose to
drain.
8. Disconnect the lift hose from the main
manifold and remove from the truck.
Installation
1. Position the lift hose in the truck.
2. Connect the fittings at the manifold and
the main lift cylinder feed hoses.
3. If applicable, reinstall the lift amp/shroud
assembly. See “Component Specific
Service/Torque Chart” on page A-4.
4. Position and reinstall the display and Lift
Motor mounting bracket bolts. See
“Component Specific Service/Torque
Chart” on page A-4.
the key switch ON.
operation.

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Mast, Chain, Hose, Cable Hose and Cable, Over-the-Mast
Hose and Cable, Figure 7-171. Over-the-Mast Hose/Cable, view from forks
R1018766_C03.cgm
Over-the-Mast
Figure 7-170. Over-the-Mast Hose/Cable, view from tractor
R1018766_C1.cgm
Main Lift
Cylinder
Hose/Cable
Retainer Upper Free Lift
Cylinder
Hose/Cable
Retainer
Carriage
Hose/Cable
Retainer
Lower Free Lift

Cylinder
Hose/Cable
Retainer
NOTE: For replacement of the over-the-mast

electrical cable only, see “Cable,
Over-the-Mast” on page 7-149.

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Hose and Cable, Over-the-Mast Mast, Chain, Hose, Cable
Removal NOTE: There may be shims between the

manifold and carriage.
1. Remove top cover, left front cover, and
mast guard. 7. Disconnect and plug/cap the
over-the-mast hoses and fittings at the
2. Lower carriage to floor and block scissor auxiliary manifold.
Figure 7-172. Blocking Scissor Assembly the key switch ON.
OTM_1.jpg
9. Elevate and block carriage at an

appropriate height to access the
hose/cable retainer and guide at the back
of the carriage from the tractor side.
11. Remove hose/cable retaining block from
back of carriage. See Figure 7-174.
Figure 7-174. Hose/Cable Retainer on Carriage

OTM_2.jpg

4. Disconnect the over-the-mast cable at
connector JPS3 in tractor.
5. Remove auxiliary manifold cover from
carriage and disconnect the over-the-mast
cable at terminal strip TS2.
See Figure 7-173.
Figure 7-173. Auxiliary Manifold access

DSC_0942a.jpg
12. Feed hoses and cable through guide at

back of carriage.
13. Feed hoses and cable through pulley
bracket at top of free lift cylinder.
14. Remove upper hose/cable retainer from
free lift cylinder. See Figure 7-171 on
page 7-143.
the key switch ON.
16. Carefully elevate the telescopics high
enough to access the lower retainer on free
lift cylinder and the retainer on the
telescopic from the tractor side. Place a
6. Remove auxiliary manifold mounting hardwood block of sufficient length
screws to permit access to the between the outer and inner telescopics.
over-the-mast hose fittings at the This removes tension from the
manifold. over-the-mast hoses and the lift hose and
makes the removal and installation of the

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retainers easier. Carefully lower the mast Figure 7-176. Positioning hose retainer
until you have the desired tension. See
OTM_4.JPG
Figure 7-175.
Figure 7-175. Blocking telescopics

OTM_3.JPG
NOTE: Over-the-mast hose lengths on

Model 7600 lift trucks are equal.
Reference Figure 7-200 on page 7-161
for correct hose/cable routing.
the battery connector. 1. While observing correct routing, connect
hoses to auxiliary manifold at carriage and
18. Remove the lower free lift cylinder
the cable to terminal strip TS2.
hose/cable retainer and the hose/cable
retainer from the bottom of the inner 2. Mount auxiliary manifold to carriage.
telescopic. Apply thread-locking compound
(P/N 990-536) to mounting bolt threads
19. Feed hoses and cable through pulley at
and torque to 21 ft. lb. (29 Nm).
top of inner telescopic.
20. Remove hose/cable retainer at left main
the key switch ON.
lift cylinder.
4. Carefully elevate and block carriage high
enough to access the hose/cable retainer
the key switch ON.
and guide at the back of the carriage.
22. Carefully elevate telescopics and remove
blocking.
23. Fully lower mast and carriage.
6. Feed hoses and cable through guide and
24. Turn the key switch OFF and disconnect retainer.
7. Remove slack from hoses and cable
25. Disconnect and plug/cap hoses and between retainer and manifold. Adjust and
fittings at A1 and A2 on the main tension the cable to allow the cable to loop
manifold. away at the bottom edge of the hose/cable
26. Feed hoses and cable through opening in bracket on the carriage. This loop should
tractor bulkhead. be 0.75 ±0.25 in. (19 ±6.35 mm) below the
bracket. Make sure the cable is long
enough to remove the auxiliary manifold
Installation cover and access TS2. Tighten the
NOTE: To help install the retainers, use two retainer. See Figure 7-177.
modified (M6-1 x 70) bolts to locate and
support the retainer during assembly.
See Figure 7-176.

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Figure 7-177. Carriage Hose/Cable Retainer Figure 7-178. Free Lift Pulley Routing of Hoses and Cable
1045742_D6.cgm 1045742_B7.jpg
Aux Hose A2 Aux Hose A2
Aux Hose A1 Electrical Cable Aux Hose A1
Electrical Cable
8. Attach manifold cover to carriage. Apply 13. Install hoses, cable, and retainer at top of
thread-locking compound (P/N 990-536) free lift cylinder. See Figure 7-179.
to the mounting bolt threads and torque to
30 ft. lb. (42 Nm). Figure 7-179. Upper Hose/Cable Retainer, Main Lift and
Free Lift Cylinders
9. Reconnect the battery connector and turn 1045742_D8.cgm
the key switch ON. Main Lift

10. Fully lower carriage to the floor. Retainer
12. Feed hoses and cable through free lift
pulley, from fork side to tractor side. Make
sure hoses and cable do not cross each
other. The electrical cable is in the
left-hand position. See Figure 7-178.
Free Lift
Retainer

between upper free lift cylinder and
carriage retainers. Temporarily tighten
retainer.
15. Find the correct L2 value from Table 7-16.
Measure and mark hoses above the upper
free lift cylinder retainer, using the L2
value. L2 equals the length the hoses are
to be stretched over the free lift cylinder.
See Figure 7-180.

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Figure 7-180. Marking L2 dimension 24. Install over-the-mast hoses, lift hose, and
cable in retainer at left main lift cylinder.
OTM_5.jpg
stretch
25. Remove slack from hoses and cable.
Adjust cable grip and spring so that spring
is stretched to an overall length of
1.75 ±0.12 in. (44.5 ±3 mm) across the
coils. Leave sufficient bend of slack hose
L2 dimension so that an additional 0.5 in. (13 mm) of
cable length can be taken up if required.
Temporarily tighten retainer.
26. Measure and mark the lift hose above the
retainer with the appropriate L3 value in
Table 7-16. Measure and mark the
over-the-mast hoses above the retainer
16. Reconnect the battery connector and turn with the appropriate L1 value in
the key switch ON. Table 7-16.
17. Place block under carriage and lower 27. Repeat step 17 of installation procedure.
carriage to relieve tension on hoses. 28. Pull down on the hoses until marks are
18. Pull down on the hoses until marks are flush with the top of the retainers. Tighten
flush with top of retainers. Tighten the retainers.
four retainer bolts. Do not tighten the 29. Reconnect the battery connector and turn
lower clamp bolts on the retainer assembly the key switch ON. Remove blocking from
yet. telescopics. Turn the key switch OFF and
19. Install hoses, cable, retainer, and clamp at disconnect the battery connector.
bottom of free lift cylinder and inner 30. Tighten two lower clamp bolts on upper
telescopic. Carefully elevate the telescopics free lift cylinder hose/cable retainer.
high enough to access the lower retainer 31. Secure hoses and cable to the free lift
on free lift cylinder and the retainer on the cylinder with cable ties every 16 to 24 in.
telescopic from the tractor side. Place a (40 to 60 cm).
hardwood block of sufficient length
between the outer and inner telescopics. 32. Route hoses and cable through the tractor
Carefully lower the mast until you have opening, along the tractor bulkhead and
the desired tension. Observe correct attach with the hose/cable clamps. See
routing to make sure hoses and cable have Figure 7-181.
sufficient clearance. See Figure 7-175.
between inner telescopic retainer and
upper retainer on free lift cylinder.
Temporarily tighten retainer and clamp.
the key switch ON. Remove blocking from
telescopics. Turn the key switch OFF and
disconnect the battery connector.
23. Feed hoses and cable through pulleys at
top of telescopic, from fork side to tractor
side. Make sure hoses and cable do not
cross each other.

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Figure 7-181. Hose/Cable Retainer Clamps on Tractor
R1018766_C7.cgm
L1 L2 L3
(OTM hoses (over free (lift hose
OACH over tele) lift cyl) over tele)
in. (mm) in. (mm) in. (mm)
110 1.98 (50.3) 1.04 (26.4) 2.14 (54.4)
114 2.10 (53.3) 1.07 (27.2) 2.26 (57.4)
118 2.22 (56.4) 1.10 (27.9) 2.38 (60.5)
122 2.34 (59.4) 1.13 (28.7) 2.50 (63.5)
128 2.52 (64) 1.18 (30) 2.68 (68.1)
131 2.61 (66.3) 1.20 (30.5) 2.77 (70.4)
133 2.67 (67.8) 1.21 (30.7) 2.83 (71.9)
135 2.73 (69.3) 1.23 (31.2) 2.89 (73.4)
138 2.82 (71.6) 1.25 (31.8) 2.98 (75.7)
141 2.91 (73.9) 1.27 (32.3) 3.07 (78)

33. Observing correct routing, connect 143 2.97 (75.4) 1.29 (32.8) 3.13 (79.5)
over-the-mast hoses to A1 and A2 at the
main manifold. Connect the over-the-mast 146 3.09 (78.5) 1.31 (33.3) 3.25 (82.6)
cable to connector JPS3.
the key switch ON. Test the lift truck for
correct operation and check for leaks.
35. Cycle all auxiliary functions several times
to purge air from the hydraulic system.
36. Check hydraulic fluid level and add fluid
as required.
37. Install mast guard and covers.
Table 7-16. Over-the-Mast Hose Stretch Values
L1 L2 L3
(OTM hoses (over free (lift hose
OACH over tele) lift cyl) over tele)
in. (mm) in. (mm) in. (mm)
87 1.29 (32.8) 0.87 (22.1) 1.45 (36.8)
95 1.53 (38.9) 0.93 (23.6) 1.69 (42.9)
100 1.68 (42.7) 0.97 (24.6) 1.84 (46.7)
102 1.74 (44.2) 0.98 (24.9) 1.90 (48.3)
104 1.80 (45.7) 1.00 (25.4) 1.96 (49.8)
107 1.89 (48) 1.02 (25.9) 2.05 (52.1)

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Mast, Chain, Hose, Cable Cable, Over-the-Mast
Cable, Over-the-Mast Figure 7-182. Cable Grip on TS2 end of OTM cable
DSCF1362.JPG
Over-the-Mast Cable
Replacement
This procedure describes the installation of the
new cable as the old one is being removed.
1. Mark the OTM hoses at all the hose/cable
retainers to make sure the correct stretch
when reassembled. (If required use
Table 7-16.)
2. Remove the top cover, left front cover, and
mast guard.
11. If installing bulk cable, strip 3 in.
(76 mm) of insulation from cable, strip
wires, and attach spade lugs.
4. Disconnect the OTM cable at connector
12. Attach a cable tie around the braided end
TS3 in the tractor.
of the cable grip to prevent the grip from
5. Remove the auxiliary manifold cover from slipping. Do not tighten at this time.
the carriage and disconnect the OTM cable
13. Install the new cable in the carriage
at TS2.
retainer/guide and route to TS2.
6. Reconnect battery connector and turn key
NOTE: Position the hoses using the marks
switch ON.
made in step 1 and make sure that there
7. Elevate and block the carriage at an is enough slack in the cable for the
appropriate height to access the installation and removal of the auxiliary
hose/retainer and guide at the back of the manifold cover.
carriage from the operator compartment.
This also relieves tension on the hoses for 14. Reconnect battery connector and turn key
easier assembly. switch ON. Remove blocking and lower the
carriage. Turn key switch OFF and
disconnect battery connector.
15. Connect cable spade lugs to TS2.
9. Remove the cable from the retainer/guide
at the back of the carriage and the free lift 16. Attach aux manifold cover to carriage.
cylinder pulley. See Figure 7-171. 17. Reconnect the battery connector and turn
10. Position the cable grip on the replacement the key switch ON. Elevate and block
cable so that the spring anchor end of the carriage as in step 7. Turn the key switch
cable grip is oriented towards the TS2 end OFF.
of the cable and the loop is approx 20 in. 18. Tighten the carriage hose and cable
(51 cm) from the end of the cable. See retainer.
Figure 7-182. 19. Turn the key switch ON. Remove blocking
and lower the carriage. Turn the key
switch OFF.
20. Feed the cable through the free lift pulley
and position it in the upper free lift
cylinder retainer. Do not tighten at this
time.

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Cable, Over-the-Mast Mast, Chain, Hose, Cable
NOTE: Remove all twist from the cable when 26. Place a hardwood block of sufficient length
installing. (approx 30 in. [0.75 m]) between the outer
and inner telescopics. This removes the
21. Turn the key switch ON. Elevate and block
tension from the OTM hoses and the lift
carriage. Turn the key switch OFF.
hose to make the removal and installation
22. Adjust and tension the cable to allow the of the retainers easier. Carefully lower the
cable to loop away at the bottom edge of mast until you have the desired tension.
the hose/cable bracket on the carriage. See Figure 7-184.
This loop should be 0.75 ±0.25 in. (19
±6.35 mm) below the bracket. See Figure 7-184. Blocking Telescopics
Figure 7-183. DSCF1361.JPG
Figure 7-183. Service Loop (Standard Carriage shown)

1045742_B5.cgm
Carriage
Hose/Cable
Guide
Service Loop
27. Turn the key switch OFF.

28. Remove and install the cable at the lower
free lift cylinder and bottom inner
Tension Spring
telescopic hose/cable retainers. Observe
correct routing to make sure hoses and
cable have sufficient clearance. Tighten
the retainers.
23. Position the hoses and cable using the
29. Remove and feed the cable through the
marks made in step 1 and tighten the
pulley at the top of the inner telescopic.
upper 4 bolts, but not the bottom 2 bolts
Observe correct routing and make sure the
of the upper free lift cylinder retainer.
cable is not twisted.
24. Set the tension on the spring at the
30. For bulk cable installation:
carriage by sliding the cable grip to
produce a length of 1.75 ±0.12 in. a. If old cable is loose in the main lift
(44.5 ±3.0 mm) across the coils. Do not cylinder cable retainer, the passage
over tension. Tighten the cable tie on the hole in the retainer has already been
cable grip. See Figure 7-183. enlarged. Remove the old cable and
insert the new cable through the
NOTE: Orient the loop of the cable grip fore-aft passage hole.
so that as the cable passes through the
loop of the cable grip and the latch of
the cable tie, it does not interfere with
the free lift cylinder mounting pin.
25. Turn the key switch ON. Carefully elevate
the telescopics high enough to access the
lower retainer on the free lift cylinder and
the retainer on the telescopic from the
operator’s compartment.

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Mast, Chain, Hose, Cable Cable, Over-the-Mast
b. If the old cable is held in place by the the cable at the top of the retainer. Tighten
main lift cylinder cable retainer, you the retainer bolts.
must enlarge the passage hole. To do 36. Set the tension on the spring at the
this, remove both parts of the retainer, carriage by sliding the cable grip to
clamp them together, and drill out the produce a length of 1.75 ±0.12 in.
passage hole for the electrical cable (not (44.5 ±3.0 mm) across the coils. Do not
the hoses) with a 9/16 in. drill bit. over tension. Tighten the cable tie on the
Reassemble the retainer, aligning cable grip. See Figure 7-186.
witness marks on the hoses, and
tighten the bolts. Insert the new cable Figure 7-186. Main Lift Cylinder Retainer Cable Spring
through the passage hole. Tension
See Figure 7-185. DSCF1352.JPG
Figure 7-185. Retainer Modification for Electrical Cable

1045742_D8.cgm
Electrical Lift Hose Aux Hose

Cable Hole Hole Hole
37. For bulk cable installation, see “For bulk

cable installation, do the following:” on
page 7-152.
For exact replacement cable

installation, do the following:
1. Turn the key switch ON. Elevate the
carriage and place a hardwood block
31. If installing bulk cable, install cable grip between the inner and outer telescopic.
with the loop pointing down towards the Carefully lower the carriage to relieve the
tractor. Go to step 33. hose and cable tension. Turn the key
32. Turn the key switch ON. Remove the switch OFF.
blocking between the inner and outer 2. Position the cable so that the mark on the
telescopic. cable is 0.5 in. (13 mm) above the retainer.
33. Tighten the bottom two bolts of the free lift 3. Position the OTM hoses and the lift hose
cylinder hose/cable retainer. as marked in step 1 of Over-the-Mast
34. Secure hoses and cable to the free lift Cable Replacement. Tighten the retainer.
cylinder with cable ties every 16 to 24 in. 4. Turn the key switch ON. Remove the block
(40.6 to 60.9 mm) as you lower the between the inner and outer telescopic.
carriage all the way. Turn the key switch
OFF. 5. Lower the carriage. Turn the key switch
OFF.
35. If installing exact replacement cable, pull
the cable through the main lift cylinder 6. Remove and route the cable along the
retainer until all slack is removed. Mark tractor bulkhead, through the tractor

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Cable, Over-the-Mast Mast, Chain, Hose, Cable
opening and attach with the hose/cable 2. Strip 3 in. of insulation from the cable,
clamps. strip the wires, and attach spade lugs.
7. Connect the OTM cable to connector TS3. 3. Connect the wires to the terminal strip.
See Figure 7-187. Go to step 5 in Bulk See Table 7-17.
Cable Replacement procedure. See
NOTE: Colors will not match at TS2.
Table 7-17.
4. Attach cable to frame with cable tie and
Figure 7-187. Cabling at Terminal Strip self-adhesive cable tie anchor. See
DSCF0449.JPG
Figure 7-187.
5. Install the mast guard, top cover and front
left cover.
TS3
Table 7-17. OTM Cable Connections
New Carriage
Terminal Terminal
Strip Strip
TS3 TS2
TS3-1 TS2-1
TS3-2 TS2-2
TS3-3 TS2-3
TS3-4 TS2-4
TS3-5 TS2-5
TS3-6 TS2-6
For bulk cable installation, do the

following:
1. Cut the OTM cable 20 in. (508 mm) past
the bottom of the main lift cylinder
retainer.

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Mast, Chain, Hose, Cable Hose/Tubing, Free Lift Feed
Hose/Tubing, Free Lift Figure 7-188. Free Lift Feed Hose/Tube, Model 7600
1045742_D5.cgm
Feed
Removal
2. Raise the telescopics until the bottom of
the free lift feed tubing is accessible from
the operator’s compartment.
3. Place a block of sufficient length between
the outer telescopic crosstie and the main
frame to hold the position in step 2.
4. Fully lower the carriage. Figure 7-189. Free Lift Tubing, Model 7620/7640
1067160_C1.cgm
5. Extend the reach mechanism to allow

easier removal of the free lift feed tubing.
7. Place a pan below the free lift tubing.
8. Remove the necessary components. See
Installation
1. Replace the necessary components. Make
sure the assembly is tight and correctly
positioned on the crosstie.
the key switch ON.
3. Remove the block between the outer
telescopic crosstie and the main frame.
operation.

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Mast, Model 7600 Mast, Chain, Hose, Cable
Mast, Model 7600 NOTE: Make sure the weight of the mast is fully
supported by the hoist and the tractor is
blocked where it meets the mast before
Disassembly loosening the mast mounting bolts.
13. Place blocks snugly under the tractor near
Separation of Tractor and Mast the mast.
• Do this procedure with a minimum 14. Attach a lifting strap around the top
of two technicians in a shop crossties of all three mast sections. Draw
equipped with a suitable hoist. tight with hoist. Make sure the weight of
the mast is supported by the hoist.
• Do not permit observers to stand
nearby. 15. Use an impact wrench to remove the mast
mounting bolts inside the battery
• Wear gloves, safety glasses,
compartment; four on the top, eight on the
steel-toed safety boots, and a safety
bottom.
helmet (hard hat).
16. Using a lift truck, carefully separate the
1. Lower and retract the fork carriage
tractor about 6 in. (15 cm).
completely.
17. Remove the hose/cable retaining bracket
on the front of the tractor bulkhead.
the battery connector. Remove battery
gates. Using a suitable battery removal 18. Remove the hose/cable retainer on the
device, remove the battery. main lift cylinder.
3. Remove the top cover and the left and right 19. Reinstall mast mounting bolts and
front covers. washers and tighten lightly (to prevent
misplacing them).
5. Secure a hoist strap around the overhead
guard. Take the weight off the guard.
Hose/Cable, Free Lift Cylinder, and
Remove mounting bolts. Remove the Carriage Removal
guard. 1. Remove the auxiliary manifold cover from
6. Disconnect and cap right side main lift the carriage. See Figure 7-190.
hose at the tractor bulkhead fitting.
Figure 7-190. Auxiliary Manifold Access
7. Disconnect the ambient temperature DSC_0942a.jpg
sensor connector JPA on the tractor deck.

8. Disconnect the mast switch connector
JPS4 (near the lift pump). Feed harness
through tractor opening at left side.
9. Disconnect over-the-mast cable connector
TS3.
10. Disconnect the hose/cable retaining
clamp from the left front corner of the
tractor near the opening in the bulkhead.
11. Disconnect and plug hydraulic hoses A1
and A2 at the main manifold, labeling as
needed for correct reassembly. Feed hoses
through opening in tractor bulkhead. 2. Disconnect the wires of the over-the-mast
12. Disconnect the main lift hose fitting at the cable from the terminal strip, labeling as
left side of the tractor. needed for reconnection.

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Mast, Chain, Hose, Cable Mast, Model 7600
3. Remove auxiliary manifold mounting Main Lift Chain Removal

screws to permit access to the
over-the-mast hose fittings at the 1. Rig a lifting strap of one hoist around the
manifold. lower crosstie of the main frame (the one
where the overhead guard attaches).
NOTE: There may be shims between the
2. Rig a lifting strap of another hoist around
the top crossties of both inner and outer
4. Disconnect and plug/cap the telescopics. Using the hoist, raise the
over-the-mast hoses and fittings at the telescopics about 10 in. (25 cm).
auxiliary manifold. Label as needed to 3. Remove chain anchor bolt and access
make sure correct reconnection. cover from sides of main frame.
5. Remove cable ties on upper hose retaining 4. Remove the chain anchor pin by using a
block. Loosen upper and lower hose/cable slide hammer or by using a large socket
retaining blocks. (1 1/16 in.), an M8 x 50 mm bolt, and
6. Jack carriage up about 3 in. (7.6 cm). washers to act as a pulling device.
Remove master links on free lift chains. See Figure 7-191 and Figure 7-146.
Feed free lift chains through pulleys and
drape over front of carriage. Figure 7-191. Main Lift Chain Upper Chain Anchor
R1020561_A1.cgm
7. Remove hose/cable retaining block on Bolt

back of carriage.
8. Remove hoses and cable from guide at Cover
back of carriage.
9. Remove upper and lower hose/cable
retainers from free lift cylinder. Pin
10. Feed hoses and cable through right side
free lift cylinder pulley.
Chain
11. Remove tee tubing from free lift cylinders. Anchor
12. Remove set screws from bottom of right
free lift cylinders. Lift each free lift cylinder
off the mounting hook at the top and the
mounting block at the bottom. Install set 5. Pull the chain anchor/mast stop out of the
screws so they are not misplaced. main frame.
13. Remove carriage stops from back of 6. Feed main lift chains from inside to
carriage. outside over the chain sheave.
14. Remove the lower hose/cable pulley from
the top of the outer telescopic. Separation of Telescopics
15. Remove the upper hose/cable pulley from 1. Using the hoists, carefully lower the mast
the top of the outer telescopic. to a horizontal position on jack stands.
16. Disconnect the tee tubing to the right side 2. Loosen the L-bracket bolts holding the
main lift cylinder. main lift cylinders to the telescopic.
17. Disconnect and cap the hose to the left 3. Remove the top mounting bolt, washer,
main lift cylinder. and sleeve holding the main lift cylinder to
18. Rig lifting straps around the carriage. the outer telescopic. See Figure 7-192.
Using a hoist, carefully lift the carriage out
of the inner telescopic and lower the
carriage to the floor.

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Figure 7-192. Main Lift Cylinder Mounting Hardware Figure 7-194. Outer Telescopic Lower Bearing and
R1020561_A2.cgm
Anti-Rattle Pads
Mounting Bolt R1020561_A4.cgm
Washer
Shim
Sleeve
Outer
Telescopic
Pad Cover
4. Remove main lift chain sheaves from top of

outer telescopic. Sheaves attach with a pin 6. Remove anti-rattle pads and shims from
and a set screw on the inside. See bottom of inner telescopic. See
Figure 7-193. Figure 7-195.
Figure 7-193. Main Lift Chain Sheave Figure 7-195. Inner Telescopic Lower Bearing and
1043786_A7.cgm
Anti-Rattle Pads
Sheave Set Screw 1043786_A6.cgm
Spacer Chain Shim
Pad
Bearing
Snap Ring
Pin
5. Remove anti-rattle pads and shims from

bottom of outer telescopic. See
Figure 7-194. Shim
Pad
7. Using a suitable hoist, pull the inner

telescopic halfway out of the outer
telescopic.

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8. Remove the upper roller bearings and Assembling and Shimming

shims from the top of the outer telescopic.
See Figure 7-196.
Outer Telescopic to Main Frame
Figure 7-196. Outer Telescopic Upper Bearing Lower Bearings of Outer Telescopic
R1020561_A6.cgm
Sleeve 1. Begin the assembly with the main frame

Stud positioned horizontally on jack stands.
2. Attach the lower roller bearing to one side
Shims of the outer telescopic. Make sure the flat
spot on the bearing outer stud is correctly
positioned against the mast. This is
important because the correct bearing
alignment is canted with respect to the
channel. See Figure 7-194.
3. Using a suitable hoist, insert the outer
Bearing telescopic into the main frame as far as
the crosstie.
4. Attach the lower roller bearing to the other
9. Remove the lower roller bearings and
side of the outer telescopic.
shims from the bottom of the inner
telescopic. See Figure 7-195. 5. Using a pry bar, move the outer telescopic
and bearing to one side.
10. Using a suitable hoist, remove the inner
telescopic from the outer telescopic. 6. Use spare shims as a gauge to determine
the amount of shims required to cause the
11. Using a suitable hoist, pull the outer
roller bearing to contact the main frame.
telescopic halfway out of the main frame.
7. Remove both lower bearings. Install one
12. Remove the upper roller bearings and
half of the total shim thickness required to
shims from the main frame. See
each roller bearing. Reinstall the bearings.
Figure 7-197.
Figure 7-197. Main Frame Upper Bearing (P/N 990-536) to the bearing mounting
1043786_A10.cgm bolt and torque to 260 ft. lb. (352 Nm).
Bolt 8. If the inner race of the bearing does not
Stud protrude past the end of the bearing stud
Shims flat washer to contact the bearing to
prevent the bearing from walking on the
stud shaft. See Figure 7-198.
Bearing

shims from the outer telescopic. See
Figure 7-194.
14. Using a suitable hoist, remove the outer
telescopic from the main frame.

