7400 Mantenimiento

Maintenance Manual
Model 7400/7420/7440 Reach-Fork ® Truck

With The ACR System™
Series Serial Numbers

AA, AB 00001 and UP
BA, BB
CA, CB
DA, DB
EA, EB
FA, FB
1026304C Issued: 22 Apr 2009

Replaces 1026304B Issued: 15 Jul 2007
This publication, 1026304C applies to the Model 7400/7420/7440 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.
For revision information, see “Page Revision Record” on page v.
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, iPort, iAlert, iControl, iWarehouse, The ACR System,
and Vantage Point. All other brand and product names are trademarks or registered trademarks of
their respective companies.
Model 7400/7420/7440 Reach-Fork ® Truck Table of Contents
Table of Contents
Page Revision Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-v

Service Bulletin List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-vi
Product Improvement Notice List . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-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 7400 Series 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 . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Symptom Tables: Electrical Symptoms . . . . . . . . . . . . . . . . . . . . . . 5-21
Symptom Tables: Vantage Point System . . . . . . . . . . . . . . . . . . . . . 5-23
Messages, Codes, and Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Power Amp LED Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Messages and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Analog Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Input Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
Output Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-101
Publication: 1026304, Issued: 22 Apr 2009 i

Table of Contents Model 7400/7420/7440 Reach-Fork ® Truck
Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Component Locator Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Special Tools, Decals, and Chassis . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Decals and Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Baselegs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Steering and Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Steer Tiller Encoder (AC Lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Steer Limit Switch (S11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Steerable Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Steering Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Drive and Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
Brake (Adjustable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
Brake (Floating Disk) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66
Deadman Switch (S2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68
Inertial Dampener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
Battery Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Wiring and Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77
Contactor Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
AC Motor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84
Steer Amplifier (AC Lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-92
Cold Storage Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-93
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-95
Hydraulic System Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-96
Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-97
Lift Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99
Manual Lowering of Fork Carriage . . . . . . . . . . . . . . . . . . . . . . . . . 7-100
Proportional Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-101
Auxiliary Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-102
Manifold, Main, AC Lift, Model 7400 . . . . . . . . . . . . . . . . . . . . . . . 7-103
Manifold, Main, AC Lift, Model 7420/7440 . . . . . . . . . . . . . . . . . . 7-104
Manifold, Main, DC Lift, Model 7400 . . . . . . . . . . . . . . . . . . . . . . . 7-105
Manifold, Auxiliary (Standard Reach) . . . . . . . . . . . . . . . . . . . . . . 7-106
Manifold, Reach (Deep-Reach ®) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-108
Manifold, Tilt/Sideshift (Deep-Reach ®) . . . . . . . . . . . . . . . . . . . . . 7-110
Manifold Solenoids, Fittings, and Attachments . . . . . . . . . . . . . . . 7-111
Hydraulic Components, Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 7-113
Lift Cylinder, Free Lift, Remove/Install . . . . . . . . . . . . . . . . . . . . . 7-114
Lift Cylinder, Free Lift, Exploded Parts Drawing . . . . . . . . . . . . . . 7-118
Lift Cylinder, Free Lift, Seal Repacking . . . . . . . . . . . . . . . . . . . . . 7-121
Lift Cylinder, Main, Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . 7-124
Lift Cylinder, Main Lift, Exploded Parts Drawing . . . . . . . . . . . . . . 7-129
Lift Cylinder, Main, Seal Repacking . . . . . . . . . . . . . . . . . . . . . . . . 7-131
Lift Cylinder Lowering Cushion . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-133
Reach Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-136
Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-139
Flow Limiter, Main Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-141
Flow Limiter, Free Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-142
ii Publication: 1026304, Issued: 22 Apr 2009

Model 7400/7420/7440 Reach-Fork ® Truck Table of Contents
Mast, Chain, Hose, Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-145

Reach Carriage Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-146
Mast Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-147
Bow Pads - Model 7400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-149
Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-151
Chain Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-154
Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-160
Height Encoder Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-165
Hose, Main Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-169
Hose and Cable, Over-the-Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-170
Hose Guard Addition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-176
Hose/Cable Retainer Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-177
Cable, Over-the-Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-178
Hose/Tubing, Free Lift Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-183
Mast, Model 7400 (Complete Disassembly) . . . . . . . . . . . . . . . . . . 7-184
Mast, Model 7400 (Complete Assembly) . . . . . . . . . . . . . . . . . . . . . 7-188
Carriage, Free Lift Cylinder, and Hose/Cable Installation . . . . . . . . 7-214
Mating Tractor to Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-218
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Traction System Functional Operation . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Cold Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Hydraulic System Functional Operation (AC Lift) . . . . . . . . . . . . . . . . 8-7
Hydraulic System Functional Operation (DC Lift) . . . . . . . . . . . . . . . 8-13
Electric Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Pinout Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Lubrication Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Thread Adhesives, Sealants, and Lubricants . . . . . . . . . . . . . . . . . . . A-3
Component Specific Service/Torque Chart . . . . . . . . . . . . . . . . . . . . . A-4
Torque Chart - Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Torque Chart - Straight Thread Face Seal O-Rings . . . . . . . . . . . . . . . A-8
Torque Chart - Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Torque Chart - Metric (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11
Torque Chart - Standard (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12
Torque Chart - Metric (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14
Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-16
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-17
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
Publication: 1026304, Issued: 22 Apr 2009 iii

Table of Contents Model 7400/7420/7440 Reach-Fork ® Truck
iv Publication: 1026304, Issued: 22 Apr 2009

Model 7400/7420/7440 Reach-Fork ® Truck Page Revision Record
Page Revision Record

This section is a record of all revised pages in this manual. Whenever a page is revised, this section
is updated and included in the revision package.
Pages are revised due to technical and non-technical changes described as follows:
• Technical changes – These changes are identified by a vertical line (change bar) in the left
margin next to the change. Pages affected by technical changes are identified with
“Page Revised: Mo/Day/Yr” in the footer. These pages are also available on the Raymond iNet.
• Non-technical changes – These changes consist of typographical and grammatical corrections,
paragraph renumbering, repagination, and so on. Non-technical changes are not identified
with a change bar, however, affected pages are identified with “Page Revised: Mo/Day/Year” in
the footer.
1026304A Original Issue . . . . . . . 15 Jun 2004
1026304B . . . . . . . . . . . . . . . . . . .15 Jul 2007

. . . . . . . . . . . . . replaced REV A in its entirety
1026304C . . . . . . . . . . . . . . . . . . 22 Apr 2009

. . . . . . . . . . . . . replaced REV B in its entirety
Publication: 1026304, Issued: 22 Apr 2009 v

Service Bulletin List Model 7400/7420/7440 Reach-Fork ® Truck
Service Bulletin List

The following Service Bulletins have been incorporated into this manual.
NOTE: All applicable Service Bulletins published before 15 Oct 2007 were incorporated into
previous revisions of this manual.
Use the blank rows below to log Service Bulletins when they are added to this manual.
Document Number Subject Date
RSB RCH-07-011A Software Version VM 5.0, DM 3.4, and Power Amplifier 3.2 10 Oct 2007
RSB RCH-08-004 Loose Free Lift Staging Ram Piston Plugs 19 Mar 2008
RSB RCH-08-006 Drive Motor Pinion Nut 21 May 2008
vi Publication: 1026304, Issued: 22 Apr 2009

Model 7400/7420/7440 Reach-Fork ® Truck Product Improvement Notice List
Product Improvement
Notice List
The following Product Improvement Notices have been incorporated into this manual.
NOTE: All applicable Product Improvement Notices published before 15 Oct 2007 were incorporated
into previous revisions of this manual.
Use the blank rows below to log Product Improvement Notices when they are added to this manual.
Document Number Subject Date
RPIN RCH-07-R015 New Electric Brake Available 02 Nov 2007
RPIN RCH-08-R001A AC Lift Trucks Without a Height Encoder 11 Sep 2008
RPIN RCH-08-R003 Stiff Steering 12 Feb 2008
RPIN RCH-08-R004 Free Lift Staging Ram Glands 19 Mar 2008
RPIN RCH-08-R007 Replacement of Drive Motor Encoder Bearing 16 May 2008
RPIN RCH-08-R008A Update to Tests I02 and I24 11 Sep 2008
RPIN RCH-08-R009 Proximity Switch Adjustment 11 Sep 2008
RPIN RCH-08-R010 Using FlashWare to Clear and Program the VM 14 Oct 2008
RPIN GEN-08-R001 Warning Light Failures 25 Feb 2008
Publication: 1026304, Issued: 22 Apr 2009 vii

Product Improvement Notice List Model 7400/7420/7440 Reach-Fork ® Truck
viii Publication: 1026304, Issued: 22 Apr 2009

Model 7400/7420/7440 Reach-Fork ® Truck Section 1. How to Use This Manual
Section 1. How to Use This Manual
Publication: 1026304, Issued: 22 Apr 2009 1-1

Section 1. How to Use This Manual Model 7400/7420/7440 Reach-Fork ® Truck
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: 1026304, Issued: 22 Apr 2009

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
7400/7420/7440 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 truck.
Design of the Manual)
• 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.

Abbreviations and Symbols
Abbreviations and
Symbols
These abbreviations, acronyms and symbols are used in this manual.
Term/Symbol Definition Term/Symbol Definition
A Ampere E UL Electric Truck Type

AC Alternating Current Certification Rating with
AGND Analog Ground safeguards against inherent
amp Ampere or amplifier fire and electrical shock
ANSI American National hazards
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
BSOC Battery State-of-Charge ESDS Electrostatic Discharge
Sensitive
C Celsius or Centigrade
CAN Controller Area Network F Fahrenheit
CB Counterbalance valve ft. foot or feet
CCW Counterclockwise ft. lb. foot pound(s)
CD Coil Driver FR Flow Regulator
CE Compensating Element FU Fuse
(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
DGND Digital Ground JP jack and pin connector
diam. diameter
DOT US Department of
Transportation
DVM Digital Voltmeter or
Multimeter

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

Term/Symbol Definition
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
T/S Troubleshoot
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

Model 7400/7420/7440 Reach-Fork ® Truck Section 2. Safety
Section 2. Safety

Section 2. Safety Model 7400/7420/7440 Reach-Fork ® Truck
Definitions
Definitions
Throughout this manual, you will see two kinds
of safety reminders:
Warning means a potentially hazardous

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

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

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.
jewelry.eps
Do not operate this lift truck if it needs repair or

if it is in any way unsafe.
6173_004.eps
Follow the scheduled lubrication, maintenance,

and inspection steps.
schedmnt.eps

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

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

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.

Static Precautions
Static Precautions • If you are removing or installing

static-sensitive components, place them
on a correctly grounded anti-static mat.
Electronic circuit boards can contain
• To transport static sensitive components,
Electrostatic Discharge Sensitive (ESDS)
including failed components being
devices.
returned, place the components in an
anti-static bag or box (available from your
Static charges can accumulate from normal
local authorized Raymond dealer).
operation of the lift truck as well as movement
or contact between non-conductive materials
Test the wrist strap and related accessories
(plastic bags, synthetic clothing, synthetic soles
before each use to make sure they are working
on shoes, styrofoam coffee cups, and so forth.)
correctly.
Accumulated static electricity can be
Figure 2-2 shows the components of the
discharged to a circuit board or component by
Raymond anti-static field service kit,
touching the parts. Electrostatic Discharge
P/N 1-187-059. The kit includes a wrist strap,
(ESD) is also possible through the air when a
ground cord and static-dissipative work surface
charged object is placed close to another
(mat). Follow the instructions packaged with
surface at a different electrical potential. Static
the kit.
discharge can occur without seeing or feeling it.
Figure 2-2. Anti-Static Kit with Wrist Strap and Mat
Whenever working on or near ESDS devices, 2mat2.tif
follow these precautions.

• Wear an ESD wrist strap. The wrist strap
should be equipped with a 1 megohm
resistor to dissipate static charges slowly.
• Connect the wrist strap plug to the ground
jack on the lift truck. See Figure 2-1. If
you cannot use the ground jack, connect
the ground clip to an unpainted, grounded
surface on the lift truck frame.
Figure 2-1. ESD Ground Jack Location

7074_004.tif
Wrist straps (P/N 1-187-058/001) are available

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

available.
Contact your local Raymond dealer for

information.
ESD Ground Jack
• Handle circuit boards by the edges only.

Avoid touching the edge connectors.

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

hole that it passes through is excessively these areas
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.
Figure 2-3. A-frame Down-Travel Adjustment Bolt

13y7s001.tif
No Jack Area
A-frame Springs
A-frame
To elevate the rear of the lift
Down-Travel truck:
Adjustment Bolt
1. Place the jack in the specified jacking
position. See Figure 2-4.
7. Place the jack under the designated
jacking points. See Figure 2-4. 2. Jack the rear of the lift truck so that the
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.

Jacking Safety
To elevate either side of the lift

truck:
1. Place the jack in the specified jacking
position. See Figure 2-4.
2. Jack the side of the 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.

Tie-Down for Transport
Tie-Down for Transport

To transport your Raymond Model
7400/7420/7440 Reach-Fork 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.

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.

Welding Safety

Model 7400/7420/7440 Reach-Fork ® Truck Section 3. Systems Overview
Section 3. Systems Overview

Section 3. Systems Overview Model 7400/7420/7440 Reach-Fork ® Truck
Introduction
Introduction
This manual provides information for
maintenance and repair of the Model
7400/7420/7440 Reach-Fork ® 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.

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: The lift truck serial number can also

also be 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 truck.

Model 7400 Series Designation
Model 7400 Series

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
3500 lb.
7400 R35TT
(1587 kg)
Standard
4500 lb.
7400/ R45TT
(2041 kg)
7420/
7440 3200 lbs. Deep-Reach ®
DR32TT
(1451 kg)
Tractor Series
The serial number consists of a three-digit
model abbreviation, two-digit year of
manufacture, two-digit tractor series
designator, and five-digit serial number.
Table 3-2. Tractor Series Designation
Model Tractor Lift Lift

Stance
(abbrev.) Series Motor Pump
AA, AB Single
740 DC
BA, BB Dual
Fore-Aft
740/742/
CA, CB AC
744 Single
DA, DB
740 DC
EA, EB Dual Side
Stance
740/742/
FA, FB AC Single
744

Battery Specifications
Battery Specifications
Table 3-3. 36V Battery Specifications
Weight
Width (in.) lb. (kg) Hours Amps
Min Max
2000 2300
16.5 930
(908) (1044)
2300 2600
18.5 6 1085
(1044) (1180)
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.

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 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 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 truck
Requirements opening screen appears. 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 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 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.
Configuration and Truck Setup
To install FlashWare on the PC, double-click the Options
installation file and follow the instructions on
the screen. The software package is a The Truck Setup screen feature allows you to:

FlashWare
• enable options that were added to the

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 truck. See Figure 3-3.
Figure 3-3. Typical Truck Setup Screen

37400 Flashware 1.jpg

FlashWare
To Change an Option Setting: be copied to other trucks. Refer to “Vertical Hold

Data Copy” on page 3-11.
The pull down screen near the middle of the NOTE: Vertical Hold requires the Un-nested
window lists the Truck Options. Speed Switch and HTI options be
installed and enabled.
Check the required option box. To disable an
option, remove the check mark. See Figure 3-3. HTI - enables digital fork height and tilt
When the options are correctly configured, click indicator.
“SEND Changes to Truck” button.
NOTE: Options displayed in red require HI - enables digital fork height indicator.
authorization codes. When these options
are selected, a pop up window appears Embedded Statistics - records truck utilization
requesting the authorization code. (lift and travel) is programmable in truck
Contact your local Raymond dealer for configuration.
the correct forms and procedure for
obtaining the authorization code. High Performance Traction - allows travel up
to 8.0 mph.
Options include (but are not limited to):
Reverse Steering - enables reverse steering for
Electronic Key - requires the operator to enter models with electric steering.
a code before operation is allowed.
Auxiliary Start Switch - enables additional
Ambient Temperature Sensor - senses switch that must be pressed to allow truck to be
ambient air temperature required for cold turned ON.
storage options.
HS Travel Limit Switch - limits speed of truck
2nd Speed Limit Switch - limits the speed of when forks are above the switch height.
the truck above a second programmable height.
Weight Height Limit Display - displays load
Un-nested Speed Switch - limits the speed of capacity vs. height information.
the truck to a programmable rate if the fork
carriage is not fully retracted. Requires the Operator Compartment Sensor - enables
installation of a switch S14. OCSS system.
Travel Alarm - allows the alarm to sound when Ext Access Enable - enables additional switch
the truck is moving as configured. that must be pressed to allow truck to be
turned ON.
Deadman Lockout - allows the operator to lift
and lower only when the deadman pedal is Key Switch Aux Start Switch Truck State
depressed.
OFF OFF Inactive
Lift Limit w/Bypass - limits lift height until Travel and
bypass switch is depressed. ON OFF
lift disabled
Secondary Handle - enables use of secondary OFF ON Inactive

handle, allowing normal travel tractor-first and ON ON Active
1 mph forks-first.
Vertical Hold - provides operator assistance in Vantage-Point - enables Vantage Point ™

storing and retrieving loads from frequently system.
referenced rack heights. Once rack heights are
programmed into a truck, the information can

FlashWare
Lift Cutout SW (No Hgt encoder) - inhibits lift 1. Click Vehicle Manager Software button on
when the forks reaches the height of the Truck Setup screen. See Figure 3-4.
optional switch.
2. Select Software version to load. See
iPort Basic - part of the iWarehouse package. Figure 3-5.
3. Click the Load VM With Selected Software
iAlert - part of the iWarehouse package. Version button. See Figure 3-5. The new
software is then installed in the truck.
iControl - part of the iWarehouse package.
4. Using the FlashWare application, load to
Sideshift - use to configure the sideshift on the the PC the latest Software Model Table, if
truck. one was provided in the package.
5. Open the Software Model Table: Click on
Reviewing Vehicle Manager Help and select “View Software Model
Number Table” from the drop down menu.
Software
6. Compare the software versions listed in
Vehicle Manager software information the table with the versions in the truck. To
management can be performed in the VM display software versions in the truck, see
Software window: “Version” under “Program Mode Menu” on
page 3-21.
• Identify current version of software
installed in the truck 7. Load updates to FlashWare and install
software to the truck as needed to make
• Update current version of software with a
sure a matching set of VM/DM software is
newer version
installed.
• Upload currently installed version of
8. When installation is complete, click Exit to
software
return to the main Truck Setup screen.
Figure 3-4. Truck Setup Screen

Click Here

FlashWare
Figure 3-5. VM Software Screen
Click Here
Select
Clearing Primary Memory Figure 3-7.

none
Remove Cleared Memory Screen
The clear primary memory feature allows you to

clear a Display Card in a truck so it can be used
in another 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 Do not cycle the key switch, or the
agree, the truck assumes that identity. primary memory will be restored to the
If all three memory locations disagree, a current truck configuration.
code AV is displayed and a programmed
Display Card and VM must be installed. 5. Remove the Display Card.
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.

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. voltage that is considered as 0% BSOC.
NOTE: Record customer-specific
Making this number smaller (down to 1) lowers
configurations, for example; speed,
the average voltage considered as 0% BSOC,
acceleration, lift, and coast from the
resulting in increasing the time to reach 0%
Truck Config screens before resetting
BSOC, by using more battery capacity.
defaults.
Figure 3-9. Configuration Reset Screen Making this number higher (up to 9) increases
3none the average voltage considered as 0% BSOC,
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.

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 truck
and enter FlashWare.
This feature is used to specify weight versus
5. From the Configuration screen, click height information on trucks equipped with an
Vertical Hold Data Copy. 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. 37400 Flashware 5.jpg
Example: R45TTB-05546.hsd. Click Open.

8. You are asked if you want to write data to
the 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 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.

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.

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.

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

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 3-18.
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.

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) indicates 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) indicates
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 operator is prompted to enter all operate normally.
the electronic key. Run Mode cannot be entered • Traction system shutdown: The lift
unless the correct electronic key is entered. Up truck is disabled for travel. Lift, lower,
to 20 different electronic keys can be set. auxiliary functions, steering, and horn
all operate normally.
Password • Lift system shutdown: The lift truck is
not permitted to lift. Lower, travel,
Password permits access to Configure Mode steering, and auxiliary functions all
only. It is intended for customer use in setting operate normally.
performance parameters within those features 4. A descending “arcade” tone indicates an
purchased with the lift truck. incorrect password or electronic key was
entered.
Superword
Superword permits access to all Program

Entering Program Mode
Modes. Superword is intended to limit service
To enter Program Mode:
access to qualified and trained service
technicians.
From Run Mode, press the enter button on the
Operator Display.
It is strongly recommended that, during
installation, you change the Superword from
An eight character password prompt field
the factory default to a code known only to the
appears, displaying underscores:
dealer and/or owner so that access to Service
Mode is limited to approved personnel. Record
________
the new Superword in a safe place. If this code
is lost or forgotten, a technician must reset the
Enter the Password or Superword for the lift
lift truck to factory default settings. This
truck. (refer to “Entering a Password or
requires the reconfiguration of all variable
Superword” in the following paragraphs).
settings.

Modes of Operation
Entering an Electronic Key,

Invalid, Try Again
Password, or Superword
7. If you make a mistake while entering a
An Electronic Key, Password, or Superword character, repeat steps 2 thru 5.
may be from one to eight characters in length,
having any combination of letters, numbers, When you have entered the correct Password or
and/or spaces (indicated by an underscore). A Superword, the following is displayed:
password of all spaces is not permitted.
VSerial # °
NOTE: No two passwords (Electronic Key,
Password, Superword) may be set to the Version
same value. If you try to do so, the lift
the second password ie treated as an Hr Mtrs
invalid code and an error message is
displayed. Each password must be set WConfig
to a unique value.
1. When the password prompt displays, an To change Password or
eight character field of underscores
appears. Initially, the left-most character
Superword
position is flashing, showing it is the 1. Enter the Configure Mode using the
currently selected position. current Password or Superword. See
2. Use the left/right buttons to select a “Using Configure Mode” on page 3-18. If
different character position. The selected Password is entered, Password is available
position flashes. for change, but Superword is not.
NOTE: After approx. 3 seconds, the display 2. Use the up/down buttons to scroll to
prompt automatically increments to the Password. Press the right button.
next position to the right. 3. Use the up/down buttons to scroll to the
Password or Superword item.
3. Once you select the character position,
use the up/down buttons to select the 4. With Password or Superword selected,
number, letter, or space you want. The press the right button. (If Password was
character set wraps between “0” and “-” entered in step 1 above, Password is
(space). In other words, to go quickly from available for change, but Superword is
the number “0” to the letter “z,” press the not.)
up button twice. 5. Enter the new password as specified under
“Entering an Electronic Key, Password, or
0123456789 Superword”.
abcdefghijklmnopqrstuvwyz-
6. With the new password displayed, press
NOTE: To enter numerical values, you can also the enter button.
use the dashboard keys 1 thru 0 on the 7. Save the new password as specified under
Operator Display panel. “To Save New Values” on page 3-19.
4. Repeat steps 2 and 3 for the remaining
characters in the Password or Superword.
5. When you have completed entering all of
Using Configure Mode
the characters in the Password or
Use Configure Mode to adjust various lift truck
Superword, press the enter button once.
performance parameters to specific customer
6. If you enter an invalid Password or requirements. To enter Configure Mode, you
Superword, a descending “arcade” tone must enter either the Password or Superword
sounds and the following message appears for the lift truck.
on the Operator Display:

Modes of Operation
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 NOTE: Changes are not saved until you exit
Mode Configure Mode and reply Save to the
Restore/Save prompt.
1. Enter Program Mode as described on
page 3-17.
To Configure Additional Items
2. Enter Password or Superword as
described on page 3-18.
After configuring the first item, press the left
3. The Operator Display shows: button. Navigate to the next item as specified
under “To configure an item.”
VSerial # °
If You Make a Mistake
Version
If you make a mistake in configuring an item,
Hr Mtrs simply navigate back to that item and configure
it again.
WConfig
4. Press the down button until Config is To Save New Values
displayed. Press the right button. The
Operator Display shows: Changes to configuration values are not saved
until you exit Configuration Mode. If you have
VDefault ° 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

3. Use the down button to select Save. Press
1. Use the up/down buttons to move to the
the enter button. Your new values are
item you want. An up (V) or down (W)
saved.
arrow in front of an item indicates there
are more items above or below that item. NOTE: You cannot exit to the main menu until
2. Use the up/down buttons to move to the you have selected either Restore or Save
item you want. and pressed the enter button.
3. To configure the selected item, press the 4. Press the left button to back out to the
right button. Follow the directions on the main menu.
Operator Display. Use up/down buttons
to select among specified values or to enter VSerial # °
a numerical value. Use right/left buttons
to move to lower/higher menu levels. Version

Modes of Operation
To Reinstate Factory Default Settings

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

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 (AC Lift only)
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
Weight 2 xxxx lb factory-configured and not editable.
Height 2 xxx in (Available with VM Ver 3.7+)
...
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.

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/series)
0.0 to 8.0 mph (0.0 to 12.8 km/h)
(8.0 mph with 7400 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
0.0 Set Travel Alarm activation speed.

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.
Lft Lmt OACH [default] Height at which lift cuts out. To bypass limit or
(Superword only) continue past limit, press and hold Up arrow on
Operator Display.
Range = overall collapsed height to maximum
elevated height
Default = overall collapsed height
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

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

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, or Superword) may be set to the same
value. If you try to do so, the second password is
treated as an invalid code and an error message
is displayed. 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, in 1 hour increments.
Default is 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)

Modes of Operation
Program Mode Menu

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

(AC lift) Minimum Minimum Energy Saving Mode is achieved by
Maximum slightly reducing maximum lift speed.
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.

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 Refer to “Loop Back Tests” on page 6-122.

Input

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

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 are displayed 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

Modes of Operation

Model 7400/7420/7440 Reach-Fork ® Truck Section 4. Scheduled Maintenance
Section 4. Scheduled Maintenance

Section 4. Scheduled Maintenance Model 7400/7420/7440 Reach-Fork ® Truck
Maintenance Guidelines
Maintenance Guidelines
Following a regularly scheduled maintenance
program:
• Promotes maximum truck performance
• Prolongs maximum 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.

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 approx. 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.
cycled (key switch OFF or battery
Afterwards, when you enter the time interval
disconnected). When control circuit power is
menu, the Operator Display shows the last
cycled, lift is disabled until Maintenance Minder
used setting. Values from 50 to 500 deadman
is reset or disabled, or the lift cutout option is
pedal hours are available. Press the right
turned OFF.
button. Use the up/down buttons to scroll to
the desired time interval. With the selected
Factory Configuration value displayed, 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.

Maintenance Minder ™ Tool
Use the up/down buttons to select the option NOTE: You will not be able to exit to the main
you want, then press the enter button. menu until you have selected either
Restore or Save and pressed the enter
Exit Program Mode as described under “Exiting button.
Program Mode”.
4. Press the left button to back out to the
main menu.
Resetting Maintenance Minder ▲Serial # ➠
If you want to reset the reminder prompt when Version

Maintenance Minder is active and you have done Hr Mtrs
scheduled maintenance, enter Configure Mode. ▼Config
With Configuration Mode selected, use the Press the left button to exit to Run Mode.
down button to display the “Mnt Mind” item. The lift truck enters the Run Mode.
Press the right button. Use the down button to
select “Setup.” Press the right button.
With “Reset” highlighted, press the right

button. Use the down buttons to scroll to “Yes.”
Press the enter button.
Exit Program Mode as described under “Exiting

Program Mode”.
Disabling
When Maintenance Minder is active and you
want to disable it, enter Configure Mode.
With Configuration Mode selected, use the

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.
Exit Program Mode as described under “Exiting

Program Mode”.
Exiting Program Mode

1. Use the left button to back out of the
menus.
2. The Operator Display shows:
Restore
Save
3. Use the down button to select Save. Press
the enter button. Your new values are
saved.

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 is 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). Refer to “Hydraulic Filter” on page 7-97 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

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.
Examine for signs of oil on the pads or rotor. If oil is present, disassemble brake, clean
rotor and replace pads.
Adjustable Style Brake (Gold Anodized Finish)
Brake
Check brake pads for wear.
Measure for correct gap: 0.012 in. (0.30 mm) lower air gap; 0.030 (0.8 mm) total air gap.
See “Brake (Adjustable)” on page 7-60.
Failure to keep brakes adjusted causes premature pad and rotor wear and excessive
motor heat.
Floating Disk Style Brake (Black Finish)
Measure for correct air gap between armature and armature plate: 0.040 in. (1 mm) max.
See “Brake (Floating Disk)” on page 7-66.
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 pedal must operate smoothly with no binding. Check for correct activation
Deadman Pedal and deactivation of the deadman switch under the pedal. Refer to “Deadman Switch (S2)”
on page 7-68.
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 (7400/7420). See “Radial Ring
Inspection” on page 7-47.

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 6-116.
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,
mast-to-tractor mounting bolts, overhead guard).
Hardware
Tighten any loose hardware. Replace any broken or missing hardware. Refer to torque
charts in “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 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. Refer to “Lubrication Points” on page 4-10.
Wipe old grease off mast uprights and apply new grease.
Inspect anti-rattle pads and anti-bow pads (7400 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).

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 in Table A-3, “Component
Specific Service/Torque Chart,” on page A-4. 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 brushes for even
wear over the full surface of the brush. If a 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 in Table A-3, “Component Specific
Service/Torque Chart,” on page A-4. 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
resistance of resistor in standoff. Resistance must measure >10K and <1.2 megohms. EE
Static Straps
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 7-26.
Steering Lubricate the steer axle assembly.
Adjust steering snubber if necessary. Refer to “Steer Tiller Encoder (AC Lift)” on
page 7-24.
Check the gap on the steer limit switch (S11). Refer to “Steer Limit Switch (S11)” on
page 7-25.
Check all switches for correct operation and adjust as needed. Refer to “Component
Switches
Specific 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.


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.

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)
3
2
4 (access on
top side)

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.)

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)

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

8 (Both Sides)

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

Lubrication Points
Figure 4-9. Lubrication Points, Mast and Carriage
46353_117g.jpg
10
11
12
13

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 7-160.
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.
Chain Elongation Wear (305 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 degreasing

Rust and corrosion Lubricate chain frequently.
new truck 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.

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.

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

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.

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.

Model 7400/7420/7440 Reach-Fork ® Truck Section 5. Troubleshooting
Section 5. Troubleshooting

Section 5. Troubleshooting Model 7400/7420/7440 Reach-Fork ® Truck
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
capacitor by jumpering the + and – • Accumulation of dirt
terminals with a 100 ohm 25W resistor. • Battery electrolyte leakage
• Motor brush dust
• Many problems can be caused by a dirty
battery. Make sure the battery is clean. • Motor brush leads touching the housing
• Save time and trouble by looking for • Breakdown in insulation
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
jacks and that the correct function and • Batteries
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
positive meter lead to the connector or • Solenoids
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 a serious short. Do not continue until this

condition is corrected. The meter may be
Shorts to Frame Test damaged if you proceed before correcting
this condition.
1. Turn the key switch OFF and disconnect
a. To identify the cause of the short to
the battery connector.
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
b. The most likely areas to check are:
damaged if you proceed before correcting
this condition. • Motors
• Heatsinks
Install another battery in the 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.
5. Reconnect the battery connector and turn
If the current is <0.0002A (0.2mA), go to
the key switch ON. If the battery was
Step 4. If the current is >0.0002A (0.2mA)
previously removed, make sure the battery
and <0.001A (1mA), remove the battery
case does not touch the lift truck frame.
from the truck, then continue with Step 4.
Make sure the battery case does not touch NOTE: The functions being checked must be
the truck frame during the remaining energized. Example: to check for shorts
tests. to frame in the travel circuit, travel must
4. With the battery disconnected (or removed be requested.
and disconnected) from the truck, use a 6. Use a DVM set to the current function to
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

lowest. If the current is <0.001A (1mA), go d. Reconnect all other components

to step 7. If the current is more than previously disconnected, measuring
0.001A (1mA), continue with the following current between steps. If a reading is
steps. more than 0.001A (1mA) when
a. To identify the cause of the short to reconnecting a component, that
frame, disconnect circuit components component or its wiring is bad. Repair
until the leakage current reads <0.001A or replace as appropriate.
(1mA). Do not reconnect components 7. When, after all components are
one at a time, but leave them reconnected, you get a reading <0.001A
disconnected until the leakage current (1mA) there is no short to frame condition
reads <0.001A (1mA). Prevent with the truck or the battery. If you
disconnected terminals or connectors previously removed the battery from the
from touching the lift truck frame or truck, re-install the battery.
other conductive surfaces.
b. The most likely areas to check are: Fuses
• Motors
• Heatsinks Test/Inspection
• Power cables Examine the fuse for signs of overheating,
• Power circuit components discoloration, cracking, or other physical
• Control circuit components damage. Replace as necessary.
c. Repair or replace the component(s)
To test a fuse, remove it from the lift truck. The
causing the leakage current.
resistance should be <1 ohm.
Repeat Step 6.
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 and floor pad heaters
FU15 2 TS2 Control Fuse for optional Fork-Laser Module (B+)
FU16 2 In-line harness near TP4 Control Fuse for optional Fork-Laser Module (B–)

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 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.”

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.

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.

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.

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

5motor_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.

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

Hydraulic Troubleshooting Guidelines
Hydraulic
Troubleshooting
Guidelines
After elevating or reaching the carriage

for troubleshooting, use blocks to secure
the carriage.
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.

Hydraulic Troubleshooting Guidelines

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 7-96.
NOTE: Reference electrical schematics
beginning on page A-19 and hydraulic
schematics beginning on page A-37.
Auxiliary Functions
No Auxiliary Functions Work (Reach/Retract, Tilt, Sideshift) - AC Lift
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.
No Auxiliary Functions Work (Reach/Retract, Tilt, Sideshift) - DC Lift
Bad K2 relay circuit Troubleshoot K2 relay circuit.
Bad SOL8 (valve or wiring) Run Test O09. Follow test recommendations.
Bad CE1 valve Repair/replace CE1 valve.
Bad LS1 shuttle Repair/replace LS1.
Bad aux directional solenoid 5B or 5T (valve or Run Tests O04 and O05. Follow test
wiring) recommendations.
Open in motor circuit Check continuity from TP2 to TP4.
All Auxiliary Functions are Slow - AC Lift
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 7-102.
Bad LS1 shuttle Replace LS1.
All Auxiliary Functions are Slow - DC Lift
Incorrect hydraulic fluid for application Replace hydraulic fluid with correct fluid. See
“Lubrication Specification Chart” on page A-2.
Aux system relief pressure too low Measure pressure; normal operation should
be below bypass pressure. See “Auxiliary
Pressure Adjustment” on page 7-102. If
pressure is still too low, replace steering
orbitrol.
Bad CE1 valve Repair/replace CE1 valve.
Bad SOL8 Check for contamination. Repair/replace

valve.
Bad aux pump Measure pressures.
Bad aux motor Measure current draw.
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
Pressure Adjustment” on page 7-102. 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
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
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 7-102. 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 7-102. 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.
Steering Does Not Work; Other Functions OK - DC Lift
Mechanical binding of linkage Repair/replace bad components as necessary.
Bad steering orbitrol Repair/replace orbitrol.
Bad hydraulic steer motor Repair/replace hydraulic steer motor.
No Steering, Reach/Retract, Tilt, or Sideshift - DC Lift
Aux system relief pressure too low:
Bad aux pump Repair/replace aux pump.
Bad aux motor Repair/replace aux motor.

Bad/contaminated pressure relief in steering Replace orbitrol.

orbitrol
Lift/Lower System
No Lift - Motor Runs - AC Lift
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 Runs - DC Lift
Check main lift pressure at main manifold If pressure is greater than bypass pressure,
port G1 check for binding of mast or cylinders.
If pressure is less than or equal to bypass

pressure, disconnect coil wires to SOL2.
• If lift works, run Test O12 and
troubleshoot per the test.
• If lift still does not work, replace REL1
main relief valve, replace SOL2 lift/lower
valve, or replace lift pump.
No Lift - Motor Does Not Run - AC Lift
Battery below BSOC cutout setting Check battery voltage and BSOC settings.
Maintenance Minder ™ interval exceeded with Display config settings for Maintenance
LCutout specified Minder.
No Lift - Motor Does Not Run - DC Lift
Battery below BSOC cutout setting Check battery voltage and BSOC settings.
Maintenance Minder ™ interval exceeded with Display config settings for Maintenance
LCutout specified Minder.

Open in Lift Motor circuit Run Test O28. Follow recommendations in

test.
Slow Lift with No Load - AC Lift
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.
Slow Lift with No Load - DC Lift
Relief valve REL1 stuck open Replace REL1. If contamination is present,

flush, fill, and bleed the hydraulic system and
clean the relief valve.
Bad lift pump Measure pressures.
Bad lift motor Test lift motor.
Unable to Pick Up a Load - AC Lift
Bad SOL3 Run Test O09. Follow recommendations in

test.
Bad lift pump Check pressures. Replace pump.
Unable to Pick Up a Load - DC Lift
Incorrect lift pressure adjustment Check and adjust lift pressure setting.
Contaminated or bad relief valve REL1 Replace relief valve. If contamination is

present, flush, fill, and bleed the hydraulic
system.
Bad lift pump Measure pressures.
Bad lift motor Test lift motor.

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 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

Symptom Tables: Travel Functions
Symptom Tables: Travel

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

Configure Mode” on page 3-18.
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 Adjust brake. See “Brake Adjustment” on

page 7-61.
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 Adjust brake. “Brake Adjustment” on

page 7-61.
Electrical:
Incorrect configuration of speed Reconfigure the lift truck. See “Using

Configure Mode” on page 3-18.
If equipped with nested switch option, bad Run Test I01.

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

Symptom Tables: Electrical Symptoms
Symptom Tables:
Electrical Symptoms
NOTE: Reference electrical schematics
beginning on page A-19 and hydraulic
schematics beginning on page A-37.
Motor Overheating
Especially DC Lift: Application exceeds Contact Dealer Service Manager to make sure
designed workload -- short runs with of application.
plugging/acceleration or 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 adjustment. See “Brake Adjustment” on
page 7-61.
Note: See also “DC Motors” on page 5-5 and “AC Motors” on page 5-9.
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 7-77.
Short to frame See “Shorts to Frame” on page 5-2.

Symptom Tables: Electrical Symptoms
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
“Matching Software Versions” on page 7-317.
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.

Symptom Tables: Vantage Point System
Symptom Tables:
Vantage Point System
NOTE: Refer to Figure A-3 on page A-21.
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.

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.
See also “Testing and System Setup” on
page 7-289, step 4.

Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Messages, Codes, and Tests
Section 6. Messages, Codes, and Tests

Section 6. Messages, Codes, and Tests Model 7400/7420/7440 Reach-Fork ® Truck
Power Amp LED Diagnostics
Power Amp 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.

Messages and Codes Summary List

Code 1H - TPA Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Code 1T - Battery Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Code 1V - LPA Overheated (AC Lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Code 2A - Traction Motor Approaching Overtemp . . . . . . . . . . . . . . . . . . . . . 6-5
Code 2C - TPA Temp Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
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 (AC Lift) . . . 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 (AC Lift) . . . . . . . . . . . . . 6-10
Code 5M - TPA CAN Watchdog Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Code 5P - LPA CAN Watchdog Timeout (AC Lift) . . . . . . . . . . . . . . . . . . . . . 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 1st 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
1st Speed Limiting Switch (S12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Code 6D - Pressure Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Code 6F - Lift Motor Overtemp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 6G - Lift Motor Temp Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . . . 6-14
Code 6S - LPA Temp Sensor Out-of-Range (AC Lift) . . . . . . . . . . . . . . . . . . . 6-14
Code 6T - LPA Current Calibration Error (AC Lift) . . . . . . . . . . . . . . . . . . . . 6-14
Code 6U - Excessive Lift Motor Brush Wear (DC Lift) . . . . . . . . . . . . . . . . . . 6-14
Code 6V - LPA Failure (AC Lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Code 6W - Failure Detected in Lift Motor Speed Sensor (AC Lift) . . . . . . . . . 6-15
Code 6X - LPA Fault: Overcurrent (AC Lift) . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Messages and Codes Summary List Model 7400/7420/7440 Reach-Fork ® Truck
Code 6Y - LPA Fault: High DC Voltage (AC Lift) . . . . . . . . . . . . . . . . . . . . . . 6-15

Code 6Z - FlashWare Parameters Do Not Match Stored Values . . . . . . . . . . 6-15
Code 80 - Primary Throttle Pot Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 81 - Lift/Lower Pot Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 8C - Deadman Pedal Signals Do Not Agree . . . . . . . . . . . . . . . . . . . . . 6-17
Code 8F - Lift/Lower Pot Out-of-Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 8G - Secondary Throttle Pot Out-of-Range . . . . . . . . . . . . . . . . . . . . . 6-17
Code 8H - Secondary Throttle Pot Out-of-Neutral . . . . . . . . . . . . . . . . . . . . 6-17
Code 8J - Ambient Air Temp Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . 6-18
Code 8K - Deadman Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 8L - Brake Feedback Current Out-of-Range . . . . . . . . . . . . . . . . . . . . 6-18
Code 8M - Internal Handle Heater Failure . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 8N - Optional Start Switch Closed at Start-Up . . . . . . . . . . . . . . . . . . 6-18
Code A0 - Mismatched Software Versions . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code AH - Bad Display Card Checksum . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code AJ - Bad VM Flash Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code AK - Bad VM RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code AL - Bad VM Battery Backed-Up RAM . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code AM - Bad Operator Display Flash Memory . . . . . . . . . . . . . . . . . . . . . 6-20
Code AN - Bad Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code AV - Primary Memory Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code EH - Invalid Interrupt - Operator Display . . . . . . . . . . . . . . . . . . . . . . 6-21
Code F4 - VM COP Time-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code F5 - Bad Op Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code F8 - VM COP Not Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code FE - VM Not Calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code FG - 5 and/or 12V Power Supply Out-of-Range . . . . . . . . . . . . . . . . . 6-22
Code FH - Battery Voltage Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code FN - Relays Did Not Open at Power Off . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code FP - VM Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code FR - VM Config Item Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code FT - VM Internal Software Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code FV - Display Internal Software Error . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code G0 - Steer Tiller 1 Channel A/B Fault (AC Lift) . . . . . . . . . . . . . . . . . . 6-23
Code G3 - Steer Feedback Prox Sensor Fault (AC Lift) . . . . . . . . . . . . . . . . . 6-24
Code G4 - Open Detected in Steer Control Circuit (AC Lift) . . . . . . . . . . . . . 6-24
Code G5 - Short Detected in Steer Motor Encoder Circuit (AC Lift) . . . . . . . 6-24
Code G7 - Steer Tiller 2 Channel A/B Fault (AC Lift) . . . . . . . . . . . . . . . . . . 6-24
Code GD - Open Detected in Steer Motor Encoder Circuit (AC Lift) . . . . . . . 6-25
Code GE - Steer Encoder Failure (AC Lift) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Code T0 - SOL5T Current Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Code T1 - SOL5B Current Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Code T2 - SOL3 Current Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Code T3 - SOL2 Current Incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Code X4 - Switch Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

Messages and Codes
Messages and Codes

Code 1H Overheated. Allow Time to Cool

Icon Code Title/Reason Test to Run Notes/Corrective Action
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 6-39) cooled.
Test O23 - Toggle Fans Note: The VM cannot cause this
(Page 6-116) 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
(AC Lift) (AC Lift) (Page 6-44) to clear after LPA has cooled.
The LPA has reported its internal Test O23 - Toggle Fans Note: The VM cannot cause this
temperature is >239°F (115°C). (Page 6-116) 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
The TPA senses the Traction Motor (Page 6-36) cooled.
is approaching overtemperature. Note: The VM cannot cause this
code.
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.
The TPA temperature sensor is (Page 6-39) Note: The VM cannot cause this
open or shorted. code.

Messages and Codes
Code 2E Inform Service

Code 2E - Traction Motor Temp Test A08 - Traction Traction performance is limited.
Sensor Out-of-Range Motor Temperature Self resetting.
The Traction Motor temperature (Page 6-36) Note: The VM cannot cause this
sensor 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.
The Traction Motor speed sensor (Page 6-75) 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+

The TPA failed to precharge at the TPA+ terminal. Cycle key
correctly. 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
The 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.
Code 2T Inform Service

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

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

Messages and Codes
Code 2U Inform Service

Code 2U - TPA Overcurrent or Test A11 - Traction Traction is disabled. Cycle key
Short Circuit Motor Current switch to clear.
The TPA has sensed current in (Page 6-40) Note: The VM cannot cause this
excess of 540A. Note: This code may be code.
caused by a shorted
TPC diode.
Code 2V Inform Service

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

Voltage switch to clear. If code occurs
The TPA has detected >50VDC at during plugging, replace all
TPA+. 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
AC Lift: the LPA detected an (Page 6-104) contribute to burnt tips. If
incorrect voltage at LPA+ during contactor tips are welded or
SelfTest. burnt, check the BSOC setting in
DC Lift: the VM detected >10VDC Config Mode menu.
at JPC22-20 (FU3 Sense) after the
LPC was commanded open.

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
AC Lift: the LPA detected <12VDC (Page 6-104) code on trucks with AC Lift.
at LPA+ after the LPC coil was
energized.
DC Lift: the VM detected <18VDC
at JPC22-20 after the LPC coil was
energized.

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
The TPA detected an incorrect (Page 6-102) contribute to burnt tips. If
voltage 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 6-102) code.
after the TPC coil was energized. In Active Service, run
Test A15 - Battery
Voltage (Page 6-43) 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 6-103)
The VM detected >10VDC at If open, run Test
JPC22-19 when the STR coil was I14 - Steering Fuse
de-energized. (FU1) (Page 6-73)

Code 4C - Steer Contactor If contactor closes, run Cycle key switch to clear.
Detected Open When Test I14 - Steering Fuse
Commanded Closed (FU1) (Page 6-73)
The VM detected <10VDC at If contactor does not
JPC22-19 when the STR coil was close, run Test
energized. O01 - Toggle the STR
Contactor (Page 6-103)

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,
(AC Lift) and wiring between JPF1-3 and
The LPA detected an incorrect LPA+ for correct resistance and
pre-charge voltage (<25VDC) at continuity.
LPA+. 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 6-78) 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.

Messages and Codes

Code 59 - CAN Transmission Test I23 - CAN Bus Cycle key switch to clear.
Buffer Error Test (Page 6-78) 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 6-78) 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 6-78) 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 6-78) 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 (AC Lift) Test (Page 6-78) Check for shorts to frame, static,
The VM has received no and electrical leakage from
communication from the LPA. battery.

Messages and Codes

Code 5M - TPA CAN Watchdog Test I23 - CAN Bus Cycle key switch to clear.
Timeout Test (Page 6-78) 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 (AC Lift) Test (Page 6-78) 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 6-78) 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 6-78) 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.

Messages and Codes

Code 5T - No CAN Message from Test I23 - CAN Bus Cycle key switch to clear.
any Node Test (Page 6-78)
The VM is not receiving CAN
message from any node.

Code 61 - Mast Switch #1 Not Test I02 - 1st Speed Cross mast switch #1.
Crossed Limiting Switch (S12)
AC Lift: Too many height encoder (Page 6-66)
pulses were seen without detecting
mast switch #1 opening.
DC Lift: Too much time has elapsed
without crossing mast switch #1
while a lift request is above a
certain threshold.

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 1st Test I02 - 1st Speed [VM ver. < 2.1] Cycle key switch to
Speed Limiting Switches Do Limiting Switch (S12) clear.
Not Agree (Page 6-66) [VM ver. 2.1+] Cross the 1st speed
The VM reads the 1st speed Test I61 - High Speed limiting switch several times.
limiting switch as closed when the Travel Switch (S25) Note: Check the error log to see if
HS travel switch or Switch 2 reads (Page 6-91) a Code 64 or 67 preceded the
open. Code 63. If so, troubleshoot per
that code.
Note: Switch 2 must be on for
trucks with an elevated height
above 331 in.

Messages and Codes

Code 64 - No Pulses Seen from Test I02 - 1st Speed Lower the carriage, then lift past
Height Indicator Encoder Limiting Switch (S12) the first mast switch.
With the lift pump running or (Page 6-66) Troubleshoot HTI system. Code
SOL2 energized, the first mast limit Test I42 - Lift Height clears when pulses are detected.
switch is open, but the VM (Page 6-89) Cycle key switch.
detected no pulses from the Height or If code is intermittent, cause
Indicator encoder. Test I86 - Lift Height could be proportional valve.
(Page 6-96) Adjust valve - see “Proportional
Valve Adjustment” on page 7-101.

Code 66 - Calculated Height Test I42 - Lift Height Lower the carriage below the
Greater Than Configured (Page 6-89) configured maximum height to
Height or clear.
The carriage height calculated by Test I86 - Lift Height Check actual mast height against
the VM, from information from the (Page 6-96) 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 - 1st Speed Lift the carriage through the 1st
Not Match 1st Speed Limiting Limiting Switch (S12) speed limiting switch height or
Switch (S12) (Page 6-66) 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 6-41)
<300 psi) or >5.0V (indicating
>3999 psi).

Messages and Codes
Code 6F Overheated. Allow time to cool

Code 6F - Lift Motor Overtemp Test A09 - Lift Motor Allow time to cool. Self resetting.
AC Lift: The LPA has detected the Temperature
Lift Motor is overheated (Page 6-37)
(>300°F/149°C).
DC Lift: The VM has detected the
Lift Motor is overheated
(>279°F/137°C).

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 (AC Lift) 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 (AC Lift) Replace the LPA.
The LPA has detected an internal Note: The VM cannot cause this
fault. code.
Code 6U Inform Service

Code 6U - Excessive Lift Motor None Cycle key switch to clear.

Brush Wear (DC Lift) Replace brushes.
The VM has detected more than
+10VDC at JPC22-15
(BrushWear1) or JPC22-16
(BrushWear2).

Messages and Codes
Code 6V Inform Service

Code 6V - LPA Failure (AC Lift) 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 (AC Lift) Note: The VM cannot cause this
(AC Lift) (Page 6-76) code.
The lift feedback circuit, as seen by
the LPA, is not functioning.
Code 6X Inform Service

Code 6X - LPA Fault: Overcurrent Test A20 - Lift Motor Cycle key switch to clear.
(AC Lift) Current (AC Lift) Note: The VM cannot cause this
The LPA has detected >675A or a (Page 6-45) code.
shorted output.
Code 6Y Inform Service

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

Voltage (AC Lift) Install good battery. Replace TPA.
The LPA has detected a DC input
voltage exceeding 50V at LPA (+).
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.

Messages and Codes

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 6-48)

Code 81 - Lift/Lower Pot Test A05 - Lift/Lower Cycle key switch to clear.
Out-of-Range Pot Voltage (Page 6-35)
The VM detected <0.15V or >2.1V Test A26 - +5VDC
at JPC12-2. Power Supply
(Page 6-48)

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 6-48)

Code 84 - Brake - Not Applied Test I19 - Traction Cycle key switch to clear.
The Traction Motor speed sensor Motor Speed Sensor Adjust brake. See “Brake
indicated movement during (Page 6-75) Adjustment” on page 7-61.
SelfTest.

Code 88 - +5VDC Power Supply Test A26 - +5VDC Cycle key switch to clear.
Out-of-Range Power Supply
Control Handle +5VDC power (Page 6-48)
supply (located on the VM) is
out-of-range.

Messages and Codes
Code 8A Inform Service

Code 8A - OCSS Photo Sensor Test I80 - OCSS Upper Cycle key switch to clear.
Fault Beam (Page 6-92)
The VM senses the beams are ON Test I81 - OCSS Lower
with the deadman pedal UP. Beam (Page 6-94)

Code 8C - Deadman Pedal Signals Test A28 - Deadman Cycle key switch to clear.
Do Not Agree Sensor (VR4)
Voltages at the VM from the (Page 6-49)
Deadman Switch and the Deadman Test I00 - Deadman
Sensor indicate one is activated Switch (S2) (Page 6-64)
and the other is not.
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.

Code 8G - Secondary Throttle Test A26 - +5VDC Return control handle to neutral.
Pot Out-of-Range Power Supply Cycle key switch to clear.
The VM detected <0.1V or >2.2V at (Page 6-48)
JPC4-4. Test A29 - Secondary
Traction Throttle Pot
(VR3) Voltage (optional)
(Page 6-50)
Code 8H Inform Service

Code 8H - Secondary Throttle Test A26 - +5VDC Return control handle to neutral.
Pot Out-of-Neutral Power Supply Cycle key switch to clear.
Secondary throttle pot (VR3) out of (Page 6-48)
learned neutral value. Test A29 - Secondary
Traction Throttle Pot
(VR3) Voltage (optional)
(Page 6-50)

Messages and Codes
Code 8J Inform Service

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 6-57) off when this code is present.
ambient air temp sensor is outside
the reference range.
Code 8K Inform Service

Code 8K - Deadman Sensor Test A28 - Deadman Cycle key switch to clear.
Out-of-Range Sensor (VR4)
The voltage measured by the VM (Page 6-49)
from the deadman sensor is <2.0V
or >4.9V.
Code 8L Inform Service

Code 8L - Brake Feedback Test A35 - Brake Cycle key switch to clear.
Current Out-of-Range Armature (Page 6-56) 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 6-60)
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 6-90)

Messages and Codes
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.
Code AH Inform Service

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

Checksum 1. If the problem is
The Display Card and VM software intermittent, check for
checksums do not match. shorts to frame. See “Shorts
to Frame” on page 5-2.
2. Re-flash the software. See
“Software Configuration” on
page 7-317.
3. Replace the VM.
4. If the correct software
version appears on the
Operator Display, replace the
Display Card.
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
page 7-317.
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
page 7-317.
3. Replace the VM.

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
“FlashWare” on page 3-6.
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 “Reviewing Vehicle Manager
test failed during SelfTest. The Software” on page 3-9.
Operator Display and VM software
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.

Messages and Codes
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
page 7-317.
3. Replace Operator
Display.
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
page 7-317.
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
page 7-317.
3. Replace the VM.

Messages and Codes

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

1. If the problem is
intermittent, check for
page 7-317.
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.
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 6-42) 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 6-43) 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 6-121) battery connector.
Check other relays and circuits
associated with the K4 relay tips.

Messages and Codes
Code FP Inform Service

Code FP - VM Internal Fault None Brake engages.

Cycle key switch.
Replace VM.
Code FR (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.
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 (AC Lift) Encoder 1 Connect
Steer tiller 1 is missing pulses Detect (AC Lift)
compared to steer tiller 2, or (Page 6-84)
intermittent connection detected at Test I35 - Steer Tiller
JPC10-6 or JPC18-5. Encoder 1 - Channels
A & B (AC Lift)
(Page 6-86)

Messages and Codes

Code G3 - Steer Feedback Prox Test I24 - Steer Cycle key switch.
Sensor Fault (AC Lift) Feedback Prox Sensor
A steer motor encoder count (AC Lift) (Page 6-80)
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.

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

Steer Control Circuit (AC Lift) Pulses (AC Lift)
The VM did not detect either (Page 6-88)
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 (AC Lift)
(AC Lift) (Page 6-81)
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 (AC Lift) Encoder 2 Connect
Steer tiller 2 is missing pulses Detect (AC Lift)
compared to steer tiller 1, or (Page 6-85)
intermittent connection detected at Test I36 - Steer Tiller
JPC10-7 or JPC18-6. Encoder 2 - Channels
A & B (AC Lift)
(Page 6-87)

Messages and Codes
Code GD Inform Service

Code GD - Open Detected in Test I25 - Steer Motor Cycle key switch.
Steer Motor Encoder Circuit Encoder (AC Lift) Verify correct steer flag is
(AC Lift) (Page 6-81) 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 6-97)
were detected.
Code GE Inform Service

Code GE - Steer Encoder Failure Test I33 - Steer Tiller Cycle key switch.
(AC Lift) Encoder 1 Connect
The VM detected connect-detect Detect (AC Lift)
failures or abnormal inputs on (Page 6-84)
both channels of the steer tiller Test I34 - Steer Tiller
encoder. Encoder 2 Connect
Detect (AC Lift)
(Page 6-85)
Test I35 - Steer Tiller
Encoder 1 - Channels
A & B (AC Lift)
(Page 6-86)
A & B (AC Lift)
(Page 6-87)
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 6-52)
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 6-53)
seen by the VM, is not at the
expected level.

Messages and Codes

Code T2 - SOL3 Current Test A33 - Aux Dump Cycle key switch. Dump valve
Incorrect (SOL3)/Main Relief fault causes shut down of Aux
Current being drawn by SOL3, as Dump (SOL8) Current functions.
seen by the VM, is not at the (Page 6-54)
expected level.

Code T3 - SOL2 Current Test A34 - Lift/Lower Cycle key switch.

Incorrect Current (SOL2)
Current being drawn by SOL2, as (Page 6-55)
seen by the VM, is not at the
expected level.
Code X4 Inform Service

Code X4 - Switch Mismatch Test I02 - 1st 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 6-66) Lift Cutout Switch (S27).
Cutout Switch) ON at the same Test I22 - Lift Cutout
time. Switch (S27)
(Page 6-77)

Electrical Connections
Terminology
Figure 6-1. Molex Jack and Pin Connector
8c04013s.tif
Pin Identifier Lines

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

Chart
See legend on electrical schematic beginning on
page A-23.

