4700 00001-Up MM LNK 1160093A

Maintenance Manual
Model 4700 Sit-Down Counterbalanced Lift

Truck With The ACR System™
1DSC0012B_silouette.jpg,acrLogo.eps,4700CoverColor.jpg
Model Serial No.

4700 C30/C40/C50 470-06-XX00001 and up
4700 C50HM
4700 C50HP
4700 C50L
4700 C60
1160093A Issued: 20 May 2013

This publication, 1160093A, applies to Raymond Model 4700 Sit-Down Counterbalanced Lift Trucks.
Changes occur periodically to the information in this publication.
For revision information, see “Page Revision Page” on page iii.
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 Sales and Service Center, go to www.raymondcorp.com.
©2013 The Raymond Corporation.

The following terms are trademarks of The Raymond Corporation: Safety On The Move, ACR System and
Raymond. All other brand and product names are trademarks or registered trademarks of their respective
companies.
Model 4700 Sit-Down Counterbalanced Lift Truck Table of Contents
Table of Contents
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Manual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Interactive Electronic Technical Manuals . . . . . . . . . . . . . . . . . . . . . . 1-3
Abbreviations and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Static Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Jacking Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Lift Truck Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
FlashWare Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Alternative LEARN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Initial 90 Day/250 Pump Hour Maintenance . . . . . . . . . . . . . . . . . . . 4-3
Every 180 Days or 500 Pump Hours . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
First 1500 Pump Hours - Trucks S/N 10677 and up . . . . . . . . . . . . . 4-7
Every 360 Days or 2000 Pump Hours . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Chain Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Hydraulic Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . 5-13
Symptom Tables: Travel Functions . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Symptom Tables: Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . 5-15
Messages and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Operator Display Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
List of Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Component Locator Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Special Tools, Decals, and Chassis . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Steering and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Drive and Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
System Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Traction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Auxiliary Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Publication 1160093, Issued: 20 May 2013 i

Table of Contents Model 4700 Sit-Down Counterbalanced Lift Truck
Pinout Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Lubrication Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Thread Adhesives, Sealants, and Lubricants . . . . . . . . . . . . . . . . . . . A-3
Component Specific Torque/Information Chart . . . . . . . . . . . . . . . . . A-4
Torque Chart - Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Torque Charts - Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Torque Chart - Thread-Forming Screws . . . . . . . . . . . . . . . . . . . . . . . A-7
Torque Chart - Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Torque Chart - Straight Thread Face Seal O-Rings . . . . . . . . . . . . . . A-9
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
ii Publication 1160093, Issued: 20 May 2013

Model 4700 Sit-Down Counterbalanced Lift Truck Document Revision History
Document Revision History
Revision Date Description of Changes
This manual replaces Maintenance Manual 1056865C for all Model 4700
1160093A 20 May 2013
applications.
Publication 1160093, Issued: 20 May 2013 iii

Service Information List Model 4700 Sit-Down Counterbalanced Lift Truck
Service Information List

The following Service Information documents have been incorporated into this manual.
Use the blank rows below to log Service Information documents when they are added to this
manual.
Document Number Subject Date
iv Publication 1160093, Issued: 20 May 2013

Model 4700 Sit-Down Counterbalanced Lift Truck Section 1. How to Use This Manual
Section 1. How to Use This Manual
Publication 1160093, Issued: 20 May 2013 1-1

Section 1. How to Use This Manual Model 4700 Sit-Down Counterbalanced Lift Truck
Manual Design
Manual Design • 7. Component Procedures gives

step-by-step procedures for removal,
installation, and adjustment of truck
This manual is designed with the following components. Components are grouped by
objectives in mind: truck system.
• provide technical coverage for expected To find a component procedure, you may
levels of user expertise 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” on
• reduce page flipping through a “one-stop page 7-2.
shopping” approach • Find the component in the “Component
Locator Photos” on page 7-5.
The two-line running page header at the top of
• Look up the component name in the
each page tells you:
Index.
• Name of the manual (Model 4700 Sit-Down
• 8. Theory of Operation explains signal
Counterbalanced Lift Truck Maintenance
flow within the electrical and hydraulic
Manual)
systems for various conditions of lift truck
• Current Chapter Title (for example, this operation. This chapter also contains a
page How to Use This Manual) detailed connection point table (Pinout
• Current topic (for example, this page Matrix) designed to assist in testing and
Manual Design) troubleshooting the truck.
• Appendix contains reference information
This manual consists of the following sections: such as torque values, lubricants, and
• 1. How to Use This Manual explains the standard/metric conversions.
manual format and design as well as • Index lists subjects alphabetically.
abbreviations and symbols used.
• 2. Safety explains warning and caution
notes, general safety rules, and safety
rules for batteries, static electricity,
jacking, and welding.
• 3. Systems Overview includes a general
lift truck description, specifications,
controls, FlashWare, and alternate Learn
information.
• 4. Scheduled Maintenance outlines the
recommended schedule of preventive
services to keep the lift truck working
most efficiently.
• 5. Troubleshooting provides specific
checks or actions (based on fault
symptoms) in order to identify a bad
component.
• 6. Messages and Codes describes the
icons and indicators on the Operator
Display. A comprehensive list of Fault
Codes and associated corrective action is
also provided.
1-2 Publication 1160093, Issued: 20 May 2013

Interactive Electronic Technical Manuals
Interactive Electronic
Technical Manuals
The electronic version of this document is an
Interactive Electronic Technical Manual (IETM).
IETMs put service and parts information at
your fingertips; no searching for and opening a
second file, or searching for the corresponding
printed manual. IETMs come in sets
(Maintenance and Parts) and are available on
iManuals or from your local authorized
Raymond Sales and Service Center.
To use IETMs:
• Place both PDF files (Maintenance Manual
and Parts Manual) in the same
directory/folder.
• Do NOT rename the files.
Important:
• IETM file names must remain exactly as
they are downloaded, and must reside in
the same folder. Any changes to the file
names, or failure to have the associated
IETM PDF files in the same folder will
disable the interactive capability of the
manuals.
• IETMs require Adobe Reader 9.0 or higher.
Blue colored text in the Maintenance Manual is

“linked” to locations within the same manual.
Clicking on a blue link automatically takes you
to the linked location.
Green colored text in the Maintenance Manual

is “linked” to a specific location in the
corresponding Parts Manual. Clicking on a
green link automatically opens the
corresponding Parts Manual to the appropriate
page.

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

A Ampere
AC Alternating Current lb. pound or pounds
Agnd analog ground
amp Ampere or amplifier LED Light Emitting Diode
approx. approximately
Assy assembly mA milliampere
aux auxiliary mm millimeter
AWG American Wire Gauge mph miles per hour
CAN Controller Area Network No. number

cc cubic centimeter Nm newton meter
Conn. Connector or Connection
CS cold storage OD Operator Display
opt. optional
DC Direct Current OTM over-the-mast
DMM Digital Multi Meter
pot potentiometer
EE UL Electric Truck Type PPA Pump Power Amplifier
Certification Rating where psi pounds per square inch
electrical equipment is P/N Part Number
completely enclosed
EPO Emergency Power Off
RPM Revolutions Per Minute
ESD Electrostatic Discharge
ESDS Electrostatic Discharge
Sensitive SAE Society of Automotive
Engineers
SOL Solenoid
ft. foot or feet
temp Temperature
gal gallon or gallons
TPA Traction Power Amplifier
GPM Gallons Per Minute
UL Underwriters Laboratories,
HCB Hydraulic Control Board Inc.
Hz Hertz V Volt or Volts
VDC Volts Direct Current
in. inch or inches VM Vehicle Manager
wrt with respect to
kg kilogram(s) w/ with
km/h kilometers per hour
kPa kilo Pascal

Term/Symbol Definition
™ trademark
© copyright
+ plus or positive
– minus or negative
± plus or minus
° degrees
°F degrees Fahrenheit
°C degrees Celsius
% percent
= equals


Model 4700 Maintenance Manual Section 2. Safety
Section 2. Safety

Section 2. Safety Model 4700 Maintenance Manual
Definitions
Definitions
Throughout this manual, you will see two kinds
of safety reminders:
Warning means a potentially hazardous

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

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

General Safety
General Safety Operate this lift truck only from the operator’s
position.
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.
Before working on this lift truck, always turn

the key switch OFF and disconnect the battery
connector (unless this manual tells you
otherwise).
Know the lift truck’s controls and what they do.
Do not wear watches, rings, or jewelry when

working on this lift truck.
Report any malfunction or unsafe condition to
your Supervisor immediately. Do not operate
this lift truck if it needs repair or if it is in any
way unsafe.
Follow the scheduled lubrication, maintenance,

and inspection steps.

General Safety
Follow exactly the safety and repair instructions Always park this lift truck indoors.
in this manual. Do not take shortcuts.
Do not wash this lift truck with a hose.

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

Do not use gasoline or other flammable liquids contact your local Raymond Sales and Service
for cleaning parts. Center to receive written manufacturer
approval.
Clean up any hydraulic fluid, oil, or grease that

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

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

without arm shields), and a rubber apron.
225l6s016.eps
As a battery is being charged, an

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

sulfuric acid and water. Battery acid
causes burns. Should any electrolyte
come in contact with your clothing or
skin, flush the area immediately with
cold water. Should the solution get on
your face or in your eyes, flush the area
with cold water and get medical help
immediately. A battery gives off explosive gases.
Never smoke, use an open flame, or use
Read, understand, and follow procedures, anything that gives off sparks near a battery.
recommendations, and specifications in the
battery and battery charger manufacturer’s Keep the charging area well-ventilated to avoid
manuals. hydrogen gas concentration.
225l6s014.eps
Wear personal protective equipment to protect Turn the key switch OFF before disconnecting
eyes, face, and skin when checking, handling, the battery from the lift truck at the battery
or filling batteries. This equipment includes connector. Do not break live circuits at the

Battery Safety
battery terminals. A spark often occurs at the Make sure the vent holes in the filler plugs are
point where a live circuit is broken. open to allow the gas to escape from the cells.
209g6s047.tif
Vent
Hole
Do not lay tools or metal objects on top of the

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

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

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

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

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

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

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

Static Precautions
Static Precautions Figure 2-1. Anti-Static Kit with Wrist Strap and Mat
Electronic circuit boards can contain

Electrostatic Discharge Sensitive (ESDS)
devices.
Static charges can accumulate from normal

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

discharged to a circuit board or component by
touching the parts. Electrostatic Discharge Figure 2-1 shows the components of the
(ESD) is also possible through the air when a Raymond antistatic field service kit,
charged object is placed close to another P/N 1-187-059. The kit includes a wrist strap,
surface at a different electrical potential. Static ground cord, and static-dissipative work
discharge can occur without seeing or feeling it. surface (mat). Follow the instructions packaged
with this kit.
Whenever working on or near static-sensitive
electronics, always use static discharge Wrist straps are available in quantities of 25, as
precautions. P/N 1-187-058/001.
• Wear an ESD wrist strap. Connect the
A wrist strap tester is available as
ground lead to the wrist strap connector.
P/N 1-187-060/100.
Connect the ground clamp to an
unpainted, grounded surface on the truck
Contact your local authorized Raymond Sales
frame. The wrist strap should be equipped
and Service Center for information.
with a 1 megohm resistor to protect
against shock hazard.
• Handle circuit boards by edges only. Avoid
touching edge connectors.
• If you are removing or installing
static-sensitive components, place them
on a correctly grounded static mat.
• To transport static-sensitive components,
including failed components being
returned, place the components in an
antistatic bag or box (available from your
Raymond Sales and Service Center).
Test the wrist strap and related accessories

before each use to make sure they are working
correctly.

Jacking Safety
Jacking Safety To elevate the lift truck:

1. Place a suitable jack under a designated
jacking point. See Figure 2-2.
General Precautions
2. Lift the truck only as far as required to
Some maintenance procedures require the lift perform the procedure.
truck to be elevated off the floor. When jacking 3. Securely block the truck in place.
the truck, observe the following safety
precautions: NOTE: It is possible to elevate the front of the
lift truck without using a jack.
1. Lower the forks completely. Remove any
load. a. Block the steerable wheels with chocks.
2. Set the parking brake and block the b. Tilt the mast back and place blocks on
wheels to prevent movement of the vehicle. the floor under the mast main frame.
3. Turn the key switch OFF and disconnect c. Tilt the mast forward, lifting the truck
the battery connector. off the floor.
4. Place the jack under the designated
jacking points. See Figure 2-2.
5. Always use solid blocks to support the
truck. Never rely on jacks or chains to
support the truck.
Use extreme care whenever the 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.
Figure 2-2. Correct Jacking Locations

Jack only in
these areas

Welding Safety
Welding Safety
Disconnect the battery before you
attempt to inspect, service, or repair the
lift truck.
Flame cutting or welding on painted
surfaces may produce potentially
harmful fumes, smoke, and vapors.
Prior to performing flame cutting or
welding operations, it is recommended Before removing a power amplifier,
that the coating be removed in the discharge the amplifier’s internal
vicinity where the operation(s) will be capacitor by jumpering the + and –
performed. terminals with a 100 ohm 25W resistor.
Coating removal may be by mechanical

methods, chemical methods, or a
combination of methods. Perform flame
cutting and/or welding operations only
in well ventilated areas. Use local
exhaust if necessary.
Before working on this lift truck, make sure:

• fire protection equipment is nearby
• you know the location of the nearest • Check for shorts to frame as described in
eyewash station. “Shorts to Frame” on page 5-2. If you
detect any shorts, correct them before you
proceed with the welding operation.
• Clean the area to be welded.
• Protect all lift truck components from
heat, weld spatter, and debris.
• Attach the ground cable as close to the
weld area as possible.
• Disconnect all electrical circuit cards
before doing any type of electric resistance
welding.
• Do not perform any welding operations
near the electrical components.
• If you must do welding near the battery
compartment, remove the battery from the
lift truck.
• When you are finished welding, re-install
circuit cards and perform all ground tests
and electrical inspections before operating
the lift truck.

Welding Safety

Model 4700 Maintenance Manual Section 3. Systems Overview
Section 3. Systems Overview

Section 3. Systems Overview Model 4700 Maintenance Manual
General
General Serial Number Designations

The truck serial number consists of a
This lift truck can be configured to operate with three-digit model abbreviation, two-digit year of
a 36V or 48V battery. Operator input/command manufacture, two letter configuration code, and
signals are communicated to various electronic five-digit serial number.
components via a CAN-Bus network. Pressure
for lift, tilt, sideshift, and steering is provided by Example: 470-12-xx12345
a hydraulic pump driven by an AC motor. The
pump motor is controlled by an AC power The two letter configuration codes (xx) are
amplifier (PPA). designated as follows:
Dual Traction Motor Trucks - Two independent • SM = Single (traction) Motor
AC motor/drive unit assemblies provide • DM = Dual (traction) Motor
traction via a dual AC power amplifier (TPA). A
• HM = High Maneuverability (dual traction
multiple disc, oil bath type brake system is
motor)
located internal to the drive units.
• L or SL = Single traction motor, Long
Single Traction Motor Trucks - An AC motor chassis
coupled to a differential type drive unit provides NOTE: The mast designation is not an indicator
traction via an AC power amplifier (TPA). Trucks of the truck’s chassis or drive system.
below S/N 10677 use automotive type drum
brakes located on the drive wheels. Trucks
10677 and up use a multiple disc, oil bath type
brake system located internal to the drive unit.
Model Designations
Refer to Table 3-1 for model specific system
configuration information.
Table 3-1. Model Designations
Model System Configuration

C30 Dual traction motor; 3000 lb. capacity
C40 Dual traction motor; 4000 lb. capacity
Dual traction motor; 5000 lb. capacity
C50HM High Maneuverability (smaller turning
radius)
Single traction motor; 5000 lb. capacity
C50
Standard lift (450A AC2 PPA)
C50HP
High Performance lift (600A AC3 PPA)
C50 L
Long chassis (allows less down rating at
or SL
height)
C60 Single traction motor; 6000 lb. capacity

Lift Truck Specifications
Lift Truck Specifications

This lift truck is rated for performance by load
center and load weight. Review the specification
plate, located on the lift truck’s dash panel to
the right of the steering column, for detailed
load capacity and load center information.
Due to continuous product enhancement,

specifications are subject to change without
notice or obligation.
Serial number Maximum battery Battery voltage and

Model designation weight for this lift width
truck
Maximum power
Approximate weight rating of battery
of lift truck with
battery installed,
Attachment
minus load and
operator
Approximate weight Hour Rate

of lift truck minus
battery, load, and
operator Minimum battery
weight for this lift
truck
Battery weight
Maximum load must be between
capacity for this lift the minimum and
truck maximum weight

Controls
Controls
Figure 3-1. Operator Controls
Steering Wheel
Directional Lever
Horn Switch
Key Switch
Performance Performance Mode Select Switch

Reduction Switch
EPO Switch Accelerator Pedal
Brake Pedal
Hydraulic Function Levers

Parking Brake Lever
Hydraulic Function Fingertip Controls Forward/Reverse Accelerator

with additional horn switch (optional) pedals (optional)

Controls
Performance Modes (L•P•H)

Three selectable performance parameters, L, P,
and H, are configured for travel and lift speed,
acceleration, and hydraulic flow for
attachments.
L = low performance
P = medium performance
H = high performance
These parameters are set at the factory such

that H will be maximum speed, L will be slower,
and P will be an intermediate speed.
These parameters can be set to meet specific

application requirements via FlashWare.
NOTE: This feature is not available on EE rated
trucks.
Performance Reduction
The performance reduction (turtle) mode

reduces the performance parameters in the L,
P, and H settings. Turtle mode performance is
also configurable via FlashWare.