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Figure 7-198. Inner Race 6. Using the hoist, slide the outer telescopic
the entire length of the main frame,
mastbearshim1.jpg
checking for binding. Add or remove shims

as necessary to maintain a snug but
free-running fit.
Assembling and Shimming

Inner Telescopic to Outer
Telescopic
Lower Bearings of Inner Telescopic
1. Attach the lower roller bearing to one side
of the inner telescopic. Make sure the flat
spot on the bearing outer stud is correctly
9. Using the hoist, slide the outer telescopic positioned against the mast. See
the entire length of the main frame, Figure 7-195.
checking for binding. The tightest spots 2. Using a suitable hoist, insert the inner
are generally at the crossties. Add or telescopic into the outer telescopic as far
remove shims as necessary to maintain a as the crosstie.
snug but free-running fit. 3. Attach the lower roller bearing to the other
side of the inner telescopic.
Upper Bearings of Main Frame 4. Using a pry bar, move the inner telescopic
1. With the outer telescopic inserted halfway and bearing to one side.
into the main frame, attach the upper 5. Use spare shims as a gauge to determine
roller bearing to one side of the main the amount of shims required to cause the
frame. Make sure the flat spot on the roller bearing to contact the outer tele.
bearing outer stud is correctly positioned
against the mast. See Figure 7-197.
2. Attach, but do not tighten, the upper roller each roller bearing. Reinstall the bearings.
bearing to the other side of the main Apply thread-locking compound
frame. (P/N 990-536) to the bearing mounting
3. Use spare shims as a gauge to determine bolt and torque to 260 ft. lb. (352 Nm).
the amount of shims required to cause the 7. If the inner race of the bearing does not
roller bearing to contact the outer protrude past the end of the bearing stud
telescopic. when the bearing is fully seated, bend the
4. Remove both upper bearings. Install one flat washer to contact the bearing to
half of the total shim thickness required to prevent the bearing from walking on the
each roller bearing. Reinstall the bearings. stud shaft. See Figure 7-198.
Apply thread-locking compound 8. Using the hoist, slide the inner telescopic
(P/N 990-536) to the bearing mounting the entire length of the outer telescopic,
bolt and torque to 260 ft. lb. (352 Nm). checking for binding. Add or remove shims
5. If the inner race of the bearing does not as necessary to maintain a snug but
protrude past the end of the bearing stud free-running fit.
flat washer to contact the bearing to Upper Bearings of Outer Telescopic
stud shaft. See Figure 7-198. 1. With the inner telescopic inserted halfway
into the main frame, attach the upper

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roller bearing to one side of the outer 4. Rig lifting straps around the upper
telescopic. Make sure the flat spot on the crossties of all three mast sections.
bearing outer stud is correctly positioned 5. Using a suitable hoist, raise the mast to a
against the mast. See Figure 7-196. vertical position.
2. Attach, but do not tighten, the upper roller 6. Rig a lifting strap of one hoist around the
bearing to the other side of the outer lower crosstie of the main frame (the one
telescopic. where the overhead guard attaches).
3. Use spare shims as a gauge to determine 7. Rig a lifting strap of another hoist around
the amount of shims required to cause the the top crossties of both inner and outer
roller bearing to contact the inner telescopics. Using the hoist, lower the
telescopic. telescopics to about 10 in. (25 cm) from
4. Remove both upper bearings. Install one the floor.
half of the total shim thickness required to 8. Make sure the two holes in the upper
each roller bearing. Reinstall the bearings. chain anchor block are towards the
Apply thread-locking compound outside. Feed the main lift chain from the
(P/N 990-536) to the bearing mounting outside to the inside over the chain
bolt and torque to 260 ft. lb. (352 Nm). sheave.
5. If the inner race of the bearing does not 9. Feed the upper chain anchor block down
protrude past the end of the bearing stud between the main frame and outer
when the bearing is fully seated, bend the telescopic until holes are aligned between
flat washer to contact the bearing to block and main frame. Insert the chain
prevent the bearing from walking on the anchor bolt (without the access cover) and
stud shaft. See Figure 7-198. lightly tighten the bolt to draw the chain
6. Using the hoist, slide the inner telescopic anchor block to the main frame.
the entire length of the outer telescopic, 10. Thread a bolt into the hole in the chain
checking for binding. Add or remove shims anchor retaining pin. Insert the pin and
as necessary to maintain a snug but drive it in. Remove the bolt from the pin.
free-running fit.
11. Remove the chain anchor bolt. Apply
7. Check the clearance gap of the bow pads thread-locking compound (P/N 990-544)
between inner telescopic and outer to bolt threads. Install access cover and
telescopic. Shim as required to obtain a torque bolt to 130 ft. lb. (174 Nm).
gap of 0.03 to 0.09 in. (0.8 to 2.3 mm).
12. Lower the telescopics into the main frame
approx 3 in. (7.6 cm) from the floor.
Main Lift Chain Installation
13. Install master links to attach the main lift
1. Install anti-rattle pads and shims at chains to the lower chain anchor blocks.
bottom of inner and outer telescopics. Lower the telescopics completely. Tighten
Shim so pads are snug against mast. See the chain anchor nuts until the inner
Figure 7-194 and Figure 7-195. telescopic just lifts off its stops.
2. Install the main lift chain sheaves to the
top of the outer telescopic. Sheaves install Shimming Carriage to Inner
with a large pin and a set screw on the Telescopic
inside. See Figure 7-193.
1. Drape the free lift chains forward over the
3. Install but do not tighten a new sleeve and
carriage backrest. Rig lifting straps around
collar, washer, and mounting bolt through
the carriage.
the telescopic crosstie and into the
cylinder housing of each main lift cylinder. 2. Install the lower set of roller bearings,
See Figure 7-192. without shims, in the carriage.

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3. Using a hoist, carefully lift the carriage thread-locking compound (P/N 1013829)
and insert it into the inner telescopic until to the threads of the studs and torque as
the bearings just enter the telescopic. shown in Figure 7-199.
4. Using a pry bar, move the carriage 3. Route auxiliary hoses around lower
bearings to one side. pulleys. Attach lower hose pulley to the
5. Use spare shim(s) as a gauge to determine top of the outer telescopic. Apply
the amount of shims required to remove thread-locking compound (P/N 1013829)
side play. to the threads of the studs and torque as
shown in Figure 7-199.
6. Remove the carriage from the inner
telescopic far enough to expose the Figure 7-199. Over-the-Mast Hose/Cable Pulleys
bearings being shimmed. 1045742_D2.cgm
Torque to 130 ft. lb. (174 Nm)

7. Remove the bearings being shimmed from
the carriage. Install one half of the total
shim thickness required to each roller
bearing.
8. Using the hoist, reinsert the carriage into
the inner telescopic. Check for tight areas
while moving the carriage to the bottom of
telescopic far enough to expose the
bearings being shimmed.
10. Remove the bearings being shimmed from Torque to 43 ft. lb. (58 Nm)
the carriage.
4. Install carriage stops. Apply
NOTE: The carriage may have to be removed thread-locking compound (P/N 990-536)
several times to obtain the correct fit. to mounting bolts and torque to 35 ft. lb.
11. Install the center set of roller bearings, (47.5 Nm).
without shims, in the carriage. 5. Remove set screws from free lift mounting
12. Repeat steps 4 through 10 for the center blocks. Lift each free lift cylinder into place
set of bearings. over the mounting hook at the top and the
mounting block at the bottom. Apply
13. Install the upper set of roller bearings, thread-locking compound (P/N 990-403)
without shims, in the carriage. to set screw threads and install set screws
14. Repeat steps 4 through 10 for the upper in mounting blocks.
set of bearings. 6. Reference Figure 7-200 for the following
steps that route the hoses/cable.
Carriage, Free Lift Cylinder, and
Hose/Cable Installation
the carriage. Using a hoist, carefully lift
the carriage, insert it into the inner
telescopic, and lower the carriage to about
3 in. (7.6 cm) above the floor.
2. Route cable and hoses around upper
pulleys. Attach upper hose/cable pulley to
the top of the outer telescopic. Apply

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Figure 7-200. Over-the-Mast Hose and Cable Installation Figure 7-201. Free Lift Cylinder Tee Tubing
R1018766_C1.cgm R1018766_C2.cgm
8. Feed hydraulic hoses and electrical cable

through the free lift pulley, from tractor
side to forks side. The electrical cable
must be on the left-hand side.
See Figure 7-202.
Figure 7-202. OTM Hoses and Cable at Free Lift Pulley

1045742_B7.jpg
Aux Hose A2
Aux Hose A1
Electrical Cable
9. Attach, but do not tighten, the hose/cable

7. Connect tee tubing to free lift cylinders.
retainer bracket at the bottom of the free
See Figure 7-201.
lift cylinder. See Figure 7-203.

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Figure 7-203. Lower Hose/Cable Retainer, Free Lift Figure 7-205. Hose/Cable Guide on Carriage
Cylinder 1045742_D6.CGM
R1027396_DB.cgm
Gap
10. Assemble, but do not tighten, the

hose/cable retainer at the top of the free
Figure 7-204. Upper Hose/Cable Retainer, Free Lift

Cylinder
1045742_D8.CGM
12. Feed the free lift chains over free lift

pulleys, from forks side to tractor side.
Install master links to attach the free lift
chains to the chain anchor blocks.
13. Take slack out of hoses and cable. Make
sure hoses do not cross each other. See
Figure 7-206.
11. Feed hoses and cable around the guide on

the carriage. Attach the cable tension
spring and position the cable grip to
provide a 0.75 in. (19 mm) gap between
the over-the-mast electrical cable and the
bottom of the hose guide. See
Figure 7-205.

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Figure 7-206. OTM hose and cable routing 17. With the auxiliary manifold removed from
the carriage, connect auxiliary hydraulic
1045742_B7.jpg,1045742_D4.CGM
hoses to the manifold, making sure to

observe correct labeling.
Aux Hose A2
18. Attach the manifold to the carriage. Apply
Aux Hose A1
to the mounting bolt threads and torque to
21 ft. lb. (29 Nm).
Electrical Cable 19. Connect the over-the-mast cable wires to
the terminal block on the auxiliary
manifold cover. Attach the manifold cover
to the carriage. Apply thread-locking
compound (P/N 990-536) to the mounting
bolt threads and torque to 30 ft. lb.
(42 Nm).
20. Assemble, but do not tighten, the
hose/cable retainer on the left side main
21. Secure the mast with hoist lifting strap
wrapped loosely around the top crossties
of all three mast sections. Wrap the lifting
strap of a second hoist around the upper
crosstie of the inner telescopic. Using the
Aux Hose A2 hoist, lift the inner telescopic about 6 in.
Aux Hose A1 (15 cm).
22. Tighten the hose/cable retainer on the left
Electrical Cable
side main lift cylinder.
23. Lower the inner telescopic.
Mating Tractor to Mast

1. Position the tractor about 10 in. (25 cm)
from the mast. Place blocks under the
tractor near the mast to match the bolt
hole height in tractor and mast.
2. Attach the hose/cable retaining bracket on
the front (mast side) of the tractor
bulkhead. See Figure 7-207.
14. Install hose/cable retainer on carriage. 3. With the mast secured by a hoist, use a lift
See Figure 7-205. truck to mate the tractor to the mast.
15. Lower the carriage all the way to the floor. 4. Apply thread-locking primer
(P/N 990-666) to mast mounting bolt
16. Tighten the upper and lower hose/cable threads and hole threads. Permit to dry for
retainers on the free cylinders. Attach two several minutes.
cable ties on the upper retainer.
(P/N 990-544) to threads of mast
mounting bolts.

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6. From the battery compartment, thread 14. Secure a hoist strap around the overhead
eight mounting bolts and washers through guard or position a lift truck with pallet
bottom of the tractor frame into the mast. under the overhead guard. Lift the guard
Thread four mounting bolts and washers into position at the lower crosstie of the
through the top of the tractor frame into main frame.
the mast. Torque bolts to 165 ft. lb. (224 15. Apply thread-locking compound
Nm). (P/N 990-536) to the mounting bolt
7. Connect the main lift hose fitting at the left threads. Install mounting bolts and torque
side of the tractor. to 130 ft. lb. (174 Nm).
8. Route the auxiliary hoses and electrical 16. Install the mast guard.
cable through the tractor opening. Secure 17. Using a suitable battery moving device,
hoses and cable with retainer clamp. See install the battery. Install battery gates.
Figure 7-207.
18. Attach front covers and top cover.
Figure 7-207. Hose/Cable Retainer Clamps on Tractor 19. Make sure all hoist straps and blocks are
R1018766_C7.cgm
removed.
the key switch ON.
22. Test all lift truck functions.
Retainer 23. Elevate the inner telescopic about 12 in.
Clamps (30 cm). Torque the main cylinder top
mounting bolts. Tighten main lift cylinder
L-bracket mounting bolts to 55 ft. lb.
(74.5 Nm).
24. Using a work basket and lift truck, grease
the channels of all sections of the mast.
9. Connect auxiliary hoses A1 and A2 at the

main manifold, observing labels.
10. Connect over-the-mast cable connector
JPS3 on the tractor deck. See
Figure 7-169.
11. Feed the mast switch harness into the
tractor, across the top of the deck to the
right side near the lift pump. Connect
connector JPS4.
12. Connect the ambient temperature sensor
cable connector JPA on the tractor deck.
13. Connect the right side main lift hose to the
fitting on the tractor bulkhead.

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Mast, Model 7620 12. Place blocks snugly under the tractor near
the mast.
13. Attach a lifting strap around the top
Disassembly crossties of all three mast sections. Draw
tight with hoist. Make sure the weight of
Separation of Tractor and Mast the mast is supported by the hoist.
14. Remove the battery connector bracket to
• Do this procedure with a minimum
permit access to the top right mast
of two technicians in a shop
mounting bolts.
equipped with a suitable hoist.
15. Use an impact wrench to remove the mast
• Do not permit observers to stand
mounting bolts inside the battery
nearby.
compartment; four on the top, eight on the
• Wear gloves, safety glasses, bottom.
steel-toed safety boots, and a safety
helmet (hard hat). 16. Using a lift truck, carefully separate the
completely. 17. Reinstall mast mounting bolts and
washers and tighten lightly (to prevent
2. Turn the key switch OFF and disconnect misplacing them).
the battery connector. Remove battery
gates. Using a suitable battery removal
device, remove the battery. Hose/Cable, Free Lift Cylinder, and
3. Remove the top cover and the left and right
Carriage Removal
front covers. 1. Remove the auxiliary manifold cover from
4. Remove the mast guard. the carriage. See Figure 7-208.
5. Secure a hoist strap around the overhead 2. Disconnect the wires of the over-the-mast
guard. Take the weight off the guard. cable from terminal strip TS2, labeling as
Remove mounting bolts. Remove the needed for reconnection.
guard. 3. Remove auxiliary manifold mounting
6. Disconnect and cap right side main lift screws to permit access to the
hose at the tractor bulkhead fitting. over-the-mast hose fittings at the
manifold.
7. Disconnect the ambient temperature
sensor connector JPA on the tractor deck. NOTE: There may be shims between the
8. Disconnect the mast switch connector manifold and carriage.
JPS4 (near the lift pump). Feed harness
Figure 7-208. Auxiliary Manifold Access
through tractor opening at right side. DSC_0942a.jpg

TS3 on the tractor deck.
through opening in tractor bulkhead.
11. Disconnect the main lift hose fitting at the
left side of the tractor.
NOTE: Make sure the weight of the mast is fully
blocked where it meets the mast before
loosening the mast mounting bolts.

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4. Disconnect and plug/cap the 8. Cut cable ties on hose clamps on left side
over-the-mast hoses and fittings at the free lift cylinder.
auxiliary manifold. Label as needed to 9. Loosen the hose retaining clamp on the
make sure correct reconnection. carriage near the bottom of the left side
5. Place a chalk witness mark on the hoses to free lift cylinder. Slide clamp inward to free
aid in reassembly. the hoses. See Figure 7-211.
6. Remove hose retaining clamp near top of
Figure 7-211. Hose Retaining Clamp, Left Free Lift Cylinder,
the left side free lift cylinder.
Bottom
See Figure 7-209. 1066854_B13.cgm
Figure 7-209. Hose Retaining Clamp, Left Free Lift Cylinder

1066854_B11.cgm
Hose
Retaining
Clamp
Hose
Retaining
Clamp
10. Feed hoses and cable through free lift
cylinder pulleys.
11. Jack carriage up about 3 in. (7.5 cm) to
provide slack in chains. Remove master
7. Loosen the U-clamp on the right side free
links on free lift chains. Feed free lift
lift cylinder and feed the over-the-mast
chains through pulleys and drape over
(OTM) cable through. See Figure 7-210.
front of carriage.
Figure 7-210. U-clamp, OTM Electrical Cable 12. Remove carriage stops at the top of the
1066854_B2.cgm
inner telescopic.
13. Rig lifting straps around the carriage.
14. Disconnect and plug the hydraulic supply
hose at the bottom of the free lift cylinders.
15. Disconnect the free lift crossover hose and
cap both cylinders.
16. Remove the nylon locking nut from the
U-clamp mounting stud on the free lift cylinder. Lift
each free lift cylinder off the mounting
stud at the top and off the pin at the
bottom. See Figure 7-212.

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Figure 7-212. Free Lift Cylinder Mounting Stud and Pin Figure 7-213. Inner Telescopic Kickback Block, Pad, Shims
1051676_D.cgm 1051418_E8.cgm
Free Lift Cylinder Kickback

Mounting Stud Block
Mounting
Screws (2)
Kickback
Kickback Shim
Pad
4. Remove the chain anchor retaining nut

from the chain anchor block at the bottom
of the inner telescopic.
Free Lift Cylinder 5. Remove the bolt and access cover to the
Mounting Pin upper chain anchor at the sides of main
frame. See Figure 7-214.
6. Remove the chain anchor pin by using a
slide hammer or by using a large socket
(1 1/16 in.), an M8 x 50 mm bolt, and
See Figure 7-214 and Figure 7-146.
Figure 7-214. Main Lift Chain Upper Chain Anchor

R1020561_A1.cgm
Bolt
Cover
Main Lift Chain Removal
1. Rig a lifting strap of one hoist around the
Pin
lower crosstie of the main frame (the one
where the overhead guard attaches).
2. Rig a lifting strap of another hoist around Chain
the top crossties of both inner and outer Anchor
telescopics. Using the hoist, raise the
telescopics about 10 in. (25 cm).
3. Remove the kickback block, pads, and
shims at the bottom of the inner 7. Pull the chain anchor/mast stop out of the
telescopic. See Figure 7-213. main frame.
8. Feed main lift chains from inside to
outside over the chain sheave.
Separation of Telescopics
1. Using the hoists, carefully lower the mast
to a horizontal position on jack stands.

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2. Loosen the L-bracket bolts holding the Figure 7-217. Outer Telescopic Lower Bearing and
main lift cylinders to the telescopic. Anti-Rattle Pads
1051418_E7.cgm
3. Remove the top mounting bolt, washer,

and sleeve holding the main lift cylinder to
the outer telescopic. See Figure 7-215.
Figure 7-215. Main Lift Cylinder Mounting Hardware

1051674_B.cgm
Mounting Bolt
Washer
Sleeve
Pad Shim Cover
6. Using a suitable hoist, pull the inner

telescopic.
Outer
Telescopic
shims from the top of the outer telescopic.
4. Remove main lift chain sheaves from top of See Figure 7-218.
outer telescopic. Sheaves attach with a pin
and a retaining screw on the front. See Figure 7-218. Outer Telescopic Upper Bearing
1051418_E6.cgm
Figure 7-216.
Stud
Figure 7-216. Main Lift Chain Sheave Shim
1051418_E6.cgm
Sheave
Bearing
Spacer Chain
Bearing
Snap Ring Bearing Retaining

Screw and Washer
Pin
Retaining Screw
telescopic. See Figure 7-213.
5. Remove anti-rattle pads and shims from telescopic from the outer telescopic.
bottom of outer telescopic. See 10. Using a suitable hoist, pull the outer
Figure 7-217. telescopic halfway out of the main frame.
shims from the main frame. See
Figure 7-219.

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Figure 7-219. Main Frame Upper Bearing 7. Remove both lower bearings. Install one
1051418_E5.cgm

(P/N 990-536) to the bearing mounting
Bolt
bolt and torque to 260 ft. lb. (352 Nm).
Stud 8. If the inner race of the bearing does not
protrude past the end of the bearing stud
Bearing when the bearing is fully seated, bend the
Retaining flat washer to contact the bearing to
Shim Screw and prevent the bearing from walking on the
Washer stud shaft. See Figure 7-220.
Bearing
Figure 7-220. Inner Race
mastbearshim1.jpg

Figure 7-217.

Lower Bearings of Outer Telescopic
1. Begin the assembly with the main frame
positioned horizontally on jack stands.
2. Attach the lower roller bearing to one side 9. Using the hoist, slide the outer telescopic
of the outer telescopic. Make sure the flat the entire length of the main frame,
spot on the bearing outer stud is correctly checking for binding. The tightest spots
positioned against the mast. This is are generally at the crossties. Add or
important because the correct bearing remove shims as necessary to maintain a
alignment is canted with respect to the snug but free-running fit.
channel. See Figure 7-217.
3. Using a suitable hoist, insert the outer Upper Bearings of Main Frame
telescopic into the main frame as far as
the crosstie. 1. With the outer telescopic inserted halfway
4. Attach the lower roller bearing to the other roller bearing to one side of the main
side of the outer telescopic. frame. Make sure the flat spot on the
5. Using a pry bar, move the outer telescopic bearing outer stud is correctly positioned
and bearing to one side. against the mast. See Figure 7-219.
6. Use spare shims as a gauge to determine 2. Attach but do not tighten the upper roller
the amount of shims required to cause the bearing to the other side of the main
roller bearing to contact the main frame. frame.

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3. Use spare shims as a gauge to determine 7. If the inner race of the bearing does not
the amount of shims required to cause the protrude past the end of the bearing stud
roller bearing to contact the outer when the bearing is fully seated, bend the
telescopic. flat washer to contact the bearing to
4. Remove both upper bearings. Install one prevent the bearing from walking on the
half of the total shim thickness required to stud shaft. See Figure 7-220.
each roller bearing. Reinstall the bearings. 8. Using the hoist, slide the inner telescopic
Apply thread-locking compound the entire length of the outer telescopic,
(P/N 990-536) to the bearing mounting checking for binding. Add or remove shims
bolt and torque to 260 ft. lb. (352 Nm). as necessary to maintain a snug but
5. If the inner race of the bearing does not free-running fit.
when the bearing is fully seated, bend the Upper Bearings of Outer Telescopic
1. With the inner telescopic inserted halfway
roller bearing to one side of the outer
6. Using the hoist, slide the outer telescopic telescopic. Make sure the flat spot on the
the entire length of the main frame, bearing outer stud is correctly positioned
checking for binding. Add or remove shims against the mast. See Figure 7-213.
2. Attach but do not tighten the upper roller
free-running fit.
bearing to the other side of the outer
telescopic.
Assembling and Shimming 3. Use spare shims as a gauge to determine
Inner Telescopic to Outer the amount of shims required to cause the
Telescopic roller bearing to contact the inner
telescopic.
Lower Bearings of Inner Telescopic 4. Remove both upper bearings. Install one
1. Attach the lower roller bearing to one side each roller bearing. Reinstall the bearings.
of the inner telescopic. Make sure the flat Apply thread-locking compound
spot on the bearing outer stud is correctly (P/N 990-536) to the bearing mounting
positioned against the mast. See bolt and torque to 260 ft. lb. (352 Nm).
Figure 7-213.
5. If the inner race of the bearing does not
2. Using a suitable hoist, insert the inner protrude past the end of the bearing stud
telescopic into the outer telescopic as far when the bearing is fully seated, bend the
as the crosstie. flat washer to contact the bearing to
3. Attach the lower roller bearing to the other prevent the bearing from walking on the
side of the inner telescopic. stud shaft. See Figure 7-219.
4. Using a pry bar, move the inner telescopic 6. Using the hoist, slide the inner telescopic
and bearing to one side. the entire length of the outer telescopic,
5. Use spare shims as a gauge to determine checking for binding. Add or remove shims
the amount of shims required to cause the as necessary to maintain a snug but
roller bearing to contact the outer tele. free-running fit.
6. Remove both lower bearings. Install one 7. Check the clearance gap of the bow pads
half of the total shim thickness required to between inner telescopic and outer
each roller bearing. Reinstall the bearings. telescopic. Shim as required to obtain a
Apply thread-locking compound gap of 0.03 to 0.09 in. (0.8 to 2.3 mm).

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Main Lift Chain Installation 13. Insert chain anchor bolts into chain
anchor blocks. Lower the telescopics
1. Install anti-rattle pads and shims at completely. Tighten the chain anchor nuts
bottom of inner and outer telescopics. until the inner telescopic is 3/8 in.
Shim so pads are snug against mast. See (9.5 mm) off the outer telescopic.
2. Install the main lift chain sheaves to the Shimming Carriage to Inner
top of the outer telescopic. Sheaves install Telescopic
with a large pin and a retaining screw on
the front. See Figure 7-216. 1. Drape the free lift chains forward over the
3. Install but do not tighten a new sleeve and carriage backrest. Rig lifting straps around
collar, washer, and mounting bolt through the carriage.
the telescopic crosstie and into the 2. Install the lower set of roller bearings,
cylinder housing of each main lift cylinder. without shims, in the carriage.
See Figure 7-215. 3. Using a hoist, carefully lift the carriage
4. Rig lifting straps around the upper and insert it into the inner telescopic until
crossties of all three mast sections. the bearings just enter the telescopic.
5. Using a suitable hoist, raise the mast to a 4. Using a pry bar, move the carriage
vertical position. bearings to one side.
6. Rig a lifting strap of one hoist around the 5. Use spare shim(s) as a gauge to determine
lower crosstie of the main frame (the one the amount of shims required to remove
where the overhead guard attaches). side play.
7. Rig a lifting strap of another hoist around 6. Remove the carriage from the inner
the top crossties of both inner and outer telescopic far enough to expose the
telescopics. Using the hoist, lower the bearings being shimmed.
telescopics to about 10 in. (25 cm) from 7. Remove the bearings being shimmed from
the floor. the carriage. Install one half of the total
8. Make sure the two holes in the upper shim thickness required to each roller
chain anchor block are towards the bearing.
outside. Feed the main lift chain from the 8. Using the hoist, reinsert the carriage into
outside to the inside over the chain the inner telescopic. Check for tight areas
sheave. while moving the carriage to the bottom of
9. Feed the upper chain anchor block down the inner telescopic.
between the main frame and outer 9. Remove the carriage from the inner
telescopic until holes are aligned between telescopic far enough to expose the
block and main frame. Insert the chain bearings being shimmed.
anchor bolt (without the access cover) and
lightly tighten the bolt to draw the chain 10. Remove the bearings being shimmed from
anchor block to the main frame. the carriage.
10. Thread a bolt into the hole in the chain NOTE: You might need to remove the carriage
anchor retaining pin. Insert the pin and several times to obtain the correct fit.
drive it in. Remove the bolt from the pin. 11. Install the center set of roller bearings,
11. Remove the chain anchor bolt. Apply without shims, in the carriage.
thread-locking compound (P/N 990-544) 12. Repeat steps 4 through 10 for the center
to bolt threads. Install access cover and set of bearings.
torque bolt to 130 ft. lb. (174 Nm).
13. Install the upper set of roller bearings,
12. Lower the telescopics into the main frame without shims, in the carriage.
approx 3 in. (7.6 cm) from the floor.

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14. Repeat steps 4 through 10 for the upper Figure 7-222. Over-the-Mast Hose and Cable Installation
set of bearings.
1066854_B2.cgm
Carriage, Free Lift Cylinder, and

the carriage and insert it into the inner
telescopic and lower the carriage to about
2. Route lift hose and cable around upper
pulleys. See Figure 7-221.
3. Route auxiliary hoses around lower
pulleys. See Figure 7-221.
Figure 7-221. Over-the-Mast Hose/Cable Pulleys

1045742_D2.cgm
Cable
Main Lift
Aux Lift

4. Install carriage stops at top of inner
telescopic. Apply thread-locking
compound (P/N 990-536) to mounting
bolts and torque to 35 ft. lb. (47.5 Nm).
5. Lift each free lift cylinder into place over
the mounting stud at the top and the pin
at the bottom. See Figure 7-212.
6. Reference Figure 7-222 for the following
U-Clamp
7. Connect supply hose and crossover tubing

to free lift cylinders. See Figure 7-223.