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

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


Model 7400/7420/7440 Reach-Fork ® Truck Section 6. Electrical Tests
Electrical Test Summary List

Section 6. Electrical Tests
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Test A11 - Traction Motor Current . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Test A13 - Pressure Sensor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Test A14 - +12VDC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Test A15 - Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Test A19 - LPA Temp (AC Lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
Test A20 - Lift Motor Current (AC Lift) . . . . . . . . . . . . . . . . . . . . . . . 6-45
Test A22 - Traction Throttle (VR1) Request . . . . . . . . . . . . . . . . . . . 6-46
Test A23 - Lift Throttle (VR2) Request . . . . . . . . . . . . . . . . . . . . . . . 6-47
Test A26 - +5VDC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Test A28 - Deadman Sensor (VR4) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Test A29 - Secondary Traction Throttle Pot (VR3) Voltage (optional) . 6-50
Test A30 - Secondary Traction Throttle (VR3) Request (optional) . . . 6-51
Test A31 - Solenoid 5T (AUX1) Current . . . . . . . . . . . . . . . . . . . . . . 6-52
Test A32 - Solenoid 5B (AUX2) Current . . . . . . . . . . . . . . . . . . . . . . 6-53
Test A33 - Aux Dump (SOL3)/Main Relief Dump (SOL8) Current . . . 6-54
Test A34 - Lift/Lower Current (SOL2) . . . . . . . . . . . . . . . . . . . . . . . 6-55
Test A35 - Brake Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
Test A36 - Ambient Air Temp Sensor . . . . . . . . . . . . . . . . . . . . . . . . 6-57
Test A37 - Steer Power Amp Current . . . . . . . . . . . . . . . . . . . . . . . . 6-58
Test A39 - Analog Reference Voltage (AC Lift) . . . . . . . . . . . . . . . . . . 6-59
Test A40 - Handle Heater Reference Voltage (optional) . . . . . . . . . . . 6-60
Test A41 - Emergency Power Off (EPO) Switch . . . . . . . . . . . . . . . . . 6-61
Input Tests
Test I00 - Deadman Switch (S2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Test I01 - Nested Switch (S14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
Test I02 - 1st Speed Limiting Switch (S12) . . . . . . . . . . . . . . . . . . . . 6-66
Test I06 - Reach Switch (S4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
Test I07 - Retract Switch (S5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68
Test I08 - Tilt Up Switch (S6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69
Test I09 - Tilt Down Switch (S7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70
Test I10 - Sideshift Right Switch (S9) . . . . . . . . . . . . . . . . . . . . . . . . 6-71
Test I11 - Sideshift Left Switch (S8) . . . . . . . . . . . . . . . . . . . . . . . . . 6-72
Test I14 - Steering Fuse (FU1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73
Test I15 - Horn Switch (S3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
Test I19 - Traction Motor Speed Sensor . . . . . . . . . . . . . . . . . . . . . . 6-75
Test I20 - Lift Motor Speed Sensor (AC Lift) . . . . . . . . . . . . . . . . . . . 6-76
Test I22 - Lift Cutout Switch (S27) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
Test I23 - CAN Bus Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78
Test I24 - Steer Feedback Prox Sensor (AC Lift) . . . . . . . . . . . . . . . . 6-80

Electrical Test Summary List Model 7400/7420/7440 Reach-Fork ® Truck
Test I25 - Steer Motor Encoder (AC Lift) . . . . . . . . . . . . . . . . . . . .. . 6-81

Test I26 - Height Indicator Encoder . . . . . . . . . . . . . . . . . . . . . . .. . 6-82
Test I27 - Secondary Horn Switch (S10) . . . . . . . . . . . . . . . . . . . .. . 6-83
Test I33 - Steer Tiller Encoder 1 Connect Detect (AC Lift) . . . . . .. . 6-84
Test I34 - Steer Tiller Encoder 2 Connect Detect (AC Lift) . . . . . .. . 6-85
Test I35 - Steer Tiller Encoder 1 - Channels A & B (AC Lift) . . . . .. . 6-86
Test I36 - Steer Tiller Encoder 2 - Channels A & B (AC Lift) . . . . .. . 6-87
Test I39 - Neutral Pulses (AC Lift) . . . . . . . . . . . . . . . . . . . . . . . .. . 6-88
Test I42 - Lift Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-89
Test I60 - Security Start Switch (S23) (optional) . . . . . . . . . . . . . .. . 6-90
Test I61 - High Speed Travel Switch (S25) . . . . . . . . . . . . . . . . . .. . 6-91
Test I80 - OCSS Upper Beam . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-92
Test I81 - OCSS Lower Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-94
Test I86 - Lift Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-96
Test I90 - Degrees Turned Past Steer Flag . . . . . . . . . . . . . . . . . .. . 6-97
Test I91 - iPort ™ Communication Test . . . . . . . . . . . . . . . . . . . .. . 6-98
Test I92 - iPort ™ Error Bitmap . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-100
Output Tests
Test O00 - Toggle the TPC Contactor . . . . . . . . . . . . . . . . . . . . . . . 6-102
Test O01 - Toggle the STR Contactor . . . . . . . . . . . . . . . . . . . . . . . 6-103
Test O02 - Toggle the LPC Contactor . . . . . . . . . . . . . . . . . . . . . . . 6-104
Test O04 - Toggle Aux1 Directional (SOL5T) Solenoid . . . . . . . . . . 6-105
Test O05 - Toggle Aux2 Directional (SOL5B) Solenoid . . . . . . . . . . 6-106
Test O06 - Toggle the Reach Solenoid . . . . . . . . . . . . . . . . . . . . . . 6-107
Test O07 - Toggle the Tilt Solenoid . . . . . . . . . . . . . . . . . . . . . . . . 6-108
Test O08 - Toggle the Sideshift Solenoid . . . . . . . . . . . . . . . . . . . . 6-109
Test O09 - Aux Dump (SOL3)/Main Relief Dump (SOL8) Current . 6-110
Test O11 - Toggle the Load Hold (SOL1) Solenoid . . . . . . . . . . . . . . 6-111
Test O12 - Ramp the Proportional Lower (SOL2) Solenoid . . . . . . . 6-112
Test O18 - Toggle the Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-113
Test O19 - Audible Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-114
Test O20 - Travel Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-115
Test O23 - Toggle Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-116
Test O25 - Toggle the 2d Pump (SOL4) Solenoid . . . . . . . . . . . . . . 6-117
Test O28 - Ramp Lift Motor (AC Lift) . . . . . . . . . . . . . . . . . . . . . . . 6-118
Test O29 - Ramp Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 6-119
Test O30 - Toggle the Brake Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 6-120
Test O32 - Toggle Relays K1, K2, K3, and K4 . . . . . . . . . . . . . . . . . 6-121
Loop Back Tests

Loop Back Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-122

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.

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 6-122). 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 6-48)

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 6-122). moving the control handle back and forth.
If the voltage fluctuates erratically, replace
1. The Operator Display shows the voltage the 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 6-48)

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 truck
Limits operation to the limits listed, allow the truck to
cool and investigate the operation of the brake
• Normal operation: ambient to 258°F and drive unit. If the brake and drive unit are
(125°C) functioning correctly, look at the truck
• Speed is linearly reduced to 1.0 mph at: application for over use. If the temperature
displayed does not match the limits listed,
• Danaher Motor: 266°F (130°C) to 300°F
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
Temp. 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 an hour.
step 1 overheating
Less than T/S Traction Replace Traction

Disconnect
3 JPT3-2 JPT3-1 measurement in Motor sensor Motor temp
JPT1/Ohms
step 1 wires sensor
Temp. 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 T/S Traction Replace Traction
Disconnect
2 JPT3-2 JPT3-1 Motor sensor Motor temp
JPT3/Ohms
wires sensor

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

Temperature
This test measures the temperature of the Lift
Motor.
Limits
AC Lift
• Normal operation: ambient to 294°F
(145°C)
(146°C)
• Fault Code 6F and lift shutdown at 300°F
(149°C)
DC Lift
• Normal operation, single pump:
ambient to 271°F (133°C)
• Normal operation, dual pump:
ambient to 221°F (105°C)
(106°C), single and dual pump
• Fault Code 6F and lift shutdown at 279°F
(137°C), both single and dual pump
Run Test
NOTE: For information on how to use Service
page 3-28.
If the temperature displayed matches the truck

operation to the limits listed, allow the truck to
cool. Check the mast for binding and
investigate the operation of the pump. If the
mast and pump are functioning correctly, look
at the truck application for over use. If the
temperature displayed does not match the
limits listed, proceed to Diagnosis and Repair.

Test A09 - Lift Motor Temperature Analog Tests

Action/ Expected
Meter Scale Results
AC Lift - Temp. 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
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
AC Lift - Temp. 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
2 JPL3-2 JPL3-1 Motor temp
JPL3/Ohms sensor wires
sensor
DC Lift - Temp. Icon is illuminated OR Fault Code 6F is present and Lift Motor is hot to touch
Disconnect
1 JPC24-22 JPC24-10 >2200 ohms Perform step 2 Replace VM
JPC24/Ohms
Less than T/S cause of

Repeat step 1 after
2 measurement in overheated Perform step 3
step 1 motor
Less than Replace Lift

3 JPZ-1 JPZ-2 measurement in Motor temp
JPZ/Ohms sensor wires
step 1 sensor
DC Lift - Temp. Icon is illuminated OR Fault Code 6F is present and Lift Motor is NOT hot to touch
Disconnect
1 JPC24-22 JPC24-10 Replace VM Perform step 2
JPC24/Ohms
<2200 ohms Replace Lift
2 JPZ-1 JPZ-2 Motor temp
JPZ/Ohms sensor wires
sensor

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

Temperature NOTE: For information on how to use Service
page 3-28.
This test measures the temperature of the TPA.
The TPA heatsink temperature is displayed.
Limits
As 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 truck for 15 heat up and
O23 - Toggle
1 to 20 minutes of N/A N/A fans turn on at Replace TPA
Fans
hard operation. approx. 113°F
(Page 6-116)
(45°C)

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

clamp-on ammeter.
Current • The current should ramp evenly as the
truck accelerates and decelerates.
This test displays the current in the Traction • Phase currents should be approx. equal.
Motor power circuits. Gross differences indicate a problem.
If readings are not within reference limits, the

Limits test has failed.
• 0 to 450A while driving or plugging 1. If any one phase differs significantly from
• Above 266°F (130°C) current is reduced the other two, check power cable
linearly continuity. Replace cables as necessary.
• Maximum current up to 540A when See “Terminal Nuts” on page 7-83.
deadman pedal is released, unaffected and • If power cable continuity is OK,
unreduced by temperature troubleshoot the Traction Motor. See
“AC Motors” on page 5-9.
Run Test • If all phases give high readings, the
drive unit may be binding. Check drive
NOTE: For information on how to use Service unit.
2. The TPA may be bad. Run “Test
page 3-28.
O29 - Ramp Traction Motor” on
page 6-119.
This test shows better results in Active Service.
NOTE: For instructions on selecting Modes of
The Operator Display shows the current the Operation, see “Modes of Operation” on
TPA reads from one phase of the Traction page 3-16.
Motor.
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.

Analog Tests Test A13 - Pressure Sensor Voltage
Test A13 - Pressure

Sensor Voltage
This test measures the voltage from the
pressure sensor used for load weight sensing.
Use extreme caution when working

near the elevated forks.
Run Test
NOTE: This test can be run in Loop Back mode.
See Loop Back Tests (Page 6-122).
page 3-28.
The voltage shown on the Operator Display

should increase and decrease linearly as the
load weight is increased or decreased. If it does
not, the test has failed. If the weight display is
inaccurate, the test has failed.
Carriage Position Value Displayed (Volts)
Fully Lowered Approx. 1.0
Lifted in Free Lift Approx. 1.5
Lifted in Second Stage Approx. 2.0

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

lowered
1.5V lifted in
2 JPC24-18 JPC24-6 free lift Replace VM
DCV 2.0V in second
stage T/S pressure
sensor harness
Replace
3 JPY1-1 JPY1-3 10.5 to 13V pressure
transducer

Test A14 - +12VDC Power Supply Analog Tests
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.

Analog Tests Test A15 - Battery Voltage
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
T/S or replace battery
cables
DCV TP4 B+ T/S harness TP1 to

2 JPF4-1 Perform step 3
JPF4-1
Replace Fuse/Relay
Card
T/S harness from

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

Test A19 - LPA Temp (AC Lift) Analog Tests
Test A19 - LPA Temp

(AC Lift)
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 truck hard for 15 to 20 minutes.
Check operation of the LPA cooling fans.
Run Test O23 - Toggle Fans (Page 6-116).
3. The LPA may be bad. Replace the LPA.

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

other two, check power cable continuity.
The lift carriage and forks will move Replace cables as necessary. See “Terminal
during this test. Nuts” on page 7-83.
• If power cable continuity is OK,
troubleshoot the Lift Motor. See “AC
Motors” on page 5-9.
The area around the forks should be • If all phases give high readings, the mast
clear. The ceiling clearance should allow may be binding. Check mast.
for the highest lift. NOTE: For instructions on selecting Modes of
Operation, see “Modes of Operation” on
Limits 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
approx. 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.

Test A22 - Traction Throttle (VR1) Request Analog Tests
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 6-48)
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

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

(VR2) Request
This test displays the percentage of lift throttle
request from VR2 being read by the VM.
Run Test
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,

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 JPC12-2 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 6-48)
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

Test A26 - +5VDC Power Supply Analog Tests
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
Disconnect JPC12
1 Perform step 2 Replace VM
and JCP4/DCV
PC12-1 PC12-12 4.75 to 5.25V Repair/replace Repair/replace

Connect JCP12,
secondary primary control
2 disconnect
control handle handle and
JPC4/DCV
and harness harness

Analog Tests Test A28 - Deadman Sensor (VR4)
Test A28 - Deadman

Sensor (VR4)
This test displays the voltage the VM reads from
the deadman sensor (VR4) at JPC24-19.
Run Test
page 3-28.
Acceptable voltage ranges are:
Deadman Position Value Displayed
Released Approx. 2.5
Depressed Approx. 4.0
If the displayed voltages are outside the

reference values, the test has failed.
As the pedal is released slowly, the displayed

voltage should change smoothly. If not, the test
has failed.

Action/
Meter Scale
1 JPC20-5 JPC24-7 Perform step 2 Replace VM

10.5 to 13V
2 JPDP-1 Perform step 3 T/S wiring
DCV JPDP-2
3 JPDP-3 Increases from approx. Perform step 4 Replace sensor
2.5V to between 4 and
4 JPC24-19 JPC24-7 5V Replace VM T/S wiring

Test A29 - Secondary Traction Throttle Pot (VR3) Voltage (optional) Analog Tests
Test A29 - Secondary The test is a success if the voltage displayed is

within these limits:
Traction Throttle Pot VR3 Throttle Position Value Displayed
(VR3) Voltage (optional) Full Tractor-First 1.4 to 1.8
Neutral 0.9 to 1.3

This test displays the voltage the VM reads from
the optional secondary traction throttle Full Forks-First 0.45 to 0.8
potentiometer (VR3).
• The values should change smoothly and
adjust the throttle assembly.
evenly as the handle is moved from full
NOTE: For information on how to use Service tractor-first to full forks-first direction.
Mode, see “Using Service Mode” on • If voltages are not within reference ranges,
page 3-28. the test has failed.
Run Test

Action/
Meter Scale
1 JPC4-1 JPC4-2 approx. 5V Perform step 2 Replace VM
Neutral: approx. 1V
Test cable from
DCV Full forks-first:
handle to VM. If
2 JPC4-4 JPC4-2 approx. 1.5V Replace VM
OK, replace
Full tractor-first:
handle or pot
approx. 0.5V

Analog Tests Test A30 - Secondary Traction Throttle (VR3) Request (optional)
Test A30 - Secondary

Traction Throttle (VR3)
Request (optional)
This test displays the percentage of secondary
control handle traction throttle request from
VR3 being read by the VM.
Run Test
adjust the throttle assembly.
page 3-28.
The Operator Display shows the percentage of

throttle request the VM reads from VR3.
Full Tractor-First 0 to –100
Neutral 0
Full Forks-First 0 to +100
The values must change smoothly and evenly

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


Run “Test A29 - Secondary Traction Throttle
Pot (VR3) Voltage (optional)” on page 6-50.

Test A31 - Solenoid 5T (AUX1) Current Analog Tests
Test A31 - Solenoid 5T

(AUX1) Current
This test displays the current the Aux1
directional solenoid coil is drawing.
It does not prove the Aux1 directional solenoid

valve is functioning properly mechanically. It
does not prove the condition of the wiring or the
VM itself.
Run Test
page 3-28.
The test is a success if the current displayed is:
Function Value Displayed (amps)
Retract - Slow Approx. 0.3
Retract - High Approx. 0.6
Tilt Down/Sideshift
Approx. 0.6
Left
Because the directional coil is proportional,

current for tilt/sideshift can be different from
the current for reach/retract. If any one
function passes, run input test for failed
functions (I07, I09, or I11).
If results do not match the preceding table, the

test has failed.

Action/ Expected
Meter Scale Results
Disconnect approx. T/S wires and

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

Analog Tests Test A32 - Solenoid 5B (AUX2) Current
Test A32 - Solenoid 5B

(AUX2) Current
This test displays the current the Aux2
directional solenoid coil is drawing.
It does not prove the Aux2 directional solenoid

valve is functioning correctly mechanically. It
does not prove the condition of the wiring or the
VM itself.
Run Test
page 3-28.
Retract - Slow Approx. 0.2
Retract - High Approx. 0.6
Tilt Down/Sideshift
Approx. 0.6
Left
Because the directional coil is proportional,

current for tilt/sideshift can be different from
the current for reach/retract. If any one
function passes, run input test for failed
functions (I06, I08, or I10).

test has failed.

Action/ Expected
Meter Scale Results
Disconnect Approx. T/S wires and

JC20-19 T/S B+K2 from
2 DCV TP4 B+ Replace VM Fuse/Relay
Card

Test A33 - Aux Dump (SOL3)/Main Relief Dump (SOL8) Current Analog Tests
Test A33 - Aux Dump

(SOL3)/Main Relief
Dump (SOL8) Current
This test displays the current the dump
solenoid coil is drawing.
Run Test
page 3-28.
Any Aux Function

Approx. 0.8
Activated

test has failed.

Action/ Expected
Meter Scale Results

JC20-13 T/S B+K2 from
2 DCV TP4 B+ Replace VM Fuse/Relay
Card

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 T/S wires and

1 JC20-15 JC20-16 Approx. 13 Ohms Perform step 2
JPC20/Ohms coil
T/S B+K2 from

2 DCV PC20-15 TP4 B+ Replace VM Fuse/Relay
Card

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

Value Displayed
State of Brake
(Volts)
Approx. 0.25
Brake pulling in
for 2 seconds
Deadman Pedal Depressed/

Approx. 9
Travel Requested

test has failed.

Action/ Expected
Meter Scale Results
Disconnect T/S wires and

1 JF2-2 JC20-14 Approx. 9 Ohms Perform step 2
JPC20/Ohms coil
T/S B+K2 from

2 DCV PF2-2 TP4 B+ Replace VM Fuse/Relay
Card

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 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
JPC24-23 JPA-1 Replace temp T/S wires as

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

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

Analog Tests Test A39 - Analog Reference Voltage (AC Lift)
Test A39 - Analog

Reference Voltage
(AC Lift)
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.

Test A40 - Handle Heater Reference Voltage (optional) Analog Tests
Test A40 - Handle Run Test

Heater Reference NOTE: For information on how to use Service
Voltage (optional) page 3-28.

This test displays the voltage the Vehicle within these limits:
Manager sees going through the internal
primary control handle heater (HTR6). Heater OFF Heater ON
NOTE: Heater operation requires ambient 0V Approx. 8V
temperature sensor to be activated.
Heaters then turn on at 40°F (4.4°C).
test has failed. Verify option is turned on.

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

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

Power Off (EPO) Switch
This test shows the voltage the Vehicle Manager
is 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
switch

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

Input Tests
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.

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

Switch (S2)
This test shows what the Vehicle Manager is
reading from the deadman switch (S2).
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
S2 closed:
Disconnect JPC22 0 Ohms T/S wires and
1 JC22-8 JC18-7 Perform step 2
and JPC 18/Ohms S2 open: switch
open circuit
Disconnect
2 JPS12-2 JPS12-3 4.5V Recheck step 1 Replace VM
JPS12/DCV

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
reading from the nested switch (S14). The Operator Display shows the state of the
switch:
Mast Position Message Displayed

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 truck’s maximum
elevated height.

Action/
Meter Scale
Disconnect S14 open: open circuit T/S wires and

1 JPF2-8 JPC22-18 Perform step 2
JPF2/Ohms S14 closed: 0 Ohms switch
Verify option is
Disconnect
2 JPC22-18 TP4 S14 closed: B+ on, then replace T/S K2 circuit
JPC22/DCV
VM

Test I02 - 1st Speed Limiting Switch (S12) Input Tests
Test I02 - 1st Speed Run this test in Active Service Mode.
Limiting Switch (S12) maintenance mode, see “Using Service
reading from the 1st speed limiting mast switch The Operator Display should show the
(S12). following:
Mast Position Message Displayed
Use extreme caution when working Lowered Below

around an elevated mast. Raised Above
Run Test If these results are not observed, the test has
NOTE: This test can be run in Loop Back mode. failed.

Action/
Meter Scale
Mechanical Switch
Disconnect S12 open:

T/S wires and
1 JPC22 and JPF3-8 JPC22-1 open circuit Perform step 2
switch
JPF3/Ohms S12 closed: 0 Ohms
Replace
2 TP1 JPF3-8 B+ Perform step 3 Fuse/Relay
Disconnect Card
JPS4/DCV
T/S wires and
3 JPC22-1 TP4 Approx. 4.7V Replace VM
switch
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: 6V Replace VM
replace wire

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 control handle back and forth.
maintenance mode, see “Using Service If the voltage fluctuates erratically, replace
Mode” on page 3-28. the control handle cable.
the DB15 connector.

Action/ Expected
Meter Scale Results
Disconnect
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.

Test I07 - Retract Switch (S5) 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

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

Test I09 - Tilt Down Switch (S7) 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

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.

maintenance mode, see “Using Service If the voltage fluctuates erratically as you
Mode” on page 3-28. move the handle back and forth, replace
the control handle cable.
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

Test I11 - Sideshift Left Switch (S8) 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

Released Out

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

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 6-103).
NOTE: This test can be run in Loop Back mode. If the display message does not change when
See Loop Back Tests (Page 6-122). 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
STR Tips open: 0V T/S wiring from
3 JPC22-19 TP4 Replace VM
STR Tips closed: B+ VM to contactor

Test I15 - Horn Switch (S3) Input Tests
Test I15 - Horn Switch NOTE: For information on how to use

(S3) Mode” on page 3-28.

Use this test to monitor the state of the horn switch:
Manager is reading from the switch. Message
State of Switch
Displayed
Run Test Depressed In
NOTE: This test can be run in Loop Back mode. Released Out

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

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 T/S wiring TPA

Disconnect
2 JPT2-1 Perform step 3 to Traction
JPT2/DCV
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 T/S wiring TPA
JPT1-4 to Traction
6 JPT1-6 Replace TPA Motor

Test I20 - Lift Motor Speed Sensor (AC Lift) Input Tests
Test I20 - Lift Motor

Speed Sensor (AC Lift)
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 T/S wiring from
2 JPL2-1 Perform step 3
LPA to Lift Motor
3 JPL2-2 JPL2-4 Perform step 4 Replace

DCV
At rest: 0V or Lift Motor
4 JPL2-3 10.5 to 13V Perform step 5 speed sensor
Lifting:
5 JPL1-5 Perform step 6 T/S wiring from
JPL1-4 Approx 5V
6 JPL1-6 Replace LPA LPA to Lift Motor

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
Mast Position
Displayed
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

Test I23 - CAN Bus Test Input Tests
Test I23 - CAN Bus Test The Operator Display shows:

• T if the TPA is communicating with the VM
This test verifies the VM is communicating with • L if the LPA is communicating with the VM
the TPA, LPA, and Operator Display. • V if the Operator Display is
communicating with the VM
Run Test
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 (DC Lift)
Remove JPD1-2 and

1 JPD1-3 from n/a n/a V visible in test Perform step 2 Perform step 3
connector
Test wires for

continuity.
Approx. Make sure they
2 JPD1-2 JPD1-3
19K Ohms are not shorted
together. If OK,
Disconnect replace TPA.
Replace display
JPD1/Ohms Test wires for
continuity.
Approx. Make sure they
3 JPD1-6 JPD1-7
120 Ohms are not shorted
together. If OK,
replace VM.
Unable to enter the test and see letters (AC Lift)
Remove JPD1-2 and

1 JPD1-3 from V visible in test Perform step 2 Perform step 5
connector n/a n/a
L and V visible
2 Disconnect JPT1 Replace TPA Perform step 3
in test
Disconnect JPL1 and

jumpers between
JPL1-14 and T and V visible
3 n/a n/a Replace LPA Perform step 4
JPL1-15; and in test
between JPL1-22
and JPL1-23

Input Tests Test I23 - CAN Bus Test
Action/ Expected
Meter Scale Results
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. 120 Make sure they
5 JPD1-6 JPD1-7 Replace display
JPD1/Ohms Ohms are not shorted
together. If OK,
replace VM.
T Missing (DC Lift)
Verify LED's on
TPA are lit. If
not, test TM Troubleshoot B+
temp sensor and from K3 Relay
1 DCV JPT1-1 JPT1-8 B+
speed encoder and DGND from
circuits. Replace Display.
TPA. If OK,
perform step 2.
2 Disconnect JPT1 JPT1-23 JPD1-2 Perform step 3

0 Ohms Repair wiring
3 and JPD1/Ohms JPT1-15 JPD1-3 Replace TPA
T Missing (AC Lift)
Verify LED's on
TPA are lit. If
not, test TM Troubleshoot B+
1 DCV JPT1-1 JPT1-7 B+
circuits. Replace LPA.
TPA. If OK,
perform step 2.
2 Disconnect JPT1 JPT1-22 JPL1-23 Perform step 3

3 and JPL1/Ohms JPT1-14 JPL1-15 Replace TPA
L Missing
Verify LED's on
LPA are lit. If
not, test LM Troubleshoot B+
1 DCV JPL1-1 JPL1-7 B+
circuits. Replace Display.
LPA. If OK,
perform step 2.
2 Disconnect JPD1 JPL1-22 JPD1-2 Perform step 3

3 and JPL1/Ohms JPL1-14 JPD1-3 Replace TPA

Test I24 - Steer Feedback Prox Sensor (AC Lift) Input Tests
Test I24 - Steer Feedback

Prox Sensor (AC Lift)
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

Input Tests Test I25 - Steer Motor Encoder (AC Lift)
Test I25 - Steer Motor

Encoder (AC Lift)
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 T/S wiring to
2 JPE4-1 Perform step 3
VM
JPE4-4
3 DCV JPE4-3 Perform step 4 Replace Steer
4 JPE4-2 Perform step 5 Motor encoder
Steering: approx. 1.8V
5 JPC22-10 Not steering: 0 or 4.5V Perform step 6 T/S wiring to
JPC10-9
6 JPC22-9 Replace VM. encoder

Test I26 - Height Indicator Encoder 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: Approx. 5 or Perform step 5
(Channel B) 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

Input Tests Test I27 - Secondary Horn Switch (S10)
Test I27 - Secondary

Horn Switch (S10)
NOTE: Only with optional secondary control
handle

reading from S10.
Run Test

switch:
Message
State of Switch
Displayed
Depressed In
Released Out

test has failed.

Action/ Expected
Meter Scale Results

>4V
2 JPH3-1 Perform step 3 Repair wiring to VM
JPH3-2
3 DCV JPH3-3 Perform step 4 Replace switch S10
S10 open: >4V
S10 closed: <1V Repair wiring to switch
4 JPC4-3 JPC4-2 Replace VM
S10

Test I33 - Steer Tiller Encoder 1 Connect Detect (AC Lift) Input Tests

Encoder 1 Connect Detect
(AC Lift)
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
2 JPE1-1 JPE1-4 Repair wiring from VM
Tiller Encoder

Input Tests Test I34 - Steer Tiller Encoder 2 Connect Detect (AC Lift)

Encoder 2 Connect Detect
(AC Lift)
This test verifies the Vehicle Manager sees the
12V circuit connected to the Steer Tiller
Encoder Channel 2.
Run Test

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
2 JPE2-1 JPE2-4 Repair wiring from VM
Tiller Encoder

Test I35 - Steer Tiller Encoder 1 - Channels A & B (AC Lift) Input Tests

A & B (AC Lift)
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

Input Tests Test I36 - Steer Tiller Encoder 2 - Channels A & B (AC Lift)

A & B (AC Lift)
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:
5 JPC22-13 approx. 2.5V Perform step 6
JPC18-6 Repair or replace wiring

Test I39 - Neutral Pulses (AC Lift) Input Tests
Test I39 - Neutral Pulses

(AC Lift)
This test displays the neutral pulses seen by
the Vehicle Manager from the Steer Power
Amplifier.
Run Test

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 Up: >4V Repair wiring or replace
2 JPC6-1 Replace VM
Down: 1.7 to Steer Power Amp
3.4V

Input Tests Test I42 - Lift Height
Test I42 - Lift Height

NOTE: This test applies to trucks with VM
versions below 3.7. For trucks with VM
version 3.7 and above, refer to Test
I86 - Lift Height (Page 6-96).
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/
Meter Scale
Disconnect
1 JPD2-1 JPD2-2 Perform step 2 Replace display
JPD-2/DCV 10.5 to 13V
2 JPE3-1 Perform step 3 T/S wiring
3 JPE3-3 JPE3-4 Perform step 4

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

JPD2-2 T/S wiring
6 JPD2-4 Replace display

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

Switch (S23) (optional)
reading 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 T/S switch and
2 DCV Replace VM
S23 closed: 0V wires

Input Tests Test I61 - High Speed Travel Switch (S25)
Test I61 - High Speed The Operator Display should show the
following:
Travel Switch (S25) Mast Position Message Displayed
This test shows what the Vehicle Manager is Lowered Below

reading from the high speed travel switch (S25).
Raised Above
If these results are not observed, the test has

failed.
around an elevated mast.
Run Test
Run this test in Active Service Mode.


Action/
Meter Scale
Disconnect
1 JPC20-3 10.5 to 13V Perform step 2
JPC20/DCV
TP4 Replace VM
Disconnect
2 JPC22-4 Approx. 5V Perform step 3
JPC22/DCV
T/S wire to
3 TP1 JPS6-3 B+ Perform step 4 Fuse/Relay
Disconnect Card
JPS6/DCV
4 JPS6-2 Approx. 5V Perform step 5
T/S wire to VM
5 10.5 to 13V Perform step 6
TP4 Switch not over
JPS6-1 metal: approx. 5V
6 DCV Replace VM Replace switch
Switch over metal:
0V

Test I80 - OCSS Upper Beam Input Tests
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.
Down On
Mode” on page 3-28. Up Off

test has failed. Perform Diagnosis and Repair.
Deadman
Component LED Status
Pedal Position
Remove sensor housing covers. Turn key switch ON and verify LEDs are illuminated as follows:
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 previously, 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
PT1-8 10.7 to Replace harness
down, disconnect
(AC Lift) 13V between Expander
2 JPX1/DCV PD1-1 T/S VM
PT1-7 Module and OD/PA
(DC Lift) 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 Replace harness
Deadman pedal 13V between Expander
Replace Expander
2 down, disconnect PX2-4 PX2-9 Module and Emitter
Module
JPX2/DCV harness JX2 to JCS1

Input Tests Test I80 - OCSS Upper Beam
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,
between Expander Replace Expander
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
JT1-15
(AC Lift)
1 JX1-5 Perform step 2
JT1-14
Disconnect JPX1 (DC Lift) Repair/Replace
0 Ohms
and JPT1/Ohms JT1-23 harness JX1-JT1
(AC Lift) Replace Expander
2 JX1-2
JT1-22 Module
(DC Lift)

Test I81 - OCSS Lower Beam Input Tests
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.
Down On
Mode” on page 3-28. Up Off

test has failed. Perform Diagnosis and Repair.
Deadman
Component LED Status
Pedal Position
Remove sensor housing covers. Turn key switch ON and verify LEDs are illuminated as follows:
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
PT1-8 10.7 to Replace harness
down, disconnect
(AC Lift) 13V between Expander
2 JPX1/DCV PD1-1 T/S VM
PT1-7 Module and OD/TPA
(DC Lift) JX1 to JD1-1/JT1
Fault: EMITTER - Green LED not illuminated
Deadman pedal
Replace Emitter
1 down, disconnect JCS3-1 JCS3-2 Perform step 2
harness PCS3
JPCS3/DCV
Replace Expander
2 down, disconnect PX2-5 PX2-10 Module and Emitter
Module
JPX2/DCV harness PX2 to JCS1

Input Tests Test I81 - OCSS Lower Beam
Action/ Step
Step (+) Lead (–) Lead Expected Results Step Failed
Meter Scale Passed
Fault: RECEIVER - Green LED not illuminated
Deadman pedal
Replace Receiver
1 up, disconnect JCS4-1 JCS4-4 Perform step 2
harness PCS4
JPCS4/DCV
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
JT1-15
Disconnect
(AC Lift)
1 harness at JPX1 JX1-5 0 Ohms Perform step 2
JT1-14
and JPT1/ Ohms
(DC Lift) Repair/replace
JT1-23 harness JX1-JT1
Disconnect
(AC Lift) Replace Expander
2 harness at JPX1 JX1-2 0 Ohms
JT1-22 Module
and JPT1/ Ohms
(DC Lift)

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

NOTE: This test applies to trucks with VM
versions 3.7 and above. For trucks with
VM versions below 3.7, refer to Test
I42 - Lift Height (Page 6-89).
This test displays fork height above free lift.
Run Test
NOTE: This test cannot be run in Active Service
Mode.
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
2 JPE3-1 Perform step 3 T/S wiring
JPE3-4
Replace encoder
4 DCV JPE3-2 JPE3-4 Lifting: approx. Perform step 5
5 JPD2-3 2.4V Perform step 6

JPD2-2 T/S wiring
6 JPD2-4 Replace display

Input Tests Test I90 - Degrees Turned Past Steer Flag
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.

Test I91 - iPort ™ Communication Test Input Tests
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.

Input Tests Test I91 - iPort ™ Communication Test
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

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

Bitmap
This test is for factory use only.

Output Tests
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.

Test O00 - Toggle the TPC Contactor Output Tests
Test O00 - Toggle the

TPC Contactor
This test turns the TPC contactor ON and OFF.
Use extreme caution whenever the lift

truck is jacked up. Never block the lift
truck between the telescopic and the
floor. Use a suitable hoist to stabilize the
mast. Keep hands and feet clear from
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
Safety” on page 2-8.
Jack the drive wheel 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.
If the contactor does not cycle in/out when the

test is toggled, the test has failed.

Action/ Expected
Meter Scale Results
Disconnect JPS1
approx. 38 T/S wires and
1 from contactor JPS1-8 Perform step 2
ohms coil
panel/Ohms
JPS1-10
T/S K2 relay
2 TP4 B+ Perform step 3 and Fuse/Relay
Card
DCV
Test wire to TPA.
Test ON: 18V Test contactor
3 B+ JPS1-8 If OK, replace
Test OFF: 0V for binding
TPA

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 truck while

conducting this test.
Run Test



Action/ Expected
Meter Scale Results

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

Test O02 - Toggle the LPC Contactor 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.
If the STR contactor is shorted on a truck

with DC lift, the carriage lifts when the
LPC contactor is toggled ON.
Run Test



Action/ Expected
Meter Scale Results
Disconnect JPS1
Approx.
1 from contactor JPS1-9 Perform step 2 T/S wires and coil
38 Ohms
panel/Ohms JPS1-10
T/S K2 relay and
2 TP4 B+ Perform step 3
Fuse/Relay Card
DCV Test ON: Test wire to LPA

18V (AC Lift) Test contactor or VM. If OK,
3 B+ JPS1-9
24V (DC Lift) for binding replace LPA
Test OFF: 0V or VM

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 6-52).

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

Directional (SOL5B)
Solenoid
Refer to Test A32 - Solenoid 5B (AUX2) Current
(Page 6-53).

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.
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.

Action/ Expected
Meter Scale Results
Disconnect JPC18 Approx. T/S coil and

1 JPC18-12 Perform step 2
and JPF2/Ohms JPF2-8 41 Ohms wires
2 DCV TP4 B+ Replace VM T/S K2 circuit

Test O07 - Toggle the Tilt Solenoid 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


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


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

(SOL3)/Main Relief
Dump (SOL8) Current
Refer to Test A33 - Aux Dump (SOL3)/Main
Relief Dump (SOL8) Current (Page 6-54).

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.
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
and JPF2/Ohms 30 Ohms wires
2 DCV JPC18-10 TP4 B+ Replace VM T/S K2 circuit

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

Proportional Lower
(SOL2) Solenoid
Refer to Test A34 - Lift/Lower Current (SOL2)
(Page 6-55).

Output Tests Test O18 - Toggle the Horn

Horn
This test turns the 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.
3. When the ENTER key is pressed, the horn
must sound. If it does not sound, the test
has failed.

Action/ Expected
Meter Scale Results
T/S wires and Fuse/Relay

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

Test On: B+
TP1 T/S wires to
3 JPC18-16 Test Off: 0V Replace VM
horn

Test O19 - Audible Alarm Output Tests
Test O19 - Audible

Alarm
This test turns on the Operator Display alarm
by gradually increasing the PWM voltage.
Run Test
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 Up Button ON Display card
DCV
Sounder Sounder for 6 seconds:
2 Approx. 4.0V Replace sounder T/S wiring to sounder
B1 B2

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

NOTE: This test only applies to 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+ Test ON: B+
2 DCV TP4 Perform step 3 T/S FU9 and wiring
Test OFF: 0V
3 TP1 JPC18-18 T/S wiring to horn Replace VM

Test O23 - Toggle Fans 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 remain 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
OFF: 0V
1 TP1 JPC18-17 Perform step 2 Replace VM
DCV ON: B+
2 JPF2-3 TP4 B+ T/S wires and fans T/S K2 circuitry

Output Tests Test O25 - Toggle the 2d Pump (SOL4) Solenoid
Test O25 - Toggle the 2d 1. Turn the key switch OFF and disconnect
Pump (SOL4) Solenoid 2. Disconnect wire SOL4-1 from the 2d Pump
solenoid.
NOTE: This test only applies to DC lift trucks 3. Connect a digital ammeter in series with
with a dual pump (Series BA/BB/ the 2d Pump solenoid coil, positive lead (+)
EA/EB). to the wire removed and the negative
lead (–) to terminal SOL4-1 on the
This test turns the 2d Pump solenoid ON and solenoid.
OFF, verifying its correct operation electrically.
the key switch ON.
A successful test proves the 2d Pump solenoid
coil, wiring, and related circuitry in the Vehicle 5. Run Test O25 and toggle the solenoid coil
Manager are functioning correctly. ON. Use the ENTER button to toggle the
It does not prove the 2d Pump solenoid valve is shows ON or OFF. The ammeter must read
functioning mechanically. 650 to 900 mA.
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.

Action/ Expected
Meter Scale Results
Disconnect JPF2 T/S solenoid coil

1 JPF2-5 JPC18-1 40 Ohms Perform step 2
and JPC18/Ohms and wiring
T/S K2 relay
2 DCV JPC18-1 B– B+ Replace VM
circuit

Test O28 - Ramp Lift Motor (AC Lift) Output Tests
Test O28 - Ramp Lift The Operator Display first shows the current
RPM request.
Motor (AC Lift) 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 truck is in an area with to 0.
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.

Output Tests Test O29 - Ramp Traction Motor
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.
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.
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.
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.

Test O30 - Toggle the Brake Coil Output Tests

Brake Coil
See “Test A35 - Brake Armature” on page 6-56.

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

test has failed.
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

Approx. K3 relay coils. If OK,
1.6M ohm replace Fuse/Relay
Disconnect JPF4/ Card.
Ohms
JPF4-13 Check K4 relay coil.
Approx. 1.7K
2 JPF4-10 Perform step 3 If OK, replace
Ohm
Fuse/Relay Card.
Replace Fuse/Relay
3 Perforn step 4
Card.
DCV TP4 B+
T/S wiring from
Fuse/Relay Card.

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

Disabled Enabled
Test Connector
Value Value
Test A04 - Primary Throttle Pot (VR1) Voltage (Page 6-34) JPC-12 0.00 5.0 ±0.2V
Test A05 - Lift/Lower Pot Voltage (Page 6-35) JPC-12 0.00 5.0 ±0.2V
Test A13 - Pressure Sensor Voltage (Page 6-41) JPC-24 0.00 5.0 ±0.2V
Test A15 - Battery Voltage (Page 6-43) JPC-24 0.00 35.0 ±2V
Test A28 - Deadman Sensor (VR4) (Page 6-49) JPC-24 0.00 5.0 ±0.2V
Test A29 - Secondary Traction Throttle Pot (VR3) Voltage

JPC-04 0.00 5.0 ±0.2V
(optional) (Page 6-50)
400 to 460°F/ 44° ±10°F/

Test A36 - Ambient Air Temp Sensor (Page 6-57) JPC-24
204 to 238°C 6° ±6°C
Test A37 - Steer Power Amp Current (Page 6-58) JPC-6 650 ±20A 2 ±10A
Test A41 - Emergency Power Off (EPO) Switch (Page 6-61) JPC-22 Down Up
Test I00 - Deadman Switch (S2) (Page 6-64) JPC-22 Up Down
Test I01 - Nested Switch (S14) (Page 6-65) JPC-22 Out In
Test I02 - 1st Speed Limiting Switch (S12) (Page 6-66) JPC-22 Above Below
Test I06 - Reach Switch (S4) (Page 6-67) JPC-12 Out In
Test I07 - Retract Switch (S5) (Page 6-68) JPC-12 Out In
Test I08 - Tilt Up Switch (S6) (Page 6-69) JPC-12 Out In

Output Tests Loop Back Tests
Disabled Enabled
Test Connector
Value Value
Test I09 - Tilt Down Switch (S7) (Page 6-70) JPC-12 Out In
Test I10 - Sideshift Right Switch (S9) (Page 6-71) JPC-12 Out In
Test I11 - Sideshift Left Switch (S8) (Page 6-72) JPC-12 Out In
Test I14 - Steering Fuse (FU1) (Page 6-73) JPC-22 Blown OK
Test I15 - Horn Switch (S3) (Page 6-74) JPC-12 Out In
Test I24 - Steer Feedback Prox Sensor (AC Lift) (Page 6-80) JPC-22 Off On
Test I27 - Secondary Horn Switch (S10) (Page 6-83) JPC-04 Out In
Test I33 - Steer Tiller Encoder 1 Connect Detect (AC Lift)

JPC-10 No Yes
(Page 6-84)
Test I34 - Steer Tiller Encoder 2 Connect Detect (AC Lift)

JPC-10 No Yes
(Page 6-85)
Test I35 - Steer Tiller Encoder 1 - Channels A & B (AC Lift)

JPC-22 High Low
(Page 6-86) (35A and 35B displayed separately)
Test I36 - Steer Tiller Encoder 2 - Channels A & B (AC Lift)

JPC-22 High Low
(Page 6-87) (36A and 36B displayed separately)
Test I39 - Neutral Pulses (AC Lift) (Page 6-88) JPC-6 On Off
Test I60 - Security Start Switch (S23) (optional) (Page 6-90) JPC-10 Out In

Loop Back Tests Output Tests

Model 7400/7420/7440 Reach-Fork ® Truck Section 7. Component Procedures
Section 7. Component Procedures

Component Locator Photos . . . . . . . . . 7-3 Motors . . . . . . . . . . . . . . . . . . . . . . . . 7-83
Mast and Reach Carriage . . . . . . . . 7-3 Terminal Nuts . . . . . . . . . . . . . . . 7-83
Tractor, AC Lift, Fore-Aft Stance . . . 7-4 DC Motor Troubleshooting . . . . . . 7-83
Tractor, DC Lift, Side Stance . . . . . . 7-7 AC Motor Troubleshooting . . . . . . 7-83
Reach Carriage . . . . . . . . . . . . . . . 7-10 AC Motor Service . . . . . . . . . . . . . . . . 7-84
Underside Components . . . . . . . . . 7-11 Danaher Motors . . . . . . . . . . . . . . 7-84
Special Tools, Decals, and Chassis . . . . 7-13 Sauer Danfoss Motors . . . . . . . . . 7-88
Special Tools . . . . . . . . . . . . . . . . . . . 7-14 Steer Amplifier (AC Lift) . . . . . . . . . . . . 7-92
Decals and Plates . . . . . . . . . . . . . . . 7-15 Cold Storage Conditioning . . . . . . . . . . 7-93
Baselegs . . . . . . . . . . . . . . . . . . . . . . 7-20 Hydraulic Components . . . . . . . . . . . . 7-95
Steering and Controls . . . . . . . . . . . . . 7-23 Hydraulic System Bleeding . . . . . . . . . 7-96
Steer Tiller Encoder (AC Lift) . . . . . . . 7-24 Hydraulic Filter . . . . . . . . . . . . . . . . . . 7-97
Steer Limit Switch (S11) . . . . . . . . . . 7-25 Lift Pressure Adjustment . . . . . . . . . . . 7-99
Vertical Gap Adjustment . . . . . . . . 7-25 Manual Lowering of Fork Carriage . . 7-100
Lateral Adjustment . . . . . . . . . . . . 7-25 Proportional Valve Adjustment . . . . . 7-101
Steerable Caster . . . . . . . . . . . . . . . . 7-26 Auxiliary Pressure Adjustment . . . . . 7-102
Initial Adjustment . . . . . . . . . . . . . 7-26 Manifold, Main, AC Lift, Model 7400 . 7-103
Caster Height Adjustment . . . . . . . 7-27 Manifold, Main, AC Lift,
Steering Linkage . . . . . . . . . . . . . . . . 7-29 Model 7420/7440 . . . . . . . . . . . . . . 7-104
Control Handle . . . . . . . . . . . . . . . . . 7-30 Manifold, Main, DC Lift, Model 7400 . 7-105
Primary Control Handle - Manifold, Auxiliary (Standard Reach) 7-106
Fore-Aft Stance. . . . . . . . . . . . . . 7-30 Manifold, Reach (Deep-Reach ®) . . . . . 7-108
Side Stance Control Handle. . . . . . 7-35 Manifold, Tilt/Sideshift
Secondary Control Handle - (Deep-Reach ®) . . . . . . . . . . . . . . . . 7-110
Fore-Aft Stance. . . . . . . . . . . . . . 7-39 Manifold Solenoids, Fittings,
Drive and Brake. . . . . . . . . . . . . . . . . . 7-41 and Attachments . . . . . . . . . . . . . . 7-111
Drive Unit . . . . . . . . . . . . . . . . . . . . . 7-42 Hydraulic Components, Cylinder . . . . 7-113
Required Tools . . . . . . . . . . . . . . . 7-43 Lift Cylinder, Free Lift,
Troubleshooting . . . . . . . . . . . . . . 7-45 Remove/Install . . . . . . . . . . . . . . . . 7-114
Radial Ring Inspection . . . . . . . . . 7-47 Model 7400 . . . . . . . . . . . . . . . . 7-114
Drive Unit Removal . . . . . . . . . . . . 7-47 Model 7420/7440 . . . . . . . . . . . 7-115
Drive Unit Disassembly. . . . . . . . . 7-48 Lift Cylinder, Free Lift,
Drive Unit Assembly . . . . . . . . . . . 7-52 Exploded Parts Drawing . . . . . . . . . 7-118
Brake (Adjustable) . . . . . . . . . . . . . . . 7-60 Lift Cylinder, Free Lift,
Brake (Floating Disk) . . . . . . . . . . . . . 7-66 Seal Repacking . . . . . . . . . . . . . . . . 7-121
Deadman Switch (S2) . . . . . . . . . . . . 7-68 Lift Cylinder, Main, Remove/Install . . 7-124
Inertial Dampener . . . . . . . . . . . . . . . 7-69 Lift Cylinder, Main Lift,
Electrical Components . . . . . . . . . . . . 7-73 Exploded Parts Drawing . . . . . . . . . 7-129
Battery Procedures . . . . . . . . . . . . . . 7-74 Lift Cylinder, Main, Seal Repacking . . 7-131
Battery Connector/Cables. . . . . . . 7-74 Lift Cylinder Lowering Cushion . . . . . 7-133
Battery Exterior Cleaning . . . . . . . 7-75 Reach Cylinder . . . . . . . . . . . . . . . . . 7-136
Testing, Charging, Tilt Cylinder . . . . . . . . . . . . . . . . . . . 7-139
and Maintenance . . . . . . . . . . . . 7-76 Flow Limiter, Main Lift . . . . . . . . . . . 7-141
Battery State-of-Charge. . . . . . . . . 7-76 Flow Limiter, Free Lift . . . . . . . . . . . . 7-142
Wiring and Harness Connectors . . . . . 7-77 Mast, Chain, Hose, Cable . . . . . . . . . . 7-145
General Repair Procedures . . . . . . 7-77 Reach Carriage Bearings . . . . . . . . . . 7-146
Molex Connectors . . . . . . . . . . . . . 7-78 Mast Shimming . . . . . . . . . . . . . . . . 7-147
AMP Water-Resistant Connectors . 7-78 Bow Pads - Model 7400 . . . . . . . . . . . 7-149
Contactor Panel . . . . . . . . . . . . . . . . . 7-82

Section 7. Component Procedures Model 7400/7420/7440 Reach-Fork ® Truck
Carriage . . . . . . . . . . . . . . . . . . . . . .7-151
Model 7400 . . . . . . . . . . . . . . . . 7-151
Model 7420/7440 . . . . . . . . . . . . 7-152
Chain Anchors . . . . . . . . . . . . . . . . .7-154
Main Lift Chain Anchors . . . . . . . 7-154
Free Lift Chain Anchors . . . . . . . 7-157
Lift Chains . . . . . . . . . . . . . . . . . . . .7-160
Chains, Main Lift . . . . . . . . . . . . 7-160
Chains, Free Lift . . . . . . . . . . . . . 7-163
Height Encoder Belt . . . . . . . . . . . . .7-165
Model 7420 . . . . . . . . . . . . . . . . 7-165
Model 7440 . . . . . . . . . . . . . . . . 7-167
Hose, Main Lift . . . . . . . . . . . . . . . . .7-169
Hose and Cable, Over-the-Mast . . . . .7-170
Hose Guard Addition . . . . . . . . . . . . .7-176
Hose/Cable Retainer Upgrade . . . . . .7-177
Cable, Over-the-Mast . . . . . . . . . . . .7-178
Hose/Tubing, Free Lift Feed . . . . . . .7-183
Mast, Model 7400
(Complete Disassembly) . . . . . . . . .7-184
Mast, Model 7400
(Complete Assembly) . . . . . . . . . . . .7-188
Mast, Model 7420
Mast, Model 7420
Mast, Model 7440
Mast, Model 7440
Carriage, Free Lift Cylinder,
and Hose/Cable Installation . . . . . .7-214
Mating Tractor to Mast . . . . . . . . . . .7-218

Component Locator Photos

Mast and Reach Carriage

Figure 7-1. Mast and Carriage (R45TT Shown)
6353_117g.jpg
Main Lift
Chain
Overhead
Guard
Free Lift
Cylinder
& Chain
Main Lift
Cylinder
Mast Guard
(mesh or glass)
Operator
Manual
Lift Motor & Pocket
Power Amp
Fans
Load
Backrest Battery
Reach
Fork Carriage Mechanism
(integral
sideshift)
Forks Battery
Load Wheel Baseleg
Gate

Tractor, AC Lift, Fore-Aft Stance

Figure 7-2. Tractor, AC Lift, Fore-Aft Stance
DSC_901a.jpg
Operator Display
Primary Control
Handle
Hydraulic Fluid
Level Indicator
Fuse/Relay Card
Hydraulic
Reservoir
Vehicle Manager
Electric Steer
Motor
Contactor Panel
Horn
Brake
Traction Power
Amp
Traction
Drive Unit
(not visible)
Deadman Pedal
Motor
Compartment
Fan
Steer Idler
(not visible)
Drive Wheel


Figure 7-3. Electrical Compartment, AC Lift, Fore-Aft Stance
DSC_911a.jpg
Secondary
Primary Control Handle
Control Handle (optional)
Vehicle Manager
Contactor Panel
Traction Power
Amp
Specification
Plate
Inertial
Dampener
Traction Power ESD Ground

Amp Fan Jack


Figure 7-4. Tractor Deck, AC Lift, Fore-Aft Stance
DSC_920a.jpg
Emergency Power Off

Operator Display
Lift Pump
Fuse/Relay Card
Sounder Key Switch
Main Manifold
Lift Power Amp
Lift Motor
Operator Display
Lift Pump
Emergency Power Off
TP4 Steer Power Amplifier

Tractor, DC Lift, Side Stance

Figure 7-5. Tractor, DC Lift, Side Stance
DSC_854a.jpg
Overhead
Guard
Mast Guard
(mesh or glass)
Control Handle
Operator
Manual
Pocket
Brake
Traction Motor
Deadman
Pedal
Drive Unit
Drive Wheel
Steer Idler
(not visible)


Figure 7-6. Tractor, DC Lift, Side Stance
DSC_0837a.jpg
Emergency Power Off
Steering
Wheel
Operator
Display
Fuse/Relay
Card
Hydraulic Fluid
Level Indicator
Steering Vehicle
Orbitrol Manager
Aux Motor/
Pump Contactor
Panel
Horn
Brake Traction
Power Amp
Traction
Motor
Traction
Power Amp
Motor Fan
Compartment
Fan ESD Ground
Jack
Drive Unit
Deadman
Pedal
Steer Idler
(not visible)
Drive Wheel Hydraulic Steer Motor


Figure 7-7. Tractor Deck, DC Lift, Side Stance
DSC_0866a.jpg
Operator
Display Lift Motor Emergency Power Off Lift Pump
Hydraulic Reservoir Steering Main Control Battery TP4

Filler Cap Orbitrol Manifold Handle Connector

Reach Carriage
Figure 7-8. Standard Reach Carriage, Operator View
(Mast Guard removed for clarity)
DSC_0873a.jpg
Ambient
Temperature
Sensor
Hose
Retainer/
Guide
Free Lift
Cylinder
Chain
Anchor
Bleed Screw
Carriage
Stop
Aux
Hose
Manifold
Tensioning
Spring
Reach
Cylinder
Tilt Cylinder

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


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


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 950-042 Separate AMP connectors

All
Unlatching
End Cap 7420/7440 1090761/004 Free Lift Cylinder end cap removal/installation
End Cap 1090761/005 Free Lift Cylinder w/staging end cap

7400
removal/installation
End Cap 7420/7440 1090761/005 Main Lift Cylinder end cap removal/installation
End Cap 1090761/007 Main Lift and Free Lift Cylinder w/o staging end cap
7400
removal/installation
Fork Wear All 922-369 Inspect forks

Caliper
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

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
1 Raymond Tractor frame, aft of battery compartment

(both sides)
2 AC Tractor frame, with respect to battery

compartment opening, aligned with front edge
and bottom of decal 5.8 in. (147 mm) above
opening (both sides)
3 EE Compliance (optional) Tractor frame, centered 5 in. (127 mm) above

battery opening (both sides), above battery
warning decal
4 Battery Warning Decal Tractor frame, centered 0.25 in. (6.35 mm)
above battery compartment opening (both
sides)
5 Battery Connector Polarity Right side of tractor frame above battery

connector
6 Key Switch Key Switch
7 EPO Function EPO Knob
8 Primary Control Handle Functions Next to Primary Control Handle
9 Optional Secondary Control Handle Next to Secondary Control Handle

Functions
10 General Safety Decal Mast guard, bottom edge of decal 1.5 in.
(38 mm) above bottom of guard, left edge of
decal 11.5 in. (292 mm) inside widest tractor
dimension.
11 Specification Plate Front of operator compartment
12 Cold Storage Front of operator compartment, below spec

plate
13 Type E Specification Plate Front of operator compartment, below cold

storage decal
14 Torque Specs (motor, power amplifier, Front of operator compartment, under top
contactors) cover, centered on sloping deck
15 Patent Decal Inside of Traction Motor compartment door,

above and centered with ventilation slots
16 Lubrication Decal Inside of Traction Motor compartment door,

centered with ventilation slots, above patent
decal

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

centered with ventilation slots, above
lubrication decal
18 Hydraulic Filter Locator On reservoir, forward of filler cap
19 Mast Specification Plate Right side of mast, 2 in. (50.8 mm) above top
of baseleg
20 ISO 9001 Decal Centered on mast main frame (both sides),

61.7 in. (156.7 cm) above floor
21 Operating Instructions Centered on left mast upright under ISO9001

decal
22 Manual Replacement Centered at top of operator manual pocket
23 No Riding Centered on load backrest
24 Overhead Guard ANSI/ITSDF Inside left side of overhead guard

conformance
NOTE: Items in italics are safety decals.


Figure 7-10. Decal and Specification Plate Locations,
Tractor
R1017410_A1.CGM R1010652_A1.CGM R1017410_A2.CGM R1010652_A2.CGM
Series AA/BA/CA (Fore-Aft Stance) Series DA/EA/FA (Side Stance)
7 8
7 6
9
2
2
3
3
4
4
1
1
10 10
14 14
17
17
16 11
16 11
15
15
12
12
13
13

Decals and Plates Special Tools, Decals, and Chassis

Figure 7-11. Decal and Specification Plate Locations, Mast
R1017504_A1.cgm
24 (inside surface) 23
5 20
21
22
19
Figure 7-12. Warning/Safety Decals

1024303_02Mar04.eps,R1017269.eps,R1017233.eps,R1017232.eps,R1017362.eps,R411_587.eps

10
17
23

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 7400 shown

R1015167_Ax.cgm

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 follows:
Model 7400 Model 7420/7440
165 ft. lb. (223 Nm) 295 ft. lb. (434 Nm)

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

6. To the outside of the mounting bolt sleeve
and the inside of the baseleg hole, apply
solvent (P/N 990-589), primer
(P/N 990-533), and retaining compound
(P/N 990-575).
(P/N 1013829) to the load wheel plate
mounting bolts. Install mounting bolts,
washers and nuts. Torque as follows:
Bolt Torque
Wheel Plate, Mounting, 50 ft. lb. (68 Nm)

7400
Wheel Plate, Mounting, 150 ft. lb. (203 Nm)

7420/7440
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.