FlashWare Program
FlashWare Program If you are a Raymond Sales and Service Center

technician, obtain FlashWare from the iNet
software download site.
Overview
To install FlashWare on the PC, double-click the
FlashWare allows you to update software, view, installation file and follow the instructions on
and configure options on the truck through the the screen. The software package is a
following features: self-extracting executable file. Read the
“Readme” file in the software package for the
• Update Vehicle Manager software latest detailed installation instructions.
• Learn controls
• Reset Raymond default settings USB to CAN Adapter Driver
• Download Software Installation
• Configure LPH parameters
Refer to Help in the FlashWare menu bar for
detailed information regarding the installation
For more detailed information about FlashWare,
of USB/CAN Adapter driver installation.
click on Help in the FlashWare menu bar and
select Help Topics.
Connecting PC to Truck
Loading Power Amp software versions

less than 111 in trucks S/N 29,999 and Before connecting to the truck, make
up will cause irreparable damage to the sure the laptop battery is sufficient to
amp. Likewise, loading Power Amp complete the task. If in doubt, plug
software version 111 in trucks laptop into a reliable AC power source.
S/N 29,998 and below will cause
irreparable damage to the amp. If the laptop powers down while
flashing an amplifier, it is possible that
Requirements an unrecoverable error may occur.
FlashWare can be installed on an 1. Turn the truck key switch OFF.

IBM-compatible PC. The PC communicates with 2. Remove the dashboard cover below the
the truck software via a USB/CAN interface Operator Display.
module and associated cables (dongle). This
3. Connect a standard 9-pin serial cable from
dongle is available as P/N 230489-001.
the USB/CAN interface module to the
serial port connector.
4. Connect a standard USB cable from the
To protect your PC from possible USB/CAN interface module to a USB port
electrostatic discharge or voltage surge, on the PC.
use of surge protector P/N 154-010-801
is recommended.
Starting FlashWare
Installing FlashWare on PC 1. Turn the truck key switch ON.
2. Double-click the FlashWare icon on the
If you are a customer service technician, obtain main desktop screen or navigate via Start
FlashWare from your Raymond Sales and > Programs > FlashWare. The FlashWare
Service Center. Opening Screen appears. See Figure 3-2.

FlashWare Program
Figure 3-2. Flashware Opening Screen
3
3. From the menu bar, click “Connect to

Truck”. From the pull-down menu, select
“4700 Counterbalanced Truck”. The
“Truck Setup” screen is displayed.
NOTE: Refer to Help in the FlashWare menu
bar for specific FlashWare related topics.

Alternative LEARN
Alternative LEARN 5. Press the LPH and Turtle buttons at the

same time again and release. A flashing
“n” should be displayed and the Battery
When FlashWare is not available, learning pots Charge Indicator LEDs will flash.
and changing battery voltage can be done using
6. Press the Turtle button and release. A
the LPH and Performance Reduction (Turtle)
flashing “y” should be displayed and the
buttons on the truck steering column.
Battery Charge Indicator LEDs will flash.
NOTE: In this procedure, the LPH button can 7. Press the LPH button and release. (Learn
be considered an ENTER button and the mode is now accessed.) “Ld” should now
performance Reduction (Turtle) button be flashing on the display. Press the Turtle
can be considered a TOGGLE button to button to toggle between selections.
change selections.
Six selections are available with this procedure: Model 4700 with Software Lower
Ld (Learn drive), LL (Learn lift), Learn Right than V2.9
Steer position*, Learn Left Steer position*,
1. Press the LPH and Turtle buttons at the
Learn Center Steer position*, which are
same time and release.
indicated by the steer position LEDs, and Lb
(Learn battery). 2. Press the Turtle button and release.
3. Press the LPH button once and release. A
*Applies to dual traction motor trucks only. flashing “n” should be displayed and the
Battery Charge Indicator LEDs will flash.
4. Press the Turtle button and release. A
Read and understand this procedure flashing “y” should be displayed and the
thoroughly. Values can be mislearned Battery Charge Indicator LEDs will flash.
and the lift truck can move if these 5. Press the LPH button and release. (Learn
procedures are not performed correctly. mode is now accessed.) “Ld” should now
be flashing on the display. Press the Turtle
If, while learning the traction pot, the button to toggle between selections.
parking brake is not set or the
directional control is not in neutral, the
truck will travel.
Learn the Traction
Potentiometer
While learning the lift pot, the carriage
will lift. Make sure there are no
overhead obstructions.
The parking brake must be engaged
With the key switch ON, sitting in the seat, and the travel directional lever must be
parking brake engaged, and the travel in neutral or the truck will travel.
directional lever in neutral, do the following:
1. While in Learn mode with “Ld” flashing
(Ld = Learn drive), press and release the
Enter Learn Mode LPH button. A solid “Ld” should be
1. Press the LPH and Turtle buttons at the displayed and the Battery Charge
same time and release. Indicator LEDs will flash.
2. Press the Turtle button and release. 2. Depress and hold the traction forward
pedal (on dual pedal trucks) or traction
3. Press the LPH and Turtle buttons at the
pedal (on single pedal trucks).
same time again and release.
4. Press the LPH button once and release.

Alternative LEARN
3. Press and release the LPH button to store Learn the Steer Potentiometer
the value. A solid “Ld” should be displayed
and the Battery Charge Indicator LEDs This procedure applies to dual traction motor
should be on solid as well, indicating the trucks only.
new learned value has been stored.
Release the pedal. NOTE: When learning the steer pot, the right,
left, and center steer positions must be
4. Press and release the LPH button to exit. A learned.
flashing “Ld” should be displayed.
1. Enter Learn mode. Toggle the Turtle
5. If another selection is to be learned, toggle
button until the right steer position LED
the Turtle button until the desired
flashes.
selection is displayed. If no other
selections are to be learned, toggle the NOTE: The LED that is flashing is the position
Turtle button until the truck exits Learn that is going to be learned. For example:
mode and performs SelfTest. Cycle the key If the right LED is flashing, you must
switch after exiting Learn Mode. learn the right steer position with the
wheel turned all the way to the right,
Learn the Lift Potentiometer and so on.
2. Press and release the LPH button to select
NOTE: This procedure applies to trucks
Learn for the right steer position. The right
equipped with Lever Controls only.
steer direction LED will be on solid and the
1. While in Learn mode, toggle the Turtle Battery Charge Indicator LEDs will flash.
button until “LL” is flashing (LL = Learn 3. Depress the brake pedal to start the
lift). hydraulic pump and allow steering.
2. Press and release the LPH button. A solid 4. Steer to the right fully and hold.
“LL” should be displayed and the Battery
Charge Indicator LEDs will flash. 5. Press and release the LPH button to store
the value. The right steer direction LED
NOTE: The carriage will lift when the next step and the Battery Charge Indicator LEDs
is performed. Make sure there are no should be on solid.
overhead obstructions.
6. Press and release the LPH button to exit.
3. Pull the lift lever to the maximum lift The right steer direction LED should now
position. flash and the Battery Charge Indicator
4. Press and release the LPH button to store LEDs should go out.
the value (as soon as LPH is pressed, the 7. Toggle the Turtle button until the left
lift lever can be released). A solid “LL” steering LED is flashing.
should be displayed and the Battery 8. Press and release the LPH button to select
Charge Indicator LEDs should be on solid Learn for the left steer position. The left
as well, indicating the new learned value steer direction LED will be on solid and the
has been stored. Battery Charge Indicator LEDs will flash.
5. Press and release the LPH button to exit. A 9. Depress the brake pedal to start the
flashing “LL” should be displayed. hydraulic pump and allow steering.
6. If another selection is to be learned, toggle 10. Steer to the left fully and hold.
selection is displayed. If no other 11. Press and release the LPH button to store
selections are to be learned, toggle the the value. The left steer direction LED and
Turtle button until the truck exits Learn the Battery Charge Indicator LEDs should
mode and performs SelfTest. Cycle the key be on solid.
switch after exiting Learn Mode. 12. Press and release the LPH button to exit.
The left steer direction LED should now

Alternative LEARN
flash and the Battery Charge Indicator 6. Press and release the LPH button to store
LEDs should go out. the value. The truck should exit Learn
13. Toggle the Turtle button until the center mode and go through SelfTest.
steering LED is flashing. NOTE: If the truck displays codes and/or does
14. Press and release the LPH button to select not go through SelfTest after exiting
Learn for the center steer position. The Learn mode, cycle the key switch.
center steer direction LED will be on solid 7. Cycle the key switch.
and the Battery Charge Indicator LEDs
will flash.
15. Depress the brake pedal to start the
hydraulic pump and allow steering.
16. Steer to the center position and hold.
17. Press and release the LPH button to store
the value. The center steer direction LED
and the Battery Charge Indicator LEDs
should be on solid.
18. Press and release the LPH button to exit.
The center steer direction LED should now
flash and the Battery Charge Indicator
LEDs should go out.
19. If another selection is to be learned, toggle
selection is displayed. If no other
selections are to be learned, toggle the
Turtle button until the truck exits Learn
mode and performs SelfTest. Cycle the key
switch after exiting Learn Mode.
Check/Change Battery Voltage

This procedure should be performed whenever
multiple codes are displayed and it is suspected
that the learned battery voltage is incorrect.
NOTE: When battery voltage is changed, all
potentiometers must be re-learned.
1. While in Learn mode, toggle the Turtle
button until a flashing “Lb” is displayed
(Lb = Learn battery).
2. Press and release the LPH button. 36 or 48
should appear on the display.
3. Toggle the Turtle button to the correct
battery voltage.
4. Press and release the LPH button. A
flashing “n” should now be displayed.
5. Toggle the Turtle button until a flashing
“y” is displayed.

Model 4700 Maintenance Manual Section 4. Scheduled Maintenance
Section 4. Scheduled Maintenance

Section 4. Scheduled Maintenance Model 4700 Maintenance Manual
Maintenance Guidelines
Maintenance Guidelines
Following a regularly scheduled maintenance
program:
• promotes maximum truck performance
• prolongs truck life
• reduces costly down time
• avoids unnecessary repairs
Scheduled maintenance includes:

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

maintenance during the suggested intervals.
The time intervals given in this guide are based
on Pump Hours under normal operating
conditions.
When operating under Severe or Extreme

conditions, perform these services more often
as indicated in Table 4-1.
Table 4-1. Maintenance Frequency
Operating
Working Environment Service Frequency
Conditions
Light to An eight hour day of basic material handling 180 days or 500 pump
Moderate hours, whichever
comes first
Severe • Extended heavy duty operation 60 days or 250 hours,
• Freezer operation whichever comes first
• Sudden temperature changes such as going from freezer to
room temperature
Extreme • All UL Type EE rated lift trucks 30 days or 100 hours,
• Dusty or sandy conditions such as in cement plants, lumber whichever comes first
or flour mills, coal dust or stone-crushing areas
• High temperature areas such as in steel mills, foundries, or
enclosed (Type EE) applications
• Corrosive chemical atmosphere, such as:
• fish, meat, or poultry processing plants, tanneries, or any
other similar applications
• chlorine or salt-sea air environments
• Adverse high humidity, wet, damp, or moist conditions

Initial 90 Day/250 Pump Hour Maintenance
Initial 90 Day/250 Pump Hour Maintenance

4
Perform the following maintenance tasks 90 days after the lift truck is put into service or at
250 Pump Hours, whichever comes first.
Component Task Refer to
Drive Units - Change fluid. Page 7-22

Dual Traction
Motor Trucks
Hydraulic Change fluid and filter. Page 7-60

Reservoir
Power Retorque power cable terminal nuts to 11 ft. lb. (15 Nm). Page 7-49
Amplifiers

Every 180 Days or 500 Pump Hours

NOTE: For Severe or Extreme operating condition service intervals, refer to Table 4-1, “Maintenance
Frequency,” on page 4-2.
Perform the following tasks every 180 days/500 pump hours, whichever comes first.
Component What to do Refer to
Accelerator Pedal(s) Verify travel function is smooth and responsive through full range of
acceleration.
Battery Check the weight stamped on the battery in the lift truck against the
minimum and maximum allowable weights on the specification tag
for the lift truck. Report any lift trucks that are running with
batteries under the minimum or over the maximum allowable weight.
Check for voltage leaks to frame. If cleaning does not remove voltage
to frame, install a new 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.
Brakes In an open area, measure stopping distance. Traveling 2 to 3 mph

(3.2 to 4.8 km/h) empty, push the brake pedal. The empty lift truck
should stop within 2 to 4 ft. (0.6 to 1.2 m). During normal operation,
with a rated load and traveling at top speed, the lift truck should stop
within approx. one and one-half truck lengths. Stopping distance
depends on the load, floor, and tire condition. Check brake fluid
reservoir level. Check for fluid leaks.
Single Traction Motor Trucks below S/N 10677 - Inspect brake shoe
thickness.
Check parking brake for correct operation.
Chassis General visual inspection of structural members for cracks.
Contactors Inspect contactor tips. Replace contactors with burnt or pitted

contactor tips. Failure to replace the contactor may prevent the
contactor from opening or closing causing unscheduled downtime.
With the key switch OFF and the battery disconnected, check the
plunger for smooth operation with no binding. If binding occurs, the
lift truck may malfunction or exhibit intermittent fault codes.
Drain Holes Make sure drain holes in battery compartment are not blocked.
Drive Units Check fluid level. Inspect for leaks. Page 7-22
Electrical Cables Inspect all power cables for nicks or cuts. Replace any cable that is
damaged or shows signs of excessive heat. Failure to do so will cause
intermittent system shutdowns and/or electronic failures.
Forks Examine for excessive wear, bends, cracks, welding arcs, excessive Page 4-10
heat, or unauthorized modifications. Replace if found.
Hardware Check bolt torque of major components (motors, pump, brakes, drive
units, manifolds, mast-to-chassis mounting bolts, steer cylinder
mounting bolts). Tighten any loose hardware. Replace any broken or
missing hardware.
Horn Check that horn sounds correctly when activated.

Hydraulic Hoses Inspect all hydraulic hoses for leaks, nicks, cuts, chafing, and bulges.
Replace damaged hoses as soon as possible. Inspect fittings for leaks.
Repair any leaks immediately. Inspect OTM hoses for correct tension.
Make sure OTM pulleys spin freely and show no signs of wear.
Hydraulic Reservoir Check fluid level.
Lift Chains Check adjustment. Inspect for excessive stretch or wear. Lubricate. Page 4-9
Lights Check for correct operation.
Lubrication Apply grease to all fittings. Apply lithium grease to the travel direction
lever ball joint on the steering column. Coat all chains with spray
lubricant.
Mast Wipe old grease off mast uprights and apply new grease. Examine
mast bearings. Inspect rails for abnormal wear, metal flakes, or
shavings. Repair any grooves worn in the mast deeper than 1/8 in.
(3 mm). Check upright and guide shoe (puck) adjustment.
Motors Check cable lugs to make sure they are tight to the terminal studs.
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.
Overhead Guard Inspect guard for physical damage. If structurally damaged, replace
the guard.
Power Amplifiers Check torque on power amplifier connections. Make sure power
and Fan amplifier heat sink fins are free of debris and that air flows freely
through them.
Seat Belt Check for signs of wear, fraying, or damage.
Seat Switch Check for correct activation and deactivation of the seat switch.
Shorts to Frame Check for electrical shorts to frame. Wipe compartments clean.
Static Strap Make sure static strap is not worn or broken. Clean debris from
straps. Check resistance of resistor in standoff; should be 200 to
250k ohm. EE Labeled trucks require a phosphor bronze static strap;
do not use steel braided cable on EE labeled lift trucks.
Steering Inspect hoses and cylinder for leaks. Check steer cylinder mounting
holes, screws, and dowel pins for damage.
Switches Check all switches for correct operation and adjust as needed.
Travel Alarm If equipped, check for correct operation.
Ventilation Slots Make sure ventilation slots in the chassis are clear of obstructions
and debris. Clean the fan filter.
Warning Decals Replace missing, illegible, or damaged decals.
Warning Light If equipped, check for correct operation.