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Figure 7-223. Free Lift Cylinder Hose Connection Figure 7-225. OTM Hoses and Cable at Free Lift Pulley
1066854_B9.cgm 1066854_B3.cgm
Aux Hoses Electrical Cable
Supply Hose
Crossover Tubing
8. Attach and tighten the hose retainer

bracket at the bottom of the free lift
cylinder. See Figure 7-224.
Figure 7-224. Lower Hose/Cable Retainer, Free Lift

Cylinder
1066854_B4.cgm
10. Attach and tighten the hose retaining

clamp on the carriage near the bottom of
the left side free lift cylinder. See
Figure 7-211.
11. Replace cable ties on hose clamps on left
side free lift cylinder.
12. Feed the over-the-mast (OTM) electrical
cable through the U-clamp on the right
side free lift cylinder. See Figure 7-222.
13. Attach and tighten the hose retaining
clamp near top of the left side free lift
cylinder. See Figure 7-209.
15. Take slack out of hoses and cable.
9. Feed hydraulic hoses and electrical cable
through the free lift pulleys, from tractor 16. Lower the carriage all the way to the floor.
side to forks side. See Figure 7-225. 17. Tighten the upper and lower hose clamps
on the free cylinders.
18. With the auxiliary manifold removed from
the carriage, connect auxiliary hydraulic
hoses to the manifold, making sure to
observe correct labeling.
19. Attach the manifold to the carriage. Apply


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to the mounting bolt threads and torque to 13. Secure a hoist strap around the overhead
21 ft. lb. (29 Nm). guard or position a lift truck with pallet
20. Connect the over-the-mast cable wires to under the overhead guard. Lift the guard
the terminal block on the auxiliary into position at the lower crosstie of the
manifold cover. Attach the manifold cover main frame.
to the carriage. Apply thread-locking 14. Apply thread-locking compound
compound (P/N 990-536) to the mounting (P/N 990-536) to the mounting bolt
bolt threads and torque to 30 ft. lb. threads. Install mounting bolts and torque
(42 Nm). to 130 ft. lb. (174 Nm).
Mating Tractor to Mast 16. Using a suitable battery moving device,
1. Position the tractor about 10 in. (25 cm) install the battery. Install battery gates.
from the mast. Place blocks under the 17. Attach front covers and top cover.
tractor near the mast to match the bolt 18. Make sure all hoist straps and blocks are
hole height in tractor and mast. removed.
2. With the mast secured by a hoist, use a lift 19. Reconnect the battery connector and turn
truck to mate the tractor to the mast. the key switch ON.
3. Apply thread-locking primer
(P/N 990-666) to mast mounting bolt
threads and hole threads. Permit to dry for
several minutes. 21. Test all lift truck functions.
4. Apply thread-locking compound 22. Elevate the inner telescopic about 12 in.
(P/N 990-544) to threads of mast (30 cm). Torque the main cylinder top
mounting bolts. mounting bolts. Tighten main lift cylinder
L-bracket mounting bolts to 55 ft. lb.
5. From the battery compartment, thread (74.5 Nm).
eight mounting bolts and washers through
bottom of the tractor frame into the mast. 23. Using a work basket and lift truck, grease
Thread four mounting bolts and washers the channels of all sections of the mast.
through the top of the tractor frame into
the mast. Torque bolts to 165 ft. lb.
(224 Nm).
6. Connect the main lift hose fitting at the left
7. Route the auxiliary hoses and electrical
cable through the tractor opening.
9. Connect over-the-mast cable connector
TS3 on the tractor deck. See Figure 7-169.
tractor near the lift pump. Connect
connector JPS4.

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Mast, Model 7640 blocked where it meets the mast before

loosening the mast mounting bolts.
11. Place blocks snugly under the tractor near
Disassembly the mast.
12. Attach a lifting strap around the top
Separation of Tractor and Mast crossties of all three mast sections. Draw
• Do this procedure with a minimum tight with hoist. Make sure the weight of
of two technicians in a shop the mast is supported by the hoist.
equipped with a suitable hoist. 13. Remove the battery connector bracket to
• Do not permit observers to stand permit access to the top right mast
nearby. mounting bolts.
• Wear gloves, safety glasses, 14. Use an impact wrench to remove the mast
steel-toed safety boots, and a safety mounting bolts inside the battery
helmet (hard hat). compartment; four on the top, eight on the
bottom.
completely. 15. Using a lift truck, carefully separate the
the battery connector. Remove battery 16. Reinstall mast mounting bolts and
gates. Using a suitable battery removal washers and tighten lightly (to prevent
device, remove the battery. misplacing them).
3. Remove the top cover and the left and right
front covers. Hose/Cable, Free Lift Cylinder, and
4. Remove the mast guard. Carriage Removal
5. Remove or disconnect any options 1. Remove the auxiliary manifold cover from
mounted on the overhead guard. Secure a the carriage. See Figure 7-226.
hoist strap around the overhead guard. 2. Disconnect the wires of the over-the-mast
Take the weight off the guard. Remove cable from the terminal strip, labeling as
mounting bolts. Remove the guard. needed for reconnection.
6. Disconnect and cap the left end of the 3. On the standard reach carriage, remove
right side main lift hose at the tractor auxiliary manifold mounting screws to
bulkhead fittings. permit access to the over-the-mast hose
7. If so equipped, disconnect the ambient fittings at the manifold.
temperature sensor connector JPA and
NOTE: There may be shims between the
HTI connector JP13 on the tractor deck.
8. Disconnect the mast switch connector
JPS4 (near the lift pump) and the encoder
connector JPS11. Feed harness through
tractor opening.
TS3 on the tractor deck.
through opening in tractor bulkhead.
NOTE: Make sure the weight of the mast is fully

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Figure 7-226. Auxiliary Manifold Access bottom and past the mounting pin at the
top.
DSC_0942a.jpg
17. Remove carriage stops at the top of the

inner telescopic.
18. Remove the forks.
19. Rig lifting straps around the carriage.
Main Lift Chain Removal

1. Rig a lifting strap of one hoist around the
lower crosstie of the main frame (the one
4. Disconnect and plug/cap the where the overhead guard attaches).
over-the-mast hoses and fittings at the 2. Rig a lifting strap of another hoist around
auxiliary manifold. Label as needed to the top crossties of both inner and outer
make sure correct reconnection. telescopics. Using the hoist, raise the
5. Jack carriage up about 3 in. (7.6 cm) to telescopics about 10 in. (25 cm).
provide slack in the free lift chains. 3. Remove master links from the upper
Remove master links on free lift chains. (adjustable) chain anchors. See
Feed free lift chains through pulleys and Figure 7-227.
drape over front of carriage.
6. Remove or loosen hose/cable retaining Figure 7-227. Main Lift Chain Upper Chain Anchor
1051602_C2a.cgm
clamps on back of carriage.

Master
7. Remove or loosen the upper clamp from Link
left free lift cylinder.
8. Remove hose/cable ties from the free lift
cylinders.
9. Separate and block the telescopics to
provide slack in the OTM lift hose.
10. Remove the OTM hose/cable retainers
Chain
11. Disconnect and cap/plug the main lift Anchor
hose at the left side free lift cylinder.
12. Remove the OTM hose/cable retainers
from the mast crosstie and left main lift 4. It will be easier to remove the lift chain if
cylinder. you separate telescopics first.
13. Remove the OTM hoses and cable from the
mast. Separation of Telescopics
14. Feed hoses and cable through free lift 1. Using the hoists, carefully lower the mast
cylinder pulleys. to a horizontal position on jack stands.
15. Remove connecting hose from free lift 2. Loosen the L-bracket bolts holding the
cylinders. main lift cylinders to the telescopic.
16. Remove top mounting hardware from each 3. Remove the top mounting bolt, washer,
of the free lift cylinders. Lift each free lift and sleeve holding the main lift cylinder to
cylinder off the mounting pin at the the outer telescopic. See Figure 7-228.

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Figure 7-228. Main Lift Cylinder Mounting Hardware 6. Remove anti-rattle pads and shims from
bottom of inner telescopic. See
R1020561_A2.cgm
Mounting Bolt Figure 7-231.

Washer Figure 7-231. Main Lift Chain Lower Chain Anchor and
Inner Telescopic Lower Roller Bearing
Sleeve 1051602_C8.cgm
Master
Link
Chain
Outer Anchor
Telescopic Shim
Bearing
4. Remove main lift chain sheaves from top of
outer telescopic. See Figure 7-229.
Figure 7-229. Main Lift Chain Sheave

1051602_C9.cgm
Anti-Rattle Pad
Bearing Sheave 7. Using a suitable hoist, pull the inner

telescopic. Keep tension on the main lift
chains while pulling the inner telescopic.
8. Remove the main lift chains at the lower
chain anchor. See Figure 7-231.
Snap Ring shims from the top of the outer telescopic.
See Figure 7-232.
Figure 7-232. Outer Telescopic Upper Bearing

1051602_C9.cgm
Stud
5. Remove anti-rattle pads and shims from

bottom of outer telescopic. See
Figure 7-230.
Figure 7-230. Outer Telescopic Lower Bearing and

Anti-Rattle Pads
R1020561_A4.cgm
Stud
Bearing
Shim
Retaining Screw
Shim
and Washer
telescopic. See Figure 7-231.
telescopic from the outer telescopic.
Anti-Rattle Pad Cover

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12. Using a suitable hoist, pull the outer Assembling and Shimming
telescopic halfway out of the main frame.
13. Disconnect the height encoder belt at the
top of the outer telescopic. See “Height
Lower Bearings of Outer Telescopic
Encoder Belt” on page 7-140.
14. Remove the height encoder from the main 1. Begin the assembly with the main frame
frame. positioned horizontally on jack stands.
15. Reconnect the encoder belt at the 2. Attach both ends of the height encoder
telescopic. belt to the mast.
16. Remove the upper roller bearings and 3. Attach the lower roller bearing to one side
shims from the main frame. See of the outer telescopic. Make sure the flat
Figure 7-233. spot on the bearing outer stud is correctly
positioned against the mast. This is
Figure 7-233. Main Frame Upper Bearing important because the correct bearing
1051602_C6.cgm
alignment is canted with respect to the
Bolt channel. See Figure 7-230.
4. Using a suitable hoist, insert the outer
telescopic into the main frame as far as
the crosstie.
5. Attach the lower roller bearing to the other
side of the outer telescopic.
6. Using a pry bar, move the outer telescopic
and bearing to one side.
7. Use spare shims as a gauge to determine
the amount of shims required to cause the
Stud Shim Bearing
roller bearing to contact the main frame.
Stop Block prevent the bearing from walking on the
17. Pull the telescopic until the lower stop
access cutouts align with the stop blocks
mounted to the main frame. Remove the
stop blocks on the main frame. See
Figure 7-233.
Figure 7-230.

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Figure 7-234. Inner Race 5. If the inner race of the bearing does not
mastbearshim1.jpg

6. Using the hoist, slide the outer telescopic
checking for binding. Add or remove shims
free-running fit.
7. When the upper mast bearing shimming is
complete, reinstall the height encoder.

10. Using the hoist, slide the outer telescopic Inner Telescopic to Outer
checking for binding. The tightest spots
Telescopic
will generally be at the crossties. Add or
remove shims as necessary to maintain a Lower Bearings of Inner Telescopic
snug but free-running fit. 1. Attach the lower roller bearing to one side
11. Align mast stop cutouts on the outer of the inner telescopic. Make sure the flat
telescopic with the stop locations on the spot on the bearing outer stud is correctly
main frame. Install mast stops on the positioned against the mast. See
main frame. Figure 7-231.
2. Using a suitable hoist, insert the inner
Upper Bearings of Main Frame telescopic into the outer telescopic as far
as the crosstie.
1. With the outer telescopic inserted halfway
into the main frame, attach the upper 3. Attach the lower roller bearing to the other
roller bearing to one side of the main side of the inner telescopic.
frame. Make sure the flat spot on the 4. Using a pry bar, move the inner telescopic
bearing outer stud is correctly positioned and bearing to one side.
against the mast. See Figure 7-233.
5. Use spare shims as a gauge to determine
2. Attach, but do not tighten, the upper roller the amount of shims required to cause the
bearing to the other side of the main roller bearing to contact the outer tele.
frame.
3. Use spare shims as a gauge to determine half of the total shim thickness required to
the amount of shims required to cause the each roller bearing. Reinstall the bearings.
roller bearing to contact the outer Apply thread-locking compound
telescopic. (P/N 990-536) to the bearing mounting
4. Remove both upper bearings. Install one bolt and torque to 260 ft. lb. (352 Nm).
half of the total shim thickness required to 7. If the inner race of the bearing does not
each roller bearing. Reinstall the bearings. protrude past the end of the bearing stud
Apply thread-locking compound when the bearing is fully seated, bend the
(P/N 990-536) to the bearing mounting flat washer to contact the bearing to
bolt and torque to 260 ft. lb. (352 Nm). prevent the bearing from walking on the

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8. Using the hoist, slide the inner telescopic 2. Install the main lift chain sheaves to the
the entire length of the outer telescopic, top of the outer telescopic. See
checking for binding. Add or remove shims Figure 7-229.
as necessary to maintain a snug but 3. Install a new sleeve and collar, washer,
free-running fit. and mounting bolt through the telescopic
9. When the lower mast bearing shimming is crosstie and into the cylinder housing of
complete, attach the main lift chains to the each main lift cylinder. Apply
lower chain anchors. Keep tension on the thread-locking compound (P/N 1013829)
chains as the inner telescopic is inserted to the threads of the bolt and leave a 0.12
into the outer telescopic. in. (3 mm) gap between the bolt head and
washer. See Figure 7-228.
Upper Bearings of Outer Telescopic 4. Rig lifting straps around the upper
crossties of all three mast sections.
1. With the inner telescopic inserted halfway
into the main frame, attach the upper 5. Using a suitable hoist, raise the mast to a
roller bearing to one side of the outer vertical position.
telescopic. Make sure the flat spot on the 6. Rig a lifting strap of one hoist around the
bearing outer stud is correctly positioned lower crosstie of the main frame (the one
against the mast. See Figure 7-232. where the overhead guard attaches).
2. Attach, but do not tighten, the upper roller 7. Lower the telescopics into the main frame
bearing to the other side of the outer approx 3 in. (7.5 cm) from the floor.
telescopic. 8. Insert chain anchor bolts into chain
3. Use spare shims as a gauge to determine anchor blocks. Lower the telescopics
the amount of shims required to cause the completely. Tighten the chain anchor nuts
roller bearing to contact the inner until the inner telescopic is 3/8 in.
telescopic. (9.5 mm) off of the outer telescopic at the
4. Remove both upper bearings. Install one upper crossties.
each roller bearing. Reinstall the bearings. Shimming Carriage to Inner
Apply thread-locking compound Telescopic
bolt and torque to 260 ft. lb. (352 Nm). 1. Drape the free lift chains forward over the
the carriage.
when the bearing is fully seated, bend the 2. Install the lower set of roller bearings,
flat washer to contact the bearing to without shims, in the carriage.
prevent the bearing from walking on the 3. Using a hoist, carefully lift the carriage
stud shaft. See Figure 7-234. and insert it into the inner telescopic until
6. Using the hoist, slide the inner telescopic the bearings just enter the telescopic.
the entire length of the outer telescopic, 4. Using a pry bar, move the carriage
checking for binding. Add or remove shims bearings to one side.
5. Use spare shim(s) as a gauge to determine
free-running fit.
the amount of shims required to remove
side play.
Main Lift Chain Installation
1. Install anti-rattle pads and shims at telescopic far enough to expose the
bottom of inner and outer telescopics. bearings being shimmed.
Shim so pads are snug against mast. See

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the carriage. Install one half of the total
shim thickness required to each roller
bearing.
8. Using the hoist, reinsert the carriage into
the inner telescopic. Check for tight areas
while moving the carriage to the bottom of
telescopic far enough to expose the
bearings being shimmed.
the carriage.
NOTE: The carriage may have to be removed
several times to obtain the correct fit.
11. Install the center set of roller bearings,
without shims, in the carriage.
12. Repeat steps 4 through 10 for the center
set of bearings.
13. Install the upper set of roller bearings,
without shims, in the carriage.
14. Repeat steps 4 through 10 for the upper
set of bearings.

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Carriage, Free Lift Cylinder, and Hose/Cable Installation Mast, Chain, Hose, Cable
Carriage, Free Lift Figure 7-236. Over-the-Mast Hose and Cable Installation
1051959_B2.cgm
Cylinder, and
the carriage and insert it into the inner
telescopic and lower the carriage to about
2. Attach the manifold block at the bottom of
the mast between the main and free lift
cylinders. Apply thread-locking compound
(P/N 990-536) to bolt threads and torque
to 15 ft. lb. (21 Nm).
3. Connect the tee tubing for the main lift
cylinders.
4. Route cable and hoses around upper
pulleys.
Figure 7-235. Over-the-Mast Hose/Cable Pulleys

1051959_B9.cgm
5. Install carriage stops at top of inner

telescopic. Apply thread-locking
compound (P/N 990-536) to mounting
bolts and torque to 35 ft. lb. (47.5 Nm).
6. Lift each free lift cylinder into place over
the mounting pin at the bottom and the
mounting pin at the top.
7. Attach the lift hose to the free lift cylinder.
9. Connect hose to free lift cylinders. See
8. Reference Figure 7-236 for the following Figure 7-237.

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Mast, Chain, Hose, Cable Carriage, Free Lift Cylinder, and Hose/Cable Installation
Figure 7-237. Free Lift Cylinder Hose Connection Figure 7-239. Deep-Reach ® Carriage Hose Routing
1067160_C1.cgm
10. Attach the OTM hoses to the reach

manifold and the OTM cable to the
carriage terminal strip.
11. Position the hoses and cable into their
clamps at the back of the carriage and
tighten. See Figure 7-238 and
Figure 7-239.
Figure 7-238. Standard Carriage Hose Routing

12. Feed OTM hoses and cable through free lift
cylinder pulleys. See Deep-Reach ®
Carriage Hose Routing.
13. Position hoses in the retaining clamp at
the top of the left free lift cylinder. See
Figure 7-240. Remove all slack.
14. Find the correct L5 value from Table 7-18.
Measure and mark hoses above the clamp,
using the L5 value. L5 equals the length
the hoses are to be stretched over the free
lift cylinder.
the key switch ON.
16. Place block under carriage and lower
carriage to relieve tension on hoses.
17. Pull down on the hoses until marks are
flush with top of retainers.
18. Set the tension on the cable spring at the
top of the right free lift cylinder by sliding
the cable grip to produce a spring length of
1.75 ±0.12 in. (44.5 ±3.0 mm) across the
coils.
19. Route hoses and cable down free lift
cylinders. Remove slack. Fasten hoses and
cable to cylinders with cable ties.

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Carriage, Free Lift Cylinder, and Hose/Cable Installation Mast, Chain, Hose, Cable
Figure 7-240. Over-the-Mast Hose/Cable Retainer 20. Fasten the cable to the free lift cylinder
Locations (Model 7640) connecting tube and position cable into
1051959_B2.cgm,1051959_B3.cgm
retainers at the bottom of the inner

telescopic.
21. Position hoses into the retainers at the
bottom of the inner telescopic. Remove all
slack and tighten the retainers.
22. Route and feed the hoses and cable
through the pulley assembly at the top of
the telescopic.
23. Feed the hoses and cable through the
L4 retainer at the main frame crosstie. See
See Figure 7-240. Remove all slack.
24. Find the correct L4 values from
Table 7-18. Measure and mark hoses
above the retainer.
25. Block between the telescopics to provide
slack in the hoses.
L5
26. Pull down on the hoses until marks are
flush with top of retainers.
27. Set the tension on the cable spring by
sliding the cable grip to produce a spring
length of 1.75 ±0.12 in. (44.5 ±3.0 mm)
across the coils.
28. Feed cable and hoses through remaining
retainers. Remove all slack and tighten.
Table 7-18. Over-the-Mast Hose stretching values (Model 7640)
L4 (Lift and Aux Hoses) L5 (Aux Hoses)
OACH in. mm OACH in. mm
142 to 147 2.75 69.9 142 to 158 1.50 38.1
148 to 154 3.00 76.2
155 to 163 3.25 82.6 159 to 184 1.75 44.5
164 to 171 3.50 88.9
172 to 180 3.75 95.3
181 to 184 4.00 101.6

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Mast, Chain, Hose, Cable Mating Tractor to Mast
Mating Tractor to Mast 16. Install the mast guard.

17. Using a suitable battery moving device,
1. Position the tractor about 10 in. (25 cm) install the battery. Install battery gates.
from the mast. Place blocks under the 18. Attach front covers and top cover.
tractor near the mast to match the bolt 19. Make sure all hoist straps and blocks are
hole height in tractor and mast. removed.
2. With the mast secured by a hoist, use a lift
truck to mate the tractor to the mast.
the key switch ON.
3. Apply thread-locking primer 21. Bleed the hydraulic system. See
(P/N 990-666) to mast mounting bolt “Hydraulic System Bleeding” on page 7-74.
threads and hole threads. Permit to dry for
several minutes. 22. Test all lift truck functions.
4. Apply thread-locking compound 23. Apply thread-locking compound and
(P/N 990-544) to threads of mast tighten main lift cylinder L-bracket
mounting bolts. mounting bolts to 55 ft. lb. (74.5 Nm).
5. From the battery compartment, thread 24. Using a work basket and lift truck, grease
eight mounting bolts and washers through the channels of all sections of the mast.
bottom of the tractor frame into the mast.
Thread four mounting bolts and washers
through the top of the tractor frame into
the mast. Torque bolts to 165 ft. lb.
(224 Nm).
6. Connect the main lift hose fitting at the left
7. Install the battery connector bracket.
9. Connect over-the-mast cable to TS3 (refer
to Table 7-17 on page 7-152).
tractor, across the top of the deck to the
right side near the lift pump. Connect
connector JPS4.
12. Connect HTI encoder to JP13 and JPS11.
14. Secure a hoist strap around the overhead
guard or position a lift truck with pallet
under the overhead guard. Lift the guard
into position at the lower crosstie of the
main frame.
(P/N 990-536) to the mounting bolt
threads. Install mounting bolts and torque
to 130 ft. lb. (174 Nm).

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Mating Tractor to Mast Mast, Chain, Hose, Cable

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Model 7600/7620/7640 Reach-Fork ® Truck Section 8. Theory of Operation
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Section 8. Theory of Operation

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Section 8. Theory of Operation Model 7600/7620/7640 Reach-Fork ® Truck
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Traction System Functional Operation
Traction System • The processor in the VM looks at

BATTERY_SENSE_IN (JPC24-24) and
Functional Operation verifies it is within the required
parameters for the amps, 28 to 45V. If it is,
there is an output from the processor to
Battery Connected RELAY_ENABLE at JPC14-6 taking the
relay coils for K1, K2, K3, and K4 to B–
When the battery is connected, the truck has internal to the VM. The VM also uses this
B+ and B– supplied to the following points: input to calculate BSOC and compares it
to the last battery voltage in its memory.
• B+ to JPF4-3 and 4-4 through FU7 and to
The VM then determines if the display
the normally open tips of K1 relay and
requires updating.
JPF4-15.
• The tips of K1, K2, K3, and K4 close,
• B+ to JPF4-1 and 4-2 through FU5 to the
supplying B+ to the following:
normally open tips of K2, K3, K4, and the
key switch S1. JPF4-1 and JPF4-2 also • the Lift Power Amplifier (LPA) and the
supply the VM with BATTERY_SENSE_IN Traction Power Amplifier (TPA)
at JPC24-24. It is protected by a pre-charge circuits from B+K3. B+K3 at
thermistor for overcurrent conditions JPT1-1 and JPL1-1 are used by the
caused by shorts in the wiring. This is amplifiers to power their internal
used by the VM to make sure that battery circuitry that includes power supplies.
voltage is within the requirements for the The power supplies provide 12V to the
lift and traction amps prior to powering encoders and temperature sensors for
them up. the Traction Motor and the Lift Motor.
When K3 is open, it supplies a path for
• B+ to the normally open tips of the Steer,
the capacitors in the amplifiers
Traction, and Lift contactors.
pre-charge circuits to discharge to B–.
• B– is supplied to all points labeled B–, B–F, Both pre-charge circuits have a
any sensor connection with a (–) negative thermistor in them (on the Fuse/Relay
label, and DGND. Card) to protect from overcurrent
damage if there is an open in the motor
Key Turned ON power circuitry or contactors.
• Reach, Tilt, Sideshift, Aux 1, Aux 2,
When the key switch is turned ON, B+ is L/L, L/H, and Dump solenoids, Nested
supplied to the following points: Switch, Horn, and fans T, FW, FW2 and
• through the EPO switch to the coils of K1, DU are supplied by B+K2.
K2, and K3. • connections for optional devices at
• to JPC14-12 at the VM as B+ Key. This, JPF2-9 by B+K1.
internal to the VM, activates the power • B+ is supplied to the VM by B+K4 to be
supply circuits that supply all 12V and 5V used internally.
outputs from the VM and activates the • With all microprocessors powered up,
microprocessor in the VM. The power SelfTest continues:
supplies maintains a steady output as
long as battery voltage remains above 17V. • the VM checks to make sure its power
With the power supplies activated, 12V is supplies are within range.
supplied to the display. The display • the VM checks the BUS to make sure
contains a microprocessor that requires communications are functioning with
firmware updates any time the VM is all other devices (DISPLAY, LPA, and
updated. TPA).

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• the amplifiers check the pre-charge maximum voltages. They are

circuit voltages to make sure they are continuously monitored and messages
in range. If not, a message is sent over are displayed if activated prior to
the BUS to the VM and a code is closing the deadman switch.
displayed. • the TPA is commanded to activate the
• the VM asks the TPA and LPA for the Traction Motor to make sure current is
status of the TPC and LPC contactors to seen and there are no motor encoder
make sure they are open. This is only inputs. This is to make sure the power
checked during SelfTest. It is checked circuits are functional and the brake is
continuously after the truck has passed applying resistance to the Traction
SelfTest and the VM has not Motor.
commanded it to be closed. • the VM checks the state of the control
• the VM verifies the Steer Contactor is handle switches to make sure they are
open. This is only done during SelfTest. in the open position. They are
• the VM commands the LPA and TPA continuously monitored and messages
over the BUS to close the LPC and TPC. are displayed if activated prior to
The VM activates the circuitry to close closing the Deadman Switch.
the STR contactor. The LPC, TPC and • the VM checks the information from the
STR contactors are checked to make TPA and LPA to make sure the motor
sure power is supplied through the temperature sensor readings are within
contactor tips to the motors circuits. range and determines if speed limiting
The LPA and TPA report the state of the is required.
LPC and TPC over the BUS. They are • the VM checks pressure transducer
monitored via the (+) connections on readings to make sure they are within
the amplifiers. When the contactor range.
closes, the amplifiers see a higher
voltage than seen from the pre-charge • the VM checks to make sure the
circuit. The VM monitors the STR Ambient Temperature Sensor is within
contactor via JPC22-19. the acceptable range.
• the VM verifies the EPO switch is • the VM checks its memory for all
closed. previously logged faults that have not
been cleared.
• the software and configured parameters
are checked in the LPA, TPA, Display, • after SelfTest is complete, the LPC and
and VM to make sure they are within TPC contactors remain energized for
limits and correct. approximately 30 seconds. If no
function requests are made by the
• the amplifiers check to make sure there operator, they open. The STR contactor
are no shorts in the power circuits. opens as soon as the circuits are tested.
• the VM checks to make sure the The VM also monitors the temperature
Deadman Switches are open. inputs from the TPA and LPA. Anytime
• the VM checks to make sure the Steer one of the readings goes above 113°F
Tiller Encoder is connected. (45°C), the VM turns on fans T, FW,
FW2, and DU.
• the VM checks to make sure the lift
potentiometer (VR2) and throttle
potentiometer (VR1) are within 0.2V of
the learned neutral position and are not
outside the allowable minimum and

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Deadman Pedal Depressed NEUTRAL_PULSE is created by the VM sending

a very low steering command over the CCW and
When one of the deadman pedals is depressed, CW wires to the Steer Amplifier. These
the brake is released. The brake does not get commands are alternated back and forth
applied until the truck is at a complete stop and between CCW and CW. This creates a toggling
the deadman switch is opened. high/low input on the NEUTRAL_PULSE line
that changes about 10 times a second. When a
With the Deadman Switch closed, the VM tells steer command is present, this input does not
the LPA and TPA it is closed and commands the toggle as fast and the VM ignores it. When the
LPC, TPC, and STR contactors to be closed. The operator turns the steering wheel, a set of
VM now reacts to any request from control pots square wave voltages (chopped DC voltage) is
or switches for lift/lower, travel, and aux sent to the VM on Channels A _1, B_1, A _2, and
functions. When the Deadman Switch is opened B_2. The VM looks at the square waves as sets.
again, the LPC and TPC remain energized for 30 A _1 and B_1 are one set and A _2 and B_2 are
seconds with no functions commanded and another set. Based on which channel of the set
then open. The STR contactor remains is seen first, A or B, the VM determines the
energized for 3 seconds and then opens. One of direction the operator has requested the drive
the deadman switches then has to be closed unit to turn. The VM determines the requested
again for the contactors to be energized. speed by the amount of time between the
square waves. Less off time between them
With one of the deadman switches closed, the means a faster rotation was requested. Two sets
TPA continuously monitors the input from the are used so the VM can compare them and
Traction Motor encoder. If no travel request is verify the encoder is functioning correctly. Once
seen from the control handle and inputs are this information is processed, the VM sends out
seen from the sensor, the TPA powers the a chopped DC voltage to the Steer Amplifier
Traction Motor as required to keep the truck in over CCW_PWM or CW_PWM. CCW_PWM is a
the same position. This prevents unwanted request for the drive unit to be turned in the
movement on uneven surfaces, dock plates or counterclockwise direction and CW_PWM is a
ramps, or if placing a pallet in the rack system. command to turn in the clockwise direction.
Based on the off time between the square
waves, the Steer Amplifier determines the speed
Electric Steering of rotation requested and sends the appropriate
NOTE: This information is based on a truck voltage to the Steer Motor. Direction of Steer
that is not programmed for Reverse Motor/Drive Unit rotation is controlled by the
Steering. If programmed for Reverse side of the Steer Motor that has positive voltage
Steering, the VM reverses the CW and applied to it, MS-A1 or MS-A2. The VM then
CCW commands to the Steer Amplifier. monitors the inputs from the Steer Motor
It also looks for feedback from the Steer Encoder to determine the direction and speed
Motor Encoder in the opposite direction. the motor is turning and compares it to the
request. The VM also monitors the Steer Motor
On trucks with electric steering, when the VM current from the Steer Amplifier on JPC6-3,
closes the STR contactor, the VM begins to STEER_CURRENT. Current limit for the Steer
monitor the inputs from the Steer Amplifier, Motor is approx 100 amps and is controlled by
Steer Tiller Encoder, and the Steer Motor the Steer Amplifier. The VM uses this input
Encoder. The VM is looking for a current draw when checking the steering system for shorts or
on the 12V lines that power the two Steer Tiller opens in the power circuit. The VM also
Encoder channels. With no steer requests from monitors the input from the END OF STEER
the Steer Tiller Encoder, the VM looks for an ROTATION SWITCH (S11), mounted next to the
input from the Steer Amplifier on JPC6-1, drive unit. This is a proximity switch that is
NEUTRAL_PULSE. This feedback from the Steer turned ON and OFF by a metal ring mounted to
Amplifier informs the VM that the Amplifier is the drive unit. As the drive unit nears the end of
connected and powered up. The its rotation, the metal ring is no longer under

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the proximity switch and the switch opens prior

to hitting the drive unit’s mechanical stop.
When the input to the VM goes high at
JPC22-22 STEER_LIMIT, the VM no longer
sends out a steer command in that direction. It
only sends out commands when there is a
request in the opposite direction from the
operator. This prevents the steering system
from being held in current limit.
Travel Request
With one of the Deadman Switches (DS1 or
DS2) closed, the VM constantly sends an RPM
request that causes the TPA to maintain the
speed requested by the operator. With the
control handle in neutral, the request is always
at 0 RPM. When the VM sees a change in the
learned neutral voltage from the VR1 at
JPC12-3, it first checks for any inputs that
activate a speed limit condition. If none are
seen, it calculates the direction and percent of
full speed requested based on the learned
values. A message is sent to the TPA over the
BUS as a command to travel in the appropriate
direction at the RPM to obtain the requested
speed. The TPA then determines the correct
sequence to energize the motor leads (U, V, and
W) to move the truck in the correct direction.
The TPA also determines the required amount
of DC voltage to send through the motor leads
based on the acceleration parameters
programmed and the requested RPM. The TPA
then monitors the feedback from the Traction
Motor encoder to adjust the voltage to the
Traction Motor to maintain the requested RPM
and direction. Any conditions that prevent the
TPA from maintaining these requests are sent
over the BUS to the VM. The VM tells the
Display over the BUS to display a message
informing the operator. The VM also invokes
any system shut down or limitations based on
the information from the TPA.