Baselegs Special Tools, Decals, and Chassis

Steering and Controls
Steering and Controls


Steer Tiller Encoder (AC Lift) Steering and Controls
Steer Tiller Encoder 3. Assemble the snubber and tighten the jam
nut on the eyebolt so that the force
(AC Lift) required to turn the steering wheel is 5 to
7 in. lb. (0.5 to 0.7 Nm).
Removal (P/N 990-536) to the steering wheel cap
1. Turn the key switch OFF and disconnect screws.
the battery connector. 5. Position the steering wheel over the steer
tiller encoder. Install cap screws.
6. Install the steering wheel cover.
Use correct electrostatic discharge 7. Attach the steering wheel cover to the
precautions. See “Static Precautions” on steering wheel with two bolts.
page 2-7. 8. Apply anti-seize compound (P/N 990-452)
to the shoulder bolt. Install the steering
2. Remove the top cover and steering cover. knob.
(You must remove the knob, steering wheel
9. Install the top cover.
cover, and steering wheel before removing
the steering cover.)
3. Remove the snubber adjustment nut and
swing the halves of the snubber out of the
way. See Figure 7-15.
Figure 7-15. steer Tiller Encoder and Snubber

6353_108g.jpg
Snubber
Adjustment Nut
4. Disconnect encoder harness connectors

JPE1 and JPE2. Cut cable ties as needed.
5. Remove three bolts holding the steer tiller
encoder to the bracket.
Installation
1. Route wiring harness of new encoder
through the hole in the bracket. Install
encoder to bracket with three bolts.
2. Route encoder harness and install cable
ties where previously removed. Connect
harness connectors JPE1 and JPE2.

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

Figure 7-16. 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.

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 7-18.
performance. A misadjusted caster can cause
excessive braking distances, poor stability, or
Figure 7-18. 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 7-17. A
Figure 7-17. Setting Drive Wheel Parallel Steering Steering

Link Link
R86758a.eps
Straightedge Drive Tire Locking Adjusting

Bolts (4) Bolts (2)
E E
C c. Loosen jam nuts on center steering link

adjusting bolts and adjust the bolts to
get both wheels parallel to the tractor
frame.
d. Apply thread-locking compound
(P/N 990-536) to steering link adjusting
bolts and locking bolts.
C e. Tighten the jam nuts on the adjusting
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
side tractor frame. Measure the distance re-install the lift truck battery.
from the straightedge to the front edge of Re-install battery gates.
the caster wheel and to the back edge. If
the dimensions are not equal, adjust as Caster height adjustment varies, depending
follows. upon the type of mast. See “Caster Height
a. Turn the key switch OFF and
disconnect the battery connector.
Remove battery gates. Using a suitable
battery removing device, remove the
battery and battery rollers from the lift

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 7-19. floor. Use a suitable hoist to stabilize the
Figure 7-19. Inertial Dampener Cover Plate vehicle while jacking the lift truck. After
7074_004.tif

Figure 7-21. 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 7-20. Make sure
it is installed correctly. If the bolt is
missing, the A-frame could drop and allow
the springs to escape when the truck is
jacked up.
Figure 7-20. A-frame Down-Travel Adjustment Bolt 3. Jack the lift truck until the caster is clear
of the floor.
13y7s001.tif
A-frame Spring Nuts 4. Turn the A-frame down-travel adjustment

bolt to obtain an initial gap of 1.0 in.
(25 mm) between the arm and frame.
Adjust the A-frame spring nuts to obtain
an initial spring length of 6.0 in.
(152 mm). See Figure 7-20 and
Figure 7-21.
5. Lower the lift truck back onto the floor.
A-frame Make sure the lift truck is sitting on a flat
Down-Travel floor surface.
Adjustment Bolt 6. Adjust the A-frame spring nuts to obtain
the spring length in the table that follows.
The dimension is measured from the top of

Steerable Caster Steering and Controls
the spring to the top of the caster, not the 10. Apply thread-locking compound
frame. (P/N 990-536) to the A-frame up-travel
stop bolt. Tighten the jam nut.
11. Test the lift truck for correct braking
Elevated Height Spring Length
action.
Below 330 in. (8328 mm) 5.75 in. (146 mm) 12. Reinstall the inertial dampener cover
plate.
Above 331 in. (8407 mm) 5.50 in. (140 mm)

(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 7-21 and the table below.
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 7-22.
Figure 7-22. 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 as follows (See
Figure 7-22):
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)

Steering and Controls Steering Linkage
Steering Linkage
Use Figure 7-23 as a reference when
removing/replacing steering linkage
components. After replacing any components,
make sure the steering is adjusted correctly.
Figure 7-23. 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

Control Handle Steering and Controls
Control Handle Travel Pot Repair/Replacement

1. Carefully peel the flex heater from the
travel pot. It is attached to the pot with
Primary Control Handle - double-sided tape. See Figure 7-25.
Fore-Aft Stance
Figure 7-25. Control Handle, Fore-Aft Stance
If a ThermaKit component fails, replace both HNDL_FA2.jpg
handle shells; however, it may be more cost Travel Pot Heater

effective to replace the entire handle.
Lift Pot
Disassembly
1. Remove the lift knob.
NOTE: The outer spring paddle may fall off
when the lift knob is removed.
Lift Pot
Connector Connector
Use correct electrostatic discharge ThermaKit Connector

precautions. See “Static Precautions” on 2. Press the latch on the travel pot connector
page 2-7. and disconnect the travel pot from the flex
circuit. See Figure 7-25.
2. Remove the socket head cap screws from
the handle shell. 3. Slide the travel pot out of the pivot shaft
assembly. See Figure 7-26.
3. Slide out the cable clamp.
NOTE: Do not lose the D-shaped clip inside the
4. Remove the screws securing the harness
pivot shaft.
connector.
5. Carefully pull the flex circuit down the Figure 7-26. Pivot Shaft Assembly
cable clamp slot. See Figure 7-24.
HNDL_FA3.jpg
D-Clip
Figure 7-24. Flex Circuit in Cable Clamp Slot
HNDL_FA1.jpg
Spring Snap Ring

Flex Circuit
Pin
Paddle
4. Remove the external snap ring.

NOTE: Observe orientation of the spring and
paddles on the pivot shaft.
5. Remove the spring and paddles from the
pivot shaft. See Figure 7-26.
6. Apply a thin coat of lubricant
6. Lift off the upper handle shell. If
(P/N 990-635) to the inside surface of the
ThermaKit equipped, the upper shell can
spring. Assemble spring between the
be removed but wiring will connect the two
spring paddles. See Figure 7-27.
halves.

Steering and Controls Control Handle

Figure 7-27. Travel Pot Spring Assembly 2. Slide the inner spring paddle off the lift pot
shaft.
HNDL_FA4.jpg
3. Press the latch on the lift pot connector

and disconnect the lift pot from the flex
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.
7. Slide the spring and paddles part way
down the pivot shaft to engage the lower 6. Slide the lift pot out of the lift pot bracket.
spring tang. 7. Slide a new lift pot into the lift pot bracket.
8. Using the upper paddle, press the upper The lift pot tang must slide into the slot on
spring tang over the pin on the pivot shaft. the lift pot bracket. See Figure 7-29.
With one paddle and one spring tang on
each side of the pin, slide all parts down to Figure 7-29. Lift Pot and Bracket
HNDL_FA6.jpg
expose the snap ring groove. See

Figure 7-26. Slot in
Tang
9. Install the external snap ring. See Bracket
Figure 7-26.
10. Slide the travel pot shaft into the pivot
shaft assembly (make sure D-clip is in
pivot shaft).
11. Re-tape the flex heater to the travel pot
body. Replace the double-sided tape if 8. Slide the inner spring paddle onto the lift
necessary. See Figure 7-25. pot bracket.
12. Re-seat the travel pot flex connector in the 9. Apply a thin coat of lubricant
handle shell. Re-connect the travel pot to (P/N 990-635) to the inside surface of the
the flex circuit. See Figure 7-25. spring. Install the spring with one tang
resting on the inner spring paddle (not the
Lift Pot Repair/Replacement dowel pin).
1. Slide the outer paddle and lift pot spring 10. Slide the outer spring paddle part way
off the lift pot shaft. See Figure 7-28. onto the lift pot shaft to engage the outer
spring tang.
NOTE: Observe orientation of the lift pot spring,
11. Using the outer paddle, press the outer
paddles, and dowel pin.
spring tang over the dowel. Slide parts
Figure 7-28. Lift Pot and Spring Assembly together until the outer paddle is flush
HNDL_FA5.jpg with the lift pot bracket. See Figure 7-28.
Lift Pot Paddle (flush 12. Make sure the tilt/sideshift card is
with bracket correctly positioned. Slide the lift
stem) pot/bracket assembly into the lower
handle shell. See Figure 7-30.
Lift Pot Shaft
Connector Dowel Pin

Paddle Spring


Figure 7-30. Lift Pot Bracket Position Figure 7-32. ThermaKit Heaters and Connector
HNDL_FA11.jpg HNDL_FA7.jpg
ThermaKit Horn Reach/Retract

Slot in Shell Buttons
Connector Button
Tab on Pot
Bracket
ThermaKit
13. Re-tape the flex heater to the lift pot body. Heaters Tilt/Sideshift Card
Replace the double-sided tape if
necessary. Use a screwdriver blade to
press the heater against the pot body.
14. Re-connect the ThermaKit (if so equipped)
to the flex circuit. 2. Hold the tilt/sideshift button and card
between thumb and forefinger. Tip the
15. Align the tang on the travel pot with the
card back and remove from the handle
2nd rib on the flex circuit side of the lower
shell (the gasket on the tilt/sideshift
handle shell. See Figure 7-31.
button may fall off as the tilt/sideshift
Figure 7-31. Travel Pot Alignment in Shell card is removed from the handle shell).
HNDL_FA12.jpg
3. Carefully remove the lift pot connector

Tang from the slot in the handle shell.
4. Remove the reach/retract and horn
buttons from the handle shell.
5. Carefully remove the ThermaKit and travel
pot connectors from the slots in the handle
shell. See Figure 7-25.
6. Lift the flex circuit out of the handle shell.
Rib
7. Remove the tilt/sideshift button and
spring from the flex circuit by removing
one screw from the back of the
Flex Circuit Repair/Replacement tilt/sideshift card.
1. Press the latch on the ThermaKit 8. To install the tilt/sideshift button and
connector and disconnect the ThermaKit spring on the tilt/sideshift card, place the
(if so equipped) from the flex circuit. See spring over the post on the back of the
Figure 7-32. tilt/sideshift button. Align the “A” on the
back of the button with the “A” on the
card. See Figure 7-33. Press the button
against the card so the post protrudes
through the back of the card. Thread the
screw into the post until it just bottoms,
then tighten an additional 1/8 turn. Do
not overtighten.


Figure 7-33. Tilt/Sideshift Card and Button 2. Position the upper handle shell over the
lower shell and ease it into position. See
HNDL_FA8.jpg
Orientation Letter ”A” Figure 7-35. Make sure:

• A - travel pot tang is entering the slot in
the shell
• B - plastic alignment post on upper
shell is entering the alignment hole on
the lower shell
• C - travel shaft pin on upper shell is
Tilt/Sideshift
passing between the paddles of the
Button Circuit Card
pivot shaft assembly
9. Slide the horn button over the positioning • D - reach/retract buttons are entering
pin. the holes in the handle shell
10. Press the ThermaKit and travel pot • E - backing ribs that hold the horn
connectors into the slots in the lower button in place are not pinching the
handle shell. See Figure 7-25. flex circuit
11. Place the gasket over the tilt/sideshift • F - harness connector end of the flex
button. Gently position the tilt/sideshift circuit is entering the cable clamp slot
card in the handle shell. The bottom of the without pinching.
card sits forward of a ridge in the handle;
the card edge nearest the lift knob sits Figure 7-35. Primary Control Handle Assembly - Fore-Aft
behind a ridge in the handle. Confirm that Stance
the gasket is in place on the tilt/sideshift HNDL_FA13.jpg
button. See Figure 7-34.

D
Figure 7-34. Tilt/Sideshift Card Position
HNDL_FA10.jpg
F A
D A
Card Sits
Forward B
of Ridge
Card Sits
C E
Behind
Ridge B
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
12. Correctly position the reach/retract
pin in the upper handle shell is between
buttons and route the harness connector
the paddles. Do not over-rotate the shaft,
end of the flex circuit through the locating
as this can cause damage. You should feel
slots.
spring tension immediately and there
should be no free play in the pivot shaft. If
Assembly you do not feel spring tension, lift off the
upper handle shell, and repeat step 2.
1. Confirm the flex circuit is routed correctly
through the locating slots. 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.

6. Install the socket head cap screws.

Tighten each screw until it bottoms, plus
an additional 1/4 turn. Do not
overtighten.
7. Slide the cable clamp into the cable clamp
slot and secure.
8. Confirm the two spring paddles and spring
are in place. The outer paddle must be
flush with the end of the lift pot bracket.
See Figure 7-28.
9. Set the flat on the lift pot shaft 90° to the
top spring paddle. See Figure 7-36.
Figure 7-36. Lift Pot Shaft Alignment

HNDL_FA14.jpg
Dowel Pin Paddles
10. Install the lift knob with the dowel pin in

between the paddles.
11. Tighten the steel set screw until it
bottoms, plus an additional 1/4 turn.
12. Install the nylon set screw. Run the nylon
set screw down flush or below the surface
of the knob.

Side Stance Control Handle 4. Lift the travel pot shaft out of the lower
handle shell.
If a ThermaKit component fails, replace both 5. Slide the travel pot out of the pivot shaft
handle shells; however, it may be more cost assembly. See Figure 7-37.
effective to replace the entire handle.
pivot shaft.
Disassembly
6. Remove the external snap ring.
1. Remove the lift knob.
Figure 7-38. Pivot Shaft Assembly
NOTE: The outer spring paddle may fall off HNDL_FA3.jpg
when the lift knob is removed.

D-Clip
Spring Snap Ring

Use correct electrostatic discharge
precautions. See “Static Precautions” on Pin
page 2-7.
Paddle
2. Remove the socket head cap screws from
the handle shell. NOTE: Observe orientation of the spring and
3. Lift off the upper handle shell. If paddles on the pivot shaft.
ThermaKit equipped, the upper shell can
7. Remove the spring and paddles from the
be removed but wiring will connect the two
pivot shaft. See Figure 7-38.
halves.
Travel Pot Repair/Replacement
spring. Assemble spring between the
1. Carefully peel the flex heater from the spring paddles. See Figure 7-39.
travel pot. It is attached to the pot with
double-sided tape. Figure 7-39. Travel Pot Spring Assembly
HNDL_FA4.jpg
2. Remove harness connector and travel pot

heater from lower shell. See Figure 7-37.
Figure 7-37. 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.
10. Using the upper paddle, press the upper
spring tang over the pin on the pivot shaft.
With one paddle and one spring tang on
Travel Pot Heater Pivot Shaft
each side of the pin, slide all parts down to
Harness Connector expose the snap ring groove. See
3. Press the latch on the travel pot connector Figure 7-39.
and disconnect the travel pot from the flex 11. Install the external snap ring. See
circuit. See Figure 7-37. Figure 7-38.

12. Slide the travel pot shaft into the pivot Figure 7-41. Handle Shell - Side Stance
shaft assembly (make sure D-clip is in
HNDL_SS5.jpg
pivot shaft). Flex Circuit Reach/Retract Buttons Lift Pot

13. Insert the pivot shaft assembly into the
Horn Button
lower handle shell. Make sure the tang on
the travel pot enters the center slot in the
shell. See Figure 7-40. Lift Pot Connector
Figure 7-40. Travel Pot Tang Alignment

HNDL_SS4.jpg
Tang
ThermaKit Connector
Lift Pot Heater Tilt/Sideshift Button

2. Slide the inner spring paddle off the lift pot
shaft.
3. Press the latch on the lift pot connector
and disconnect the lift pot from the flex
4. Carefully peel the flex heater from the lift
pot. It is attached to the pot with
Slot
double-sided tape.
5. Pull the lift pot/bracket assembly out of
14. Re-tape the flex heater to the travel pot
the handle shell.
body. Replace the double-sided tape if
necessary. See Figure 7-37. 6. Slide the lift pot out of the lift pot bracket.
15. Re-seat the travel pot flex connector in the 7. Slide a new lift pot into the lift pot bracket.
handle shell. Re-connect the travel pot to The lift pot tang must slide into the slot on
the flex circuit. See Figure 7-37. the lift pot bracket. See Figure 7-42.
Figure 7-42. Lift Pot Tang and Bracket Slot

Lift Pot Repair/Replacement HNDL_SS8.jpg
1. Slide the outer paddle and lift pot spring Tang and Slot
off the lift pot shaft. See Figure 7-28.
NOTE: Observe orientation of the lift pot spring,
paddles, and dowel pin.
8. Slide the inner spring paddle onto the lift

pot bracket.
spring. Install the spring with one tang
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.

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 7-41.
with the lift pot bracket. See Figure 7-42. 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 7-43. tilt/sideshift card.
Figure 7-43. 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 7-44. 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 7-44. 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 7-41.
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 7-41. 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 7-45.
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.


Figure 7-45. 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 7-47.
1. Confirm the flex circuit is routed correctly
through the locating slots. Figure 7-47. Lift Pot Shaft Alignment
HNDL_SS12.jpg
2. Position the upper handle shell over the

lower shell and ease it into position. See
Figure 7-46. 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 7-46. Sidestance 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.
B
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,

Secondary Control Handle - Figure 7-49.

HNDL_SEC2.jpg
Secondary Control Handle End Cap
Fore-Aft Stance End Plug M4x8 mm
Travel Pot Repair/Replacement

1. Remove the travel pot from the handle
shell.
pivot shaft.
4. Remove the travel pot from the handle

Use correct electrostatic discharge shell.
precautions. See “Static Precautions” on NOTE: Do not lose the D-shaped clip inside the
page 2-7. pivot shaft.
2. Attach the foam pad to the back of the new 5. Remove the snap ring in the handle shell.
travel pot body. See Figure 7-48.
3. Turn the travel pot shaft so the flat on the 6. Remove the pivot shaft assembly from
shaft aligns with the tang on the pot body. handle shell.
See Figure 7-48. 7. Observe the orientation of parts on the
pivot shaft and remove. See Figure 7-50.
Figure 7-48. Secondary Control Handle Travel Pot
HNDL_SEC1.jpg
Figure 7-50. Secondary Handle Pivot Shaft Components
D-Clip Slot HNDL_SEC3.jpg
Tang
Snap Ring
4. Insert travel pot into the handle shell,

aligning the flat on the shaft with the 8. Apply a thin coat of lubricant
D-clip, and the tang on the pot body with (P/N 990-635) to the inside surface of the
the slot in the shell. See Figure 7-48. spring. Assemble parts in the correct order
on the shaft.
Disassembly/Assembly 9. Slide the spring and paddles part way
down the pivot shaft to engage the lower
1. Remove the end plug from the end of the spring tang.
handle. See Figure 7-49.
10. Using the upper paddle, press the upper
2. Remove the two button-head socket spring tang over the tab on the pivot shaft.
screws from the end of the handle. See With one paddle and one spring tang on
Figure 7-49. each side of the pin, slide all parts down to
3. Remove the handle grip from the handle expose the snap ring groove. See
shell. Figure 7-51.


Figure 7-51. Secondary Control Handle Pivot Shaft 2. Remove the 2 in. (50.8 mm) length of
Alignment shrink tubing from the wires. See
HNDL_SEC4.jpg
Figure 7-52.
Paddle/Tang
Spring 3. Remove the snap ring from the back of the
Tab on Shaft
horn button. See Figure 7-53.
Paddle/Tang Figure 7-53. Secondary Control Handle Horn Button

HNDL_SEC6.jpg
Tab on Shell Shell
11. Install the external snap ring and two

nylon washers.
12. Confirm that the D-clip is inside the pivot
shaft. Snap Ring
13. Insert the pivot shaft assembly into the

handle shell. Make sure the tab on the 4. Pull wiring out through the channel in the
shell slides between the paddles on the handle grip.
shaft assembly. See Figure 7-51. 5. Thread new wires down the channel in the
14. Insert travel pot into the handle shell, handle grip.
aligning the flat on the shaft with the 6. Install the horn button in the grip and
D-clip, and the tang on the pot body with secure it with the snap ring.
the slot in the shell. See Figure 7-48. 7. Install a 2 in. (50.8 mm) length of shrink
15. Slide the handle grip over the handle shaft tubing over the wire ends.
and shell assembly. Orient the notch in 8. Re-connect connector PH3 to the horn
the handle flange with the harness button wires: red to pin 1, black to pin 2,
channel in the grip. white to pin 3. Make sure there is a
16. Install the two button-head socket screws connector seal on the connector.
at the end of the handle and end plug. 9. Shrink the tubing.
10. Reassemble handle.
Horn Button
1. With the handle disassembled, remove the
three wires from the PH3 connector, noting
their colors and locations for later
re-connection. See Figure 7-52.
Figure 7-52. Secondary Handle, PH3 Connector

HNDL_SEC5.jpg
Insulation

Drive and Brake
Drive and Brake


Drive Unit Drive and Brake
Drive Unit
Figure 7-54. Drive Unit Exploded View
R1008858_C.cgm
22 23 21 20 19 25 26
24
4
27
3
2
18
6
12 16
13
29
5 9
28 8 10 11 7 14 15 32

Drive and Brake Drive Unit
Table 7-3. Drive Unit Set-Up Legend 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 7-4 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 7-4. 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
18 Ring, Pivot
Pry bars
19 Pin, Spiral
Tube 12 in. diam. x 6 in. long
20 Plug, Bearing Filler
Tube 8 in. diam. x 6 in. long
21 Fitting, Grease
Torque wrench, 150 ft. lb. (210 Nm) capacity
22 Screw
23 Washer, Flat
24 Kit, Ring Set
25 Bearing, Ball
26 Gear, Spur, Drive Unit
27 Fitting, Grease
28 Shim
29 Shim
32 Cover, Shim

Special Tools
The tool shown in Figure 7-55 is recommended

for removal/installation of the drive unit.
Figure 7-55. 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.
shown on a 10.5 in. 5/16 in. (8 mm) steel
(266.7 mm) bolt circle (used to
(266.7 mm) bolt circle plate 11.25 in.
separate tool from drive unit)
(286 mm) in diameter

Troubleshooting
Table 7-5. 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

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

Radial Ring Inspection Figure 7-56.

7400_radialRing1.jpg
Dial Indicator Placement
NOTE: This inspection applies to Model 7400

and 7420 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.

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 7-56.
NOTE: When positioning the indicator, try to
align it with a feature on the truck (such Drive Unit Removal
as a grease fitting). This will help 1. Turn the key switch OFF and disconnect
maintain consistent results between the battery connector.
trucks.
2. Drain the oil from the drive unit.
3. Zero the indicator and lower the truck to 3. Loosen the drive tire lug nuts.
the floor. Observe the new indicator
reading. 4. Remove the horn assembly.
4. If the reading exceeds 0.090 in. (2.3 mm), 5. Disconnect the power cables from the
the radial rings should be replaced. Traction Motor, labeling the cables if
necessary for later installation. Use two
NOTE: Any looseness which results in the pivot wrenches to avoid twisting the motor
ring casting contacting the drive unit studs.
housing as the unit turns during
6. Disconnect remainder of wires and brake
steering requires the radial rings to be
hose.
changed immediately.
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, Drive Unit Disassembly
construct the tool shown in Figure 7-55.
Attach the tool to the top of the drive unit Numbers within brackets [ ] correspond to item
using the screws which held the Traction shown in exploded view, Figure 7-54 on
Motor. page 7-42.
11. Remove the dust shield between the ring
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 (12].
Visually inspect the outside of the housing [1]

Use extreme caution whenever the lift 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 [18], remove the grease
vehicle while jacking the lift truck. See fitting [21] and the bearing filler plug [20].
“Jacking Safety” on page 2-8. Inspect the bearing filler plug hole for
uneven wear.
12. Secure the lift truck with a suitable
capacity hoist attached to the overhead Figure 7-57. Remove Grease Fitting and Filler Plug
guard. Jack the rear of tractor so that the 1018_003.tif
bottom edge of the bumper is approx. Filler Plug

6.5 in. (16.5 cm) off the floor.
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
Pivot Ring
in Step 10.
2. Turn the pivot ring [18] to remove the steel

Drive unit weighs approx. 175 lb. balls [25] through the bearing filler plug
(80 kg.) hole.
NOTE: If the pivot ring does not spin or turn, it
16. Loosen, then remove the four mounting is an indication of damaged radial rings
screws holding the drive unit to the tractor and/or excessive wear to the channel in
frame. The steering stop also becomes housing. If this is the case, replace the
unattached at this stage. entire drive unit. No further disassembly
17. Lower the drive unit to the floor. Tip the is necessary.
drive unit over on its side and remove the
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.


Figure 7-58. Remove Steel Ball Bearings Figure 7-60. Remove Radial Rings
1018_002.tif 1018_001.tif
Radial Rings
3. After removing all the steel balls, remove

the pivot ring [18] by working it off toward Main Cover and Output Shaft
drive end of the housing. Disassembly
Figure 7-59. Remove Pivot Ring 1. Visually inspect the housing around the
1018_004.tif
main cover [16] for wear outside the cover

bolts [13]. Refer to Figure 7-61.
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.
2. Remove the main cover bolts [13].
3. Using a mallet, knock the flanged output
shaft [9] to break the seal on the main
cover [16].
4. Remove the radial rings [24] from the 4. Remove the main cover and output shaft
channel in the housing and inside the assembly. Refer to Figure 7-61.
pivot ring. 5. You need a press and 8 x 6 in. tube to
remove the bearing cup [14] on the end of
the output shaft.
Due to normal wear, the edges of the
radial rings could be very sharp.
5. Clean the grease from the radial ring

channel in the housing. Inspect the
channel for uneven wear. Also clean and
inspect the inside of the pivot ring.

flanged output shaft [9] and the output

bearing spacer [10] out.
Always watch for pinch points when 9. Remove the exterior retaining ring [11].
using a press or pressing tools.
Figure 7-63. Press Out Output Shaft
1018_011.tif
Figure 7-61. Remove Cover and Output Shaft

1018_005.tif
Main Cover
10. To remove the bevel gear [7], support the

main cover assembly on 8 x 6 in. tube
under press. Press the output shaft
[Item 9] down through the bevel gear. The
Safety glasses are required after this bearing cone [14] is removed at the same
point in disassembly. time.
6. Place the main cover assembly, gear side Figure 7-64. Remove Bevel Gear
down, on the tube under press. Press the 1018_012.tif
output shaft [9] down slightly to create a

space between the bevel gear [7] and the
output bearing spacer [10].
Figure 7-62. Press Down Output Shaft

1018_010.tif
Output Shaft
Output Shaft
11. Remove the bearing cup [8] from the main

cover with a race driver and pry bars.
12. Remove the lip seal [15] from the main
Bevel Gear cover.
7. Tighten a bearing puller clamp under the

lip of the output bearing spacer, being
careful not to catch the exterior retaining
ring [11]. Refer to Figure 7-63.
8. Place the main cover assembly, gear side
up, on 12 x 6 in. tube so the bearing puller
clamp is resting on the tube. Press the


Figure 7-65. Remove Bearing Cup and Lip Seal Figure 7-67. Remove Clamp Nut
1018_013.tif 1018_006.tif
Lip Seal
Clamp Nut
13. Remove the output shaft bearing cone [8] 2. Using a brass punch and hammer, drive
in the base of the housing using two pry the spiral pinion [7] out of the housing.
bars. Insert the pry bars under bottom
NOTE: You may need to remove the spiral
edge of the cone on opposite sides. Apply
pinion with a press or pressing device
even pressure on both tools to lift the cone
equivalent.
out.
Figure 7-68. Remove Spiral Pinion
Figure 7-66. Remove Output Shaft Bearing Cone 1018_007.tif
1018_009.tif
Helical Gear
Output Shaft
Bearing Cone
3. Remove the helical gear [3] and the

14. Remove the shims [28] from the housing
bearing cone [5] from the housing.
bore. Save shims for reference only, as
they are usually damaged when removing 4. Drive out the bearing cup [6]. Inspect the
the bearing cone. New shims are provided bearing cup and housing bores for wear.
with Kits #1 and #2. NOTE: The bearing cups and cones are usually
15. Remove the cover shims [32]. Save the damaged during removal. Replace them
shims for reference only. Replacement as sets; they are included with Kits #1
shims are provided with Kits #1 and #2. and #2.
Spiral Pinion Disassembly

NOTE: The spiral pinion and bevel gear are a
matched set. Their alignment is critical.
Do not replace them separately.
1. Loosen the set screw on the clamp nut [4]
on the spiral pinion [7]. Remove the clamp
nut.


Figure 7-69. Remove Bearing Cup
1018_008.tif
Always watch for pinch points when

using a press or pressing tools.
3. Press the bearing cone [5] onto the spiral

pinion [7] until it is seated.
Figure 7-71. Press Bearing onto Spiral Pinion

1018_015.tif
Bearing Cup
Bearing Cone
Thoroughly wash the housing and visually
inspect entire housing again for excessive
damage, wear, or cracks.
Spiral Pinion
Drive Unit Assembly
Safety glasses are required. Main Cover and Output Shaft

Assembly
Prepare the housing for assembly by running a
tap through all bolt and screw holes. Cleaning 1. Prior to installing the output shaft lip seal
the threads also makes sure that there is no [15], apply a thin layer of sealing adhesive
damage. around the seal surface of the main
housing, to prevent leaking. Install the lip
Spiral Pinion Assembly seal, spring side down, in the housing.
2. Press the lip seal [15] into the housing
1. Using a press or mallet, install the bearing until it is just below flush with housing
cup into the housing bore. surface.
2. Install the second bearing cup [6] into the
housing bore on the opposite side. Figure 7-72. Press Lip Seal
1018_016.tif
Figure 7-70. Drive In Bearing Cup

1018_014.tif
Lip Seal
Bearing Cup 3. Press the output bearing cup [14] into

main cover until it is seated. Place the
bearing cone into the bearing cup.

4. Push down on the bearing and turn to seat Figure 7-75. Install Main Cover and Bearing Cone
bearing into the bearing cup.
1018_021.tif
Bearing Cone
Figure 7-73. Press Output Bearing Cup
1018_017.tif
Output
Bearing Cup
Output Shaft
10. Press the bearing cone onto the output

shaft.
5. Take a measurement from the edge of the Figure 7-76. Press on Bearing Cone
bearing cone [14] to the flange surface of
1018_020.tif
main cover [16]. Make sure that dial

indicator tips come into contact with
flange surface.
Figure 7-74. Bearing Cone to Flange Measurement

1826_127.tif
11. Place the bevel gear [7] down over the

output shaft, teeth side up. Pressing the
bevel gear down seats the bearing cone
[14] into the bearing cup.
Figure 7-77. Press on Bevel Gear

6. The reading on the two dial indicators
1018_022.tif
should be the same. If they are different, Bevel Gear

repeat steps 4 and 5 until the readings are
identical. Record final reading as
Measurement D on flange surface. This is
required during final assembly.
7. Remove the bearing cone [14] in
preparation for installing the flanged
output bearing shaft [9].
8. Use a light oil on the surface of the lip seal
[15] and inside the bearing cup [Item 14]. Bearing Cone
9. Place the main cover down over the output
12. Install the external retaining ring [11] on
shaft, flange side up. Place the bearing
the output shaft [9]. Pull up on the bevel
cone [14] down over the output shaft [9].
gear [7] to make sure the external
retaining ring is installed securely.

13. Place the output bearing spacer [10], with Figure 7-80. Bearing Cup to Flange Measurement
the recessed area down, over the output
1826_130.tif
shaft. Place the bearing cone [Item 8] on

top of the output shaft.
14. Press the bearing cone [8] down until it is
fully seated against the spacer and snap
ring.
Figure 7-78. Press Down Bearing Cone

1018_023.tif
Bearing Cone
18. Record final readings as Measurement E.

This is required during final assembly.
Helical Gear Assembly

Output NOTE: The pinion shaft and bevel gear are a
Bearing matched set. Their alignment is critical.
Spacer
Do not replace them separately.
15. Place the main cover assembly, flange side
up. Press the bearing cone [8] into place.
At the same time, pull the gear sideways to
eliminate any backlash in the spline area. Bearing can become extremely hot. Use
gloves to protect hands from burns.
Figure 7-79. Eliminate Backlash
1018_024.tif
1. Preheat the bearing cone with a bearing

heater. Install the heated bearing cone in
Bearing Cup the bearing cup [6] in the housing.
NOTE: Complete steps 2 thru 4 before the
bearing cools.
2. Place the helical gear [3] into the housing.
3. Install the spiral pinion [7] up through the
helical gear [3].
4. Put the clamp nut [4] on the end of the
spiral pinion [7] and hand tighten until the
16. Place bearing cup [8] onto bearing and bearing cools.
rotate cup while applying downward
pressure to seat bearing.
17. Position dial indicator onto the main cover
so that the tips rest on the bearing cup.
The readings on the two dial indicators
should be the same. If they are different,
repeat steps 15 and 16 until the readings
are identical.


Figure 7-81. Install Helical Gear and Pinion S2 = E + S1 - B - 0.006 preload
1018_027.tif
Clamp Nut S2 = Shim amount between cover plate face to

set preload of bearings for output shaft (S2).
S3 = J – F – G
S3 = Shim amount between drive unit housing

and lower bearing on spiral pinion.
Figure 7-82. Bearing Cone to Flange Measurement

1826_127.tif
Helical Gear
5. Remove clamp nut [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 [6] is cooling,
calculate the formula for determining the
required shim [28] thickness.
Calculate Shim Formulas

Figure 7-83. Bearing Cup to Flange Measurement
• A = Dimension A stamped on housing 1826_130.tif
(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 7-82)
• E = Distance from bearing cup to flange
surface (see Figure 7-83)
• F = Mounting distance etched on spiral
pinion
• G = Distance from top of teeth on spiral Installing and Testing Shims
pinion to top of lower bearing cup on spiral
1. Remove any end play in the bearings
pinon
between the helical gear [3] and the spiral
• J = Distance from centerline of output gear [7] using lock nut wrench. Wedge the
shaft to top of lower bearing cup on spiral helical gear, and tighten the clamp nut [4]
pinion until there is no end play between the
gears.
S1 = (B - A - E + D + C)
S1 = Shim amount behind bearing cup in main

housing to position gear for correct backlash
(S1).


Figure 7-84. Remove End Play Figure 7-85. Mark Spiral and Bevel Gears
1018_028.tif 1018_029.tif
Spiral Gear
2. Preload the helical gear [3] for 0.000 to 7. Place the predetermined shims [28] into
0.002. the housing bore for the bearing cup [8].
3. Remove any oil from the clamp nut Install the bearing cup into the housing
[Item 4]. Apply thread-locking compound bore over the shims.
(P/N 990-544) to the threads in the clamp 8. Install the cover shims [32].
nut. Tighten the set screw in the clamp
nut to 140 in. lb. (15.8 Nm). Figure 7-86. Install Cover Shims
1018_030.tif
4. Spin the helical gear [3] to make sure the

bearings are not too tight. The helical gear
must spin freely for at least one full
rotation.
5. Only perform the following procedure if
the helical gear assembly is too tight.
a. Unscrew the clamp nut [4] the width of
one spanner slot (0.188 in./4.77 mm).
b. Tap the spiral bevel gear [7] to unseat
Cover Shim
the bearing cone.
c. Place the predetermined shims
9. Place the main cover assembly over the
[29] in the housing bore for the bearing
shims, making sure to line up the marked
cup [5].
teeth on both the spiral and bevel gears
d. Install the spiral pinion gear and helical [7].
gear. See “Helical Gear Assembly” on
10. Put in four housing cover bolts [13], evenly
page 7-54.
spaced, and tighten to 40 ft. lb. (54 Nm).
e. Repeat steps 1 thru 4 until the helical
gear spins at least one full rotation.
6. One tooth on the spiral gear [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 [7] to check
backlash. One tooth on the matching bevel
gear is also marked. Mark that tooth
surface also.


Figure 7-87.
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 [32] and the main
cover assembly. Install the main cover
bolts [13], and torque to 40 ft. lb. (54 Nm).
Pivot Ring Assembly

Bevel Gear
Safety glasses are required.

Measuring Backlash
1. On the inside of the pivot ring [18], make
NOTE: Backlash tolerance is critical to the sure the roll pins [19] are installed and in
performance of the drive unit. Improperly good condition on either side of the
adjusted units will experience premature bearing filler plug hole. If they are missing
failure. or damaged, install new roll pins.
1. Wedge the helical gear [3], then slightly
turn the output shaft to determine Figure 7-89. Install Roll Pins
1018_035.tif
backlash. Backlash reading on the dial

indicator should be between 0.004 and Pivot Ring
0.006.
Figure 7-88. Backlash Measurement

1826_131.tif
Roll Pin
2. Install the grease fitting [27] on the outside

of the pivot ring.
3. Screw the grease fitting [21] in the bearing
filler plug.
4. Install radial rings [24]. Install the flat
2. Calculate any necessary adjustments to
radial ring on the inside flat surface of the
the shims. Remove the main cover
pivot ring. Place the ends of the chamfered
assembly and the bearing cup, and adjust
radial rings against the roll pins [19] to
the shims. Repeat Steps 6 thru 9
install them in the pivot ring.
“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.


Figure 7-90. Install Radial Rings Figure 7-92. Install Ball Bearings
1018_036.tif 1018_038.tif
Radial Rings Steel Ball
Roll Pins
5. Install the outer radial rings [24] on the

housing. Refer to Figure 7-91.
Figure 7-91. Install Outer Radial Rings Excessive thread-locking compound will
1018_037.tif damage the ball bearings and pivot
ring. Use thread-locking compound
Outer
Radial Ring
sparingly.

(P/N 990-536) sparingly to the filler plug
bolts [22]. Install the bolts and washers
[23] on either side of the bearing filler plug
[20] and tighten to 20 ft. lb. (27 Nm).
11. Grease and then test the pivot ring,
checking to see that it spins freely.
Figure 7-93. Install Bearing Filler Plug

6. Lift the drive end of the housing and slide 1018_040.tif
the pivot ring over the housing. Be careful

Filler Plug and
not to jar the radial rings out of place. Filler Plug Bolt
Grease Fitting
Slide the pivot ring into place just behind
the spur gear [26].
7. Make sure the pivot ring bearing filler plug
hole is on top, in preparation for installing
the steel balls [25].
8. Put one ball at a time into the pivot ring
filler hole. Use a screwdriver to direct the
steel balls first to one side then the other. Washer
Continue until all 70 balls are installed.
9. Install the bearing filler plug [20] with the
grease fitting [21] pointing toward the spur Drive Unit Installation
gear [26].
1. Place the new drive unit in position.
(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 toque 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.

Brake (Adjustable) Drive and Brake
Brake (Adjustable)
NOTE: This procedure applies to adjustable
style brakes with a gold anodized finish.
Figure 7-94. Brake cross-section

Brake Engaged-7400-Gold.jpg
Coil Body Locking

Brake Armature 0.007 in. Bolt
Pad Plate Shim
Shoulder Total
Bolt Air Gap
Rotor 0.030 in.
Adjuster
Lock Nut
Total
Lower Air Gap
Air Gap Adjuster
0.012 in.
Base Brake
Plate Pad
Lower
Air Gap Encoder
Adjuster Bearing
Figure 7-95. Brake gaps

Brake Disengaged-7400-Gold.jpg
0.007 in.
Gap
0.011 in.
Gap
0.012 in.
Gap
0.030 in.
Total
Air Gap

Drive and Brake Brake (Adjustable)

Figure 7-96. Brake Assembly
R1025424_D.cgm
Brake Pads
Baseplate
Brake Pads (3)
Spacer
Lower Air Gap

Adjusters Springs
Coil Body
Rotor
Air Gap Adjusters Armature

Plate
Locking Bolts
Brake Adjustment 2. Turn the steering wheel all the way left or
right.
Use extreme caution whenever the lift 4. Open Traction Motor compartment door.
truck is jacked up. Never block the lift Remove cable ties holding the cable
truck between the telescopic and the bundle to the brake assembly.
mast. Keep hands and feet clear from NOTE: Make sure to adjust both the total air
vehicle while jacking the lift truck. After gap and lower air gap. See Figure 7-94
the lift truck is jacked, place solid blocks and Figure 7-95 on page 7-60.
or jack stands beneath it to support it. 5. Adjust the total air gap at each of the three
DO NOT rely on the jack alone to total air gap adjusters:
a. Loosen the locking bolt.
b. Turn the total air gap adjuster until
NOTE: If black lower air gap adjuster nuts there is a 0.030 in. (0.762 mm) gap
crack, replace with zinc-plated nuts. between the armature plate and the coil
body, close to the adjuster and at the
1. Jack up the lift truck so the drive wheel is
outer perimeter of the brake
off the ground.
(Figure 7-98).


Figure 7-97. Loosening brake locking bolt b. Turn the hex head adjuster under the
base plate (Figure 7-101) until there is
D20000054_5bw.jpg
a 0.012 in. (0.305 mm) gap between the

adjuster and the top surface of the
Traction Motor (Figure 7-100).
c. Tighten the locking nut while holding
the adjuster with another wrench.
Figure 7-100. Measuring brake lower air gap

D20000054_3bw.jpg
Figure 7-98. Adjusting total air gap

D20000054_6bw.jpg
Figure 7-101. Adjusting brake lower air gap

D20000054_4bw.jpg
c. Tighten the locking bolt before

measuring the gap.
6. Adjust the air gap at each of the three
lower air gap adjusters:
a. Loosen the locking nut on top of the
base plate.
Figure 7-99. Loosening brake base plate locking nut

D20000054_2bw.jpg
the key switch ON.
8. Turn the steering wheel carefully until the
next set of adjusters is accessible. Make
sure the loose cables do not catch on
adjacent parts.
10. Repeat steps 6 thru 9 until you have
adjusted all air gap adjuster sets.
11. Torque total air gap locking screws to
17 ft. lb. (23 Nm).

12. Measure all gaps again. Readjust as brake rotor as the retaining nut is
needed. removed.
13. Install cable ties removed previously.
Figure 7-102. Locking Brake Rotor
14. Close the motor compartment door. image037.jpg
Remove blocks and lower the lift truck to

the floor. Coil Body Locking Bolt
15. Reconnect the battery connector and turn “Brake3.doc” photo 8
the key switch ON.
16. Test the brake for correct operation.
Brake Pad Inspection

Spacer
Replace brake pads if they are:
• contaminated by oil or other chemicals
(contamination cannot be removed by Upper Pressure Plate
cleaning with solvents)
8. Remove the retaining nut from the
• worn to within 0.020 in. (0.5 mm) of the
Traction Motor shaft.
rivet heads
9. If you used an air wrench to remove the
Brake Assembly nut, skip to step10. Otherwise, loosen the
locking nut. Remove the spacer.
Removal and Disassembly 10. Remove the three shoulder bolts that hold
the brake base plate to the motor end bell.
NOTE: You can remove the entire brake
assembly without disassembling it and 11. Using a brake puller threaded for M6,
without using the brake release bolts. remove the brake assembly from the lift
truck. See Figure 7-103.
the battery connector. Figure 7-103. Pulling brake assembly
DSCF2954c.JPG
2. Chock the drive tire to prevent movement.

3. Remove the top cover and open the motor
compartment door.
4. Note the location of cable ties securing the
cable bundle to the cable bracket. Cut
cable ties to free the cables from the
bracket. Remove the cable bracket.
5. Scribe a witness mark down the side of the
brake to help orientation during
reassembly.
6. If you are replacing only the brake coil or
upper brake pad, skip to step 12.
7. If you have an air wrench available, skip to
step 8. Otherwise, loosen one of the
locking bolts enough to insert a penny or 12. Install and tighten brake release bolts in
similar spacer between the armature plate brake release holes. See Figure 7-94 on
and coil body. Do not turn the total air gap page 7-60.
adjuster. See Figure 7-102. Tighten the 13. Remove the three bolts holding the coil
locking bolt to lock the armature plate to and armature plate to the base plate.
the coil body. This prevents rotation of the Remove coil and armature plate (with

upper brake pad). If you performed steps 7 Figure 7-104. Lower Cable Bracket
thru 11, the rotor and base plate (with
bracket2.jpg
lower brake pad) are now free. Sleeve Spacer

14. Remove the three total air gap adjusters
from the brake coil body.
15. The brake release bolts are under tension
from springs inside the coil body. Carefully
loosen and remove the brake release bolts.
Separate the coil from the armature plate.
Motor
Reassembly and Installation Harness
1. With the new coil inverted, make sure all Lower
springs are inserted into the holes in the Bracket
coil body.
2. Place the thin washer shaped spacer on 11. Install the brake assembly over the
the springs. See Figure 7-96 on page 7-61. Traction Motor shaft, aligning holes with
the Traction Motor end bell.
3. Place the inverted armature plate on the
coil directly on the spacer. 12. Thread three shoulder bolts through the
base plate into the motor end bell. Torque
4. Thread the three total air gap adjusters to 16 ft. lb. (21.7 Nm).
into the brake coil body.
13. Remove brake release bolts and install in
5. Thread the brake release bolts through the their storage locations.
coil and armature plate and draw tight.
14. Loosen one of the locking bolts enough to
6. Assemble base plate, rotor, and armature insert a penny or similar spacer between
plate/coil. Witness mark on parts not the armature plate and coil body. Do not
replaced may aid in orientation. Install turn the total air gap adjuster. See
three locking bolts through coil, armature, Figure 7-102 on page 7-63. Tighten the
and base plate. locking bolt to lock the armature plate to
7. Torque the three locking bolts to 16 ft. lb. the coil body. This prevents rotation of the
(21.7 Nm). brake rotor as the retaining nut is
8. If you did not previously remove the entire removed.
brake assembly (rotor and base plate), 15. Install the rotor retaining nut and washer
skip to step 17. and torque to 150 ft. lb. (203 Nm).
9. Traction Motor P/N 1029753/600 or 16. Loosen the locking bolt. Remove the
1029754/600 only: Make sure the sleeve spacer.
spacer on the Traction Motor shaft is 17. Adjust the brake gap. See “Brake
seated all the way down onto the encoder Adjustment” on page 7-61.
bearing. See Figure 7-105 on page 7-65.
18. Attach the motor cable bracket to the
10. Traction Motor P/N 1029753/600 or brake. Apply thread-locking compound
1029754/600 only: Make sure the (P/N 990-536) to the bolts and torque to
improved lower cable bracket P/N 6 ft. lb. (8 Nm).
1047867 is installed on the Traction Motor
end bell. See Figure 7-104. 19. Attach the cable bundle to the cable
bracket with cable ties installed where
previously removed.
20. Make sure brake operates correctly and
Traction Motor rotates without
interference to motor cables.

NOTE: When the truck is stationary, depressing

and releasing the deadman pedal should
cause the brake to release and engage.
When the truck is traveling, the brake
should remain released (coil energized)
until the truck speed reaches zero.
Figure 7-105. Traction Motor Shaft Sleeve Spacer Orientation (Motors P/N 1029753/600 and 1029754/600)
710680_NOK_Full.cgm,10680_OK_Full.cgm,10680_NOK_detail.cgm,10680_OK_detail.cgm
Incorrectly Seated Correctly Seated
Motor Shaft
Sleeve Spacer
End Bell
Encoder Bearing
Motor Shaft Motor Shaft
Sleeve Spacer Sleeve Spacer
End Bell
End Bell
Shoulder
Shoulder
Encoder Encoder
Bearing Bearing

Brake (Floating Disk) Drive and Brake
Brake (Floating Disk) 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
NOTE: This procedure applies to floating disk
measured total air gap (non-energized) and
style brakes with a black anodized
insert between the armature plate and the
finish.
coil body. Tighten the locking bolt just
enough to prevent rotation of the motor
Inspection shaft.
1. Turn the key switch OFF and disconnect 7. Remove the retaining nut and washer from
the battery connector. the motor shaft. See Figure 7-106.
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 7-106. If air gap exceeds 0.040 in.
(1 mm), replace the brake pads. See “Pad Pad Replacement
Replacement”.
1. Install the brake release bolts.
Figure 7-106. Checking Brake Air Gap
brake3.JPG
NOTE: Do not overtighten the brake release
bolts.
2. Turn the brake assembly over and remove
Motor the three bolts securing the adapter plate.
Shaft
See Figure 7-107.
Brake Figure 7-107. Adapter Plate Removal
Mounting brake1.JPG
Bolt (qty. 3)
Armature
Armature
Plate
Adapter Spacer
Plate
Brake Removal
2. Block the drive tire to prevent movement. Adapter
Plate Bolts
3. Open the motor compartment door.
4. Note the location of cable ties securing the
motor cable bundle to the cable bracket. 3. Remove adapter plate. Inspect spacers and
Cut cable ties to free the cables from the replace if damaged.
bracket. Remove the cable bracket. 4. Remove old pads from carrier and install
5. Disconnect brake armature lead new pads. See Figure 7-108.
connection.

Drive and Brake Brake (Floating Disk)

Figure 7-108. Pad Replacement
brake1.JPG
Brake Installation
Small Flange 1. Correctly position brake assembly on
Carrier
(large flange motor, making sure the keyways on the
opposite side) motor shaft and carrier are correctly
aligned.
NOTE: On Traction Motors P/N 1029753/600
and P/N 1029754/600 only, make sure
the sleeve spacer (P/N 1070472) is
installed on the motor shaft and seated
all the way down on the bearing.
2. Gently tap the carrier flange onto motor
shaft until seated.
Pad (qty. 6)
(P/N 990-536) and install the three brake
5. Install adapter plate. Torque adapter plate mounting bolts. Torque to 16 ft. lb.
bolts to 6 ft. lb. (8.6 Nm). (21.7 Nm).
NOTE: Leave the brake release bolts installed 4. Remove brake release bolts and install in
for reassembly to motor. their storage locations.
5. Loosen one of the retainer bolts and insert
Coil Replacement a 0.030 to 0.040 in. (0.76 to 1 mm) spacer
between the armature plate and coil body.
1. If installed, carefully remove the brake Tighten the retainer bolt just enough to
release bolts. Separate the coil from the prevent rotation of the motor shaft as the
armature plate. retaining nut is being torqued.
NOTE: The brake release bolts are under 6. Install retaining nut and a new washer to
tension from the springs inside the coil motor shaft. Torque retaining nut to 150
body. ft. lb. (203 Nm).
2. With the coil inverted, make sure all eight 7. Loosen the retainer bolt and remove the
springs are inserted into the cavities. spacer.
NOTE: On coils with ten spring cavities, the two 8. Attach the motor cable bracket. Apply
empty cavities must be 180° apart. thread-locking compound (P/N 990-536)
to the bolts and torque to 6 ft. lb. (8.6 Nm).
3. Place the thin washer shaped spacer over
the springs. 9. Attach the cable bundle to the cable
bracket with cable ties and connect the
4. Note the orientation and place the inverted brake armature lead connector.
armature plate on the coil directly over the
spacer. 10. Unblock the drive tire. Reconnect the
battery connector and turn the key switch
5. Assemble the armature and coil: ON.
a. Using a clamp, mate the armature plate 11. Make sure brake operates correctly and
to the coil. Make sure the thin washer traction motor rotates without interference
is correctly aligned. to motor cables.
b. Install the brake release bolts through
NOTE: When the truck is stationary, depressing
the coil and armature plate and tighten.
and releasing the deadman pedal should
6. Install carrier, pads, and adapter plate. cause the brake to release and engage.
Torque adapter plate bolts to 6 ft. lb. When the truck is traveling, the brake
(8.6 Nm). should remain released (coil energized)
until the truck speed reaches 0.5 mph.

Deadman Switch (S2) Drive and Brake
Deadman Switch (S2)

Figure 7-109. Deadman Sensor and Switch
R1011291_D1.cgm,R1011291_D2.cgm
Connector
Sensor VR4
Jam Nuts
Switch S2
Adjustment 3. With the deadman pedal adjusted and in

the fully up position, set the gap between
1. Adjust deadman pedal height by adjusting deadman switch roller and the cam
the two jam nuts on the pedal pushrod surface on the pedal casting.
until the dimension between top of pedal
a. Loosen switch mounting screws and
tip and top surface of bracket bottom is:
slide the switch to establish a gap of
a. Series AA/BA/CA (Fore-Aft Stance): 0.001 to 0.005 in. (0.025 to 0.127 mm).
3.50 in. (89 mm) Retighten screws.
b. Series DA/EA/FA (Side Stance): 4. Repeat steps 2 and 3 until both pedal
3.58 in. (91 mm) travel and switch gap dimensions are
Tighten the jam nuts against each other. correct.
2. Adjust the deadman switch S2 by
loosening the two switch mounting screws
and sliding the switch along the curved
slots. Retighten mounting screws.
a. Switch should activate when pedal is
depressed 0.50 to 0.75 in. (13 to
19 mm) from the top. Verify switch
activation either by hearing the click or
by measuring continuity across switch
terminals with a DVM.

Drive and Brake Inertial Dampener
Inertial Dampener
Figure 7-110. 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 7-111. 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
(1 (1
9/16
9/16
in.in.
oror
4040
mm)
Caster” on page 7-26. If extra A-frame
travel is required such that stop bolt
adjustment cannot be maintained, Spring
remove the inertial dampener. 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 7-111. clearance between the dampener bolts and
the bottom of the slot in the slide plate.
See Figure 7-112 and Figure 7-116 on
page 7-71.

Inertial Dampener Drive and Brake
6. Remove the cap screws holding the slide Figure 7-113. Inertial Dampener (A-frame springs, slide
plate mounting bracket to the frame. plate removed)
13y7s004.tif
Remove the bracket. See Figure 7-112.

Friction Plate
Figure 7-112. Inertial Dampener (nuts, retainer, springs,
friction plate removed)
13y7s002.tif
Cap Screws
A-frame
Spring Slide
Plate Bolt
Figure 7-114. Inertial Dampener (jacked up for shoulder

A-frame Down-Travel bolt removal)
Adjustment Bolt 13y7s005.tif
A-frame Friction Plate

7. Loosen the A-frame down-travel Down-Travel
adjustment bolt and remove the bolt and Adjustment
washers. Bolt Hole

floor. Use a suitable hoist to stabilize the Bolt
mast. Keep hands and feet clear from Thread-Locking
vehicle while jacking the lift truck. After Compound
or jack stands beneath it to support it. Installation and Adjustment
support the lift truck. See “Jacking 1. Attach the friction plate to the A-frame
Safety” on page 2-8. yoke with the bolt and nylon lock nut.
2. Install the A-frame springs. Lower the lift
8. Jack the tractor up approx. 2 in. (5 cm) at truck slightly on the jack to seat the
the tractor frame and block. See springs in their retainer holes.
Figure 7-114.
3. Install the A-frame down-travel
9. Remove the A-frame springs. See adjustment bolt with the plastic washer
Figure 7-112 and Figure 7-113. between the metal washer and the frame.
10. Remove the bolt holding the friction plate Tighten until the distance between the top
to the A-frame yoke. See Figure 7-113 and of the A-frame and the bottom of the
Figure 7-114. A-frame spring upper weldment is 7 in.
(17.7 cm).

Drive and Brake Inertial Dampener

Figure 7-115. 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).
Figure 7-116. 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.
Reference Figure 7-115 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 7-111 on
page 7-69.
7. Adjust the idler. See “Steerable Caster” on
page 7-26.

Inertial Dampener Drive and Brake

Electrical Components
Electrical Components

Battery Procedures Electrical Components
Battery Procedures 5. Look inside the connector. Check all

internal contacts for damage, dirt, or
corrosion. Do not use a metal object to
clean the connector.
Before working on the battery, review

Battery Safety, beginning on page 2-5.
Batteries for this lift truck weigh Some degreasers and parts cleaners will
between 2000 and 2900 lb. (908 to cause the connector shell to disintegrate.
1316 kg). Use extreme care during Avoid contacting battery connectors with
replacement. Use a suitable battery solvents.
moving device or hoist for lifting. Do not
extend a battery more than 1/3 of its Removal, Replacement, and
length outside the battery compartment Installation
without being attached to a
battery-moving device. The cables to either half of the connector have a
lip on their forward end. This lip snaps over a
Battery Connector/Cables spring-loaded retainer that is part of the
connector.
Location Figure 7-118. Battery Cable and Connector
Battcon2.tif
The battery connector is located at the

front-right of the tractor, above the battery.
Figure 7-117. Battery Connector location

6353_118g.jpg
Battery
Connector
When replacing battery cable ends,

remove only one end at a time from the
Inspection connector to avoid the cable ends
touching and causing a short circuit. Do
1. Turn the key switch OFF and disconnect not allow the metal cable end to touch
the battery connector. the battery. Use insulated tools and
2. Check the battery connector for damaged avoid contact with battery case or cable
cables. ends.
3. Check to see if battery cables are pulling 1. To remove a cable from the connector,
out of the connector. push the retainer down while pulling the
4. Check the cables at the battery terminals. battery cable towards the rear and out of
Connections should be tight, with no the connector. See Figure 7-119 and
corrosion. Figure 7-118.

Electrical Components Battery Procedures

Figure 7-119. Battery Cable Removal from Connector 2. Wear personal protective equipment. See
“Battery Safety” on page 2-5.
Battcon1.tif

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 7-120. Battery Cable and Filler Plug

09g6s047.tif
Battery Cable
2. Do not attempt to repair battery cables by
crimping new terminals. Replace the
cable.
Disconnect blocks
Model 7400/7420/7440 lift trucks use an

electrical EPO system, so battery connectors do
not need to have battery disconnect blocks
installed. Filler Plug
Vent Hole
Beginning with serial number 05498, battery
connectors with disconnect blocks attached can 5. Keep the top of the battery clean and dry.
experience interference with the side plate of Corrosion, dust, and moisture provide a
the tractor. conducting path to short-circuit cells or
create shorts to ground.
In such cases, remove the disconnect block
from the connector. If this is not practical,
replace the battery connector mounting bracket
(P/N 1009263) with a new style (P/N 1063890). Do not clean the top of the battery with
the soda solution while it is installed in
Battery Exterior Cleaning the lift truck. Water can seep into the
electrical components and cause serious
1. Read, understand, and follow procedures, damage.
recommendations and specifications in the
battery and battery charger 6. Wash dirty batteries (or any that have had
manufacturer’s manuals. electrolyte spilled on them) with a solution
25l6s014.eps
of 1 lb. (0.45 kg) of baking soda added to
0.5 gal. (1.9 liters) of hot water.
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.

Battery Procedures Electrical Components
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
Battery State-of-Charge
Battery State-of-Charge (BSOC) is a feature that
monitors and remembers the charge level of the
battery connected to the lift truck and prevents
excessive discharging of that battery. Operating
a lift truck using a discharged battery can
damage both the battery and the electrical
components of the lift truck. Refer to page 5-10
for a detailed description of how BSOC works
and the procedure for setting BSOC Cutout.