Wheels/Tires Examine for bond failure, chunking, and excessive or uneven wear.

First 1500 Pump Hours - Trucks S/N 10677 and up
First 1500 Pump Hours - Trucks S/N 10677 and up

Drive Unit Change fluid after the first 1500 hours of operation. Page 7-27


Perform all 180 day/500 pump hour tasks plus the following maintenance tasks every 360 days or
2000 pump hours, whichever comes first.
Drive Units Change fluid. Page 7-22

Page 7-27
Hydraulic Reservoir Change fluid and filter. Page 7-60
Lift Pump Separate lift pump and motor. Apply molybdenum anti-seize
compound (P/N 990-638) to the splines.
Steering Inspect wheel bearings for side play. There should be no more than
0.002 in. (0.05 mm) of movement. If excessive, torque the retaining
nut to 44 ft. lb. (60 Nm) and spin the wheel in both directions 2 to 3
turns. Back off retaining nut and torque to 14.7 ft. lb. (20 Nm). Check
for side play and make sure the bearing is not binding. If binding,
replace bearings.

Chain Maintenance
Chain Maintenance Figure 4-1. Chain Gauge
Lift Chain Inspection Chain
A
A
Wear
Make sure chains are not damaged. Check the Scale
chain for wear using a Chain Gauge
(P/N 950-350/CG). See Figure 4-1.
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
Condition Cause Maintenance Procedure
Chain Elongation Wear Use a chain gauge or lay the chain on a flat surface
and push it together. Measure and mark a 12 in.
(305 mm) length that has operated over the pulley
sheave. Stretch the chain; if more than 1/3 in. (8.5
mm) play is detected, replace the chain.
Rust and corrosion Steam cleaning or degreasing Lubricate chain frequently.

new truck chains
Cracked Plates Infrequent Oiling Replace the chain.
Rust
Corrosion
Chain Fatigue
Tight Joints Bent pins or plates Replace the chain.
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 0.005 for

maximum allowable deviation.
• Length of blade _____ x 0.005 = ______
The following tools are required to perform fork
inspection: • Height of shank _____ x 0.005 = ______
• Fork Wear Caliper (P/N 922-369) 3. Place a straight edge on the blade of the
fork, 2 in. away from the heel of the fork.
• Tape Measure or ruler
Measure any deviation and compare to the
• 24 in. Framing Square number calculated in step 2 for length of
• 4 ft. Level blade.
4. Place a straight edge on the shank of the
Do the following when performing Scheduled fork, 2 in. away from the heel of the fork.
Maintenance. Measure any deviation and compare to the
number calculated in step 2 for height of
Surface Inspection shank.
5. If either maximum deviation is exceeded,
Remove the forks from the carriage. Visually remove the fork from service.
inspect all fork surfaces for signs of damage,
including, but not limited to:
Fork Angle
• cracks
NOTE: This measurement can be done with the
• excessive wear
forks on or removed from the carriage.
• excessive heat
1. Place the fork caliper on the blade. Make
• deformation sure that the two extruded points are
• unauthorized modifications touching the blade of the fork. See
Figure 4-3.
Pay special attention to the heel and welds 2. Now open and move the caliper so the two
attaching mounting components. If any damage extruded points are touching the shank.
is found, remove the fork from service. See Figure 4-3.
Figure 4-3. Fork Angle
Straightness of Blade and
Shank Shank
NOTE: This measurement can be done with the
forks on or removed from the carriage.
1. Measure the length of the blade and the
height of the shank. See Figure 4-2.
Figure 4-2. Measuring Fork Blade and Shank
Indicator
Lines
Blade
Shank
Blade

Fork Inspection
3. When all four extruded points are in Figure 4-4. Measuring Fork Tip Height
contact with the fork, gently remove the Forks
caliper and note the reading on the
indicator line, located right above the
hinge pin. See Figure 4-3.
4. If the deviation is greater than 3° of the
original angle, remove the fork from
service.
Distance
NOTE: Most forks are manufactured with a 90° from tip
angle; therefore, a reading greater than Level of fork
93° or less than 87° is unacceptable.
However, there are some forks that are
purposely manufactured to angles
greater than or less than 90°.
Fork Tip Height Tips

1. With truck parked on a level surface and 6. Compare this measurement to the
forks on the carriage, measure the length maximum deviation.
of the blade. See Figure 4-2.
7. If the maximum deviation number is
• For forks 42 in. (106.7 cm) or less, max. exceeded, remove the fork from service.
deviation is 0.25 in. (6.3 mm).
• If length of fork is >42 in. (106.7 cm),
multiply length of blade by 0.03.
Positioning Locks (if applicable)
Blade length _____in. x 0.03 = _____in. 1. With the forks on the carriage, visually
This is the maximum deviation. inspect the positioning locks for damage.
2. Elevate forks approx. 4 ft. (1.2 m) off the 2. Test the positioning locks to verify they
floor. work correctly.
3. Place a 4 ft. level across the tips of the 3. If the positioning locks are damaged or do
forks. See Figure 4-4. not work correctly, remove the fork from
4. Raise one end of the level to make it level. service.
See Figure 4-4.
5. Measure the distance from the tip of the Wear
fork. See Figure 4-4.
Fork Blade and Shank
1. Remove the forks from the carriage.
2. Approximately half way up the shank, set
the front teeth of the jaws of the caliper on
the shank. Make sure the caliper is held
square across the shank to get an
accurate reading. The caliper is now set to
measure fork blade wear. Carefully remove
the caliper from the shank. See Figure 4-5.

Fork Inspection
Figure 4-5. Measuring Fork Shank
If there is greater than 10% wear of the

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

up to 4 in. (100 mm). It is not to be used
on full or lumber tapered forks. For
these forks, you must know the original
fork blade thickness and take a
measurement of the fork arm thickness.
If the difference in the measurement
exceeds 10% of the original thickness,
the fork must be removed from service.
3. Measure 2 in. (50 mm) out from the heel of

the fork.
Fork Hooks
4. Place the caliper over the flanks of the fork 1. Remove the forks from the carriage.
arm blade at this 2 in. (50 mm) point. See 2. Determine the fork mounting class.
Figure 4-6.
a. Measure the height of the carriage or
Figure 4-6. Measuring Fork Blade Wear the distance between the hooks. See
Figure 4-7.
Figure 4-7. Determining Fork Mounting Class
Distance between hooks
Carriage Height
b. Compare this measurement to the table

below.
Fork Distance Carriage

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

caliper for the fork mounting class. See
Figure 4-8.

Fork Inspection
4. Slide the extruded edge up into the fork

pocket. See Figure 4-8.
5. If the caliper’s extruded edge completely
slides up into the fork pocket, remove the
fork from service. See Figure 4-8.
Figure 4-8. 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.

Fork Inspection

Model 4700 Maintenance Manual Section 5. Troubleshooting
Section 5. Troubleshooting

Section 5. Troubleshooting Model 4700 Maintenance Manual
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 will
Shorts to frame may be metallic connections,
prevent accidents caused by unexpected
such as a wire conductor contacting metal
lift 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 circuits 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

Shorts to Frame Test damaged if you proceed before correcting

this condition.
1. Turn the key switch OFF and disconnect
the battery connector. a. To identify the cause of the short to
frame, disconnect circuit components
2. To test the battery for shorts to case, until the low resistance condition
connect a 12V test light to the battery case disappears. Do not reconnect
from battery B+, and then to the battery components one at a time, but leave
case from battery B–. If the light them disconnected until the low
illuminates at all, even momentarily, there resistance reading disappears. Prevent
is a serious problem with the battery, disconnected terminals or connectors
either external contamination or internal from touching the lift truck frame or
damage. Do not continue until this condition other conductive surfaces.
is corrected. The meter may be damaged if
you proceed before correcting this The most likely areas to check are:
condition.
• Motors
Install another battery in the truck and • Heatsinks
repeat this procedure from Step 1. • Power cables
If the test light does not illuminate, • Power circuit components

continue to the next step. • Control circuit components
3. Use a DMM set on the ampere function to b. Repair or replace the component
measure the current leakage from the causing the low resistance condition.
battery case to battery B+ and from the Repeat Step 4.
battery case to battery B–. Begin
c. 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.
d. When, after all components are
Install another battery in the lift truck and reconnected, you get readings greater
repeat this procedure from Step 1. than 1000 ohms, continue with the
next step.
If the current is <0.0002A (0.2mA), go to 5. Reconnect the battery connector and turn
Step 4. If the current is greater than the key switch ON. If the battery was
0.0002A (0.2mA) and <0.001A (1mA), previously removed, make sure the battery
remove the battery from the truck, then case does not touch the lift truck frame.
continue with Step 4. Make sure the
battery case does not touch the truck NOTE: The functions being checked must be
frame during the remaining tests. energized. Example: to check for shorts
to frame in the travel circuit, travel must
4. With the battery disconnected (or removed be requested.
and disconnected) from the truck, use a
DMM to measure the resistance from lift 6. Use a DMM set to the current function to
truck frame to truck B+, to truck B– (not measure current leakage to the truck
battery B+ and B–), and to all fuses and frame from B+, B–, and all fuses and DC
motors. A reading of <1000 ohms indicates motor terminals. Begin measuring at the
a serious short. Do not continue until this highest ampere scale and work toward the
condition is corrected. The meter may be lowest. If the current is <0.001A (1mA), go
to step 7. If the current is more than

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.
The most likely areas to check are:

Fuses
• Motors
Test/Inspection
• Heatsinks
• Power cables Examine the fuse for signs of overheating,
discoloration, cracking, or other physical
• Power circuit components
damage. Replace the fuse if you find any of
• Control circuit components these conditions. To test a fuse, remove it from
b. Repair or replace the component(s) the lift truck. The resistance should be <1 ohm.
causing the leakage current. Refer to Table 5-1 for fuse locations.
Repeat Step 6. NOTE: The DC/DC Converter on earlier trucks
c. Reconnect all other components has a 12A fuse located on the end
previously disconnected, measuring opposite the connector.
Table 5-1. Fuse Location
Fuse Rating Location Function

FT 400A B+ to the Traction Power Amp
Traction Power Amp
*500A
FP 400A B+ to the Pump Power Amp
Pump Power Amp
**500A
F1 10A B+ to Key Switch
F2 20A B+ to the DC/DC Converter
Main Fuse Panel
F3 10A B+ to opt. Hydraulic Control Board (HCB)
F4 5A B+ for opt. equipment

Fuse Rating Location Function

F5 5A +24V to Motor Drivers Cooling Fan
F6 5A +24V to Horn
F7 4A Not Used
F8 +24V for opt. Lift-Limit Bypass
4A
*+24V for opt. Warning Light (>S/N 10676)
F9 0.5A Not Used
F10 +24V to opt. Travel Alarm
4A
+24V Fuse Panel *+24V for opt. Rear Work Lights (>S/N 10676)
F11 +24V to opt. Warning Light
4A
*+24V for opt. Forward Work Lights (>S/N 10676)
F12 +24V to opt. Forward Work Lights
4A
*+24V for opt. Bottler’s Tilt (>S/N 10676)
F13 +24V to opt. Rear Work Lights
4A
*+24V for opt. Travel Alarm (>S/N 10676)
F14 0.5A +24V to Operator Display and opt. Armrest Board
F15 4A +24V for opt. Fingertip Control - Lift/Lower
F16 4A +24V for opt. Fingertip Control - Tilt
F17 4A Fuse Panel on +24V for opt. Fingertip Control - Sideshift
armrest bracket
F18 4A near HCB +24V for opt. Fingertip Control - 4th Aux
F19 4A Not Used
F20 4A
F21 Fuse Panel on +24V for Drain Solenoid
4A armrest bracket
near HCB
F22 4A *+24V for opt. Lift/Lower Limit Solenoid
+24V Fuse Panel
F23 4A *+24V for opt. Tilt Limit Solenoid
* = Single Traction Motor Truck
** = Single Traction Motor Truck with AC-3 Pump Power Amplifier

Motor Troubleshooting
AC motors used on this truck are brushless,
3-phase, internally delta-connected, variable
speed motors.
The AC motor has a rotor (in place of the DC

armature) and a stator (in place of the DC field).
There is no electrical connection to the rotor;
current is induced in the rotor. The stator has
three windings staggered 120° apart, and three
external connections labeled U, V, and W. See
Figure 5-1.
Figure 5-1. Traction Motor Circuits
AC
3φ
V W
Open Winding
If the AC motor fails with an open winding, the

motor will move unevenly, as if hunting, and
there will be a ticking sound. Rotation is much
slower than normal.
Using a clamping ammeter, measure current in

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

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

each of the motor power cables. The shorted
phase will read significantly higher than the
other two phases.

Wiring Figure 5-2. Molex Jack and Pin Connector
Pin Identifier Lines

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

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

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

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

cable harnesses. Avoid attaching cables to
hydraulic hoses that expand with pressure,
pinching the attached electrical cables.
Use a DMM to check for wiring continuity.
Electrical Connections
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 5-2.

Connector Locator Tables

Table 5-2. Connector Chart
* = Dual Traction Motor Trucks

** = Single Traction Motor Trucks S/N <10677
*** = Single Traction Motor Trucks S/N >10676
Connector Truck Location Function/Destination
JAM HCB (Not Used)
JAP Pump Power Amplifier *(Not Used)
JAT Traction Power Amplifier *CAN-Bus Connector for TPA
***Connector for C60 and EE Configuration
JBP Pump Power Amplifier *Pump Motor Configuration jumper
***Main Connector for PPA
JBT Traction Power Amplifier *(Not Used)
***(Not Used)
JCM HCB Connector for Solenoids from HCB
JCP Pump Power Amplifier *CAN-Bus Connector for PPA
***CAN-Bus Connector for PPA
JCT Traction Power Amplifier *Main Connector for TPA
***CAN-Bus Connector for PPA
JDP Pump Power Amplifier *Connector for Lift Motor Encoder
***Configuration Jumper
JDT Traction Power Amplifier ***(Not Used)
JEP Pump Power Amplifier *Pump Motor Configuration jumper
Traction Power Amplifier ***Connector for Pump Motor Encoder
JET Traction Power Amplifier ***Connector for Traction Motor Encoder
JFP Pump Power Amplifier *Main Connector for PPA
JP2 Pump Power Amplifier **Configuration Jumper
JP4 **CAN-Bus Connector for PPA
JP6 **Connector for Pump Motor Encoder
JP8 **(Not Used)
JP12 **Main Connector for PPA
JP14 **(Not Used)
JT2 Traction Power Amplifier **(Not Used)
JT4 **CAN-Bus Connector for TPA
JT6 **Connector for Traction Motor Encoder
JT8 **(Not Used)
JT12 **Main Connector for TPA
JT14 **(Not Used)
J1+/– Near Battery Battery Connector


J4 Brake Fluid Reservoir Connector for Low Brake Fluid Sensor (SW3)
J8 Steering Column Connector for Horn Push Button switch (PB4)
J9 Connector for Key switch (SW1)
J11 Under floor board near Horn Connector for Horn (HR1)
J13 Near Pump Motor Connector for Pump Motor encoder (EN3) and temp
switch (TS3)
J14 Near Steer Pot Connector for Steer Pot (P1)
J15 Near Right Traction Motor Connector for Right Traction Motor encoder (EN1) and
temperature switch (TS1)
J16 Near Left Traction Motor Connector for Left Traction Motor encoder (EN2) and
temperature switch (TS2)
J20 Near Battery Connector Intermediate Connector for Seat switch (SW2)
J21 Front Cover Connector for Emergency Disconnect (PB1)
J22 Front side of Front Cover Intermediate Connector for Seat switch (SW2)
J23 Near Battery Gate Connector for Battery Gate Interlock switch
J30 Front side of Front Cover Connector for Parking Brake switch (SW7)
J31 Under floor board near Connector for Brake Pedal switch (SW6)
switch
J32 Connector for Travel Pot (P2) and Travel Enable switch (SW8)
J33 Connector for Forward Pedal (SW4) and Reverse Pedal (SW5)
switches (Dual Pedal System)
J34 Front Cover (large VM Connector to Vehicle Manager
connector)
J35 Front side of Front Cover Intermediate Connector for various switches
J36 Steering Column Connector for LPH switch (PB3)
J37 Connector for Speed Reduction switch (PB2)
J39 Connector for Forward Hand Direction switch (SW9) and
Backward Hand Direction switch (SW10)
J40 Front Cover (small VM Connector to Vehicle Manager
connector)
J41 Near Valves Connector for Lift Pot (P3)
J42 Connector for Lift switch (SW11)
J43 Connector for Tilt switch (SW12)
J44 Connector for Sideshift switch (SW13)
J45 Connector for 4th Function switch (SW14)
J46 Not Used
J47 Near Valves Connector for Lowering switch (SW15)
J48 Under floor board Intermediate Connector for Hydraulic Functions
J49 Not Used