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Cold Storage
Cold Storage
On trucks with the Cold Storage option, the VM
looks at the Ambient Temperature Sensor
mounted on the overhead guard. If the
temperature indicates the truck is parked
inside the freezer, the VM does not turn off the
RELAY_ENABLE circuit when the key switch is
opened. When the key is turned OFF, K1, K2,
and K3 all open because they are powered from
the key switch. The K4 coil and tips receive
power directly from the battery through FU5.
When the tips are closed, K4 supplies B+ to
internal circuitry of the VM. This is only used
on trucks equipped with the optional Cold
Storage package. The VM uses the input from
the K4 tips to keep its circuitry powered up.
This is done so the VM can keep the circuitry
activated for the control handle heater. The
display is shut down and no other functions are
operable until the key is turned ON and the
truck is powered up.

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Hydraulic System Functional Operation
Hydraulic System Tilt Cylinder
Functional Operation The tilt cylinder is a double-acting hydraulic

cylinder used to tilt the forks up and down.
System Components Load Holding Valve (SOL1)
Main Lift/Aux Pump (P1) The load holding valve is a normally closed
solenoid valve used to hold the carriage in an
Pump P1 is a positive displacement gear pump elevated position. It incorporates an override to
that rotates clockwise from the shaft end. P1 is allow lowering the carriage manually.
used for all lift and aux functions.
Proportional Lower Valve (SOL2)
Main Lift System
The proportional lower valve is a pressure
The main lift system consists of four single compensated flow control solenoid valve used to
acting hydraulic cylinders. Hydraulic fluid flows lower the carriage. As the voltage to the valve
from the main manifold through a tee-fitting in increases, the flow through the valve increases,
the tractor, through fittings in the left and right regardless of the pressure.
front of the tractor bulkhead. The right side
hose feeds the right side main lift cylinder. The Proportional Relief (SOL3/Dump)
left side divides again at a tee-fitting, supplying
both the left side main lift cylinder and the free SOL3 is a proportional solenoid used as a
lift cylinders. At the bottom of the free lift system relief. In addition, SOL3 is used to divert
cylinders, another tee-fitting divides the flow hydraulic fluid from Pump P1 back to the
between left and right free lift cylinders. A flow reservoir after a lift is stopped and the pump is
limiter is installed at one of the free lift and one still spinning. It also acts as a valve to port
or both of the main lift cylinders. excess hydraulic fluid back to the reservoir from
the auxiliary functions.
When the operator requests lift, the entire lift
system is pressurized. Since the carriage
weighs less than the carriage plus telescopic, SOL5B/SOL5T
the free lift cylinders extend first, elevating the
carriage. When they reach the limit of their SOL5 is a directional solenoid valve providing
travel, the main lift cylinders extend, elevating directional control to the reach, tilt, and
the telescopics. sideshift functions. De-energized, flow is
blocked to the aux functions and directed to the
reservoir. When SOL5B is energized, flow is
Reach/Retract Cylinder directed to port A2 for tilt up, sideshift right, or
reach. When SOL5T is energized, flow is
The reach/retract cylinder is a double-acting directed to port A1 for tilt down, sideshift left, or
hydraulic cylinder used for extending and retract.
retracting the forks from the mast.
Reach/Retract Solenoid (R/R SOL)
Sideshift Cylinder
R/R SOL is a normally closed solenoid valve
The sideshift cylinder is a double-acting used to block (de-energized) or allow (energized)
hydraulic cylinder used to shift the load left and fluid flow to and from the reach cylinders.
right with respect to the mast.

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Sideshift Solenoid (S/S SOL) Lift Motor Temperature Sensor

S/S SOL is a normally closed solenoid valve The Lift Motor Temperature Sensor is mounted
used to block (de-energized) or allow (energized) internally in the Lift Motor. Its purpose is to tell
fluid flow to and from the sideshift cylinder. the lift power amplifier the temperature of the
lift motor.
Tilt Solenoid (TILT SOL)
Load Shuttle (LS-1)
TILT SOL is a normally closed solenoid valve
used to block (de-energized) or allow (energized) The load shuttles are 2-input, pressure
fluid flow to and from the tilt cylinder. activated, 2-position valves. In each shuttle, the
higher of the input pressures passes through
the valve at the pressure out port. The output
Flow Limiter Valve port provides flow used to operate pressure-
activated devices such as piloted relief or
Flow limiter valves are used to limit the metering valves. The load shuttles provide
maximum lower speed of the forks. A check pressure feedback to the pilot line of the PODS
valve forces restricted flow through the valve valve to allow it to position itself for correct
during lower, but allows free flow during lift. auxiliary and lift function operation.
Aux Relief Valve (REL2) Priority On Demand Spool (PODS)

REL2 is a relief valve used to protect auxiliary This is a pilot operated spring return valve that
system components against excessive pressure. divides flow between the lift and auxiliary
It is factory-adjusted to 2000 psi (13790 kPa). A functions as requested. It also provides a path
manual adjustment knob can be turned to the reservoir for excess hydraulic fluid from
clockwise to increase the relief pressure, or P1.
counterclockwise to decrease the relief
pressure.
Theory of Lift/Aux Functions
Hydraulic Filter
Lift
The hydraulic system has two filters in the
main manifold. Their purpose is to filter Lift speed varies directly with Lift Motor rpm.
impurities from the hydraulic system. They The voltage supplied to the Lift Motor is
filter all hydraulic fluid on the return to the proportional to the amount of lift request from
reservoir. There is no internal bypass. VR2 (faster lift = higher motor voltage).
Maximum lift speed for a given weight load is
governed by software.
Lift Motor (LM)
Weight is calculated from inputs to the VM from
The Lift Motor is a brushless, three-phase
the pressure transducer. Weight of the empty
internally delta connected variable-speed AC
carriage and telescopic is calculated during
motor.
Learn Mode.
Lift Motor Encoder Prior to requesting a lift, all valves are in the
de-energized state.
The Lift Motor encoder is a two-channel
encoder. Its purpose is to tell the lift power When VR2 is moved to request lift, a voltage is
amplifier the motor speed for motor speed sent to the VM at JPC12-2. The VM sees a
regulation during lift and auxiliary functions. voltage different from the “learned” neutral
voltage, and sends a request to the lift power

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amplifier via BUS+/BUS– (JPC14-11 and requested rate of lower via a signal from the VM
JPC14-4 through the Operator Display to at JPC20-16.
JPL1-22 and JPL1-14).
The LPA internally supplies B- to the Lift

Auxiliary Functions
Contactor Coil (LPC) at JPL1-2, that closes the
normally open contactor tips. Tilt
The LPC is energized either by depressing one of Fork tilt allows the operator to raise or lower the
the Deadman Switches (DS1 or DS2), or tips of the forks. Standard fork tilt is 5° up and
rotating the lift pot (VR2) out of neutral to the 2° down.
lift position.
When the deadman pedal is depressed, the VM
When the LPC is energized, the contactor tips sends a command over BUS+/BUS- lines to the
close, allowing B+ to be supplied to the LPA, LPA to energize the LPC.
that supplies voltage to the Lift Motor to make it
rotate. The LPA internally supplies B- to the LPC coil at
JPL1-2, that closes the normally open contactor
The PODS valve (POD-1) receives pressure at tips.
port 4, placing pressure on the pilot line of the
valve. This pressure moves the spool in the The Tilt Up Switch (S6) is depressed,
valve to allow flow out port 2 to CV-1, the completing a circuit between JPC12-5 and
de-energized Load Holding Solenoid (SOL1), JPC12-12 at the VM.
through the flow limiters in the base of the lift
cylinders, and into the lift cylinders, producing The VM energizes the following solenoids via
lift. internal coil drivers:
• SOL3 (Dump) at JPC20-12
When the lift knob is returned to neutral, the
• SOL5B at JPC20-20
Lift Motor is ramped down. SOL3 is opened to
relieve any pressure spikes in the system. • TILT SOL at JPC18-15
Pump P1 rotates at a speed predetermined in

Lower
software. Flow is ported to the PODS valve at
port 3 and out at port 4. Fluid then flows
Variable lowering is accomplished via the
through SOL5B or SOL5T, depending on the
Proportional Lower Solenoid (SOL2). Lowering
direction of the function requested. SOL5 is a
speed is not a function of weight on the forks.
proportional solenoid, but the VM sends a fixed
An increasing voltage increases the flow
voltage to it, regulating the speed of the
through the valve regardless of the pressure in
requested function. If more oil than is needed
the system.
flows to SOL5, back pressure is present at port
4, which is also the pilot line for the PODS
When VR2 is moved to request Lower. A voltage
valve. This shifts the spool of the PODS valve
is sent to the VM at JPC12-2. The VM sees a
and sends the excess oil to SOL3 via port 2.
voltage different from the “learned” neutral
SOL3 opens to allow the excess oil to flow back
voltage.
to the filter and reservoir. After leaving SOL5,
the oil flows to the LS-1. The LS-1 ports oil back
The VM energizes internal coil drivers for SOL1
to the PODS valve at port 1 to help regulate the
at JPC18-10. SOL2 opens proportionally to the
flow to the auxiliary function. From LS-1, the
requested rate of lower via a signal from the VM
fluid flows to the Tilt Solenoid (TILT SOL) on the
at JPC20-16.
carriage. The TILT SOL allows fluid flow to the
requested function.
The VM energizes internal coil drivers for SOL1
at JPC18-10. SOL2 opens proportionally to the

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NOTE: LS-1 also supplies a pilot pressure to Pump P1 rotates at a speed predetermined in
REL2 to open the auxiliary relief if software. Flow is ported to the PODS valve at
pressure gets too high. port 3 and out at port 4. Fluid then flows
through SOL5B or SOL5T, depending on the
Fluid flows through the energized TILT SOL and direction of the function requested. SOL5 is a
then to the tilt cylinder. proportional solenoid, but the VM sends a fixed
Reach/Retract requested function. If more oil flows to SOL5
than is needed, back pressure is present at port
Reach extends the forks away from the mast 4, which is also the pilot line for the PODS
assembly. Retract moves the forks inward valve. This shifts the spool of the PODS valve
towards the mast assembly. The reach/retract and sends the excess oil to SOL3 via port 2.
function can be configured to have single speed SOL3 is opened to allow the excess oil to flow
reach/retract or two speed reach/retract. back to the filter and reservoir. After leaving
Single speed moves at the speed of high-speed. SOL5, the oil flows to the LS-1. The LS-1 ports
oil back to the PODS valve (at port 1) to help
To use two speed reach, depress S5 after regulate the flow to the auxiliary function. From
depressing S4. Doing this switches from low LS-1, the fluid flows to the reach solenoid on
speed to high-speed reach. For high speed the carriage. The Reach/Retract Solenoid allows
retract, depress S4 then S5. fluid flow to the requested function.
NOTE: LS-1 also supplies a pilot pressure to
High-speed or single-speed reach/retract REL2 to open the auxiliary relief if
pressure gets too high.
When one of the deadman pedals is depressed,
the VM sends a command over BUS+/BUS– Fluid flows through the energized
lines to the LPA to energize the LPC. Reach/Retract Solenoid and then to the reach
cylinders.
The LPA internally supplies B- to the LPC at
JPL1-2, that closes the normally open contactor
Sideshift
tips.
Sideshift allows the operator to move the fork
When the Reach Switch (S4) or the Retract
carriage to the left or right relative to the mast.
Switch (S5) is depressed, a circuit is completed
The amount of sideshift is 2 or 4 in. (5 or 10 cm)
to the VM.
depending on the baseleg opening.
On lift trucks with two speed selected, the VM
When one of the deadman pedals is depressed,
activates high speed when the other switch is
the VM sends a command over BUS+/BUS–
also depressed.
lines to the LPA to energize the LPC.
NOTE: To change the speed of the reach (high
speed versus low speed), the VM adjusts The LPA internally supplies B– to the LPC at
the voltage to SOL5 to regulate the valve JPL1-2, that closes the normally open contactor
for more or less flow. tips.
The VM energizes the following solenoids via When the Sideshift Right Switch (S9) is
internal coil drivers: depressed, a circuit is completed between
• SOL3 (Dump) at JPC20-12 JPC12-9 and JPC12-12 at the VM.
• SOL5B at JPC20-20 The VM energizes the following solenoids via

• REACH SOL at JPC18-12 internal coil drivers:
• SOL3 (Dump) at JPC20-12
• SOL5B at JPC20-20

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• SIDESHIFT SOL at JPC18-14 In order to operate reach or retract, S4 or S5 is

used to send an input to the VM at JPC12-4 or
Pump P1 rotates at a speed predetermined in JPC12-11.
software. Flow is ported to the PODS valve at
port 3 and out at port 4. Fluid then flows When the request to lift and reach is made, the
through SOL5B or SOL5T, depending on the VM energizes the following solenoids via
direction of the function requested. SOL5 is a internal coil drivers:
proportional solenoid, but the VM sends a fixed • SOL3 (Dump) at JPC20-12
requested function. If more oil flows to SOL5 • SOL5T at JPC20-18 or SOL5B at
than is needed, back pressure is present at port JPC20-20, depending on the direction of
4, which is also the pilot line for the PODS the function chosen
valve. This shifts the spool of the PODS valve • One of the following:
and sends the excess oil to SOL3 via port 2. REACH SOL at JPC18-12
SOL3 is opened to allow the excess oil to flow SIDESHIFT SOL at JPC18-14
back to the filter and reservoir. After leaving TILT SOL at JPC18-15
SOL5, the oil flows to the LS-1. The LS-1 ports
oil back to the PODS valve (at port 1) to help As Pump P1 begins to rotate, fluid flows into the
regulate the flow to the auxiliary function. From PODS valve at port 3. The PODS valve is used to
LS-1, the fluid flows to the Sideshift Solenoid on bias flow between lift and aux. Port 3 is
the carriage. The Sideshift Solenoid allows fluid connected to port 4. With pressure at port 4,
flow to the requested function. the pilot line works to move the spool to its
second position.
NOTE: LS-1 also supplies a pilot pressure to
REL2 to open the auxiliary relief if
With the valve in its second position, fluid flows
pressure gets too high.
to Check Valve 1 (CV1). Fluid flows through
CV1 and the de-energized SOL1. From there,
Lift while using Aux Functions fluid passes through the free flow portion of the
flow limiters (located in the base of the lift
The LPC is energized by depressing the cylinders) and into the lift cylinders.
Deadman Switch (S2).
SOL3 (Dump) is used as a proportional relief to
The LPA internally supplies B– to the LPC at limit system pressure to a safe level. With this
JPL1-2, that closes the normally open contactor valve: 0V = 3500 psi (24132 kPa). The pressure
tips. relief is set by the VM and firmware at approx
2V, which equals 3200 (22063 kPa) psi.
When the LPC coil is energized, the contactor
tips close, allowing B+ to be supplied to the The PODS valve also meters fluid to the
LPA, suppling voltage to the Lift Motor. requested aux function. As the metered flow
enters SOL5B or SOL5T (depending on the
When VR2 is moved to request lift, a voltage is direction of function requested), the voltage
sent to the VM at JPC12-2. The VM sees a applied to the valve by the VM causes it to open.
voltage different from the “learned” neutral
voltage, and sends a request to the LPA via SOL5 is a proportional solenoid. The VM sends
BUS+/BUS– (JPC14-11 and JPC14-4 to a fixed voltage to it to open it a specific amount,
JPL1-22 and JPL1-14). depending on the function requested.
The voltage supplied to the Lift Motor is The load shuttle sends pressure to the pilot line
proportional to the amount of lift requested of the PODS valve to allow the valve to correctly
from VR2 (faster lift = higher motor voltage). divide the fluid between lift and auxiliary.
NOTE: The Lift Motor/pump is variable speed.

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When using auxiliary functions only (no lift),

the speed of the motor is approx 400 rpm. If
slow lift is used along with an aux function, the
motor/pump speed may increase due to the
need for more fluid to the functions.

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Electric Brake
Electric Brake Brake Application

If the lift truck is traveling when the deadman
Overview pedal is released, the VM causes the lift truck to
plug to a stop. When the VM senses the lift
The Model 7600/7620/7640 lift truck uses an truck has stopped, it de-energizes the brake
electric brake. With the brake coil de-energized, coil. The magnetic field holding the brake
the brake is in a “normally applied” state due to released now collapses. The springs in the
spring pressure. With the brake coil energized, brake coil push the armature plate and pads
the brake is held in a released state due to down on the top of the rotor. Upward pressure
magnetic force. of the springs against the coil body causes the
base plate and pads to be pulled up against the
The brake assembly of coil, armature plate, bottom of the rotor. The brake pads prevent the
base plate, and pads slides up and down on rotor, and the Traction Motor shaft from
three shoulder bolts threaded into the end bell rotating.
of the Traction Motor. The armature plate and
base plate are spaced apart by three hollow Brake Release Screws
total air gap adjusters (spacers). The total gap is
adjusted by the amount the adjuster is Two brake release screws are stored in the
threaded into the coil body. Once this gap is set, brake coil body. These screws are not used
it is held in place by three locking bolts that when removing the entire brake assembly from
thread through the coil and the total air gap the Traction Motor, but are used when
adjusters. disassembling the brake itself. The brake
release bolts are threaded through the coil. The
When the brake is electrically released, the screws press on the base plate, overcoming the
assembly slides down the shoulder bolts and spring pressure and separating the base plate
rests on the lower air gap adjusters. The lower and coil body. The three locking bolts, total air
air gap adjusters are threaded pedestals that gap adjusters, and rotor can now be removed.
are set so as to divide the total air gap evenly
between the rotor and the top and bottom brake
pads.
Brake Release
When the deadman pedal is depressed, the
brake coil is energized. The current flow creates
a magnetic field that draws the armature plate
against the coil body, compressing the brake
coil springs. The brake assembly of coil body,
armature plate, base plate, and pads lowers by
the amount of the lower air gap. Half of the total
air gap (minus a 0.007 in. shim) is between the
rotor and the pads on the base plate. The
remainder of the total air gap is between the
rotor and the pads on the armature plate. The
rotor, attached to the Traction Motor shaft, is
free to rotate.

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Pinout Matrix
Pinout Matrix • Normal Level: the approximate voltage

that you should see on that wire for the
state indicated. Unless otherwise
The pinout matrix table lists functions and indicated, voltages are measured with
normal voltages of terminals and harness respect to (wrt) B– at TP4.
connector pins. The matrix columns have the
• Signal Source: the device or connection
following meanings:
that supplies the signal directly to the
• Item #: sequential number to aid in wire.
reference.
• Signal User: the device or connection to
• Connection: the actual wire numbers or which the wire directly delivers the signal.
component abbreviations on the electrical
schematic.
• Function Description: brief definition of
the signal carried on the wire.
• Theory of Operation:
• A detailed description of the signal
carried on the wire. If the signal is
variable, it indicates the state of a
related component that causes the
signal to vary.
• Identifies possible causes for lack of
correct signal.
Table 8-1. Pinout Matrix
Function Normal Signal Signal

Item Connection Theory of Operations
Description Level Source User
1 JPC3-1 thru USB Communication Port - Not Used

4
2 JPC6-1 NEUTRAL_ This input tells the VM that the Steer Deadman Up: VM Steer
PULSE Amplifier is connected and functioning. 4.6VDC; Amplifier
CCW steer:
4.5VDC;
CW steer:
0.0VDC;
No steering:
voltage varies
3 JPC6-2 CW_PWM This is a control voltage used to rotate the At rest: VM Steer
drive unit in the CW direction. The average 11.5VDC; Amplifier
DC value varies depending on the amount CCW steer:
and speed of steering requested. 11.6VDC;
CW steer fast:
5VDC;
CW steer
slow: 9VDC;

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Pinout Matrix

4 JPC6-3 STEER_ Analog voltage which varies with the steer Steering CW: Steer VM
CURRENT motor current and is sent from the Steer 1.8VDC; Amplifier
Amplifier to the VM. This voltage is used by At rest:
the VM to establish current reading for 2.5VDC;
opens or shorts in the steer system. Steering
CCW:
3.2VDC
5 JPC6-4 DGND Reference for the control circuits in the Steer <0.5VDC VM Steer
Amplifier. If missing, the steer amplifier wrt B– Amplifier
does not power up.
6 JPC6-5 CCW_PWM This is a chopped voltage used to rotate the Steering CW: VM Steer
drive unit in the CCW direction. The 11.6VDC; Amplifier
average DC value varies depending on the At rest:
amount and speed of steering requested. 11.5VDC;
Steering
CCW:
9V slow
5V fast
7 JPC6-6 +12VP Operating voltage from the VM for the +10.7 to VM Steer
control circuits in the steer amplifier. If this is 13VDC Amplifier
missing, the steering is inoperable.
8 JPC9 FlashWare Connection
9 JPC10-1 & 2 Not Used
10 JPC10-3 THERM_EN Voltage from the VM to the ThermaKit ON: VM Control

Control Card to control the heater in the <0.5VDC; Handle
control handle. OFF: Heater
>10.5VDC
11 JPC10-4 Not Used
12 JPC10-5 BUS_E– Carries negative component of the digital 2.53VDC VM WMM

communications between the VM and the
optional Warehouse Management Module
(WMM). If missing, the VM cannot
communicate. Troubleshoot using resistance
checks. No useful information can be
gained by measuring the voltage on this
wire.
13 JPC10-6 +12V_EN1 Used as a connect detect to verify the Steer Encoder VM Steer Tiller
Tiller Encoder is connected to the VM. connected: Encoder
9.0VDC;
Disconnected:
+10.7 to
13VDC
14 JPC10-7 +12V_EN2 Used as a connect detect to verify the Steer Encoder VM Steer Tiller
Tiller Encoder is connected to the VM. connected: Encoder
9.0VDC;
Disconnected:
+10.7 to
13VDC

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Pinout Matrix

15 JPC10-8 ON Input to the VM from the Deadman Switch Released: DS2 VM

DEADMAN (DS2). Used by the VM to determine >+4VDC;
(DS2) whether to ignore or comply with Depressed:
operational requests. <0.5VDC
16 JPC10-9 DGND Reference for the Steer Motor Encoder. <0.5VDC VM Steer
wrt B– Motor
Encoder
17 JPC10-10 BUS_E+ Carries positive component of the digital 2.53VDC VM WMM

communications between the VM and the
optional WMM. If missing, the WMM
cannot communicate. Troubleshoot using
resistance checks. No useful information
can be gained by measuring the voltage on
this wire.
18 JPC12-1 +5VP +5VDC supply to the solid state 4.9VDC VM Control

potentiometers and switches in the control Handle
handle. If this is less than 4.75, the handle
will not function correctly. Measure wrt
DGND JPC12-12.
19 JPC12-2 LIFT Input to the VM from the wiper of the lift Neutral: 1.0V; VR2 VM
control. Measure wrt DGND JPC12-12. Full Forward:
1.84VDC;
Full Reverse:
0.30VDC
20 JPC12-3 P_THROTTLE Input to the VM from the wiper of the throttle Neutral: VR1 VM
control. Measure wrt DGND JPC12-12. 1.2VDC;
Full Forward:
1.9VDC;
Full Reverse:
0.45VDC
21 JPC12-4 REACH Input to the VM from the reach switch (S4). S4 open: S4 VM
Note: When other aux function switches >4.0VDC;
are activated, reading can change by as S4 closed:
much as 0.5V. <0.5VDC
22 JPC12-5 TILT UP Input to the VM from the tilt up button (S6). S6 open: S6 VM
23 JPC12-6 TILT DOWN Input to the VM from the tilt down button S7 open: S7 VM
(S7). Note: When other aux function >4.0VDC;
switches are activated, reading can change S7 closed:
by as much as 0.5V. <0.5VDC
24 JPC12-7 H_HTR DC supply to handle heater (HTR6). OFF: VM Control

<0.5VDC; Handle
ON: 7.5 to
8.5VDC

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Pinout Matrix

25 JPC12-8 SSHIFT_LEFT Input to the VM from the sideshift left button S8 open: S8 VM
(S8). Note: When other aux function >4.0VDC;
switches are activated, reading can change S8 closed:
by as much as 0.5V. <0.5VDC
26 JPC12-9 SSHIFT_RIGHT Input to the VM from the sideshift right S9 open: S9 VM

button (S9). Note: When other aux >4.0VDC;
function switches are activated, reading S9 closed:
can change by as much as 0.5V. <0.5VDC
27 JPC12-10 P_HORN Input to the VM from the horn switch (S3). S9 open: S3 VM
28 JPC12-11 RETRACT Input to the VM from the retract switch (S5). S5 open: S5 VM
29 JPC12-12 DGND Reference for all switches and <0.5VDC VM Control

potentiometers in the control handle. If this wrt B– Handle
voltage is not <0.5VDC wrt TP4 on the
power panel, then intermittent handle codes
may appear.
30 JPC14-1 B–F Connects B–F on the VM to TP4 (B–) through <0.5VDC Fuse/Relay VM
FU6 on the Fuse/Relay Card. wrt B– Card
31 JPC14-2 DGND Connects DGND and AGND on the VM to <0.5VDC Fuse/Relay VM

TP4(B–) through FU6 on the Fuse/Relay wrt B– Card
Card. This is the reference for all circuits on
the truck that are referenced to either
DGND or AGND.
32 JPC14-3 DGND Reference for the control circuits in the TPC, <0.5VDC VM TPC,LPC
LPC, and Operator Display. wrt B– and
Display
33 JPC14-4 BUS_E– Carries negative component of the digital 2.24VDC VM TPA, LPA,
BUS_I– communications between the VM and the and
TPA, LPA, and the Operator Display. If Display
missing, the LPA and Operator Display
cannot communicate with the VM.
Troubleshoot using resistance checks in
Test I23. No useful information can be
gained by measuring the voltage on this
wire.
34 JPC14-5 +12VP Operating voltage from the VM to the +10.5 to VM Display

Operator Display. 13VDC
35 JPC14-6 RELAY_ Control path for K1, K2, K3, and K4 on the Relays OFF: VM K1, K2,
ENABLE Fuse/Relay Card. After S1 is closed, all B+; K3, and
relays are energized simultaneously during Relays ON: K4
SelfTest if the voltage at Battery_Sense_In is <3.0VDC
at an acceptable level.