Electrical Components Wiring and Harness Connectors
Wiring and Harness When replacing wires, follow these guidelines:

• Use the appropriate tools to remove and
Connectors insert terminations at each connector.
• Remove damaged terminations and
discard. Never reuse a termination from a
General Repair Procedures wire.
See “Electrical Troubleshooting” on page 5-2. • Do not cut away a terminal lug and reuse
the wire strands that were crimped into
Whenever working on the lift truck, use care the original lug.
around wiring harnesses. • When stripping wire, use new wire strands
• Carefully connect and disconnect all for new terminations. Make sure to use a
connections. new wire with extra length to allow for
cutting and stripping of the ends to install
• Do not pry connectors apart with
new terminations.
unspecified tools.
• Use a new wire that is the same gauge
There should be a wire marker at each (typically gauge 18 AWG), size, type, and
termination. If the marker is missing or color as the wire it is replacing.
unreadable, remark the wire to allow easier • Use a hand stripper capable of stripping
identification. by wire gauge number. Use care not to
NOTE: It is normal to find unused connectors nick or cut any of the wire strands.
for uninstalled options that have had Discard and replace a wire with damaged
heat shrink applied over them and have strands. Insert the wire strands the
been strapped to the harness. correct length into termination before
crimping.
Repair
Soldering Procedures
To prevent damage from excessive heat when

Use correct electrostatic discharge soldering small components in assemblies,
precautions. See “Static Precautions” on follow these guidelines:
page 2-7. • Make sure the soldering tip is clean. A
dirty tip does not transfer heat well and
When pulling a wire out through a bundle, cut encourages long dwell time and greater
off the pin or socket so it does not snag. When pressure. Apply light pressure on the
replacing wires, in some cases you can tape or terminal.
solder one end of a new wire to one end of the • Flux: rosin base
failed wire. Then you can pull the old wire out of
the bundle and pull the new wire into the • Solder: 60/40 rosin core or equivalent
bundle, all at the same time. Make sure to • Solder Iron: 15-25 watt “pencil-type”
disconnect the old wire from the new wire. maximum
• Tip Size: 3 mm (0.118 in.) diameter x
In other cases, it is easier to secure a new wire 30 mm (1.182 in.) long screwdriver tip.
to the outside of the existing wire bundle with Make sure the tip is clean.
straps of an appropriate size. You can leave the
failed wire in the bundle, or pull it by one end to • After soldering, clean the terminals with a
remove it from the bundle. brush dampened with an alcohol-based
cleaner (P/N 990-600/FOF). Do not allow
any cleaner to seep into the switches or
potentiometers, or contact contamination
may occur.

Wiring and Harness Connectors Electrical Components
Molex Connectors Molex connector, depress these locking ears far

enough to clear the ridge in the connector.
Figure 7-121. Molex Connector, end view
Pin Extraction
Molex.wmf
Socket To remove a pin from a Molex connector, use

pin extraction tool P/N 950-026.
1. Insert the extraction tool over the pin and
Pin push all the way into the connector. This
releases the locking ears on the pin.
2. Pull the wire and pin from the connector.
Pin Insertion
Locking
To insert a pin into a Molex connector, insert
Ears
the pin into the back side of the connector and
push the wire all the way in until it clicks. The
For pin orientation of Molex connectors, see
locking ears have now engaged the connector.
Figure 6-1 on page 6-27. Molex connectors have
pins with locking ears that engage ridges in the Figure 7-122. Pin Extraction
plastic connector body. To remove a pin from a Molex1.wmf
Top view of
connector Tool inserted over
pin
Extraction
Locking Tool
ears
Side view of
connector
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.


Figure 7-123. 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 2. Pull the wire gently until you feel the
seals, use the following procedures when contact locking lances disengage.
working with AMP connectors. 3. Holding the wire seal and connector
housing together, rotate the wire while
Pin Extraction pulling it through the wire seal. This
prevents damage to the seal. See
To aid in separating AMP connectors, use Figure 7-125.
unlatching tool Raymond P/N 950-042. To
remove a pin from an AMP connector, use pin Figure 7-125. Removing Wire
4570_008.tif
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
Figure 7-124.
Figure 7-124. AMP Pin Extraction

4570_009.tif
Extraction Tool
Rotate and Pull
Pin Insertion
1. Make sure the connector has a wire seal
attached to the connector back. See
Figure 7-126.
Locking
Lance

Wiring and Harness Connectors Electrical Components

Figure 7-126. Wire Seal 4. Remove sealing plugs by pulling with
needle-nose pliers while grasping the wire
4570_002.tif
Wire Seal seal and connector.
Figure 7-128. Sealing Plug

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. Grasp the wire close behind the contact
insulation barrel and push the wire 5. Use an interface seal between pin and jack
straight through the wire seal into the halves of the connector. To prevent
socket until it clicks. Pull back gently to damage to the seal, use the matching
make sure the contact is locked in place. connector cap to slide the interface seal
See Figure 7-127. over the contact silos on the pin housing.
See Figure 7-129.
Figure 7-127. Wire Insertion
4570_004.tif
Figure 7-129. Interface Seal

4570_003.tif
Interface
Seal
Pin Contact
Pin Housing
Seals 6. When mating connectors, make sure

1. Use a wire seal at the back (wire end) of polarized silos are correctly oriented. Push
each connector half. See Figure 7-126. pin and jack halves of the connector
together until locking latches engage. See
2. Plug unused pin positions with sealing Figure 7-130.
plugs. See Figure 7-128.
3. Align the split tapered end of the sealing
plug with the unused opening in the wire
seal. Push the plug through the wire seal
into the connector until it snaps into
position.


Figure 7-130. Latching AMP Connector
4570_006.tif
Locking
Latches

Contactor Panel Electrical Components
Contactor Panel
AC Lift
Figure 7-131. Contactor Panel layout, AC Lift
R1020143_A.cgm
DC Lift
Figure 7-132. Contactor Panel layout, DC Lift
R1013882_A.cgm

Electrical Components Motors
Motors
Terminal Nuts
Table 7-6. 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.

AC Motor Service Electrical Components
AC Motor Service 5. Reinstall cover/door previously removed/

opened.
Refer to the applicable procedure that follows
the key switch ON.
based on the AC motor installed.
7. Test truck for correct operation.
Danaher Motors
Speed Sensor (Encoder) Bearing
Replacement - Lift Motor
Temperature Sensor - Traction and
Lift Removal
Temperature sensors (TMT and LMT) in the AC 1. Turn the key switch OFF and disconnect
Traction and Lift Motors are integral to the the battery connector.
motor. When a motor temperature sensor fails, 2. Remove the lift motor. Place the motor on a
replace it with an externally mounted sensor. bench.
3. Remove the six end bell rod nuts securing
Figure 7-133. Traction Motor External Temperature Sensor
4612_019.tif
the end bells to the motor. A vise grip
pliers is useful in gripping the rods.
Temperature 4. Remove the three machine screws

Sensor securing the encoder assembly to the
upper end bell.
5. Remove the motor end bell.
6. Remove the snap ring securing the speed
sensor bearing.
Power 7. Using a wheel puller behind the bearing
Cables retainer, remove the bearing from the
motor shaft. See Figure 7-134.
Figure 7-134. Speed Sensor Removal

4472_015.tif
Installation (External) Wheel Puller

Bearing Retainer

precautions. See “Static Precautions” on
Sensor Bearing
page 2-7.
2. Disconnect the temperature sensor

connector JPT3 (Traction Motor) or JPL3 Snap Ring
(Lift Motor). Cut the wires from JT3 or JL3
close to the motor body and discard the
cut off connector.
3. Mount the external sensor in a recess
groove in the motor housing and fasten
with adhesive provided with the sensor kit.
4. Reconnect JPT3 or JPL3.

Electrical Components AC Motor Service

Figure 7-135. Speed Sensor Removed Figure 7-137. Shimming the Motor Shaft
4472_016.tif P1010738r.JPG
Bearing Sensor Encoder Bearing

Retainer Bearing
Support Ring
Shim Here
Snap Ring Snap Ring
4. Place the bearing retainer over the

Installation bearing, feeding the cable harness through
1. Make sure you install the bearing retainer the slot in the retainer. Position the
over the motor shaft with the recess bearing so the cable harness is aligned
towards the end bell. with the motor power cables.
2. Place the sensor bearing over the motor 5. Use one of the end bell rods to align the
shaft with the wiring harness in line with end bell temporarily with the bearing
the motor power cables. Place a deep retainer. See Figure 7-138.
socket or pipe nipple with a 1.25 in.
(30 mm) inside diameter over the motor Figure 7-138. Aligning End Bell with Bearing Retainer
4472_018.tif
shaft and onto the bearing inner race. Seat

the bearing firmly with a hammer.
See Figure 7-136.
Figure 7-136. Seating the Bearing

4472_017.tif
3. Install the snap ring. On

P/N 570-610/603 only, use a feeler gauge
to measure the gap between the support 6. Install and tighten the machine screws
ring and snap ring. See Figure 7-137. securing the bearing and retainer to the
Install shims as needed to fill the gap. end bell.

7. Install and tighten the nuts securing the 9. Remove the shield and end bell from the
end bell to the end bell rods. Torque to motor.
55 in. lb. (6.2 Nm).
Figure 7-140. Shield and Harness Orientation
8. Re-install the Lift Motor. rch_08_R007_2.tif
Speed Sensor (Encoder) Bearing

Replacement - Traction Motor
Removal
2. Remove the brake assembly from the
traction motor.
3. Remove the traction motor from the truck
and place it on a suitable work surface.
4. Mark the position of the top end bell
relative to the stator.
10. Remove the connector shield at the side of
5. Remove the four bolts that secure the top
the motor and remove the encoder cable
end bell to the stator.
from the grommet.
6. Remove the three screws from the end bell
11. Using a suitable bearing puller, remove the
that secure the encoder bearing (speed
encoder bearing. See Figure 7-141.
sensor) retainer ring.
7. Work the end bell shield assembly over the Figure 7-141. Bearing Removal
encoder bearing retainer ring and bearing rch_08_R007_3.tif
to allow access to the three screws that

secure the shield to the end bell. See
Figure 7-139.
Figure 7-139. End Bell Shield

rch_08_R007_1.tif
Installation
1. Install the new encoder bearing into the
8. Note the orientation of the shield and end bell noting the routing of the cable.
cable. Remove the three screws that See Figure 7-142.
secure the shield and cable to the end bell. 2. Position the bearing retainer and secure to
See Figure 7-140. the end bell. Torque the retainer screws to
12 to 19 in. lb. (1.4 to 2.2 Nm).


Figure 7-142. Encoder Bearing Cable Routing Figure 7-144. Encoder Cable Grommet
rch_08_R007_4.tif rch_08_R007_6.tif
3. Place the cable in the cloth insulator,

position it on the shield, and fasten it to
5. Place a standard steel pipe with a 1.25 in.
the end bell.
I.D and a 1.5 in. O.D over the motor shaft
NOTE: Make sure the cable is not pinched and press or drive the end bell encoder
during assembly. See Figure 7-143. assembly onto the motor shaft until fully
seated.
Figure 7-143. Harness Position on Shield
rch_08_R007_5.tif NOTE: Do not press on the end bell to install
the encoder bearing. Bearing must be
installed by pressing on the inner race
only. See . Figure 7-145
Figure 7-145. Pressing Encoder Assembly onto Motor Shaft

rch_08_R007_7.tif
4. Align the end bell assembly to the stator.

As the end bell is being positioned, insert
the cable into the rubber grommet. See
Figure 7-144.
6. Insert the four bolts that secure the end

bell to the stator. Torque to 159 to 194 in.
lb. (18 to 22 Nm).
7. Position the encoder connector and fasten
the connector shield.

8. Re-install the traction motor and brake 3. Remove the four bolts that secure the top
assembly. end bell to the bottom end bell.
4. Remove the top end bell.
Sauer Danfoss Motors 5. Cut the bad temperature sensor cable.
6. Install a new temperature sensor using the
Temperature Sensor Replacement high temperature silicone (neutral curing)
supplied with the temperature sensor.
Traction Motor Mount the sensor close to the location of
1. Turn the key switch OFF and disconnect the original.
the battery connector. 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. 10. Reconnect the battery connector and turn
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 - Internal
7. Remove the top end bell using a puller. Bearing Type
8. Cut the bad temperature sensor cable. Traction Motor
9. Install a new temperature sensor using the 1. Turn the key switch OFF and disconnect
high temperature silicone (neutral curing) the battery connector.
supplied with the temperature sensor.
Mount the sensor close to the location of 2. Remove the brake assembly.
the original. Secure the cable with a cable 3. Disconnect the temperature sensor
tie to one of the power leads for stress connector.
relief. 4. Disconnect motor power cables. Note
10. Re-install the top end bell. locations for reassembly later.
11. Re-install the four bolts that secure the 5. Remove the traction motor.
top end bell to the bottom end bell. 6. Place the motor on a suitable work surface
12. Re-install the brake assembly. and remove the nut that secures the
13. Connect the new temperature sensor pinion gear. Remove the gear and key
cable. using a suitable puller.
14. Install the terminal board and reconnect 7. Remove the clamps that secure the
power cables. Torque motor cable securing encoder bearing cable. See Figure 7-146.
nuts to 18 ft. lb. (24 Nm). (Pry the inner clamp up to release the
cable.)
the key switch ON.
Lift Motor
2. Disconnect the temperature sensor
connector.


Figure 7-146. Sensor Bearing Cable Clamps Figure 7-148. 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 7-147. end bell to the bottom end bell. See
Figure 7-149.
Figure 7-147. Component Orientation Marking
rch_06_R011A_2.tif
Figure 7-149. Motor Disassembly
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 7-150.
9. Unscrew the four bolts securing the brake

end flange and remove. See Figure 7-148.


Figure 7-150. Sensor Bearing Removal Figure 7-152. Sensor Bearing Alignment and Insertion
rch_06_R011A_5.tif rch_06_R011A_7.tif
13. Remove the oil seal. See Figure 7-151. Notch

14. Make sure the O-ring and wavey washer
are correctly positioned in the bottom bell
bearing pocket. See Figure 7-151.
Figure 7-151. Bearing Pocket Components Clamps

rch_06_R011A_6.tif
18. Carefully press the bottom end bell to the

O-Ring Wavey Washer stator. See Figure 7-153.
NOTE: Press on inner race of bearing only.
Figure 7-153. 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 7-152.
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 7-152.

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 7-154.
Figure 7-154. 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.
Speed Sensor Replacement -

Externally Mounted
Speed sensors on newer Sauer Danfoss traction

and lift motors are mounted externally. It is not
necessary to disassemble the motor to replace a
bad speed sensor.

Steer Amplifier (AC Lift) Electrical Components
Steer Amplifier (AC Lift) Figure 7-156. Contactor/Fuse Panel

R1020143_A.cgm
Removal
2. Fore-Aft Stance: Remove the top cover,
right side cover, primary control handle
cover, and right front cover.

precautions. See “Static Precautions” on
page 2-7. 6. Open the Traction Motor compartment.
7. Disconnect the steer motor primary power
3. Disconnect wire from TP4. wires at A1 and A2 on the motor. Cut cable
ties as needed.
Figure 7-155. Steer Amplifier Removal
6353_116g.jpg
8. Remove bolts holding steer amplifier to
frame.
Installation
1. Install steer amplifier to frame with bolts.
2. Route steer motor wires to steer motor and
connect. Install cable ties where previously
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.
Steer
TP4 5. Install the contactor cover, right front
Amplifier
cover, primary control handle cover, right
side cover, and front cover. Close the
4. Remove the contactor/fuse panel cover. Traction Motor compartment door.
5. Disconnect wire STR-1 from the contactor,
removing cable ties as necessary.

Electrical Components Cold Storage Conditioning
Cold Storage NOTE: Self-sealing AMP connectors (reference

page 7-78) do not need sealing
Conditioning treatment.
NOTE: Conversion of Model 7400/7420/7440 Treat the following parts to prevent moisture
lift trucks for cold storage operation from entering:
requires prior Raymond approval via • TS3 - located on left side of tractor
Form S207. bulkhead
• TS2 - located on top of reach carriage
New Model 7400/7420/7440 lift trucks to be
• Deadman switch terminals
operated in a cold storage environment require
the following: • Proportional valve (SOL2) terminals
Components Corrosion Inhibitor Coating

• All-weather hydraulic fluid (P/N 1017238) Coat or spray bare metal surfaces listed below
NOTE: Do not add any additve to this hydraulic with Corrosion Inhibitor Coating (P/N 990-644):
fluid. • Reach cylinder cotter pins
• Ambient temperature sensor • Main and free lift chain pulleys and shafts
• Special cold storage control handle • Main and free lift chain anchors and
assemblies with heaters threaded pins
• Wire mesh mast guard • Drive unit dipstick
• Suggested on fore-aft stance trucks:
Condensation drip guard (P/N 1036240) Condensation Drip Guard
• Optional heated floor pad
To add the control handle condensation drip
guard (P/N 1036240) to the overhead guard of
Lubricants fore-aft stance lift trucks, do the following:
See the “Lubrication Specification Chart” on 1. Remove from the overhead guard the
page A-2 for special hydraulic fluid and drive right-hand lower hex head cap screw,
unit lubricants for cold storage operation. located almost directly above the control
handle.
Coat battery roller shafts with all-weather 2. Install an M16 flat washer onto the cap
grease (P/N 1012992). screw.
3. Reinstall the cap screw with flat washer
Lubricate carriage fittings with all-weather and drip guard. See Figure 7-157.
grease (P/N 1012992).
Sealing Treatment
Fill sockets and the front and back of both
halves of unsealed connectors with cold storage
sealing compound (P/N 990-445). Connect
wires and connectors. Coat the outside and
where connectors attach to the circuit board.
Coat terminals and terminal strips.

Cold Storage Conditioning Electrical Components

Figure 7-157. Condensation Drip Guard
RCH_05_002.tif
Control Handle Modification

Control handles of early fore-aft stance lift
trucks lacked a drain hole.
To better drain these control handles, do the

following:
1. Remove the control handle.
2. Drill a 0.15 in. (5/32 in.) hole in the center
of the recessed area below the handle
shaft. See Figure 7-158.
3. Reinstall the control handle.
Figure 7-158. Drain Hole Location

RCH_04_010.jpg
Drill hole here

Hydraulic Components
Hydraulic Components

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.
You must bleed the hydraulic system to remove
Figure 7-160. 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
carriage all the way forward and backward
Figure 7-159. Bleed Screw, Main Lift Cylinder several times.
bleedermain.JPG
12. If the truck is equipped with sideshift,

shift the carriage all the way to the left and
right several times.
13. Series AA/BA/DA/EA (DC lift): Step on the
deadman pedal and turn the steering
wheel from stop to stop for approx. 2
minutes.
14. Thoroughly clean up any spilled hydraulic
Bleed Screw fluid.
15. Check the hydraulic reservoir level and
refill as necessary. Do not overfill the
reservoir.
5. When hydraulic fluid starts flowing from
the bleed screw hole, securely tighten the
bleed screw.

Hydraulic Components Hydraulic Filter
Hydraulic Filter Figure 7-162. 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.
2. Install the new filter, making sure it seats
Figure 7-161. 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.
Filter Type 2
Plug
5. Remove the spring on top of the filter. Removal

6. Using the extraction bolt installed in the NOTE: Model 7400 DC lift trucks use a filter
manifold, remove the filter. cartridge with a shield.
Models 7420/7440 use two filter
cartridges in the main manifold.
2. If you have not drained the reservoir,
elevate the mast to lower the hydraulic
fluid level to minimize hydraulic fluid
leakage.

Hydraulic Filter Hydraulic Components
4. Remove the plug retaining the hydraulic Figure 7-165. Filter Cartridge (without shield)
fluid filter, using a 3/4 in. socket.
newfilter3.jpg
Figure 7-163. Filter Plug

newfilter1.jpg
3. Install and torque the hex plug to 30 ft. lb.

(40 Nm).
5. Remove the filter cartridge.
the key switch ON.
6. If contamination is evident, remove the 5. Lower the mast and check for leaks.
cartridge core and clean as required.
7. Inspect the O-ring on the core and replace
if necessary.
Installation
1. Install the cartridge core into the manifold
making sure the core seats correctly into
the nose of the cavity.
Figure 7-164. Cartridge Core

newfilter2.jpg
2. Install the new filter cartridge onto the

cartridge core.

Hydraulic Components Lift Pressure Adjustment
Lift Pressure Adjustment 12. Continue trying to elevate and turn the
relief valve adjusting screw to obtain a
pressure reading 200 psi (1379 kPa)
AC Lift greater than that required to lift the
maximum rated load (the value recorded
Lift pressure is set by software in trucks with in step 8). Turn the adjusting screw
AC lift. clockwise to increase pressure,
counterclockwise to decrease pressure.
See Table 7-7 for maximum lift pressure.
For maximum permissible lift pressure,
Table 7-7. Maximum LIft Pressures see Table 7-7.
13. Tighten the lock nut on the lift pressure
Model/Mast Maximum Lift Pressure relief valve.
14. Check the pressure again. If the value has
7400/R45TT mast 3300 psi (22,753 kPa)
changed, repeat this procedure until the
7400/DR32TT mast 3600 psi (24,821 kPa) correct pressure reading is obtained.
7420 and 15. Turn the key switch OFF and disconnect
2950 psi (20,339 kPa) the battery connector.
7440/R45TT mast
16. Remove the pressure gauge from the lift
7420 and 7440/
2600 psi (17,926 kPa) pressure test port and replace the cap.
DR32TT mast
17. Reinstall the top cover. Reconnect the
battery connector and turn the key switch
DC Lift ON.
1. Lower the carriage completely.

4. Remove the cap from the G1 lift pressure
test port on the main manifold. See
“Manifold, Main, DC Lift, Model 7400” on
page 7-105.
5. Connect a pressure gauge capable of
reading at least 5000 psi (34,470 kPa).
the key switch ON.
7. Place the maximum rated load on the
forks.
8. Elevate the carriage past free lift, that is,
until the telescopics begin to lift. Record
the pressure required to lift the load.
9. Lower the carriage and remove the load.
10. Loosen the lock nut on the main lift
pressure relief valve (REL1) on the main
manifold. See “Manifold, Main, DC Lift,
Model 7400” on page 7-105.
11. Elevate the carriage until the upper limit is
reached.

Manual Lowering of Fork Carriage Hydraulic Components
Manual Lowering of DC Lift

Fork Carriage 1. Turn the key switch OFF and disconnect
2. Loosen and remove the lock nut on the
If the fork carriage is hung up and unable to be
main relief valve REL1. See “Manifold,
lowered normally, use the following procedure
Main, DC Lift, Model 7400” on page 7-105.
to lower the carriage.
Note the number of threads exposed on
NOTE: Make sure the forks and carriage are the lift pressure relief valve.
free from racks and other obstructions 3. Turn the lift pressure adjusting screw
before lowering. slowly counterclockwise until the fork
carriage begins to lower.
AC Lift 4. When you have resolved the cause of the
1. Manually open the load holding valve hung carriage, you must reset the lift
SOL1. See “Manifold, Main, AC Lift, Model pressure.
7400” on page 7-103. On the top of SOL1 5. Turn the lift pressure adjusting screw
is a small knurled knob. Depress the knob clockwise until the same number of
and turn counterclockwise until the knob threads are exposed as you noted in
pops up. step 2.
2. If there is power on the lift truck, try to 6. Install, but do not tighten, the lock nut on
lower by using the lift/lower knob. the relief valve.
a. If this is successful, go to step 4. 7. Perform the procedure to adjust lift
pressure. See “Lift Pressure Adjustment”
b. If this is unsuccessful, continue to the
on page 7-99.
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

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, AC Lift, Model 7400”
on page 7-103 or “Manifold, Main, DC Lift,
Model 7400” on page 7-105. 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 in
Active Service Mode. Carriage movement
should start at approx. 9 to 10% request.
12. Reinstall the top cover.

Auxiliary Pressure Adjustment Hydraulic Components
Auxiliary Pressure
Adjustment
AC Lift
3. Loosen the lock nut on the aux pressure
relief valve (REL2) on the main manifold.
See Figure 7-166 on page 7-103.
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.
DC Lift
Auxiliary pressure is fixed at 1800 psi
(12,410 kPa) on trucks with DC Lift. There is no
pressure adjustment.

Hydraulic Components Manifold, Main, AC Lift, Model 7400
Manifold, Main, AC Lift,

Model 7400
Figure 7-166. Main Manifold, Model 7400 Series CA/FA
(AC lift)
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

Manifold, Main, AC Lift, Model 7420/7440 Hydraulic Components
Manifold, Main, AC Lift,

Model 7420/7440
Figure 7-167. Main Manifold, Model 7420/7440 Series
CA/FA (AC lift)
1044947_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

Hydraulic Components Manifold, Main, DC Lift, Model 7400
Manifold, Main, DC Lift,

Model 7400
Figure 7-168. Main Manifold, Model 7400 Series
AA/BA/DA/EA (DC lift)
R1020534_A1.cgm,R1020534_A2.cgm
A2 A1 Hydraulic
CV-2 P2 Fore-Aft
Filter
P2 Side Stance
CYL-1
SOL 5
SOL 4
SOL 2
CV-1
CYL-P
SOL 1
LS-1 REL-1
G2 port
S-RET P2
PWR BYND
TANK
CE-1
HTI CASE DRAIN SOL 8 LS-1 SOL 5

Manifold, Auxiliary (Standard Reach) Hydraulic Components
Manifold, Auxiliary
(Standard Reach)
Figure 7-169. Manifold, Aux (Standard Reach), with Reach,
Tilt, Sideshift
R1015154_A1.cgm,R1015154_A2.cgm
Sideshift
Solenoid
Tilt
Solenoid
Reach
Solenoid
Tilt
Sideshift Solenoid
Solenoid
A1
A2
SSL TR

Hydraulic Components Manifold, Auxiliary (Standard Reach)
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 approx. 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 7-96.
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
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 7-10 on
page 7-112.
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
and torque to 21 ft. lb. (29 Nm).

Manifold, Reach (Deep-Reach ®) Hydraulic Components
Manifold, Reach
(Deep-Reach ®)
Figure 7-170. Manifold, Reach (Deep-Reach Carriage)
R1020906_B1.cgm,R1020906_B2.cgm,R1020906_B3.cgm
Reach CB-1 CB-2 REL-3

Solenoid
RR
RC
CV-3
Removal 1. Install all fittings in the new manifold in

the same orientation that they were in the
1. Reach the carriage out and lower to the manifold removed.
floor. Block the reach mechanism so that
the scissors cannot retract.
coils.
3. Position the manifold and connect all the
hydraulic hoses.
3. Remove the two manifold mounting bolts
4. Reconnect the solenoid wires.
to gain access to all hydraulic fittings.
5. Mount the manifold to the scissors.
4. Label as required all the solenoid wires
and remove. 6. Reconnect the battery connector and turn
the key switch ON.
5. Disconnect and cap all hydraulic hoses.
Note the location of each of the hoses. 7. Remove the blocking.
6. Remove the manifold from the truck. 8. Bleed the hydraulic system. See
“Hydraulic System Bleeding” on page 7-96.
Installation 9. Test the auxiliary functions for correct
operation and check connections for leaks.
page 7-112.

Hydraulic Components Manifold, Reach (Deep-Reach ®)
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.
3. Clean the surface of the reach manifold to
avoid contamination.
4. Remove relief valve REL-3.
5. Remove counterbalance valve CB-1.
6. Removed the reach solenoid coil.
7. Remove counterbalance valve CB-2, using
an offset 15/16 in. open-end wrench.
8. Install the new relief valve REL-3.
9. Reinstall counterbalance valve CB-2.
10. Install the new counterbalance valve CB-1.
11. Reinstall the reach solenoid coil.
12. Remove the blocking from the scissor
mechanism.
the key switch ON.
14. Bleed the auxiliary system by fully
extending the reach mechanism several
times. Hold over the relief until the system
times out if air remains present.
15. Test reach and retract functions for
correct operation.

Manifold, Tilt/Sideshift (Deep-Reach ®) Hydraulic Components
Manifold, Tilt/Sideshift
(Deep-Reach ®)
Figure 7-171. Manifold, Tilt/Sideshift (Deep-Reach)
R1014583_A1.cgm
Sideshift Tilt
Solenoid Solenoid
Refer to Parts Manual for “Tilt Only” Manifold
Removal 4. Connect the hydraulic hoses.

5. Connect the wiring to the solenoids.
1. Reach the fork carriage out and fully lower
to the floor. 6. Reconnect the battery connector and turn
the key switch ON.
2. Tilt the forks fully down.
7. Bleed the hydraulic system.
the battery connector. 8. Test the auxiliary functions for correct
operation and the connections for leaks.
4. Disconnect the wiring for the solenoids.
5. Disconnect and cap the hydraulic hoses.
Note the location of the hoses.
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
page 7-112.
1. Install all fittings in the new manifold in
the same orientation that they were in the
manifold removed.
coils.
3. Mount the manifold to the carriage.

Hydraulic Components Manifold Solenoids, Fittings, and Attachments
Manifold Solenoids, Table 7-9. Series AA/BA/DA/EA (DC lift) Main

Manifold Attachment Torques
Fittings, and
Solenoid/ Torque
Attachments Attachment/Fitting ft. lb. (Nm)
35 (47)
Table 7-8. Main Manifold Attachment Torques - AC Lift SOL1 Load Holding
coil nut: 5 (6.8)
95 (129)
Solenoid/ Torque SOL2 Lift/Lower
coil nut: 0.5 (0.7)
Attachment/Fitting ft. lb. (Nm)
20 (28)
SOL1 Load Holding w/locking 50 (68) SOL4 2d Pump
coil nut: 5 (6.8)
tab coil nut: 5 (6.8)
25 (34)
95 (129) SOL5B/5T Aux
SOL2 Lift/Lower coil nut: 5 (6.8)
coil nut: 0.5 (0.7)
20 (27)
SOL3 Proportional Main 25 (34) SOL8 Aux Dump
coil nut: 5 (6.8)
Relief/Dump coil nut: 5 (6.8)
A1 & A2 21 (28)
20 (27)
SOL5B/5T Aux
coil nut: 5 (6.8) Case Drain 12 (16)
A1 & A2 21 (28) CE1 Compensating Element 25 (34)
CV-1 Check Valve 30 (41) CV-1 Check Valve 35 (47)
CYL-1 55 (75) CV-2 Check Valve 20 (27)
CYL-P Pressure Transducer 12 (16) CYL-P Pressure Transducer 12 (16)
Filter Plug 30 (41) CYL-1 55 (75)
G1 & G2 21 (28) Filter Plug 30 (41)
HTI Pressure Switch 12 (16) G1 & G2 21 (28)
LS-1 Load Shuttle 20 (27) HTI Pressure Switch 12 (16)
P1 55 (75) LS-1 Load Shuttle 20 (27)
POD-1 Priority on Demand 35 (47) P2

21 (28)
REL-2 Aux Relief 25 (34) PWR BYND
Return (Suction) to Pump 55 (75) REL-1 Main Relief 25 (34)
S-RET 21 (28) Return to Pump P1

55 (75)
TANK 55 (75) Return to Pump P3
S-RET 21 (28)
TANK 55 (75)

Manifold Solenoids, Fittings, and Attachments Hydraulic Components

Table 7-10. Aux Manifold and Cylinder Attachment
Torques
Solenoid/ Torque
Attachment/Fitting ft. lb. (Nm)
A1 & A2 (Standard Reach) 15 (20)
20 (27) standard
Reach Valve 25 (34) deep reach
coil nut: 5 (6.8)
RC & RR 15 (20)
20 (27)
Tilt Valve
coil nut: 5 (6.8)
TC & TR 15 (20)
20 (27)
Sideshift Valve
coil nut: 5 (6.8)
SSR & SSL 15 (20)
Flow Limiter (7420/7440

85 (115)
Free Lift Cylinder)
Pump & Tank 15 (20)
A1 & A2 (Deep-Reach) 15
A1 & A2 (Deep-Reach Tilt or

15
Tilt/Sideshift)
REL-3 Deep-Reach Relief n/a
CV-3 Deep-Reach Check

25 (34)
valve
CB-1 & CB-2 Deep-Reach

35 (47)
Counterbalance

Hydraulic Components, Cylinder
Hydraulic Components, Cylinder


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 7400 catch any hydraulic fluid when the line
is disconnected.
Left Side Free Lift Cylinder
13. Remove the eyelet retainer pin at the top of
the cylinder housing.
Removal
14. Position the carriage at an appropriate
1. Remove mast guard.
height to allow removal of the cylinder.
2. Elevate telescopics to access the
over-the-mast (OTM) hoses/cable clamp at
cylinder.
the bottom of the free lift cylinder.
3. Remove the clamp and the free lift cylinder Installation
set screw at the bottom of the cylinder
mounting bracket. Remove any cable ties NOTE: The left side free lift cylinder contains a
securing the hoses/cable to the cylinder. flow limiter located in the manifold block
at the bottom of the cylinder. See “Flow
4. Fully lower the telescopics carefully so as Limiter, Free Lift” on page 7-142.
not to damage the hoses and cable.
1. Install the flow control, fitting, and feed
5. Using a suitable lifting device, lift the
hose at the bottom of the cylinder.
carriage to relieve the tension on the lift
chains and hoses. 2. Position the cylinder into the truck.
6. Turn the key switch OFF and disconnect 3. Install the upper eyelet retainer pin and
the battery connector. the set screw at the bottom of the cylinder.
7. Remove the master link from the free lift 4. Connect the hydraulic line at the bottom of
chain at the free lift cylinder anchor bolt. the cylinder.
8. Drape the chain over the carriage 5. Lift the carriage assembly to provide slack
assembly. in the lift chains and hoses for assembly.
9. Remove the chain pulley to access the 6. Apply thread-locking compound
pulley bracket assembly mounting bolt. (P/N 1013829) to the threads of the
Remove the pulley bracket assembly from mounting bolt and install the pulley
the piston and set to the side with the bracket assembly.
hoses and cable in place. 7. Install the chain pulley and the free lift
10. Mark the OTM hoses and cable at the chain.
upper free lift cylinder retainer for the 8. Install the OTM upper free lift cylinder
correct stretch when re-assembled. retainer, noting the marks made on the
Remove the retainer. hoses/cable when removed.
11. Using the lifting device, lift and block the 9. Lower the carriage and remove the lifting
carriage assembly to a height that permits device.
access to the tubing at the bottom of the
cylinder.
the key switch ON.
NOTE: As the carriage is being lifted, feed the 11. Carefully lift the telescopics to access the
right side free lift chain towards the bottom of the free lift cylinder.
operator compartment to avoid jamming
of the chain. 12. Install the OTM hoses/cable clamp at the
bottom of the free lift cylinder. Make sure
there is correct clearance between the

Hydraulic Components, Cylinder Lift Cylinder, Free Lift, Remove/Install
bracket, hoses/cable, and the front plate 12. Remove the set screw at the bottom of the
of the tractor. cylinder.
13. Bleed the hydraulic system. See 13. Position the carriage at an appropriate
“Hydraulic System Bleeding” on page 7-96. height to permit removal of the cylinder.
14. Check the truck for leaks and correct 14. Using a suitable lifting device, remove the
operation. cylinder.
15. Install the mast guard.
Installation
Right Side Free Lift Cylinder 1. Position the cylinder into the truck.
2. Install the upper eyelet retainer pin.
Removal 3. Position and block carriage to permit
1. Remove the upper eyelet retainer pin. access to bottom of the cylinder.
NOTE: You can gain easier access by raising the 4. Install the set screw at the bottom of the
telescopics. cylinder.
2. Fully lower the forks to the floor. 5. Connect the hydraulic line at the bottom of
the cylinder.
the battery connector. 6. Lift the carriage assembly to provide slack
to install the free lift chain.
4. Remove the mast guard.
7. Install the ring adapter. Apply
5. 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.
6. Remove the master link from the free lift 8. Install the chain pulley and the free lift
chain at the free lift anchor bolt. chain.
7. Remove and drape the chain over the 9. Lower the carriage and remove the lifting
carriage assembly. device.
NOTE: Twist the pulley assembly to permit the 10. Reconnect the battery connector and turn
removal of the chain. the key switch ON.
8. Remove the chain pulley to access the 11. Bleed the hydraulic system. See
pulley bracket assembly mounting bolt. “Hydraulic System Bleeding” on page 7-96.
9. Remove the pulley bracket assembly and 12. Check the truck for leaks and correct
ring adapter. operation.
10. Using the lifting device, lift and block the 13. Install the mast guard.
carriage assembly to a height that permits
access to the bottom of the cylinder.
Model 7420/7440
NOTE: As the carriage is being lifted, feed the
left side free lift chain toward the Left Side Free Lift Cylinder
operator compartment to avoid jamming
the chain. Removal
11. Disconnect the hydraulic line at the 1. Elevate the fork carriage approx. 4 in.
bottom of the cylinder. Plug and cap the (10 cm) above the floor.
fitting to avoid contamination from
2. Place hardwood blocks under the carriage.
entering the system.
3. Lower the carriage to slacken the chains.
NOTE: Place a pan below the main frame to
catch any hydraulic fluid when the line
is disconnected.

Lift Cylinder, Free Lift, Remove/Install Hydraulic Components, Cylinder
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.
12. Remove blocking.
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 approx. 4 in. (10
12. Remove the pulley bracket from the 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
2. Using a hoist or other suitable lifting over the pulley.
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.
4. Attach the cylinder retaining nylon nut 14. Disconnect and cap/plug the hydraulic
snug to the shoulder. line at the bottom of the cylinder.
5. Reattach the pulley bracket to the 15. Remove the nut from the cylinder
cylinder. retaining anchor at the inner telescopic
6. Install the pulley, pin, and securing screw. crosstie.
7. Using a new master link, install the free 16. Wrap a hoist strap securely around the
lift chain to the upper chain anchor. cylinder at the retaining bracket.
8. Secure the hoses to the hose clamps with 17. Using a hoist or other suitable lifting
cable ties. device, carefully lift the cylinder out.

Hydraulic Components, Cylinder Lift Cylinder, Free Lift, Remove/Install
Installation
1. Wrap a hoist strap securely around the
cylinder at the retaining bracket.
2. Using a hoist or other suitable lifting
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.

Lift Cylinder, Free Lift, Exploded Parts Drawing Hydraulic Components, Cylinder
Lift Cylinder, Free Lift,

Exploded Parts Drawing
Model 7400, Staging (AC Lift)
Figure 7-172. Free Lift Cylinder, Staging, Model 7400
1023208_G.cgm
Lowering Cushion Assembly

O-Ring
Snap
Ring
Decel Piston Retaining

Ring
Piston Ring
Decel Spring
Plug
O-Ring Decel Bearing
Hydraulic Return Spring
Fluid Port
Check Valve
O-Ring
Piston Plug
(Cushion
Housing)
Piston Rod
Pressure Ring
Ram Spacer Ring
Wiper Seal
Backup Ring Piston Ring
Sleeve
O-Ring
Staging Zone Spring
Packing Seal
O-Ring
Gland
Snap Ring
Staging Zone Stop

Screw (3)
Bleed
Screw

Hydraulic Components, Cylinder Lift Cylinder, Free Lift, Exploded Parts Drawing
Model 7400, Non-Staging

(DC Lift)
Figure 7-173. Free Lift Cylinder, Non-Staging, Model 7400
1023600_G.cgm
Snap Ring
Lowering Cushion Piston
Cap Screw
Retaining
Seal Ring
Piston Rod
Spring
Square Seal
Wiper Seal
Piston Seal
Gland

Lift Cylinder, Free Lift, Exploded Parts Drawing Hydraulic Components, Cylinder
Model 7420/7440, Staging

Figure 7-174. Free Lift Cylinder, Staging, Model
7420/7440
1048548_C.cgm
Lowering Cushion Assembly O-Ring

Snap
Ring
Decel Piston
Retaining
Ring
Piston Ring
Decel Spring
Plug
O-Ring
Decel Bearing
Hydraulic
Fluid Port Return Spring
Check Valve
O-Ring
Piston Plug
(Cushion
Housing)
Piston Rod
Piston Ring
Sleeve Staging Zone
Stop Screw (3)
Bleed Screw
O-Ring
Packing Pressure Ring
Seal
Staging Zone Spring
Gland
Wiper Seal

Hydraulic Components, Cylinder Lift Cylinder, Free Lift, Seal Repacking
Lift Cylinder, Free Lift, NOTE: If necessary, use the piston to extract
the gland by removing the three staging
Seal Repacking zone stop screws and the bleeder screw
and lifting the cylinder with the use of a
hoist.
Model 7400 10. On a clean work surface, remove the wiper
seal, packing seal, O-rings, and backup
AC Lift ring from the gland. Note the position and
orientation of each when removing.
Refer to Figure 7-172 on page 7-118. 11. Inspect the surfaces of the gland for any
scratches or damage. Remove minor
Disassembly imperfections using fine emery cloth.
Trucks with AC lift have a staging zone 12. Clean the gland.
mechanism in the free lift cylinders in addition 13. Inspect the inside of the housing for
to a cushion at the bottom of the cylinder. damage and clean as required.
Reassembly
2. Lower the carriage onto a suitable block
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
in step 8 of the disassembly procedure.
the battery connector. 2. Lubricate the wiper seal, packing seal,
O-rings, and backup ring with new
4. Remove the free lift chain master link at hydraulic fluid and install into their
the free lift cylinder anchor bolt and lay respective grooves on the gland. Make sure
the chain over the carriage. they are correctly positioned.
NOTE: Twist the right side pulley to remove the 3. Install the pressure ring with the seal
chain from the pulley. towards the open end of the housing. See
5. Remove the chain pulley to access the Figure 7-175.
pulley bracket mounting bolt.
Figure 7-175. Pressure Ring Orientation
6. Remove the pulley bracket assembly. Set 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.
4. Apply lubricant (P/N 990-652) to the
NOTE: When the snap ring is removed, a spring outside surface of gland.
behind the packing plug should push
the gland out of the housing.

Lift Cylinder, Free Lift, Seal Repacking Hydraulic Components, Cylinder
5. Lubricate the piston rod with new 4. Remove the free lift chain master link at
hydraulic fluid. Carefully slide the gland the free lift cylinder anchor bolt and lay
over it. the chain over the carriage.
6. Using the seal installation driver NOTE: Twist the right side pulley to remove the
(P/N 401-000-051), push the gland into chain from the pulley.
the housing and compress the spring.
5. Remove the chain pulley to access the
7. Apply a film of lubricant (P/N 990-652) to pulley bracket mounting bolt.
the top of the gland and housing to
prevent moisture entry. 6. Remove the pulley bracket assembly. Set
the left side to one side, keeping the hoses
8. Install the snap ring inside the housing. and cable in place.
Make sure that the snap ring is fully
seated in the groove. 7. For 3 in. lowered height option, remove the
adapter ring.
9. Wipe away any excess hydraulic fluid.
8. Using cylinder end cap tool (P/N A9587),
10. Tighten the upper OTM retainer, if remove the end cap (gland).
previously loosened.
9. On a clean work surface, remove the
11. For 3 in. lowered height option, install the piston seal, wiper seal, and square seal
adapter ring. from the end cap. Note the position and
12. Apply thread-locking compound orientation of each when removing.
(P/N 1013829) to the threads of the 10. Inspect the surfaces of the gland for any
mounting bolt and install the pulley scratches or damage. Use fine emery cloth
bracket assembly. to remove minor imperfections.
13. Install the chain pulley and the free lift 11. Clean the threads on the gland and the
chain. cylinder.
14. Reconnect the battery connector and turn 12. Inspect the inside of the housing for
the key switch ON. damage and clean as required.
15. Remove the block from beneath the
carriage. Reassembly
16. Bleed the hydraulic system. See 1. Lubricate with new hydraulic fluid, the
“Hydraulic System Bleeding” on page 7-96. piston seal, wiper seal, and square seal
17. Check the truck for leaks and correct and install into their respective grooves on
operation. the gland. Make sure they are correctly
seated within the grooves and not twisted.
(P/N 990-571) to the threads of the gland.
DC Lift
3. Lubricate the piston rod with new
Refer to Figure 7-173 on page 7-119. hydraulic fluid, and carefully install the
gland.
Disassembly 4. Torque the end cap to 200 ft. lb. (271 Nm).
1. Remove the mast guard. 5. For 3 in. lowered height option, install the
2. Lower the carriage onto a suitable block adapter ring.
and fully lower cylinder to relieve the 6. Apply thread-locking compound
tension on the hoses, cable and free lift (P/N 1013829) to the threads of the
chains. mounting bolt and install the pulley
3. Turn the key switch OFF and disconnect bracket assembly.
the battery connector. 7. Install the chain pulley and the free lift
chain.

Hydraulic Components, Cylinder Lift Cylinder, Free Lift, Seal Repacking
8. Reconnect the battery connector and turn Reassembly

the key switch ON.
1. Lubricate with new hydraulic fluid the
9. Remove the block from beneath the
packing seal, wiper seal, and O-ring and
carriage.
install into their respective grooves on the
10. Bleed the hydraulic system. See gland. Make sure that they are correctly
“Hydraulic System Bleeding” on page 7-96. seated within the grooves.
11. Check the truck for leaks and correct 2. Apply thread-locking compound
operation. (P/N 990-571) to the threads of the gland.
12. Install the mast guard. Do not apply compound to the first
threads to engage.
Model 7420/7440 3. Lubricate the piston rod with new

hydraulic fluid. Carefully slide the gland
over the piston rod.
Refer to Figure 7-174 on page 7-120.
4. Torque the gland to 200 ft. lb. (271 Nm).
Disassembly 5. Apply thread-locking compound
(P/N 1013829) 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.
7. Install the pulley shaft locking screw.
3. Collapse the cylinder.
8. Route the free lift chain over the pulley
4. Disconnect the lift chain master link from and attach to the chain anchor with a
the chain anchor. master link.
5. Secure the lift chain to the crosstie with a 9. Reconnect the battery connector and turn
welding or sheet metal locking clamp. This the key switch ON.
minimizes rethreading of chain later.
10. Slowly request lift, lift the carriage, remove
6. Remove the nut from the tractor side of the blocking, and lower the carriage.
the free lift cylinder mounting bracket.
11. Bleed the cylinder as required. See
7. Remove the locking screw from the pulley “Hydraulic System Bleeding” on page 7-96.
shaft.
12. Test lift and lower functions. Check for
8. Drive out the pulley shaft. leaks.
9. Remove the pulley bracket.
NOTE: With slack in hoses and cable, it is not
necessary to remove the hoses or cable.
10. Using a 2 in. spanner wrench, remove the
end cap (gland).
11. On a clean work surface, remove the wiper
seal, packing seal, and O-ring from the
gland.
12. Inspect the surfaces of the gland for any
scratches or damage. Remove minor
imperfections using fine emery cloth.

Lift Cylinder, Main, Remove/Install Hydraulic Components, Cylinder
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.
Left Side Main Lift Cylinder, cylinder from the truck.
Model 7400
Installation
Removal
1. Install the fitting and feed hose at the
1. Remove mast guard, top cover, and left bottom of the cylinder.
front cover.
2. Attach the mast guard bracket onto the
2. Remove the retainer bolt at the bottom of cylinder.
the cylinder.
3. Position the cylinder into the truck.
3. Place a block approx. 18 in. long between
4. Apply thread-locking primer
the inner telescopic crosstie and the outer
(P/N 990-666) to both the right and left
telescopic crosstie. Place a block approx.
mast mounting bolt threads and the hole
12 in. (305 mm) in length between the
threads. Permit to dry for several minutes.
outer telescopic crosstie and the main
frame crosstie.
(P/N 990-544) to the threads of the mast
NOTE: This will provide the necessary mounting bolts. Install the mast connector
hose/cable slack and clearance to and torque the bolts to 160/170 ft. lb.
remove the cylinder. (217/230 Nm).
4. Fully lower the carriage. 5. Install the mast connector snap ring.
5. Turn the key switch OFF and disconnect 6. Remove the jack.
the battery connector. 7. Connect the feed hose at the bulkhead
6. Remove the bolt, washer, and spacer at the fitting.
top of the piston. 8. Attach the OTM hose/cable retainer
7. Remove the cylinder mounting bracket to the cylinder.
L-bracket(s). 9. Install the cylinder mounting L-bracket(s)
NOTE: Models with an OACH of 131 in. with sleeves and bolts. Do not tighten at
(333 cm) and above will have two this time.
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 13. Apply thread-locking compound
the bottom of the cylinder to assist in (P/N 1013829) to the threads and tighten,
removal. leaving a 0.12 in. (3 mm) gap between the
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.

Hydraulic Components, Cylinder Lift Cylinder, Main, Remove/Install
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 7-96. 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
Model 7400 a flow limiter located in the manifold
block at the bottom of the cylinder. See
“Flow Limiter, Main Lift” on page 7-141.
Removal
1. Install the flow control, fitting, and feed
1. Remove mast guard, top cover, and right
hose at the bottom of the cylinder.
front cover.
2. Attach mast guard bracket to cylinder.
2. Elevate telescopics and remove the
retainer bolt at bottom of cylinder. 3. Position the cylinder into the truck.
3. Place a block at least 12 in. (305 mm) in 4. Apply thread-locking primer
length between the main frame and the (P/N 990-666) to mast mounting bolt
outer telescopic crosstie and fully lower threads and the hole threads. Permit to
the carriage. dry for several minutes. Apply
NOTE: This length provides the clearance to the threads of the mast mounting bolts.
required to remove the cylinder. Install the mast connector and torque the
4. Fully lower the carriage. bolts to 160/170 ft. lb. (217/230 Nm).
5. Turn the key switch OFF and disconnect 5. Install the mast connector snap ring.
the battery connector. 6. Remove the jack from the truck.
6. Remove the bolt, washer, and spacer at the 7. Connect the feed hose at the tractor
top of the piston and outer telescopic bulkhead fitting.
crosstie. 8. Install the cylinder mounting L-bracket(s)
7. Remove the cylinder mounting with sleeves and bolts. Do not tighten at
L-bracket(s). this time.
NOTE: Models with an OACH of 131 in. 9. Install the retainer bolt at the bottom of
(333 cm) and above will have two upper the cylinder.
brackets. 10. Reconnect the battery connector and turn
8. Place a pan below the tractor. Disconnect the key switch ON.
the cylinder feed hose at the tractor 11. Carefully rotate the lift knob to raise the
bulkhead. Plug and cap the fittings to piston to the telescopic crosstie.
prevent contamination from entering the 12. Install the bolt, washer, and spacer at the
system. crosstie to the top of the piston.
NOTE: The feed hose can remain connected to NOTE: Install thread-locking compound
the cylinder to assist in removal of the
(P/N 1013829) to bolt threads and
cylinder.
tighten, leaving a 0.12 in. (3 mm) gap
9. From inside the battery compartment, between head of the bolt and washer.
loosen the left side mast bolts.
13. Tighten the cylinder mounting L-bracket
10. Remove the right side mast bolts and the bolts to 55 ft. lb. (75 Nm).
mast connector snap ring.

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 7-96. 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
Left and Right Side Main Lift the bottom of the tractor frame.
Cylinder, Model 7420/7440 13. Working from the top of the tractor,
remove two mast mounting bolts from
Removal each side.
1. Turn the key switch OFF and disconnect 14. Remove the tractor to provide working
the battery connector. space at the mast.
2. Remove the top cover. 15. Wrap hoist straps around each baseleg
where they join the mast. Extend the hoist
3. Remove the mast guard. straps in the direction of the tractor and
4. Disconnect the auxiliary hydraulic hoses attach to a 3-ton hoist or other suitable
at the main manifold. Cap hoses and plug lifting device.
ports. 16. Keeping tension on the top of the mast,
5. Disconnect the over-the-mast electrical carefully begin lifting at the baseleg straps.
cable at connector JPS3 near the main The mast will tip forward toward the
manifold. carriage.
6. Remove the battery gate. Using a suitable 17. Continue lowering the mast unto jack
battery moving device, remove the battery. stands.
7. Remove the battery connector mounting 18. Remove the main lift hose at the cylinder
bracket (for access to the mast mounting manifold. Plug the fitting.
bolts). See Figure 7-176. 19. Remove the upper and lower cylinder
mounting bolts and sleeves at the main
Figure 7-176. Battery Connector and Mast Mounting Block
R1008505_B1.cgm
frame crossties.
Figure 7-177. Cylinder Mounting Bolts, Model 7420/7440

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.

Hydraulic Components, Cylinder Lift Cylinder, Main, Remove/Install
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. See the main frame crossties.
Figure 7-178. 4. Install the cylinder top mounting bolt.
Figure 7-178. 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).
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.
14. Connect the over-the-mast electrical cable
1. Support the mast securely on jack stands,
at connector JPS3 near the main manifold.
carriage side down. Wrap hoist straps
around each baseleg where they join the 15. Attach the forks onto the fork carriage.
mast. Extend the hoist straps in the 16. Attach the battery connector mounting
direction of the tractor and attach to a bracket near the mast mounting bolts on
3-ton hoist or other suitable lifting device. the right side.

17. Using a suitable battery moving device,

install the battery. Install the battery gate.
the key switch ON.
21. Test lift and lower functions for correct
operation. Check for hydraulic fluid leaks.

Hydraulic Components, Cylinder Lift Cylinder, Main Lift, Exploded Parts Drawing
Lift Cylinder, Main Lift,

Exploded Parts Drawing
Model 7400
Figure 7-179. Main Lift Cylinder, Model 7400
1024919_E1.CGM
Snap Ring
Cap Screw
Retaining
Seal
Ring
Piston Rod
Spring
Square Seal
Wiper Seal
Piston Seal
Gland

Lift Cylinder, Main Lift, Exploded Parts Drawing Hydraulic Components, Cylinder
Model 7420/7440
Figure 7-180. Main Lift Cylinder, Model 7420/7440
1054090_B.CGM
Snap Ring
Cap Screw
Seal Retaining
Ring
Piston Rod
Spring
Square Seal
Wiper Seal
Piston Seal
Gland

Hydraulic Components, Cylinder Lift Cylinder, Main, Seal Repacking
Lift Cylinder, Main, Seal 4. Torque the gland to 200 ft. lb. (271 Nm).
Repacking the key switch ON.
6. Carefully rotate the lift knob to raise the
Model 7400
7. Install the bolt, washer, and spacer at the
Refer to Figure 7-179 on page 7-129. crosstie to the top of the piston.
NOTE: Apply thread-locking compound
Disassembly (P/N 1013829) to the threads of the bolt
and tighten, leaving a 0.12 in. (3 mm)
1. Slightly elevate the mast and place a block
gap between the head of the bolt and the
between the outer telescopic crosstie and
washer.
the main frame.
2. Fully lower the carriage. 8. Remove the block from between the outer
telescopic crosstie and the main frame.
the battery connector. 9. Bleed the hydraulic system.
10. Check the truck for leaks and correct
4. Remove the bolt, washer, and spacer at the
operation.
top of the piston and the outer telescopic
crosstie.
5. Retract the piston into the housing enough Model 7420/7440
to allow the removal of the end cap (gland).
Refer to Figure 7-180 on page 7-130.
6. Using cylinder end cap tool (P/N A9587),
remove the end cap (gland).
Disassembly
7. On a clean working surface, remove the
packing seal, wiper seal, and square seal 1. Elevate the mast to produce a 6 to 8 in. (15
from the end cap. Note position and to 20 cm) gap between the outer telescopic
orientation of each when removing. crosstie and the main frame.
8. Inspect the surfaces of the gland for any 2. Block the mast between the inner and
scratches or damage. Remove minor outer telescopics and between the outer
imperfections using fine emery cloth. telescopic and the main frame.
9. Inspect the inside of the housing for 3. Remove the cylinder mounting bolt at the
damage and clean as required. top of the cylinder.
10. Clean the threads on the gland and the 4. Collapse the cylinder (push on cylinder
cylinder. while requesting lower).
Reassembly the battery connector.
1. Lubricate with new hydraulic fluid, the 6. Using a 2 in. spanner wrench, remove the
packing seal, wiper seal, and square seal, end cap (gland).
and install into their respective grooves on 7. On a clean working surface, remove the
the gland. Make sure they are correctly packing seal, wiper seal, and O-ring from
seated within the grooves and are not the gland. Note position and orientation of
twisted. each when removing.
2. Apply thread-locking compound 8. Inspect the surfaces of the gland for any
(P/N 990-571) to the threads of the gland. scratches or damage. Remove minor
3. Lubricate the piston rod with new imperfections using fine emery cloth.
hydraulic fluid and carefully install the
gland.

Lift Cylinder, Main, Seal Repacking Hydraulic Components, Cylinder
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 threads of the gland.
3. Lubricate the piston rod with new
hydraulic fluid and carefully install the
gland.
4. Torque the gland to 200 ft. lb. (271 Nm).
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.

Hydraulic Components, Cylinder Lift Cylinder Lowering Cushion
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 7400, refer to Figure 7-179 on
with a drill bit or drift pin inserted in one
page 7-129. For Models 7420/7440, refer to
of the hydraulic fluid ports in the cushion
Figure 7-180 on page 7-130.
housing.
5. Install the snap ring.
Removal
6. Carefully release cushion pressure.
1. Remove the main lift cylinder.
7. Reassemble the cylinder. See “Lift
a. For Model 7400, refer to page 7-124. Cylinder, Main, Seal Repacking” on
b. For Model 7420/7440, refer to page 7-131.
page 7-126. 8. Install the cylinder.
2. Remove the piston rod from the cylinder. a. For Model 7400, refer to page 7-124.
See “Lift Cylinder, Main, Seal Repacking”
b. For Model 7420/7440, refer to
on page 7-131.
page 7-126.
3. Place the piston rod on a clean padded
working surface.
Free Lift Cylinders - AC Lift
with a drill bit or drift pin inserted in one NOTE: For Model 7400, refer to Figure 7-172
of the hydraulic fluid ports in the cushion on page 7-118. For Model 7420/7440,
housing. refer to Figure 7-174 on page 7-120.
Removal
When the snap ring is removed, the
Trucks with AC lift have a staging zone
cushion spring ejects the cushion from
mechanism in the free lift cylinders in addition
the piston. Keep body away from the
to a cushion at the bottom of the cylinder.
piston end when performing this
procedure. 1. Using an eye bolt and hoist, remove the
piston rod from the cylinder.
5. Remove the snap ring from inside of the a. For Model 7400, perform steps 1 thru 9
cylinder. of “Lift Cylinder, Free Lift, Seal
6. Release the cushion slowly. Repacking”, “Model 7400”, “AC Lift”,
“Disassembly” on page 7-121.
7. Remove the ring retainer and seal from the
cushion. b. For Model 7420/7440, perform steps 1
thru 10 of “Lift Cylinder, Free Lift, Seal
8. Replace the cushion, spring, seal, and/or
Repacking”, “Model 7420/7440”,
retainer components as necessary. If
“Disassembly” on page 7-123,
replacing the cushion, install the cap
screw in the end of the cushion. 2. Place the piston rod on a clean padded
working surface.
Reassembly 3. Compress the spring and hold it in place
1. Lubricate the inside of the piston surface of the hydraulic fluid ports in the cushion
with clean hydraulic fluid. housing.