J50 Under Battery Connector Intermediate Power Connector from Battery
J52 Under floor board Connector for B+ to DC/DC converter and other components
J60 Near HCB Intermediate Connector for Hydraulic Solenoids from HCB
J61
J70+/– Under rear plastic cover, Connector for opt. Travel Alarm (BZ1)
above lift motor
J71 Front of Fan Connector for Power Amp Fan (FN1)
J80 HCB Connector for B– to HCB
J90 24V Fuse Panel Intermediate Connector for 24V
J91 Left rear under Amps Connector for Left Brake and Tail Lights
J92 Front side of Front Cover Intermediate Connector for opt. Forward Right Working Light
(LP6)
J93 Intermediate Connector for opt. lights
J94 Front Cover Connector for opt. Backward Work Lights switch (SW29)
J95 Connector for opt. Warning Lamp switch (SW27)
J96 Under floor board Connector for DC/DC converter
J97 Front Cover Connector for opt. Warning Light (LP5)
J98 Near Valves Connector for Lift-Limit Bypass valve (EV12)
J99 Front Cover Connector for opt. Forward Work Lights switch (SW28)
J100 Front side of Front Cover Connector for Auxiliary Power strip
J101 Front Cover Connector for opt. Lift-Limit Push Button switch (PB9)
J102 Right rear Connector for Right Brake and Tail Lights
J103 At Light Connector for opt. Forward Right Work Light (LP6)
J104 Connector for opt. Forward Left Work Light (LP7)
J105 Connector for opt. Backward Left Work Light (LP9)
J106 Connector for opt. Backward Right Work Light (LP8)
J107 Near Valves Connector for Lowering Solenoid (EVP1)
J108 Connector for Lifting Solenoid (EV2)
J109 Connector for Tilt Forward Solenoid (EV3)
J110 Near Valves Connector for Tilt Backward Solenoid (EV4)
J111 Connector for Left Sideshift Solenoid (EV5)
J112 Connector for Right Sideshift Solenoid (EV6)
J113 Connector for 4th Function Solenoid (EV7)
J114
J117 Connector for Drain Solenoid (EVP)
J118 Not Used


J119 Near Valves Connector for Lift/Lower Limit Solenoid (EV12)
J131 Near Battery Connector Intermediate Connector for opt. Armrest Board
J132 Right side Front Cover Connector for CAN-Bus Interface
J137 Connector for Operator Display
J138 Bottom of Armrest Board Intermediate Connector for opt. Armrest Board
J139 Armrest Board Connector for opt. Armrest Board
J140 HCB Main Connector for HCB
J400 Armrest Board Connector for Lift/Lower switches (SW17 and SW18) and
Pot (P4)
J401 Connector for Tilt switches (SW19 and SW20) and Pot (P5)
J402 Connector for Sideshift switches (SW21 and SW22) and
Pot (P6)
J403 Connector for 4th Aux switches (SW23 and SW24) and Pot (P7)
J404 Not Used
J405 Armrest Board Connector for Horn (PB12) and opt. switches
J406 Connector for Lift/Lower switches (SW17 and SW18) and
Pot (P4)
J407 Connector for Tilt switches (SW19 and SW20) and Pot (P5)
J408 Connector for Sideshift switches (SW21 and SW22) and
Pot (P6)
J409 Connector for 4th Aux switches (SW23 and SW24) and Pot (P7)
J411 Connector for Horn switch (PB12)
J412 thru Not Used
414
PPA B+ Pump Power Amplifier Connector for B+ to PPA
PPA B– Connector for B– to PPA
PPA (U) Connector for 1 of 3 AC outputs to Pump Motor
PPA (V)
PPA (W)


TPA B+ Traction Power Amplifier Connector for B+ to TPA
TPA B– Connector for B– to TPA
TPA (U) Connector for 1 of 3 AC outputs to Traction Motor
TPA (V)
TPA (W)
TPA (UM) Connector for 1 of 3 AC outputs to Right Traction Motor
TPA (VM)
TPA (WM)
TPA (US) Connector for 1 of 3 AC outputs to Left Traction Motor
TPA (VS)
TPA (WS)

Hydraulic Troubleshooting Guidelines
Hydraulic
Troubleshooting
Guidelines
After elevating the carriage for

troubleshooting, make sure to 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 center the

sideshift.
Stabilize the top of the mast with an overhead

chain hoist.
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.

Symptom Tables: Travel Functions
Symptom Tables:
Travel Functions
Reference electrical schematics.
Refer to the Theory of Operation “Pinout Matrix”

on page 8-14 for troubleshooting individual
conductors or components.
Dead Truck
Condition Cause/Action
No Display • Low or bad battery
• Check EPO.
• Check B– to TPA.
• Check key switch circuit.
• Check DC/DC converter per Pinout Matrix.
• Check 24V per Pinout Matrix.
Display Working Follow the codes displayed.
Slow or Sluggish Acceleration, Normal Lift

Mechanical • Debris in the wheel hub, axle, or steer tire assembly
• Check adjustment of the parking brake.
• Check the drive motor shaft and bearings.
Electrical • Verify TPA setting using FlashWare.
• Check steer pot.
• Check motor encoders.
• Replace TPA.

Symptom Tables: Hydraulic Functions
Symptom Tables:
Hydraulic Functions
If hydraulic fluid contamination is suspected,
flush the hydraulic system and fill with new
fluid. See “Hydraulic Fluid” on page 7-60.
No Hydraulic Functions - Travel OK

Pump Motor Runs Check pump discharge pressure.
Pump Motor Does Not • Verify power cables and connections to the lift motor.
Run • Verify current to the lift motor:
• If all phases are approx. equal, replace lift motor.
• If one phase is significantly higher or lower than the other two or if all phases
are absent, replace PPA.
No Lift or Aux Functions - Steering and Travel OK

Pump Motor Runs • Check for fluid pressure on the Load Sensing hose at the steer orbitrol.
• Check the hydraulic circuit between the priority valve and the control valve
assembly.
• Replace the priority valve.
• Lever Controls - inspect “check valve” in lever assembly for contamination.
• Fingertip Controls - check +V from HCB to solenoids.
Pump Motor Does Not • Lever Controls - check for the presence of B– at J48-6.
Run • Fingertip Controls - check for the presence of B+ at J48-12 and B– at J48-14.
No or Sluggish Steering - All Other Hydraulic Functions OK and

Travel OK
Pump Motor Runs Check steer pressure. Replace the priority valve.

Symptom Tables: Hydraulic Functions
Individual Hydraulic Function Not Working; Other Auxiliary

Functions OK - Steering and Travel OK
Pump Motor Does Not Lever or Fingertip Controls:
Run When Individual • Check output voltage from the appropriate switch while requesting function per
Aux Function the Pinout Matrix.
Requested • Check valve for mechanical binding or contamination.
Fingertip Controls Only:
• Check output voltage from appropriate potentiometer while requesting function
per the Pinout Matrix.
• Check output voltage to the appropriate solenoid while requesting function per
the Pinout Matrix.
Slow Lift, Normal Lower - All Other Hydraulic Functions OK

System NOT in Bypass • Check lift pressure.
• Fingertip Controls - check EV2 for correct operation/contamination.
• Verify lift pot voltage per Pinout Matrix. Learn lift pot.
• Check lift settings in FlashWare.
System in Bypass • Fingertip Controls - check EVP1.
• Check mast for binding.
• Check flow control V1.
• Check spool valve for contamination.
No or Slow Lower
Bad Flow Control Check the lift flow control for contamination, wear, or damage.
Bad EV14 Check EV14 (Lower Blocking Valve) per Pinout Matrix.
Load Drift on Quad Mast

Quad Mast cylinder Inspect Quad Mast check valves. See “Check Valve Inspection” on page 7-65.
check valve(s) may be
loose

Model 4700 Maintenance Manual Section 6. Messages and Codes
Section 6. Messages and Codes

Section 6. Messages and Codes Model 4700 Maintenance Manual
Operator Display Messages
Operator Display Figure 6-1. Operator Display
Messages 1 2 3 4 5 6 7
When the key switch is turned ON, the

Operator Display cycles all of the indicator
icons/lights.
Refer to Figure 6-1 and Table 6-1 for the icons

present on the Operator Display and their
function or meaning.
8 9 10 11 12 13 14
Table 6-1. Operator Display Icons and Definitions
Item Icon Description Function

1 Battery Charge With the battery fully charged, the right green LED is
Indicator illuminated. As the battery discharges, the LEDs
illuminate from right to left. When the battery has
discharged to within 10% of the configured cutback
setting, the first red LED is illuminated and the Lift
+ Reduction icon (5) begins to blink. This represents that
the battery is in reserve and must be recharged. When
the battery has discharged to the configured cutback
setting, the first red LED will blink and the Lift
Reduction icon is illuminated.
2 Dual Traction Motor Illuminates when the motor temperature has exceeded
Trucks - Left Traction 266°F/130°C (36V); 248°F/120°C (48V).
Motor overtemperature
icon
Single Traction Motor
Trucks - Traction Motor
overtemperature icon
3 Parking Brake icon Illuminates when the parking brake is ON.
P
4 Brake Fluid Low icon Illuminates when the level of brake fluid in the reservoir
has fallen below the minimum level.
5 Lift Reduction icon Blinks when the battery has discharged to within 10% of
the configured cutback setting. Illuminates when the
battery has discharged to the configured cutback
setting, indicating lift speed is reduced.
6 Seat icon Illuminates when:
• operator leaves the seat without turning the Key
switch OFF
• optional battery gate switches are open
Travel is disabled.

Operator Display Messages
Item Icon Description Function

7 Steer direction indicator Indicates steer direction.
(present on Dual
Traction Motor Trucks
only)
8 Electronic hour meter The hour meter provides readings in hours and tenths of
an hour. It is activated when the pump is activated.
9 Alphanumeric error Displays error codes.

code display
10 Performance mode Identifies which performance mode is selected:

L P H indicator • L = low performance
• P = medium performance
• H = high performance
11 Performance reduction Illuminates when the performance reduction function is
(turtle) icon active.
12 Pump motor Illuminates when the motor temperature has exceeded

overtemperature icon 266°F/130°C (36V); 248°F/120°C (48V).
13 Right traction motor Illuminates when the motor temperature has exceeded
overtemperature icon 266°F/130°C (36V); 248°F/120°C (48V).
(present on Dual
Traction Motor Trucks
only)
14 Travel direction icon Indicates the direction of travel selected.

Fault Codes
Fault Codes Check communication wires between all

modules for continuity and shorts to frame per
Pinout Matrix. If OK, replace affected manager.
Intermittent Codes NOTE: The Operator’s Display is a read-only
device. “d-series” codes indicate that the
If a code appears intermittently, check for display is not receiving communication
shorts to frame. Refer to Shorts to Frame on from one or more managers. Check
page 5-2. Check or install static strap. communication lines between the
display and affected manager(s). Check
Multiple Codes for communication codes between
affected manager(s) and other
If multiple codes are displayed, compare all managers.
codes to determine if they have anything in
common. Examine the functions of the truck –
what works and what does not. Compare the
codes with truck functions to determine the
best starting point for troubleshooting. This will
help avoid replacement of parts that do not
resolve the issue.
A code can be displayed and then another

seemingly unrelated code will follow. Codes are
generated by multiple managers. The first code
displayed does not necessarily mean it is more
significant than subsequently displayed codes.
In some cases, it is possible for codes to be

displayed that should not be displayed on the
truck (option not on truck, truck specific code
not for this truck). This can be caused by a bad
TPA, PPA, VM, Armrest Board, or Hydraulic
Control Board, shorts to frame, or swapping
parts. If an invalid code is displayed, use
FlashWare to determine if the truck’s identity or
options have been changed.
Communication Codes
Check power to all managers. This includes the
TPA, PPA, VM, Armrest Board, and Hydraulic
Control Board.
Using FlashWare, determine if the truck

identity or options have been changed. Look for
software model versions that are either
incorrect or missing. If a manager is not able to
communicate with FlashWare this can help
identify where to start looking for problems.

Fault Codes
Code Summary List
Code 01: Master TPA Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Code 05: Battery Sense Out-of-Range/Master TPA . . . . . . . . . . . . . . . 6-9
Code 06: Short in Master TPA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Code 07: Open in Master TPA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Code 08: Traction Contactor Open When Commanded Closed . . . . . 6-10
Code 09: Master TPA Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Code 10: Master TPA Precharge Failure . . . . . . . . . . . . . . . . . . . . . . 6-10
Code 11: Master TPA Overtemperature . . . . . . . . . . . . . . . . . . . . . . 6-10
Code 12: Right Traction Motor Temperature Out-of-Range . . . . . . . . 6-10
Code 13: Right Traction Motor Encoder Error . . . . . . . . . . . . . . . . . 6-10
Code 14: Master TPA Temperature Sensor Out-of Range . . . . . . . . . 6-10
Code 15: Amplifier Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Code 16: Master TPA Detected CAN-Bus Error . . . . . . . . . . . . . . . . . 6-11
Code 17: CAN-Bus Node Offline . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Code 18: Relay 1 Not Energized By TPA . . . . . . . . . . . . . . . . . . . . . . 6-11
Code 19: Traction Contactor Driver Shorted . . . . . . . . . . . . . . . . . . . 6-11
Code 1A: Slave TPA Not Responding . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Code 1C: Battery Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Code 1E: Traction Contactor Closed When Commanded Open . . . . . 6-12
Code 20: Traction Contactor Coil Driver Error . . . . . . . . . . . . . . . . . 6-12
Code 21: Traction Contactor Coil Shorted . . . . . . . . . . . . . . . . . . . . 6-12
Code 22: Steer Pot Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Code 23: Seat Switch Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Code 25: Incorrect Battery Installed . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Code 26: Incorrect Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Code 28: Steer Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Code 29: Requesting Travel In Both Directions . . . . . . . . . . . . . . . . 6-13
Code 2A: Master TPA Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Code 2C: Master TPA Parameter Restore Error . . . . . . . . . . . . . . . . . 6-13
Code 2E: Parking Brake Switch Error . . . . . . . . . . . . . . . . . . . . . . . 6-13
Code 31: PPA Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Code 35: Battery Sense Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 36: Short in PPA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 37: Open in PPA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 38: Pump Contactor Open When Commanded Closed . . . . . . . 6-14
Code 40: PPA Precharge Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 41: PPA Overtemperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Code 42: Pump Motor Temperature Out-of-Range . . . . . . . . . . . . . . 6-15
Code 43: Pump Motor Encoder Error . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Code 44: PPA Temperature Sensor Out-of Range . . . . . . . . . . . . . . . 6-15
Code 45: Amplifier Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Fault Codes
Code 46: PPA Detected CAN-Bus Error . . . . . . . . . . . . . . . . . . . ... 6-15