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Pinout Matrix

36 JPC14-7 B+K4 B+ provided to the VM when K4 tips are K4 tips closed: K4 tips Cold
closed. This voltage is used to power the B+; Storage
heaters in cold storage trucks. If the ambient K4 tips open: Package
temp sensor detects the room temp to be 0.2V heater
<40°F, the VM keeps this circuit alive to
power the heaters, even with the key switch
turned OFF.
37 JPC14-8 B–F Connects DGND and AGND on the VM to <0.5VDC Fuse/Relay VM

TP4 (B–) through FU6 on the Fuse/Relay wrt B– Card
DGND or AGND.
38 JPC14-9 B–F Connects DGND and AGND on the VM to <0.5VDC Fuse/Relay VM

DGND or AGND.
39 JPC14-10 DGND Connects DGND and AGND on the VM to <0.5VDC Fuse/Relay VM

DGND or AGND.
40 JPC14-11 BUS_I+ Carries the positive component of the 2.8VDC VM TPA, LPA, &
digital communications between the VM Display
and the TPA, LPA, and the Operator
Display. If missing, the VM cannot
communicate. Troubleshoot using resistance
checks in Test I23. No useful information
can be gained by measuring the voltage on
this wire.
41 JPC14-12 B+KEY B+ that is switched by Key Switch (S1) and S1 closed: B+; S1 VM
used to power functions on the VM that are S1 open:
initiated after S1 is closed, and are not 0.3VDC
affected by the EPO. This includes the VM
power supplies and the operation of the
microprocessor.
42 JPC14-13 B+K2 B+ provided to the VM when K2 tips are K2 tips closed: K2 tips Hydraulic
closed. This voltage is used to power the B+; Solenoids
hydraulic solenoids on the tractor and on K2 tips open:
the carriage. They are de-energized when 0.3VDC
the EPO is open.
43 JPC14-14 B+K2 B+ provided to the VM when K2 tips are K2 tips closed: K2 tips Hydraulic
closed. This voltage is used to power the B+; Solenoids
hydraulic solenoids on the tractor and on K2 tips open:
the carriage. They are de-energized when 0.3VDC
the EPO is open.
44 JPC18-1 thru Not Used

JPC18-4

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Pinout Matrix

45 JPC18-5 DGND Reference for channel 1 of the Steer Tiller <0.5VDC VM Steer Tiller
Encoder at JPC14-10 and JPC14-2. wrt B– Encoder
46 JPC18-6 DGND Reference for channel 2 of the Steer Tiller <0.5VDC VM Steer Tiller
Encoder at JPC14-10 and JPC14-2. wrt B– Encoder
47 JPC18-7 DGND Reference for the deadman switches (DS1 <0.5VDC VM DS1 & DS2
and DS2). wrt B–
49 JPC18-10 L/H Control path for the load holding solenoid De-energized VM L/H SOL1
SOL1 that is switched to B– by the VM to (K2 tips
energize the L/H solenoid coil (lowering). closed): B+;
Energized:
13.3VDC
50 JPC18-11 STR Control path for the steer contactor that is De-energized VM STR
CONTACTOR switched to B– by the VM to energize the (K2 tips Contactor
coil. closed): B+;
Energized:
13.4VDC
51 JPC18-12 REACH Control path for Reach solenoid coil. De-energized VM Reach
(K2 tips Solenoid
closed): B+;
Energized:
13.2VDC
52 JPC18-13 Not Used
53 JPC18-14 SIDESHIFT Control path for Sideshift solenoid coil. De-energized VM Sideshift
(K2 tips Solenoid
closed): B+;
Energized:
13.1VDC
54 JPC18-15 TILT Control path for Tilt solenoid coil. De-energized VM Tilt
(K2 tips Solenoid
closed): B+;
Energized:
13.1VDC
55 JPC18-16 HORN Control path for the horn coil that is De-energized VM Horn
switched to B– by the VM to energize the (K2 tips
coil. closed): B+;
Energized:
0.02 VDC
56 JPC18-17 FAN Control path for the amplifier and motor De-energized VM Fans
compartment fans that are controlled (K2 tips
together by the VM. closed): B+;
Energized:
0.09VDC
57 JPC20-1 +12VP +12VDC supply for 1st Speed Limiting +10.7 to VM S12
Switch (S12). 13VDC

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Pinout Matrix

58 JPC20-2 +12VP Not Used +10.7 to VM n/a

13VDC
59 JPC20-3 +12VP +12VDC supply for optional High Speed +10.7 to VM S25
Travel Switch (S25). 13VDC
60 JPC20-4 +12VP +12VDC supply for the pressure transducer. +10.7 to VM Pressure
13VDC Transducer
61 JPC20-5 Not Used
62 JPC20-6 +12VP +12VDC supply for the optional Lift Cutout +10.7 to VM S27
Switch (S27). 13VDC
63 JPC20-7 +12VP +12VDC supply for the Steer Motor +10.7 to VM Steer
Encoder. 13VDC Motor
Encoder
64 JPC20-8 Not Used
65 JPC20-9 +12VP +12VDC supply to the Steer Limit Switch +10.7 to VM S11
(S11). 13VDC
66 JPC20-10 & Not Used

11
67 JPC20-12 DUMP Control path for SOL3, a combination De-energized: VM SOL3

proportional relief and dump valve. This is B+;
used both as a variable system relief and to When lift
dump oil back to the reservoir when lift is request stops:
no longer requested and the Lift 12VDC for 1
Motor/pump is slowing down. This permits to 2 seconds;
immediate lower without waiting for the Aux functions
pump to stop turning. energized:
24VDC
68 JPC20-13 B+DUMP B+ from the K2 tips to SOL3. B+ VM SOL3
69 JPC20-14 BRAKE Control path for the electrically released Brake fully on: VM Brake
brake on the Traction Motor. B+;
Brake
released:
0VDC at first,
then 9VDC
70 JPC20-15 B+L/L B+ supplied to SOL2 from K2 tips when K2 B+ VM SOL2

is energized.
71 JPC20-16 L/L Control path for the Lift/Lower Solenoid De-energized: VM SOL2
SOL2. Voltage present during lower B+;
depends on the lower request from VR2. No lower:
37.6VDC
varies propor-
tionally to
Full lower:
18.8VDC
72 JPC20-17 B+AUX1 B+ supply for SOL5T solenoid. B+ VM SOL5T

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Pinout Matrix

73 JPC20-18 AUX1 Control path for one of the directional De-energized: VM SOL5T
solenoids (SOL5T) for the aux functions B+;
sideshift left, tilt down, and retract. Energized:
Sideshift Left:
20VDC;
Tilt Down:
17.5V;
Retract High:
20VDC;
Retract Low:
24VDC
74 JPC20-19 B+AUX2 B+ supply for SOL5B solenoid. B+ VM SOL5B
75 JPC20-20 AUX2 Control path for one of the directional De-energized: VM SOL5B
solenoids (SOL5B) for the aux functions B+;
sideshift right, tilt up, and reach. Energized:
Sideshift Right:
20VDC;
Tilt Up: 18.0V;
Reach High:
20VDC;
Reach Low:
24VDC
76 JPC22-1 SPEED_LIMIT_ Used by the VM to determine when the Telescopics S12 VM

1 telescopic is unnested. Speed is reduced at nested:
this point to the value set in Configure <0.5VDC;
Mode. Telescopics
unnested:
>4VDC
78 JPC22-4 HS TRAVEL Used by the VM to determine when the Open: 5VDC; S25 VM
SW carriage is above S25. Closed: 0VDC
79 JPC22-5 CHANNEL_A_ Channel_A_1 is one part of the steering Either Steer Tiller VM
1 request from the Steer Tiller Encoder on >4.5VDC or Encoder
electric steer trucks when the steering tiller is <0.5VDC
moved. It is a square wave signal (0VDC & when tiller
4.5VDC) identical to Channel_B_1 but stationary. DC
different phase. The VM uses the phase value when
relationship of the two channels to turning handle
determine the direction and speed of the approx
steering request. When the tiller is 2.5VDC.
stationary, the voltage can be either high or
low.
80 JPC22-6 LIFT CUTOUT Used by the VM to determine when the Open: 5VDC; S27 VM
SW carriage is above S27. Closed: 0VDC
81 JPC22-7 Not Used
82 JPC22-8 ON Input to the VM from the Deadman Switch Released: DS1 VM

DEADMAN (DS1). Used by the VM to determine >+4VDC;
whether to ignore or comply with Depressed:
operational requests. <0.5VDC

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Pinout Matrix

83 JPC22-9 CHANNEL_A_ Channel_A_4 is one part of the steering Not turning: Steer Motor VM
4 position feedback from the Steer Motor either 0VDC Encoder
Encoder when the drive unit is rotated. It is or 4.5VDC;
a square wave signal (0VDC & 4.5VDC) Turning either
identical to Channel_B_4 but different direction:
phase. The VM uses the phase relationship 1.8VDC
of the two channels to determine that the
direction and speed of the steering
response is the same as that requested.
When the drive unit is stationary, the
voltage can be either high or low.
84 JPC22-10 CHANNEL_B_ Channel_B_4 is one part of the steering Not turning: Steer Motor VM
4 position feedback from the Steer Motor either 0VDC Encoder
Encoder when the drive unit is rotated. It is or 4.5VDC;
a square wave signal (0VDC & 4.5VDC) Turning either
identical to Channel_A_4 but different direction:
phase. The VM uses the phase relationship 1.8VDC
of the two channels to determine that the
direction and speed of the steering
response is the same as that requested.
When the drive unit is stationary, the
voltage can be either high or low.
85 JPC22-11 DGND Reference for Steer Limit Switch (S11). <0.5VDC VM S11
wrt B–
86 JPC22-12 CHANNEL_B_ Channel_B_1 is one part of the steering Not turning: Steer Tiller VM
1 request from the Steer Tiller Encoder on either Encoder
electric steer trucks when the steering tiller is >4.5VDC or
moved. It is a square wave signal (0VDC & <0.5VDC;
4.5VDC) identical to Channel_A_1 but Turning either
different phase. The VM uses the phase direction:
relationship of the two channels to approx
determine the direction and speed of the 2.5VDC.
steering request. When the tiller is
low.
87 JPC22-13 CHANNEL_A_ Channel_A_2 is one part of the steering Not turning: Steer Tiller VM
4.5VDC) identical to Channel_B_2 but Turning either
low.

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Pinout Matrix

88 JPC22-14 CHANNEL_B_ Channel_B_2 is one part of the steering Not turning: Steer Tiller VM
4.5VDC) identical to Channel_A_2 but Turning either
low.

thru 17
90 JPC22-18 NESTED Control path for the optional Nested Switch K2 tips Closed K2 tips VM
SWITCH (S14) on the carriage. Voltage will be B+ (carriage
when the carriage is nested & K2 tips nested): B+;
closed and 0VDC when the carriage is not Open
nested. The VM reduces travel speed to the (unnested):
configured value (0 to 3.5mph [0 to 5.76 0VDC
km/hr]) when the switch is open.
91 JPC22-19 FU1_SENSE B+ when there is not an open between B+ Closed: B+; STR2 VM
and STR2. This voltage is used by the VM to Open: Voltage
determine the state of FU1 and the STR drops slowly
contactor tips. to 0VDC
93 JPC22-21 EPO_SENSE Sense wire used by the VM to determine EPO closed: EPO VM
when the EPO is open. B+;
Open: 0VDC
94 JPC22-22 STEER_LIMIT The Steer Limit Switch (S11) stops drive unit Open (metal): S11 VM
rotation when closed. This switch is closed 4 to 7VDC;
just before the hard stops are reached for Closed (air):
both CW and CCW rotation. 0.7VDC
95 JPC24-1 Not Used

thru 5
96 JPC24-6 DGND Reference for the pressure transducer. <0.5VDC VM Pressure

wrt B– Transducer
97 JPC24-7 thru Not Used

10
98 JPC24-11 DGND Reference for the ambient temperature <0.5VDC Ambient VM

sensor. wrt B– Temp Sensor

thru 17

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Pinout Matrix

100 JPC24-18 PRESSURE Analog DC voltage that varies directly as No load: Pressure VM
the pressure varies. 1.0VDC; Transducer
1000lb. (454
kg) out of free
lift: 1.8VDC;
2500 lb.
(1134 kg):
2.5VDC

thru 22
102 JPC24-23 ROOM_TEMP Input to the VM from the ambient 73°F Ambient VM
temperature sensor. This is used to tell the (22.8°C): Temp Sensor
optional heaters when to turn ON. 3VDC
103 JPC24-24 BATTERY_ Used by the VM to determine the correct B+ B+ at JPF4-1 VM

SENSE _IN battery has been connected. It accepts any (Drops no
voltage between 28VDC and 45VDC. If the voltage)
correct battery is sensed, Relay_Enable is
energized during start-up. After start-up, this
voltage is used to determine BSOC.
104 JPF1-1 B– B– for FU8, B– 15A fuse for optional Aux <0.5VDC Power Panel Optional
power. wrt B– TP4 Aux Power
105 JPF1-2 B– B– for FU8, B– 15A fuse for optional Aux <0.5VDC Power Panel Optional
power. wrt B– TP4 Aux Power
106 JPF1-3 B+F or B–F Provides either B+ or B– to the lift power K3 FU5 to B+ LPA
amplifier pre-charge circuit, depending on De-energized: FU6 to B–
the state of relay K3. Voltage drops
slowly to 0;
Energized: B+
107 JPF1-4 B–F B–F from FU8 to power the optional WMM. <0.5VDC FU8 to B– Aux Power,
wrt B– WMM
108 JPF1-5 B+F or B–F Provides B+ or B– to the TPA pre-charge K3 FU5 to B+ TPA
circuit, depending on the state of relay K3. De-energized: FU6 to B–
B–;
Energized: B+
109 JPF1-6 B+F OR B–F Provides B+F or B–F to the B+K3 on the Lift K3 FU5 to B+ LPA, TPA
(JPL1-1) and the Traction (JPT1-1) Power De-energized: FU6 to B–
Amplifiers. B–;
Energized: B+
110 JPF2-1 B+K2 B+K2 to power TPC, LPC, and STR K2 Energized: K2 tips TPC, LPC,
contactors. B+ and STR
Contactors
111 JPF2-2 B+K2 B+K2 to power the horn. K2 Energized: K2 tips Horn
B+
112 JPF2-3 B+K2 B+K2 to power the compartment fans. K2 Energized: K2 tips Fans
B+

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Pinout Matrix

113 JPF2-4 B+K4 B+K4 to the VM. K2 Energized: K4 tips VM

B+
114 JPF2-5 B+K2 B+K2 to power SOL1. K2 Energized: K2 tips L/H SOL1
B+

B+

B+
117 JPF2-8 B+K2 B+K2 to the reach, sideshift, and tilt K2 Energized: K2 tips Carriage
solenoids, and Nested Switch (S14). B+ Functions
118 JPF2-9 B+K1 B+ to TS1. K2 Energized: K1 TS1

B+
119 JPF3-1 B– B– for FU6 (15A), that provides B– to the <0.5VDC Power Panel VM
VM. wrt B– TP4
120 JPF3-2 B– B– for FU6 (15A), that provides B– to the <0.5VDC Power Panel VM
VM. wrt B– TP4
121 JPF3-3 B–F B–F for DGND on the VM. <0.5VDC FU6 VM
wrt B–
122 JPF3-4 B–F B–F for DGND on the VM. <0.5VDC FU6 VM
wrt B–
123 JPF3-5 B–F B–F for the VM. <0.5VDC FU6 VM

wrt B–
124 JPF3-6 B–F B–F for the VM <0.5VDC FU6 VM

wrt B–
125 JPF3-7 B–F B–F for the VM. <0.5VDC FU6 VM

wrt B–
126 JPF3-8 B–F B–F for S12, 1st Speed Limiting Switch on <0.5VDC FU6 S12
mast. wrt B–
127 JPF4-1 B+ B+ from TP1 to FU5, to supply K2, K3, and B+ TP1 FU5 & VM
K4 relay tips; K4 relay coil; and key switch
(S1). This also supplies Battery_Sense_In on
the VM.
128 JPF4-2 B+ B+ from TP1 to FU5, to supply K2, K3, and B+ TP1 FU5 & VM
K4 relay tips; K4 relay coil; and Key Switch
(S1). This also supplies Battery_Sense_In on
the VM.
129 JPF4-3 B+ B+ from TP1 to FU7 to supply auxiliary B+ 1 FU7 and

power option and Warehouse Aux Power
Management Module.
130 JPF4-4 B+ B+ from TP1 to FU7 to supply auxiliary B+ TP1 FU7 and
power option. Aux Power

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Pinout Matrix

131 JPF4-5 B+EPO B+ supply from EPO to K1, K2, and K3. All S1 and EPO EPO K1, K2, &
functions associated with those functions closed: B+; K3
are inoperable when the EPO is open. This Either open:
also supplies voltage to EPO_Sense on the 0.05VDC
VM.
132 JPF4-6 B+EPO B+ to EPO_Sense on the VM. Tells the VM if S1 and EPO EPO VM EPO
the EPO is open or closed. closed: B+; Sense
Either open:
0.05VDC
133 JPF4-7 BATTERY_ B+ to Battery_Sense_In on the VM. B+ TP1 VM

SENSE_IN
134 JPF4-8 B+KEY B+Key to supply all functions powered from S1 closed: B+ FU5 Various
Key Switch (S1).
135 JPF4-10 B+ B+ from FU5 to Key Switch (S1). FU5 good: B+ FU5 Key switch
FU5 open: S1
0VDC
136 JPF4-11 B+KEY B+ from Key Switch (S1) to the VM. S1 closed: B+ S1 VM
137 JPF4-12 B+KEY B+ from Key Switch (S1) to the EPO. S1 closed: B+ S1 EPO
138 JPF4-13 RELAY_ Return path for relays K1, K2, K3, and K4. Key ON & all VM K1, K2,
ENABLE relays K3, & K4
De-energized:
B+;
Key OFF, or
Key ON & any
relay
Energized:
<1.5VDC
139 JPF4-14 Not Used
140 JPF4-15 B+ B+ for battery connected to aux power. B+ FU7 Optional

Aux Power
141 JPL1-1 B+K3 B+ present when K3 is energized. This is K3 Energized: K3 LPA

used to power the control circuits of the LPA. B+
It is also used by the LPA to produce
+12VDC for the L Vel Sensor + and the
internal circuits of the LPA. If voltage is not
present, check K3 coil and tip circuit.
142 JPL1-2 LPC Control path for the LPC Contactor. The lift LPC LPA LPC
CONTACTOR power amplifier supplies B– to the contactor De-energized: Contactor
by way of the B– terminal. B+;
LPC
Energized:
18VDC to
22VDC.
143 JPL1-3 L VEL +12VDC supply to the Lift Motor encoder. +10.9 to LPA Lift Encoder
SENSOR+ This voltage is produced by the lift power 13VDC
amplifier B+K3.

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Pinout Matrix

144 JPL1-4 L VEL Return path for the Lift Motor encoder. <0.5VDC DGND on Lift Encoder
SENSOR– Returns through DGND JPL1-7 through the wrt B– VM
Operator Display to the VM.
145 JPL1-5 L VEL PHASE A This square wave is generated whenever Motor Lift Encoder LPA
there is movement of the encoder in the Lift Stationary:
Motor. It is either high (>8VDC) or low Either >8VDC
(<1VDC). The frequency varies directly with or <1VDC;
the speed of the Lift Motor. Identical Turning: 4VDC
formation to L Vel Phase B, except for the to 6VDC.
phasing between the two. The LPA uses the
quadrature phase relationship between
Phases A and B to determine lift speed.
146 JPL1-6 L VEL PHASE B This square wave is generated whenever Motor Lift Encoder LPA
there is movement of the encoder in the Lift Stationary:
Motor. It is either high (>8VDC) or low Either >8VDC
(<1VDC). The frequency varies directly with or <1VDC;
the speed of the Lift Motor. Identical Turning: 4VDC
formation to L Vel Phase A, except for the to 6VDC.
phasing between the two. The LPA uses the
quadrature phase relationship between
Phases A and B to determine lift speed.
147 JPL1-7 DGND DGND from VM through the Operator <0.5VDC Display LPA
Display to the LPA. If it is missing, the LPA wrt B–
and TPA do function.
148 JPL1-8 DGND B– Provides DGND to the TPA from the LPA. <0.5VDC LPA TPA
wrt B–
149 JPL1-9 thru Not Used

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150 JPL1-14 BUS_I– Carries negative component of the digital 2.2VDC Display LPA
communications between the Operator
Display and the LPA and VM. If missing, the
LPA and TPA cannot communicate with the
Operator Display or VM. Troubleshoot
using resistance checks in Test I23. No
useful information can be gained by
measuring the voltage on this wire.
151 JPL1-15 BUS_I– Carries negative component of the digital 2.2VDC LPA TPA
communications between the LPA and the
TPA. If missing, the TPA cannot
communicate with the LPA, Display, or VM.
Troubleshoot using resistance checks in Test
I23. No useful information can be gained
by measuring the voltage on this wire.
152 JPL1-16 L TEMP+ Analog voltage that varies with the Lift 75°F (24°C): LM Temp LPA
Motor temperature. Used by the LPA to approx Sensor
adjust motor performance when a motor 1.5VDC
overtemp condition exists.
153 JPL1-17 L TEMP– Reference for the Lift Motor temperature <0.5VDC DGND on Temp
sensor. wrt B– VM Sensor

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Pinout Matrix

154 Not Used
155 JPL1-22 BUS I+ Carries positive component of the digital 2.94VDC Display LPA
communications between the LPA and the
Operator Display and VM. If missing, the
LPA and TPA cannot communicate with the
Operator Display or VM. Troubleshoot
using resistance checks in Test I23. No
useful information can be gained by
measuring the voltage on this wire.
156 JPL1-23 BUS I+ Carries the positive component of the 2.94VDC LPA TPA
digital communications between the LPA
and the TPA. If missing, the TPA cannot
communicate with the LPA, Display, or VM.
157 JPT1-1 B+K3 B+ present when K3 is energized. Used to K3 K3 TPA

power control circuits of the TPA. Also used Energized: B+
by the TPA to produce +12VDC for the T Vel
Sensor+ and internal circuits of the TPA. If
voltage is not present, check K3 coil and tip
circuit.
158 JPT1-2 TPC Control path for the TPC Contactor. The TPA TPC TPA TPC
CONTACTOR supplies B– to the contactor by way of the De-energized: Contactor
B– terminal. B+;
TPC
Energized:
18 to 22VDC.
159 JPT1-3 T VEL +12VDC supply to the Traction Motor +10.7 to TPA Travel
SENSOR+ encoder. This voltage is produced by the 13VDC Encoder
traction power amp from B+K3.
160 JPT1-4 T VEL Return path for the Traction Motor encoder. <0.5VDC DGND on Travel
SENSOR– Returns through DGND JPT1-7 to the LPA, wrt B– VM Encoder
Operator Display, and to the VM.
161 JPT1-5 T VEL PHASE A This is generated whenever there is Motor Travel TPA
movement of the Traction Motor. It is a Stationary: Encoder
square wave that is either high (>8VDC) or Either >8VDC
low (<1VDC). The frequency varies directly or <1VDC;
with the speed of the Traction Motor. Turning: 4VDC
Identical information to T Vel Phase B, to 6VDC.
except for the phasing between the two.
The VM uses the quadrature phase
relationship between Phases A and B to
determine travel direction and speed.

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Pinout Matrix

162 JPT1-6 T VEL PHASE B This is generated whenever there is Motor Travel TPA
movement of the Traction Motor. It is a Stationary: Encoder
square wave that is either high (>8VDC) or Either >8VDC
low (<1VDC). The frequency varies directly or <1VDC;
with the speed of the Traction Motor. Turning: 4VDC
Identical information to T Vel Phase A, to 6VDC.
except for the phasing between the two.
The VM uses the quadrature phase
relationship between Phases A and B to
determine travel direction and speed.
163 JPT1-7 DGND DGND for the TPA from the LPA. <0.5VDC LPA TPA
wrt B–
164 JPT1-8 thru Not Used

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165 JPT1-14 BUS_I– Carries negative component of the digital 2.2VDC LPA TPA
communications from the LPA and VM to the
communicate with the VM, LPA, or Display.
166 JPT1-15 Not Used
167 JPT1-16 T TEMP+ Analog voltage that varies with Traction 75°F (24°C): Tracion TPA
Motor temperature. Used by the TPA to approx Motor Temp
adjust motor performance when a motor 1.0VDC Sensor
overtemp condition exists.
168 JPT1-17 T TEMP– Reference for the Traction Motor Temp <0.5VDC DGND on Temp
sensor. wrt B– VM Sensor
169 JPT1-18 thru Not Used

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170 JPT1-22 BUS_I+ Carries positive component of the digital 2.93VDC LPA TPA
communications from the LPA and VM to the
communicate with the VM, LPA, or Display.
171 LPA (+) LPA B+ B+ to the LPA used to pre-charge the Fully charged B+K3 and LPA
amplifier and also to produce the AC or LPC B+ from LPC
phases U, V, and W when the LPC is closed Energized; B+
to power the Lift Motor. The voltage present
increases from 0VDC to B+ as the amplifier
charges.
172 LPA B– LPA B– B– from TP4 on the Power Panel. It is used <0.5VDC TP4 LPA
for the power circuits on the LPA. Without wrt B–
B– U, V, and W cannot be produced and
the Lift Motor will not operate.
173 LPA B+ Not Used

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Pinout Matrix

174 TPA (+) TPA B+ B+ to the TPA used to pre-charge the Fully charged B+K3 and TPA
amplifier and also to produce the AC or TPC B+ from TPC
phases U, V, and W when the TPC is closed Energized: B+
to power the Traction Motor. Voltage
increases from 0VDC to B+ as the amplifier
charges.
175 TPA B– TPA B– B– from TP4 on the Power Panel. It is used <0.5VDC TP4 TPA
for the power circuits on the TPA. Without wrt B–
B– U, V, and W cannot be produced and
the Traction Motor does not operate.
176 TPA B+ Not Used
177 U on LPA LIFT MOTOR One of three phases from the LPA to the Lift ACV between LPA Lift Motor
PHASE U Motor. This AC voltage is produced by LPA phases.
and is dependent on B+ at the (+) terminal Stationary:
and B– of the LPA. This AC voltage is 0VAC;
measured between any two phases and Full lift:
varies from 0VAC at rest to about 24VAC 24VAC
on full lift request. When lift knob is initially
moved to full lift, meter reading may show
120VAC before stabilizing at about
24VAC.
178 U on TPA TRACTION One of three phases from the TPA to the ACV between TPA Traction
MOTOR Traction Motor. This AC voltage is produced phases. Motor
PHASE U by TPA and is dependent on B+ at the (+) Stationary:
terminal and B– of the TPA. This AC voltage 0VAC;
is measured between any two phases and Full travel:
varies from 0VAC at rest to about 24VAC 24VAC;
on full acceleration. Stall condition Stall: approx
produces about 4VAC. 4VAC
179 V on LPA LIFT MOTOR One of three phases from the LPA to the Lift ACV between LPA Lift Motor
PHASE V Motor. This AC voltage is produced by LPA phases.
24VAC.
180 V on TPA TRACTION One of three phases from the TPA to the ACV between TPA Traction
PHASE V by TPA and is dependent on B+ at the (+) Stationary:

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Pinout Matrix

181 W on LPA LIFT MOTOR One of three phases from the LPA to the Lift ACV between LPA Lift Motor
PHASE W Motor. This AC voltage is produced by LPA phases.
24VAC.
182 W on TPA TRACTION One of three phases from the TPA to the ACV between TPA Traction
PHASE W by TPA and is dependent on B+ at the (+) Stationary:

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Pinout Matrix

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Model 7600/7620/7640 Reach-Fork ® Truck Section A. Appendix
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Section A. Appendix
Publication: 1087967, Issued: 15 Apr 2009 A-1

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Section A. Appendix Model 7600/7620/7640 Reach-Fork ® Truck
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Lubrication Specification Chart
Lubrication Specification
Chart
Table A-1. 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 liters)
Oil
(all applications) Lubricant 990-655/003 (1 gal./3.8 liters)
API Service GL-5
Hydraulic Reservoir 990-616/04 (1 qt./0.9 liter)

(Non-CS trucks) Hydraulic 990-616/01 (1 gal./3.8 liters)
ISO VG 46
+50° to +120°F Fluid 990-616/02 (2 gal./7.6 liters)
(+10° to +49°C) 990-616/03 (5 gal./18.9 liters)
Hydraulic Reservoir
(CS trucks - in and out of
Hydraulic 1017238
freezer) ISO VG 32
Fluid Note: Do not add any additives.
0° to +50°F
(–18° 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° to 0°F
(–29° to –18°C)
Mast Uprights, Bearings,

and so forth
(all-weather) Grease NLGI 2 1012992
–20° to +120°F
(–29° to +49°C)
Teflon
Lift Chains Aerosol 990-652/001 (spray)
Grease
A-2 Publication: 1087967, Issued: 15 Apr 2009

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Thread Adhesives, Sealants, and Lubricants
Thread Adhesives,
Sealants, and Lubricants
Table A-2. 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. 990-536 242/Blue
Thread-locking 1/4 to 3/4 in. contamination tolerant 990-462 243/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 990-538 707
Thread-locking Primer 990-533 T747
Primerless Thread-locking 1 1/2 in. and below 1013829 2440
Hydraulic Sealant 990-552 569
RTV Silicone Sealant 990-659 5900/Black
Other
Manufacturer
designation
Molybdenum Anti-Seize Compound (Molykote) 990-638 /Silver
Corrosion Inhibitor Coating 990-644
Cold Storage Silicone Sealing Compound 990-445
NOTE: *Loctite is a registered trademark of the Loctite Corporation. Brand endorsement is not
implied here, but listed only as a commonly identified product.