Lift Cylinder Lowering Cushion Hydraulic Components, Cylinder
11. Release the cushion slowly.

12. Reassemble the cylinder.
When the snap ring is removed, the a. For Model 7400, 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 7400”, “AC Lift”,
piston end when performing this “Reassembly” on page 7-121.
procedure.
b. For Model 7420/7440, perform steps 3
4. Remove the snap ring from inside of the thru 12 of “Lift Cylinder, Free Lift, Seal
cylinder. Repacking”, “Model 7420/7440”,
“Reassembly” on page 7-123.
6. Remove the retaining ring and the two Free Lift Cylinders - DC Lift
O-rings on the inside and outside of the
ring. NOTE: Refer to Figure 7-173 on page 7-119.
7. Remove the spring and decel piston.
8. Remove the decel bearing and piston ring Removal
from the decel piston. 1. Using an eye bolt and hoist, remove the
9. Remove the spring and plug from the piston rod from the cylinder. Perform steps
cushion housing (piston plug). 1 thru 8 of “Lift Cylinder, Free Lift, Seal
10. Remove the O-ring from the plug. Repacking”, “Model 7400”, “DC Lift”,
“Disassembly” on page 7-122.
Reassembly 2. Place the piston rod on a clean padded

working surface.
1. Lubricate new O-rings, piston ring, and 3. Compress the cushion to relieve the
decel bearing with clean hydraulic fluid. pressure on the snap ring.
2. Install the new piston ring and decel 4. Compress the spring and hold it in place
bearing in the decel piston. with a drill bit or drift pin inserted in one
3. Lubricate the inside of the piston surface of the hydraulic fluid ports in the cushion
with clean hydraulic fluid. housing.
4. Install the new O-ring in the groove in the
plug and install the plug in the cushion
housing.
When the snap ring is removed, the
5. Seat the plug in the housing by inserting cushion spring ejects the cushion from
the spring and the decel piston in the the piston. Keep body away from the
cushion housing. piston end when performing this
6. Install the other spring. procedure.
7. Install new O-rings on the inside and
5. Remove the snap ring from inside of the
outside of the retaining ring.
cylinder.
8. Install the retaining ring on the shaft of
the decel piston.
7. Remove the ring retainer and seal from the
cushion.
of the hydraulic fluid ports in the cushion 8. Replace the cushion, spring, seal, and/or
housing. retainer components as necessary. If
replacing the cushion, install the cap
10. Install the snap ring in the cushion
screw in the end of the cushion.
housing.

Hydraulic Components, Cylinder Lift Cylinder Lowering Cushion
Reassembly
1. Lubricate the inside of the piston surface
with clean hydraulic fluid.
2. Lubricate the seal with clean hydraulic
fluid and install on the cushion. Install the
retainer ring on the cushion.
3. Insert and seat the cushion spring in the
center of the piston. Insert and seat the
cushion on the end of the cushion spring.
of the hydraulic fluid ports in the cushion
housing.
5. Install the snap ring.
6. Carefully release cushion pressure.
7. Reassemble the cylinder. Perform steps 3
thru 12 of “Lift Cylinder, Free Lift, Seal
Repacking”, “Model 7400”, “DC Lift”,
“Reassembly” on page 7-122.

Reach Cylinder Hydraulic Components, Cylinder
Reach Cylinder 11. Slide the cushion sleeve off the rod. Note
the direction of the taper.
12. Remove the head assembly.
Removal 13. Remove the head static seal O-rings,
1. Remove the mast guard. backup washers, rod inside diameter
dynamic seal, and the rod wiper. Use care
2. Raise the carriage until the reach cylinder to avoid scratching the groove.
is accessible from the operator’s
compartment. 14. Remove the O-ring and backup washers
from the piston assembly.
3. Fully retract the carriage.
Reassembly
5. Place a pan below the reach cylinder. 1. Remove any burrs or sharp edges caused
from disassembly before installing the new
6. Remove and cap the reach hoses at the
seals.
reach cylinder.
2. Clean all parts with solvent. Lubricate
7. Remove the screw and cotter pin holding
parts with petroleum jelly or clean
the piston yoke in place.
hydraulic fluid as indicated.
8. Remove the clevis pin and spacers.
3. Lubricate and install the new rod,
9. Remove the screw and cotter pin at the dynamic seal, and rod wiper in their
housing end. respective inside grooves of the head
10. While supporting the cylinder, remove the assembly.
clevis pin and spacers holding the cylinder 4. Lubricate and install the new head static
in place. seal O-rings and head static seal backup
washers on the outside grooves of the head
Disassembly assembly.
5. Lubricate the head assembly inside seals
1. With the cylinder removed, drain all
and carefully slide the head assembly onto
hydraulic fluid from the cylinder assembly.
the rod assembly.
2. Clamp the cylinder base end in a bench
vise. Cover the ports with a clean rag.
3. Remove the external lock ring.
4. Push the head assembly into the tube
assembly approx. 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).
9. Clamp the rod at the wrench flats or clevis
in a soft-jawed vise. Loosen the retaining
nut on the piston assembly.
10. Slide the piston assembly off the end of the
rod.

Hydraulic Components, Cylinder 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” on page 7-137.
operation.
Adjustment
The top of the scissor roller must not protrude
Figure 7-181. Reach Cylinder more than 0.90 in. (22.8 mm) from the top of
R1022181_B.cgm
6. Install the piston O-ring and backup the roller channel on the fork carriage. This
washers in the outside groove of the piston takes precedence over the extended dimension.
assembly.
Figure 7-182. Scissor Roller Dimension
7. Slide the cushion sleeve onto the rod. 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
groove in the tube assembly bore.
12. Grip the rod firmly and pull outward until
the head assembly is tight against the lock
ring.
13. Install the spacer and external lock ring in
the head assembly.

Reach Cylinder Hydraulic Components, Cylinder
When the reach is fully extended, the (Standard Reach). This is a backup stop only.
dimension from the front of the main frame to Shim the plastic block to produce a gap of:
the face of the forks when level should be:
Carriage Gap
Carriage Dimension
Standard Reach 0.125 to 0.250 in.
R35TT 28.25 in. (717.6 mm) (3.2 to 6.4 mm)
R45TT 28.38 in. (720.00 mm) Deep-Reach 0.125 to 0.375 in.

(3.2 to 9.5 mm)
DR32TT 53.40 in. (1356.4 mm)
Reach Scissor Roller Shimming

Figure 7-183. Reach Fully Extended Dimension
rchadj2.jpg
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 7-184.
Figure 7-184. 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 that
follows.
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 7400/7420/7440 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

Hydraulic Components, Cylinder Tilt Cylinder
Tilt Cylinder Figure 7-185. 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 7-185 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.

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.
back-up 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.
9. Bleed the hydraulic system. See
8. Apply red thread-locking compound “Hydraulic System Bleeding” on page 7-96.
(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.

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 lpm). These flow 2. Install the fitting in the manifold block.
limiters can be replaced without removing the
cylinder. 3. Reconnect the hose to the cylinder.
On Model 7400, 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 7-96.
On Models 7420 and 7440, 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 7-186. Flow Limiter

mainlimiter.jpg

Flow Limiter, Free Lift Hydraulic Components, Cylinder
Flow Limiter, Free Lift Flow Limiter
On Model 7400, the free lift flow limiter is

located in the manifold block at the bottom of
the left side free lift cylinder.
On Models 7420 and 7440, 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 7400
Figure 7-187. Free Lift Flow Limiter, Model 7400
Removal
1045742_D5.cgm
1. Remove the mast guard. Installation

2. Raise the telescopics until the bottom of 1. Install the flow limiter. On Model 7400,
the left free lift cylinder is accessible from make sure the arrow points in the down
the operator’s compartment. direction.
3. Place a block of sufficient length (approx. 2. Install the fitting in the manifold block.
24 in./610 mm) between the outer
3. Install the set screw at the bottom of the
telescopic crosstie and the main frame to
cylinder.
hold the position in step 2.
4. Reconnect the hydraulic line at the bottom
4. Fully lower the carriage. of the cylinder.
5. Extend the reach mechanism to allow 5. Reconnect the battery connector and turn
easier removal of the free lift lines and the key switch ON.
fittings.
6. Remove the block between the outer
telescopic and main frame.
7. Place a pan below the baseleg at the left
free lift cylinder.
8. From the operator’s compartment, remove operation.
and cap the hydraulic line at the bottom of
the free lift cylinder. See Figure 7-187. 9. Install the mast guard.
9. Remove the set screw at the bottom of the
free lift cylinder to permit the cylinder to Model 7420/7440
rotate for the removal of the fitting.
NOTE: The number and location of flow
10. Remove the fitting from the manifold limiter(s) may vary among trucks.
block.
11. Remove the flow limiter noting the Removal
direction of the arrow.
1. Fully lower the mast.
3. Using a suitable hoist, raise the carriage at
least 4 ft. (1.2 m) and secure.

Hydraulic Components, Cylinder Flow Limiter, Free Lift
4. Place a shallow pan below the flow limiter.

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
bottom of the cylinder.
the key switch ON.
4. Using the hoist, lower the carriage
completely.
operation.
Figure 7-188. Free Lift Flow Limiter, Model 7420/7440

1067160_C1.cgm
Flow
Limiter

Flow Limiter, Free Lift Hydraulic Components, Cylinder

Mast, Chain, Hose, Cable
Mast, Chain, Hose, Cable


Reach Carriage Bearings Mast, Chain, Hose, Cable
Reach Carriage Bearings the bearing is fully seated, bend the flat
washer to contact the bearing so the
bearing does not walk on the shaft.
The upper reach carriage roller bearing is
5. Repeat steps 1 thru 4 for the five
accessible when the carriage is elevated. The
remaining bearings.
reach carriage must be removed to access the
middle and lower bearings. The bearings are 6. Clean and re-grease the telescopic
shimmed at the factory to a 0.00 ±0.010 overall channels.
interference between the bearings and the inner 7. Re-install the carriage. See “Carriage” on
telescopic after the inner telescopic is shimmed page 7-151.
and inserted in the outer telescopic. Inspect
8. Test the reach/retract function of the
bearings for damage or wear and replace as
carriage.
required.
Removal Adjustment
1. Remove the carriage. See “Carriage” on Test reach carriage operation. If there is any
page 7-151. kick or forks are not level, adjust eccentric pins
2. Remove the socket head cap screw and as necessary. Start with lower carriage roller
washer on the end of the bearing. bearing pins.
3. The bearing should slide off the shaft with

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./0.25 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.
4. If the inner race of the bearing does not
protrude past the end of the shaft when

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
which is not too tight or too loose. If you find correctly shimmed.
any 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 7-189. Inner Race
2. Place a block between the outer telescopic mastbearshim1.jpg
crosstie and the main frame.

3. Fully lower the carriage.
NOTE: When removing the upper bearings, use
caution not to let the bearing fall down
into the mast assembly. If the bearings
are worn or damaged, replace them.
5. Remove the bolt and roller stud sleeve
securing the roller bearing to the
respective mast or telescopic.
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).

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.

Mast, Chain, Hose, Cable Bow Pads - Model 7400
Bow Pads - Model 7400 Figure 7-191. Inner Telescopic Bow Pads
RPINRCH06R008_img006.jpg
Inspection and Adjustment

1. DR32TT and R45TT: Elevate the mast to
expose the bow pads mounted on the
outside of the inner telescopic. Pads are on
the leading (forks side) edge of the rail. See
2. R35TT: Elevate the mast to expose the bow
pads mounted on the outside of the inner
telescopic and the outside of the outer
telescopic. Pads are on both leading and
trailing edges of the rail. See Figure 7-193
on page 7-150. 4. Shim as required to obtain a gap of 0.03 to
0.09 in. (0.8 to 2.3 mm). On the R35TT
3. DR32TT, R45TT and R35TT: Examine each mast, measure the gaps between the outer
bow pad and measure its thickness. If the telescopic and main frame by elevating the
thickness is <0.187 in. (4.75 mm), replace mast so that the pads are at the top of the
the pad. Lower the mast. Using a suitable main frame.
feeler gauge, check the clearance gap of
the bow pads between the inner telescopic Figure 7-192. Outer Telescopic Bow Pads Model 7400
and the outer telescopic. R35TT Mast
Figure 7-190. Inner Telescopic Bow Pads Model 7400

R45TT/R45TT/DR32TT Mast

Bow Pads - Model 7400 Mast, Chain, Hose, Cable

Figure 7-193. Bow Pad Locations
1043120_C12.cgm,1043120_C13.cgm,1043786_A5.cgm
R35TT Mast R45TT/DR32TT

Mast
2 Bow Pads on each 3 Bow Pads on each

leading and trailing edge of leading edge of
inner and outer telescopic — inner telescopic —
total of 16 pads total of 6 pads

Mast, Chain, Hose, Cable Carriage
Carriage 14. Carefully lift the carriage assembly out of

the mast assembly.
NOTE: Twist the left side free lift pulley to allow
Model 7400 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 approx. 880 lb. (363 kg). A appropriate height and reconnect free lift
Deep-Reach ® carriage without forks chains to the anchors.
weighs approx. 1100 lb. (500 kg). 3. Connect the OTM hoses to the auxiliary
manifold.
Removal 4. Remove the lifting device.
1. Remove mast guard and top cover. 5. Connect the cable to JS2 at carriage and
2. Remove forks. JPS3 in tractor.
3. Remove the mounting bolts from the 6. Attach the manifold cover to the carriage.
hose/cable guide and retainer at the back Apply thread-locking compound
of the carriage. (P/N 1013829) to the mounting bolts and
torque to 30 ft. lb. (42 Nm).
4. Retract scissor assembly.
7. Mount the auxiliary manifold to the
5. Disconnect the OTM cable at JPS3 in the
carriage. Apply thread-locking compound
tractor.
(P/N 990-536) to the mounting bolts and
6. Remove the auxiliary manifold cover and torque to 21 ft. lb. (29 Nm).
disconnect the over-the-mast (OTM) cable
8. Extend the reach. Block the carriage at an
at TS2. Remove the auxiliary manifold
appropriate height to relieve the tension
mounting screws.
on the OTM hoses and cable to install the
7. Elevate the carriage to gain access from hose/cable guide retainer at the back of
the operator’s compartment to the carriage the carriage.
stops and the OTM hose fittings at the
auxiliary manifold.
(P/N 1013829) to the mounting bolts and
8. Turn the key switch OFF and disconnect install the hose/cable guide retainer at the
the battery. back of the carriage.
9. Remove the OTM hoses from the carriage 10. Install the carriage stops.
manifold. Cap hoses and plug the fittings.
11. Install the forks.
10. Remove the carriage stops.
12. Check the tension of the hoses, cable, and
11. Using a suitable lifting device, lift the free lift chains and adjust as required.
carriage assembly to relieve the tension
from the free lift chains.
12. Remove the master link from the free lift
14. Check for leaks and test the truck for
chains at the free lift cylinder anchor
correct operation.
bolts. Twist the right side pulley to allow
the removal of the chain. 15. Install the top cover and mast guard.
13. Drape the chains over the carriage
assembly.

Carriage Mast, Chain, Hose, Cable
Model 7420/7440 Figure 7-194. Model 7440 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 approx. 880 lbs. (363 kg). A
Deep-Reach ® carriage without forks
weighs approx. 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 approx. 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.
6. Using a hoist or other suitable lifting Remove
device, lift the carriage slightly to slacken these
the chains. screws
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
necessary for re-assembly. Do not
remove
11. Loosen and remove the auxiliary hose
these
clamp on the carriage See Figure 7-194. screws
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.

Mast, Chain, Hose, Cable Carriage
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 over-tighten.
NOTE: Observe the four kickback pads and 9. Connect the over-the-mast cable wires at
shims located between the carriage and terminal strip TS-2.
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 7-195. 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.

Chain Anchors Mast, Chain, Hose, Cable
Chain Anchors Figure 7-197. Upper Main Lift Chain Anchor Removal,
Model 7400/7420
chain2.jpg
Main Lift Chain Anchors

Preparation for Removal - 7400 and
7420
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 7-196.
Figure 7-196. 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.), an M8 x 50 mm bolt, and
washers to act as a pulling device. See
Figure 7-198.
Figure 7-198. Anchor Pin Removal, Model 7400/7420

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 - 7400

and 7420
1. Remove the chain anchor bolt and the
3. To hold the chain in position, attach a pair
anchor pin retainer. See Figure 7-197.
of locking pliers to the chain nearest the
chain sheave.
4. Remove the chain anchor from the lift
chain.
Upper Chain Anchor Removal - 7440


Mast, Chain, Hose, Cable Chain Anchors
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 7-196 on telescopic crossties.
page 7-154.
7. Adjust the lift chains until there is a
2. Turn the key switch OFF and disconnect 0.25 in. (6.4 mm) - Model 7400
the battery connector. 0.375 in. (9.5 mm) - Model 7420
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 -
7440
Figure 7-199. Upper Main Lift Chain Anchor, Model 7440
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. (12.7 mm) gap at the narrowest
Adjusting Nut point between the inner and outer
telescopics when the carriage is fully
lowered. Make sure there is equal tension
Upper Chain Anchor Installation - on the lift chains after the adjustment.
7400 and 7420 6. Test the truck for correct operation.
1. Install the mast stop to the chain anchor.

Lower Chain Anchor Removal - 7400
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).


Figure 7-200. Lower Main Lift Chain Anchor, Model 7400 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 - 7440
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 7-202.
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 - 7420 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 7-201.
Figure 7-202. Lower Main Lift Chain Anchor, Model 7440
Figure 7-201. Anti-Kickback Pad and Block, Model 7420 1051602_C8.cgm
Master Link
1051418_E8.cgm
Chain Anchor
Chain Anchor
Block
Bearing Boss
Bearing
Boss
Mounting
Bolt
Lower Chain Anchor Installation -

7400
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 will be used as a anchor block and thread the adjusting nut
preliminary adjustment when on to the distance recorded earlier. Install
re-installing.

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. (12.7 mm) gap at the narrowest
0.25 in. (6.4 mm) gap at the narrowest point between the inner and outer
point between the inner and outer telescopics when the carriage is fully
telescopics when the carriage is fully lowered. Make sure there is equal tension
lowered. Make sure there is equal tension on the lift 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
7420 Upper Chain Anchor Removal - 7400
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.
lowered. Make sure there is equal tension Figure 7-203. Upper Free Lift Chain Anchor, Model 7400
on the lift chains after the adjustment. R1022604_A4.cgm
8. Test the truck for correct operation.
Lower Chain Anchor Installation - Master Link

7440
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

Upper Chain Anchor Removal - 7420 5. Test the truck for correct operation.
and 7440
Figure 7-204. Upper Free Lift Chain Anchor,
1. Elevate the carriage to a convenient Model 7420/7440
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 - 7400

7400 NOTE: Model 7400 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 -

7420 and 7440
1. Install a new master link to the lift chain
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.


Figure 7-205. Lower Free Lift Chain Anchor, Model 7400
R1022604_A1.cgm
Master Link
Chain Anchor
Chain Anchor
Block

7400
1. Screw the chain anchor into the chain
anchor block.
2. Attach a new master link to the chain
3. Reinstall the mast guard.
the key switch ON.
5. Remove blocking from the carriage
6. Test truck for correct operation.
Lower Chain Anchors - 7420 and

7440
Model 7420/7440 lower free lift chain anchors

are welded to the carriage.

Lift Chains Mast, Chain, Hose, Cable
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 7400 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 7-196 on page 7-154. 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 7-198 on
page 7-154. 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
washers to act as a pulling device.
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.

Mast, Chain, Hose, Cable Lift Chains

Figure 7-206. Eccentric Bushing for Main Lift Chain Sheave crosstie. This provides the required slack
in the chains for their removal. See
RSBRCH07004A.jpg

Eccentric
2. Lower the carriage and block at a height
Bushing
that allows access to the chain anchor at
the bottom of the inner telescopic.
Chain the battery connector.
Sheave
4. Remove the anti-kickback pad and block
See Figure 7-207.
Shaft
Figure 7-207. Anti-Kickback Pad and Block, Model 7420
1051418_E8.CGM
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.
the key switch ON.
11. Cycle the telescopic several times to make
sure the lift chain is tracking correctly.
12. Prick punch the eccentric bushing
through the existing set screw hole.
13. Drill a hole 0.13 in. deep on the prick Anti-Kickback Anti-Kickback
punch mark, using the following drill Pad Block
sizes:
5. Note the distance of the adjusting nut
R45TT/DR32TT Mast 7/32 in. (5.5 mm) threads. This distance is used as a
preliminary adjustment when
R35TT Mast 5/32 in. (4 mm) re-installing.
6. Remove the nut from the chain anchor
14. Apply thread-locking compound to the bolt.
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 7-208.
place.
Model 7420
Removal
slightly longer block between the inner
telescopic crosstie and the outer telescopic


Figure 7-208. Upper Main Lift Chain Anchor Removal, 6. Install the chain anchor into the chain
Model 7420 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
point between the inner and outer
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 7440
8. Grasp the chain and remove the anchor
pin. See Figure 7-198 on page 7-154. 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.

Mast, Chain, Hose, Cable Lift Chains
4. Reattach the lower bearing bosses and a. Model 7400: The right side requires the
bearings in the inner telescopic. Torque to removal of a retainer tab and pin rather
130 ft. lb. (176 Nm). than a cotter pin.
5. Lower the inner telescopic to slacken the b. Model 7420/7440: Both sides require
hoist strap. Remove the strap. the removal of a retainer tab and pin
6. Adjust the lift chains until there is a rather than a cotter pin.
Figure 7-210. Retainer Tab (right side)
point between the inner and outer flchain2.jpg

lowered. Make sure there is equal tension
on the lift chains after the adjustment.
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. 7. Remove the chains.
Figure 7-209. Carriage Chain Anchor

flchain1.jpg
Installation
1. Position the chain over the pulley and
fasten the chain to the carriage anchor
with a new master link.
a. Model 7400: Secure the left side with a
cotter pin and the right side with the
pin and retainer tab, applying
thread-locking compound
retainer screw.
b. Model 7420/7440: Secure both sides
with the pin and retainer tab, applying
thread-locking compound
2. Activate “lower” to relieve the tension on retainer screw.
the free lift chains. 2. Fasten the chain to the adjustable chain
3. Turn the key switch OFF and disconnect anchor with a new master link and secure
the battery connector. with a new cotter pin.
4. Remove the mast guard. NOTE: Bend the ends of the cotter pins over 90°
5. Remove the master links at the adjustable after installation.
chain anchors. 3. Reinstall the mast guard.
6. Remove the master links at the carriage 4. Reconnect the battery connector and turn
chain anchors. 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.
7. Fully lower the carriage.
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.

Mast, Chain, Hose, Cable Height Encoder Belt
Height Encoder Belt Figure 7-212. Height Encoder Assembly, 7420

7420HTEncoderAssy.jpg
Do Not Remove These Screws

Model 7420
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 7-211.
Installation
Figure 7-211. Height Encoder Assembly, 7420
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. Accessing the spring through the hole at
the bottom of the mast channel, attach the
spring to the bracket. See Figure 7-213.
Figure 7-213. Height Encoder Belt Tension Spring, 7420
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 7-212.

Height Encoder Belt Mast, Chain, Hose, Cable
4. Thread the belt through the encoder Figure 7-215. Height Encoder Belt and Mast Bearing, 7420
assembly, making sure it is routed
7420HTEncodeMastBearing.jpg
correctly around the toothed gear and Belt

idler. See Figure 7-214.
Figure 7-214. Height Encoder Belt Routing, 7420

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. (12 mm)
Toothed Gear tighter to apply tension to the spring, and
tighten the cable ties. Trim any excess belt
at the loop. See Figure 7-216.
Encoder Assembly
Mounting Screws Figure 7-216. Height Encoder Belt, Top, 7420
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 7-211.
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 7-212.
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 7-215.
11. Elevate the mast, remove the blocking. Lift
and lower the carriage to test correct
operation.

Mast, Chain, Hose, Cable Height Encoder Belt
Model 7440 Figure 7-218. Height Encoder Assembly, 7440

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 7-217. retrieve all the broken pieces. There is an
access hole at the bottom of the outer
Figure 7-217. Height Encoder Assembly, 7440 telescopic.

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 7-219.
Remove These Nuts
Figure 7-219. Height Encoder Belt Tension Spring, 7440
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 7-218. Add Cable
Ties Here
Bracket
3. Thread the belt through the encoder

assembly, making sure it is routed

Height Encoder Belt Mast, Chain, Hose, Cable
correctly around the toothed gear and Figure 7-221. Height Encoder Belt, Top, 7420
idler. See Figure 7-220.
1051604_D6.cgm
Figure 7-220. Height Encoder Belt Routing, 7440

1051610_C2.cgm
Encoder Assembly
Mounting Screws
Hook Eye
Idler
Add Cable
Ties Here
Belt
Belt
Toothed Gear

the key switch ON.
9. Elevate the mast, remove the blocking. Lift
4. Attach the top end of the belt to a stiff wire
and lower the carriage to test correct
and feed the belt up through the encoder
operation.
assembly hole.
5. Loop the belt around the eye at the top of
the mast and clamp it temporarily in
place.
6. Secure the height encoder assembly.
a. If there is an access plate, install the
access plate with the nylon locking
nuts. See Figure 7-217.
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 7-218.
7. 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. (12 mm)
tighter to apply tension to the spring, and
tighten the cable ties. Trim any excess belt
at the loop. See Figure 7-216.

Mast, Chain, Hose, Cable Hose, Main Lift
Hose, Main Lift

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.
4. Position and reinstall the display and Lift
Motor mounting bolts.
the key switch ON.
operation.
8. Install the top cover and the right and left
front cover.

Hose and Cable, Over-the-Mast Mast, Chain, Hose, Cable
Hose and Cable, Figure 7-223. Over-the-Mast Hose/Cable, view from forks
R1018766_C03.cgm
Over-the-Mast
Figure 7-222. 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 7-178.

Mast, Chain, Hose, Cable Hose and Cable, Over-the-Mast
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.
assembly. See Figure 7-224.
Figure 7-224. 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 7-226.
Figure 7-226. 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 7-225.
Figure 7-225. 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 7-223 on
page 7-170.
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

retainers easier. Carefully lower the mast Figure 7-228. Positioning hose retainer
until you have the desired tension. See
OTM_4.JPG
Figure 7-227.
Figure 7-227. Blocking telescopics

OTM_3.JPG
NOTE: Over-the-mast hose lengths on

Model 7400 lift trucks are equal.
Reference Figure 7-259 on page 7-192
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 in. ±0.25 in. below the bracket.
Make sure the cable is long enough to
remove the auxiliary manifold cover and
Installation access TS2. Tighten the retainer. See
NOTE: To help install the retainers, use two Figure 7-229.
modified (M6-1 x 70) bolts to locate and
support the retainer during assembly.
See Figure 7-228.


Figure 7-229. Carriage Hose/Cable Retainer Figure 7-230. 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 7-231.
to the mounting bolt threads and torque to
30 ft. lb. (42 Nm). Figure 7-231. 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.
Free Lift
Retainer

between upper free lift cylinder and
carriage retainers. Temporarily tighten
retainer.
15. Find the correct L2 value from Table 7-11
on page 7-175. 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 7-232.


Figure 7-232. Marking L2 dimension side. Make sure hoses and cable do not
cross each other.
OTM_5.jpg
stretch
24. Install over-the-mast hoses, lift hose, and
cable in retainer at left main lift cylinder.
25. Remove slack from hoses and cable.
Adjust cable grip and spring so that spring
is stretched to an overall length of
L2 dimension 1.75 ±0.12 in. (44.5 ±3 mm) across the
coils. Leave sufficient bend of slack hose
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
16. Reconnect the battery connector and turn Table 7-11 on page 7-175. Measure and
the key switch ON. mark the over-the-mast hoses above the
17. Place block under carriage and lower retainer with the appropriate L1 value in
carriage to relieve tension on hoses. Table 7-11 on page 7-175.
18. Pull down on the hoses until marks are 27. Repeat step 17 of installation procedure.
flush with top of retainers. Tighten the 28. Pull down on the hoses until marks are
four retainer bolts. Do not tighten the flush with the top of the retainers. Tighten
lower clamp bolts on the retainer assembly retainers.
yet. 29. Reconnect the battery connector and turn
19. Install hoses, cable, retainer, and clamp at the key switch ON. Remove blocking from
bottom of free lift cylinder and inner telescopics. Turn the key switch OFF and
telescopic. Carefully elevate the telescopics disconnect the battery connector.
high enough to access the lower retainer 30. Tighten two lower clamp bolts on upper
on free lift cylinder and the retainer on the free lift cylinder hose/cable retainer.
telescopic from the tractor side. Place a
hardwood block of sufficient length 31. Secure hoses and cable to the free lift
between the outer and inner telescopics. cylinder with cable ties every 16 to 24 in.
Carefully lower the mast until you have (40 to 60 cm).
the desired tension. Observe correct 32. Route hoses and cable through the tractor
routing to make sure hoses and cable have opening, along the tractor bulkhead and
sufficient clearance. See Figure 7-227 on attach with the hose/cable clamps. See
page 7-172. Figure 7-233.
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


Figure 7-233. 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 7-11. 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)

Hose Guard Addition Mast, Chain, Hose, Cable
Hose Guard Addition

Service Kit P/N 1061876 contains parts to add
a hose guard to retain slack hoses on the
pulleys in the event forks hang up in the rack
as the mast begins to lower.
(P/N 1013829) to the M6 x 12 flat socket
head screws. Attach the guard weldment
to the new hose guard, but do not tighten
the screws.
2. Remove and discard the existing hose
guard from the pulleys by removing two
M10 x 16 flat socket head screws. Save
screws.
(P/N 1013829) to the M10 x 16 screws.
Install the new hose guard assembly,
using the M10 screws saved in previous
step.
4. Adjust the guard weldment so the 0.5 in.
(12.7 mm) diameter bar sits approx. 0.125
in. (3 mm) from the surface of the auxiliary
hoses. Tighten the M6 x 12 screws the
secure the guard.
Figure 7-234. OTM Hose Pulley Guard

RSB06008.jpg
New Guard
Reuse M10
Screw
Bar
New M6
Screws
New
Weldment
Reuse M10
Screw

Mast, Chain, Hose, Cable Hose/Cable Retainer Upgrade
Hose/Cable Retainer 2. Place a 4 x 4 in. block between the inner

and outer telescopic upper crossties to
Upgrade provide slack in the over-the-mast hoses
and cable.
Early Model 7400 lift trucks used hex head cap 3. Fully lower the carriage.
screws in the main lift cylinder hose/cable 4. Turn the key switch OFF and disconnect
retainer. the battery connector.
5. Mark the over-the-mast hoses and cable to
Later Model 7400 lift trucks use studs and lock aid in tensioning when re-assembling.
nuts in this retainer. This revision helps prevent
hose damage from the retainer hardware. 6. One at a time, remove the four hex head
cap screws from the standoff plate and
Figure 7-235. Main Lift Cylinder Hose/Cable Retainer replace them with studs and lock nuts.
Location Use thread-locking compound
R1018766_C03.cgm
(P/N 990-669) on the stud threads.
NOTE: The insertion end of the stud (end with
shorter length of thread) should not
protrude beyond the front face of the
standoff plate,
Main Lift Figure 7-236. Old and New Style Retainer Hardware
Cylinder R1018766_C4.cgm,1045742_D8.cgm
Hose/Cable Old Style: Hex Head Cap Screws

Retainer
New Style: Studs and Lock Nuts
7. Make sure the over-the-mast hoses and

Conversion Procedure cable are correctly tensioned.
Use the following procedure to convert to the 8. Reconnect the battery connector and turn
newer style hose/cable retainer hardware: the key switch ON. Elevate the carriage
and remove the block. Lower the carriage.
9. Reinstall the mast guard.

Cable, Over-the-Mast Mast, Chain, Hose, Cable
Cable, Over-the-Mast 4. If the tractor frame has pre-drilled holes

for the terminal strip, omit steps 5, 6, and
8.
Terminal Strip Addition for Bulk 5. Using the terminal strip as a template,
Cable Use center punch the tractor frame for the top
mounting hole.
Use the following procedure to convert a Model 6. Drill a hole through the deck using a #36
7400 lift truck for the use of bulk electrical or 0.107 in. bit.
cable in the over-the-mast (OTM) application. 7. Mount the terminal strip with a
thread-forming screw and lock washer.
Table 7-12. Parts for Terminal Strip Conversion
8. Center punch and drill the second hole.
Part Part Number 9. Fasten the terminal strip with the second
thread-forming screw and lock washer.
Terminal strip 1-030-010
10. Cut the electrical OTM cable at deck
Terminal trip numbers 1-030-009 height.
18 spade lugs 1-010-256 11. Strip 3 in. of insulation from tractor end of
OTM cable, strip wires ends and attach
Mounting screws (2) 5-014-004 spade lugs.
Lock washers (2) 5-019-002 12. Attach wires to terminal strip (TS3). See
Table 7-13 and Figure 7-238.
Drill bit #36 or 0.107 in.
13. Secure cable to frame with cable tie and
Cable tie 611-028 adhesive-backed cable tie anchor.
Adhesive-backed cable tie 611-044
Table 7-13. OTM Cable Connections
anchor
JPS3 TS3 TS2

1. Turn lift truck OFF and disconnect the (Tractor) (New) (Carriage)
battery connector.
JS3-1 TS3-1 TS2-1
2. Remove the left front cover.
JS3-2 TS3-2 TS2-2
3. Locate the terminal strip (TS3) on the
outside of the tractor frame between the JS3-3 TS3-3 TS2-3
power amplifier mounting bolts, 3.75 in.
JS3-4 TS3-4 TS2-4
(95 mm) from tractor deck top edge to top
of strip and 1.25 in. (32 mm) from the JS3-5 TS3-5 TS2-5
inside edge of frame to edge of strip. See
Figure 7-237. JS3-6 TS3-6 TS2-6
Figure 7-237. Terminal Strip TS3 Location

DSCF0420.JPG

Mast, Chain, Hose, Cable Cable, Over-the-Mast

Figure 7-238. OTM Cable from Tractor to TS3 Figure 7-239. Blocking the Carriage
DSCF0424.JPG DSCF0427.JPG

Over-the-Mast Cable the battery connector.
Replacement 9. Remove the cable from the retainer/guide
at the back of the carriage and the free lift
This procedure describes the installation of the cylinder pulley. See Figure 7-223 on
new cable as the old one is being removed. You page 7-170.
can use this procedure either with or without 10. Position the cable grip onto the
the terminal strip modification for bulk cable replacement cable so that the spring
use. anchor end of the cable grip is oriented
1. Mark the OTM hoses at all the hose/cable towards the TS2 end of the cable and the
retainers to ensure the correct stretch loop is approx. 20 in. (51 cm) from the end
when reassembled. (If required use of the cable. See Figure 7-240.
Table 7-11, “Over-the-Mast Hose Stretch
Values,” on page 7-175.) Figure 7-240. Cable Grip on TS2 end of OTM cable
DSCF1362.JPG
2. Remove the top cover, left front cover, and

mast guard.
4. Disconnect the OTM cable at connector
JPS3 in the tractor.
5. Remove the auxiliary manifold cover from
the carriage and disconnect the OTM cable
at TS2.
6. Reconnect battery connector and turn key
switch ON.
7. Elevate and block the carriage at an
appropriate height to access the 11. If installing bulk cable, strip 3 in. (76 mm)
hose/retainer and guide at the back of the of insulation from cable, strip wires, and
carriage from the operator compartment. attach spade lugs.
This also relieves tension on the hoses for 12. Attach a cable tie around the braided end
easier assembly. See Figure 7-239. of the cable grip to prevent the grip from
slipping. Do not tighten at this time.
13. Install the new cable in the carriage
retainer/guide and route to TS2.

NOTE: Position the hoses using the marks Figure 7-241. Service Loop (Standard Carriage shown)
made in step 1 and make sure that there
1045742_B5.cgm
is enough slack in the cable for the Carriage

installation and removal of the auxiliary Hose/Cable
Guide
manifold cover.
14. Reconnect battery connector and turn key
switch ON. Remove blocking and lower the
carriage. Turn key switch OFF and
disconnect battery connector. Service Loop
15. Connect cable spade lugs to TS2.
16. Attach aux manifold cover to carriage.
the key switch ON. Elevate and block
carriage as in step 7. Turn the key switch
Tension Spring
OFF.
18. Tighten the carriage hose and cable
retainer.
19. Turn the key switch ON. Remove blocking 23. Position the hoses and cable using the
and lower the carriage. Turn the key marks made in step 1 and tighten the
switch OFF. upper 4 bolts, but not the bottom 2 bolts
20. Feed the cable through the free lift pulley of the upper free lift cylinder retainer.
and position it in the upper free lift 24. Set the tension on the spring at the
cylinder retainer. Do not tighten at this carriage by sliding the cable grip to
time. produce a length of 1.75 ±0.12 in.
NOTE: Remove all twist from the cable when (44.5 ±3.0 mm) across the coils. Do not
installing. over tension. Tighten the cable tie on the
cable grip. See Figure 7-241.
21. Turn the key switch ON. Elevate and block
carriage. Turn the key switch OFF. NOTE: Orient the loop of the cable grip fore-aft
so, as the cable passes through the loop
22. Adjust and tension the cable to allow the of the cable grip and the latch of the
cable to loop away at the bottom edge of cable tie, it does not interfere with the
the hose/cable bracket on the carriage. free lift cylinder mounting pin.
This loop should be 0.75 in. ±0.25 in.
below the bracket. See Figure 7-241. 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.
26. Place a hardwood block of sufficient length
(approx. 30 in.) between the outer and
inner telescopics. This removes the
tension from the OTM hoses and the lift
hose to make the removal and installation
of the retainers easier. Carefully lower the
mast until you have the desired tension.
See Figure 7-242.

Mast, Chain, Hose, Cable Cable, Over-the-Mast

Figure 7-242. Blocking Telescopics Figure 7-243. Retainer Modification for Electrical Cable
DSCF1361.JPG 1045742_D8.cgm
Electrical Lift Hose Aux Hose

Cable Hole Hole Hole
27. Turn the key switch OFF.

28. Remove and install the cable at the lower
free lift cylinder and bottom inner
telescopic hose/cable retainers. Observe
correct routing to make sure hoses and
cable have sufficient clearance. Tighten
the retainers. 31. If installing bulk cable, install cable grip
with the loop pointing down towards the
29. Remove and feed the cable through the tractor. Go to step 33.
pulley at the top of the inner telescopic.
Observe correct routing and make sure the 32. Exact replacement cable: In order to pass
cable is not twisted. connector PS3 past the main lift cylinder
retainer, disassemble the retainer. Remove
30. For exact replacement cable installation, the old cable, insert the new cable.
go to step 32. For bulk cable installation: Reassemble the retainer, but do not
a. If old cable is loose in the main lift tighten.
cylinder cable retainer, the passage 33. Turn the key switch ON. Remove the
hole in the retainer has already been blocking between the inner and outer
enlarged. Remove the old cable and telescopic.
insert the new cable through the
passage hole. 34. Tighten the bottom two bolts of the free lift
cylinder hose/cable retainer.
b. If the old cable is held in place by the
35. Secure hoses and cable to the free lift
main lift cylinder cable retainer, you
cylinder with cable ties every 16 to 24 in.
must enlarge the passage hole. To do
(40.6 to 60.9 cm) as you lower the carriage
this, remove both parts of the retainer,
all the way. Turn the key switch OFF.
clamp them together, and drill out the
passage hole for the electrical cable (not 36. If installing exact replacement cable, pull
the hoses) with a 9/16 in. drill bit. the cable through the main lift cylinder
Reassemble the retainer, aligning retainer until all slack is removed. Mark
witness marks on the hoses, and the cable at the top of the retainer. Tighten
tighten the bolts. Insert the new cable the retainer bolts.
through the passage hole. See 37. Set the tension on the spring at the
Figure 7-243. 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.


Figure 7-244. Main Lift Cylinder Retainer Cable Spring 2. Strip 3 in. (76 mm) of insulation from the
Tension cable, strip the wires, and attach spade
DSCF1352.JPG
lugs.
3. Connect the wires to the terminal strip.
See Table 7-13 on page 7-178.
NOTE: Colors will not match at TS2.
4. Attach cable to frame with cable tie and
self-adhesive cable tie anchor. See
Figure 7-245.
Figure 7-245. Cabling at Terminal Strip

DSCF0449.JPG
38. If replacing cable with bulk cable, refer to

“Bulk Cable Installation”.
Replacement Cable Installation

1. Turn the key switch ON. Elevate the
carriage and place a hardwood block
between the inner and outer telescopic.
Carefully lower the carriage to relieve the
hose and cable tension. Turn the key
switch OFF. 5. Install the mast guard, top cover, and front
2. Position the cable so that the mark on the left cover.
cable is 0.5 in. (13 mm) above the retainer.
3. Position the OTM hoses and the lift hose
as marked in step 1 of Over-the-Mast
Cable Replacement. Tighten the retainer.
4. Turn the key switch ON. Remove the block
between the inner and outer telescopic.
5. Lower the carriage. Turn the key switch
OFF.
6. Remove and route the cable along the
tractor bulkhead, through the tractor
opening, and attach with the hose/cable
clamps.
7. Connect the OTM cable to connector JPS3.
Go to step 5 in Bulk Cable Replacement
procedure.
Bulk Cable Installation

1. Cut the OTM cable 20 in. (508 mm) past
the bottom of the main lift cylinder
retainer.

Mast, Chain, Hose, Cable Hose/Tubing, Free Lift Feed
Hose/Tubing, Free Lift Figure 7-246. Free Lift Feed Hose/Tube, Model 7400
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 7-247. Free Lift Tubing, Model 7420/7440
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
Figure 7-246 and Figure 7-247.
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.

Mast, Model 7400 (Complete Disassembly) Mast, Chain, Hose, Cable
Mast, Model 7400 blocked where it meets the mast before

loosening the mast mounting bolts.
(Complete Disassembly) 13. Place blocks snugly under the tractor near
the mast.
Separation of Tractor and Mast 14. Attach a lifting strap around the top
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. 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 16. Using a lift truck, carefully separate the
helmet (hard hat). tractor about 6 in. (15 cm).
1. Lower and retract the fork carriage
17. Remove the hose/cable retaining bracket
completely.
on the front of the tractor bulkhead.
2. Turn the key switch OFF and disconnect 18. Remove the hose/cable retainer on the
the battery connector. Remove battery main lift cylinder.
gates. Using a suitable battery removal
device, remove the battery. 19. Reinstall mast mounting bolts and
washers and tighten lightly (to prevent
3. Remove the top cover and the left and right misplacing them).
front covers.
Hose/Cable, Free Lift Cylinder,
5. Secure a hoist strap around the overhead
guard. Take the weight off the guard.
and Carriage Removal
Remove mounting bolts. Remove the 1. Remove the auxiliary manifold cover from
guard. the carriage. See Figure 7-248 on
6. Disconnect and cap right side main lift page 7-185.
hose at the tractor bulkhead fitting. 2. Disconnect the wires of the over-the-mast
7. Disconnect the ambient temperature cable from the terminal strip, labeling as
sensor connector JPA on the tractor deck. needed for reconnection.
8. Disconnect the mast switch connector 3. Remove auxiliary manifold mounting
JPS4 (near the lift pump). Feed harness screws to permit access to the
through tractor opening at left side. over-the-mast hose fittings at the
manifold.
9. Disconnect over-the-mast cable connector
JPS3 on the tractor deck. NOTE: There may be shims between the
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.
12. Disconnect the main lift hose fitting at the
left side of the tractor.
NOTE: Make sure the weight of the mast is fully
supported by the hoist and the tractor is

Mast, Chain, Hose, Cable Mast, Model 7400 (Complete Disassembly)

Figure 7-248. Auxiliary Manifold Access 17. Disconnect and cap the hose to the left
main lift cylinder.
DSC_0942a.jpg
18. Rig lifting straps around the carriage.

Using a hoist, carefully lift the carriage out
of the inner telescopic and lower the
carriage to the floor.
Main Lift Chain Removal

1. Rig a lifting strap of one hoist around the
lower crosstie of the main frame (the one
where the overhead guard attaches).
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
ensure 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. See
Remove master links on free lift chains. Figure 7-249 this page and Figure 7-198
Feed free lift chains through pulleys and on page 7-154.
drape over front of carriage.
Figure 7-249. Main Lift Chain Upper Chain Anchor
7. Remove hose/cable retaining block on R1020561_A1.cgm
back of carriage. Bolt

8. Remove hoses and cable from guide at
back of carriage. Cover
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.
11. Remove tee tubing from free lift cylinders. Chain
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
screws so they are not misplaced. 5. Pull the chain anchor/mast stop out of the
main frame.
13. Remove carriage stops from back of
carriage. 6. Feed main lift chains from inside to
outside over the chain sheave.
14. Remove the lower hose/cable pulley from
the top of the outer telescopic.
15. Remove the upper hose/cable pulley from
Separation of Telescopics
the top of the outer telescopic. 1. Using the hoists, carefully lower the mast
16. Disconnect the tee tubing to the right side to a horizontal position on jack stands.
main lift cylinder.

2. Loosen the L-bracket bolts holding the Figure 7-252. Outer Telescopic Lower Bearing and
main lift cylinders to the telescopic. Anti-Rattle Pads
R1020561_A4.cgm
3. Remove the top mounting bolt, washer,

and sleeve holding the main lift cylinder to
the outer telescopic. See Figure 7-250. Shim
Figure 7-250. Main Lift Cylinder Mounting Hardware

R1020561_A2.cgm
Mounting Bolt
Washer
Sleeve
Pad Cover
6. Remove anti-rattle pads and shims from

Outer bottom of inner telescopic. See
Telescopic Figure 7-253.
Figure 7-253. Inner Telescopic Lower Bearing and

Anti-Rattle Pads
4. Remove main lift chain sheaves from top of 1043786_A6.cgm
outer telescopic. Sheaves attach with a pin

and a set screw on the inside. See
Shim
Figure 7-251.
Figure 7-251. Main Lift Chain Sheave Pad

1043786_A7.cgm
Sheave Set Screw
Spacer Chain
Bearing
Snap Ring
Pin
Shim
Pad
bottom of outer telescopic. See
Figure 7-252.
7. Using a suitable hoist, pull the inner

telescopic halfway out of the outer
telescopic.

8. Remove the upper roller bearings and

shims from the top of the outer telescopic.
See Figure 7-254.
Figure 7-254. Outer Telescopic Upper Bearing

R1020561_A6.cgm
Sleeve
Stud
Shims
Bearing
9. Remove the lower roller bearings and

shims from the bottom of the inner
telescopic. See Figure 7-253.
10. Using a suitable hoist, remove the inner
telescopic from the outer telescopic.
11. Using a suitable hoist, pull the outer
telescopic halfway out of the main frame.
shims from the main frame. See
Figure 7-255.
Figure 7-255. Main Frame Upper Bearing

1043786_A10.cgm
Bolt
Stud
Shims
Bearing

shims from the outer telescopic. See
Figure 7-252.
14. Using a suitable hoist, remove the outer
telescopic from the main frame.

Mast, Model 7400 (Complete Assembly) Mast, Chain, Hose, Cable
Mast, Model 7400 Figure 7-256. Inner Race

mastbearshim1.jpg
(Complete Assembly)
Assembling and Shimming
Outer Telescopic to Main Frame
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
of the outer telescopic. Make sure the flat
spot on the bearing outer stud is correctly
positioned against the mast. This is
9. Using the hoist, slide the outer telescopic
important because the correct bearing
the entire length of the main frame,
alignment is canted with respect to the
checking for binding. The tightest spots
channel. See Figure 7-252.
are generally at the crossties. Add or
3. Using a suitable hoist, insert the outer remove shims as necessary to maintain a
telescopic into the main frame as far as snug but free-running fit.
the crosstie.
4. Attach the lower roller bearing to the other Upper Bearings of Main Frame
side of the outer telescopic.
1. With the outer telescopic inserted halfway
5. Using a pry bar, move the outer telescopic
into the main frame, attach the upper
and bearing to one side.
roller bearing to one side of the main
6. Use spare shims as a gauge to determine frame. Make sure the flat spot on the
the amount of shims required to cause the bearing outer stud is correctly positioned
roller bearing to contact the main frame. against the mast. See Figure 7-255.
7. Remove both lower bearings. Install one 2. Attach, but do not tighten, the upper roller
half of the total shim thickness required to bearing to the other side of the main
each roller bearing. Reinstall the bearings. frame.
3. Use spare shims as a gauge to determine
(P/N 990-536) to the bearing mounting
the amount of shims required to cause the
bolt and torque to 260 ft. lb. (352 Nm).
roller bearing to contact the outer
8. If the inner race of the bearing does not telescopic.
protrude past the end of the bearing stud
4. Remove both upper bearings. Install one
half of the total shim thickness required to
each roller bearing. Reinstall the bearings.
prevent the bearing from walking on the
stud shaft. See Figure 7-256.

Mast, Chain, Hose, Cable Mast, Model 7400 (Complete Assembly)
6. Using the hoist, slide the outer telescopic as necessary to maintain a snug but
the entire length of the main frame, free-running fit.
checking for binding. Add or remove shims
as necessary to maintain a snug but Upper Bearings of Outer Telescopic
free-running fit.
1. With the inner telescopic inserted halfway
7. R35TT mast only: Check the clearance
gap of the bow pads between outer
roller bearing to one side of the outer
telescopic and main frame. Shim as
telescopic. Make sure the flat spot on the
required to obtain a gap of 0.03 to 0.09 in.
bearing outer stud is correctly positioned
(0.8 to 2.3 mm).
against the mast. See Figure 7-254.
2. Attach, but do not tighten, the upper roller
Assembling and Shimming bearing to the other side of the outer
Inner Telescopic to Outer telescopic.
Telescopic 3. Use spare shims as a gauge to determine
Lower Bearings of Inner Telescopic roller bearing to contact the inner
telescopic.
of the inner telescopic. Make sure the flat 4. Remove both upper bearings. Install one
spot on the bearing outer stud is correctly half of the total shim thickness required to
positioned against the mast. See each roller bearing. Reinstall the bearings.
Figure 7-253. Apply thread-locking compound
2. Using a suitable hoist, insert the inner bolt and torque to 260 ft. lb. (352 Nm).
telescopic into the outer telescopic as far
as the crosstie. 5. If the inner race of the bearing does not
3. Attach the lower roller bearing to the other when the bearing is fully seated, bend the
side of the inner telescopic. flat washer to contact the bearing to
4. Using a pry bar, move the inner telescopic prevent the bearing from walking on the
and bearing to one side. stud shaft. See Figure 7-256.
5. Use spare shims as a gauge to determine 6. Using the hoist, slide the inner telescopic
the amount of shims required to cause the the entire length of the outer telescopic,
roller bearing to contact the outer checking for binding. Add or remove shims
telescopic. as necessary to maintain a snug but
6. Remove both lower bearings. Install one free-running fit.
half of the total shim thickness required to 7. Check the clearance gap of the bow pads
each roller bearing. Reinstall the bearings. between inner telescopic and outer
Apply thread-locking compound telescopic. Shim as required to obtain a
(P/N 990-536) to the bearing mounting gap of 0.03 to 0.09 in. (0.8 to 2.3 mm).
7. If the inner race of the bearing does not Main Lift Chain Installation
1. Install anti-rattle pads and shims at
bottom of inner and outer telescopics.
Shim so pads are snug against mast. See
Figure 7-252 and Figure 7-253.
2. Install the main lift chain sheaves to the
8. Using the hoist, slide the inner telescopic
top of the outer telescopic. Sheaves install
the entire length of the outer telescopic,
with a large pin and a set screw on the
inside. See Figure 7-251.

3. Install but do not tighten a new sleeve and Shimming Carriage to Inner
collar, washer, and mounting bolt through Telescopic
the telescopic crosstie and into the
cylinder housing of each main lift cylinder. 1. Drape the free lift chains forward over the
See Figure 7-250. carriage back rest. Rig lifting straps
around the carriage.
4. Rig lifting straps around the upper
crossties of all three mast sections. 2. Install the lower set of roller bearings,
5. Using a suitable hoist, raise the mast to a without shims, in the carriage.
vertical position. 3. Using a hoist, carefully lift the carriage
6. Rig a lifting strap of one hoist around the and insert it into the inner telescopic until
lower crosstie of the main frame (the one the bearings just enter the telescopic.
where the overhead guard attaches). 4. Using a pry bar, move the carriage
bearings to one side.
the top crossties of both inner and outer 5. Use spare shim(s) as a gauge to determine
telescopics. Using the hoist, lower the the amount of shims required to remove
telescopics to about 10 in. (25 cm) from side play.
the floor. 6. Remove the carriage from the inner
8. Make sure the two holes in the upper telescopic far enough to expose the
chain anchor block are towards the bearings being shimmed.
outside. Feed the main lift chain from the 7. Remove the bearings being shimmed from
outside to the inside over the chain the carriage. Install one half of the total
sheave. shim thickness required to each roller
9. Feed the upper chain anchor block down bearing.
between the main frame and outer 8. Using the hoist, reinsert the carriage into
telescopic until holes are aligned between the inner telescopic. Check for tight areas
block and main frame. Insert the chain while moving the carriage to the bottom of
anchor bolt (without the access cover) and the inner telescopic.
lightly tighten the bolt to draw the chain
9. Remove the carriage from the inner
anchor block to the main frame.
telescopic far enough to expose the
10. Thread a bolt into the hole in the chain bearings being shimmed.
anchor retaining pin. Insert the pin and
10. Remove the bearings being shimmed from
drive it in. Remove the bolt from the pin.
the carriage.
11. Remove the chain anchor bolt. Apply
thread-locking compound (P/N 990-544) NOTE: The carriage may have to be removed
to bolt threads. Install access cover and several times to obtain the correct fit.
torque bolt to 130 ft. lb. (174 Nm). 11. Install the center 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. 12. Repeat steps 4 thru 10 for the center set of
13. Install master links to attach the main lift bearings.
chains to the lower chain anchor blocks. 13. Install the upper set of roller bearings,
Lower the telescopics completely. Tighten without shims, in the carriage.
the chain anchor nuts until the inner
14. Repeat steps 4 thru 10 for the upper set of
telescopic just lifts off its stops.
bearings.

Carriage, Free Lift Cylinder, and Figure 7-258. Over-the-Mast Hose/Cable Pulleys
(newer style)
Hose/Cable Installation 1045742_D2.cgm
Torque to 130 ft. lb. (174 Nm)

1. Drape the free lift chains forward over the
carriage back rest. Rig lifting straps
around 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
thread-locking compound (P/N 1013829)
to the threads of the studs and torque as
shown in Figure 7-257 and Figure 7-258.
3. Route auxiliary hoses around lower Torque to 43 ft. lb. (58 Nm)
pulleys. Attach lower hose pulley to the 4. Install carriage stops. Apply
top of the outer telescopic. Apply thread-locking compound (P/N 990-536)
thread-locking compound (P/N 1013829) to mounting bolts and torque to 35 ft. lb.
to the threads of the studs and torque as (47.5 Nm).
shown in Figure 7-257 and Figure 7-258. 5. Remove set screws from free lift mounting
blocks. Lift each free lift cylinder into place
Figure 7-257. Over-the-Mast Hose/Cable Pulleys
(older style) over the mounting hook at the top and the
R1018766_C6.cgm mounting block at the bottom. Apply
Torque to to set screw threads and install set screws
130 ft. lb. in mounting blocks.
(174 Nm)
6. Reference Figure 7-259 for the following
steps, that route the hoses/cable.
NOTE: Lift trucks below S/N 03069 require
rerouting of the over-the-mast cable and
hoses and/or modification. See
Raymond Service Bulletin RCH-05-018
dated 30 August 2005.


Figure 7-259. Over-the-Mast Hose and Cable Installation Figure 7-260. 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 7-261.
Figure 7-261. 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

retainer bracket at the bottom of the free
7. Connect tee tubing to free lift cylinders.

See Figure 7-260.


Figure 7-262. Lower Hose/Cable Retainer, Free Lift Figure 7-264. 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 7-263. 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.
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 7-264.


Figure 7-265. OTM hose and cable routing 18. Attach the manifold to the carriage. Apply
1045742_B7.jpg,1045742_D4.CGM
to the mounting bolt threads and torque to

21 ft. lb. (29 Nm).
Aux Hose A2
19. Connect the over-the-mast cable wires to
the terminal block on the auxiliary
Aux Hose A1
manifold cover. Attach the manifold cover
to the carriage. Apply thread-locking
compound (P/N 990-536) to the mounting
Electrical Cable
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
hoist, lift the inner telescopic about 6 in.
(15 cm).
22. Tighten the hose/cable retainer on the left
side main lift cylinder.
Aux Hose A2
23. Lower the inner telescopic.
Aux Hose A1
Electrical Cable 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 7-266.
3. With the mast secured by a hoist, use a lift
truck to mate the tractor to the mast.
(P/N 990-666) to mast mounting bolt
14. Install hose/cable retainer on carriage. threads and hole threads. Permit to dry for
See Figure 7-264. several minutes.
15. Lower the carriage all the way to the floor. 5. Apply thread-locking compound
16. Tighten the upper and lower hose/cable (P/N 990-544) to threads of mast
retainers on the free cylinders. Attach two mounting bolts.
cable ties on the upper retainer. 6. From the battery compartment, thread
17. With the auxiliary manifold removed from eight mounting bolts and washers through
the carriage, connect auxiliary hydraulic bottom of the tractor frame into the mast.
hoses to the manifold, making sure to Thread four mounting bolts and washers
observe correct labeling. through the top of the tractor frame into
the mast. Torque to 165 ft. lb. (224 Nm).