Code 47: CAN-Bus Node Offline . . . . . . . . . . . . . . . . . . . . . . . . . ... 6-15
Code 48: CT2 Contactor Open When Commanded Closed . . . . . ... 6-16
Code 49: Pump Contactor Driver Shorted . . . . . . . . . . . . . . . . . ... 6-16
Code 4C: Battery Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 6-16
Code 4E: Pump Contactor Closed When Commanded Open . . . . ... 6-16
Code 50: Pump Contactor Coil Driver Error . . . . . . . . . . . . . . . . ... 6-16
Code 51: Pump Contactor Coil Shorted . . . . . . . . . . . . . . . . . . . ... 6-16
Code 53: Seat Switch Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 6-16
Code 55: Incorrect Battery Installed . . . . . . . . . . . . . . . . . . . . . ... 6-16
Code 56: Incorrect Start Up Sequence . . . . . . . . . . . . . . . . . . . . ... 6-17
Code 57: Hydraulic Control Board Time-Out . . . . . . . . . . . . . . . ... 6-17
Code 58: PPA Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 6-17
Code 5A: PPA Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 6-17
Code 5C: PPA Parameter Restore Error . . . . . . . . . . . . . . . . . . . ... 6-17
Code 61: Slave TPA Internal Fault . . . . . . . . . . . . . . . . . . . . . . . ... 6-17
Code 65: Slave TPA Detected Battery Sense Out-of-Range . . . . . ... 6-18
Code 66: Short in Slave TPA . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 6-18
Code 67: Open in Slave TPA . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 6-18
Code 68: Traction Contactor Open When Commanded Closed . . ... 6-18
Code 70: Slave TPA Precharge Failure . . . . . . . . . . . . . . . . . . . . ... 6-18
Code 71: Slave TPA Over Temperature . . . . . . . . . . . . . . . . . . . . ... 6-19
Code 72: Left Traction Motor Temperature Out-of-Range . . . . . . ... 6-19
Code 73: Left Traction Motor Encoder Error . . . . . . . . . . . . . . . ... 6-19
Code 74: Slave TPA Temperature Sensor Out-of Range . . . . . . . ... 6-19
Code 76: Slave TPA Detected CAN-Bus Error . . . . . . . . . . . . . . . ... 6-19
Code 77: Slave TPA CAN-Bus Node Offline . . . . . . . . . . . . . . . . . ... 6-19
Code 79: Traction Contactor Driver Shorted . . . . . . . . . . . . . . . ... 6-19
Code 7A: Master KO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 6-20
Code 7C: Slave TPA Internal Fault . . . . . . . . . . . . . . . . . . . . . . . ... 6-20
Code 80: Traction Contactor Coil Driver Error . . . . . . . . . . . . . . ... 6-20
Code 81: Directional Microswitch Closed . . . . . . . . . . . . . . . . . . ... 6-20
Code 83: Traction Pot Open Circuit . . . . . . . . . . . . . . . . . . . . . . ... 6-20
Code 84: Travel Enable Switch Failure . . . . . . . . . . . . . . . . . . . ... 6-20
Code 85: Warning Configuration Error . . . . . . . . . . . . . . . . . . . ... 6-20
Code 86: Traction Potentiometer Out-of-Range . . . . . . . . . . . . . ... 6-21
Code 87: Seat/Battery Gate Interlock Switch Open . . . . . . . . . . ... 6-21
Code 89: Parking Brake Switch Error . . . . . . . . . . . . . . . . . . . . ... 6-21
Code 8A: VM Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 6-21
Code 8B: TPA Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 6-21
Code 8C: TPA Communication Error . . . . . . . . . . . . . . . . . . . . . ... 6-21
Code 8D: Lift Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 6-21
Code 8E: Bottler’s Tilt Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 6-22
Code 8F: Requesting Travel In Both Directions . . . . . . . . . . . . . ... 6-22
Code 91: Configuration Error . . . . . . . . . . . . . . . . . . . . . . . . . . ... 6-22
Code 92: Communication Error Detected By The VM . . . . . . . . . ... 6-22
Code 93: Communication Error Detected By The VM . . . . . . . . . ... 6-22
Code 94: Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 6-22

Fault Codes
Code 96: VM Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

Code 97: Jumper Configuration Error . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code A1: Hydraulic Control Board Internal Fault . . . . . . . . . . . . . . . 6-23
Code A2: Solenoid Valve Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code A3: CAN-Bus Error Detected By Hydraulic Control Board . . . . 6-23
Code A4: Internal Hydraulic Control Board Fault . . . . . . . . . . . . . . . 6-23
Code AA: Incorrect Battery Installed . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Code AB: Hydraulic Control Board Driver Fault . . . . . . . . . . . . . . . . 6-24
Code AC: Solenoid Group 1 Driver Error . . . . . . . . . . . . . . . . . . . . . 6-24
Code AD: Solenoid Group 2 Driver Error . . . . . . . . . . . . . . . . . . . . . 6-24
Code AE: Solenoid Group 3 Driver Error . . . . . . . . . . . . . . . . . . . . . 6-25
Code AF: Solenoid Group 4 Driver Error . . . . . . . . . . . . . . . . . . . . . 6-25
Code B0: Coil Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Code B1: Hydraulic Control Board Power Supply Failure . . . . . . . . . 6-25
Code B2: EVP Driver KO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Code B3: EV11 Driver KO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Code B4: Internal Hydraulic Control Board Fault . . . . . . . . . . . . . . . 6-25
Code B5: EVP Driver Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Code C1: Open in Brake Light Circuit . . . . . . . . . . . . . . . . . . . . . . . 6-26
Code C2: Open in Fore or Aft Working Light Circuits . . . . . . . . . . . . 6-26
Code C3: Open in Fore/Aft Working Light or Brake Light Circuits . . 6-26
Code C4: Open in Tail Light Circuits . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Code C5: Open in Brake or Tail Light Circuits . . . . . . . . . . . . . . . . . 6-26
Code C8: Option. Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Code d.1: TPA Power Supply or CAN-Bus Failure . . . . . . . . . . . . . . . 6-26
Code d.2: VM Power Supply or CAN-Bus Failure . . . . . . . . . . . . . . . 6-26
Code d.3: d.1 + d.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Code d.4: PPA Power Supply or CAN-Bus Failure . . . . . . . . . . . . . . . 6-27
Code d.5: d.1 + d.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Code d.6: d.4 + d.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Code d.7: d.4 + d.2 + d.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Code d.8: Armrest Board Power Supply or CAN-Bus Failure . . . . . . 6-27
Code d.A: d.8 + d.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Code d.A: d.8 + d.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Code d.B: d.8 + d.2 + d.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Code d.C: d.8 + d.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Code d.d: d.8 + d.4 + d.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Code d.E: d.8 + d.4 + d.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Code d.F: d.8 + d.4 + d.2 + d.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Code E1: Incorrect Start Procedure for the Armrest Board or Levers 6-28
Code E2: Lift Potentiometer (Lever Control) Out-of-Range . . . . . . . . 6-28
Code E3: Tilt Potentiometer Out-of-Range . . . . . . . . . . . . . . . . . . . . 6-28
Code E4: Sideshift Potentiometer Out-of-Range . . . . . . . . . . . . . . . . 6-28
Code E5: 4th Function Potentiometer Out-of-Range . . . . . . . . . . . . . 6-29
Code E7: Armrest Board Warning . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Code E8: Armrest Board Internal Fault . . . . . . . . . . . . . . . . . . . . . . 6-29
Code E9: Armrest Board Internal Fault . . . . . . . . . . . . . . . . . . . . . . 6-29
Code EA: Hydraulic Control Board or PPA Error . . . . . . . . . . . . . . . 6-29

Fault Codes
Code EB: Armrest Board Internal Fault . . . . . . . . . . . . . . . . . . ... . 6-29

Code EC: Armrest Board Internal Fault . . . . . . . . . . . . . . . . . . ... . 6-29
Code ED: CAN-Bus Error Detected By Hydraulic Control Board .. . 6-29
Code EE: CAN-Bus Error Detected By PPA . . . . . . . . . . . . . . . ... . 6-30
Code EF: Requesting Travel In Both Directions . . . . . . . . . . . . ... . 6-30

Fault Codes
Refer to the “Pinout Matrix” located in Theory of Operation section for all voltage and resistance
values and component interconnection.
Code Description Notes/Corrective Action
01 Code 01: Master TPA Internal Fault Check voltage to TPA. If OK, replace the TPA.
The power amplifier has detected an Check communication wires between all modules for
internal fault. continuity and shorts to frame.
02 Code 02: Master TPA Internal Fault If code does not clear by cycling key, replace the TPA.
Fault in the area of memory in which If code clears, the adjustable parameters have been reset
the adjustment parameters are stored. to default values and require resetting to customer’s
requirements via FlashWare.
03 Code 03: Master TPA Internal Fault Check voltage to TPA.

The power amplifier has detected an If OK, replace the TPA.
internal fault.
04 Code 04: Master TPA Internal Fault Check motor cables for continuity. Check motor cable
The power amplifier has detected an connections for correct torque. Compare current from all
internal fault. 3 phases. If one phase is significantly higher or lower than
the other two, replace the motor. If OK, replace the TPA.
05 Code 05: Battery Sense Verify battery voltage. If wrong voltage, set correct voltage
Out-of-Range/Master TPA via FlashWare (and relearn pots) or install correct voltage
The TPA monitors battery voltage at battery.
B+Key. If voltage does not match If battery is correct but voltage is >63VDC, replace
configured voltage or is below set battery.
threshold, the code is displayed. The Test power cables to the motor for shorts to frame and
TPA also monitors the voltage on its other cables.
internal capacitors. If voltage goes Test the motor for shorts to frame. Resistance must be
above 63VDC, the code is displayed. >1 Meg ohm. If OK, replace the TPA.
06 Code 06: Short in Master TPA Measure voltage and resistance across coil. Check cables
When the Key switch is turned ON, the to the motor and TPA for continuity and correct torque.
TPA momentarily powers each motor Swap the connections from the TPA to the other traction
phase and monitors current. If current motor using appropriately sized jumper cables and turn
is seen when it should not be, this the Key switch ON. If code changes, replace the motor. If
code is displayed. the code is still displayed, replace the TPA.
07 Code 07: Open in Master TPA Check voltage to the TPA. Check cables to the motor and
When the Key switch is turned ON, the TPA for continuity and correct torque. Swap the
TPA monitors each motor phase for connections from the PPA and pump motor with the TPA
current draw. If current is not seen and traction motor using appropriately sized jumper
when it should be, this code is cables and turn the Key switch ON. If code changes,
displayed. replace the motor. If the code is still displayed, replace the
TPA.

Fault Codes
08 Code 08: Traction Contactor Open Inspect the contactor for physical binding and welded
When Commanded Closed tips. Check fuse for the TPA (FT). Measure voltage and
Correct voltage is not seen by the TPA resistance across coil. Check cables from battery to TPA
at +V when CT3 is commanded closed. for continuity and correct torque. If OK, replace the TPA.
09 Code 09: Master TPA Internal Fault Check power cables at the motor and TPA for continuity
Failure of the current sensor. and correct torque. Replace the TPA.
10 Code 10: Master TPA Precharge Check for B– at the TPA power input.
Failure Check for B+ from CT3 to the B+ connection on the TPA. If
When CT3 is closed, the TPA attempts not present, check the fuse for the TPA (FT).
to charge the internal capacitors. If the Measure voltage and resistance across CT3 coil.
capacitors are not charged to B+ in a If OK, replace the TPA.
certain amount of time, this code is
displayed.
11 Code 11: Master TPA Check fan for correct operation. Fan should operate
Overtemperature within about one minute after turning key ON. If not,
Internal temperature on the Master troubleshoot fan. Check/clean air filter. Allow TPA time to
TPA is >167°F (75°C). Performance is cool. If code clears, check cables to the motor and TPA for
reduced to 212°F (100°C); travel is continuity and correct torque. Check for brake drag. If
shut down above 212°F (100°C). code does not clear, replace the TPA.
12 Code 12: Right Traction Motor If motor temperature is <266°F (130°C), check wiring to
Temperature Out-of-Range switch.
Right traction motor overtemperature, If motor temperature is >266°F (130°C), compare current
above 266°F (130°C), or temperature across the 3 phases for excessive current draw per the
switch is bad. Pinout Matrix. Check drive unit for binding. If OK, replace
the TPA.
13 Code 13: Right Traction Motor Test the +12V and GND inputs to both encoders and the
Encoder Error output from channels A and B to the amp from both
Incorrect or no input seen by the encoders. Check resistor between 12V and Gnd. If OK,
Master TPA from the right traction check for shorts to frame. Check voltage to the TPA. If OK,
motor encoder. replace the TPA.
14 Code 14: Master TPA Temperature Check fan for correct operation. Fan should operate
Sensor Out-of Range within about one minute after turning Key switch ON. If
Temperature sensor has exceeded not, troubleshoot fan.
values expected. If OK, replace the TPA.

Fault Codes
15 Code 15: Amplifier Enable Check for B– at the TPA power input.
No B– input seen by the TPA. If OK, replace the TPA.
16 Code 16: Master TPA Detected Test battery voltage under load. Check for shorts to
CAN-Bus Error frame. Check voltage to TPA and PPA. Check
The Master TPA has not received a communication wires between all modules for continuity
communication message from the VM, and shorts to frame. Check both traction motor encoders.
HCB, or PPA. If OK, replace the TPA.
17 Code 17: CAN-Bus Node Offline Check power to TPA, PPA, and VM. Check cables to the
Too much time between motor(s) and TPA for continuity and correct torque. Check
communication from the VM and PPA both traction motor encoders, temperature sensors, and
to the TPA has elapsed. This code can connections. Check communication wires between VM,
also be caused by an open in a cable TPA, and PPA for continuity and shorts to frame. If OK,
from the amplifier to the traction replace the TPA.
motors.
18 Code 18: Relay 1 Not Energized By Check Relay 1 by disconnecting from circuit.
TPA Check output to Relay 1 from TPA.
The TPA commanded Relay 1 to If OK, replace Relay 1.
energize with truck configured for a If not OK, replace the TPA.
48V battery. Did not receive correct
feedback.
19 Code 19: Traction Contactor Driver Check the CT3 contactor for physical binding and welded
Shorted tips.
The TPA did not see a voltage drop Measure voltage and resistance across coil.
when the CT3 contactor was If OK, replace the TPA.
commanded closed.
1A Code 1A: Slave TPA Not Responding Verify connections to TPA.

No or low current is seen by the Slave Replace the TPA.
TPA's internal current sensor during
operation.
1C Code 1C: Battery Low Check battery voltage and specific gravity - static and
The voltage at the B+ Key input to the under load. Refer to battery manufacturer for correct
TPA is down to 10% of charge level voltage and specific gravity information.
(performance reduction). Current will If OK, replace the TPA.
be reduced to 50% of programmed
levels.

Fault Codes
1E Code 1E: Traction Contactor Closed Check the contactor for physical binding and welded tips.
When Commanded Open Measure voltage and resistance across coil. Check motors
The TPA commanded the CT3 for shorts from windings to case.
contactor open and the tips are still If OK, replace the TPA.
closed.
20 Code 20: Traction Contactor Coil Measure voltage and resistance across coil.
Driver Error If OK, replace the TPA.
Failure of the contactor driver.
21 Code 21: Traction Contactor Coil Check the contactor for physical binding and welded tips.
Shorted Measure voltage and resistance across coil.
The TPA did not see a voltage drop If OK, replace the TPA.
when the contactor was commanded
closed.
22 Code 22: Steer Pot Fault Learn steer pot.
23 Code 23: Seat Switch Open Troubleshoot seat switch, optional battery gate switches,
The seat switch or an optional battery and associated wiring.
gate switch opened during operation. If OK, replace the TPA.
25 Code 25: Incorrect Battery Installed Verify battery voltage. If wrong voltage, set correct voltage
When the Key switch is turned ON, the via FlashWare (and re-learn pots) or install correct voltage
TPA checks the battery voltage and battery.
compares it with the "SET BATTERY" If battery and parameter setting is OK, replace the TPA.
parameter setting. If the actual voltage
is 20% higher or lower than the set
value, this code is displayed.
26 Code 26: Incorrect Start Procedure If the directional switch is left in forward or reverse
General incorrect starting procedure. position when the operator leaves the seat, Code 81 is
May appear in conjunction with displayed after a brief time-out (approx. 30 sec). If the
Code 81. code still appears after lever is returned to neutral, cycle
the Key switch to clear. Test switches for correct
operation. Check continuity of wires from switches to
cards.

Fault Codes
28 Code 28: Steer Sensor Out-of-Range Check wires to the pot for opens or shorts. Check pot
The input voltage from the steer pot is supply and output voltage. Check pot mounting and
outside the required values. connection. Check for shorts to frame. Adjust pot to
approx. 5.5V with wheels straight. Run default Learn.
29 Code 29: Requesting Travel In Both Troubleshoot switches and wiring.

Directions If OK, replace the TPA.
Forward and Reverse switches are
closed at the same time.
2A Code 2A: Master TPA Internal Fault Verify connections to TPA.

Master TPA has an incorrect Replace the TPA.
configuration.
2C Code 2C: Master TPA Parameter Verify connections to TPA.