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Component Specific Service/Torque Chart
Component Specific
Service/Torque Chart
Table A-3. Component Specific Service/Torque Chart
Thread-Locking
Component Sub-Component(s) Torque to:
Compound P/N
Baseleg baseleg mounting bolts 990-544 165 ft. lb. (223 Nm)
Apply anti-seize compound
(P/N 990-638) to locating pins. load wheel plate mtg bolts 990-536 50 ft. lb. (68 Nm)
Battery Gate Switches Adjust the gap between the switch and target to 0.16 in. (4 mm) max.
Deadman Pedal Assembly (DS1) assembly to frame 990-536 15 ft. lb. (21 Nm)
Deadman Pedal Assembly (DS2) assembly to frame 990-536 15 ft. lb. (21 Nm)
Drive Wheel mounting bolts n/a 170 ft. lb. (230 Nm)
EPO Switch n/a 990-536 6 ft. lb. (8.6 Nm)
Adjustment: Fully lower carriage and adjust gap between switch and
High Speed Travel Switch (S25)
rail from 0.10 to 0.22 in. (2.54 to 5.58 mm).
Horn bracket to frame 990-536 15 ft. lb. (21 Nm)
Hose, Over-the-Mast pulley stud 1013289 130 ft. lb. (174 Nm)
Adjustment:
1. Fully raise carriage and adjust gap between switch and rail from
Lift Cutout Switch (S27) 0.10 to 0.25 in. (2.54 to 6.35 mm).
2. Align the vertical center line of the switch just below the bottom
edge of the rail so the sensor LED is OFF.
lift pump mtg bolts 55 ft. lb. (72 Nm)

Lift Motor
Apply anti-seize compound motor mtg bolts to bracket 990-536
15 ft. lb. (21 Nm)
(P/N 990-638) to pump spline and bracket mtg bolts to deck
mating surfaces.
lift motor power cables n/a 18 ft. lb. (24.4 Nm)
Lift Pump P1 fitting 85 ft. lb. (115 Nm)

Apply anti-seize compound
input fitting 120 ft. lb. (163 Nm)
(P/N 990-638) to spline, mating
surfaces. lift pump mounting bolts 990-536 55 ft. lb. (72 Nm)
Manifold, Auxiliary 990-536

mounting bolts 21 ft. lb. (29 Nm)
(Reach/Tilt/Sideshift)
Manifold, Main Mounting bolts 990-536 21 ft. lb. (29 Nm)
990-666 (primer)
Mast mast to tractor 165 ft. lb. (224 Nm)
990-544 (locker)

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Component Specific Service/Torque Chart
Thread-Locking
Component Sub-Component(s) Torque to:
Compound P/N
amplifier bolts to bracket 6 ft. lb. (8.6 Nm)
Power Amplifier, Lift bracket mtg bolts to deck 15 ft. lb. (21 Nm)
power cables 11 ft. lb. (15 Nm)
amplifier bolts to bracket n/a 6 ft. lb. (8.6 Nm)
Power Amplifier, Traction bracket mtg nuts to deck 15 ft. lb. (21 Nm)
power cables 11 ft. lb. (15 Nm)
Proportional Valve n/a 95 ft. lb. (129 Nm)
Pulleys, Over-the-Mast pulley stud 1013289 130 ft. lb. (174 Nm)
switch bracket to drive

Steer Limit Switch S11 990-536 9 ft. lb. (12 Nm)
unit
Adjustment:
1. Lower carriage and adjust gap between switch and rail from 0.10
Speed Limiting Switch, First (S12) to 0.25 in. (2.54 to 6.35 mm).
2. Align the vertical center line of the switch just above the bottom
edge of the rail so the sensor LED is ON.
pinion gear set screw 45 ft. lb. (61 Nm)

Steer Motor, Electric
Note: Apply anti-seize compound pinion gear mtg bolt 1013829 13 ft. lb. (17 Nm)
(P/N 990-638) to pinion gear. Orient
pinion gear with shoulder toward motor mtg bolts 18 ft. lb. (24.4 Nm)
mounting bolt.
flange mtg bolts 990-536 95 ft. lb. (129 Nm)
Stops, Carriage n/a 990-536 35 ft. lb. (47.5 Nm)
pinion gear nut 85 ft. lb. (115 Nm)

Traction Motor 990-536
Apply anti-seize compound mounting bolts
(P/N 990-638) to pinion gear. Orient 18 ft. lb. (24.4 Nm)
pinion gear with shoulder toward power cables n/a
mounting bolt.
steer limit sensing rail 9 ft. lb. (12 Nm)
990-536
Travel Light n/a 23 ft. lb. (31 Nm)

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Torque Chart - Hydraulic Fittings
Torque Chart - Hydraulic

Fittings
Table A-4. Torque Chart - Hydraulic Fittings
JIC SAE Straight Thread Steel Plugs

SAE
Thread (37° Flare Thread)
Dash Hollow Hex Head Plug HP50N Hex Head Plug P50N
Size
Size
ft. lb. Nm ft. lb. Nm ft. lb. Nm
-2 5/16-24 3 ±1 4 ±1 3 ±0.5 4 ±0.6 7.5 ±0.5 10 ±0.6
-3 3/8-24 6 ±1 8 ±1 5 ±0.5 7 ±0.6 14 ±1 19 ±1
-4 7/16-20 12 ±1 16 ±1 11 ±1 15 ±1 18 ±1 24 ±1
-5 1/2-20 15 ±1 20 ±1 15 ±1 20 ±1 22 ±1 30 ±1
-6 9/16-18 21 ±1 28 ±1 18 ±1 24 ±1 27 ±2 37 ±3
-8 3/4-16 45 ±2 61 ±3 46 ±2 62 ±3 48 ±2 65 ±3
-10 7/8-14 60 ±5 81 ±7 75 ±5 102 ±7 90 ±5 122 ±7
-12 1 1/16-12 85 ±5 115 ±7 85 ±5 115 ±7 110 ±5 149 ±7
-14 1 3/16-12 105 ±5 142 ±7 130 ±6 176 ±8 145 ±6 197 ±8
-16 1 5/16-12 120 ±5 163 ±7 135 ±6 183 ±8 160 ±6 217 ±8
-20 1 5/8-12 170 ±10 230 ±14 225 ±12 305 ±16 225 ±12 305 ±16
-24 1 7/8-12 200 ±15 271 ±20 250 ±12 339 ±16 250 ±12 339 ±16
-32 2 1/2-12 270 ±20 366 ±27 325 ±15 441 ±20 325 ±15 441 ±20

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Torque Chart - Straight Thread Face Seal O-Rings
Torque Chart - Straight

Thread Face Seal
O-Rings
Table A-5. Torque Chart - Straight Thread Face Seal
O-Rings
SAE Dash Tube Size

ft. lb. Nm
Size Thread Size
-4 9/16-18 18 ±1 24 ±1
-6 11/16-18 27 ±2 37 ±3
-8 13/16-16 40 ±2 54 ±3
-10 1-14 63 ±3 85 ±4
-12 1 3/16-12 90 ±4 122 ±5
-14 1 5/16-32 95 ±6 129 ±8
-16 1 7/16-12 120 ±8 163 ±11
-20 1 11/16-12 140 ±8 190 ±11
-24 2-12 165 ±8 224 ±11
-32 2 1/2-12 360 ±10 488 ±14

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Torque Chart - Standard (Ferrous)
Torque Chart - Standard

(Ferrous)
Table A-6. Torque Chart - Standard Ferrous
Grade
Identification None
Marking
SAE Grade 2 Bolts SAE Grade 5 Bolts SAE Grade 8 Bolts

Size Tightening Torque Tightening Torque Tightening Torque
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

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Torque Chart - Standard (Ferrous)
Grade
Identification None
Marking
SAE Grade 2 Bolts SAE Grade 5 Bolts SAE Grade 8 Bolts

Size Tightening Torque Tightening Torque Tightening Torque
Dry Oiled Dry Oiled Dry Oiled
ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb.
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.

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Torque Chart - Metric (Ferrous)
Torque Chart - Metric

(Ferrous)
Table A-7. Torque Chart - Ferrous Metric
Ferrous Metric Bolts, Coarse Thread

(Grade rating stamped on head of bolt)
Grade 8.8 Grade 10.9

Diameter
Torque (bolts oiled) Torque (bolts oiled)
(in millimeters)
ft. lb. Nm ft. lb. Nm
6 6 8.1 9 12.2
8 15 20.3 21 28.4
10 30 40.7 43 58.3
12 55 74.6 75 101.7
16 130 176.3 181 245.4
20 255 345.7 350 474.5
24 435 589.8 605 820.3
NOTE: Use “oiled” values for bolts with thread-locking compound.

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Torque Chart - Standard (Brass)
Torque Chart - Standard

(Brass)
Table A-8. Torque Chart - Standard Brass
Brass MS63 Standard Bolts, Coarse Thread
Torque (bolts oiled)

Size
in. lb. Nm
4-40 3.3 0.37
4-48 3.6 0.40
6-32 6.1 0.69
6-40 6.8 0.77
8-32 11 1.24
8-36 11 1.24
10-24 14 1.58
10-32 17 1.92
1/4-20 35 3.96
1/4-28 40 4.52
5/16-18 73 8.25
5/16-24 81 9.15
3/8-16 130 14.69
3/8-24 147 16.61
NOTE: Use “oiled” values for bolts with

thread-locking compound.

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Torque Chart - Metric (Brass)
Torque Chart - Metric

(Brass)
Table A-9. Torque Chart - Brass Metric
Brass MS63 Metric Bolts, Coarse Thread
Diameter Torque (bolts oiled)

(in millimeters) in. lb. Nm
3 4.4 0.5
3.5 7.0 0.79
4 10 1.1
5 19 2.1
6 34 3.8
8 79 9
10 150 17
NOTE: Use “oiled” values for bolts with

thread-locking compound.

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Decimal Equivalent Chart

Table A-10. Decimal Equivalent Chart
To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
1/64 .016 .02 .397
1/32 .031 .03 .794
3/64 .047 .05 1.191
1/16 .062 .06 1.587
5/64 .078 .08 1.984
3/32 .094 .09 2.381
7/64 .109 .11 2.778
1/8 .125 .12 3.175
9/64 .141 .14 3.572
5/32 .156 .16 3.969
11/64 .172 .17 4.366
3/16 .188 .19 4.762
13/64 .203 .20 5.159
7/32 .219 .22 5.556
15/64 .234 .23 5.593
1/4 .250 .25 6.350
17/64 .266 .27 6.747
9/32 .281 .28 7.144
19/64 .297 .30 7.540
5/16 .312 .31 7.937
21/64 .328 .33 8.334
11/32 .344 .34 8.731
23/64 .359 .36 9.128
3/8 .375 .38 9.525
25/64 .391 .39 9.922
13/32 .406 .41 10.319
27/64 .422 .42 10.716
7/16 .438 .44 11.112
29/64 .453 .45 11.509
15/32 .469 .47 11.906
31/64 .484 .48 12.303
1/2 .500 .50 12.700
33/64 .516 .52 13.097
17/32 .531 .53 13.494
35/64 .547 .55 13.891
9/16 .562 .56 14.288
37/64 .578 .58 14.684
19/32 .594 .59 15.081

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To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
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

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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. lb.) to Newton Meters (Nm) Inch Pounds x 0.113
Newton Meters (Nm) to Inch Pounds (in. lb.) Newton Meters x 8.85
Foot Pounds (ft. lb.) to Newton Meters (Nm) Foot Pounds x 1.3568
Newton Meters (Nm) to Foot Pounds (ft. lb.) Newton Meters x 0.737
Volume
Pints to Liters Pints x 0.473
Liters to Pints Liters x 2.113
Quarts to Liters Quarts x 0.946
Liters to Quarts Liters x 1.057
Gallons to Liters Gallons x 3.785
Liters to Gallons Liters x 0.26

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Schematics
Schematics

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Figure A-3. 7600/7620/7640 Electrical Schematic - Component Legend (Sheet 3 of 3)
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Model 7600/7620/7640 Reach-Fork ® Truck Index
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Index
A Bearings
Mast, Shimming . . . . . . . . . . . . . . . . 7-121
Carriage to Inner Tele
Abbreviations, List of . . . . . . . . . . . . . . . . . 1-4 Model 7600 . . . . . . . . . . . . . . 7-159
AC Motors . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Model 7620 . . . . . . . . . . . . . . 7-171
Acceleration Model 7640 . . . . . . . . . . . . . . 7-180
Lift, Configuring . . . . . . . . . . . . . . . . 3-23 Inner Tele to Outer Tele
Lower, Configuring . . . . . . . . . . . . . . . 3-23 Model 7600 . . . . . . . . . . . . . . 7-158
Travel, Configuring . . . . . . . . . . . . . . 3-22 Model 7620 . . . . . . . . . . . . . . 7-170
Acronyms, List of . . . . . . . . . . . . . . . . . . . 1-4 Model 7640 . . . . . . . . . . . . . . 7-179
Active Service Mode . . . . . . . . . . . . . 3-27, 3-29 Outer Tele to Main Frame
Adjustment Model 7600 . . . . . . . . . . . . . . 7-157
Auxiliary Pressure . . . . . . . . . . . . . . . 7-80 Model 7620 . . . . . . . . . . . . . . 7-169
Lift Pressure . . . . . . . . . . . . . . . . . . . 7-77 Model 7640 . . . . . . . . . . . . . . 7-178
Proportional Valve . . . . . . . . . . . . . . . 7-79 Reach Carriage . . . . . . . . . . . . . . . . . 7-120
Reach Cylinder . . . . . . . . . . . . . . . . 7-111 Bleeding Hydraulic System . . . . . . . . . . . . 7-74
Alarm, Travel, Configuring . . . . . . . . . . . 3-22 Bow Pads . . . . . . . . . . . . . . . . . . . . . . . . 7-123
AMP Connectors . . . . . . . . . . . . . . . . . . . 7-61 Brake
Analog Tests . . . . . . . . . . . . . . . . 6-33 to 6-57 Application, Theory . . . . . . . . . . . . . . . 8-13
Summary List . . . . . . . . . . . . . . . . . . 6-31 Coil Replacement . . . . . . . . . . . . . . . . 7-51
See Tests, Analog for Individual Tests Installation . . . . . . . . . . . . . . . . . . . . . 7-51
Anchors, Chain . . . . . . . . . . . . . . . . . . . 7-127 Overview . . . . . . . . . . . . . . . . . . . . . . . 8-13
Auto Power Off ™Device . . . . . . . . . . . . . . 3-25 Pad Replacement . . . . . . . . . . . . . . . . 7-50
Auxiliary Functions, Troubleshooting . . . 5-13 Pads . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50
Auxiliary Manifold . . . . . . . . . . . . . . . 7-83, A-4 Release Screws, Use of . . . . . . . . . . . . 8-13
Auxiliary Pressure Adjustment . . . . . . . . 7-80 Release, Theory . . . . . . . . . . . . . . . . . . 8-13
Auxiliary Valve SOL5B/5T Removal . . . . . . . . . . . . . . . . . . . . . . . 7-50
Location - 7620/7640 . . . . . . . . . . . . 7-82 Theory of Operation . . . . . . . . . . . . . . 8-13
Location - 7600 . . . . . . . . . . . . . . . . . 7-81 BSOC (Battery State-of-Charge) . . . 5-10, 7-58
Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88 Configuring . . . . . . . . . . . . . . . . . . . . . 3-23
Setting BSOC Cutout . . . . . . . . . . . . . 5-10
B
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Backlash, Drive Unit . . . . . . . . . . . . . . . . 7-47
Baseleg . . . . . . . . . . . . . . . . . . . . . . . 7-16, A-4 Cable Installation, Mast
Battery Model 7600 . . . . . . . . . . . . . . . . . . . . 7-160
Charging . . . . . . . . . . . . .. . . . . . . . . 7-58 Model 7620 . . . . . . . . . . . . . . . . . . . . 7-172
Cleaning Exterior . . . . . . .. . . . . . . . . 7-57 Model 7640 . . . . . . . . . . . . . . . . . . . . 7-182
Connector/Cables . . . . . .. . . . . . . . . 7-56 Cable Removal, Mast
Maintenance . . . . . . . . . .. . . . . . . . . 7-58 Model 7600 . . . . . . . . . . . . .. . . . . . . 7-154
Safety . . . . . . . . . . . . . . .. . . . . . . . . . 2-5 Model 7620 . . . . . . . . . . . . .. . . . . . . 7-165
State-of-Charge (BSOC) . .. . . . . 5-10, 7-58 Model 7640 . . . . . . . . . . . . .. . . . . . . 7-175
Configuring . . . . . . . .. . . . . . . . . 3-23 Cable, Over-the-Mast . . . . . . . .. . . . . . . 7-143
Testing . . . . . . . . . . . . . .. . . . . . . . . 7-58 Cable Only Replacement . . .. . . . . . . 7-149
Battery Gate Switches . . . . . .. . . . . . . . . . A-4 Cable, Terminology . . . . . . . . . .. . . . . . . . 6-27
Card
Fuse/Relay . . . . . . . . . . . . . . . . . 6-29, 7-6
Tilt/Sideshift Switch . . . . . . . . . . . . . . 7-29
Publication: 1087967, Issued: 15 Apr 2009 I-1

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Carriage . . . . . . . . . . . . . . . . . . . . . . . . .7-124 Codes

Bearings . . . . . . . . . . . . . . . . . . . . . .7-120 Fault Codes
Configuring Reach/Retract . . . . . . . . 3-24 See Fault Codes . . . . . . . . . . . . . . 6-25
Installation into Mast Power Amplifier . . . . . . . . . . . . . . . . . . 6-2
Model 7600 . . . . . . . . . . . . . . . . .7-160 Summary List . . . . . . . . . . . . . . . . . . . . 6-3
Model 7620 . . . . . . . . . . . . . . . . .7-172 Cold Storage Conditioning . . . . . . . . . . . . 7-70
Model 7640 . . . . . . . . . . . . . . . . .7-182 Cold Storage, Theory of Operation . . . . . . . 8-6
Manually Lowering . . . . . . . . . . . . . . 7-78 Component Specific Service/Torque Chart . A-4
Removal from Mast Configure Mode . . . . . . . . . . . . . . . 3-16, 3-19
Model 7600 . . . . . . . . . . . . . . . . .7-154 Factory Defaults, Restoring . . . 3-20, 3-22
Model 7620 . . . . . . . . . . . . . . . . .7-165 Menu Settings . . . . . . . . . . . . 3-22 to 3-26
Model 7640 . . . . . . . . . . . . . . . . .7-175 See also Individual Parameter Name
Stops . . . . . . . . . . . . . . . . . . . . . . . . . A-5 Connectors
Caster Assembly . . . . . . . . . . . . . . . . . . . 7-22 AMP . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
Height Adjustment . . . . . . . . . . . . . . 7-23 Fuse/Relay Card . . . . . . . . . . . . . . . . 6-29
Caster, Steerable . . . . . . . . . . . . . . . . . . . 7-22 Molex . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
Height Adjustment . . . . . . . . . . . . . . 7-23 Vehicle Manager . . . . . . . . . . . . . . . . . 6-28
Caution, Definition . . . . . . . . . . . . . . . . . . 2-2 Contactor Panel . . . . . . . . . . . . . . . . . . . . . 7-5
CB1 and CB2 Counterbalance Valve Lift Potentionmeter . . . . . . . . . . . . . . . 7-27
Torque . . . . . . . . . . . . . . . . . . . . . . . 7-88 Location . . . . . . . . . . . . . . . . . . . . . . . . 7-6
CB1 and CB2 Counterbalance Valve Steer Contactor . . . . . . . . . . . . . . . . . . 7-6
Location - Deep Reach . . . . . . . . . . . . 7-85 Control Handle . . . . . . . . . . . . . . . 7-26 to 7-29
Chains Assembly . . . . . . . . . . . . . . . . . . . . . . 7-29
Anchors . . . . . . . . . . . . . . . . . . . . . .7-127 Disassembly . . . . . . . . . . . . . . . . . . . . 7-26
Condition-Cause Chart . . . . . . . . . . . 4-16 Pot Heaters . . . . . . . . . . . . . . . . . . . . . 7-27
Free Lift . . . . . . . . . . . . . . . . . . . . . .7-136 ThermaKit Heater . . . . . . . . . . . . . . . . 7-28
Main Lift Controls, Learn . . . . . . . . . . . . . . . . . . . . 3-27
7600 . . . . . . . . . . . . . . . . . . . . . .7-133 Conversion
7620 . . . . . . . . . . . . . . . . . . . . . .7-134 Decimal to Fraction . . . . . . . . . . . . . . A-13
7640 . . . . . . . . . . . . . . . . . . . . . .7-135 Fraction to Decimal . . . . . . . . . . . . . . A-13
Maintenance . . . . . . . . . . . . . . . . . . . 4-16 Standard/Metric . . . . . . . . . . . . . . . . A-15
Changing Password or SuperWrd . . . . . . 3-18 Corrosion Inhibitor, Cold Storage . . . . . . . 7-70
Check Valve Counterbalance Valve CB1 and CB2
CV-1 Location - Deep-Reach . . . . . . . . . . . . 7-85
Location - 7620/7640 . . . . . . . . . 7-82 Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88
Torque . . . . . . . . . . . . . . . . . . . . . 7-88 Cushion, Lift Cylinder Lowering
CV-1 Check Valve Free Lift . . . . . . . . . . . . . . . . . . . . . . 7-108
Location - 7600 . . . . . . . . . . . . . . 7-81 Main Lift . . . . . . . . . . . . . . . . . . . . . . 7-108
CV-3 Cutout, Lift, Configuring . . . . . . . . . . . . . 3-23
Location - Deep-Reach . . . . . . . . . 7-85 CV-1 Check Valve
Torque . . . . . . . . . . . . . . . . . . . . . 7-88 Location - 7620/7640 . . . . . . . . . . . . . 7-82
Circuit Card Connectors Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88
Fuse/Relay Card . . . . . . . . . . . . . . . . 6-29 CV-3 Check Valve
Vehicle Manager . . . . . . . . . . . . . . . . 6-28 Location - Deep-Reach . . . . . . . . . . . . 7-85
Cleaning Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88
Lift Truck . . . . . . . . . . . . . . . . . . . . . . 2-4
Clock, Setting . . . . . . . . . . . . . . . . . . . . . 3-25
Coast Distance, Configuring . . . . . . . . . . 3-22
I-2 Publication: 1087967, Issued: 15 Apr 2009

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Cylinder Drive Unit . . . . . . . . . . . . . . . . . . . 7-32 to 7-49

Free Lift . . . . . . . . . . . . . . . . . 7-90 to 7-93 Assembly . . . . . . . . . . . . . . . . 7-41 to 7-48
Exploded Parts Drawing . . . . . . . . 7-94 Helical Gear . . . . . . . . . . . . . . . . . 7-44
Lowering Cushion . . . . . . . . . . . 7-108 Output Shaft . . . . . . . . . . . . . . . . . 7-42
Model 7600 . . . . . . . . . . . 7-154, 7-160 Pivot Ring . . . . . . . . . . . . . . . . . . . 7-47
Model 7620 . . . . . . . . . . . 7-165, 7-172 Spiral Pinion . . . . . . . . . . . . . . . . . 7-42
Model 7640 . . . . . . . . . . . 7-175, 7-182 Backlash Measurement . . . . . . . . . . . . 7-47
Seal Repacking . . . . . . . . 7-96 to 7-98 Disassembly . . . . . . . . . . . . . . 7-38 to 7-41
Main Lift . . . . . . . . . . . . . . . 7-99 to 7-105 Output Shaft . . . . . . . . . . . . . . . . . 7-39
Exploded Parts Pivot Ring . . . . . . . . . . . . . . . . . . . 7-38
Drawings . . . . . . . . 7-104 to 7-105 Spiral Pinion . . . . . . . . . . . . . . . . . 7-41
Lowering Cushion . . . . ....... 7-108 Exploded Parts Diagram . . . . . . . . . . . 7-32
Seal Repacking . . . . . . 7-106 to 7-107 Helical Gear Assembly . . . . . . . . . . . . 7-44
Reach . . . . . . . . . . . . . . . . ....... 7-110 Installation . . . . . . . . . . . . . . . . . . . . . 7-48
Adjustment . . . . . . . . . ....... 7-111 Output Shaft
Tilt . . . . . . . . . . . . . . . . . . ....... 7-113 Assembly . . . . . . . . . . . . . . . . . . . 7-42
CYL-P Pressure Transducer Disassembly . . . . . . . . . . . . . . . . . 7-39
Location - 7600 . . . . . . . . . . . . . . . . . 7-81 Pivot Ring
Location - 7620/7640 . . . . . . . . . . . . 7-82 Assembly . . . . . . . . . . . . . . . . . . . 7-47
Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88 Disassembly . . . . . . . . . . . . . . . . . 7-38
Removal . . . . . . . . . . . . . . . . . . . . . . . 7-37
Shim Formulas . . . . . . . . . . . . . . . . . . 7-45
D Shim Installation . . . . . . . . . . . . . . . . 7-45
Spiral Pinion
DC Motor Assembly . . . . . . . . . . . . . . . . . . . 7-42
Troubleshooting . . . . . . . . . . . . . . . . . 5-5 Disassembly . . . . . . . . . . . . . . . . . 7-41
DC Motor Test . . . . . . . . . . . . . . . . . . . . . . 5-7 Troubleshooting . . . . . . . . . . . . . . . . . 7-35
Deadman Drive Wheel and Tire . . . . . . . . . . . . . . . . .A-4
Pedal Assembly . . . . . . . . . . . . . . . . . . A-4
Deadman? . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 E
Decals and Plates . . . . . . . . . . . . 7-11 to 7-15
Deceleration
Lift, Configuring . . . . . . . . . . . . . . . . 3-23 Electric Steering Motor . . . . . . . . . . . . . . . .A-5
Lower, Configuring . . . . . . . . . . . . . . . 3-23 Electrical Schematic . . . . . . . . . . . . . . . . .A-17
Decimal to Fraction Conversion . . . . . . . . A-13 Electrical Tests
Deep-Reach Analog Tests . . . . . . . . . . . . . . . . . . . . 6-33
Reach Manifold . . . . . . . . . . . . . . . . . 7-85 Input Tests . . . . . . . . . . . . . . . . . . . . . 6-59
Tilt/Sideshift Manifold . . . . . . . . . . . . 7-87 Output Tests . . . . . . . . . . . . . . . . . . . 6-97
Diagnostic Mode Summary List . . . . . . . . . . . . . . . . . . . 6-31
See Service Mode Electrical Troubleshooting
Digital Input Tests . . . . . . . . . . . . 6-59 to 6-95 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
See Tests, Input for Individual Tests General . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Digital Output Tests . . . . . . . . . 6-97 to 6-116 Shorts to Frame . . . . . . . . . . . . . . . . . . 5-2
See Tests, Output for Individual Tests Symptoms . . . . . . . . . . . . . . . 5-19 to 5-22
Display, Operator . . . . . . . . . . . . . . . . . . 3-15 Electronic Operator Key . . . . . . . . . 3-17, 3-25
Troubleshooting . . . . . . . . . . . . . . . . 5-20 Electrostatic Discharge
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . A-5 See Static Precautions
Power Cable Terminal Nuts . . . . . . . . 7-64 Embedded Statistics, Configuring . . . . . . . 3-25
Sensor
Speed . . . . . . . . . . . . . . . . . . . . . . 7-65
Temperature . . . . . . . . . . . . . . . . 7-65