7. Connect the main lift hose fitting at the left 16. Install the mast guard.
side of the tractor. 17. Using a suitable battery moving device,
8. Route the auxiliary hoses and electrical install the battery. Install battery gates.
cable through the tractor opening. Secure 18. Attach front covers and top cover.
hoses and cable with retainer clamp. See
Figure 7-266. 19. Make sure all hoist straps and blocks are
removed.
Figure 7-266. Hose/Cable Retainer Clamps on Tractor 20. Reconnect the battery connector and turn
R1018766_C7.cgm
the key switch ON.

22. Test all lift truck functions.
23. Elevate the inner telescopic about 12 in.
(30 cm). Torque the main cylinder top
mounting bolts. Tighten main lift cylinder
Retainer
Clamps
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 7-221.
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.
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).

Mast, Model 7420 12. Place blocks snugly under the tractor near
the mast.
(Complete Disassembly) 13. Attach a lifting strap around the top
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.
• Do this procedure with a minimum 14. Remove the battery connector bracket to
of two technicians in a shop permit access to the top right mast
equipped with a suitable hoist. mounting bolts.
• Do not permit observers to stand 15. Use an impact wrench to remove the mast
nearby. 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. Reinstall mast mounting bolts and
2. Turn the key switch OFF and disconnect washers and tighten lightly (to prevent
the battery connector. Remove battery misplacing them).
device, remove the battery. Hose/Cable, Free Lift Cylinder,
3. Remove the top cover and the left and right and Carriage Removal
front covers.
1. Remove the auxiliary manifold cover from
the carriage. See Figure 7-267 on
5. Secure a hoist strap around the overhead page 7-197.
guard. Take the weight off the guard.
2. Disconnect the wires of the over-the-mast
Remove mounting bolts. Remove the
cable from terminal strip TS-2, labeling as
guard.
needed for reconnection.
6. Disconnect and cap right side main lift
3. Remove auxiliary manifold mounting
hose at the tractor bulkhead fitting.
screws to permit access to the
7. Disconnect the ambient temperature over-the-mast hose fittings at the
sensor connector JPA on the tractor deck. manifold.
8. Disconnect the mast switch connector
NOTE: There may be shims between the
JPS4 (near the lift pump). Feed harness
through tractor opening at right side.
JPS3 on the tractor deck.
needed for correct reassembly. Feed hoses
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


Figure 7-267. Auxiliary Manifold Access Figure 7-269. U-clamp, OTM Electrical Cable
DSC_0942a.jpg 1066854_B2.cgm
U-clamp
4. Disconnect and plug/cap the

over-the-mast hoses and fittings at the
auxiliary manifold. Label as needed to
ensure correct reconnection.
5. Place a chalk witness mark on the hoses to 8. Cut cable ties on hose clamps on left side
aid in reassembly. free lift cylinder.
6. Remove hose retaining clamp near top of 9. Loosen the hose retaining clamp on the
the left side free lift cylinder. carriage near the bottom of the left side
See Figure 7-268. free lift cylinder. Slide clamp inward to free
the hoses. See Figure 7-270.
Figure 7-268. Hose Retaining Clamp, Left Free Lift Cylinder
1066854_B11.cgm
Figure 7-270. Hose Retaining Clamp, Left Free Lift Cylinder,

Bottom
1066854_B13.cgm
Hose
Retaining
Clamp
Hose
Retaining
Clamp
7. Loosen the U-clamp on the right side free

lift cylinder and feed the over-the-mast
cylinder pulleys.
(OTM) cable through. See Figure 7-269.
11. Jack carriage up about 3 in. (7.6 cm) to
provide slack in chains. Remove master
links on free lift chains. Feed free lift

chains through pulleys and drape over Main Lift Chain Removal
front of carriage.
12. Remove carriage stops at the top of the
inner telescopic.
where the overhead guard attaches).
the top crossties of both inner and outer
telescopics. Using the hoist, raise the
telescopics about 10 in. (25 cm).
14. Disconnect and plug the hydraulic supply
3. Remove the kickback block, pads, and
hose at the bottom of the free lift cylinders.
shims at the bottom of the inner
15. Disconnect the free lift crossover hose and telescopic. See Figure 7-272.
cap both cylinders.
16. Remove the nylon locking nut from the Figure 7-272. Inner Telescopic Kickback Block, Pad, Shims
1051418_E8.cgm
mounting stud on the free lift cylinder. Lift

each free lift cylinder off the mounting Kickback
stud at the top and off the pin at the Block
bottom. See Figure 7-271.
Figure 7-271. Free Lift Cylinder Mounting Stud and Pin Mounting
1051676_D.cgm
Screws (2)
Free Lift Cylinder
Mounting Stud
Kickback Kickback
Pad Shim
4. Remove the chain anchor retaining nut

from the chain anchor block at the bottom
of the inner telescopic.
5. Remove the bolt and access cover to the
upper chain anchor at the sides of main
frame. See Figure 7-273.
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
Free Lift Cylinder
washers to act as a pulling device.
Mounting Pin
See Figure 7-273 this page and


Figure 7-273. Main Lift Chain Upper Chain Anchor Figure 7-275. Main Lift Chain Sheave
R1020561_A1.cgm 1051418_E6.cgm
Bolt Sheave
Cover Chain
Spacer
Bearing
Pin
Snap Ring
Chain
Anchor
Pin
Retaining Screw
7. Pull the chain anchor/mast stop out of the

main frame.
8. Feed main lift chains from inside to bottom of outer telescopic. See
outside over the chain sheave. Figure 7-276.
Figure 7-276. Outer Telescopic Lower Bearing and

Separation of Telescopics Anti-Rattle Pads
1051418_E7.cgm
1. Using the hoists, carefully lower the mast

to a horizontal position on jack stands.
2. Loosen the L-bracket bolts holding the
main lift cylinders to the telescopic.
the outer telescopic. See Figure 7-274.
Figure 7-274. Main Lift Cylinder Mounting Hardware

1051674_B.cgm
Mounting Bolt
Washer Pad Shim Cover
Sleeve 6. Using a suitable hoist, pull the inner

telescopic.
See Figure 7-277.
Outer
Telescopic
4. Remove main lift chain sheaves from top of

outer telescopic. Sheaves attach with a pin
and a retaining screw on the front. See
Figure 7-275.


Figure 7-277. Outer Telescopic Upper Bearing
1051418_E6.cgm
Stud
Shim
Bearing
Bearing Retaining
Screw and Washer

shims from the main frame. See
Figure 7-278.
Figure 7-278. Main Frame Upper Bearing

1051418_E5.cgm
Bolt
Stud
Bearing
Retaining
Shim Screw and
Washer
Bearing

shims from the outer telescopic. See
Figure 7-276.


mastbearshim1.jpg
(Complete Assembly)
of the outer telescopic. Make sure the flat
spot on the bearing outer stud is correctly
positioned against the mast. This is
9. Using the hoist, slide the outer telescopic
important because the correct bearing
the entire length of the main frame,
alignment is canted with respect to the
checking for binding. The tightest spots
channel. See Figure 7-276.
are generally at the crossties. Add or
3. Using a suitable hoist, insert the outer remove shims as necessary to maintain a
telescopic into the main frame as far as snug but free-running fit.
the crosstie.
4. Attach the lower roller bearing to the other Upper Bearings of Main Frame
5. Using a pry bar, move the outer telescopic
roller bearing to one side of the main
6. Use spare shims as a gauge to determine frame. Make sure the flat spot on the
the amount of shims required to cause the bearing outer stud is correctly positioned
roller bearing to contact the main frame. against the mast. See Figure 7-278.
7. Remove both lower bearings. Install one 2. Attach but do not tighten the upper roller
half of the total shim thickness required to bearing to the other side of the main
each roller bearing. Reinstall the bearings. frame.
roller bearing to contact the outer
8. If the inner race of the bearing does not telescopic.

6. Using the hoist, slide the outer telescopic roller bearing to one side of the outer
the entire length of the main frame, telescopic. Make sure the flat spot on the
checking for binding. Add or remove shims bearing outer stud is correctly positioned
as necessary to maintain a snug but against the mast. See Figure 7-272.
free-running fit. 2. Attach but do not tighten the upper roller
bearing to the other side of the outer
Assembling and Shimming telescopic.
Inner Telescopic to Outer 3. Use spare shims as a gauge to determine
Telescopic the amount of shims required to cause the
roller bearing to contact the inner
telescopic.
Lower Bearings of Inner Telescopic
1. Attach the lower roller bearing to one side half of the total shim thickness required to
of the inner telescopic. Make sure the flat each roller bearing. Reinstall the bearings.
spot on the bearing outer stud is correctly Apply thread-locking compound
positioned against the mast. See (P/N 990-536) to the bearing mounting
Figure 7-272. bolt and torque to 260 ft. lb. (352 Nm).
2. Using a suitable hoist, insert the inner 5. If the inner race of the bearing does not
telescopic into the outer telescopic as far protrude past the end of the bearing stud
as the crosstie. when the bearing is fully seated, bend the
3. Attach the lower roller bearing to the other flat washer to contact the bearing to
side of the inner telescopic. prevent the bearing from walking on the
4. Using a pry bar, move the inner telescopic
and bearing to one side. 6. Using the hoist, slide the inner telescopic
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
between inner telescopic and outer
telescopic. Shim as required to obtain a
gap of 0.03 to 0.09 in. (0.8 to 2.3 mm).
Main Lift Chain Installation
protrude past the end of the bearing stud 1. Install anti-rattle pads and shims at
when the bearing is fully seated, bend the bottom of inner and outer telescopics.
flat washer to contact the bearing to Shim so pads are snug against mast. See
prevent the bearing from walking on the Figure 7-276 and Figure 7-272.
stud shaft. See Figure 7-279. 2. Install the main lift chain sheaves to the
8. Using the hoist, slide the inner telescopic top of the outer telescopic. Sheaves install
the entire length of the outer telescopic, with a large pin and a retaining screw on
checking for binding. Add or remove shims the front. See Figure 7-275.
as necessary to maintain a snug but 3. Install but do not tighten a new sleeve and
free-running fit. collar, washer, and mounting bolt through
the telescopic crosstie and into the
Upper Bearings of Outer Telescopic cylinder housing of each main lift cylinder.
See Figure 7-274.

4. Rig lifting straps around the upper 3. Using a hoist, carefully lift the carriage
crossties of all three mast sections. and insert it into the inner telescopic until
5. Using a suitable hoist, raise the mast to a the bearings just enter the telescopic.
vertical position. 4. Using a pry bar, move the carriage
6. Rig a lifting strap of one hoist around the bearings to one side.
lower crosstie of the main frame (the one 5. Use spare shim(s) as a gauge to determine
where the overhead guard attaches). the amount of shims required to remove
7. Rig a lifting strap of another hoist around side play.
the top crossties of both inner and outer 6. Remove the carriage from the inner
telescopics. Using the hoist, lower the telescopic far enough to expose the
telescopics to about 10 in. (25 cm) from bearings being shimmed.
the floor. 7. Remove the bearings being shimmed from
8. Make sure the two holes in the upper the carriage. Install one half of the total
chain anchor block are towards the shim thickness required to each roller
outside. Feed the main lift chain from the bearing.
outside to the inside over the chain 8. Using the hoist, reinsert the carriage into
sheave. the inner telescopic. Check for tight areas
9. Feed the upper chain anchor block down while moving the carriage to the bottom of
between the main frame and outer the inner telescopic.
telescopic until holes are aligned between 9. Remove the carriage from the inner
block and main frame. Insert the chain telescopic far enough to expose the
anchor bolt (without the access cover) and bearings being shimmed.
lightly tighten the bolt to draw the chain
anchor block to the main frame. 10. Remove the bearings being shimmed from
the carriage.
10. Thread a bolt into the hole in the chain
anchor retaining pin. Insert the pin and NOTE: You might need to remove the carriage
drive it in. Remove the bolt from the pin. several times to obtain the correct fit.
11. Remove the chain anchor bolt. Apply 11. Install the center set of roller bearings,
thread-locking compound (P/N 990-544) without shims, in the carriage.
to bolt threads. Install access cover and 12. Repeat steps 4 thru 10 for the center set of
torque bolt to 130 ft. lb. (174 Nm). bearings.
12. Lower the telescopics into the main frame 13. Install the upper set of roller bearings,
approx. 3 in. (7.6 cm) from the floor. without shims, in the carriage.
13. Insert chain anchor bolts into chain 14. Repeat steps 4 thru 10 for the upper set of
anchor blocks. Lower the telescopics bearings.
completely. Tighten the chain anchor nuts
until the inner telescopic is 3/8 in.
(9.5 mm) off of the outer telescopic. Carriage, Free Lift Cylinder, and
Hose/Cable Installation
Shimming Carriage to Inner 1. Drape the free lift chains forward over the
Telescopic carriage backrest. Rig lifting straps around
the carriage. Using a hoist, carefully lift
1. Drape the free lift chains forward over the the carriage and insert it into the inner
carriage back rest. Rig lifting straps telescopic and lower the carriage to about
around the carriage. 3 in. (7.6 cm) above the floor.
2. Install the lower set of roller bearings, 2. Route lift hose and cable around upper
without shims, in the carriage. pulleys. See Figure 7-280.

3. Route auxiliary hoses around lower Figure 7-281. Over-the-Mast Hose and Cable Installation
pulleys. See Figure 7-280.
1066854_B2.cgm

(newer style)
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 7-271 on
page 7-198.
6. Reference Figure 7-281 for the following
steps, which route the hoses/cable.
NOTE: Lift trucks below S/N 03069 require
rerouting of the over-the-mast cable and
hoses and/or modification. See
Raymond Service Bulletin RCH-05-018
dated 30 August 2005.
U-Clamp
7. Connect supply hose and crossover tubing

to free lift cylinders. See Figure 7-282.


Figure 7-282. Free Lift Cylinder Hose Connection Figure 7-284. 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 7-283.
Figure 7-283. 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
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 7-281 on
page 7-204.
13. Attach and tighten the hose retaining
clamp near top of the left side free lift
cylinder. See Figure 7-268 on page 7-197.
14. 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.
9. Feed hydraulic hoses and electrical cable 15. Take slack out of hoses and cable.
through the free lift pulleys, from tractor
side to forks side. See Figure 7-284. 16. Lower the carriage all the way to the floor.
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

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.
(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.
Figure 7-221.
tractor near the lift pump. Connect
connector JPS4.

Mast, Model 7440 needed for correct reassembly. Feed hoses

(Complete Disassembly)
Separation of Tractor and Mast Make sure the weight of the mast is fully
blocked where it meets the mast before
Perform this procedure with a minimum
of two technicians in a shop equipped 11. Place blocks snugly under the tractor near
with a suitable hoist. the mast.
12. Attach a lifting strap around the top
Do not permit observers to stand crossties of all three mast sections. Draw
nearby. tight with hoist. Make sure the weight of
the mast is supported by the hoist.
Wear gloves, safety glasses, steel-toed 13. Remove the battery connector bracket to
safety boots, and a safety helmet (hard permit access to the top right mast
hat). mounting bolts.
14. Use an impact wrench to remove the mast
1. Lower and retract the fork carriage
mounting bolts inside the battery
completely.
compartment, four on the top, eight on the
2. Turn the key switch OFF and disconnect bottom.
the battery connector. Remove battery
15. Using a lift truck, carefully separate the
tractor about 6 in. (15 cm).
device, remove the battery.
16. Reinstall mast mounting bolts and
3. Remove the top cover and the left and right
washers and tighten lightly (to prevent
front covers.
misplacing them).
5. Remove or disconnect any options Hose/Cable, Free Lift Cylinder,
mounted on the overhead guard. Secure a
hoist strap around the overhead guard. and Carriage Removal
Take the weight off the guard. Remove 1. Remove the auxiliary manifold cover from
mounting bolts. Remove the guard. the carriage. See Figure 7-285 on
6. Disconnect and cap the left end of the page 7-208.
right side main lift hose at the tractor 2. Disconnect the wires of the over-the-mast
bulkhead fittings. cable from the terminal strip, labeling as
7. If so equipped, disconnect the ambient needed for reconnection.
temperature sensor connector JPA and 3. On the standard reach carriage, remove
HTI connector JP13 on the tractor deck. auxiliary manifold mounting screws to
8. Disconnect the mast switch connector permit access to the over-the-mast hose
JPS4 (near the lift pump) and the encoder fittings at the manifold.
connector JPS11. Feed harness through NOTE: There may be shims between the
tractor opening. manifold and carriage.
JPS3 on the tractor deck.


Figure 7-285. 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.
Main Lift Chain Removal

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
ensure correct reconnection. telescopics. Using the hoist, raise the
5. Jack carriage up about 3 in. (7.5 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 7-286.
drape over front of carriage.
6. Remove or loosen hose/cable retaining Figure 7-286. Main Lift Chain Upper Chain Anchor
clamps on back of carriage.
1051602_C2a.cgm
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
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
of the free lift cylinders. Lift each free lift
cylinder off the mounting pin at the
the outer telescopic. See Figure 7-287.


Figure 7-287. Main Lift Cylinder Mounting Hardware Figure 7-289. Outer Telescopic Lower Bearing and
R1020561_A2.cgm
Anti-Rattle Pads
Mounting Bolt R1020561_A4.cgm
Washer
Shim
Sleeve
Outer
Telescopic
Anti-Rattle Pad Cover
4. Remove main lift chain sheaves from top of

outer telescopic. See Figure 7-288. 6. Remove anti-rattle pads and shims from
bottom of inner telescopic. See
Figure 7-288. Main Lift Chain Sheave Figure 7-290.
1051602_C9.cgm
7. Using a suitable hoist, pull the inner

Bearing Sheave
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 7-290.
Figure 7-290. Main Lift Chain Lower Chain Anchor and

Snap Ring Inner Telescopic Lower Roller Bearing
1051602_C8.cgm
Master
Link
Stud
Chain
Anchor
5. Remove anti-rattle pads and shims from Shim
bottom of outer telescopic. See
Figure 7-289. Bearing
Anti-Rattle Pad

See Figure 7-291.


Figure 7-291. Outer Telescopic Upper Bearing Figure 7-292. Main Frame Upper Bearing
1051602_C9.cgm 1051602_C6.cgm
Bolt
Stud
Bearing
Retaining Screw
Shim Stud Shim Bearing
and Washer
13. Disconnect the height encoder belt at the
top of the outer telescopic. See “Height
Encoder Belt” on page 7-167. Stop Block
14. Remove the height encoder from the main

frame. 17. Pull the telescopic until the lower stop
access cutouts align with the stop blocks
15. Reconnect the encoder belt at the mounted to the main frame. Remove the
telescopic. stop blocks on the main frame. See
16. Remove the upper roller bearings and Figure 7-292.
shims from the main frame. See 18. Remove the lower roller bearings and
Figure 7-292. shims from the outer telescopic. See
Figure 7-289.


mastbearshim1.jpg
(Complete Assembly)
2. Attach both ends of the height encoder
belt to the mast.
of the outer telescopic. Make sure the flat 10. Using the hoist, slide the outer telescopic
spot on the bearing outer stud is correctly the entire length of the main frame,
positioned against the mast. This is checking for binding. The tightest spots
important because the correct bearing will generally be at the crossties. Add or
alignment is canted with respect to the remove shims as necessary to maintain a
channel. See Figure 7-289. snug but free-running fit.
4. Using a suitable hoist, insert the outer 11. Align mast stop cutouts on the outer
telescopic into the main frame as far as telescopic with the stop locations on the
the crosstie. main frame. Install mast stops on the
5. Attach the lower roller bearing to the other main frame.
6. Using a pry bar, move the outer telescopic Upper Bearings of Main Frame
7. Use spare shims as a gauge to determine into the main frame, attach the upper
the amount of shims required to cause the roller bearing to one side of the main
roller bearing to contact the main frame. frame. Make sure the flat spot on the
8. Remove both lower bearings. Install one bearing outer stud is correctly positioned
half of the total shim thickness required to against the mast. See Figure 7-292.
each roller bearing. Reinstall the bearings. 2. Attach, but do not tighten, the upper roller
Apply thread-locking compound bearing to the other side of the main
(P/N 990-536) to the bearing mounting frame.
9. 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.

when the bearing is fully seated, bend the checking for binding. Add or remove shims
flat washer to contact the bearing to as necessary to maintain a snug but
prevent the bearing from walking on the free-running fit.
stud shaft. See Figure 7-293. 9. When the lower mast bearing shimming is
6. Using the hoist, slide the outer telescopic complete, attach the main lift chains to the
the entire length of the main frame, lower chain anchors. Keep tension on the
checking for binding. Add or remove shims chains as the inner telescopic is inserted
as necessary to maintain a snug but into the outer telescopic.
free-running fit.
7. When the upper mast bearing shimming is Upper Bearings of Outer Telescopic
complete, reinstall the height encoder.
Assembling and Shimming roller bearing to one side of the outer
Inner Telescopic to Outer telescopic. Make sure the flat spot on the
Telescopic bearing outer stud is correctly positioned
against the mast. See Figure 7-291.
Lower Bearings of Inner Telescopic 2. Attach, but do not tighten, the upper roller
bearing to the other side of the outer
1. Attach the lower roller bearing to one side telescopic.
of the inner telescopic. Make sure the flat 3. Use spare shims as a gauge to determine
spot on the bearing outer stud is correctly the amount of shims required to cause the
positioned against the mast. See roller bearing to contact the inner
Figure 7-290. telescopic.
2. Using a suitable hoist, insert the inner 4. Remove both upper bearings. Install one
telescopic into the outer telescopic as far half of the total shim thickness required to
as the crosstie. each roller bearing. Reinstall the bearings.
3. Attach the lower roller bearing to the other Apply thread-locking compound
side of the inner telescopic. (P/N 990-536) to the bearing mounting
4. Using a pry bar, move the inner telescopic bolt and torque to 260 ft. lb. (352 Nm).
and bearing to one side. 5. If the inner race of the bearing does not
5. Use spare shims as a gauge to determine protrude past the end of the bearing stud
the amount of shims required to cause the when the bearing is fully seated, bend the
roller bearing to contact the outer flat washer to contact the bearing to
telescopic. prevent the bearing from walking on the
6. Remove both lower bearings. Install one
half of the total shim thickness required to 6. Using the hoist, slide the inner telescopic
each roller bearing. Reinstall the bearings. the entire length of the outer telescopic,
Apply thread-locking compound checking for binding. Add or remove shims
(P/N 990-536) to the bearing mounting as necessary to maintain a snug but
bolt and torque to 260 ft. lb. (352 Nm). free-running fit.

protrude past the end of the bearing stud Main Lift Chain Installation
when the bearing is fully seated, bend the 1. Install anti-rattle pads and shims at
flat washer to contact the bearing to bottom of inner and outer telescopics.
prevent the bearing from walking on the Shim so pads are snug against mast. See
stud shaft. See Figure 7-293. Figure 7-289 and Figure 7-290.
8. Using the hoist, slide the inner telescopic

2. Install the main lift chain sheaves to the shim thickness required to each roller
top of the outer telescopic. See bearing.
Figure 7-288. 8. Using the hoist, reinsert the carriage into
3. Install a new sleeve and collar, washer, the inner telescopic. Check for tight areas
and mounting bolt through the telescopic while moving the carriage to the bottom of
crosstie and into the cylinder housing of the inner telescopic.
each main lift cylinder. Apply 9. Remove the carriage from the inner
thread-locking compound (P/N 1013829) telescopic far enough to expose the
to the threads of the bolt and leave a bearings being shimmed.
0.12 in. (3 mm) gap between the bolt head
and washer. (See Figure 7-287.) 10. Remove the bearings being shimmed from
the carriage.
4. Rig lifting straps around the upper
crossties of all three mast sections. NOTE: The carriage may have to be removed
several times to obtain the correct fit.
5. Using a suitable hoist, raise the mast to a
vertical position. 11. Install the center set of roller bearings,
6. Rig a lifting strap of one hoist around the without shims, in the carriage.
lower crosstie of the main frame (the one 12. Repeat steps 4 thru 10 for the center set of
where the overhead guard attaches). bearings.
7. Lower the telescopics into the main frame 13. Install the upper set of roller bearings,
approx. 3 in. (7.5 cm) from the floor. without shims, in the carriage.
8. Insert chain anchor bolts into chain 14. Repeat steps 4 thru 10 for the upper set of
anchor blocks. Lower the telescopics bearings.
completely. Tighten the chain anchor nuts
until the inner telescopic is 3/8 in.
(9.5 mm) off of the outer telescopic at the
upper crossties.
Shimming Carriage to Inner

Telescopic
carriage backrest. Rig lifting straps around
the carriage.
2. Install the lower set of roller bearings,
without shims, in the carriage.
3. Using a hoist, carefully lift the carriage
and insert it into the inner telescopic until
the bearings just enter the telescopic.
4. Using a pry bar, move the carriage
bearings to one side.
5. Use spare shim(s) as a gauge to determine
the amount of shims required to remove
side play.
6. Remove the carriage from the inner
telescopic far enough to expose the
bearings being shimmed.
7. Remove the bearings being shimmed from
the carriage. Install one half of the total

Carriage, Free Lift Cylinder, and Hose/Cable Installation Mast, Chain, Hose, Cable
Carriage, Free Lift Figure 7-295. Over-the-Mast Hose and Cable Installation
1051959_B2.cgm
Cylinder, and
Hose/Cable Installation
carriage back rest. Rig lifting straps
around the carriage. Using a hoist,
carefully lift the carriage and insert it into
the inner telescopic and lower the carriage
to about 3 in. (7.5 cm) above the floor.
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.

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 7-295 for the following Figure 7-296.
steps that route the hoses/cable.

Mast, Chain, Hose, Cable Carriage, Free Lift Cylinder, and Hose/Cable Installation
Figure 7-296. Free Lift Cylinder Hose Connection
1067160_C1.cgm
Standard Carriage
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 7-297. Deep-Reach ® Carriage
Figure 7-297. Carriage Hose Routing

1051959_B13.cgm,1051959_B14.cgm
12. Feed OTM hoses and cable through free lift

cylinder pulleys.
13. Position hoses in the retaining clamp at
the top of the left free lift cylinder. See

Carriage, Free Lift Cylinder, and Hose/Cable Installation Mast, Chain, Hose, Cable
Figure 7-298 on page 7-217. Remove all 28. Feed cable and hoses through remaining
slack. retainers. Remove all slack and tighten.
14. Find the correct L5 value from Table 7-14 29. Feed the free lift chains over free lift
on page 7-217. Measure and mark hoses pulleys, from forks side to tractor side.
above the clamp, using the L5 value. L5 Install master links to attach the free lift
equals the length the hoses are to be chains to the chain anchor blocks.
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.
20. Fasten the cable to the free lift cylinder
connecting tube and position cable into
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
retainer at the main frame crosstie. See
Figure 7-298 on page 7-217. Remove all
slack.
24. Find the correct L4 values from Table 7-14
on page 7-217. Measure and mark hoses
above the retainer.
25. Block between the telescopics to provide
slack in the hoses.
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.

Mast, Chain, Hose, Cable Carriage, Free Lift Cylinder, and Hose/Cable Installation
Figure 7-298. Over-the-Mast Hose/Cable Retainer Locations (Model 7440)
1051959_B2.cgm,1051959_B3.cgm
L4
L5
Table 7-14. Over-the-Mast Hose Stretching Values (Model 7440)
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
164 to 171 3.50 88.9

159 to 184 1.75 44.5
172 to 180 3.75 95.3
181 to 184 4.00 101.6

Mating Tractor to Mast Mast, Chain, Hose, Cable
Mating Tractor to Mast threads. Install mounting bolts and torque

to 130 ft. lb. (174 Nm).
1. Position the tractor about 10 in. (25 cm) 16. Install the mast guard.
from the mast. Place blocks under the 17. Using a suitable battery moving device,
tractor near the mast to match the bolt install the battery. Install battery gates.
hole height in tractor and mast. 18. Attach front covers and top cover.
2. With the mast secured by a hoist, use a lift
19. Make sure all hoist straps and blocks are
truck to mate the tractor to the mast.
removed.
3. Apply thread-locking primer 20. Reconnect the battery connector and turn
(P/N 990-666) to mast mounting bolt the key switch ON.
threads and hole threads. Permit to dry for
several minutes. 21. Bleed the hydraulic system. See
(P/N 990-544) to threads of mast 22. Test all lift truck functions.
mounting bolts. 23. Apply thread-locking compound and
5. From the battery compartment, thread tighten main lift cylinder L-bracket
eight mounting bolts and washers through mounting bolts to 55 ft. lb. (74.5 Nm).
bottom of the tractor frame into the mast. 24. 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. Install the battery connector bracket.
Figure 7-221.
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.
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

Model 7400/7420/7440 Reach-Fork ® Truck Section 8. Theory of Operation
Section 8. Theory of Operation

Section 8. Theory of Operation Model 7400/7420/7440 Reach-Fork ® Truck
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 velocity sensors (encoders) and
them up. temperature sensors for the Traction
Motor and the Lift Motor. When K3 is
• B+ to the normally open tips of the Steer,
open, it supplies a path for the
Traction and Lift contactors.
capacitors in the amplifiers pre-charge
• B– is supplied to all points labeled B–, B–F, circuits to discharge to B–. Both
any sensor connection with a (–) negative pre-charge circuits have a thermistor in
label and DGND. them (on the Fuse/Relay Card) to
protect from overcurrent damage if
Key Turned ON there is an open in the motor power
circuitry or contactors.
When the key switch is turned ON, B+ is • Reach, Tilt, Sideshift, Aux 1, Aux 2,
supplied to the following points: L/L, L/H, and Dump solenoids, Nested
• through the EPO switch to the coils of K1, Switch, Horn, and fans T, FW, FW2 and
K2, and K3. DU are supplied by B+K2.
• to JPC14-12 at the VM as B+ Key. This, • connections for optional devices at

internal to the VM, activates the power JPF2-9 by B+K1.
supply circuits that supply all 12V and 5V • B+ is supplied to the VM by B+K4 to be
outputs from the VM and activates the used internally.
microprocessor in the VM. The power • With all microprocessors powered up,
supply’s maintain a steady output as long SelfTest continues:
as battery voltage remains above 17V.
With the power supplies activated, 12V is • the VM checks to make sure its power
supplied to the display. The display supplies are within range.
contains a microprocessor that requires • the VM checks the BUS to make sure
firmware updates any time the VM is communications are functioning with
updated. all other devices (DISPLAY, LPA and
TPA).

• 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 velocity
make sure they are open. This is only sensor (encoder) inputs. This is to make
checked during SelfTest on trucks with sure the power circuits are functional
traction or lift amplifiers. On trucks and the brake is applying resistance to
with DC lift, the VM checks the LPC. It the Traction Motor.
is checked continuously after the truck • the VM checks the state of the control
has passed SelfTest and the VM has not handle switches to make sure they are
commanded it to be closed. in the open position. They are
• the VM verifies the Steer Contactor is continuously monitored and messages
open. This is only done during SelfTest. are displayed if activated prior to
• the VM commands the LPA and TPA closing the Deadman Switch.
over the BUS to close the LPC and TPC. • the VM checks the information from the
The VM activates the circuitry to close TPA and LPA to make sure the motor
the STR contactor. The LPC, TPC, and temperature sensor readings are within
STR contactors are checked to make range and determines if speed limiting
sure power is supplied through the is required.
contactor tips to the motors circuits. • the VM checks pressure transducer
The LPA and TPA report the state of the readings to make sure they are within
LPC and TPC over the BUS. They are range.
monitored via the (+) connections on
the amplifiers. When the contactor • the VM checks to make sure the
closes, the amplifiers see a higher Ambient Temperature Sensor is within
voltage than seen from the pre-charge the acceptable range.
circuit. The VM monitors the STR • the VM checks its memory for all
contactor via JPC22-19. previously logged faults that have not
• the VM verifies the EPO switch is been cleared.
closed. • after SelfTest is complete, the LPC and
• the software and configured parameters TPC contactors remain energized for
are checked in the LPA, TPA, Display, approx. 30 seconds. If no function
and VM to make sure they are within requests are made by the operator, they
limits and correct. open. On trucks with DC lift, the TPC
remains closed for approx. 30 seconds
• the amplifiers check to make sure there and the LPC contactor opens after
are no shorts in the power circuits. circuits are tested. The STR contactor
• the VM checks to make sure the opens on both trucks as soon as the
Deadman Switch is open. circuits are tested. The VM also
• the VM checks to make sure the Steer monitors the temperature inputs from
Tiller Encoder is connected. the TPA and LPA. Anytime one of the
readings goes above 113°F (45°C), the
• the VM checks to make sure the lift VM turns on fans T, FW, FW2, and DU.
potentiometer (VR2) and throttle
potentiometer (VR1) are within 0.2V of
the learned neutral position and are not
outside the allowable minimum and

Deadman Pedal Depressed Electric Steering

NOTE: This information is based on a truck
When the deadman pedal is depressed, the
that is not programmed for Reverse
Deadman Switch (S2) is closed, supplying the
Steering. If programmed for Reverse
VM with B– through JPC22-8, ON DEADMAN.
Steering, the VM reverses the CW and
This activates circuitry that informs the VM the
CCW commands to the Steer Amplifier.
switch is closed. At the same time, the pedal
It also looks for feedback from the Steer
moves the Deadman Sensor (VR4), which is a
Motor Encoder in the opposite direction.
potentiometer connected to the pedal. The VM
sees the input from the sensor increase from
On trucks with electric steering, when the VM
neutral voltage. If a change is not seen from
closes the STR contactor, the VM begins to
both inputs, an error is displayed. The input
monitor the inputs from the Steer Amplifier,
from VR4 is used by the VM to determine
Steer Tiller Encoder, and the Steer Motor
plugging strength of the traction motor. The
Encoder. The VM is looking for a current draw
further the deadman pedal is released, the more
on the 12V lines that power the two Steer Tiller
aggressive the plugging command. The brake is
Encoder channels. With no steer requests from
released. The brake does not get applied until
the Steer Tiller Encoder, the VM looks for an
the truck is at a complete stop and the
input from the Steer Amplifier on JPC6-1,
deadman switch is opened.
NEUTRAL_PULSE. This feedback from the Steer
Amplifier informs the VM that the Amplifier is
With the Deadman Switch closed, the VM tells
connected and powered up. The
the LPA and TPA it is closed and commands the
NEUTRAL_PULSE is created by the VM sending
LPC, TPC, and STR contactors to be closed on
a very low steering command over the CCW and
trucks with AC lift. Trucks with DC lift do not
CW wires to the Steer Amplifier. These
close the LPC until there is a lift request seen by
commands are alternated back and forth
the VM. The VM now reacts to any request from
between CCW and CW. This creates a toggling
control pots or switches for lift/lower, travel,
high/low input on the NEUTRAL_PULSE line
and aux functions. When the Deadman Switch
that changes about 10 times a second. When a
is opened again, the LPC and TPC remain
steer command is present, this input does not
energized for 30 seconds with no functions
toggle as fast and the VM ignores it. When the
commanded and then open. The STR contactor
operator turns the steering wheel, a set of
remains energized for 3 seconds and then
square wave voltages (chopped DC voltage) is
opens. The Deadman Switch then closes again
sent to the VM on Channels A _1, B_1, A _2, and
for the contactors to energize.
B_2. The VM looks at the square waves as sets.
A _1 and B_1 are one set and A _2 and B_2 are
With the Deadman Switch closed, the TPA
another set. Based on which channel of the set
continuously monitors the input from the
is seen first, A or B, the VM determines the
Traction Motor Encoder (TME). If no travel
direction the operator has requested the drive
request is seen from the control handle and
unit to turn. The VM determines the requested
inputs are seen from the sensor, the TPA
speed by the amount of time between the
powers the Traction Motor as required to keep
square waves. Less off time between them
the truck in the same position. This prevents
means a faster rotation was requested. Two sets
unwanted movement on uneven surfaces, dock
are used so the VM can compare them and
plates or ramps, or if placing a pallet in the rack
verify the encoder is functioning correctly. Once
system.
this information is processed, the VM sends out
a chopped DC voltage to the Steer Amplifier
over CCW_PWM or CW_PWM. CCW_PWM is a
request for the drive unit to be turned in the
counterclockwise direction and CW_PWM is a
command to turn in the clockwise direction.
Based on the off time between the square

waves, the Steer Amplifier determines the speed correct sequence to energize the motor leads (U,
of rotation requested and sends the appropriate V, and W) to move the truck in the correct
voltage to the Steer Motor. Direction of Steer direction. The TPA also determines the required
Motor/Drive Unit rotation is controlled by the amount of DC voltage to send through the
side of the Steer Motor that has positive voltage motor leads based on the acceleration
applied to it, MS-A1 or MS-A2. The VM then parameters programmed and the requested
monitors the inputs from the Steer Motor RPM. The TPA then monitors the feedback from
Encoder to determine the direction and speed the TME to adjust the voltage to the Traction
the motor is turning and compares it to the Motor to maintain the requested RPM and
request. The VM also monitors the Steer Motor direction. Any conditions that prevent the TPA
current from the Steer Amplifier on JPC6-3, from maintaining these requests are sent over
STEER_CURRENT. Current limit for the Steer the BUS to the VM. The VM tells the Display
Motor is approx. 100 amps and is controlled by over the BUS to display a message informing
the Steer Amplifier. The VM uses this input the operator. The VM also invokes any system
when checking the steering system for shorts or shut down or limitations based on the
opens in the power circuit. The VM also information from the TPA.
monitors the input from the END OF STEER
ROTATION SWITCH (S11), mounted next to the Secondary Control Handle
drive unit. This is a proximity switch that is
turned ON and OFF by a metal ring mounted to Travel requests from the Secondary Control
the drive unit. As the drive unit nears the end of Handle are processed in the same way as the
its rotation, the metal ring is no longer under Primary Control Handle. The only difference is
the proximity switch and the switch opens prior that forks-first travel speed is limited by the
to hitting the drive unit’s mechanical stop. VM.
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 the Deadman Switch (S2) closed, the VM

constantly sends an RPM request that causes
the TPA to maintain the speed requested by the
operator. With the Primary Control Handle in
neutral, the request is always at 0 RPM. When
the VM sees a change in the learned neutral
voltage from the Primary Control Handle travel
pot (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

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.

Hydraulic System Functional Operation (AC Lift)
Hydraulic System Tilt Cylinder
Functional Operation The tilt cylinder is a double-acting hydraulic

cylinder used to tilt the forks up and down.
(AC Lift)
Load Holding Valve (SOL1)
System Components The load holding valve is a normally closed
solenoid valve used to hold the carriage in an
Main Lift/Aux Pump (P1) elevated position. It incorporates an override to
allow lowering the carriage manually.
Pump P1 is a positive displacement gear pump
that rotates clockwise from the shaft end. P1 is
Proportional Lower Valve (SOL2)
used for all lift and aux functions.
The proportional lower valve is a pressure
Main Lift System compensated flow control solenoid valve used to
lower the carriage. As the voltage to the valve
The main lift system consists of four single increases, the flow through the valve increases,
acting hydraulic cylinders. Hydraulic fluid flows regardless of the pressure.
from the main manifold through a tee-fitting in
the tractor, through fittings in the left and right
Proportional Relief (SOL3/Dump)
front of the tractor bulkhead. The right side
hose feeds the right side main lift cylinder. The
SOL3 is a proportional solenoid used as a
left side divides again at a tee-fitting, supplying
system relief. In addition, SOL3 is used to divert
both the left side main lift cylinder and the free
hydraulic fluid from Pump P1 back to the
lift cylinders. At the bottom of the free lift
reservoir after a lift is stopped and the pump is
cylinders, another tee-fitting divides the flow
still spinning. It also acts as a valve to port
between left and right free lift cylinders. A flow
excess hydraulic fluid back to the reservoir from
limiter is installed at one of the free lift and one
the auxiliary functions.
or both of the main lift cylinders.
When the operator requests lift, the entire lift SOL5B/SOL5T

system is pressurized. Since the carriage
weighs less than the carriage plus telescopic, SOL5 is a directional solenoid valve providing
the free lift cylinders extend first, elevating the directional control to the reach, tilt, and
carriage. When they reach the limit of their sideshift functions. De-energized, flow is
travel, the main lift cylinders extend, elevating blocked to the aux functions and directed to the
the telescopics. reservoir. When SOL5B is energized, flow is
directed to port A2 for tilt up, sideshift right, or
retract. When SOL5T is energized, flow is
Reach/Retract Cylinder
directed to port A1 for tilt down, sideshift left, or
reach.
The reach/retract cylinder is a double-acting
hydraulic cylinder used for extending and
retracting the forks from the mast. Reach/Retract Solenoid (R/R SOL)
R/R SOL is a normally closed solenoid valve

Sideshift Cylinder
used to block (de-energized) or allow (energized)
fluid flow to and from the reach cylinders.
The sideshift cylinder is a double-acting
hydraulic cylinder used to shift the load left and
right with respect to the mast.

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 one (7400) or two
(7420/7440) filters in the main manifold. Their Lift speed varies directly with Lift Motor rpm.
purpose is to filter impurities from the The voltage supplied to the Lift Motor is
hydraulic system. They filter all hydraulic fluid proportional to the amount of lift request from
on the return to the reservoir. There is no VR2 (faster lift = higher motor voltage).
internal bypass. 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 pressure transducer. Weight of the empty
The Lift Motor is a brushless, three-phase
carriage and telescopic is calculated during
internally delta connected variable-speed AC
Learn Mode.
motor.
Prior to requesting a lift, all valves are in the
Lift Motor Encoder de-energized state.
The Lift Motor Encoder is a two-channel When VR2 is moved to request lift, a voltage is
encoder. Its purpose is to tell the lift power sent to the VM at JPC12-2. The VM sees a
amplifier the motor speed for motor speed voltage different from the “learned” neutral
regulation during lift and auxiliary functions. voltage, and sends a request to the lift power

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 the Fork tilt allows the operator to raise or lower the
Deadman Switch (S2), or rotating the lift pot tips of the forks. Standard fork tilt is 5° up and
(VR2) out of neutral to the lift position. 2° down.
When the LPC is energized, the contactor tips When the deadman pedal is depressed, the VM
close, allowing B+ to be supplied to the LPA, sends a command over BUS+/BUS- lines to the
that supplies voltage to the Lift Motor to make it LPA to energize the LPC.
rotate.
The LPA internally supplies B- to the LPC coil at
The PODS valve (POD-1) receives pressure at JPL1-2, that closes the normally open contactor
port 4, placing pressure on the pilot line of the tips.
valve. This pressure moves the spool in the
valve to allow flow out port 2 to CV-1, the The Tilt Up Switch (S6) is depressed,
de-energized Load Holding Solenoid (SOL1), completing a circuit between JPC12-5 and
through the flow limiters in the base of the lift JPC12-12 at the VM.
cylinders and into the lift cylinders, producing
lift. The VM energizes the following solenoids via
internal coil drivers:
When the lift knob is returned to neutral, the • SOL3 (Dump) at JPC20-12
Lift Motor is ramped down. SOL3 is opened to
• SOL5B at JPC20-20
relieve any pressure spikes in the system.
• TILT SOL at JPC18-15
Lower
Pump P1 rotates at a speed predetermined in
software. Flow is ported to the PODS valve at
Variable lowering is accomplished via the
port 3 and out at port 4. Fluid then flows
Proportional Lower Solenoid (SOL2). Lowering
through SOL5B or SOL5T, depending on the
speed is not a function of weight on the forks.
direction of the function requested. SOL5 is a
An increasing voltage increases the flow
proportional solenoid, but the VM sends a fixed
through the valve regardless of the pressure in
voltage to it, regulating the speed of the
the system.
requested function. If more oil than is needed
flows to SOL5, back pressure is present at port
When VR2 is moved to request Lower. A voltage
4, which is also the pilot line for the PODS
is sent to the VM at JPC12-2. The VM sees a
valve. This shifts the spool of the PODS valve
voltage different from the “learned” neutral
and sends the excess oil to SOL3 via port 2.
voltage.
SOL3 opens to allow the excess oil to flow back
to the filter and reservoir. After leaving SOL5,
The VM energizes internal coil drivers for SOL1
the oil flows to the LS-1. The LS-1 ports oil back
at JPC18-10. SOL2 opens proportionally to the
to the PODS valve at port 1 to help regulate the
requested rate of lower via a signal from the VM
flow to the auxiliary function. From LS-1, the
at JPC20-16.
fluid flows to the Tilt Solenoid (TILT SOL) on the
carriage. The TILT SOL allows fluid flow to the
The VM energizes internal coil drivers for SOL1
requested function.
at JPC18-10. SOL2 opens proportionally to the

NOTE: LS-1 also supplies a pilot pressure to port 3 and out at port 4. Fluid then flows
REL2 to open the auxiliary relief if through SOL5B or SOL5T, depending on the
pressure gets too high. direction of the function requested. SOL5 is a
proportional solenoid, but the VM sends a fixed
Fluid flows through the energized TILT SOL and voltage to it, regulating the speed of the
then to the tilt cylinder. requested function. If more oil flows to SOL5
than is needed, back pressure is present at port
Reach/Retract 4, which is also the pilot line for the PODS
valve. This shifts the spool of the PODS valve
Reach extends the forks away from the mast and sends the excess oil to SOL3 via port 2.
assembly. The reach/retract function can be SOL3 is opened to allow the excess oil to flow
configured to have single speed reach/retract or back to the filter and reservoir. After leaving
two speed reach/retract. Single speed moves at SOL5, the oil flows to the LS-1. The LS-1 ports
the speed of high-speed. oil back to the PODS valve (at port 1) to help
regulate the flow to the auxiliary function. From
To use two speed reach, depress S5 after LS-1, the fluid flows to the reach solenoid on
depressing S4. Doing this switches from low the carriage. The Reach/Retract Solenoid allows
speed to high-speed reach. For high speed fluid flow to the requested function.
retract, depress S4 then S5. NOTE: LS-1 also supplies a pilot pressure to
REL2 to open the auxiliary relief if
High-speed or single-speed reach/retract pressure gets too high.
When the deadman pedal is depressed, the VM Fluid flows through the energized
sends a command over BUS+/BUS– lines to the Reach/Retract Solenoid and then to the reach
LPA to energize the LPC. cylinders.
The LPA internally supplies B– to the LPC at

Sideshift
JPL1-2, that closes the normally open contactor
tips.
Sideshift allows the operator to move the fork
carriage to the left or right relative to the mast.
When the Reach Switch (S4) or the Retract
The amount of sideshift is 2 or 4 in. (5 or 10 cm)
Switch (S5) is depressed, a circuit is completed
depending on the baseleg opening.
to the VM.
When the deadman pedal is depressed, the VM
On lift trucks with two speeds selected, the VM
sends a command over BUS+/BUS– lines to the
activates high speed when the other switch is
LPA to energize the LPC.
also depressed.
NOTE: To change reach speed (high speed The LPA internally supplies B– to the LPC at
versus low speed), the VM adjusts the JPL1-2, that closes the normally open contactor
voltage to SOL5 to regulate the valve for tips.
more or less flow.
When the Sideshift Right Switch (S9) is
The VM energizes the following solenoids via depressed, a circuit is completed between
internal coil drivers: JPC12-9 and JPC12-12 at the VM.
• SOL3 (Dump) at JPC20-12
The VM energizes the following solenoids via
• SOL5B at JPC20-20 internal coil drivers:
• REACH SOL at JPC18-12 • SOL3 (Dump) at JPC20-12
Pump P1 rotates at a speed predetermined in • SOL5B at JPC20-20

software. Flow is ported to the PODS valve at • SIDESHIFT SOL at JPC18-14

Pump P1 rotates at a speed predetermined in In order to operate reach or retract, S4 or S5 is

software. Flow is ported to the PODS valve at used to send an input to the VM at JPC12-4 or
port 3 and out at port 4. Fluid then flows JPC12-11.
through SOL5B or SOL5T, depending on the
direction of the function requested. SOL5 is a When the request to lift and reach is made, the
proportional solenoid, but the VM sends a fixed VM energizes the following solenoids via
voltage to it, regulating the speed of the internal coil drivers:
requested function. If more oil flows to SOL5 • SOL3 (Dump) at JPC20-12
than is needed, back pressure is present at port
4, which is also the pilot line for the PODS • SOL5T at JPC20-18 or SOL5B at
valve. This shifts the spool of the PODS valve JPC20-20, depending on the direction of
and sends the excess oil to SOL3 via port 2. the function chosen
SOL3 is opened to allow the excess oil to flow • One of the following:
back to the filter and reservoir. After leaving REACH SOL at JPC18-12
SOL5, the oil flows to the LS-1. The LS-1 ports SIDESHIFT SOL at JPC18-14
oil back to the PODS valve (at port 1) to help TILT SOL at JPC18-15
regulate the flow to the auxiliary function. From
LS-1, the fluid flows to the Sideshift Solenoid on As Pump P1 begins to rotate, fluid flows into the
the carriage. The Sideshift Solenoid allows fluid PODS valve at port 3. The PODS valve is used to
flow to the requested function. bias flow between lift and aux. Port 3 is
connected to port 4. With pressure at port 4,
NOTE: LS-1 also supplies a pilot pressure to
the pilot line works to move the spool to its
REL2 to open the auxiliary relief if
second position.
pressure gets too high.
With the valve in its second position, fluid flows
Lift while using Aux Functions to Check Valve 1 (CV1). Fluid flows through
CV1 and the de-energized SOL1. From there,
The LPC is energized by depressing the fluid passes through the free flow portion of the
Deadman Switch (S2). flow limiters (located in the base of the lift
cylinders) and into the lift cylinders.
The LPA internally supplies B– to the LPC at
JPL1-2, that closes the normally open contactor SOL3 (Dump) is used as a proportional relief to
tips. limit system pressure to a safe level. With this
valve: 0V = 3500 psi (24132 kPa). The pressure
When the LPC coil is energized, the contactor relief is set by the VM and firmware at approx.
tips close, allowing B+ to be supplied to the 2V, which equals 3200 (22063 kPa) psi.
LPA, which supplies voltage to the Lift Motor.
The PODS valve also meters fluid to the
When VR2 is moved to request lift, a voltage is requested aux function. As the metered flow
sent to the VM at JPC12-2. The VM sees a enters SOL5B or SOL5T (depending on the
voltage different from the “learned” neutral direction of function requested), the voltage
voltage, and sends a request to the LPA via applied to the valve by the VM causes it to open.
BUS+/BUS– (JPC14-11 and JPC14-4 to
JPL1-22 and JPL1-14). SOL5 is a proportional solenoid. The VM sends
a fixed voltage to it to open it a specific amount,
The voltage supplied to the Lift Motor is depending on the function requested.
proportional to the amount of lift requested
from VR2 (faster lift = higher motor voltage). The load shuttle sends pressure to the pilot line
NOTE: The Lift Motor/pump is variable speed. of the PODS valve to allow the valve to correctly
divide the fluid between lift and auxiliary.

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.

Hydraulic System Functional Operation (DC Lift)
Hydraulic System pressure is set at approx. 1600 psi (11,031

kPa).
Functional Operation
Lift/Lower System
(DC Lift)
System Components
Steering System
Load Holding Valve (SOL1)
System Components
The Load Holding Valve is a normally closed
solenoid valve used to hold the carriage in an
Steer Valve
elevated position. It incorporates an override to
allow lowering the carriage manually.
The Steer Valve is an orbital type rotary flow
valve with an auxiliary port. When no steering
Proportional Lift/Lower Valve (SOL2)
is requested, fluid flows through the auxiliary
port (E). When steering is requested, fluid flows
The Proportional Lift/Lower Valve is a pressure
first through the steer valve, hydraulic motor,
compensated solenoid valve used to lift and
and the steer return port (T). Any excess flow
lower the carriage. As the voltage to the valve
exits through the auxiliary port.
increases, the flow through the valve increases,
regardless of the pressure.
Theory of Steering Function
Second Stage Solenoid (SOL4)
When the operator presses the deadman pedal,
a circuit is completed at the VM between SOL4 is a two position normally open solenoid
JPC22-8 and JPC18-7. whose function is to feed oil from Pump P2 to
the lift cylinders for high speed lift. When
The VM energizes the STR contactor by way of de-energized, oil is ported from P2 to the
JPC18-11. reservoir.
With the STR contactor energized, current flows Proportional Directional Solenoid
to the Steer Motor, causing it to run. (SOL5B/SOL5T)
The steering system has priority over all other SOL5 is a proportional directional solenoid
auxiliary functions. valve providing directional control to the reach,
tilt, and sideshift functions. De-energized, flow
Pressurized hydraulic fluid from the Steer is blocked to the aux functions and directed to
Pump flows to the Steering Orbitrol. the reservoir. When SOL5B is energized, flow is
directed to port A1 for tilt up, sideshift right, or
Turning the steering wheel directs hydraulic reach. When SOL5T is energized, flow is
fluid to one side of the Steer Motor. Turning the directed to port A2 for tilt down, sideshift left, or
steering wheel in the opposite direction directs retract.
fluid to the other side of the motor.
Aux Dump (SOL8)
When steering is requested, oil leaving the
steering valve returns to the reservoir via the SOL8 is a two position normally open solenoid.
S-RET line. Its purpose is to provide a path for oil from P3
back to the reservoir when aux functions and
Maximum hydraulic pressure in the steering steering are not being used.
system is limited by the pressure relief valve.
The relief is located on the steer valve. Relief

Reach/Retract Solenoid (R/R SOL) • The VM senses the decrease in voltage at

JPC12-2. The VM energizes the LPC coil at
R/R SOL is a normally closed solenoid valve JPC18-9. This closes the contactor tips
used to block (de-energized) or allow (energized) and starts the Lift Motor (LM).
fluid flow to and from the reach cylinders. • Initially, the VM commands the SOL2 to
move to the full open position (back to
Sideshift Solenoid (S/S SOL) tank), then positions it proportionally to
the output request of VR2. For a slow lift
S/S SOL is a normally closed solenoid valve rate, the proportional valve opens more,
used to block (de-energized) or allow (energized) allowing more fluid to return to the
fluid flow to and from the sideshift cylinder. reservoir than it would for faster lifting
rates.
Tilt Solenoid (TILT SOL)
Lift Motor voltage is monitored at JPC22-20
TILT SOL is a normally closed solenoid valve FU3_Sense.
used to block (de-energized) or allow (energized)
fluid flow to and from the tilt cylinder. The weight of the load on the forks is
determined by inputs to the VM from the
Brush Wear Indicators pressure sensor at JPC24-18.
The brush wear indicators are located on the PP is used for Pump Pressure and G1 is used to
Lift Motor. Their purpose is to provide an check the pressure in the system.
indication when the motor brushes are worn
and need replacement. High-Speed Lift (lift trucks with dual lift
pump)
Lift Motor Temperature Sensor
High speed lift (SOL4), is activated when the
The Lift Motor Temperature Sensor is a voltage from VR2 is at least 90% of the
thermistor used to indicate the temperature of maximum Learned value for Lift. When this
the Lift Motor. It is mounted in the outer case of voltage is reached, SOL4 is energized, stopping
the motor. oil from the second Lift Pump (P2) from going to
the reservoir. Hydraulic flow from both sections
Theory of Lift/Lower Function of the lift pump is sent to the lift cylinder.
When the key switch is turned ON, the L/L High speed lift operating parameters vary for
proportional valve moves to the full open different mast configurations.
position. This relieves any pressure in the
hydraulic line by diverting any residual fluid SOL2 is electrically positioned by the following:
back to the tank. The L/L proportional valve • Voltage generated by VR2 is sent to and
then closes. processed by the VM.
With the key switch ON, moving the lift/lower • A signal from the VM drives L/L.
control on the multi-function control handle to • Voltage across the coil of L/L is initially
lift causes: approx. 19V and decreases as the
lift/lower control moves to faster lift
Variable Lift positions. This causes L/L to be fully
opened at maximum voltage and fully
Variable lift is activated when: closed at minimum voltage.
• VR2 output voltage becomes lower than
when in the neutral position. When VR2 returns to the neutral position, the
lift contactor is immediately de-energized; but
L/L is kept energized until the Lift Motor stops

turning. This is done because a spinning motor With SOL1 energized, fluid flows out of the lift
does not stop instantly; the motor rotation is cylinders, through the regulated portion of the
sensed at JPC22-20. If L/L was de-energized at flow limiters, through SOL1, and then through
the same time as the motor, the fork carriage energized SOL2. After fluid exits these valves, it
would jump. Leaving L/L open until the motor returns to the tank via the hydraulic fluid filter.
stops diverts any excess hydraulic fluid back to
the reservoir.
Auxiliary System
The VM monitors vehicle operation and controls
performance as required to ensure safe System Components
operation and prevent damage to various
systems of the lift truck. A temperature sensor Load Shuttle (LS-1)
on the Lift Motor detects overheating of the
motor. The output of the temperature sensor is The LS-1 is a two input, pressure activated, two
fed into the VM. As the temperature rises in the position valve. In the shuttle, the higher of the
Lift Motor, the VM cuts out power to the SOL4, input pressures passes through the valve at the
controlling the second Lift Pump (P2), thus pressure out port. While the output port gives
diverting the hydraulic fluid coming from P2 no usable flow, it is used to operate
back to the reservoir. The temperature that P2 pressure-activated devices such as other
diverts fluid back to the reservoir is approx. shuttles, piloted check valves, or piloted
240°F (115°C). This decreases the load on the metering valves. In this application, LS-1 reacts
motor and should cool it down. If the to the pressure applied from SOL5B or SOL5T
temperature continues to rise (greater than to the auxiliary functions and applies a
262°F/128°C), the VM cuts out lift entirely. pressure feedback to a pilot on the logic
element in the auxiliary manifold.
NOTE: On trucks equipped with dual pumps,
the maximum lift speed may be reduced Logic Element
(SOL4 disabled) when forks travel above
freelift (S10 opens) and the load exceeds The Logic Element is a metering valve that uses
a specified weight, as determined by the manifold pressure input from the supply side of
pressure transducer. the hydraulic circuit (Pilot 1), pressure feedback
from load shuttles in the load side of the circuit
Lower (Pilot 3), and a calibrated spring to meter
hydraulic fluid flow to the auxiliary functions.
Lowering is accomplished via the proportional Fluid not needed for the selected function is
valve SOL2 (L/L). Lowering speed is not a returned back to the reservoir through port 2.
function of weight on the forks. An increasing
voltage increases the flow through the valve Theory of Auxiliary Functions
regardless of the pressure in the system. The
maximum lowering speed is determined by flow Reach
regulator FR2 in the back lift cylinder.
Reach extends the forks away from the mast
When VR2 is moved to request Lower, a voltage assembly. The reach/retract function can be
is sent to the VM at JPC12-2. The VM sees a configured to have single speed reach/retract or
voltage different from the “learned” neutral two speed reach/retract. Single speed reach
voltage. moves at the speed of high-speed reach.
The VM energizes internal coil drivers for SOL1 In order to use two speed reach, depress S5
at JPC18-10. SOL2 opens proportionally to the after depressing S4. Doing this switches from
requested rate of lower via a voltage from the low speed to high-speed reach. Speed of the
VM at JPC20-16. reach is dependent on how it is configured.