Restore Error Replace the TPA.
Internal failure of the Master TPA.
2E Code 2E: Parking Brake Switch Troubleshoot switch and wiring.

Error
SW7 is closed when travel is detected.
31 Code 31: PPA Internal Fault Check voltage to the PPA. Check communication wires
The power amplifier has detected an between PPA, TPA, and VM for continuity and shorts to
internal fault. frame. If OK, replace the PPA.
32 Code 32: PPA Internal Fault If code does not clear by cycling Key switch, replace the
Fault in the area of memory where the PPA. If code clears, the adjustable parameters have been
adjustable parameters are stored. reset to default values and require resetting to customer’s
33 Code 33: PPA Internal Fault Check voltage to the PPA.

Internal Failure of the PPA. If OK, replace the PPA.

Fault Codes
34 Code 34: PPA Internal Fault Check battery voltage and specific gravity - static and
Correct current draw by the motor is under load. Refer to battery manufacturer for correct
not seen by the PPA. voltage and specific gravity information. Check for shorts
to frame. Check voltage to the PPA. Check cables to the
motor for continuity and correct torque. Compare current
from all 3 phases. If one phase is significantly higher or
lower than the other two, replace the motor. If OK, replace
the PPA.
35 Code 35: Battery Sense Verify battery voltage. If wrong voltage, set correct voltage
Out-of-Range via FlashWare (and re-learn pots) or install correct voltage
The PPA monitors the battery voltage battery.
at B+Key. If voltage does not match Test the power cables to the motor for shorts to the truck
configured voltage or is below set frame and/or other cables.
threshold, this code is displayed. The Test the motor for shorts to frame. Resistance must be
PPA also monitors the voltage on its >1 Meg ohm.
internal capacitors. If voltage goes If OK, replace the PPA.
above 63VDC, this code is displayed.
36 Code 36: Short in PPA Check battery voltage and specific gravity - static and
When the Key switch is turned ON, the under load. Refer to battery manufacturer for correct
PPA momentarily powers each motor voltage and specific gravity information. Check for shorts
phase and monitors current. If no to frame. Measure voltage and resistance across CT2 coil.
current is seen, this code is displayed. Check cables to the motor and PPA for continuity and
correct torque. Swap the connections from the PPA and
pump motor with the TPA and traction motor using
appropriately sized jumper cables and turn the Key
switch ON. If code changes, replace the motor. If the code
is still displayed, replace the PPA.
37 Code 37: Open in PPA Check voltage to the PPA. Check cables to the motor and
When the Key switch is turned ON, the PPA for continuity and correct torque. Swap the
PPA monitors each motor phase for connections from the PPA and pump motor with the TPA
current draw. If current is seen when and traction motor using appropriately sized jumper
it should not be, this code is displayed. cables and turn the Key switch ON. If code changes,
replace the motor. If the code is still displayed, replace the
PPA.
38 Code 38: Pump Contactor Open Inspect the contactor for physical binding and welded
When Commanded Closed tips. Check fuse for the PPA (FP). Measure voltage and
Correct voltage is not seen by the PPA resistance across coil. Check cables from battery to PPA
at +V when CT2 is commanded closed. for continuity and correct torque. If OK, replace the PPA.

Fault Codes
39 Code 39: PPA Internal Fault Check cables to the motor and PPA for continuity and
Failure of the current sensor. correct torque. If OK, replace the PPA.
40 Code 40: PPA Precharge Failure Check for B– at the PPA power input.
When CT2 is closed, the PPA attempts Check for B+ from CT2 to the B+ connection on the PPA. If
to charge the internal capacitors. If the not present, check the fuse for the PPA (FP).
capacitors are not charged to B+ in a Measure voltage and resistance across CT2 coil.
certain amount of time, this code is If OK, replace the PPA.
displayed.
41 Code 41: PPA Overtemperature Check fan for correct operation. Fan should operate
Internal temperature of the PPA is within about one minute after turning Key switch ON. If
>167°F (75°C). Performance is reduced not, troubleshoot fan. Allow PPA time to cool. If code
to 212°F (100°C); travel and lift is shut clears, check cables to pump motor and PPA for
down above 212°F (100°C). continuity and correct torque. If code does not go away,
replace the PPA.
42 Code 42: Pump Motor Temperature If motor temperature is <266°F (130°C), check wiring to
Out-of-Range switch. If motor temperature is >266°F (130°C), compare
Pump motor overtemperature, >266°F current across the 3 phases for excessive current draw
(130°C), or temperature switch bad. per the Pinout Matrix. If OK, replace the PPA.
Note: Temperature is reported to VM in Single Traction
Motor Trucks.
43 Code 43: Pump Motor Encoder Error Test the +12V and GND inputs to the encoder and the
Incorrect or no input seen by the PPA output from channels A and B to amplifier.
from the pump motor encoder. This If OK, check for shorts to frame.
code can also be caused by a lack of Check voltage to PPA.
power to the PPA when there is a If OK, replace the PPA.
pump request.
44 Code 44: PPA Temperature Sensor Check fan for correct operation. Fan should operate
Out-of Range within approx. one minute after turning key ON. If not,
troubleshoot fan. If OK, replace the PPA.
45 Code 45: Amplifier Enable Check for B– at the PPA power input. Make sure gray
No B– input seen by the PPA. jumper wire is connected between JFP-5 and 11. Check
voltage from JFP-5 wrt 11. Replace PPA.

Fault Codes
46 Code 46: PPA Detected CAN-Bus Check voltage to TPA, PPA, VM, and HCB. Check
Error communication wires between all modules for continuity
The PPA has not received a and shorts to frame. Check pump motor encoder. If OK,
communication message from the VM, replace the PPA.
HCB, or TPA.
47 Code 47: CAN-Bus Node Offline Check power to TPA, PPA, VM, and HCB. Check power
Too much time between cable connections to the pump motor and PPA for
communication from the VM, HCB, continuity and correct torque. Check lift motor encoder,
and TPA to the PPA has elapsed. This temperature sensor, and connections. Check
code can also be caused by an open in communication wires between all modules for continuity
a cable from the amplifier to the pump and shorts to frame. If OK, replace the PPA.
motor.
48 Code 48: CT2 Contactor Open When Check the contactor for physical binding and welded tips.
Commanded Closed Check the fuse for the PPA (FP). Measure voltage and
Correct voltage is not seen by the PPA resistance across coil. Check cables from battery to PPA
at +V when CT2 is commanded closed. for continuity and correct torque. If OK, replace PPA.
49 Code 49: Pump Contactor Driver Check the CT2 contactor for physical binding and welded
Shorted tips.
The PPA did not see a voltage drop Measure voltage and resistance across coil.
when the CT2 contactor was If OK, replace the PPA.
commanded closed.
4C Code 4C: Battery Low Check battery voltage and specific gravity - static and
The voltage at the B+Key input to the under load. Refer to battery manufacturer for correct
PPA is below level programmed in voltage and specific gravity information.
cutout. If OK, replace PPA.
4E Code 4E: Pump Contactor Closed Check the contactor for physical binding and welded tips.
When Commanded Open Measure voltage and resistance across coil.
The PPA commanded the CT2 If OK, replace the PPA.
contactor open and the tips are still
closed.
50 Code 50: Pump Contactor Coil Measure voltage and resistance across coil.
Driver Error If OK, replace the PPA.

Fault Codes
51 Code 51: Pump Contactor Coil Check the contactor for physical binding and welded tips.
Shorted Measure voltage and resistance across coil.
Failure on the contactor driver CT2. If OK, replace the PPA.
53 Code 53: Seat Switch Open Troubleshoot seat switch, optional battery gate switches,
Seat switch open during lift. lift switch, and associated wiring.
55 Code 55: Incorrect Battery Installed Check battery voltage.

When the Key switch is turned ON, the Set correct battery voltage via FlashWare (and re-Learn
PPA checks the battery voltage and pots) or replace battery with correct voltage battery.
compares it with the "SET BATTERY" If battery and parameter setting is OK, replace PPA.
parameter setting. If the actual voltage
is 20% higher or lower than the set
value, this code is displayed.
56 Code 56: Incorrect Start Up If the directional switch is left in forward or reverse
Sequence position when the operator leaves the seat, Code 81 may
Incorrect start procedure. May appear be displayed after a brief timeout (approx. 30 sec). If code
in conjunction with Code 81. still appears after lever is returned to neutral, cycle the
Key switch to clear. Test switches for correct operation.
Check continuity of wires from switches to cards.
57 Code 57: Hydraulic Control Board Check voltage to PPA and HCB.
Time-Out Check communication wires between PPA, VM, and HCB
An error was detected in for continuity and shorts to frame.
communication between the Hydraulic If OK, replace the PPA.
Control Board and the PPA.
58 Code 58: PPA Internal Fault Check cables to the motor and PPA for continuity and
Failure on the current sensor. correct torque. Replace the PPA.
5A Code 5A: PPA Internal Fault Replace the PPA.

PPA internal failure.
5C Code 5C: PPA Parameter Restore Replace the PPA.

Error
PPA internal failure.

Fault Codes
61 Code 61: Slave TPA Internal Fault Check voltage to the TPA.
The Slave TPA has detected an If OK, replace the TPA.
internal fault.
62 Code 62: Slave TPA Internal Fault If code does not clear by cycling Key switch, replace the
Fault in the area of memory where the TPA. If code clears, the adjustable parameters have been
adjustable parameters are stored. reset to default values and require resetting to customer’s
63 Code 63: Slave TPA Internal Fault Check voltage to the TPA.
The power amplifier has detected an If OK, replace the TPA.
internal fault.
64 Code 64: Slave TPA Internal Fault Check voltage to the TPA. Check motor cables for
Correct current draw by the motor is continuity and correct torque. Compare current from all 3
not seen by the TPA. phases. If one phase is significantly higher or lower than
the other two, replace the motor. If OK, replace the TPA.
65 Code 65: Slave TPA Detected Verify battery voltage. If wrong voltage, set correct voltage
Battery Sense Out-of-Range via FlashWare (and re-learn pots) or install correct voltage
The Slave TPA monitors the battery battery. If battery is correct but voltage is >63VDC,
voltage at B+Key. If voltage does not replace battery. Test the power cables to the motor for
match configured voltage or is below shorts to the truck frame and the other cables. Test the
set threshold, this code is displayed. motor for shorts to frame. Resistance must be
The TPA also monitors the voltage on >1 Meg ohm. If OK, replace the TPA.
its internal capacitors. If voltage goes
above 63VDC, this code is displayed.
66 Code 66: Short in Slave TPA Measure voltage and resistance across coil. Check cables
When the Key switch is turned ON, the to the motor and TPA for continuity and correct torque.
Slave TPA momentarily powers each Swap the connections from the TPA to the other traction
motor phase and monitors current. If motor using appropriately sized jumper cables and turn
current is seen when it should not be, the Key switch ON. If code changes, replace the motor. If
this code is displayed. the code is still displayed, replace the TPA.
67 Code 67: Open in Slave TPA Check voltage to the TPA. Check cables to the motor and
When the Key switch is turned ON, the TPA for continuity and correct torque. Swap the
Slave TPA monitors each motor phase connections from the PPA and pump motor with the TPA
for current draw. If current is not seen and traction motor using appropriately sized jumper
when it should be, this code is cables and turn the Key switch ON. If code changes,
displayed. replace the motor. If the code is still displayed, replace the
TPA.

Fault Codes
68 Code 68: Traction Contactor Open Inspect the contactor for physical binding and welded
When Commanded Closed tips. Check the fuse for the TPA (FT). Measure voltage and
Correct voltage is not seen by the TPA resistance across coil. Test cables from battery to TPA for
at +V when CT3 is commanded closed. continuity and correct torque. If OK, replace the TPA.
69 Code 69: Slave TPA Internal Fault Check cables to the motors and TPA for continuity and
The TPA has detected an internal correct torque.
fault. If OK, replace the TPA.
70 Code 70: Slave TPA Precharge Check for B– at the TPA power input.
Failure Check for B+ from CT3 to the B+ connection on the TPA. If
When CT3 is closed, the Slave TPA not present, check the fuse for the TPA (FT).
attempts to charge the internal Measure voltage and resistance across CT3 coil.
capacitors. If the capacitors are not If OK, replace the TPA.
charged to B+ in a certain amount of
time, this code is displayed.
71 Code 71: Slave TPA Over Check fan for correct operation. Fan should operate
Temperature within about one minute after turning Key switch ON. If
Internal temperature of the Slave TPA not, troubleshoot fan. Allow TPA time to cool. If code
is >167°F (75°C). Performance is clears, check cables to traction motor and TPA for correct
reduced to 212°F (100°C); travel is torque and continuity. Check for brake drag. If code does
shut down above 212°F (100°C). not go away, replace TPA.
72 Code 72: Left Traction Motor If motor temperature is <266°F (130°C), check wiring to
Temperature Out-of-Range switch from VM. If motor temperature is >266°F (130°C),
Left traction motor overtemperature, compare current across the 3 phases for excessive
>266°F (130°C), or temperature switch current draw per the Pinout Matrix. Check drive unit for
is bad. binding. If OK, replace the TPA.
73 Code 73: Left Traction Motor Test the +12V and GND inputs to both encoders and the
Encoder Error output from channels A and B to the amp from both
Incorrect or no input seen by the TPA encoders. If OK, check for shorts to frame. Check voltage
from the Left Traction Motor encoder. to the TPA. If OK, replace the TPA.
74 Code 74: Slave TPA Temperature Check fan for correct operation. Fan should operate
Sensor Out-of Range within approx. one minute after turning Key switch ON. If
Temperature sensor has exceeded not, troubleshoot fan.
values expected. If OK, replace the TPA.

Fault Codes
76 Code 76: Slave TPA Detected Check voltage to TPA.

CAN-Bus Error Check communication wires between all modules for
The Slave TPA has not received a continuity and shorts to frame.
communication message from the VM, If OK, replace the TPA.
HCB, or PPA.
77 Code 77: Slave TPA CAN-Bus Node Verify battery voltage. If wrong voltage, set correct voltage
Offline via FlashWare (and re-Learn pots) or install correct
Too much time between voltage battery. Check power cable connections to the TPA
communication from the VM and PPA and motors for continuity and correct torque. Check both
to the TPA has elapsed. This code can traction motor encoders, temperature sensors, and
also be caused by an open in a cable connections. Check communication wires between VM,
from the amplifier to the traction TPA, and PPA for continuity and shorts to frame. If OK,
motors. replace the TPA.
79 Code 79: Traction Contactor Driver Check the CT3 contactor for physical binding and welded
Shorted tips.
The TPA did not see a voltage drop Measure voltage and resistance across coil.
when the contactor was commanded If OK, replace the TPA.
closed.
7A Code 7A: Master KO Check voltage to the TPA. If OK, replace the TPA.
Failure of Master Unit.
7C Code 7C: Slave TPA Internal Fault Check voltage to the TPA. If OK, replace the TPA.
Slave TPA internal fault.
80 Code 80: Traction Contactor Coil Measure voltage and resistance across coil.
Driver Error
81 Code 81: Directional Microswitch If the directional switch is left in forward or reverse
Closed position when the operator leaves the seat, Code 81 is
VM detected directional microswitches displayed after a brief time-out (approx. 30 seconds).
(SW9 or SW10; SW4 or SW5 on dual If the code still appears after lever is returned to neutral,
pedal trucks) closed prior to power up. cycle the Key switch to clear.
This code can also be caused by Test switches for correct operation.
having travel enable switch (SW8) Check continuity of wires from switches to cards.
activated before seat switch (SW2) Flash truck components with latest version of software
and/or optional battery gate switch and re-Learn pots. Replace the VM.
(SW30) is activated.

Fault Codes
83 Code 83: Traction Pot Open Circuit Test for correct voltage to and from the traction pot.
VM detected the voltage from the If voltage is not correct, check continuity of the wires.
traction pot is below the allowable If OK, replace the VM.
voltage range. If not OK, replace the pot.
84 Code 84: Travel Enable Switch Troubleshoot switch and wiring. Check for shorts to
Failure frame. Troubleshoot SW5 and SW10 switches and wiring.
VM detected travel enable microswitch If OK, replace the VM. If not OK, repair/replace the
(SW8) failure. switch/wiring.
85 Code 85: Warning Configuration Check configured battery voltage (36V or 48V) with
Error FlashWare. If incorrect, set correct battery voltage in
Software error. FlashWare or replace battery with correct voltage battery.
Replace VM.
86 Code 86: Traction Potentiometer If code is displayed in conjunction with another code,
Out-of-Range troubleshoot per that code. Verify battery voltage. If wrong
Traction Pot is outside the learned voltage, set correct voltage via FlashWare (and re-Learn
voltage range. This code can also be pots) or install correct voltage battery. Check both
displayed if there is no power to the traction motor encoders, temperature sensors, and
TPA or if one of the power cables to the connections. Check power to the TPA. Check the power
traction motor(s) is open. cables to the traction motor(s). Check pot voltages. Check
resistance of resistor in static strap standoff; should be
200 to 250k ohm. Verify configuration jumpers are in
place on PPA. If OK, run Learn. If not OK, replace the pot.
87 Code 87: Seat/Battery Gate Troubleshoot switches and wiring.