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Encoder Code 43 - LPC Detected Open When

AC Lift Motor Temperature Commanded Closed . . . . . . . . . . . . 6-7
(Sauer Danfoss) . . . . . . . . . . . . . . 7-65 Code 44 - TPC Detected Closed When
AC Traction Motor Speed Commanded Open . . . . . . . . . . . . . 6-8
(Sauer Danfoss) . . . . . . . . . . . . . . 7-65 Code 45 - TPC Detected Open When
Height (HTI/HI) . . . . . . . . . . . . . . . . .7-138 Commanded Closed . . . . . . . . . . . . 6-8
Temperature Sensor Replacement Code 4B - Steer Contactor Detected Closed
Steering . . . . . . . . . . . . . . . . . . . . 7-20 When Commanded Open . . . . . . . . 6-8
Energy Saving Mode, Configuring . . . . . . 3-26 Code 4C - Steer Contactor Detected Open
English Units, Configuring Display for . . 3-23 When Commanded Closed . . . . . . . 6-8
Entering a Password or SuperWrd . . . . . . 3-18 Code 4D - No Pre-Charge Traction DC Input
EPO Switch . . . . . . . . . . . . . . . . . . . . . . . . A-4 Voltage During Start-Up . . . . . . . . . 6-9
Error Log . . . . . . . . . . . . . . . . . . . . 3-27, 3-29 Code 4E - No Pre-Charge Lift DC Input
Error Messages Voltage During Start-Up . . . . . . . . . 6-9
Fault Codes . . . . . . . . . . . . . . . . . . . . 6-25 Code 57- VM Not Responding to Operator
Power Amplifier . . . . . . . . . . . . . . . . . . 6-2 Display . . . . . . . . . . . . . . . . . . . . . . 6-9
Summary List . . . . . . . . . . . . . . . . . . . 6-3 Code 58 - OCSS CAN Communication
ES Mode, Configuring . . . . . . . . . . . . . . . 3-26 Error . . . . . . . . . . . . . . . . . . . . . . . 6-9
ESD Ground Jack . . . . . . . . . . . . . . . . . . . 2-7 Code 59 - CAN Transmission Buffer
Error . . . . . . . . . . . . . . . . . . . . . . 6-10
Code 5A - CAN Bus Error/VM for
F BUS_I . . . . . . . . . . . . . . . . . . . . . . 6-10
Code 5B - CAN Receive Bus Error/VM 6-10
Factory Default Configure Settings . 3-20, 3-22 Code 5G - No Communications Received
Fan from TPA . . . . . . . . . . . . . . . . . . . . 6-10
Lift Motor Code 5J - No Communications Received
7-5 from LPA . . . . . . . . . . . . . . . . . . . . 6-10
Motor Compartment Cooling . . . . . . . . 7-4 Code 5M - TPA CAN Watchdog
Traction Motor . . . . . . . . . . . . . . . . . . 7-4 Timeout . . . . . . . . . . . . . . . . . . . . 6-11
Traction Power Amplifer . . . . . . . . . . . 7-6 Code 5P - LPA CAN Watchdog Timeout 6-11
Fault Codes . . . . . . . . . . . . . . . . . . . . . . 6-25 Code 5Q - Display Manager Not
Code 1H - TPA Overheated . . . . . . . . . 6-5 Responding . . . . . . . . . . . . . . . . . . 6-11
Code 1T - Battery Low . . . . . . . . . . . . . 6-5 Code 5R - Secondary CAN Bus Error for
Code 1V - LPA Overheated . . . . . . . . . . 6-5 BUS_E . . . . . . . . . . . . . . . . . . . . . 6-11
Code 2A - Traction Motor Approaching Code 5T - No CAN Message from any
Overtemp . . . . . . . . . . . . . . . . . . . . 6-5 Node . . . . . . . . . . . . . . . . . . . . . . . 6-12
Code 2C - TPA Temp Sensor Code 61 - Mast Switch #1 Not Crossed 6-12
Out-of-Range . . . . . . . . . . . . . . . . . 6-6 Code 62 - LPA Reverted to Default
Code 2E - Traction Motor Temp Sensor Parameters . . . . . . . . . . . . . . . . . . 6-12
Out-of-Range . . . . . . . . . . . . . . . . . 6-6 Code 63 - HS Travel and First Speed
Code 2H - Traction Motor Speed Sensor Limiting Switches Do Not Agree . . 6-12
Failure . . . . . . . . . . . . . . . . . . . . . . 6-6 Code 64 - No Pulses Seen from Height
Code 2M - TPA Failed . . . . . . . . . . . . . 6-6 Indicator Encoder . . . . . . . . . . . . . 6-13
Code 2P - TPA Reverted to Default Code 66 - Calculated Height Greater Than
Parameters . . . . . . . . . . . . . . . . . . 6-6 Configured Height . . . . . . . . . . . . . 6-13
Code 2T - TPA Current Calibration Code 67 - Calculated Height Does Not
Error . . . . . . . . . . . . . . . . . . . . . . . 6-7 Match First Speed Limiting
Code 2U - TPA Overcurrent or Switch (S12) . . . . . . . . . . . . . . . . . 6-13
Short Circuit . . . . . . . . . . . . . . . . . 6-7 Code 6D - Pressure Sensor
Code 2V - TPA High DC Bus Voltage . . 6-7 Out-of-Range . . . . . . . . . . . . . . . . 6-13
Code 42 - LPC Detected Closed Code 6F - Lift Motor Overtemp . . . . . . 6-13
When Commanded Open . . . . . . . . 6-7

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Code 6G - Lift Motor Temp Sensor Out-of-Range . . . . . . . . . . . . . . . . 6-21

Out-of-Range . . . . . . . . . . . . . . . . 6-14
Code 6S - LPA Temp Sensor Code FN - Relays Did Not Open
Out-of-Range . . . . . . . . . . . . . . . . 6-14 at Power Off . . . . . . . . . . . . . . . . . 6-21
Code 6T - LPA Current Calibration Code FP - VM Internal Fault . . . . . . . . 6-21
Error . . . . . . . . . . . . . . . . . . . . . . 6-14 Code FR - VM Config Item
Code 6V - LPA Failure . . . . . . . . . . . . 6-14 Out-of-Range . . . . . . . . . . . . . . . . 6-21
Code 6W - Failure Detected in Lift Code FT - VM Internal Software Error . 6-22
Motor Speed Sensor . . . . . . . . . . . 6-14 Code FV - Display Internal
Code 6X - LPA Fault Overcurrent . . . . 6-15 Software Error . . . . . . . . . . . . . . . . 6-22
Code 6Y - LPA Fault High DC Voltage . 6-15 Code G0 - Steer Tiller 1
Code 80 - Primary Throttle Pot Channel A/B Fault . . . . . . . . . . . . 6-22
Out-of-Range . . . . . . . . . . . . . . . . 6-15 Code G3 - Steer Feedback
Code 81 - Lift/Lower Pot Prox Sensor Fault . . . . . . . . . . . . . 6-22
Out-of-Range . . . . . . . . . . . . . . . . 6-15 Code G4 - Open Detected in
Code 83 - Primary Throttle Pot Steer Control Circuit . . . . . . . . . . . 6-23
Out-of-Neutral . . . . . . . . . . . . . . . 6-16 Code G5 - Short Detected in
Code 84 - Brake Not Applied . . . . . . . 6-16 Steer Motor Encoder Circuit . . . . . 6-23
Code 88 - +5VDC Power Supply Code G7 - Steer Tiller 2
Out-of-Range . . . . . . . . . . . . . . . . 6-16 Channel A/B Fault . . . . . . . . . . . . 6-23
Code 8A - OCSS Photo Sensor Fault . 6-16 Code GD - Open Detected in
Code 8F - Lift/Lower Pot Steer Motor Encoder Circuit . . . . . 6-23
Out-of-Neutral . . . . . . . . . . . . . . . 6-16 Code GE - Steer Tiller Encoder Failure 6-24
Code 8J - Ambient Air Temp Sensor Code T0 - SOL5T Current Incorrect . . . 6-24
Out-of-Range . . . . . . . . . . . . . . . . 6-17 Code T1 - SOL5B Current Incorrect . . 6-24
Code 8L - Brake Feedback Current Code T2 - SOL3 Current Incorrect . . . . 6-24
Out-of-Range . . . . . . . . . . . . . . . . 6-17 Code T3 - SOL2 Current Incorrect . . . . 6-24
Code 8M - Internal Handle Heater Code X4 - Switch Mismatch . . . . . . . . 6-25
Failure . . . . . . . . . . . . . . . . . . . . . 6-17 Power Amplifier . . . . . . . . . . . . . . . . . . . 6-2
Code 8N - Optional Start Switch Summary List . . . . . . . . . . . . . . . . . . . . 6-3
Closed at Start-Up . . . . . . . . . . . . 6-17 Filter, Hydraulic . . . . . . . . . . . . . . . . . . . . 7-75
Code A0 - Mismatched Software Filter Type 1
Versions . . . . . . . . . . . . . . . . . . . . 6-17 Installation . . . . . . . . . . . . . . . . . . 7-75
Code AH - Bad Operator Display Removal . . . . . . . . . . . . . . . . . . . . 7-75
Checksum . . . . . . . . . . . . . . . . . . 6-18 Filter Type 2
Code AJ - Bad VM Flash Memory . . . . 6-18 Installation . . . . . . . . . . . . . . . . . . 7-76
Code AK - Bad VM RAM . . . . . . . . . . . 6-18 Removal . . . . . . . . . . . . . . . . . . . . 7-75
Code AL - Bad VM Battery Location - 7600 . . . . . . . . . . . . . . . . . . 7-81
Backed-Up RAM . . . . . . . . . . . . . . 6-19 Location - 7620/7640 . . . . . . . . . . . . . 7-82
Code AM - Bad Operator Display Flash Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88
Memory . . . . . . . . . . . . . . . . . . . . 6-19 Firmware
Code AN - Bad Operator Display . . . . 6-19 Displaying Version . . . . . . . . . . 3-16, 3-21
Code AV - Primary Memory Mismatch 6-19 FlashWare . . . . . . . . . . . . . . . . . . . . . . . 3-6
Code EH - Invalid Interrupt - Operator Matching VM and DM . . . . . . . . . . . . . . 3-9
Display . . . . . . . . . . . . . . . . . . . . 6-19 FlashWare Program . . . . . . . . . . . . . . . . . . 3-6
Code F4 - VM COP Time-out . . . . . . . 6-20 Flow Limiter
Code F5 - Bad Op Code . . . . . . . . . . . 6-20 Free Lift . . . . . . . . . . . . . . . . . . . . . . 7-116
Code F8 - VM COP Not Enabled . . . . . 6-20 Torque . . . . . . . . . . . . . . . . . . . . . 7-88
Code FE - VM Not Calibrated . . . . . . . 6-20 Main Lift . . . . . . . . . . . . . . . . . . . . . . 7-115
Code FG - 5 and/or 12V Power Supply
Out-of-Range . . . . . . . . . . . . . . . . 6-21
Code FH - Battery Voltage

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Forks Hose
Angle . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Free Lift . . . . . . . . . . . . . . . . . . . . . . 7-153
Hooks . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Installation, Mast
Inspection . . . . . . . . . . . . . . . . . . . . . 4-17 Model 7600 . . . . . . . . . . . . . . . . . 7-160
Markings . . . . . . . . . . . . . . . . . . . . . . 4-20 Model 7620 . . . . . . . . . . . . . . . . . 7-172
Positioning Locks . . . . . . . . . . . . . . . 4-18 Model 7640 . . . . . . . . . . . . . . . . . 7-182
Straightness . . . . . . . . . . . . . . . . . . . 4-17 Main Lift . . . . . . . . . . . . . . . . . . . . . . 7-142
Tip Height . . . . . . . . . . . . . . . . . . . . . 4-18 Over-the-Mast . . . . . . . . . . . . . 7-143, A-4
Wear . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Removal, Mast
Fraction to Decimal Conversion . . . . . . . A-13 Model 7600 . . . . . . . . . . . . . . . . . 7-154
Free Lift Cylinder . . . . . . . . . . . . 7-90 to 7-93 Model 7620 . . . . . . . . . . . . . . . . . 7-165
Model 7600 . . . . . . . . . . . . . . 7-154, 7-160 Model 7640 . . . . . . . . . . . . . . . . . 7-175
Model 7620 . . . . . . . . . . . . . . 7-165, 7-172 Hour Meters . . . . . . . . . . . . . . . . . . 3-16, 3-21
Model 7640 . . . . . . . . . . . . . . 7-175, 7-182 HTI
Seal Repacking . . . . . . . . . . . 7-96 to 7-98 Belt Replacement . . . . . . . . . . . . . . . 7-138
Fuse/Relay Card Location . . . . . . . . . . . . . 7-6 Codes and Tests
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Test I26 . . . . . . . . . . . . . . . . . . . . 6-78
Test I86 . . . . . . . . . . . . . . . . . . . . 6-91
Pressure Switch Torque . . . . . . . . . . . 7-88
G Hung-Up Carriage, Lowering . . . . . . . . . . 7-78
Hydraulic Filter . . . . . . . . . . . . . . . . . . . . 7-75
Grease Fittings Filter Type 1
See Lubrication Points Installation . . . . . . . . . . . . . . . . . . 7-75
Ground Jack, ESD . . . . . . . . . . . . . . . . . . 2-7 Removal . . . . . . . . . . . . . . . . . . . . 7-75
Filter Type 2
Installation . . . . . . . . . . . . . . . . . . 7-76
H Removal . . . . . . . . . . . . . . . . . . . . 7-75
Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88
Hydraulic Manifold
Harness
See Manifold
Inspection . . . . . . . . . . . . . . . . . . . . . 7-59
Hydraulic System
Repair . . . . . . . . . . . . . . . . . . . . . . . . 7-59
Bleeding . . . . . . . . . . . . . . . . . . . . . . . 7-74
Soldering Procedures . . . . . . . . . . . . . 7-59
Functional Operation . . . . . . . . . . . . . . 8-7
Terminology . . . . . . . . . . . . . . . . . . . 6-27
Troubleshooting
Heater
Guidelines . . . . . . . . . . . . . . . . . . 5-11
Control Handle
Symptoms . . . . . . . . . . . . 5-13 to 5-17
Potentiometers . . . . . . . . . . . . . . . 7-27
ThermaKit . . . . . . . . . . . . . . . . . . 7-28
Control Handle ThermaKit . . . . . . . . . 7-28 I
heater . . . . . . . . . . . . . . . . . . . . . . . 7-26, 7-28
Height Encoder Belt . . . . . . . . . . . . . . . .7-138
Helical Gear Assembly, Drive Unit . . . . . . 7-44 Inertial Dampener . . . . . . . . . . . . . . . . . . 7-52
High Speed Travel Switch (S25) . . . . . . . . . A-4 Input Tests . . . . . . . . . . . . . . . . . . . . . . . 6-59
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Summary List . . . . . . . . . . . . . . . . . . . 6-31
Switch See Tests, Input for Individual Tests
Test 018 . . . . . . . . . . . . . . . . . . .6-109
Test I15 . . . . . . . . . . . . . . . . . . . . 6-70 J
Jacking Safety . . . . . . . . . . . . . . . . . . . . . . 2-8

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L Loctite®
See Thread Adhesives
Loop Back Tests . . . . . . . . . . . . 6-117 to 6-118
Learn Function . . . . . . . . . . . . . . . . 3-16, 3-27 Summary List . . . . . . . . . . . . . . . . . . . 6-32
Controls . . . . . . . . . . . . . . . . . . . . . . 3-27 Lower Acceleration, Configuring . . . . . . . . 3-23
Weight . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Lower Deceleration, Configuring . . . . . . . . 3-23
Lift Acceleration, Configuring . . . . . . . . . 3-23 Lower Function
Lift Chains Speed, Configuring . . . . . . . . . . . . . . . 3-23
Inspection . . . . . . . . . . . . . . . . . . . . . 4-16 Theory of Operation . . . . . . . . . . . . . . . 8-9
See Chains Troubleshooting . . . . . . . . . . . . . . . . . 5-17
Lift Cutout Switch (S27) . . . . . . . . . . . . . . A-4 Lowering Carriage Manually . . . . . . . . . . . 7-78
Lift Cutout, Configuring . . . . . . . . . . . . . 3-23 LS-1 Load Shuttle
Lift Cylinder Location 7600 . . . . . . . . . . . . . . . . . . . 7-81
Free Lift . . . . . . . . . . . . . . . . . 7-90 to 7-93 Location 7620/7640 . . . . . . . . . . . . . . 7-82
Model 7600 . . . . . . . . . . . 7-154, 7-160 Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88
Model 7620 . . . . . . . . . . . 7-165, 7-172 Lubrication Points . . . . . . . . . . . . 4-10 to 4-15
Model 7640 . . . . . . . . . . . 7-175, 7-182 Lubrication Specification Chart . . . . . . . . .A-2
Main Lift . . . . . . . . . . . . . . . 7-99 to 7-105
Exploded Parts
Drawings . . . . . . . . 7-104 to 7-105 M
Lift Deceleration, Configuring . . . . . . . . . 3-23
Lift Function Main Lift Cylinder . . . . . . . . . . . . 7-99 to 7-105
Theory of Operation . . . . . . . . . . . 8-8, 8-11 Exploded Parts Drawings . . 7-104 to 7-105
Troubleshooting . . . . . . . . . . . . . . . . 5-16 Seal Repacking . . . . . . . . . . 7-106 to 7-107
Lift Hose . . . . . . . . . . . . . . . . . . . . . . . . 7-142 Main Manifold . . . . . . . . . . . . . . . . . . . . . .A-4
Lift Limit Cutout, Configuring . . . . . . . . . 3-23 Model 7600 . . . . . . . . . . . . . . . . . . . . . 7-81
Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Model 7620/7640 . . . . . . . . . . . . . . . . 7-82
Speed Sensor (Sauer Danfoss) . . . . . . 7-65 Maintenance Minder ™ Tool . . . . . . . . 3-25, 4-3
Lift Power Amplifier . . . . . . . . . . . . . . . . . . A-5 Maintenance Mode
Lift Pressure Adjustment . . . . . . . . . . . . . 7-77 See Service Mode
Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Manifold
Lift/Lower System Troubleshooting . . . . . 5-16 Auxiliary . . . . . . . . . . . . . . . . . . . 7-83, A-4
Lift/Lower Valve SOL2 Main . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Location - 7600 . . . . . . . . . . . . . . . . . 7-81 Model 7600 . . . . . . . . . . . . . . . . . . 7-81
Location 7600 . . . . . . . . . . . . . . . . . . 7-81 Model 7620/7640 . . . . . . . . . . . . . 7-82
Location 7620/7640 . . . . . . . . . . . . . 7-82 Reach (DR only) . . . . . . . . . . . . . . . . . 7-85
Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88 Tilt/Sideshift (DR only) . . . . . . . . . . . . 7-87
Limit Switch, Speed, First (S12) . . . . . . . . . A-5 Manual Design . . . . . . . . . . . . . . . . . . . . . . 1-3
Limit Switch, Steer S11 . . . . . . . . . . . 7-21, A-5 Manual Lowering of Carriage . . . . . . . . . . 7-78
Linkage, Steering . . . . . . . . . . . . . . . . . . 7-25 Map, Navigating the Manual . . . . . . . . . . . . 1-2
Load Holding Valve SOL1
Location - 7600 . . . . . . . . . . . . . . . . . 7-81
Location - 7620/7640 . . . . . . . . . . . . 7-82
Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88
Load Shuttle LS-1
Location - 7600 . . . . . . . . . . . . . . . . . 7-81
Location - 7620/7640 . . . . . . . . . . . . 7-82
Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88
Locator Photos
Components . . . . . . . . . . . . . . . 7-3 to 7-8
Lubrication Points . . . . . . . . . 4-10 to 4-15

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Mast Hour Meters . . . . . . . . . . . . 3-16, 3-21

Model 7600 Serial Number . . . . . . . . . . . 3-16, 3-21
Assembly . . . . . . . . . . . .7-157 to 7-164 Service . . . . . . . . . . . . 3-16, 3-27, 3-28
Disassembly . . . . . . . . .7-154 to 7-157 Active . . . . . . . . . . . . . . 3-27, 3-29
Main Lift Chain Installation . . . . .7-159 Error Log . . . . . . . . . . . . 3-27, 3-29
Main Lift Chain Removal . . . . . . .7-155 Learn . . . . . . . . . . . . . . 3-16, 3-27
Mating Tractor to Mast . . . . . . . .7-163 Controls . . . . . . . . . . . . . . 3-27
Separation of Telescopics . . . . . . .7-155 Weight . . . . . . . . . . . . . . . . 3-27
Separation of Tractor and Mast . .7-154 Static . . . . . . . . . . . . . . . . . . . 3-28
Model 7620 Version . . . . . . . . . . . . . . . . 3-16, 3-21
Assembly . . . . . . . . . . . .7-169 to 7-174 Run . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Disassembly . . . . . . . . .7-165 to 7-169 Tones . . . . . . . . . . . . . . . . . . . . . . 3-17
Main Lift Chain Installation . . . . .7-171 Molex Connectors . . . . . . . . . . . . . . . . . . . 7-60
Main Lift Chain Removal . . . . . . .7-167 Motors
Mating Tractor to Mast . . . . . . . .7-174 AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Separation of Telescopics . . . . . . .7-167 Lift Temperature Sensor
Separation of Tractor and Mast . .7-165 (Sauer Danfoss) . . . . . . . . . . . . 7-65
Model 7640 Open Winding . . . . . . . . . . . . . . . . . 5-9
Assembly . . . . . . . . . . . .7-178 to 7-185 Shorted Winding . . . . . . . . . . . . . . . 5-9
Disassembly . . . . . . . . .7-175 to 7-178 Traction Temperature Sensor
Main Lift Chain Installation . . . . .7-180 (Sauer Danfoss) . . . . . . . . . . . . 7-65
Main Lift Chain Removal . . . . . . .7-176 Armature . . . . . . . . . . . . . . . . . . . . . . . 5-8
Mating Tractor to Mast . . . . . . . .7-185 DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Separation of Telescopics . . . . . . .7-176 Field Winding Test . . . . . . . . . . . . . 5-8
Separation of Tractor and Mast . .7-175 Grounded Motor Test . . . . . . . . . . . 5-7
Shimming . . . . . . . . . . . . . . . . . . . . .7-121 Open Circuit Test . . . . . . . . . . . . . . 5-7
Types . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Short Circuited Armature . . . . . . . . 5-8
Mast Bearing Shimming Drive . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Carriage to Inner Tele Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Model 7600 . . . . . . . . . . . . . . . . .7-159 Power Cable Terminals . . . . . . . . . . . . 7-64
Model 7620 . . . . . . . . . . . . . . . . .7-171 Steering Electric . . . . . . . . . . . . . . . . . . A-5
Model 7640 . . . . . . . . . . . . . . . . .7-180 Traction Speed Sensor Replacement . . 7-65
Inner Tele to Outer Tele Troubleshooting . . . . . . . . . . . . . . . . . 5-19
Model 7600 . . . . . . . . . . . . . . . . .7-158 AC . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Model 7620 . . . . . . . . . . . . . . . . .7-170 DC . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Model 7640 . . . . . . . . . . . . . . . . .7-179
Outer Tele to Main Frame
Model 7600 . . . . . . . . . . . . . . . . .7-157 O
Model 7620 . . . . . . . . . . . . . . . . .7-169
Model 7640 . . . . . . . . . . . . . . . . .7-178 OCSS
Messages and Codes Test I80 – Upper Beam . . . . . . . . . . . . 6-87
Power Amplifier . . . . . . . . . . . . . . . . . . 6-2 Test I81 – Lower Beam . . . . . . . . . . . . 6-89
Meters, Hour . . . . . . . . . . . . . . . . . . 3-16, 3-21 Open Circuit DC Motor Test . . . . . . . . . . . . 5-7
Metric Units, Configuring Display for . . . 3-23 Open Winding AC Motor . . . . . . . . . . . . . . . 5-9
Metric/Standard Conversion . . . . . . . . . . A-15 Operator Compartment Sensor System
Modes of Operation . . . . . . . . . . . 3-16 to 3-29 Test I80 – Upper Beam . . . . . . . . . . . . 6-87
Overview . . . . . . . . . . . . . . . . . . . . . . 3-16 Test I81 – Lower Beam . . . . . . . . . . . . 6-89
Program . . . . . . . . . . . . . . . . . . 3-16, 3-17 Operator Display . . . . . . . . . . . . . . . . . . . 3-15
Configure . . . 3-16, 3-19, 3-22 to 3-26 Troubleshooting . . . . . . . . . . . . . . . . . 5-20
Restoring Factory Operator Key, Electronic . . . . . . . . 3-17, 3-25
Defaults . . . . . . . 3-20, 3-22

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Output Tests . . . . . . . . . . . . . . . . . . . . . . 6-97 Pressure Switch, HTI

Summary List . . . . . . . . . . . . . . . . . . 6-32 Location - 7600 . . . . . . . . . . . . . . . . . . 7-81
See Tests, Output for Individual Tests Location - 7620/7640 . . . . . . . . . . . . . 7-82
Outrigger Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88
See Baseleg Pressure Transducer CYL-P
Over-the-Mast Hose . . . . . . . . . . . . . . . . . A-4 Location - 7600 . . . . . . . . . . . . . . . . . . 7-81
Over-the-Mast Hose/Cable . . . . . . . . . . 7-143 Location - 7620/7640 . . . . . . . . . . . . . 7-82
Cable Only Replacement . . . . . . . . . 7-149 Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88
Priority-on-Demand POD-1
Location - 7620/7640 . . . . . . . . . . . . . 7-82
P Priority-on-Demand Valve POD-1 . . . . . . . 7-81
Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88
Passwords Product Improvement Notices Included . . . . -vii
Changing Password or SuperWrd . . . . 3-18 Program Mode . . . . . . . . . . . . . . . . 3-16, 3-17
Configuring . . . . . . . . . . . . . . . . . . . . 3-18 Menu Settings . . . . . . . . . . . . . 3-21 to 3-27
Electronic Operator Key . . . . . . . 3-17, 3-25 See also Individual Parameter Name
Entering Password or SuperWrd . . . . 3-18 Proportional Valve Adjustment . . . . . . . . . 7-79
Password . . . . . . . . . . . . . . . . . . 3-17, 3-25 Pulleys, Over-the-Mast . . . . . . . . . . . . . . . .A-5
SuperWrd . . . . . . . . . . . . . . . . . 3-17, 3-25 Pump
Pin Extraction Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
AMP Connectors . . . . . . . . . . . . . . . . 7-61 Location . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Molex Connectors . . . . . . . . . . . . . . . 7-60
Pin Insertion R
AMP Connectors . . . . . . . . . . . . . . . . 7-62
Molex Connectors . . . . . . . . . . . . . . . 7-60
Pinout Matrix . . . . . . . . . . . . . . . 8-14 to 8-31 Reach Carriage
Pivot Ring, Drive Unit See Carriage
Assembly . . . . . . . . . . . . . . . . . . . . . . 7-47 Reach Cylinder . . . . . . . . . . . . . . . . . . . . 7-110
Disassembly . . . . . . . . . . . . . . . . . . . 7-38 Adjustment . . . . . . . . . . . . . . . . . . . . 7-111
POD-1 Priority-on-Demand Valve Reach Function
Location - 7600 Configuring Speed . . . . . . . . . . . . . . . 3-24
Auxiliary Valve SOL5B/5T Theory of Operation
Location - 7600 . . . . . . . . . . . 7-81 Retract . . . . . . . . . . . . . . . . . . . . . . 8-10
Location - 7620/7640 . . . . . . . . . . . . 7-82 Troubleshooting . . . . . . . . . . . . 5-13, 5-15
Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88 Reach Manifold (DR) . . . . . . . . . . . . . . . . . 7-85
Potentiometer Reach Speed, Configuring . . . . . . . . . . . . . 3-24
Lift/Lower (VR2) . . . . . . . . . . . . . . . . A-17 Reach Valve
8-8, 8-9, 8-11 Deep-Reach . . . . . . . . . . . . . . . . . . . . 7-85
Travel (VR1) . . . . . . . . . . . . . . . . . . . . A-17 Location, Single Reach . . . . . . . . . . . . 7-83
8-5 Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88
Potentiometer, Lift/Lower (VR2) . . . 8-3 REL-2 Relief Valve
Power Amplifier Loation . . . . . . . . . . . . . . . . . . . . . . . . 7-82
Discharging Internal Capacitor . . . . . . 5-2 Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88
LED Diagnostics . . . . . . . . . . . . . . . . . 6-2 REL-3 Relief Valve (DR)
Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 Location . . . . . . . . . . . . . . . . . . . . . . . 7-85
Traction . . . . . . . . . . . . . . . . . . . . . . . . A-5 Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88
Power Cables, Motor . . . . . . . . . . . . . . . . 7-64 Relief Valve REL-2
Preset Lift Heights, Configuring . . . . . . . . 3-26 Location . . . . . . . . . . . . . . . . . . . . . . . 7-82
Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28 Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88
Pressure Adjustment Relief Valve REL-3 (DR)
Auxiliary . . . . . . . . . . . . . . . . . . . . . . 7-80 Location . . . . . . . . . . . . . . . . . . . . . . . 7-85
Lift . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77 Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88