High-speed or single-speed reach Low-Speed (or two-speed) Reach
When S4 is depressed, a circuit is completed Low-speed reach is activated by depressing the

between JPC12-4 and JPC12-12 at the VM. S4 only, when configured for two-speed reach.
On lift trucks with two speed reach, when S5 is Low-speed reach is accomplished by opening
also depressed, a circuit is completed between SOL5B or SOL5T, thus providing less oil flow to
JPC12-11 and JPC12-12 at the VM. the reach cylinders. Since SOL5 is a
proportional solenoid, a lower voltage to the
The VM completes the path to the STR solenoid results in the lower speed.
contactor coil at JPC18-11. This is
accomplished by turning on the coil driver Sideshift
located in the VM. This causes the STR
contactor tips to close, making the Steer Motor Sideshift allows the operator to move the fork
(MS) rotate and causing Pump P3 to pump oil. carriage to the left or right relative to the mast.
The amount of sideshift is 2 or 4 in. (5 or 10 cm)
P3 is used for steering and auxiliary functions. depending on the baseleg opening.
Because steering is not requested, oil enters the
steer valve at port P and exits at port E. From In the following discussion, the fork carriage is
there, it flows through the Power Beyond (Pwr sideshifted to the right.
Bynd) port to SOL5. Depending on the direction
of the function requested, either SOL5B or When S9 is depressed, a circuit is completed
SOL5T is energized by the VM at JPC20-2 between JPC12-9 and JPC12-12 at the VM. The
(SOL5B) or JPC20-17 (SOL5T). SOL5 is a VM completes the path to the STR contactor coil
proportional solenoid. The VM sends a fixed at JPC18-11. This is accomplished by turning
voltage to it, depending on the function on the coil driver located in the VM. This causes
requested. In order to keep all of the oil being the STR contactor tips to close, making the
dumped from returning to the reservoir, SOL8 Steer Motor (MS) rotate, and causing Pump P3
(Aux Dump) is energized by the VM at to pump oil.
JPC20-12.
P3 is used for steering and auxiliary functions.
With SOL8 closed, oil flows to the Because steering is not requested, oil enters the
Compensator/Logic Element (CE-1). The steer valve at port P and exits at port E. From
amount that CE-1 opens depends on the there, it flows through the Power Beyond (Pwr
pressure at port 1 of CE-1. With SOL5 Bynd) port to SOL5. Depending on the direction
energized, fluid flows to the LS-1. LS-1 sends its of the function requested, either SOL5B or
pilot pressure out of port 2 to CE-1 at port 3. SOL5T is energized by the VM at JPC20-2
CE-1 has an internal calibrated spring. The (SOL5B) or JPC20-17 (SOL5T). SOL5 is a
pilot pressure at port 3 aids the spring to proportional solenoid. The VM sends a fixed
regulate how much oil flows back to the voltage to it, depending on the function
reservoir in order to keep the function operating requested. In order to keep all of the oil being
at the correct speed. Once the oil passes LS-1, it dumped from returning to the reservoir, SOL8
exits the main manifold and flows to the Reach (Aux Dump) is energized by the VM at
Solenoid, that is energized by the VM at JPC20-12.
JPC18-12.

With SOL8 closed, oil flows to the back to the reservoir. Once the oil passes LS-1,
Compensator/Logic Element (CE-1). The it exits the main manifold, and flows to the Tilt
amount that CE-1 opens depends on the Solenoid, that is energized by the VM at
pressure at port 1 of CE-1. With SOL5 JPC18-13.
energized, fluid flows to LS-1. LS-1 sends its
pilot pressure out of port 2 to CE-1 at port 3.
CE-1 has an internal calibrated spring. The
pilot pressure at port 3 aids the spring to
regulate how much oil flows back to the
reservoir. Once the oil has passed LS-1, it exits
the main manifold, and flows to the sideshift
solenoid, that is energized by the VM at
JPC18-14.
Tilt
Fork tilt allows the operator to raise or lower the

tips of the forks. Standard fork tilt is 5° up and
2° down.
When switch S6 (Tilt Up) is depressed, a circuit

is completed between JPC12-5 and JPC12-12 at
the VM. The VM completes the path to the STR
(steer and aux) contactor coil at JPC18-11. This
is accomplished by turning on the coil driver
located in the VM. This causes the STR
contactor tips to close, making the Steer Motor
(MS) rotate, and causing Pump P3 to pump oil.
Pump P3 is used for steering and auxiliary

functions. Because steering is not requested, oil
enters the steer valve at port P and exits at port
E. From there, it flows through the Power
Beyond (Pwr Bynd) port to SOL5. Depending on
the direction of the function requested, either
SOL5B or SOL5T is energized by the VM at
JPC20-2 (SOL5B) or JPC20-17 (SOL5T). SOL5
is a proportional solenoid. The VM, however,
sends a fixed voltage to it. In order to keep all of
the oil being dumped from returning to the
reservoir, SOL8 (Aux Dump) is energized by the
VM at JPC20-12.
With SOL8 closed, oil flows to the

Compensator/Logic Element (CE-1). The
amount that CE-1 opens depends on the
pressure at port 1 of CE-1. With SOL5
energized, fluid flows to the Load Shuttle (LS-1).
The LS-1 sends its pilot pressure out of port 2
to CE-1 at port 3. CE-1 has an internal
calibrated spring. The pilot pressure at port 3
aids the spring to regulate how much oil flows

Electric Brake Operation
Electric Brake Operation plug to a stop. When the VM senses the lift
truck has stopped, it de-energizes the brake
coil. The magnetic field holding the brake
Overview released now collapses. The springs in the
brake coil push the armature plate and pads
The Model 7400/7420/7440 lift truck uses an down on the top of the rotor. Upward pressure
electric brake. With the brake coil de-energized, of the springs against the coil body causes the
the brake is in a “normally applied” state due to base plate and pads to be pulled up against the
spring pressure. With the brake coil energized, bottom of the rotor. The brake pads prevent the
the brake is held in a released state due to rotor and the Traction Motor shaft from
magnetic force. rotating.
The brake assembly of coil, armature plate, Brake Release Screws

base plate, and pads slides up and down on
three shoulder bolts threaded into the end bell Two brake release screws are stored in the
of the Traction Motor. The armature plate and brake coil body. These screws are not used
base plate are spaced apart by three hollow when removing the entire brake assembly from
total air gap adjusters (spacers). The total gap is the Traction Motor, but are used when
adjusted by the amount the adjuster is disassembling the brake itself. The brake
threaded into the coil body. Once this gap is set, release bolts are threaded through the coil. The
it is held in place by three locking bolts that screws press on the base plate, overcoming the
thread through the coil and the total air gap spring pressure, and separate the base plate
adjusters. and coil body. The three locking bolts, total air
gap adjusters, and rotor can now be removed.
When the brake is electrically released, the
assembly slides down the shoulder bolts and
rests on the lower air gap adjusters. The lower
air gap adjusters are threaded pedestals that
are set 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.
Brake Application
If the lift truck is traveling when the deadman
pedal is released, the VM causes the lift truck to

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 4 USB Communications Port - Not Used
2 JPC4-1 +5VDC +5VDC supply to the solid state 5 ±0.25VDC VM Secondary

potentiometer and switch in the optional Control
Secondary Control Handle. Measure wrt Handle
DGND JPC12-12.
3 JPC4-2 AGND Reference for the switches and <0.5VDCwrt VM Secondary

potentiometer in the optional Secondary B– Control
Control Handle. If this voltage is not correct, Handle
intermittent handle codes may appear.
4 JPC4-3 S_HORN Input to the VM from horn button (S10) in S10 Open: VM Secondary
the optional Secondary Control Handle. >4.5VDC; Control
Closed: Handle
<0.5VDC
5 JPC4-4 S_THROTTLE Input to the VM from the wiper of the Neutral: Secondary VM
Secondary Control Handle potentiometer. 1.1VDC; Control
Measure wrt AGND JPC4-2. Full Handle
Tractor-first:
1.6VDC;
Full Forks-first:
0.5VDC

Pinout Matrix

6 JPC6-1 NEUTRAL_ This input tells the VM that the steer Deadman Up: VM Steer
(AC Lift) PULSE amplifier is connected and functioning. 4.6VDC; Amplifier
CCW steer:
4.5VDC;
CW steer:
0.0VDC;
No steering:
voltage varies
7 JPC6-2 CW_PWM This is a control voltage used to rotate the At rest: VM Steer
(AC Lift) 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
8 JPC6-3 STEER_ Analog voltage which varies with the steer Steering CW: Steer VM
(AC Lift) 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
9 JPC6-4 DGND Reference for the control circuits in the steer <0.5VDC wrt VM Steer
(AC Lift) amplifier. If missing, the steer amplifier does B– Amplifier
not power up.
10 JPC6-5 CCW_PWM This is a chopped voltage used to rotate the Steering CW: VM Steer
(AC Lift) 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
11 JPC6-6 +12VP Operating voltage from the VM for the +10.7 to VM Steer
(AC Lift) control circuits in the steer amplifier. If this is 13VDC Amplifier
missing, the steering is inoperable.
12 JPC9 FlashWare Connection
13 JPC10-1 & 2 Not Used
14 JPC10-3 THERM_EN Voltage from the VM to the Thermakit ON: VM Heaters

Control Card to control heaters in the <0.5VDC;
Primary and Secondary Control Handles OFF:
and heated floor pad. >10.5VDC
15 JPC10-4 Not Used

Pinout Matrix

16 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 this connection is missing, the
VM cannot communicate. Troubleshoot
using resistance checks. No useful
information can be gained by measuring
the voltage on this wire.
17 JPC10-6 +12V_EN1 Used as a connect detect to verify the Steer Encoder VM Steer Tiller
Series Tiller Encoder is connected to the VM. connected: Encoder
CA/FA (AC 9.0VDC;
lift) Disconnected
+10.7 to
13VDC
18 JPC10-7 +12V_EN2 Used as a connect detect to verify the Steer Encoder VM Steer Tiller
(AC Lift) Tiller Encoder is connected to the VM. connected: Encoder
9.0VDC;
Disconnected
+10.7 to
13VDC
19 JPC10-8 Not Used
20 JPC10-9 DGND Reference for the Steer Motor Encoder. <0.5VDC wrt VM Steer
(AC Lift) B– Motor
Encoder
21 JPC10-10 BUS_E+ Carries positive component of the digital 2.53VDC VM WMM

communications between the VM and the
optional WMM. If this connection is
missing, the WMM cannot communicate.
Troubleshoot using resistance checks. No
useful information can be gained by
measuring the voltage on this wire.
22 JPC12-1 +5VP +5VDC supply to the solid state 4.9VDC VM Primary

potentiometers and switches in the Primary Control
Control Handle. If this is <4.75, the handle Handle
will not function correctly. Measure wrt
DGND JPC12-12.
23 JPC12-2 LIFT Input to the VM from the wiper of the Neutral: VR2 VM
primary lift control. Measure wrt DGND 1.0V;
JPC12-12. Full Forward:
1.84VDC;
Full Reverse:
0.30VDC
24 JPC12-3 P_THROTTLE Input to the VM from the wiper of the Neutral: VR1 VM
Primary Throttle Control. Measure wrt 1.2VDC;
DGND JPC12-12. Full Forward:
1.9VDC;
Full Reverse:
0.45VDC

Pinout Matrix

25 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
26 JPC12-5 TILT_UP Input to the VM from the tilt up button (S6). S6 open: S6 VM
27 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
28 JPC12-7 H_HTR DC supply to handle heater (HTR6). OFF: VM Primary

<0.5VDC; Control
ON: 7.5 to Handle
8.5VDC
29 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
30 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
31 JPC12-10 P_HORN Input to the VM from the primary (primary S9 open: S3 VM

control handle) horn switch (S3). >4.0VDC;
Note: When other aux function switches S3 closed:
are activated, reading can change by as <0.5VDC
much as 0.5V.
32 JPC12-11 RETRACT Input to the VM from the retract switch (S5). S5 open: S5 VM
33 JPC12-12 DGND Reference for all switches and <0.5VDC wrt VM Primary
potentiometers in the primary control B– Control
handle. If this voltage is not <0.5VDC wrt Handle
TP4 on the power panel, then intermittent
handle codes may appear.
34 JPC14-1 B–F This connects B–F on the VM to TP4 (B–) <0.5VDC wrt Fuse/Relay VM
through FU6 on the Fuse/Relay Card. B– Card
35 JPC14-2 DGND This connects DGND and AGND on the VM <0.5VDC wrt Fuse/Relay VM
to TP4(B–) through FU6 on the Fuse/Relay B– Card
Card. This is the reference for all circuits on
the truck that are referenced to either
DGND or AGND.
36 JPC14-3 DGND Reference for the control circuits in the TPC, <0.5VDC VM TPC, LPC,
LPC, and Operator Display. Display

Pinout Matrix

37 JPC14-4 BUS_E– Carries negative component of the digital 2.24VDC VM TPA, LPA, &
BUS_I– communications between the VM and the Display
TPA, LPA (AC Lift), & the Operator Display.
If 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.
38 JPC14-5 +12VP Operating voltage from the VM to the +10.5 to VM Display

Operator Display. 13VDC
39 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, & K4
relays are energized simultaneously during Relays ON:
SelfTest if the voltage at Battery_Sense_In is <3.0VDC
at an acceptable level.
40 JPC14-7 B+K4 B+ provided to the VM when K4 is closed. K4 closed: K4 Cold

This voltage is used to power the heaters in B+; Storage
cold storage trucks. If the Ambient Temp K4 open: Package
Sensor detects <40°F, the VM keeps this 0.2V heaters
circuit on to power the heaters, even with
the Key Switch turned OFF.
41 JPC14-8 B–F Connects DGND and AGND on the VM to <0.5VDC wrt Fuse/Relay VM
TP4 (B–) through FU6 on the Fuse/Relay B– Card
DGND or AGND.
42 JPC14-9 B–F Connects DGND and AGND on the VM to <0.5VDC wrt Fuse/Relay VM
DGND or AGND.
43 JPC14-10 DGND Connects DGND and AGND on the VM to <0.5VDC wrt Fuse/Relay VM
DGND or AGND.
44 JPC14-11 BUS_I+ Carries positive component of the digital 2.8VDC VM TPA, LPA, &
communications between the VM and the Display
TPA, LPA (AC Lift), 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.

Pinout Matrix

45 JPC14-12 B+KEY B+ that is switched by Key Switch (S1) and S1 closed: S1 VM

used to power functions on the VM that are B+;
initiated after S1 is closed, and are not S1 open:
affected by the EPO. This includes the VM 0.3VDC
power supplies and the operation of the
microprocessor.
46 JPC14-13 B+K2 B+ provided to the VM when K2 is closed. K2 closed: K2 Hydraulic

This voltage is used to power the hydraulic B+; solenoids
solenoids on the tractor and on the K2 open:
carriage. They are de-energized when the 0.3VDC
EPO is open.
47 JPC14-14 B+K2 B+ provided to the VM when K2 is closed. K2 closed: K2 Hydraulic

This voltage is used to power the hydraulic B+; solenoids
solenoids on the tractor and on the K2 open:
carriage. They are de-energized when the 0.3VDC
EPO is open.
48 JPC18-1 2nd_STAGE Control path for the 2nd pump solenoid. De-energized: K2 VM
(DC Lift) This solenoid diverts oil to the lift cylinder B+;
when it is energized and to the tank when Energized:
de-energized. Its operation is controlled by 24V
the VM based on lift request and weight on
forks.
49 JPC18-2 thru Not Used

4
50 JPC18-5 DGND Reference for Channel 1 of the Steer Tiller <0.5VDC wrt VM Steer Tiller
(AC Lift) Encoder at JPC14-10 and JPC14-2. B– Encoder
51 JPC18-6 DGND Reference for Channel 2 of the Steer Tiller <0.5VDC wrt VM Steer Tiller
(AC Lift) Encoder at JPC14-10 and JPC14-2. B– Encoder
52 JPC18-7 DGND Reference for the deadman switch (S2). <0.5VDC wrt VM S2
B–
53 JPC18-8 Not Used
54 JPC18-9 LIFT_ Control path for the lift contactor (LPC). The De-energized: K2 VM
(DC Lift) CONTACTOR voltage is controlled by a coil driver inside B+;
the VM. Energized:
12.3VDC
55 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 closed):
energize the L/H solenoid coil (lowering). B+;
Energized:
13.3VDC
56 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 closed): Contactor
coil. B+;
Energized:
13.4VDC

Pinout Matrix

57 JPC18-12 REACH_SOL Control path for Reach solenoid coil. De-energized VM Reach
(K2 closed): Solenoid
B+;
Energized:
13.2VDC
58 JPC18-13 Not Used
59 JPC18-14 SIDESHIFT_ Control path for Sideshift solenoid coil. De-energized VM Sideshift
SOL (K2 closed): Solenoid
B+;
Energized:
13.1VDC
60 JPC18-15 TILT_SOL Control path for Tilt solenoid coil. De-energized VM Tilt
(K2 closed): Solenoid
B+;
Energized:
13.1VDC
61 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 closed):
coil. B+;
Energized:
0.02 VDC
62 JPC18-17 FAN Control path for the amplifier and motor De-energized VM Fans
compartment fans that are controlled (K2 closed):
together by the VM. B+;
Energized:
0.09VDC
63 JPC20-1 +12VP +12VDC supply for 1st Speed Limiting +10.7 to VM S12
Switch (S12). 13VDC
64 JPC20-2 +12VP Not Used +10.7 to VM N/A

13VDC
65 JPC20-3 +12VP +12VDC supply for optional High Speed +10.7 to VM S25
Travel Switch (S25). 13VDC
66 JPC20-4 +12VP +12VDC supply for the Pressure Transducer. +10.7 to VM Pressure
13VDC Transducer
67 JPC20-5 +12VP +12VDC supply to the Deadman Sensor +10.7 to VM VR4

potentiometer (VR4). 13VDC
68 JPC20-6 +12VP +12VDC supply for the optional Lift Cutout +10.7 to VM S27
Switch (S27). 13VDC
69 JPC20-7 +12VP +12VDC supply for the Steer Motor +10.7 to VM Steer
Encoder. 13VDC Motor
Encoder
70 JPC20-8 +12VP Not Used +10.7 to VM N/A

13VDC
71 JPC20-9 +12VP +12VDC supply to the Steer Limit Switch +10.7 to VM S11
(S11). 13VDC

Pinout Matrix

72 JPC20-10 & Not Used

11
73 JPC20-12 DUMP Control path for SOL3, a combination De-energized: VM SOL3

(AC Lift) 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 Motor/ 12VDC for 1
pump is slowing down. This permits to 2 seconds;
immediate lower without waiting for the Aux functions
pump to stop turning. energized:
24VDC
74 JPC20-12 AUXDUMP Control path for the aux dump solenoid De-energized: VM SOL8
(DC Lift) SOL8. This solenoid diverts steering/ B+;
auxiliary hydraulic fluid to the reservoir Energized:
when de-energized (no aux function 3.7VDC
requested) and to the aux functions when
energized.
75 JPC20-13 B+DUMP B+ from K2 to SOL3. B+ VM SOL3

(AC Lift)
76 JPC20-13 B+AUXDUMP B+ from K2 to SOL8. B+ VM SOL8

(DC Lift)
77 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
78 JPC20-15 B+L/L B+ supplied to SOL2 when K2 is energized. B+ VM SOL2
79 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
80 JPC20-17 B+AUX1 B+ supply for SOL5T solenoid. B+ VM SOL5T
81 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

Pinout Matrix

82 JPC20-19 B+AUX2 B+ supply for SOL5B solenoid. B+ VM SOL5B
83 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
84 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
86 JPC22-4 HS TRAVEL Used by the VM to determine when the Open: 5VDC S25 VM
SW carriage is above S25. Closed:
0VDC
87 JPC22-5 CHANNEL_A_ Channel_A_1 is one part of the steering >4.5VDC or Steer Tiller VM
(AC Lift) 1 request from the Steer Tiller Encoder on <0.5VDC Encoder
electric steer trucks when the steering tiller is when tiller
moved. It is a square wave signal (0VDC & stationary. DC
4.5VDC) identical to Channel_B_1 but value when
different phase. The VM uses the phase turning
relationship of the two channels to 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.
88 JPC22-6 LIFT CUTOUT Used by the VM to determine when the Open: 5VDC S27 VM
SW carriage is above S27. Closed:
0VDC
89 JPC22-7 Not Used
90 JPC22-8 ON Input to the VM from the Deadman Switch Released: S2 VM

DEADMAN (S2). This is used by the VM to determine >+4VDC;
whether to ignore or comply with other Depressed:
operational requests from either of the <0.5VDC
control handles.

Pinout Matrix

91 JPC22-9 CHANNELA_4 ChannelA_4 is one part of the steering Not turning: Steer Motor VM
(AC Lift) 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 ChannelB_4 but different phase. direction:
The VM uses the phase relationship of the 1.8VDC
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.
92 JPC22-10 CHANNELB_4 ChannelB_4 is one part of the steering Not turning: Steer Motor VM
(AC Lift) 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 ChannelA_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.
93 JPC22-11 DGND Reference for Steer Limit Switch (S11). <0.5VDC wrt VM S11
(AC Lift) B–
94 JPC22-12 CHANNEL_B_ Channel_B_1 is one part of the steering Not turning: Steer Tiller VM
(AC Lift) 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.
95 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.

Pinout Matrix

96 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.
97 JPC22-15 BRUSH_WEAR Brush wear indicator on the armature (A1 Brushes not Armature VM
Series _1 brush) of the Lift Motor. The VM uses this worn: 0VDC;
AA/BA/DA/ voltage to stop lift and sound an alarm Brushes worn:
EA (DC lift) when the brushes are worn. Armature
voltage
34VDC
98 JPC22-16 BRUSH_WEAR Brush wear indicator on the armature (A2 Brushes not Armature VM
Series _2 brush) of the Lift Motor. The VM uses this worn: 0VDC;
AA/BA/DA/ voltage to stop lift and sound an alarm Brushes worn:
EA (DC lift) when the brushes are worn. Armature
voltage
34VDC
100 JPC22-18 NESTED Control path for the optional Nested Switch K2 Closed K2 VM
SWITCH (S14) on the carriage. The VM reduces (carriage
travel speed to the configured value (0 to nested): B+;
3.5 mph/5.76 km/hr) when the switch is Open
open. (unnested):
0VDC
101 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:
determine the state of FU1 and the STR Voltage drops
contactor. slowly to
0VDC
102 JPC22-20 FU3_SENSE B+ when there is not an open between B+ STR & LPC LPC1 VM
(DC Lift) and LPC1. This voltage is used by the VM to closed: B+;
determine the state of the LPC, FU3, and the Either open:
STR contactor. 0VDC when
lifting
103 JPC22-21 EPO_SENSE Sense wire used by the VM to determine EPO closed: EPO VM
when the EPO is open. B+;
Open: 0VDC
104 JPC22-22 STEER_LIMIT The Steer Limit Switch (S11) stops drive unit Open (metal): S11 VM
(AC Lift) 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
105 JPC24-1 thru Not Used

5

Pinout Matrix

106 JPC24-6 DGND Reference for pressure transducer. <0.5VDC wrt VM Pressure
B– Transducer
107 JPC24-7 DGND Reference for the deadman pot (VR4). <0.5VDC wrt VM VR4
B–
109 JPC24-10 AGND Reference for the Lift Motor temperature <0.5VDC wrt VM VM
(DC Lift) sensor. B–
110 JPC24-11 DGND Reference for the Ambient Temperature <0.5VDC wrt Ambient VM
Sensor. B– Temp Sensor

thru 17
112 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
113 JPC24-19 DEADMAN Analog voltage that varies with the position Deadman VR4 VM
of the deadman pedal. This is used by the fully
VM to apply proportional braking. depressed:
4.5VDC;
Fully
released:
2.5VDC
114 JPC24-20 & Not Used

21
115 JPC24-22 LIFT_MOT_ Analog DC voltage that varies directly as 70°F (21°C): VM VM
(DC Lift) TEMP the temperature of the Lift Motor changes. 2.2VDC;
The VM uses this voltage to eliminate lift at Open or
279°F (137°C). disconnected:
5VDC
116 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
117 JPC24-24 Battery_Sense Used by the VM to determine the correct B+ B+ at JPF4-1 VM

_In battery has been connected. It accepts any
voltage between 28VDC and 45VDC. If the
correct battery is sensed, Relay_Enable is
energized during start-up. After start-up, this
voltage is used to determine BSOC.
118 JPF1-1 B– B– for FU8, B– 15A fuse for optional Aux <0.5VDC wrt TP4 Optional
power. B– Aux Power

Pinout Matrix

119 JPF1-2 B– B– for FU8, B– 15A fuse for optional Aux <0.5VDC wrt TP4 Optional
power. B– Aux Power
120 JPF1-3 B+F or B–F Provides B+ or B– to the LPA pre-charge K3 FU5 to B+ LPA
(AC Lift) circuit, depending on the state of relay K3. De-energized FU6 to B–
Voltage drops
slowly to 0;
Energized: B+
121 JPF1-4 B–F B–F from FU8 to power the optional WMM. <0.5VDC wrt FU8 to B– Aux Power,
B– WMM
122 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+
123 JPF1-6 B+F or B–F Provides B+F or B–F to B+K3 on the Lift K3 FU5 to B+ LPA, TPA
(JPL1-1 AC Lift) and Traction (JPT1-1) Power De-energized: FU6 to B–
Amplifiers. B–;
Energized: B+
124 JPF2-1 B+K2 B+K2 to power TPC, LPC, and STR K2 energized: K2 TPC, LPC,
contactors. B+ and STR
Contactors
125 JPF2-2 B+K2 B+K2 to power the horn. K2 energized: K2 Horn

B+
126 JPF2-3 B+K2 B+K2 to power the compartment fans. K2 energized: K2 Fans
B+
127 JPF2-4 B+K4 B+K4 to the VM. K4 energized: K4 VM

B+
128 JPF2-5 B+K2 B+K2 to power SOL1. K2 energized: K2 L/H SOL1

B+

B+

B+
131 JPF2-8 B+K2 B+K2 to the reach, sideshift, tilt solenoids, K2 energized: K2 Carriage
and Nested Switch (S14). B+ Functions
132 JPF2-9 B+K1 B+ to TS1. K1 energized: K1 TS1

B+
133 JPF3-1 B– B– for FU6 (15A), that provides B– to the <0.5VDC wrt TP4 VM
VM. B–
134 JPF3-2 B– B– for FU6 (15A), that provides B– to the <0.5VDC wrt TP4 VM
VM. B–
135 JPF3-3 B–F B–F for DGND on the VM. <0.5VDC wrt FU6 VM
B–

Pinout Matrix

136 JPF3-4 B–F B–F for DGND on the VM. <0.5VDC wrt FU6 VM
B–
137 JPF3-5 B–F B–F for the VM. <0.5VDC wrt FU6 VM
B–
B–
B–
140 JPF3-8 B–F B–F for 1st Speed Limiting Switch (S12) on <0.5VDC wrt FU6 S12
mast. B–
141 JPF4-1 B+ B+ from TP1 to FU5, to supply K2, K3, and B+ TP1 FU5 & VM
K4 relay; K4 relay coil; and Key Switch
(S1). Also supplies Battery_Sense_In on the
VM.
142 JPF4-2 B+ B+ from TP1 to FU5, to supply K2, K3, and B+ TP1 FU5 & VM
K4 relay; K4 relay coil; and Key Switch
(S1). Also supplies Battery_Sense_In on the
VM.
143 JPF4-3 B+ B+ from TP1 to FU7 to supply auxiliary B+ TP1 FU7 and
power option and WMM. Aux Power
144 JPF4-4 B+ B+ from TP1 to FU7 to supply auxiliary B+ TP1 FU7 and
power option. Aux Power
145 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.
146 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
147 JPF4-7 BATTERY_ B+ to Battery_Sense_In on the VM. B+ TP1 VM

SENSE_IN
148 JPF4-8 B+Key B+Key to supply all functions powered from S1 closed: B+ FU5 Various
Key Switch (S1).
149 JPF4-10 B+ B+ from FU5 to Key Switch (S1). FU5 good: B+ FU5 S1
FU5 open:
0VDC
150 JPF4-11 B+Key B+ from Key Switch (S1) to the VM. S1 closed: B+ S1 VM
151 JPF4-12 B+Key B+ from Key Switch (S1) to the EPO. S1 closed: B+ S1 EPO

Pinout Matrix

152 JPF4-13 Relay_Enable Return path for relays K1, K2, K3, and K4. Key ON & all VM K1, K2,
relays K3, & K4
De-energized:
B+;
Key OFF, or
Key ON &
any relay
Energized:
<1.5VDC
153 JPF4-14 Not Used
154 JPF4-15 B+ B+ for battery connected aux power. B+ FU7 Optional

Aux Power
155 JPL1-1 B+K3 B+ present when K3 is energized. This is K3 Energized: K3 LPA

(AC Lift) 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.
156 JPL1-2 LPC Control path for the LPC Contactor. LPC LPA LPC
(AC Lift) CONTACTOR De-energized: Contactor
B+;
LPC
Energized:
18 to 22VDC.
157 JPL1-3 L VEL +12VDC supply to the Lift Motor encoder. +10.9 to LPA Lift Motor
(AC Lift) SENSOR+ 13VDC Encoder
158 JPL1-4 L VEL Return path for the Lift Motor Encoder. <0.5VDC DGND on Lift Motor
(AC Lift) SENSOR– Returns through DGND JPL1-7 through the VM Encoder
Operator Display to the VM.
159 JPL1-5 L VEL PHASE A This square wave is generated whenever Motor Lift Motor LPA
(AC Lift) there is movement of the encoder in the Lift Stationary: Encoder
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: 4 to
formation to L Vel Phase B, except for the 6VDC.
phasing between the two. The LPA uses the
quadrature phase relationship between
Phases A and B to determine lift speed.
160 JPL1-6 L VEL PHASE B This square wave is generated whenever Motor Lift Motor LPA
(AC Lift) there is movement of the encoder in the Lift Stationary: Encoder
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: 4 to
formation to L Vel Phase A, except for the 6VDC.
phasing between the two. The LPA uses the
Phases A and B to determine lift speed.

Pinout Matrix

161 JPL1-7 DGND DGND from VM through the Operator <0.5VDC wrt Operator LPA
(AC Lift) Display to the LPA. If missing, the LPA and B– Display
TPA do not function.
162 JPL1-8 DGND B– Provides DGND to the TPA from the LPA. <0.5VDC wrt LPA TPA
(AC Lift) B–
163 JPL1-9 thru Not Used

13 (AC lift)
164 JPL1-14 BUS_I– Carries negative component of the digital 2.2VDC Operator LPA
(AC Lift) communications between the Operator Display
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
165 JPL1-15 BUS_I– Carries negative component of the digital 2.2VDC LPA TPA
(AC Lift) 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.
166 JPL1-16 L TEMP+ Analog voltage that varies with Lift Motor 75°F (24°C): LM Temp LPA
(AC Lift) temperature. Used by the LPA to adjust approx. Sensor
motor performance when a motor overtemp 1.5VDC
condition exists.
167 JPL1-17 L TEMP– Reference for the Lift Motor temperature <0.5VDC wrt DGND on LM Temp
(AC Lift) sensor. B– VM Sensor
168 JPL1-18 thru Not Used

21 (AC Lift)
169 JPL1-22 BUS_I+ Carries positive component of the digital 2.94VDC Operator LPA
(AC Lift) communications between the LPA and the Display
Operator Display and VM. If missing, the
LPA and TPA cannot communicate with the
Operator Display or VM. Troubleshoot
170 JPL1-23 BUS_I+ Carries positive component of the digital 2.94VDC LPA TPA
(AC Lift) communications between the LPA and the
communicate with the LPA, Display, or VM.

Pinout Matrix

171 JPT1-1 B+K3 B+ present when K3 is energized. Used to K3 Energized: K3 TPA

(AC Lift) power control circuits of the TPA. Also used B+
by the TPA to produce +12VDC for T Vel
Sensor+ and internal circuits of the TPA. If
voltage is not present, check K3 coil and tip
circuit.
172 JPT1-2 TPC Control path for the TPC Contactor. TPC TPA TPC
CONTACTOR De-energized: Contactor
B+;
TPC
Energized:
18 to 22VDC
173 JPT1-3 T VEL +12VDC supply to the Traction Motor +10.7 to TPA TME
SENSOR+ Encoder (TME). 13VDC
174 JPT1-4 T VEL Return path for the TME. Returns through <0.5VDC wrt DGND on TME
SENSOR– DGND JPT1-7 to the LPA, Operator Display, B– VM
and to the VM.
175 JPT1-5 T VEL PHASE A Generated when there is movement of the Motor TME TPA
Traction Motor. It is a square wave that is Stationary:
either high (>8VDC) or low (<1VDC). Either >8VDC
Frequency varies directly with speed of or <1VDC;
Traction Motor. Identical information to T Turning: 4 to
Vel Phase B, except for the phasing 6VDC
between the two. The VM uses the
Phases A and B to determine travel
direction and speed.
176 JPT1-6 T VEL PHASE B Generated when there is movement of the Motor TME TPA
Traction Motor. It is a square wave that is Stationary:
either high (>8VDC) or low (<1VDC). Either >8VDC
Frequency varies directly with speed of or <1VDC;
Traction Motor. Identical information to Turning: 4 to
T Vel Phase A, except for the phasing 6VDC.
between the two. The VM uses the
Phases A and B to determine travel
direction and speed.
177 JPT1-7 DGND DGND for the TPA from the LPA. <0.5VDC wrt LPA TPA
(AC Lift) B–
178 JPT1-7 DGND DGND from the VM for the control side of <0.5VDC wrt VM TPA
(DC Lift) the TPA. If missing, the TPA does not B–
function.
179 JPT1-8 DGND DGND from the VM via the Operator <0.5VDC wrt VM TPA
(DC Lift) Display for the TPA. If missing, the TPA does B–
not function.
180 JPT1-9 thru Not Used

13

Pinout Matrix

181 JPT1-14 BUS_I– Carries negative component of the digital 2.2VDC LPA TPA
(AC Lift) communications from the LPA and VM to the
communicate with the VM, LPA, or Display.
182 JPT1-14 BUS_I– Carries negative component of the digital 2.2VDC VM TPA
(DC Lift) communications between the VM and TPA.
If missing, the TPA cannot communicate with
the VM. Troubleshoot using resistance
this wire.
183 JPT1-15 BUS_I– Carries negative component of the digital 2.2VDC TPA Display
(DC Lift) communications between the TPA and
Operator Display. If missing, the Operator
Display cannot communicate. Troubleshoot
184 JPT1-16 T TEMP+ Analog voltage that varies with Traction 75°F (24°C): Traction TPA
Motor temperature. Used by the TPA to approx. Motor Temp
adjust motor performance when a motor 1.0VDC Sensor
overtemp condition exists.
185 JPT1-17 T TEMP– Reference for the Traction Motor Temp <0.5VDC wrt DGND on Traction
sensor. B– VM Motor
Temp
Sensor
186 JPT1-18 thru Not Used

21
187 JPT1-22 BUS_I+ Carries positive component of the digital 2.93VDC LPA TPA
(AC Lift) communications from the LPA and VM to the
communicate with the VM, LPA, or Display.
188 JPT1-22 BUS_I+ Carries positive component of the digital 2.93VDC VM TPA
(DC Lift) communications between the VM and TPA.
If missing, the TPA cannot communicate with
the VM. Troubleshoot using resistance
this wire.

Pinout Matrix

189 JPT1-23 BUS_I+ Carries positive component of the digital 2.93VDC TPA Display
(DC Lift) communications between the TPA and
Operator Display. If this connection is
missing, the TPA cannot communicate.
190 LPA (+) LPA B+ B+ to the LPA used to pre-charge the Fully Charged B+K3 and B+ LPA
(AC Lift) amplifier and also to produce the AC or LPC from LPC
phases U, V, and W when the LPC is closed Energized: B+
to power the Lift Motor. Voltage increases
from 0VDC to B+ as the amplifier charges.
191 LPA B– LPA B– B– from TP4 on the Power Panel. Used for <0.5VDC wrt TP4 LPA
(AC Lift) power circuits on the LPA. Without B–, U, V, B–
and W cannot be produced and the Lift
Motor does not operate.
192 LPA B+ Not Used

(AC Lift)
193 TPA (+) TPA B+ B+ to the TPA used to pre-charge the B+ fully B+K3 and B+ TPA
amplifier and also to produce the AC charged or from TPC
phases U, V, and W when the TPC is closed TPC
to power the Traction Motor. Voltage energized.
increases from 0VDC to B+ as the amplifier
charges.
194 TPA B– TPA B– B– from TP4 on the Power Panel. It is used <0.5VDC wrt TP4 TPA
for the power circuits on the TPA. Without B–
B–, U, V, and W cannot be produced and
Traction Motor does not operate.
195 TPA B+ Not Used
196 U on LPA LIFT MOTOR One of three phases from the LPA to the Lift ACV between LPA Lift Motor
(AC Lift) 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. When Full lift:
lift knob is initially moved to full lift, meter 24VAC
reading may show 120VAC before
stabilizing at about 24VAC.
197 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. Full travel:
24VAC;
Stall: approx.
4VAC

Pinout Matrix

198 V on LPA LIFT MOTOR One of three phases from the LPA to the Lift Stationary: LPA Lift Motor
(AC Lift) PHASE V Motor. This AC voltage is produced by LPA 0VAC;
and is dependent on B+ at the (+) terminal Full lift:
and B– of the LPA. This AC voltage is 24VAC
measured between any two phases. When
lift knob is initially moved to full lift, meter
199 V on TPA TRACTION One of three phases from the TPA to the Stationary: TPA Traction
MOTOR Traction Motor. This AC voltage is produced 0VAC; Motor
PHASE V by TPA and is dependent on B+ at the (+) Full travel:
is measured between any two phases. Stall: approx.
4VAC
190 W on LPA LIFT MOTOR One of three phases from the LPA to the Lift Stationary: LPA Lift Motor
(AC Lift) PHASE W Motor. This AC voltage is produced by LPA 0VAC;
and is dependent on B+ at the (+) terminal Full lift:
and B– of the LPA. This AC voltage is 24VAC
measured between any two phases. When
lift knob is initially moved to full lift, meter
191 W on TPA TRACTION One of three phases from the TPA to the Stationary: TPA Traction
MOTOR Traction Motor. This AC voltage is produced 0VAC; Motor
PHASE W by TPA and is dependent on B+ at the (+) Full travel:
is measured between any two phases. Stall: approx.
4VAC

Model 7400/7420/7440 Reach-Fork ® Truck Section A. Appendix
Section A. Appendix
Publication: 1026304, Issued: 22 Apr 2009 A-1

Section A. Appendix Model 7400/7420/7440 Reach-Fork ® Truck
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°F to +120°F Fluid 990-616/02 (2 gal./7.6 liters)
(+10°C 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°F to +50°F
(–18°C to +10°C)
Hydraulic Reservoir
(CS trucks - confined to
Hydraulic 990-618/TX1 (1 gal./3.8 liters)
freezer) MIL-H-5606E
Fluid 990-618/01 (1 gal./3.8 liters)
–20°F to 0°F
(–29°C to –18°C)
Mast Uprights, Bearings,

and so forth
(all-weather) Grease NLGI 2 1012992
–20°F to +120°F
(–29°C to +49°C)
Teflon
Lift Chains Aerosol 990-652/001 (spray)
Grease
A-2 Publication: 1026304, Issued: 22 Apr 2009

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
990-533 T7471
Thread-locking Primer
990-666 7649 (19269)
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.

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
Auxiliary Motor Series

motor mtg bolts 990-536 15 ft. lb. (21 Nm)
Auxiliary Pump Series pressure fitting torque n/a 45 ft. lb. (61 Nm)
AA/BA/DA/EA (DC lift) mounting bolts 990-536 11 ft. lb. (15 Nm)
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

Pedal travel:
Series AA/BA/CA (Fore-Aft
assembly to frame n/a 15 ft. lb. (21 Nm)
Stance): 3.50 in. (90 mm)
Series DA/EA/FA (Side Stance):
3.58 in. (99 mm)
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.

Thread-Locking
Compound P/N
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 bracket mtg bolts to deck
and mating surfaces.
lift motor power cables 18 ft. lb. (24.4 Nm)
P1 fitting Series CA/FA

85 ft. lb. (115 Nm)
(AC lift)
input fitting Series CA/FA

120 ft. lb. (163 Nm)
Lift Pump (AC lift) n/a
Apply anti-seize compound
P1 fitting Series
(P/N 990-638) to spline, mating 85 ft. lb. (115 Nm)
surfaces.
P2 fitting Series
60 ft. lb. (81 Nm)
lift pump mounting bolts 55 ft. lb. (72 Nm)
Manifold, Auxiliary
mounting bolts 990-536 21 ft. lb. (29 Nm)
(Reach/Tilt/Sideshift)
Manifold, Main Mounting bolts 21 ft. lb. (29 Nm)
990-666 (primer)
Mast mast to tractor 165 ft. lb. (224 Nm)
990-544 (locker)
amplifier bolts to bracket 6 ft. lb. (8.6 Nm)
Power Amplifier, Lift (AC 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)
Steer Limit Switch S11 Series switch bracket to drive

990-536 9 ft. lb. (12 Nm)
CA/FA (AC lift) 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.

Thread-Locking
Compound P/N
pinion gear set screw 6 ft. lb. (8.6 Nm).

Steer Motor, Electric (AC Lift)
Note: Apply anti-seize compound pinion gear mtg bolt 1013829 21 ft. lb. (29 Nm)
(P/N 990-638) to pinion gear. Orient
pinion gear with shoulder toward motor mtg bolts 30 ft. lb. (42 Nm)
mounting bolt.
flange mtg bolts 95 ft. lb. (129 Nm)
spur gear 6.25 ft. lb. (8.5 Nm)

990-536
mounting bolts 55 ft. lb. (72 Nm)
Steer Motor, Hydraulic (DC Lift) flange mtg bolts 75 ft. lb. (102 Nm)
pressure fittings 60 ft. lb. (81 Nm)

n/a
drain connection 21 ft. lb. (28 Nm)
Steering Orbitrol (DC Lift) mounting bolts 15 ft. lb. (21 Nm)
990-536
Stops, Carriage n/a 35 ft. lb. (47.5 Nm)
Temperature Sensor, DC Lift Apply heatsink compound (P/N 990-508) to sensor threads. Make sure
Motor sensor does not touch field poles when retaining nut is tightened.
pinion gear nut 45 ft. lb. (61 Nm)

Traction Motor 990-536
Note: When replacing Traction mounting bolts 13 ft. lb. (17 Nm)
Motor, thoroughly clean motor
shaft, keyway, and threads with power cables n/a 18 ft. lb. (24.4 Nm)
P/N 990-666.
steer limit sensing rail 9 ft. lb. (12 Nm)
990-536
Travel Light n/a 23 ft. lb. (31 Nm)

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

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

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

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.

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.

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.

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.

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

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

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

Schematics
Schematics

Schematics

Section A. Schematics
Figure A-1. Electrical Schematic (Sheet 1 of 5)

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Model 7400/7420/7440 Reach-Fork ® Truck Section I. Index
Section I. Index
Numerics Battery
Charging . . . . . . . . . . . . . . . . . . . . 7-76
2d Pump Valve SOL4 Cleaning Exterior . . . . . . . . . . . . . 7-75
Torque . . . . . . . . . . . . . . . . . . . . .7-111 Connector/Cables . . . . . . . . . . . . . 7-74
Maintenance . . . . . . . . . . . . . . . . . 7-76
Safety . . . . . . . . . . . . . . . . . . . . . . . 2-5
A State-of-Charge (BSOC) . . . . 5-10, 7-76
Configuring . . . . . . . . . . . . . . . . 3-23
Abbreviations, List of . . . . . . . . . . . . . . 1-4 Testing . . . . . . . . . . . . . . . . . . . . . 7-76
AC Motors . . . . . . . . . . . . . . . . . . . . . . 5-9 Battery Gate Switches . . . . . . . . . . . . . A-4
Acceleration Bearings
Lift, Configuring . . . . . . . . . . . . . 3-23 Mast, Shimming . . . . . . . . . . . . . 7-147
Lower, Configuring . . . . . . . . . . . . 3-23 Carriage to Inner Tele
Travel, Configuring . . . . . . . . . . . 3-22 Model 7400 . . . . . . . . . . . . . . 7-190
Acronyms, List of . . . . . . . . . . . . . . . . 1-4 Model 7420 . . . . . . . . . . . . . . 7-203
Active Service Mode . . . . . . . . . . 3-27, 3-29 Model 7440 . . . . . . . . . . . . . . 7-213
Adjustment Inner Tele to Outer Tele
Auxiliary Pressure . . . . . . . . . . . .7-102 Model 7400 . . . . . . . . . . . . . . 7-189
Lift Pressure . . . . . . . . . . . . . . . . 7-99 Model 7420 . . . . . . . . . . . . . . 7-202
Proportional Valve . . . . . . . . . . . .7-101 Model 7440 . . . . . . . . . . . . . . 7-212
Reach Cylinder . . . . . . . . . . . . . .7-137 Outer Tele to Main Frame
Alarm, Travel, Configuring . . . . . . . . 3-22 Model 7400 . . . . . . . . . . . . . . 7-188
AMP Connectors . . . . . . . . . . . . . . . . 7-78 Model 7420 . . . . . . . . . . . . . . 7-201
Analog Tests . . . . . . . . . . . . . 6-33 to 6-61 Model 7440 . . . . . . . . . . . . . . 7-211
Summary List . . . . . . . . . . . . . . . 6-31 Reach Carriage . . . . . . . . . . . . . . 7-146
See Tests, Analog for Individual Tests Bleeding Hydraulic System . . . . . . . . . 7-96
Anchors, Chain . . . . . . . . . . . . . . . . .7-154 Bow Pads . . . . . . . . . . . . . . . . . . . . . 7-149
Auto Power Off ™Device . . . . . . . . . . . 3-25 Brake
Auxiliary Dump Valve SOL8 Adjustable . . . . . . . . . . . . . . . . . . 7-60
Torque . . . . . . . . . . . . . . . . . . . . .7-111 Adjustment . . . . . . . . . . . . . . . . 7-61
Auxiliary Functions, Troubleshooting 5-13 Assembly/Disassembly . . . . . . . 7-63
Auxiliary Manifold . . . . . . . . . . . 7-106, A-5 Pad Inspection . . . . . . . . . . . . . . 7-63
Auxiliary Motor (DC lift) . . . . . . . . . . . . A-4 Application, Theory . . . . . . . . . . . . 8-18
Auxiliary Pressure Adjustment . . . . .7-102 Floating Disk . . . . . . . . . . . . . . . . 7-66
Auxiliary Pump (DC lift) . . . . . . . . . . . . A-4 Coil Replacement . . . . . . . . . . . . 7-67
Auxiliary Valve SOL5B/5T Installation . . . . . . . . . . . . . . . . 7-67
Torque . . . . . . . . . . . . . . . . . . . . .7-111 Pad Replacement . . . . . . . . . . . . 7-66
Removal . . . . . . . . . . . . . . . . . . 7-66
B Overview . . . . . . . . . . . . . . . . . . . . 8-18
Release Screws, Use of . . . . . . . . . 8-18
Backlash, Drive Unit . . . . . . . . . . . . . 7-57 Release, Theory . . . . . . . . . . . . . . . 8-18
Baseleg . . . . . . . . . . . . . . . . . . . . 7-20, A-4 Theory of Operation . . . . . . . . . . . 8-18
BSOC (Battery State-of-Charge) 5-10, 7-76
Configuring . . . . . . . . . . . . . . . . . . 3-23
Setting BSOC Cutout . . . . . . . . . . 5-10
Publication: 1026304, Issued: 22 Apr 2009 I-1

Section I. Index Model 7400/7420/7440 Reach-Fork ® Truck
C Check Valve
CV-1 Torque . . . . . . . . . . . . . . . . 7-111
Cable Installation, Mast CV-2 Torque . . . . . . . . . . . . . . . . 7-111
Model 7400 . . . . . . . . . . . . . . . . . 7-191 CV-3 Torque . . . . . . . . . . . . . . . . 7-112
Model 7420 . . . . . . . . . . . . . . . . . 7-203 Circuit Card Connectors . . . . . . . . . . 6-28
Model 7440 . . . . . . . . . . . . . . . . . 7-214 Relay/Control Fuse Panel . . . . . . . 6-29
Cable Removal, Mast Vehicle Manager . . . . . . . . . . . . . . 6-28
Model 7400 . . . . . . . . . . . . . . . . . 7-184 Cleaning Lift Truck . . . . . . . . . . . . . . . 2-4
Model 7420 . . . . . . . . . . . . . . . . . 7-196 Clock, Setting . . . . . . . . . . . . . . . . . . . 3-25
Model 7440 . . . . . . . . . . . . . . . . . 7-207 Coast Distance, Configuring . . . . . . . . 3-22
Cable, Over-the-Mast . . . . . . . . . . . . 7-170 Codes
Cable Only Replacement . . . . . . . 7-179 Power Amplifier . . . . . . . . . . . . . . . 6-2
Conversion for Bulk Cable Use . . 7-178 Summary List . . . . . . . . . . . . . . . . . 6-3
Cable, Terminology . . . . . . . . . . . . . . . 6-27 Cold Storage Conditioning . . . . . . . . . 7-93
Card Cold Storage, Theory of Operation . . . . 8-6
Relay/Control Fuse Panel . . . . . . . 6-29 Compensating Element Valve CE1
Tilt/Sideshift Switch Torque . . . . . . . . . . . . . . . . . . . . 7-111
Fore-Aft Stance . . . . . . . . 7-33, 7-37 Configure Mode . . . . . . . . . . . . .3-16, 3-18
Vehicle Manager . . . . . . . . . . . . . . 6-28 Factory Defaults, Restoring .3-20, 3-22
Carriage . . . . . . . . . . . . . . . . . . . . . . 7-151 Menu Settings . . . . . . . . . 3-22 to 3-26
Bearings . . . . . . . . . . . . . . . . . . . 7-146 See also Individual Parameter Name
Configuring Reach/Retract . . . . . . 3-24 Connectors
Installation into Mast AMP . . . . . . . . . . . . . . . . . . . . . . . 7-78
Model 7400 . . . . . . . . . . . . . . . 7-191 Circuit Card . . . . . . . . . . . . . . . . . 6-28
Model 7420 . . . . . . . . . . . . . . . 7-203 Molex . . . . . . . . . . . . . . . . . . . . . . 7-78
Model 7440 . . . . . . . . . . . . . . . 7-214 Relay/Control Fuse Panel . . . . . . . 6-29
Manually Lowering . . . . . . . . . . . 7-100 Vehicle Manager . . . . . . . . . . . . . . 6-28
Removal from Mast Contactor Panel . . . . . . . . . . . . . . . . . 7-82
Model 7400 . . . . . . . . . . . . . . . 7-184 Control Handle
Model 7420 . . . . . . . . . . . . . . . 7-196 Fore-Aft Stance
Model 7440 . . . . . . . . . . . . . . . 7-207 Primary . . . . . . . . . . . . . 7-30 to 7-34
Stops . . . . . . . . . . . . . . . . . . . . . . .A-6 Flex Circuit Assembly . . . . . . . 7-30
Caster Assembly . . . . . . . . . . . . . . . . . 7-26 Pot Heaters . 7-30, 7-31, 7-32, 7-35,
Height Adjustment . . . . . . . . . . . . 7-27 7-36, 7-37
Caster, Steerable . . . . . . . . . . . . . . . . . 7-26 Shell Disassembly . . . . . .7-30, 7-35
Height Adjustment . . . . . . . . . . . . 7-27 ThermaKit Heater . 7-32, 7-33, 7-37
Caution, Definition . . . . . . . . . . . . . . . .2-2 Secondary . . . . . . . . . . . 7-39 to 7-40
CB1 & CB2 Counterbalance Valve ThermaKit Heater . . . . . . . . . . 7-39
Torque . . . . . . . . . . . . . . . . . . . . 7-112 Side Stance . . . . . . . . . . . 7-35 to 7-38
CE1 Compensating Element Valve Pot Heaters . . . . . . . . . . . .7-35, 7-38
Torque . . . . . . . . . . . . . . . . . . . . 7-111 Controls, Learn . . . . . . . . . . . . . . . . . 3-27
Chains Conversion
Anchors . . . . . . . . . . . . . . . . . . . 7-154 Decimal to Fraction . . . . . . . . . . . A-14
Condition-Cause Chart . . . . . . . . . 4-16 Fraction to Decimal . . . . . . . . . . . A-14
Free Lift . . . . . . . . . . . . . . . . . . . 7-163 Conversions, Standard/Metric . . . . . . A-16
Main Lift Corrosion Inhibitor, Cold Storage . . . . 7-93
7400 . . . . . . . . . . . . . . . . . . . . 7-160 Counterbalance Valve CB1 & CB2
7420 . . . . . . . . . . . . . . . . . . . . 7-161 Torque . . . . . . . . . . . . . . . . . . . . 7-112
7440 . . . . . . . . . . . . . . . . . . . . 7-162 Cushion, Lift Cylinder Lowering
Maintenance . . . . . . . . . . . . . . . . . 4-16 Free Lift . . . . . . . . . . . . 7-133 to 7-135
Changing Password or SuperWrd . . . . 3-18 Main Lift . . . . . . . . . . . . . . . . . . . 7-133
Cutout Switch, Lift (S27) . . . . . . . . . . . A-4
I-2 Publication: 1026304, Issued: 22 Apr 2009

Cutout, Lift, Configuring . . . . . . . . . . 3-23 Drive Unit . . . . . . . . . . . . . . . . 7-42 to 7-59

CV-1 Check Valve Torque . . . . . . . . .7-111 Assembly . . . . . . . . . . . . . 7-52 to 7-58
CV-2 Check Valve Torque . . . . . . . . .7-111 Helical Gear . . . . . . . . . . . . . . . . 7-54
CV-3 Check Valve Torque . . . . . . . . .7-112 Output Shaft . . . . . . . . . . . . . . . 7-52
Cylinder Pivot Ring . . . . . . . . . . . . . . . . . 7-57
Free Lift . . . . . . . . . . . . .7-114 to 7-120 Spiral Pinion . . . . . . . . . . . . . . . 7-52
Exploded Parts Drawings 7-118 to 7-120 Backlash Measurement . . . . . . . . . 7-57
Lowering Cushion . . .7-133 to 7-135 Disassembly . . . . . . . . . . . 7-48 to 7-52
Model 7400 . . . . . . . . . 7-184, 7-191 Output Shaft . . . . . . . . . . . . . . . 7-49
Model 7420 . . . . . . . . . 7-196, 7-203 Pivot Ring . . . . . . . . . . . . . . . . . 7-48
Model 7440 . . . . . . . . . 7-207, 7-214 Spiral Pinion . . . . . . . . . . . . . . . 7-51
Seal Repacking . . . . . .7-121 to 7-123 Exploded Parts Diagram . . . . . . . . 7-42
Main Lift . . . . . . . . . . . .7-124 to 7-130 Helical Gear Assembly . . . . . . . . . 7-54
Exploded Parts Installation . . . . . . . . . . . . . . . . . . 7-58
Drawings . . . . . . . . .7-129 to 7-130 Output Shaft
Lowering Cushion . . . . . . . . . .7-133 Assembly . . . . . . . . . . . . . . . . . . 7-52
Seal Repacking . . . . . .7-131 to 7-132 Disassembly . . . . . . . . . . . . . . . 7-49
Reach . . . . . . . . . . . . . . . . . . . . .7-136 Pivot Ring
Adjustment . . . . . . . . . . . . . . .7-137 Assembly . . . . . . . . . . . . . . . . . . 7-57
Tilt . . . . . . . . . . . . . . . . . . . . . . .7-139 Disassembly . . . . . . . . . . . . . . . 7-48
CYL-P Pressure Transducer Removal . . . . . . . . . . . . . . . . . . . . 7-47
Torque . . . . . . . . . . . . . . . . . . . . .7-111 Shim Formulas . . . . . . . . . . . . . . . 7-55
Shim Installation . . . . . . . . . . . . . 7-55
D Spiral Pinion
Assembly . . . . . . . . . . . . . . . . . . 7-52
Disassembly . . . . . . . . . . . . . . . 7-51
DC Motor Troubleshooting . . . . . . . . . 5-5
Troubleshooting . . . . . . . . . . . . . . 7-45
DC Motor Test . . . . . . . . . . . . . . . . . . . 5-7
Drive Wheel and Tire . . . . . . . . . . . . . . A-4
Deadman
Pedal Assembly . . . . . . . . . . . 7-68, A-4
Sensor VR4 . . . . . . . . . . . . . . . . . 7-68 E
Switch S2 . . . . . . . . . . . . . . . . . . 7-68
Decals and Plates . . . . . . . . . 7-15 to 7-18 Electric Steering Motor (AC Lift) . . . . . . A-6
Deceleration Electrical Tests . . . . . . . . . . . 6-31 to 6-123
Lift, Configuring . . . . . . . . . . . . . 3-23 Summary List . . . . . . . . . . . . . . . . 6-31
Lower, Configuring . . . . . . . . . . . . 3-23 See also Tests Analog, Tests Input, and
Decimal to Fraction Conversion . . . . . A-14 Tests Output
Deep-Reach Electrical Troubleshooting
Reach Manifold . . . . . . . . . . . . . .7-108 Symptoms . . . . . . . . . . . . 5-21 to 5-22
Tilt/Sideshift Manifold . . . . . . . . .7-110 Electronic Operator Key . . . . . . 3-17, 3-25
Diagnostic Mode Electrostatic Discharge
See Service Mode See Static Precautions
Digital Input Tests . . . . . . . . .6-63 to 6-100 Embedded Statistics, Configuring . . . . 3-25
Summary List . . . . . . . . . . . . . . . 6-31 Encoder
See Tests, Input for Individual Tests AC Lift Motor Speed (Danaher) . . . 7-84
Digital Output Tests . . . . . .6-101 to 6-121 AC Lift Motor Temperature
Summary List . . . . . . . . . . . . . . . 6-32 (Sauer Danfoss) . . . . . . . . . . . . 7-88
See Tests, Output for Individual Tests AC Traction Motor Speed
Display, Operator . . . . . . . . . . . . . . . 3-15 (Danaher) . . . . . . . . . . . . . . . . 7-86
Troubleshooting . . . . . . . . . . . . . 5-21 AC Traction Motor Speed
Drive Motor . . . . . . . . . . . . . . . . . . . . . A-6 (Sauer Danfoss) . . . . . . . . . . . . 7-88
Power Cable Terminal Nuts . . . . . 7-83 Height (HTI/HI) . . . . . . . . . . . . . . 7-165
Temperature Sensor TMT . . . . . . 7-84 Steering (AC Lift) . . . . . . . . . . . . . . 7-24