Interlock Switch Open
A function was activated while the seat
or optional battery gate interlock
switch was open.
89 Code 89: Parking Brake Switch Troubleshoot switch and wiring.

Error
SW7 is closed when travel is detected.
8A Code 8A: VM Internal Fault Replace the VM.

A fault was detected by the VM during
power up.

Fault Codes
8B Code 8B: TPA Fault Check voltage to the TPA. Check for TPA codes and
The TPA informed the VM that a fault troubleshoot per them. If none are present, replace the
is present. TPA.
8C Code 8C: TPA Communication Error If code clears by cycling Key switch, the adjustable
The VM did not receive parameters have been reset to default values and require
communication from the TPA. resetting to customer’s requirements via FlashWare.
Check power to TPA. Check the power cables to the
traction motors. Check both traction motor encoders,
temperature sensors, and connections. Check
communication wires between the TPA and VM for
continuity and shorts to frame. If code does not clear by
cycling key, replace the TPA.
8D Code 8D: Lift Limit Check for correct configuration via FlashWare. (This code
Lift-Limit switch (SW31) is open. is normal and will occur when beyond limits for option.)
Check Lift-Limit/Bypass switch (SW31) and wiring.
If OK, replace PPA.
8E Code 8E: Bottler’s Tilt Limit Check for correct configuration via FlashWare. (This code
Bottler’s Tilt limit switch (SW30) is is normal and will occur when beyond limits for option.)
open. Check Bottler’s Tilt limit switch (SW30) and wiring.
If OK, replace VM.
8F Code 8F: Requesting Travel In Both Troubleshoot switches and wiring.

Directions If OK, replace TPA.
Forward and Reverse switches
(directional lever on column) are
91 Code 91: Configuration Error Check power to the Hydraulic Control Board (HCB).
The VM has detected a configuration Check communication wires between PPA, HCB, and
error due to lack of information from Armrest Board for continuity and shorts to frame. Make
the Hydraulic Control Board or sure COMBI jumpers are correctly installed at Armrest
Armrest Board during SelfTest. Board. Check software versions via FlashWare. If the HCB
and/or Armrest Board are not displayed on the Truck
Setup screen, “flash” the truck. Replace HCB or Armrest
Board.

Fault Codes
92 Code 92: Communication Error Check power to TPA, PPA, and Armrest Board. Check
Detected By The VM power cable connections to the TPA, PPA, and motors for
The VM has not received information continuity and correct torque. Check motor encoders,
from the PPA, TPA, or Armrest Board. temperature sensors, and connections. Check
communication wires between VM, TPA, PPA, and
Armrest Board for continuity and shorts to frame. Check
PPA for correct configuration jumper application. Refer to
“Electrical Jumpers” on page 7-49. If OK, replace the VM.
93 Code 93: Communication Error Check power to TPA, PPA, VM, HCB, and Operator
Detected By The VM Display. Check communication wires between VM and
The VM has not received information Display for continuity and shorts to frame. If OK, replace
from the Operator Display. the Operator Display.
94 Code 94: Internal Fault Replace the VM.

The VM has detected an internal fault.
96 Code 96: VM Internal Fault Verify battery voltage. If wrong voltage, set correct voltage
Fault in the area of memory where the via FlashWare (and re-Learn pots) or install correct
adjustable parameters are stored. voltage battery. Check for shorts to frame. If code does not
clear by cycling Key switch, replace the VM. If code clears,
the adjustable parameters have been reset to default
values and require resetting to customer’s requirements
via FlashWare. Re-Learn all pots.
97 Code 97: Jumper Configuration Verify the jumper is in place on models 470-C40 and
Error 470-C50HM. The jumper should not be installed on
The jumper between JBP-1 and 2 on model 470-C30. Verify correct PPA is installed.
the PPA (determines motor size) was
detected in the wrong position for the
truck model. If not in place, the VM
defaults to model 470-C30.
A1 Code A1: Hydraulic Control Board If code does not clear by cycling key, replace the
Internal Fault Hydraulic Control Board.
Fault in the area of memory where the If code clears, the adjustable parameters have been reset
adjustable parameters are stored on to default values and require resetting to customer’s
the Hydraulic Control Board. requirements via FlashWare.
A2 Code A2: Solenoid Valve Error Measure voltage and resistance across coil.
A short was detected in the circuits If OK, replace the Hydraulic Control Board.
between the 5th Solenoid Valve (EV11)
and the Hydraulic Control Board.

Fault Codes
A3 Code A3: CAN-Bus Error Detected by Check power to TPA, PPA, VM, and HCB.
Hydraulic Control Board Check communication wires between all modules for
The Hydraulic Control Board has not continuity and shorts to frame.
received CAN messages from the VM, If OK, replace the Hydraulic Control Board.
PPA, TPA, or Armrest Board.
A4 Code A4: Internal Hydraulic Control Replace the Hydraulic Control Board.
Board Fault
Problem in the hardware circuit.
between the Lifting Valve (EV2) and
the Hydraulic Control Board.
between the Tilting Valves (EV3 or 4)
between the Sideshift valves (EV5 or 6)
between the 4th Function valves (EV7
or 8) and the Hydraulic Control Board.
AA Code AA: Incorrect Battery Installed Check battery voltage.

When the Key switch is turned ON, the Set correct battery voltage via FlashWare and re-Learn
Hydraulic Control Board checks the pots or install correct battery.
battery voltage and compares it with If OK, replace the Hydraulic Control Board.
the "SET BATTERY" parameter setting.
If the actual voltage is 20% higher or
lower than the set value, this code is
displayed.

Fault Codes
AB Code AB: Hydraulic Control Board Measure voltage and resistance across coil.
Driver Fault If OK, replace the Hydraulic Control Board.
The positive supply to the valves is
shorted or open.
AC Code AC: Solenoid Group 1 Driver Measure voltage and resistance across coil.
Error If OK, replace the Hydraulic Control Board.
An open was detected in the circuits
between the Lifting Valve (EV2) and
the Hydraulic Control Board.
AD Code AD: Solenoid Group 2 Driver Measure voltage and resistance across coil.
between the Tilting Valves (EV3 or 4)
AE Code AE: Solenoid Group 3 Driver Verify battery voltage. If wrong voltage, set correct voltage
Error via FlashWare (and re-Learn pots) or install correct
An open was detected in the circuits voltage battery.
between the Sideshift valves (EV5 or 6) If OK, replace the Hydraulic Control Board.
AF Code AF: Solenoid Group 4 Driver Measure voltage and resistance across coil.
between the 4th Function valves (EV7
or 8) and the Hydraulic Control Board.
b.0 Code b.0: Coil Shorted Measure voltage and resistance across coil.
b.1 Code b.1: Hydraulic Control Board Check for B+ to Hydraulic Control Board.
Power Supply Failure If present, replace Hydraulic Control Board.
Low voltage is seen at the Hydraulic If not present, check circuit from the Hydraulic Control
Control Board. Board back to CT1.

Fault Codes
b.2 Code b.2: EVP Driver KO Measure voltage and resistance across coil.
An open was detected in the circuits If OK, replace the Hydraulic Control Board.
between the Drain valve (EVP) and the
Hydraulic Control Board.
b.3 Code b.3: EV11 Driver KO Measure voltage and resistance across coil.
An open was detected in the circuits If OK, replace the Hydraulic Control Board.
b.4 Code b.4: Internal Hydraulic Control Replace Hydraulic Control Board.
Board Fault
Internal failure of Hydraulic Control
Board.
b.5 Code b.5: EVP Driver Shorted Measure voltage and resistance across coil.
between the Drain valve (EVP) and the
Hydraulic Control Board.
C1 Code C1: Open in Brake Light Check bulbs.

Circuit Check for voltage to both lights.
An open was detected in the brake
light circuit.
C2 Code C2: Open in Fore or Aft Check bulbs.

Working Light Circuits Check for voltage to both lights.
An open was detected in the fore/aft
working light circuits.
C3 Code C3: Open in Fore/Aft Working Check bulbs.

Light or Brake Light Circuits Check for voltage to lights.
An open was detected in the fore/aft
working light or brake light circuits.
C4 Code C4: Open in Tail Light Circuits Check bulbs.

An open was detected in both reverse Check for voltage to both lights.
light circuits.

Fault Codes
C5 Code C5: Open in Brake or Tail Check bulbs.

Light Circuits Check for voltage to all lights.
An open was detected in the rear light
circuits.
C8 Code C8: Option. Open Circuit Check the travel alarm, warning light, working lights,
An open was detected in the travel and/or lowering control valve circuits.
alarm or warning light, or safety
lowering valve circuits.
d.1 Code d.1: TPA Power Supply or Check for power to the TPA.
CAN-Bus Failure If OK, replace the TPA.
The Display did not receive
communication from the TPA.
d.2 Code d.2: VM Power Supply or Check for power to the VM.
CAN-Bus Failure If OK, replace the VM.
The Display did not receive
communication from the VM.
d.3 Code d.3: d.1 + d.2 Use steps for Codes d.1 and d.2.
d.4 Code d.4: PPA Power Supply or Check for power to the PPA. Check for opens in the
CAN-Bus Failure communications wires between the TPA and PPA. If OK,
The Display did not receive replace the PPA.
communication from the PPA.
d.5 Code d.5: d.1 + d.4 Check for opens in the communications wires between
the TPA and the VM. Check for power to the TPA and PPA.
If OK, replace the TPA or PPA.
d.6 Code d.6: d.4 + d.2 Check for opens in the communications wires between
the TPA and PPA. Check for power to the VM and PPA. If
OK, replace the PPA or VM.

Fault Codes
d.7 Code d.7: d.4 + d.2 + d.1 Connect FlashWare and see if the versions for the Display,
TPA, PPA, and VM can be seen. If only the Display is not
shown, check connections to the Display. If OK, replace
the Display. If the other devices are not shown and the
Display is shown, check connections to the VM from the
Display. Verify power to the devices. If OK, replace the
VM. If no devices are shown, check for shorts between the
CAN High and CAN Low wires. Measure resistance
between the CAN High and CAN Low pins going into the
Display. The reading should be approx. 180 ohms. If open
or shorted, replace the Display.
d.8 Code d.8: Armrest Board Power Check for power to the Armrest Board.
Supply or CAN-Bus Failure Check for opens in the communications wires between
The Display did not receive the Armrest Board and the VM.
communication from the Armrest If OK, replace the Armrest Board.
Board.
d.9 Code d.A: d.8 + d.1 Use steps for d.8 and d.1.
d.A Code d.A: d.8 + d.2 Use steps for d.8 and d.2.
d.B Code d.B: d.8 + d.2 + d.1 Use steps for d.8, d.2, and d.1.
d.C Code d.C: d.8 + d.4 Use steps for d.8 and d.4.
d.d Code d.d: d.8 + d.4 + d.1 Use steps for d.8, d.4, and d.1.
d.E Code d.E: d.8 + d.4 + d.2 Use steps for d.8, d.4, and d.2.

Fault Codes
d.F Code d.F: d.8 + d.4 + d.2 + d.1 Connect FlashWare and see if the versions for the Display,
TPA, PPA, VM, and Armrest Board are displayed. If the
Display is not shown, check connections to the Display. If
OK, replace the Display. If the other devices are not
shown, check connections to the VM from the Display.
Verify power to the devices. If OK, replace the VM. If no
devices are shown, check for shorts between the CAN
High and CAN Low wires. Measure resistance between the
CAN High and CAN Low pins going into the Display. The
reading should be approx. 180 ohms. If open or shorted,
replace the Display.
E1 Code E1: Incorrect Start Procedure Check the lever/fingertip controls for binding.
for the Armrest Board or Levers Check the seat switch and battery gate switches.
One of the switches on the Armrest Test switches. Check resistance of resistor in static strap
Board or one of the lever control standoff; should be 200 to 250k ohm.
switches is out-of-neutral prior to key
ON or the seat switch or battery gate
switches are closed.
E2 Code E2: Lift Potentiometer (Lever Check pot for binding. Make sure battery voltage is
Control) Out-of-Range configured correctly. Learn pot. Test pot voltage. Check
Voltage from the lift pot is outside the resistance of resistor in static strap standoff; should be
expected operating range. 200 to 250k ohm. Verify configuration jumpers are in
place on PPA. Check for shorts to frame. Set amplifier and
VM defaults in FlashWare.
E3 Code E3: Tilt Potentiometer Make sure battery voltage is configured correctly.
Out-of-Range Learn pot.
Voltage from the tilt pot is outside the Test pot voltage.
expected operating range.
E4 Code E4: Sideshift Potentiometer Make sure battery voltage is configured correctly.
Out-of-Range Learn pot.
Voltage from the sideshift pot is Test pot voltage.
outside the expected operating range.
E5 Code E5: 4th Function Make sure battery voltage is configured correctly.
Potentiometer Out-of-Range Learn pot.
Voltage from the 4th Function pot is Test pot voltage.
outside the expected operating range.

Fault Codes
E7 Code E7: Armrest Board Warning Cycle the Key switch.

The Armrest Board is in the process of Default and Learn via FlashWare.
downloading default parameters. If code does not clear, replace Armrest Board.
E8 Code E8: Armrest Board Internal Cycle the Key switch.

Fault Default and Learn via FlashWare.
Failure of the restore default If code does not clear, replace Armrest Board.
parameter download.
E9 Code E9: Armrest Board Internal Replace the Armrest Board.

Fault
EA Code EA: Hydraulic Control Board Check for codes from the Hydraulic Control Board and
or PPA Error PPA and troubleshoot accordingly. Check CT2 coil from
A code is present on both the PPA per Pinout Matrix. Check pump motor and temp
Hydraulic Control Board and PPA. switch circuits. Check PPA Safety circuit between JFP-5
and 11 (dual traction motor trucks) or JP12-5 and 11
(single traction motor trucks).
EB Code EB: Armrest Board Internal Check fingertip switches for binding.
Fault Test voltage of the switch.
Lift-Limit Bypass switch on the Replace the Armrest Board.
Armrest Board is closed.
EC Code EC: Armrest Board Internal Replace the Armrest Board.

Fault
ED Code ED: CAN-Bus Error Detected Check power to HCB and Armrest Board.
By Hydraulic Control Board Check communication wires between all VM, HCB, and
The Armrest Board is unable to Armrest Board for continuity and shorts to frame.
communicate with the Hydraulic If OK, replace the Armrest Board or the HCB.
Control Board.
EE Code EE: CAN-Bus Error Detected Check power to PPA, VM, and HCB.
By PPA Check communication wires between all modules for
The Armrest Board has not received continuity and shorts to frame.
communication from the PPA. If OK, replace the PPA.

Fault Codes
EF Code EF: Requesting Travel In Both Troubleshoot switches and wiring.