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Retract Function Sensor, Temperature, Traction Motor

Configuring Speed . . . . . . . . . . . . . . . 3-24 Replacement . . . . . . . . . . . . . . . . . . . . 7-65
Troubleshooting . . . . . . . . . . . . . . . . 5-15 Serial Number
Retract Speed, Configuring . . . . . . . . . . . 3-24 Displaying from Program Mode . 3-16, 3-21
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Location on Specification Plate . . . . . . . 3-3
Tones . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Service Bulletins Included . . . . . . . . . . . . . .-vi
Service Intervals
See Scheduled Maintenance Charts
S Service Mode . . . . . . . . . . . . . 3-16, 3-27, 3-28
Active Service Mode . . . . . . . . . . . . . . 3-29
Safety Static Service Mode . . . . . . . . . . . . . . 3-28
Battery . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Shimming
Decals . . . . . . . . . . . . . . . . . . 7-11 to 7-15 Drive Unit . . . . . . . . . . . . . . . . . . . . . . 7-45
Definitions of Warning and Caution . . . 2-2 Mast Bearings . . . . . . . . . . . . . . . . . 7-121
ESD . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Carriage to Inner Tele
General . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Model 7600 . . . . . . . . . . . . . . 7-159
Jacking . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Model 7620 . . . . . . . . . . . . . . 7-171
Static Precautions . . . . . . . . . . . . . . . . 2-7 Model 7640 . . . . . . . . . . . . . . 7-180
Tie-Down for Transport . . . . . . . . . . . 2-10 Inner Tele to Outer Tele
Welding . . . . . . . . . . . . . . . . . . . . . . . 2-11 Model 7600 . . . . . . . . . . . . . . 7-158
Scheduled Maintenance Model 7620 . . . . . . . . . . . . . . 7-170
180 Days . . . . . . . . . . . . . . . . . . . . . . . 4-6 Model 7640 . . . . . . . . . . . . . . 7-179
2000 Deadman Hours . . . . . . . . . . . . . 4-9 Outer Tele to Main Frame
250 Deadman Hours . . . . . . . . . . . . . . 4-5 Model 7600 . . . . . . . . . . . . . . 7-157
360 Days . . . . . . . . . . . . . . . . . . . . . . . 4-9 Model 7620 . . . . . . . . . . . . . . 7-169
500 Deadman Hours . . . . . . . . . . . . . . 4-6 Model 7640 . . . . . . . . . . . . . . 7-178
Chains . . . . . . . . . . . . . . . . . . . . . . . 4-16 Shorted Winding on AC Motor . . . . . . . . . . 5-9
Guidelines . . . . . . . . . . . . . . . . . . . . . . 4-2 Shorts to Frame Test . . . . . . . . . . . . . . . . . 5-2
Initial 90 Days . . . . . . . . . . . . . . . . . . . 4-5 Sideshift Function
Lubrication Points . . . . . . . . . 4-10 to 4-15 Theory of Operation . . . . . . . . . . . . . . . 8-10
Maintenance Minder ™ Tool . . . . . . . . . 4-3 Troubleshooting . . . . . . . . . . . . . . . . . 5-14
Schematics Sideshift Valve
Electrical . . . . . . . . . . . . . . . . . . . . . . A-17 Location
Hydraulic . . . . . . . . . . . . . . . . . . . . . A-22 Deep-Reach . . . . . . . . . . . . . . . . . 7-87
Power Distribution Diagram . . . . . . . A-21 Single Reach . . . . . . . . . . . . . . . . . 7-83
Seal Repacking Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88
Free Lift Cylinder . . . . . . . . . 7-96 to 7-98 Software
Main Lift Cylinder . . . . . . . .7-106 to 7-107 Displaying Version . . . . . . . . . . 3-16, 3-21
Sealants, Specifications . . . . . . . . . . . . . . A-3 FlashWare . . . . . . . . . . . . . . . . . . . . . . 3-6
SelfTest . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Matching VM and DM . . . . . . . . . . . . . . 3-9
Sensor SOL-1 Load Handling Valve
AC Lift Motor Temperature Location - 7620/7640 . . . . . . . . . . . . . 7-82
(Sauer Danfoss) . . . . . . . . . . . . . . 7-65 SOL1 Load Holding Valve
AC Traction Motor Speed Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88
(Sauer Danfoss) . . . . . . . . . . . . . . 7-65 SOL-2 Lift/Lower Valve
OCSS Location - 7620/7640 . . . . . . . . . . . . . 7-82
Lower Beam Test I81 . . . . . . . . . . 6-89 SOL2 Lift/Lower Valve
Upper Beam Test I80 . . . . . . . . . . 6-87 Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88
Sensor, Speed Replacement . . . . . . . . . . 7-65 SOL-3 Proportional Main Relief/Dump Valve
Sensor, Temperature, Lift Motor Location - 7600 . . . . . . . . . . . . . . . . . 7-81
Replacement . . . . . . . . . . . . . . . 6-95, 7-65 Location - 7620/7640 . . . . . . . . . . . . . 7-82
SOL3 Proportional Main Relief/Dump

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Valve Torque . . . . . . . . . . . . . . . . . . . 7-88 Switch

SOL-5B/5T Auxiliary Valve Battery Gate . . . . . . . . . . . . . . . . . . . . .A-4
Location - 7620/7640 . . . . . . . . . . . . 7-82 Deadman (DS1) . . . . . . . . . . . . . . . . . . .A-4
SOL5B/5T Auxiliary Valve Deadman (DS2) . . . . . . . . . . . . . . . . . . .A-4
Location - 7600 . . . . . . . . . . . . . . . . . 7-81 First Speed Limit, Configuring . . . . . . 3-22
Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88 High Speed Travel (S25) . . . . . . . . . . . .A-4
Soldering Procedures . . . . . . . . . . . . . . . . 7-59 HTI Pressure (S18)
Solenoid Location - 7600 . . . . . . . . . . . . . . . 7-81
See Valve Location - 7620/7640 . . . . . . . . . . 7-82
Special Tools . . . . . . . . . . . . . . . . . . . . . . 7-10 Torque . . . . . . . . . . . . . . . . . . . . . 7-88
Specification Plate . . . . . . . . . . . . . . . . . . . 3-3 Lift Cutout (S27) . . . . . . . . . . . . . . . . . .A-4
Speed Second Speed Limiting, Configuring . . 3-22
Limit Switch 1, Configuring . . . . . . . . 3-22 Speed Limiting, First (S12) . . . . . . . . . .A-5
Limit Switch 2, Configuring . . . . . . . . 3-22 Steer Limit S11 . . . . . . . . . . . . . . 7-21, A-5
Limiting Switch, First (S12) . . . . . . . . . A-5 Tilt/Sideshift . . . . . . . . . . . . . . . . . . . 7-27
Lowering, Configuring . . . . . . . . . . . . 3-23 UnNested, Configuring . . . . . . . . . . . . 3-22
Reach, Configuring . . . . . . . . . . . . . . 3-24 Symbols, List of . . . . . . . . . . . . . . . . . . . . . 1-4
Retract, Configuring . . . . . . . . . . . . . 3-24 Symptom Tables
Travel, Configuring . . . . . . . . . . . . . . 3-22 Electrical Symptoms . . . . . . . . . . . . . . 5-19
Speed Limiting Switch, First (S12) . . . . . . . A-5 Hydraulic Functions . . . . . . . . 5-13 to 5-17
Speed Sensor Travel Functions . . . . . . . . . . . . . . . . . 5-18
Traction Motor, Replacement . . . . . . . 7-65
Spiral Pinion, Drive Unit
Assembly . . . . . . . . . . . . . . . . . . . . . . 7-42 T
Disassembly . . . . . . . . . . . . . . . . . . . 7-41
Standard/Metric Conversion . . . . . . . . . . A-15 Temperature Sensor
Static Precautions . . . . . . . . . . . . . . . . . . . 2-7 Lift Motor, Replacement . . . . . . 6-95, 7-65
Static Service Mode . . . . . . . . . . . . . . . . . 3-28 Traction Motor, Replacement . . . . . . . 7-65
Static Strap . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Temperature Sensor, Lift Motor . . . . . . . . . 7-65
Steer Limit Switch S11 . . . . . . . . . . . 7-21, A-5 Temperature Sensor, Traction Motor . . . . . 7-65
Steerable Caster . . . . . . . . . . . . . . . . . . . 7-22 Terminals, Motor Power Cable . . . . . . . . . 7-64
Height Adjustment . . . . . . . . . . . . . . . 7-23 Tests
Steering Analog . . . . . . . . . . . . . . . . . . 6-33 to 6-57
Encoder . . . . . . . . . . . . . . . . . . . . . . . 7-20 Test A04 – Primary Throttle
Limit Switch S11 . . . . . . . . . . . . . 7-21, A-5 Potentiometer (VR1) Voltage . . . 6-34
Linkage . . . . . . . . . . . . . . . . . . . . . . . 7-25 Test A05 – Lift/Lower Potentiometer
Motor, Electric . . . . . . . . . . . . . . . . . . . A-5 Voltage . . . . . . . . . . . . . . . . . . 6-35
Steerable Caster . . . . . . . . . . . . . . . . 7-22 Test A08 – Traction Motor
Height Adjustment . . . . . . . . . . . . 7-23 Temperature . . . . . . . . . . . . . . 6-36
Theory of Operation . . . . . . . . . . . . . . . 8-4 Test A09 – Lift Motor Temperature 6-37
Stops, Carriage . . . . . . . . . . . . . . . . . . . . . A-5 Test A10 – Traction Power Amplifier
SuperWrd . . . . . . . . . . . . . . . . . . . . 3-17, 3-25 Heatsink Temperature . . . . . . . 6-38
Changing . . . . . . . . . . . . . . . . . . . . . . 3-18 Test A11 – Traction Motor Current 6-39
Entering . . . . . . . . . . . . . . . . . . . . . . 3-18 Test A13 – Pressure Sensor Voltage 6-39
Test A14 – Power Supply +12V DC 6-41
Test A15 – Battery Voltage . . . . . . . 6-42
Test A20 – Lift Motor Current . . . . 6-44
Test A22 – Primary Traction
Throttle (VR1) Request . . . . . . . 6-45
Test A23 – Lift Throttle (VR2)
Request . . . . . . . . . . . . . . . . . . 6-46

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Test A26 – Travel and Lift/Lower Test I39 – Neutral Pulses . . . . . . . 6-84
+5V DC Power Supply . . . . . . 6-47 Test I60 – Security Start Switch
Test A31 – Solenoid 5T (AUX1) (optional) . . . . . . . . . . . . . . . . . 6-85
Current . . . . . . . . . . . . . . . . . 6-48 Test I61 – High Speed Travel
Test A32 – Solenoid 5B (AUX2) Switch (S25) . . . . . . . . . . . . . . 6-86
Current . . . . . . . . . . . . . . . . . 6-49 Test I80 – OCSS Upper Beam Test 6-87
Test A33 – Aux Dump (SOL3)/ Test I81 – OCSS Lower Beam Test . 6-89
Main Relief Dump (SOL8) Test I86 – Lift Height . . . . . . . . . . . 6-91
Current . . . . . . . . . . . . . . . . . 6-50 Test I90 – Degree Turned Past
Test A34 – Solenoid 2 (Lift/Lower) Steer Flag . . . . . . . . . . . . . . . . 6-92
Current . . . . . . . . . . . . . . . . . 6-51 Test I91 – iPort Communication
Test A35 – Brake Current . . . . . . 6-52 Test . . . . . . . . . . . . . . . . . . . . . 6-93
Test A36 – Ambient Temperature Test I92 – iPort Error Bitmap Test . 6-95
Sensor . . . . . . . . . . . . . . . . . . 6-53 Loop Back Tests . . . . . . . . . 6-117 to 6-118
Test A37 – Steer Power Amplifier Output
Current . . . . . . . . . . . . . . . . . 6-54 Test O00 – Toggle the TPC
Test A41 – Emergency Power Off Contactor . . . . . . . . . . . . . . . . 6-98
(EPO) Switch . . . . . . . . . . . . . 6-57 Test O01 – Toggle the STR
Input Contactor . . . . . . . . . . . . . . . . 6-99
Test I00 – Deadman Switch (DS1) 6-60 Test O02 – Toggle the LPC
Test I01 – Nested Switch (S14) . . . 6-61 Contactor . . . . . . . . . . . . . . . 6-100
Test I02 – First Speed Limiting Test O04 – Toggle Aux1 Directional
Switch (S12) . . . . . . . . . . . . . . 6-62 (SOL5T) Solenoid . . . . . . . . . . 6-101
Test I06 – Reach Switch (S4) . . . . 6-63 Test O05 – Toggle Aux2 Directional
Test I07 – Retract Switch (S5) . . . 6-64 (SOL5B) Solenoid . . . . . . . . . 6-102
Test I08 – Tilt Up Switch (S6) . . . . 6-65 Test O06 – Toggle the Reach
Test I09 – Tilt Down Switch (S7) . 6-66 Solenoid . . . . . . . . . . . . . . . . 6-103
Test I10 – Sideshift Right Test O07 – Toggle the Tilt
Switch (S9) . . . . . . . . . . . . . . . 6-67 Solenoid . . . . . . . . . . . . . . . . 6-104
Test I11 – Sideshift Left Test O08 – Toggle the Sideshift
Switch (S8) . . . . . . . . . . . . . . . 6-68 Solenoid . . . . . . . . . . . . . . . . 6-105
Test I14 – Steering Fuse (FU1) . . . 6-69 Test O09 – Aux Dump (SOL3)/ Main
Test I15 – Horn Switch (S3) . . . . . 6-70 Relief Dump (SOL8) Current . 6-106
Test I19 – Drive Motor Speed Test O11 – Toggle the Load Hold
Sensor . . . . . . . . . . . . . . . . . . 6-71 (SOL1) Solenoid . . . . . . . . . . . 6-107
Test I20 – Lift Motor Speed Sensor 6-72 Test O12 – Ramp the Proportional
Test I22 – Lift Cutout Switch (S27) 6-73 Lower (SOL2) Solenoid . . . . . . 6-108
Test I23 – CAN Bus Test . . . . . . . 6-74 Test O18 – Toggle the Horn . . . . . 6-109
Test I24 – Steer Feedback Proximity Test O19 – Audible Alarm . . . . . . 6-110
Sensor . . . . . . . . . . . . . . . . . . 6-76 Test O20 – Travel Alarm Test . . . 6-111
Test I25 – Steer Motor Encoder . . 6-77 Test O23 – Toggle Fans . . . . . . . . 6-112
Test I26 – Height Indicator Test O29 – Ramp the Traction
Encoder . . . . . . . . . . . . . . . . . 6-78 Power Amplifier . . . . . . . . . . . 6-114
Test I32 – Deadman Switch (DS2) 6-79 Test O32 – Toggle Relays K1, K2,
Test I33 – Steer Tiller Encoder 1 K3, and K4 . . . . . . . . . . . . . . 6-116
Connect Detect . . . . . . . . . . . 6-80 Shorts to Frame . . . . . . . . . . . . . . . . . . 5-2
Test I34 – Steer Tiller Encoder 2 Theory of Operation
Connect Detect . . . . . . . . . . . 6-81 BSOC . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Test I35 – Steer Tiller Encoder 1 Cold Storage . . . . . . . . . . . . . . . . . . . . . 8-6
(Channel A & B) . . . . . . . . . . . 6-82 Electric Brake . . . . . . . . . . . . . . . . . . . 8-13
Test I36 – Steer Tiller Encoder 2 Lift/Aux System, Lower . . . . . . . . . . . . 8-9
(Channel A & B) . . . . . . . . . . . 6-83

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Lift with Aux . . . . . . . . . . . . . . . . 8-11 Transducer, Presssure CYL-P

Lift without Aux . . . . . . . . . . . . . . . 8-8 Location - 7620/7640 . . . . . . . . . . . . . 7-82
Reach . . . . . . . . . . . . . . . . . . . . . 8-10 Transducer, Pressure CYL-P Torque . . . . . 7-88
Sideshift . . . . . . . . . . . . . . . . . . . 8-10 Transducer,Pressure CYL-P
System Components . . . . . . . . . . . 8-7 Location - 7600 . . . . . . . . . . . . . . . . . . 7-81
Tilt . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Transmission
Pinout Matrix . . . . . . . . . . . . 8-14 to 8-31 See Drive Unit
SelfTest . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Transport, Tie-Down for . . . . . . . . . . . . . . 2-10
Steering System . . . . . . . . . . . . . . . . . . 8-4 Travel Acceleration, Configuring . . . . . . . . 3-22
Traction System . . . . . . . . . . . . 8-2 to 8-6 Travel Alarm, Configuring . . . . . . . . . . . . . 3-22
Battery Connected . . . . . . . . . . . . . 8-2 Travel Functions, Troubleshooting . . . . . . 5-18
Deadman Pedal Depressed . . . . . . . 8-4 Travel Light . . . . . . . . . . . . . . . . . . . . . . . .A-5
Key Switch Turned On . . . . . . . . . . 8-2 Travel Speed Limit
Requesting Travel . . . . . . . . . . . . . 8-5 Switch 1, Configuring . . . . . . . . . . . . . 3-22
ThermaKit . . . . . . . . . . . . . . . . . . . . 7-28, 7-29 Switch 2, Configuring . . . . . . . . . . . . . 3-22
Thread Adhesives, Specifications . . . . . . . . A-3 Travel Speed, Configuring . . . . . . . . . . . . . 3-22
Tie-Down for Transport . . . . . . . . . . . . . . 2-10 Travel Switch, High Speed (S25) . . . . . . . . .A-4
Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . 7-113 Troubleshooting
Tilt Function Auxiliary Functions . . . . . . . . . . . . . . . 5-13
Theory of Operation . . . . . . . . . . . . . . . 8-9 Chains . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Troubleshooting . . . . . . . . . . . . . . . . 5-14 Dead Lift Truck . . . . . . . . . . . . . . . . . . 5-20
Tilt Valve Drive Unit . . . . . . . . . . . . . . . . . . . . . . 7-35
Location Electrical . . . . . . . . . . . . . . . . . . . . . . . 5-2
Deep-Reach . . . . . . . . . . . . . . . . . 7-87 Symptoms . . . . . . . . . . . . . . . . . . . 5-19
Single Reach . . . . . . . . . . . . . . . . 7-83 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Torque . . . . . . . . . . . . . . . . . . . . . . . . 7-88 Hydraulic
Tilt/Sideshift Guidelines . . . . . . . . . . . . . . . . . . . 5-11
Switch Card . . . . . . . . . . . . . . . . . . . . 7-29 Symptoms . . . . . . . . . . . . . 5-13 to 5-17
Tilt/Sideshift Manifold (DR only) . . . . . . . 7-87 Lift Function . . . . . . . . . . . . . . . . . . . . 5-16
Tire, Drive . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Lift/Lower Functions . . . . . . . . . . . . . 5-16
Tones, Run Mode . . . . . . . . . . . . . . . . . . 3-17 Loop Back Tests . . . . . . . . . 6-117 to 6-118
Tools, Special . . . . . . . . . . . . . . . . . . . . . 7-10 Lower Function . . . . . . . . . . . . . . . . . . 5-17
Torque Chart . . . . . . . . . . . . . . . . . . . . . . . A-8 Motors . . . . . . . . . . . . . . . 5-5 to 5-9, 5-19
Component Specific Service/ AC . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Torque Chart . . . . . . . . . . . . . . . . . . . . A-4 DC . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Face Seal O-Rings . . . . . . . . . . . . . . . . A-7 Operator Display . . . . . . . . . . . . . . . . . 5-20
Hydraulic Fittings . . . . . . . . . . . . . . . . A-6 Pinout Matrix . . . . . . . . . . . . . 8-14 to 8-31
Metric (Brass) . . . . . . . . . . . . . . . . . . A-12 Reach Function . . . . . . . . . . . . 5-13, 5-15
Metric (Ferrous) . . . . . . . . . . . . . . . . . A-10 Retract Function . . . . . . . . . . . . . . . . . 5-15
Solenoid Valves . . . . . . . . . . . . . 7-88 to ?? Shorts to Frame Test . . . . . . . . . . . . . . 5-2
Standard (Brass) . . . . . . . . . . . . . . . . A-11 Sideshift Function . . . . . . . . . . . . . . . 5-14
Standard (Ferrous) . . . . . . . . . . . . . . . A-8 Symptom Tables . . . . . . . . . . . . . . . . . 5-13
Torque Chart, Component Specific . . . . . . A-4 Tilt Function . . . . . . . . . . . . . . . . . . . . 5-14
TP4 Location . . . . . . . . . . . . . . . . . . . . . . . 7-6 Travel Functions . . . . . . . . . . . . . . . . . 5-18
Traction Motor Vantage Point . . . . . . . . . . . . . . . . . . . 5-21
See Drive Motor Truck Utilization System, Configuring
Speed Sensor Replacement . . . . . . . . 7-65 See Embedded Statistics
Traction Power Amplifier . . . . . . . . . . . . . . A-5
LED Diagnostics . . . . . . . . . . . . . . . . . 6-2
Location . . . . . . . . . . . . . . . . . . . . . . . 7-6
See Theory of Operation, Traction System

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U Wiring
General . . . . . . . . . . . . . . . . . . . . . . . 7-59
Harness Terminology . . . . . . . . . . . . . 6-27
Underside Components . . . . . . . . . . . . . . . 7-8 Inspection . . . . . . . . . . . . . . . . . . . . . 7-59
Units, Configuring Display . . . . . . . . . . . 3-23 Repair . . . . . . . . . . . . . . . . . . . . . . . . 7-59
UnNested Switch, Configuring . . . . . . . . . 3-22 Soldering Procedures . . . . . . . . . . . . . 7-59
Wrist strap, ESD . . . . . . . . . . . . . . . . . . . . 2-7
V
Valve
CB1 & CB2 Counterbalance Torque . 7-88
CV-1 Check Valve Torque . . . . . . . . . 7-88
CV-3 Check Valve Torque . . . . . . . . . 7-88
LS-1 Load Shuttle Torque . . . . . . . . . 7-88
POD-1 Priority-on-Demand Torque . . 7-88
Proportional, Adjustment . . . . . . . . . 7-79
Reach, Location . . . . . . . . . . . . . . . . . 7-83
Torque . . . . . . . . . . . . . . . . . . . . . 7-88
REL-2 Relief, Torque . . . . . . . . . . . . . 7-88
REL-3 Relief (DR), Torque . . . . . . . . . 7-88
Sideshift, Location
Deep-Reach . . . . . . . . . . . . . . 7-87
Single Reach . . . . . . . . . . . . . 7-83
Torque . . . . . . . . . . . . . . . . . . . . . 7-88
SOL1 Load Holding, Torque . . . . . . . . 7-88
SOL2 Lift/Lower, Torque . . . . . . . . . . 7-88
SOL3 Proportional Main Relief/Dump
Torque . . . . . . . . . . . . . . . . . . . . . 7-88
SOL5B/5T Auxiliary, Torque . . . . . . . 7-88
Tilt, Location
Deep-Reach . . . . . . . . . . . . . . 7-87
Single Reach . . . . . . . . . . . . . 7-83
Torque . . . . . . . . . . . . . . . . . . . . . 7-88
Torque Chart . . . . . . . . . . . . . . . . . . . 7-88
Vantage Point, Troubleshooting . . . . . . . . 5-21
Version, Displaying Software . . . . . . 3-16, 3-21
Vertical Hold, Configuring . . . . . . . . . . . . 3-26
Warning, Definition . . . . . . . . . . . . . . . . . . 2-2

Weight, Learn . . . . . . . . . . . . . . . . . . . . . 3-27
Welding Safety . . . . . . . . . . . . . . . . . . . . 2-11
WHLD
Display Format, Configuring . . . . . . . 3-26
Weight-Height Configuration Table . . 3-21

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!1026304B!
1087967A

7600 Maintenance Manual PDF

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h a n g e Vi h a n g e Vi

Series: Serial Number

Publication 1087967 Issued: 15 Apr 2009

To locate your local authorized Raymond dealer, go to www.raymondcorp.com.

©2009 The Raymond Corporation.

Publication 1087967, Issued: 15 Apr 2009 i

Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

ii Publication 1087967, Issued: 15 Apr 2009

Publication 1087967, Issued: 15 Apr 2009 iii

iv Publication 1087967, Issued: 15 Apr 2009

Page Revision Record

Document Revision History

Publication 1087967, Issued: 15 Apr 2009 v

Service Bulletin List

Document Number Subject Date

vi Publication 1087967, Issued: 15 Apr 2009

Document Number Subject Date

Publication 1087967, Issued: 15 Apr 2009 vii

viii Publication 1087967, Issued: 15 Apr 2009

Section 1. How to Use This Manual

Publication 1087967, Issued: 15 Apr 2009 1-1

Map of the Manual

1-2 Publication 1087967, Issued: 15 Apr 2009

Manual Design • Component Procedures gives

Publication 1087967, Issued: 15 Apr 2009 1-3

1-4 Publication 1087967, Issued: 15 Apr 2009

Term/Symbol Definition Term/Symbol Definition

K thousand OACH Overall Collapsed Height

Publication 1087967, Issued: 15 Apr 2009 1-5

WHLD Weight Height Limit Display

1-6 Publication 1087967, Issued: 15 Apr 2009

Publication 1087967, Issued: 15 Apr 2009 2-1

Warning means a potentially hazardous

Caution means a potentially hazardous

2-2 Publication 1087967, Issued: 15 Apr 2009

Do not operate or work on this lift truck unless

Before working on this lift truck, always turn

Know the lift truck’s controls and what they do.

Do not wear watches, rings, or jewelry when

if it is in any way unsafe.

Follow the scheduled lubrication, maintenance,

Publication 1087967, Issued: 15 Apr 2009 2-3

Do not wash this lift truck with a hose.

Do not add to or modify this lift truck until you

2-4 Publication 1087967, Issued: 15 Apr 2009

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

As a battery is being charged, an

serious damage or injury.

Battery electrolyte is a solution of

Keep the charging area well-ventilated to avoid

eyes, face, and skin when checking, handling,

Turn the key switch OFF before disconnecting

Publication 1087967, Issued: 15 Apr 2009 2-5

Do not lay tools or metal objects on top of the

Do not allow cleaning solution, dirt, or any

Make sure you install the correct size battery. A

Keep batteries clean. Corrosion causes shorts

Keep plugs, terminals, cables, and receptacles

Never plug a battery charger into the lift truck’s