Energy Saving Mode, Configuring . . . . 3-26 Input Voltage During Start-Up . 6-9
English Units, Configuring Display for 3-23 Code 4E - No Pre-Charge Lift DC Input
Entering a Password or SuperWrd . . . . 3-18 Voltage During Start-Up (AC Lift) 6-9
EPO Switch . . . . . . . . . . . . . . . . . . . . . .A-4 Code 57- VM Not Responding to
Error Log . . . . . . . . . . . . . . . . . 3-27, 3-29 Operator Display . . . . . . . . . . . . 6-9
Error Messages Code 58 - OCSS CAN Communication
Power Amplifier . . . . . . . . . . . . . . . .6-2 Error . . . . . . . . . . . . . . . . . . . . 6-9
Summary List . . . . . . . . . . . . . . . . .6-3 Code 59 - CAN Transmission Buffer
ES Mode, Configuring . . . . . . . . . . . . . 3-26 Error . . . . . . . . . . . . . . . . . . . 6-10
ESD Ground Jack . . . . . . . . . . . . . . . . .2-7 Code 5A - CAN Bus Error/VM for
External Speed Sensor Replacement BUS_I . . . . . . . . . . . . . . . . . . . 6-10
AC Motors . . . . . . . . . . . . . . . . . . . 7-91 Code 5B - CAN Receive Bus
Error/VM . . . . . . . . . . . . . . . . 6-10
F Code 5G - No Communications
Received from TPA . . . . . . . . . 6-10
Code 5J - No Communications
Factory Default Configure Settings 3-20, 3-22
Received from LPA (AC Lift) . . . 6-10
Fault Codes
Code 5M - TPA CAN Watchdog
Code 1H - TPA Overheated . . . . . . .6-5
Timeout . . . . . . . . . . . . . . . . . 6-11
Code 1T - Battery Low . . . . . . . . . . .6-5
Code 5P - LPA CAN Watchdog
Code 1V - LPA Overheated (AC Lift) .6-5
Timeout (AC Lift) . . . . . . . . . . . 6-11
Code 2A - Traction Motor
Code 5Q - Display Manager Not
Approaching Overtemp . . . . . . .6-5
Responding . . . . . . . . . . . . . . . 6-11
Code 2C - TPA Temp Sensor
Code 5R - Secondary CAN Bus
Out-of-Range . . . . . . . . . . . . . . .6-5
Error for BUS_E . . . . . . . . . . . 6-11
Code 2E - Traction Motor Temp
Code 5T - No CAN Message from
Sensor Out-of-Range . . . . . . . . .6-6
any Node . . . . . . . . . . . . . . . . 6-12
Code 2H - Traction Motor Speed
Code 61 - Mast Switch #1
Sensor Failure . . . . . . . . . . . . . .6-6
Not Crossed . . . . . . . . . . . . . . 6-12
Code 2M - TPA Failed . . . . . . . . . . .6-6
Code 62 - LPA Reverted to Default
Code 2P - TPA Reverted to
Parameters . . . . . . . . . . . . . . . 6-12
Default Parameters . . . . . . . . . .6-6
Code 63 - HS Travel and 1st Speed
Code 2T - TPA Current Calibration
Limiting Switches Do Not Agree 6-12
Error . . . . . . . . . . . . . . . . . . . . .6-6
Code 64 - No Pulses Seen from
Code 2U - TPA Overcurrent or
Height Indicator Encoder . . . . 6-13
Short Circuit . . . . . . . . . . . . . . .6-7
Code 66 - Calculated Height Greater
Code 2V - TPA High DC Bus Voltage 6-7
Than Configured Height . . . . . 6-13
Code 42 - LPC Detected Closed
Code 67 - Calculated Height Does
When Commanded Open . . . . . .6-7
Not Match 1st Speed Limiting
Code 43 - LPC Detected Open
Switch (S12) . . . . . . . . . . . . . . 6-13
When Commanded Closed . . . . .6-7
Code 6D - Pressure Sensor
Code 44 - TPC Detected Closed
Out-of-Range . . . . . . . . . . . . . 6-13
When Commanded Open . . . . . .6-8
Code 6F - Lift Motor Overtemp . . . 6-14
Code 45 - TPC Detected Open
Code 6G - Lift Motor Temp Sensor
When Commanded Closed . . . . .6-8
Out-of-Range . . . . . . . . . . . . . 6-14
Code 4B - Steer Contactor Detected
Code 6S - LPA Temp Sensor
Closed When Commanded Open 6-8
Out-of-Range (AC Lift) . . . . . . . 6-14
Code 6T - LPA Current Calibration
Error (AC Lift) . . . . . . . . . . . . . 6-14
Code 4C - Steer Contactor Detected
Code 6U - Excessive Lift Motor
Open When Commanded Closed 6-8
Brush Wear (DC Lift) . . . . . . . . 6-14
Code 4D - No Pre-Charge Traction DC

Code 6V - LPA Failure (AC Lift) . . 6-15 Code EH - Invalid Interrupt -

Code 6W - Failure Detected in Operator Display . . . . . . . . . . . 6-21
Lift Motor Speed Sensor Code F4 - VM COP Time-out . . . . . 6-21
(AC Lift) . . . . . . . . . . . . . . . . . 6-15 Code F5 - Bad Op Code . . . . . . . . . 6-21
Code 6X - LPA Fault Code F8 - VM COP Not Enabled . . 6-22
Overcurrent (AC Lift) . . . . . . . . 6-15 Code FE - VM Not Calibrated . . . . 6-22
Code 6Y - LPA Fault Code FG - 5 and/or 12V Power
High DC Voltage (AC Lift) . . . . . 6-15 Supply Out-of-Range . . . . . . . . 6-22
Code 6Z - FlashWare Parameters Code FH - Battery Voltage
Do Not Match Stored Values . . 6-15 Out-of-Range . . . . . . . . . . . . . 6-22
Code 80 - Primary Throttle Pot Code FN - Relays Did Not Open at
Out-of-Range . . . . . . . . . . . . . 6-16 Power Off . . . . . . . . . . . . . . . . 6-22
Code 81 - Lift/Lower Pot Code FP - VM Internal Fault . . . . . 6-23
Out-of-Range . . . . . . . . . . . . . 6-16 Code FR - VM Config Item
Code 83 - Primary Throttle Pot Out-of-Range . . . . . . . . . . . . . 6-23
Out-of-Neutral . . . . . . . . . . . . 6-16 Code FT - VM Internal Software
Code 84 - Brake - Not Applied . . . 6-16 Error . . . . . . . . . . . . . . . . . . . . 6-23
Code 88 - +5VDC Power Supply Code FV - Display Internal Software
Out-of-Range . . . . . . . . . . . . . 6-16 Error . . . . . . . . . . . . . . . . . . . . 6-23
Code 8A - OCSS Photo Sensor Code G0 - Steer Tiller 1 Channel
Fault . . . . . . . . . . . . . . . . . . . 6-17 A/B Fault (AC Lift) . . . . . . . . . 6-23
Code 8C - Deadman Pedal Signals Code G3 - Steer Feedback Prox
Do Not Agree . . . . . . . . . . . . . 6-17 Sensor Fault (AC Lift) . . . . . . . 6-24
Code 8F - Lift/Lower Pot Code G4 - Open Detected in Steer
Out-of-Neutral . . . . . . . . . . . . 6-17 Control Circuit (AC Lift) . . . . . . 6-24
Code 8G - Secondary Throttle Pot Code G5 - Short Detected in Steer
Out-of-Range . . . . . . . . . . . . . 6-17 Motor Encoder Circuit (AC Lift) 6-24
Code 8H - Secondary Throttle Pot Code G7 - Steer Tiller 2 Channel
Out-of-Neutral . . . . . . . . . . . . 6-17 A/B Fault (AC Lift) . . . . . . . . . 6-24
Code 8J - Ambient Air Temp Sensor Code GD - Open Detected in Steer
Out-of-Range . . . . . . . . . . . . . 6-18 Motor Encoder Circuit (AC Lift) 6-25
Code 8K - Deadman Sensor Code GE - Steer Encoder Failure
Out-of-Range . . . . . . . . . . . . . 6-18 (AC Lift) . . . . . . . . . . . . . . . . . . 6-25
Code 8L - Brake Feedback Current Code T0 - SOL5T Current Incorrect 6-25
Out-of-Range . . . . . . . . . . . . . 6-18 Code T1 - SOL5B Current Incorrect 6-25
Code 8M - Internal Handle Heater Code T2 - SOL3 Current Incorrect . 6-26
Failure . . . . . . . . . . . . . . . . . . 6-18 Code T3 - SOL2 Current Incorrect . 6-26
Code 8N - Optional Start Switch Code X4 - Switch Mismatch . . . . . 6-26
Closed at Start-Up . . . . . . . . . 6-18 Power Amplifier . . . . . . . . . . . . . . . . 6-2
Code A0 - Mismatched Software Summary List . . . . . . . . . . . . . . . . . 6-3
Versions . . . . . . . . . . . . . . . . . 6-19 Filter, Hydraulic . . . . . . . . . . . . . . . . . 7-97
Code AH - Bad Display Card Torque . . . . . . . . . . . . . . . . . . . . 7-111
Checksum . . . . . . . . . . . . . . . 6-19 Firmware, Displaying Version . . 3-16, 3-21
Code AJ - Bad VM Flash Memory . 6-19 FlashWare Program . . . . . . . . . . . . . . . 3-6
Code AK - Bad VM RAM . . . . . . . . 6-19 Flex Circuit Assembly
Code AL - Bad VM Battery Fore-Aft Stance . . . . . . . . . . . . . . . 7-30
Backed-Up RAM . . . . . . . . . . . 6-20 Flow Limiter
Code AM - Bad Operator Display Free Lift . . . . . . . . . . . . . . . . . . . 7-142
Flash Memory . . . . . . . . . . . . 6-20 Torque . . . . . . . . . . . . . . . . . . 7-112
Code AN - Bad Operator Display . 6-20 Main Lift . . . . . . . . . . . . . . . . . . . 7-141
Code AV - Primary Memory
Mismatch . . . . . . . . . . . . . . . . 6-20

Forks Hose
Angle . . . . . . . . . . . . . . . . . . . . . . . 4-17 Free Lift . . . . . . . . . . . . . . . . . . . 7-183
Hooks . . . . . . . . . . . . . . . . . . . . . . 4-19 Installation, Mast
Inspection . . . . . . . . . . . . . . . . . . . 4-17 Model 7400 . . . . . . . . . . . . . . . 7-191
Markings . . . . . . . . . . . . . . . . . . . . 4-20 Model 7420 . . . . . . . . . . . . . . . 7-203
Positioning Locks . . . . . . . . . . . . . 4-18 Model 7440 . . . . . . . . . . . . . . . 7-214
Straightness . . . . . . . . . . . . . . . . . 4-17 Main Lift . . . . . . . . . . . . . . . . . . . 7-169
Tip Height . . . . . . . . . . . . . . . . . . . 4-18 Over-the-Mast . . . . . . . . . . 7-170, A-4
Wear . . . . . . . . . . . . . . . . . . . . . . . 4-18 Removal, Mast
Fraction to Decimal Conversion . . . . .A-14 Model 7400 . . . . . . . . . . . . . . . 7-184
Free Lift Cylinder . . . . . . . . 7-114 to 7-120 Model 7420 . . . . . . . . . . . . . . . 7-196
Exploded Parts Drawings 7-118 to 7-120 Model 7440 . . . . . . . . . . . . . . . 7-207
Model 7400 . . . . . . . . . . . 7-184, 7-191 Hour Meters . . . . . . . . . . . . . . . .3-16, 3-21
Model 7420 . . . . . . . . . . . 7-196, 7-203 HTI
Model 7440 . . . . . . . . . . . 7-207, 7-214 Belt Replacement . . . . . . . . . . . . 7-165
Seal Repacking . . . . . . . 7-121 to 7-123 Codes and Tests
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 Test I26 . . . . . . . . . . . . . . . . . . 6-82
Test I42 . . . . . . . . . . . . . . . . . . 6-89
G Test I86 . . . . . . . . . . . . . . . . . . 6-96
Pressure Switch
Torque . . . . . . . . . . . . . . . . . . 7-111
Grease Fittings
Hung-Up Carriage, Lowering . . . . . . 7-100
See Lubrication Points
Hydraulic Filter . . . . . . . . . . . . . . . . . 7-97
Ground Jack, ESD . . . . . . . . . . . . . . . .2-7
Torque . . . . . . . . . . . . . . . . . . . . 7-111
Hydraulic Manifold
H See Manifold
Hydraulic Steer Motor (DC lift) . . . . . . . A-6
Harness Hydraulic System
Inspection . . . . . . . . . . . . . . . . . . . 7-77 Bleeding . . . . . . . . . . . . . . . . . . . . 7-96
Repair . . . . . . . . . . . . . . . . . . . . . . 7-77 Troubleshooting
Soldering Procedures . . . . . . . . . . . 7-77 Guidelines . . . . . . . . . . . . . . . . . 5-11
Terminology . . . . . . . . . . . . . . . . . 6-27 Symptoms . . . . . . . . . . . 5-13 to 5-19
Heater
Control Handle I
Fore-Aft Stance
Potentiometers 7-30, 7-31, 7-32, 7-35,
Inertial Dampener . . . . . . . . . . . . . . . 7-69
7-36, 7-37
Input Tests . . . . . . . . . . . . . 6-63 to 6-100
ThermaKit . . 7-32, 7-33, 7-37, 7-39
Summary List . . . . . . . . . . . . . . . . 6-31
Side Stance
See Tests, Input for Individual Tests
Potentiometers . . . . . . . . . . . . . 7-35
Height Encoder Belt . . . . . . . . . . . . . 7-165
Helical Gear Assembly, Drive Unit . . . . 7-54 J
High Speed Travel Switch (S25) . . . . . . .A-4
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4 Jacking Safety . . . . . . . . . . . . . . . . . . . 2-8
Switch
Test 018 . . . . . . . . . . . . . . . . . 6-113 L
Test I15 . . . . . . . . . . . . . . . . . . . 6-74
Learn Function . . . . . . . . . . . . .3-16, 3-27
Controls . . . . . . . . . . . . . . . . . . . . 3-27
Weight . . . . . . . . . . . . . . . . . . . . . 3-27
Lift Cutout Switch (S27) . . . . . . . . . . . . A-4
Lift Acceleration, Configuring . . . . . . . 3-23

Lift Chains Lower Function

Inspection . . . . . . . . . . . . . . . . . . 4-16 Speed, Configuring . . . . . . . . . . . . 3-23
See Chains Theory of Operation
Lift Cutout Switch (S27) . . . . . . . . . . . A-4 DC Lift . . . . . . . . . . . . . . . . . . . . 8-15
Lift Cutout, Configuring . . . . . . . . . . 3-23 AC Lift . . . . . . . . . . . . . . . . . . . . . 8-9
Lift Cylinder Troubleshooting . . . . . . . . . . . . . . 5-19
Free Lift . . . . . . . . . . . . .7-114 to 7-120 Lowering Carriage Manually . . . . . . . 7-100
Exploded Parts LS-1 Load Shuttle Torque . . . . . . . . . 7-111
Drawings . . . . . . . . .7-118 to 7-120 Lubrication Points . . . . . . . . . 4-10 to 4-15
Model 7400 . . . . . . . . . 7-184, 7-191 Lubrication Specification Chart . . . . . . A-2
Model 7420 . . . . . . . . . 7-196, 7-203
Model 7440 . . . . . . . . . 7-207, 7-214 M
Main Lift . . . . . . . . . . . .7-124 to 7-130
Exploded Parts
Main Lift Cylinder . . . . . . . . 7-124 to 7-130
Drawings . . . . . . . . .7-129 to 7-130
Exploded Parts Drawings 7-129 to 7-130
Lift Deceleration, Configuring . . . . . . 3-23
Seal Repacking . . . . . . . 7-131 to 7-132
Lift Function
Main Manifold . . . . . . . . . . . . . . . . . . . A-5
Theory of Operation
AC Lift, Model 7400 . . . . . . . . . . 7-103
AC Lift . . . . . . . . . . . . . . . . 8-8, 8-11
AC Lift, Model 7420/7440 . . . . . . 7-104
DC Lift . . . . . . . . . . . . . . . . . . . 8-14
DC Lift . . . . . . . . . . . . . . . . . . . . 7-105
Troubleshooting . . . . . . . . . . . . . 5-17
Maintenance Minder ™ Tool . . . . . 3-25, 4-3
Lift Hose . . . . . . . . . . . . . . . . . . . . . .7-169
Maintenance Mode
Lift Limit Cutout, Configuring . . . . . . 3-23
See Service Mode
Lift Motor . . . . . . . . . . . . . . . . . . . . . . A-5
Manifold
AC Lift Motor Temperature
Auxiliary . . . . . . . . . . . . . . . 7-106, A-5
Sensor LMT . . . . . . . . . . . . . . 7-84
Main . . . . . . . . . . . . . . . . . . . . . . . . A-5
DC Lift Motor Temperature Sensor A-6
AC Lift, Model 7400 . . . . . . . . . 7-103
Speed Sensor (Danaher) . . . . . . . . 7-84
AC Lift, Model 7420/7440 . . . . 7-104
Speed Sensor (Sauer Danfoss) . . . 7-88
DC Lift . . . . . . . . . . . . . . . . . . 7-105
Lift Power Amplifier (AC Lift) . . . . . . . . A-5
Reach (DR only) . . . . . . . . . . . . . 7-108
Lift Pressure Adjustment . . . . . . . . . . 7-99
Tilt/Sideshift (DR only) . . . . . . . . 7-110
Lift Pump . . . . . . . . . . . . . . . . . . . . . . A-5
Manual Lowering of Carriage . . . . . . 7-100
Lift/Lower System
Map, Navigating the Manual . . . . . . . . . 1-2
Lift/Lower Valve SOL2 Torque . . . . . .7-111
Limit Switch, Speed, First (S12) . . . . . . A-5
Limit Switch, Steer S11 (AC Lift) . 7-25, A-5
Linkage, Steering . . . . . . . . . . . . . . . 7-29
Load Holding Valve SOL1 Torque . . . .7-111
Load Shuttle LS-1 Torque . . . . . . . . .7-111
Locator Photos
Lubrication Points . . . . . . 4-10 to 4-15
Loctite®
See Thread Adhesives
Loop Back Tests . . . . . . . . .6-122 to 6-123
Lower Acceleration, Configuring . . . . 3-23
Lower Deceleration, Configuring . . . . 3-23

Mast Active . . . . . . . . . . . . . . .3-27, 3-29

Model 7400 Error Log . . . . . . . . . . . .3-27, 3-29
Assembly . . . . . . . . . . 7-188 to 7-195 Learn . . . . . . . . . . . . . . .3-16, 3-27
Disassembly . . . . . . . 7-184 to 7-187 Controls . . . . . . . . . . . . . . . . 3-27
Main Lift Chain Installation . . . 7-189 Weight . . . . . . . . . . . . . . . . . 3-27
Main Lift Chain Removal . . . . . 7-185 Static . . . . . . . . . . . . . . . . . . . 3-28
Mating Tractor to Mast . . . . . . 7-194 Version . . . . . . . . . . . . . . .3-16, 3-21
Separation of Telescopics . . . . . 7-185 Run . . . . . . . . . . . . . . . . . . . . . . . 3-16
Separation of Tractor and Mast 7-184 Tones . . . . . . . . . . . . . . . . . . . . 3-17
Model 7420 Molex Connectors . . . . . . . . . . . . . . . . 7-78
Assembly . . . . . . . . . . 7-201 to 7-206 Motors
Disassembly . . . . . . . 7-196 to 7-200 AC . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Main Lift Chain Installation . . . 7-202 Lift
Main Lift Chain Removal . . . . . 7-198 Speed Sensor (Danaher) . . . . . 7-84
Mating Tractor to Mast . . . . . . 7-206 Temperature Sensor
Separation of Telescopics . . . . . 7-199 (Sauer Danfoss) . . . . . . . . . . 7-88
Separation of Tractor and Mast 7-196 Open Winding . . . . . . . . . . . . . . . 5-9
Model 7440 Shorted Winding . . . . . . . . . . . . . 5-9
Assembly . . . . . . . . . . 7-211 to 7-218 Speed Sensor Replacement -
Disassembly . . . . . . . 7-207 to 7-210 Externally Mounted . . . . . . . . 7-91
Main Lift Chain Installation . . . 7-212 Traction
Main Lift Chain Removal . . . . . 7-208 Speed Sensor (Danaher) . . . . . 7-86
Mating Tractor to Mast . . . . . . 7-218 Speed Sensor Replacement -
Separation of Telescopics . . . . . 7-208 Bearing (Sauer Danfoss) . . . . 7-88
Separation of Tractor and Mast 7-207 Temperature Sensor
Shimming . . . . . . . . . . . . . . . . . . 7-147 (Sauer Danfoss) . . . . . . . . . . 7-88
Types . . . . . . . . . . . . . . . . . . . . . . .3-4 Armature . . . . . . . . . . . . . . . . . . . . 5-8
Mast Bearing Shimming Auxiliary (DC Lift) . . . . . . . . . . . . . . A-4
Carriage to Inner Tele DC . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Model 7400 . . . . . . . . . . . . . . . 7-190 Field Winding Test . . . . . . . . . . . 5-8
Model 7420 . . . . . . . . . . . . . . . 7-203 Grounded Motor Test . . . . . . . . . 5-7
Model 7440 . . . . . . . . . . . . . . . 7-213 Open Circuit Test . . . . . . . . . . . . 5-7
Inner Tele to Outer Tele Short Circuited Armature . . . . . . 5-8
Model 7400 . . . . . . . . . . . . . . . 7-189 Drive . . . . . . . . . . . . . . . . . . . . . . . A-6
Model 7420 . . . . . . . . . . . . . . . 7-202 Lift . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Model 7440 . . . . . . . . . . . . . . . 7-212 Power Cable Terminals . . . . . . . . . 7-83
Outer Tele to Main Frame Steering Electric . . . . . . . . . . . . . . . A-6
Model 7400 . . . . . . . . . . . . . . . 7-188 Temperature Sensor . . . . . . . 7-84, A-6
Model 7420 . . . . . . . . . . . . . . . 7-201 Troubleshooting . . . . . . . . . . . . . . 5-21
Model 7440 . . . . . . . . . . . . . . . 7-211 AC . . . . . . . . . . . . . . . . . . . . . . . 5-9
Messages and Codes DC . . . . . . . . . . . . . . . . . . . . . . . 5-5
Power Amplifier . . . . . . . . . . . . . . . .6-2
Meters, Hour . . . . . . . . . . . . . . . 3-16, 3-21 O
Metric Units, Configuring Display for . 3-23
Modes of Operation . . . . . . . . . 3-16 to 3-29
OCSS
Overview . . . . . . . . . . . . . . . . . . . . 3-16
Test I80 – Upper Beam . . . . . . . . . 6-92
Program . . . . . . . . . . . . . . . 3-16, 3-17
Test I81 – Lower Beam . . . . . . . . . 6-94
Configure . . .3-16, 3-18, 3-22 to 3-26
Open Circuit DC Motor Test . . . . . . . . . 5-7
Restoring Factory Defaults 3-20, 3-22
Open Winding AC Motor . . . . . . . . . . . . 5-9
Hour Meters . . . . . . . . . . . 3-16, 3-21
Operator Compartment Sensor System
Serial Number . . . . . . . . . 3-16, 3-21
Test I80 – Upper Beam . . . . . . . . . 6-92
Service . . . . . . . . . . .3-16, 3-27, 3-28
Test I81 – Lower Beam . . . . . . . . . 6-94

Operator Display . . . . . . . . . . . . . . . . 3-15 Priority-on-Demand Valve POD-1

Troubleshooting . . . . . . . . . . . . . 5-21 Torque . . . . . . . . . . . . . . . . . . . . 7-111
Operator Key, Electronic . . . . . . 3-17, 3-25 Product Improvement Notices Included 1-vii
Orbitrol, Steering (DC Lift) . . . . . . . . . . A-6 Program Mode . . . . . . . . . . . . . 3-16, 3-17
Output Tests . . . . . . . . . . . .6-101 to 6-121 Menu Settings . . . . . . . . . . 3-21 to 3-27
Summary List . . . . . . . . . . . . . . . 6-32 See also Individual Parameter Name
See Tests, Output for Individual Tests Proportional Valve Adjustment . . . . . 7-101
Outrigger Pulleys, Over-the-Mast . . . . . . . . . . . . . A-5
See Baseleg Pump
Over-the-Mast Hose . . . . . . . . . . . . . . A-4 Auxiliary (DC Lift) . . . . . . . . . . . . . . A-4
Over-the-Mast Hose/Cable . . . . . . . .7-170 Lift . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Cable Only Replacement . . . . . . .7-179
Conversion for Bulk Cable Use . .7-178 R
Retainer Upgrade . . . . . . . . . . . . .7-177
Reach Carriage
P See Carriage
Reach Cylinder . . . . . . . . . . . . . . . . . 7-136
Page Revision Record . . . . . . . . . . . . . . . v Adjustment . . . . . . . . . . . . . . . . . 7-137
Passwords Reach Function
Changing Password or SuperWrd . 3-18 Configuring Speed . . . . . . . . . . . . 3-24
Electronic Operator Key . . . . 3-17, 3-25 Theory of Operation
Entering Password or SuperWrd . 3-18 AC Lift . . . . . . . . . . . . . . . . . . . . 8-10
Password . . . . . . . . . . . . . . . 3-17, 3-25 DC Lift . . . . . . . . . . . . . . . . . . . 8-15
SuperWrd . . . . . . . . . . . . . . 3-17, 3-25 Reach Manifold (DR) . . . . . . . . . . . . . 7-108
Pin Extraction Reach Speed, Configuring . . . . . . . . . . 3-24
AMP Connectors . . . . . . . . . . . . . 7-79 Reach Valve
Molex Connectors . . . . . . . . . . . . 7-78 Location
Pin Insertion Single Reach . . . . . . . . . . . . . . 7-106
AMP Connectors . . . . . . . . . . . . . 7-79 Torque . . . . . . . . . . . . . . . . . . . . 7-112
Molex Connectors . . . . . . . . . . . . 7-78 REL-1 Relief Valve (DC Lift) Torque . . 7-111
Pinout Matrix . . . . . . . . . . . . 8-19 to 8-38 REL-2 Relief Valve (AC Lift) Torque . . 7-111
Pivot Ring, Drive Unit REL-3 Relief Valve (DR) Torque . . . . . 7-112
Assembly . . . . . . . . . . . . . . . . . . . 7-57 Relay/Control Fuse Panel
Disassembly . . . . . . . . . . . . . . . . 7-48 Circuit Card Connectors . . . . . . . . 6-29
POD-1 Priority-on-Demand Valve Relief Valve REL-1 (DC lift) Torque . . 7-111
Torque . . . . . . . . . . . . . . . . . . . . .7-111 Relief Valve REL-2 (AC lift) Torque . . 7-111
Power Amplifier Relief Valve REL-3 (DR) Torque . . . . . 7-112
Discharging Internal Capacitor . . . 5-2 Retract Function
LED Diagnostics . . . . . . . . . . . . . . 6-2 Configuring Speed . . . . . . . . . . . . 3-24
Lift (AC Lift) . . . . . . . . . . . . . . . . . . A-5 Troubleshooting . . . . . . . . . . . . . . 5-16
Traction . . . . . . . . . . . . . . . . . . . . . A-5 Retract Speed, Configuring . . . . . . . . . 3-24
Power Cables, Motor . . . . . . . . . . . . . 7-83 Run Mode . . . . . . . . . . . . . . . . . . . . . . 3-16
Preset Lift Heights, Configuring . . . . . 3-26 Tones . . . . . . . . . . . . . . . . . . . . . . 3-17
Pressure Adjustment
Auxiliary . . . . . . . . . . . . . . . . . . .7-102
Lift . . . . . . . . . . . . . . . . . . . . . . . 7-99
Pressure Switch, HTI
Torque . . . . . . . . . . . . . . . . . . . . .7-111
Pressure Transducer CYL-P
Torque . . . . . . . . . . . . . . . . . . . . .7-111
Primary Control Handle . . . . . 7-30 to 7-34

S Service Mode . . . . . . . . . . 3-16, 3-27, 3-28

Active Service Mode . . . . . . . . . . . 3-29
Safety Static Service Mode . . . . . . . . . . . 3-28
Battery . . . . . . . . . . . . . . . . . . . . . .2-5 Service/Torque Chart,
Decals . . . . . . . . . . . . . . . . 7-15 to 7-18 Component Specific . . . . . . . . . . . . A-4
Definitions of Warning and Caution .2-2 Shimming
ESD . . . . . . . . . . . . . . . . . . . . . . . .2-7 Drive Unit . . . . . . . . . . . . . . . . . . . 7-55
General . . . . . . . . . . . . . . . . . . . . . .2-3 Mast Bearings . . . . . . . . . . . . . . 7-147
Jacking . . . . . . . . . . . . . . . . . . . . . .2-8 Carriage to Inner Tele
Static Precautions . . . . . . . . . . . . . .2-7 Model 7400 . . . . . . . . . . . . . . 7-190
Tie-Down for Transport . . . . . . . . . 2-10 Model 7420 . . . . . . . . . . . . . . 7-203
Welding . . . . . . . . . . . . . . . . . . . . . 2-11 Model 7440 . . . . . . . . . . . . . . 7-213
Scheduled Maintenance Inner Tele to Outer Tele
180 Days . . . . . . . . . . . . . . . . . . . . .4-6 Model 7400 . . . . . . . . . . . . . . 7-189
2000 Deadman Hours . . . . . . . . . . .4-9 Model 7420 . . . . . . . . . . . . . . 7-202
360 Days . . . . . . . . . . . . . . . . . . . . .4-9 Model 7440 . . . . . . . . . . . . . . 7-212
500 Deadman Hours . . . . . . . . . . . .4-6 Outer Tele to Main Frame
Chains . . . . . . . . . . . . . . . . . . . . . 4-16 Model 7400 . . . . . . . . . . . . . . 7-188
Charts . . . . . . . . . . . . . . . . . .4-2 to 4-9 Model 7420 . . . . . . . . . . . . . . 7-201
Guidelines . . . . . . . . . . . . . . . . . . . .4-2 Model 7440 . . . . . . . . . . . . . . 7-211
Lubrication Points . . . . . . . 4-10 to 4-15 Shorted Winding on AC Motor . . . . . . . 5-9
Maintenance Minder ™ Tool . . . . . . .4-3 Shorts to Frame Test . . . . . . . . . . . . . . 5-2
Seal Repacking Sideshift Function
Free Lift Cylinder . . . . . 7-121 to 7-123 Theory of Operation
Main Lift Cylinder . . . . . 7-131 to 7-132 DC Lift . . . . . . . . . . . . . . . . . . . 8-16
Sealants, Specifications . . . . . . . . . . . .A-3 Series CA/FA . . . . . . . . . . . . . . 8-10
Secondary Control Handle . . . 7-39 to 7-40 Troubleshooting . . . . . . . . . . . . . . 5-15
SelfTest . . . . . . . . . . . . . . . . . . . . . . . . .8-2 Sideshift Valve
Sensor Location
AC Lift Motor Speed (Danaher) . . . 7-84 Deep-Reach . . . . . . . . . . . . . . . 7-110
AC Lift Motor Temperature Single Reach . . . . . . . . . . . . . . 7-106
(Sauer Danfoss) . . . . . . . . . . . . 7-88 Torque . . . . . . . . . . . . . . . . . . . . 7-112
AC Motor Temperature (LMT or TMT) 7-84 Software
AC Traction Motor Speed (Danaher) 7-86 Displaying Version . . . . . . . .3-16, 3-21
AC Traction Motor Speed SOL1 Load Holding Valve Torque . . . 7-111
(Sauer Danfoss) . . . . . . . . . . . . 7-88 SOL2 Lift/Lower Valve Torque . . . . . 7-111
DC Lift Motor Temperature . . . . . . .A-6 SOL3 Proportional Main
Deadman VR4 . . . . . . . . . . . . . . . . 7-68 Relief/Dump Valve Torque . . . . . 7-111
OCSS SOL4 2d Pump Valve Torque . . . . . . 7-111
Lower Beam Test I81 . . . . . . . . . 6-94 SOL5B/5T Auxiliary Valve Torque . . 7-111
Upper Beam Test I80 . . . . . . . . . 6-92 SOL8 Auxiliary Dump Valve Torque . 7-111
Speed - Bearing Soldering Procedures . . . . . . . . . . . . . 7-77
AC Traction Motor Solenoid
(Sauer Danfoss) . . . . . . . . . . . . 7-88 See Valve
Sensor - External Special Tools . . . . . . . . . . . . . . . . . . . 7-14
Speed, AC Motor . . . . . . . . . . . . . . 7-91 Specification Plate . . . . . . . . . . . . . . . . 3-3
Serial Number
Displaying from Program Mode 3-16, 3-21
Location on Specification Plate . . . .3-3
Service Bulletins Included . . . . . . . . . . 1-vi
Service Intervals
See Scheduled Maintenance Charts

Speed Second Speed Limiting,

Limit Switch 1, Configuring . . . . . 3-22 Configuring . . . . . . . . . . . . . . . 3-22
Limit Switch 2, Configuring . . . . . 3-22 Speed Limiting, First (S12) . . . . . . . A-5
Limiting Switch, First (S12) . . . . . . A-5 Steer Limit (AC Lift) S11 . . . . 7-25, A-5
Lowering, Configuring . . . . . . . . . 3-23 Tilt/Sideshift
Reach, Configuring . . . . . . . . . . . 3-24 Fore-Aft Stance . . . . . . . . 7-33, 7-37
Retract, Configuring . . . . . . . . . . 3-24 Series AA/BA/CA . . . . . . . . . . . 7-37
Sensor, AC Lift Motor (Danaher) . . 7-84 Series DA/EA/FA . . . . . . . . . . . 7-38
Sensor, AC Motor (Danaher) . . . . . 7-86 UnNested, Configuring . . . . . . . . . 3-22
Travel, Configuring . . . . . . . . . . . 3-22 Switch Adjustment . . . . . . . . . . . . . . . . A-4
Speed Limiting Switch, First (S12) . . . . A-5 Switch Gap . . . . . . . . . . . . . . . . . . . . . . A-4
Speed Sensor Replacement - Bearing Switches
AC Traction Motor (Sauer Danfoss) 7-88 Battery Gate . . . . . . . . . . . . . . . . . . A-4
Speed Sensor Replacement, AC Lift Motor EPO . . . . . . . . . . . . . . . . . . . . . . . . A-4
(Danaher) . . . . . . . . . . . . . . . . . . 7-84 Symbols, List of . . . . . . . . . . . . . . . . . . 1-4
Speed Sensor Replacement, AC Symptom Tables
Traction Motor (Danaher) . . . . . . 7-86 Electrical Symptoms . . . . . 5-21 to 5-22
Spiral Pinion, Drive Unit Hydraulic Functions . . . . . 5-13 to 5-19
Assembly . . . . . . . . . . . . . . . . . . . 7-52 Travel Functions . . . . . . . . . . . . . . 5-20
Disassembly . . . . . . . . . . . . . . . . 7-51 Vantage Point System . . . . 5-23 to 5-24
Standard/Metric Conversions . . . . . . A-16
Static Precautions . . . . . . . . . . . . . . . . 2-7 T
Static Service Mode . . . . . . . . . . . . . . 3-28
Steer Limit Switch S11 (AC lift) . . 7-25, A-5
Temperature Sensor
Steer Motor, Hydraulic (DC Lift) . . . . . . A-6
AC Motor (LMT or TMT) . . . . . . . . . 7-84
Steerable Caster . . . . . . . . . . . . . . . . 7-26
DC Lift Motor . . . . . . . . . . . . . . . . . A-6
Height Adjustment . . . . . . . . . . . . 7-27
Temperature Sensor, AC Lift Motor
Steering
(Sauer Danfoss) . . . . . . . . . . . . . . 7-88
Encoder (AC lift) . . . . . . . . . . . . . 7-24
Temperature Sensor, AC Traction Motor
Limit Switch S11 (AC Lift) . . . 7-25, A-5
(Sauer Danfoss) . . . . . . . . . . . . . . 7-88
Linkage . . . . . . . . . . . . . . . . . . . . 7-29
Terminals, Motor Power Cable . . . . . . 7-83
Motor, Electric (AC lift) . . . . . . . . . . A-6
Tests
Orbitrol (DC Lift) . . . . . . . . . . . . . . A-6
Analog . . . . . . . . . . . . . . . 6-33 to 6-61
Steerable Caster . . . . . . . . . . . . . 7-26
Test A04 – Primary Throttle
Height Adjustment . . . . . . . . . . 7-27
Potentiometer (VR1) Voltage . . . 6-34
Theory of Operation
Test A05 – Lift/Lower
DC Lift . . . . . . . . . . . . . . . . . . . 8-13
Potentiometer Voltage . . . . . . . 6-35
AC Lift. . . . . . . . . . . . . . . . . . . . . 8-4
Test A08 – Traction Motor
Temperature . . . . . . . . . . . . . . 6-36
Stops, Carriage . . . . . . . . . . . . . . . . . . A-6
Test A09 – Lift Motor
SuperWrd . . . . . . . . . . . . . . . . . 3-17, 3-25
Temperature . . . . . . . . . . . . . . 6-37
Changing . . . . . . . . . . . . . . . . . . . 3-18
Test A10 – Traction Power
Entering . . . . . . . . . . . . . . . . . . . 3-18
Amplifier Heatsink Temperature 6-39
Switch
Test A11 – Traction Motor
Deadman S2 . . . . . . . . . . . . . . . . 7-68
Current . . . . . . . . . . . . . . . . . . 6-40
First Speed Limit, Configuring . . . 3-22
Test A13 – Pressure Sensor
High Speed Travel (S25) . . . . . . . . . A-4
oltage . . . . . . . . . . . . . . . . . . . 6-40
HTI Pressure S18
Test A14 – Power Supply
Torque . . . . . . . . . . . . . . . . . . .7-111
+12VDC . . . . . . . . . . . . . . . . . 6-42
Lift Cutout (S27) . . . . . . . . . . . . . . A-4
Test A15 – Battery Voltage . . . . . 6-43
Test A20 – Lift Motor Current . . 6-45

Test A22 – Primary Traction Test I24 – Steer Feedback

Throttle (VR1) Request . . . . . . . 6-46 Proximity Sensor . . . . . . . . . . . 6-80
Test A23 – Lift Throttle (VR2 Test I25 – Steer Motor Encoder . 6-81
Request . . . . . . . . . . . . . . . . . . 6-47 Test I26 – Height Indicator
Test A26 – Travel and Lift/Lower Encoder . . . . . . . . . . . . . . . . . 6-82
+5V DC Power Supply . . . . . . . 6-48 Test I27 – Secondary Horn
Test A28 – Deadman Inductiv Switch (S10) . . . . . . . . . . . . . . 6-83
Sensor (VR4) . . . . . . . . . . . . . . 6-49 Test I33 – Steer Tiller Encoder 1
Test A29 – Secondary Throttle Connect Detect . . . . . . . . . . . . 6-84
Potentiometer (VR3) Voltage . . . 6-50 Test I34 – Steer Tiller Encoder 2
Test A30 – Secondary Tractio Connect Detect . . . . . . . . . . . . 6-85
Throttle (VR3) Request . . . . . . . 6-51 Test I35 – Steer Tiller Encoder 1
Test A31 – Solenoid 5T (AUX1) (Channel A & B) . . . . . . . . . . . 6-86
Current . . . . . . . . . . . . . . . . . . 6-52 Test I36 – Steer Tiller Encoder 2
Test A32 – Solenoid 5B (AUX2) (Channel A & B) . . . . . . . . . . . 6-87
Current . . . . . . . . . . . . . . . . . . 6-53 Test I39 – Neutral Pulses . . . . . . 6-88
Test A33 – Aux Dump (SOL3)/ Test I42 – Lift Height . . . . . . . . . 6-89
Main Relief Dump (SOL8) Test I60 – Security Start Switch
Current . . . . . . . . . . . . . . . . . . 6-54 (optional) . . . . . . . . . . . . . . . . 6-90
Test A34 – Solenoid 2 (Lift/Lower) Test I61 – High Speed Travel
Current . . . . . . . . . . . . . . . . . . 6-55 Switch (S25) . . . . . . . . . . . . . . 6-91
Test A35 – Brake Current . . . . . 6-56 Test I80 – OCSS Upper Beam . . 6-92
Test A36 – Ambient Temperature Test I81 – OCSS Lower Beam . . . 6-94
Sensor . . . . . . . . . . . . . . . . . . . 6-57 Test I86 – Lift Height . . . . . . . . . 6-96
Test A37 – Steer Power Amplifier Test I90 – Degrees Turned Past
Current . . . . . . . . . . . . . . . . . . 6-58 Steer Flag . . . . . . . . . . . . . . . . 6-97
Test A41 – Emergency Power Off Test I91 – iPort Communication . 6-98
(EPO) Switch . . . . . . . . . . . . . . 6-61 Test I92 – iPort Error Bitmap . 6-100
Input Loop Back . . . . . . . . . . 6-122 to 6-123
Test I00 – Deadman Switch (S2) . 6-64 Output
Test I01 – Nested Switch (S14) . . 6-65 Test O00 – Toggle the TPC
Test I02 – First Speed Limiting Contactor . . . . . . . . . . . . . . . 6-102
Switch (S12) . . . . . . . . . . . . . . 6-66 Test O01 – Toggle the STR
Test I06 – Reach Switch (S4) . . . 6-67 Contactor . . . . . . . . . . . . . . . 6-103
Test I07 – Retract Switch (S5) . . 6-68 Test O02 – Toggle the LPC
Test I08 – Tilt Up Switch (S6) . . . 6-69 Contactor . . . . . . . . . . . . . . . 6-104
Test I09 – Tilt Down Switch (S7) . 6-70 Test O04 – Toggle Aux1
Test I10 – Sideshift Right Switch Directional (SOL5T) Solenoid . 6-105
(S9) . . . . . . . . . . . . . . . . . . . . . 6-71 Test O05 – Toggle Aux2
Test I11 – Sideshift Left Switch Directional (SOL5B) Solenoid 6-106
(S8) . . . . . . . . . . . . . . . . . . . . . 6-72 Test O06 – Toggle the Reach
Test I14 – Steering Fuse (FU1) . . 6-73 Solenoid . . . . . . . . . . . . . . . . 6-107
Test I15 – Horn Switch (S3) . . . . 6-74 Test O07 – Toggle the Tilt
Test I19 – Drive Motor Speed Solenoid . . . . . . . . . . . . . . . . 6-108
Sensor . . . . . . . . . . . . . . . . . . . 6-75 Test O08 – Toggle the Sideshift
Test I20 – Lift Motor Speed Solenoid . . . . . . . . . . . . . . . . 6-109
Sensor . . . . . . . . . . . . . . . . . . . 6-76 Test O09 – Aux Dump (SOL3)/
Test I22 – Lift Cutout Switch Main Relief Dump (SOL8)
(S27) . . . . . . . . . . . . . . . . . . . . 6-77 Current . . . . . . . . . . . . . . . . 6-110
Test I23 – CAN Bus Test . . . . . . 6-78 Test O11 – Toggle the Load Hold
(SOL1) Solenoid . . . . . . . . . . 6-111

Test O12 – Ramp the Proportional Tilt Cylinder . . . . . . . . . . . . . . . . . . . 7-139

Lower (SOL2) Solenoid . . . . . .6-112 Tilt Function
Test O18 – Toggle the Horn . . .6-113 Theory of Operation
Test O19 – Audible Alarm . . . . .6-114 DC Lift . . . . . . . . . . . . . . . . . . . 8-17
Test O20 – Travel Alarm Test . .6-115 AC Lift . . . . . . . . . . . . . . . . . . . . . 8-9
Test O23 – Toggle Fans . . . . . .6-116 Troubleshooting . . . . . . . . . . . . . . 5-14
Test O25 – Toggle the 2d Pump Tilt Valve
(SOL4) Solenoid . . . . . . . . . . .6-117 Location
Test O29 – Ramp the Tractio Deep-Reach . . . . . . . . . . . . . . . 7-110
Power Amplifier . . . . . . . . . . .6-119 Single Reach . . . . . . . . . . . . . . 7-106
Test O32 – Toggle Relays K1, K2 Torque . . . . . . . . . . . . . . . . . . . . 7-112
K3, and K4 . . . . . . . . . . . . . . .6-121 Tilt/Sideshift
Shorts to Frame . . . . . . . . . . . . . . . 5-2 Switch Card
Summary List . . . . . . . . . . . . . . . 6-31 Fore-Aft Stance . . . . . . . . 7-33, 7-37
Theory of Operation Side Stance . . . . . . . . . . . . . . . . 7-38
BSOC . . . . . . . . . . . . . . . . . . . . . 5-10 Tilt/Sideshift Manifold (DR only) . . . 7-110
Cold Storage . . . . . . . . . . . . . . . . . 8-6 Tire, Drive . . . . . . . . . . . . . . . . . . . . . . A-4
Electric Brake . . . . . . . . . . . . . . . 8-18 Tones, Run Mode . . . . . . . . . . . . . . . . 3-17
Lift/Aux System . . . . . . . 8-13 to 8-17 Tools, Special . . . . . . . . . . . . . . . . . . . 7-14
AC Lift Torque Chart
Lift with Aux . . . . . . . . . . . . . 8-11 Face Seal O-Rings . . . . . . . . . . . . . . A-8
Lift without Aux . . . . . . . . . . . . 8-8 Hydraulic Fittings . . . . . . . . . . . . . . A-7
Reach . . . . . . . . . . . . . . . . . . 8-10 Metric (Brass) . . . . . . . . . . . . . . . . A-13
DC Lift . . . . . . . . . . . . . 8-13 to 8-17 Metric (Ferrous) . . . . . . . . . . . . . . A-11
Lift . . . . . . . . . . . . . . . . . . . . . 8-14 Solenoid Valves . . . . . . . 7-111 to 7-112
Reach . . . . . . . . . . . . . . . . . . 8-15 Standard (Brass) . . . . . . . . . . . . . . A-12
Sideshift . . . . . . . . . . . . . . . . 8-16 Standard (Ferrous) . . . . . . . . . . . . . A-9
System Components . . . 8-13, 8-15 Traction Motor
Tilt . . . . . . . . . . . . . . . . . . . . . 8-17 See Drive Motor
DC Lift Speed Sensor (Danaher) . . . . . . . . 7-86
Lower . . . . . . . . . . . . . . . . . . . 8-15 Traction Motor Temperature
AC Lift Sensor TMT . . . . . . . . . . . . . . . . . 7-84
Lower . . . . . . . . . . . . . . . . . . . . 8-9 Traction Power Amplifier . . . . . . . . . . . A-5
Sideshift . . . . . . . . . . . . . . . . 8-10 LED Diagnostics . . . . . . . . . . . . . . . 6-2
System Components . . . . . . . . 8-7 Traction System Functional Operation
Tilt . . . . . . . . . . . . . . . . . . . . . . 8-9 See Theory of Operation, Traction System
Pinout Matrix . . . . . . . . . 8-19 to 8-38 Transducer, Pressure CYL-P
SelfTest . . . . . . . . . . . . . . . . . . . . . 8-2 Torque . . . . . . . . . . . . . . . . . . . . 7-111
Steering System Transmission
DC Lift . . . . . . . . . . . . . . . . . . . 8-13 See Drive Unit
AC Lift. . . . . . . . . . . . . . . . . . . . . 8-4 Transport, Tie-Down for . . . . . . . . . . . 2-10
Traction System . . . . . . . . . 8-2 to 8-6 Travel Acceleration, Configuring . . . . . 3-22
Battery Connected . . . . . . . . . . . 8-2 Travel Alarm, Configuring . . . . . . . . . . 3-22
Deadman Pedal Depressed . . . . . 8-4 Travel Functions, Troubleshooting . . . 5-20
Key Switch Turned On . . . . . . . . 8-2 Travel Light . . . . . . . . . . . . . . . . . . . . . A-6
Requesting Travel . . . . . . . . . . . . 8-5 Travel Speed Limit
ThermaKit Switch 1, Configuring . . . . . . . . . . 3-22
Fore-Aft Stance Switch 2, Configuring . . . . . . . . . . 3-22
Primary . . . . . 7-30, 7-32, 7-33, 7-37 Travel Speed, Configuring . . . . . . . . . . 3-22
Side Stance . . . . . . . . . . . . . 7-35, 7-38 Travel Switch, High Speed (S25) . . . . . . A-4
Thread Adhesives, Specifications . . . . . A-3
Tie-Down for Transport . . . . . . . . . . . 2-10

Troubleshooting Proportional, Adjustment . . . . . . 7-101

Auxiliary Functions . . . . . . . . . . . . 5-13 Reach
Chains . . . . . . . . . . . . . . . . . . . . . 4-16 Location
Dead Lift Truck . . . . . . . . . . . . . . . 5-22 Single Reach . . . . . . . . . . . . . 7-106
Drive Unit . . . . . . . . . . . . . . . . . . . 7-45 Torque . . . . . . . . . . . . . . . . . . 7-112
Electrical . . . . . . . . . . . . . . . . . . . . .5-2 REL-1 Relief (DC Lift) Torque . . . 7-111
Symptoms . . . . . . . . . . . 5-21 to 5-22 REL-2 Relief (AC Lift) Torque . . . 7-111
Fuses . . . . . . . . . . . . . . . . . . . . . . .5-4 REL-3 Relief (DR) Torque . . . . . . 7-112
Hydraulic Sideshift
Guidelines . . . . . . . . . . . . . . . . . 5-11 Location
Symptoms . . . . . . . . . . . 5-13 to 5-19 Deep-Reach . . . . . . . . . . . . . 7-110
Lift Function . . . . . . . . . . . . . . . . . 5-17 Single Reach . . . . . . . . . . . . . 7-106
Lift/Lower Functions . . . . . . . . . . . 5-17 Torque . . . . . . . . . . . . . . . . . . 7-112
Loop Back Tests . . . . . . 6-122 to 6-123 SOL1 Load Holding Torque . . . . . 7-111
Lower Function . . . . . . . . . . . . . . . 5-19 SOL2 Lift/Lower Torque . . . . . . . 7-111
Motors . . . . . . . . . . . . 5-5 to 5-9, 5-21 SOL3 Proportional Main Relief/
AC . . . . . . . . . . . . . . . . . . . . . . . .5-9 Dump Torque . . . . . . . . . . . . 7-111
DC . . . . . . . . . . . . . . . . . . . . . . . .5-5 SOL4 2d Pump Torque . . . . . . . . 7-111
Operator Display . . . . . . . . . . . . . . 5-21 SOL5B/5T Auxiliary Torque . . . . 7-111
Pinout Matrix . . . . . . . . . . 8-19 to 8-38 SOL8 Auxiliary Dump Torque . . . 7-111
Retract Function . . . . . . . . . . . . . . 5-16 Steering Orbitrol (DC Lift) . . . . . . . . A-6
Shorts to Frame Test . . . . . . . . . . . .5-2 Tilt
Sideshift Function . . . . . . . . . . . . . 5-15 Location
Steering Function . . . . . . . . . . . . . 5-16 Deep-Reach . . . . . . . . . . . . . 7-110
Symptom Tables . . . . . . . . 5-13 to 5-24 Single Reach . . . . . . . . . . . . . 7-106
Tilt Function . . . . . . . . . . . . . . . . . 5-14 Torque . . . . . . . . . . . . . . . . . . 7-112
Travel Functions . . . . . . . . . . . . . . 5-20 Torque Chart . . . . . . . . 7-111 to 7-112
Vantage Point System . . . . 5-23 to 5-24 Vantage Point System
Truck Utilization System, Configuring Symptoms . . . . . . . . . . . . 5-23 to 5-24
See Embedded Statistics Vehicle Manager
Circuit Card Connectors . . . . . . . . 6-28
U Version, Displaying Software . . .3-16, 3-21
Vertical Hold, Configuring . . . . . . . . . 3-26
VR4 Deadman Sensor . . . . . . . . . . . . 7-68
Units, Configuring Display . . . . . . . . . 3-23
UnNested Switch, Configuring . . . . . . . 3-22
W
V
Warning, Definition . . . . . . . . . . . . . . . 2-2
Weight, Learn . . . . . . . . . . . . . . . . . . . 3-27
Valve . . . . . . . . . . . . . . . . . . 7-111 to 7-112
Welding Safety . . . . . . . . . . . . . . . . . . 2-11
CB1 & CB2 Counterbalance
WHLD
Torque . . . . . . . . . . . . . . . . . . . 7-112
Display Format, Configuring . . . . . 3-26
CE1 Compensating Element
Weight-Height Configuration Table 3-21
(DC lift) Torque . . . . . . . . . . . 7-111
Wiring
CV-1 Check Valve Torque . . . . . . 7-111
General . . . . . . . . . . . . . . . . . . . . 7-77
Harness Terminology . . . . . . . . . . 6-27
Inspection . . . . . . . . . . . . . . . . . . 7-77
LS-1 Load Shuttle Torque . . . . . . 7-111
Repair . . . . . . . . . . . . . . . . . . . . . 7-77
POD-1 Priority-on-Demand
Soldering Procedures . . . . . . . . . . 7-77
Torque . . . . . . . . . . . . . . . . . . 7-111
Wrist strap, ESD . . . . . . . . . . . . . . . . . 2-7

!1026304C!
1026304C

7400 Mantenimiento

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Maintenance Manual

Model 7400/7420/7440 Reach-Fork ® Truck

Series Serial Numbers

1026304C Issued: 22 Apr 2009

For revision information, see “Page Revision Record” on page v.

To locate your local authorized Raymond dealer, go to www.raymondcorp.com.

©2009 The Raymond Corporation.

Page Revision Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-v

Publication: 1026304, Issued: 22 Apr 2009 i

Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

ii Publication: 1026304, Issued: 22 Apr 2009

Mast, Chain, Hose, Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-145

Publication: 1026304, Issued: 22 Apr 2009 iii

iv Publication: 1026304, Issued: 22 Apr 2009

Page Revision Record

1026304A Original Issue . . . . . . . 15 Jun 2004

1026304B . . . . . . . . . . . . . . . . . . .15 Jul 2007

1026304C . . . . . . . . . . . . . . . . . . 22 Apr 2009

Publication: 1026304, Issued: 22 Apr 2009 v

Service Bulletin List

Document Number Subject Date

RSB RCH-08-006 Drive Motor Pinion Nut 21 May 2008

vi Publication: 1026304, Issued: 22 Apr 2009

Document Number Subject Date

RPIN RCH-07-R015 New Electric Brake Available 02 Nov 2007

RPIN RCH-08-R001A AC Lift Trucks Without a Height Encoder 11 Sep 2008

RPIN RCH-08-R003 Stiff Steering 12 Feb 2008

RPIN RCH-08-R004 Free Lift Staging Ram Glands 19 Mar 2008

RPIN RCH-08-R007 Replacement of Drive Motor Encoder Bearing 16 May 2008

RPIN RCH-08-R008A Update to Tests I02 and I24 11 Sep 2008

RPIN RCH-08-R009 Proximity Switch Adjustment 11 Sep 2008

RPIN GEN-08-R001 Warning Light Failures 25 Feb 2008

Publication: 1026304, Issued: 22 Apr 2009 vii

viii Publication: 1026304, Issued: 22 Apr 2009

Section 1. How to Use This Manual

Publication: 1026304, Issued: 22 Apr 2009 1-1

Map of the Manual

Map of the Manual

1-2 Publication: 1026304, Issued: 22 Apr 2009

Manual Design • Component Procedures gives

Publication: 1026304, Issued: 22 Apr 2009 1-3

Abbreviations and Symbols

Term/Symbol Definition Term/Symbol Definition

A Ampere E UL Electric Truck Type

1-4 Publication: 1026304, Issued: 22 Apr 2009

Abbreviations and Symbols

Term/Symbol Definition Term/Symbol Definition

K thousand OACH Overall Collapsed Height

Publication: 1026304, Issued: 22 Apr 2009 1-5

Abbreviations and Symbols

WHLD Weight Height Limit Display

1-6 Publication: 1026304, Issued: 22 Apr 2009

Publication: 1026304, Issued: 22 Apr 2009 2-1

Warning means a potentially hazardous

Caution means a potentially hazardous

2-2 Publication: 1026304, Issued: 22 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.