Directions If OK, replace Armrest Board.
Forward and Reverse switches are

Fault Codes

Model 4700 Maintenance Manual Section 7. Component Procedures
Section 7. Component Procedures

Section 7. List of Component Procedures Model 4700 Maintenance Manual
List of Component Procedures

Component Locator Photos. . . . . . . . . . 7-5 Main Fuses . . . . . . . . . . . . . . . . . .. 7-50
+24V Fuse Panel . . . . . . . . . . . . . .. 7-50
Special Tools and Decals . . . . . . . . . . . 7-13 DC/DC Converter Fuse . . . . . . . . .. 7-51
Optional Fingertip Control Fuses . .. 7-51
Special Tools . . . . . . . . . . . . . . . . . . . . 7-14 Potentiometers. . . . . . . . . . . . . . . . . .. 7-52
Decals and Plates . . . . . . . . . . . . . . . . . 7-15 Steer Potentiometer (P1) . . . . . . . . .. 7-52
Removal . . . . . . . . . . . . . . . . . . . .. 7-52
Steering and Controls . . . . . . . . . . . . . 7-19 Installation . . . . . . . . . . . . . . . . .. 7-52
Steering Pressure Adjustment. . . . . . . . 7-20 Travel Potentiometer (P2) . . . . . . . .. 7-52
Removal . . . . . . . . . . . . . . . . . . . .. 7-52
Drive and Brake . . . . . . . . . . . . . . . . . 7-21 Installation . . . . . . . . . . . . . . . . .. 7-52
Drive Unit/Motor Assemblies . . . . . . . . 7-22 Lift Potentiometer (P3) . . . . . . . . . .. 7-53
Dual Traction Motor Trucks . . . . . . . 7-22 Removal . . . . . . . . . . . . . . . . . . . .. 7-53
Changing Fluid . . . . . . . . . . . . . . . . 7-22 Installation . . . . . . . . . . . . . . . . .. 7-53
Drive Unit Removal . . . . . . . . . . . . . 7-22 Motor Encoder Bearing . . . . . . . . . . .. 7-54
Drive Unit Installation. . . . . . . . . . . 7-23 Removal . . . . . . . . . . . . . . . . . . . . .. 7-54
Brake Service . . . . . . . . . . . . . . . . . 7-24 Installation. . . . . . . . . . . . . . . . . . .. 7-54
Assembly . . . . . . . . . . . . . . . . . . . . 7-25 Motor Temperature Switch Repair . . .. 7-56
Storage . . . . . . . . . . . . . . . . . . . . . . . 7-26 Traction Motor . . . . . . . . . . . . . . . .. 7-56
Single Traction Motor Trucks . . . . . . 7-27 Pump Motor . . . . . . . . . . . . . . . . . .. 7-56
Changing Fluid . . . . . . . . . . . . . . . . 7-27 Connector Sealing . . . . . . . . . . . . .. 7-57
Corrosion Inhibitor Coating . . . . . .. 7-57
Drive Unit Removal . . . . . . . . . . . . . 7-28
Drive Unit Installation. . . . . . . . . . . 7-28 Hydraulic Components . . . . . . . . . . . . 7-59
Brake Service - S/Ns below 10677 . 7-29 Hydraulic Fluid . . . . . . . . . . . . . . . . . . 7-60
Brake Service - S/Ns 10677 and up 7-30 Changing Fluid. . . . . . . . . . . . . . . . . 7-60
Brake Pedal Adjustment . . . . . . . . . . . . 7-34 Bleeding the Hydraulic System . . . . . 7-60
Tire Replacement . . . . . . . . . . . . . . . . . 7-35 TF and TT Masts . . . . . . . . . . . . . . 7-60
Quad Masts . . . . . . . . . . . . . . . . . . 7-60
Electrical Components . . . . . . . . . . . . 7-37 Lift Pressure Adjustment . . . . . . . . . 7-62
Battery Procedures . . . . . . . . . . . . . . . . 7-38 Auxiliary Function Pressure
Adjustment . . . . . . . . . . . . . . . . . 7-63
Battery Exterior Cleaning . . . . . . . . . 7-38 Hydraulic Pump and Motor . . . . . . . . . 7-64
Testing, Charging, and Maintenance . 7-38
Power Cables . . . . . . . . . . . . . . . . . . . . 7-39 Separating Pump and Motor . . . . . . . 7-64
Quad Mast Cylinder Service. . . . . . . . . 7-65
Power Cable Repair . . . . . . . . . . . . . . 7-39
Wiring and Harness Connectors . . . . . . 7-41 Main or Free Lift Cylinders . . . . . . . . 7-65
Check Valve Inspection . . . . . . . . . 7-65
General Repair Procedures . . . . . . . . 7-41
Repair. . . . . . . . . . . . . . . . . . . . . . . 7-41 Valve Cartridge Replacement . . . . . 7-66
Soldering Procedures . . . . . . . . . . . 7-41
Molex Connectors . . . . . . . . . . . . . . . 7-42 Mast . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
Pin Extraction. . . . . . . . . . . . . . . . . 7-42 Mast Removal and Installation. . . . . . . 7-68
Pin Insertion . . . . . . . . . . . . . . . . . . 7-42 Dual Traction Motor Trucks . . . . . . . 7-68
AMP Harness/Harness Connectors . . 7-43 Removal . . . . . . . . . . . . . . . . . . . . . 7-68
Pin Extraction. . . . . . . . . . . . . . . . . 7-43 Installation . . . . . . . . . . . . . . . . . . 7-68
Pin Insertion . . . . . . . . . . . . . . . . . . 7-44 Single Traction Motor Trucks . . . . . . 7-69
AMP Harness/Power Amplifier Removal . . . . . . . . . . . . . . . . . . . . . 7-69
Connector. . . . . . . . . . . . . . . . . . . 7-46 Installation . . . . . . . . . . . . . . . . . . 7-70
Connector Components. . . . . . . . . . 7-46 Guide Shoe (Puck) Adjustment -
Testing . . . . . . . . . . . . . . . . . . . . . . 7-48 TF/TT Mast . . . . . . . . . . . . . . . . . . . 7-71
Power Amplifiers. . . . . . . . . . . . . . . . . . 7-49 Fork Carriage - TF/TT Mast . . . . . . . . . 7-72
Terminal Hardware . . . . . . . . . . . . . . 7-49 Removal . . . . . . . . . . . . . . . . . . . . . . 7-72
Electrical Jumpers . . . . . . . . . . . . . . 7-49 Installation. . . . . . . . . . . . . . . . . . . . 7-72
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50 Top Installation . . . . . . . . . . . . . . . 7-73
Power Amplifier Fuses . . . . . . . . . . . . 7-50 Bottom Installation . . . . . . . . . . . . 7-73

Model 4700 Maintenance Manual Section 7. List of Component Procedures
Fork Carriage with Sideshift -

TF/TT Mast . . . . . . . . . . . . . . . . . . . . 7-74
Removal . . . . . . . . . . . . . . . . . . . . . . 7-74
Installation . . . . . . . . . . . . . . . . . . . . 7-75
Free Lift Cylinder Jacking Bolt
Adjustment - TF/TT Mast . . . . . . . . . 7-76
Lift Chains . . . . . . . . . . . . . . . . . . . . . . 7-77
Adjustment . . . . . . . . . . . . . . . . . . . . 7-77
Removal . . . . . . . . . . . . . . . . . . . . . . 7-77
Installation . . . . . . . . . . . . . . . . . . . . 7-77
Lift Chain Anchor Bolts . . . . . . . . . . . 7-78
Quad Mast Service . . . . . . . . . . . . . . . . 7-79
Mast Inspection . . . . . . . . . . . . . . . . . 7-79
Disassembly . . . . . . . . . . . . . . . . . . . 7-79
Reassembly . . . . . . . . . . . . . . . . . . . . 7-80
Carriage . . . . . . . . . . . . . . . . . . . . . . 7-84
Removal - Mast on Floor . . . . . . . . . 7-84
Installation - Mast on Floor . . . . . . . 7-84
Cylinder Removal and Installation . . . 7-84
Main Lift Cylinder Removal -
Mast on Floor . . . . . . . . . . . . . . . . . 7-84
Main Lift Cylinder Installation -
Mast on Floor . . . . . . . . . . . . . . . . . 7-85
Free Lift Cylinder Removal -
Mast on Floor . . . . . . . . . . . . . . . . . 7-85
Free Lift Cylinder Installation -
Mast on Floor . . . . . . . . . . . . . . . . . 7-85
Free Lift Cylinder Supply Hose -
Tracking and Adjustment . . . . . . . 7-85
Reeving . . . . . . . . . . . . . . . . . . . . . . . 7-86
Internal Reeving . . . . . . . . . . . . . . . 7-86
Mast Tilt Adjustment . . . . . . . . . . . . . . 7-90
Mast Tilt Position Switch
Adjustment (Bottler’s Tilt Only) . . . 7-90

Section 7. List of Component Procedures Model 4700 Maintenance Manual

Component Locator Photos

Figure 7-1. Major Components
Overhead Guard
Mast
Battery
Load Backrest
Fork Carriage
Steer Wheel
Electrical Compartment
Drive Wheel

Section 7. Component Locator Photos Model 4700 Maintenance Manual

Figure 7-2. Operator Compartment Controls
Directional Lever
Steering Wheel
(standard)
Horn Switch
Key Switch
Performance Mode Select Switch (L-P-H)

Performance Reduction (Turtle) Switch
EPO Switch
Accelerator Pedal
Brake Pedal
Hydraulic Function Levers
Parking Brake Lever
Hydraulic Function Fingertip Controls Forward/Reverse Accelerator

with additional horn switch (optional) pedals (optional)

Model 4700 Maintenance Manual Section 7. Component Locator Photos

Figure 7-3. Electrical Compartments (Dual Traction Motor Trucks)
Contactor Panel Main Fuse Panel
Pump Power Amplifier Dual AC Traction Power Amplifier
Right Side Compartment
DC/DC Converter
Vehicle Manager +24V Fuse Panel

Fuse (12A)
Left Side Compartment


Figure 7-4. Electrical and Hydraulic Compartments (Single Traction Motor Trucks)
Traction Power Amplifier
Main Fuse Panel
Contactor Panel Pump Power Amplifier
+24V Fuse Panel

Fuse (12A)
Vehicle Manager DC/DC Converter
Right Side Compartment
Hydraulic Fluid Reservoir

Pump Motor
Hydraulic Pump
Left Side Compartment
Figure 7-5. Tractor Front View

Right Traction Left Traction

Motor Motor
Dual Traction Motor Truck
Drive Unit (Differential)
Single Traction Motor Truck


Figure 7-6. View Below Floor Panel (Dual Traction Motor Truck)
Tilt Cylinder
Travel Pot
(P2)
Accelerator
Pedal Assy
Right
Traction
Motor Pump
Pump Motor
Horn
Hydraulic
Reservoir
Cap/Filter
Brake Pedal
Assy
Left Traction
Motor
Tilt Cylinder


Figure 7-7. View Below Floor Panel (Single Traction Motor Truck)
Brake Pedal Accelerator Travel Pot

Tilt Cylinder Assy Horn Pedal Assy (P2) Tilt Cylinder
Hydraulic Traction Motor

Reservoir
Cap/Filter


Special Tools and Decals
Special Tools and Decals


Section 7. Component Procedures Model 4700 Maintenance Manual
Special Tools Special Tools and Decals
Special Tools
The following tools are available from your local
authorized Raymond Sales and Service Center.
Table 7-1. Special Tools
Tool Part Number Purpose
Anti-static Field Kit 1-187-059
Anti-static Wrist Straps 1-187-058/001

ESD Protection
Anti-static Wrist Strap 1-187-060/100
Tester
Chain Gauge 950-350/CG Lift chain inspection
Connector Unlatching 950-042 Separate AMP connectors
Crimp Tool 1069861 Crimp power cable lugs
End Cap A9587 Main Lift Cylinder end cap removal/installation
End Cap 1090761/005 Free Lift Cylinder w/staging end cap removal/installation
End Cap 1090761/007 Main Lift and Free Lift Cylinder w/o staging end cap
removal/installation
Fork Wear Caliper 922-369 Fork inspection
Pin Extraction 950-009 AMP connector pin extraction
Pin Extraction 950-026 MOLEX connector pin extraction
Pressure Fitting 1620-04CE Connect pressure gauge to metric port

Adapter, Metric
Seal Driver 401-000-051 Free Lift Cylinder seal installation
Surge Protector 154-010-801 ESD/voltage surge protection for serial type FlashWare
connections
USB/CAN Interface 230489-001 FlashWare connection to truck

Special Tools and Decals Decals and Plates
Decals and Plates

Table 7-2. Decal and Specification Plate List
Decals and Specification Plates
Item Number
(refer to Figures Description
7-8 thru 7-10)
1 Raymond Decal (2 places)
2 ACR Decal (2 places)
3 Model Decal (2 places)
4 EE Decal (optional) (2 places)
5 Mast Specification Plate
6 Forks Decal (2 places)
7 Hands Clear Decal (3 places)
8 Parking Brake Decal
9 Emergency Disconnect Decal
10 Key Switch
11 Specification Plate
12 Brake Fluid Decal - DOT 4 (Black Cap) or Mineral Oil (P/N 990-603/470) (Green Cap)
13 Battery Latch Decal
14 Restraint Caution Decal
15 Main Warning Decal
16 No Riding Decal
17 Battery Warning Decal
18 No Riders Warning Decal
19 Battery Removal Decal
20 Manual Replacement Decal
21 Operator Manual Location Decal
22 Tip Over Warning Decal
23 Overhead Guard ANSI/ITSDF conformance
24 Tip Over Vertical Warning Decal
25 Tip Over Horizontal Warning Decal
NOTE: Items in italics are safety decals.

Decals and Plates Special Tools and Decals

Figure 7-8. Decal and Specification Plate Locations
5 2 4
9 10
11
Use only 12
DOT 4
Brake Fluid
or
8

Special Tools and Decals Decals and Plates

Figure 7-9. Decal and Specification Plate Locations Con’t.
16
17
13
14
18
WARNING
Do not operate this truck unless
trained and authorized to do so.
Read all warnings and instructions
contained in the operator's manual
15 and on the truck.
1. Check all operating systems and safety

devices as noted in the Operator's Manual.
Report any unsafe conditions immediately. Do
not operate truck until corrected.
2. Keep all portions of the body inside the

operator's compartment.
3. When stopping, stay inside compartment until

truck comes to a complete halt.
4. Travel with the load as low as possible with

the mast tilted back and sideshift centered.
Elevate forks only for storage and retrieval.
Lift and lower with mast vertical or slightly
back. Watch out for obstructions, especially
overhead.
5. Operate truck only from operating position.

Never place any part of your body between
the mast uprights or outside the truck. Do not
carry passengers.
6. Do not allow anyone to stand or pass under

the load or lifting mechanism.
7. Do not overload truck. Check nameplate for

capacity (load weight and load center
information).
8. Start, stop, change direction, travel and brake

smoothly. Slow down for turns and on
uneven or slippery surfaces that could cause
truck to slide or tip.
19
9. Always look in direction of travel. Keep a
clear view, and when load interferes with
visibility, travel with load trailing (except
when climbing ramps).
10. Use special care when operating on ramps -

travel slowly, and do not angle or turn. When
truck is loaded, travel with load uphill. When
truck is empty, travel with lifting mechanism
downhill. Do not leave truck unattended on
WARNING
ramps.
11. Do not lift personnel except on a securely

attached ANSI/ITSDF B56.1 compliant work
platform. Use extreme care, place mast in
vertical position, center sideshift, and lift and
lower smoothly. Remain in operating position
as long as personnel is elevated.
12. Spread forks as far apart as load will permit,

Remove battery only
center forks, and push completely under load.
13. Do not handle unstable or loosely stacked

with lift mechanism down
loads. and load removed.
14. Observe applicable traffic regulations. Yield 411-964
right of way to pedestrians. Slow down and
sound horn at intersections and/or whenever
vision is obstructed.
15. When leaving truck unattended, ensure forks

are fully lowered, and remove key.
1057653

Decals and Plates Special Tools and Decals

Figure 7-10. Decal and Specification Plate Locations Con’t.
7
A B
A B
20
21
24
22
25
23
View A-A View B-B

Steering and Controls
Steering and Controls


Steering Pressure Adjustment Steering and Controls
Steering Pressure Figure 7-13. Steer Orbitrol
Adjustment
Pressure adjustment screw protective cap
Steer pressure is adjusted at the steer orbitrol
located on a bracket at the base of the steering
column.
1. Using Metric Pressure Fitting Adapter
P/N 1620-04CE, install a pressure gauge
at the pump pressure port. See Figures
7-11 and 7-12.
Figure 7-11. Pressure Port (Dual Traction Motor Trucks)
Pressure port
3. Turn the steering wheel all the way to the

right or left. Check the steer pressure.
Steering pressure should measure
between 1305 and 1450 psi (9000 and
10,000 kPa).
Figure 7-12. Pressure Port (Single Traction Motor Trucks)
4. Turn the pressure adjustment screw
clockwise to increase pressure or
Pressure port counterclockwise to decrease pressure.
5. Replace the protective cap.
2. On the steer orbitrol, remove the protective

cap using a ball-ended socket head
wrench. This allows access to the pressure
adjustment screw. See Figure 7-13.

Drive and Brake
Drive and Brake


Drive Unit/Motor Assemblies Drive and Brake
Drive Unit/Motor Figure 7-15. Filling with Funnel and Flexible Hose
Assemblies
Dual Traction Motor Trucks
The drive unit/motor assemblies, one for each
drive wheel, consist of a planetary gear type
drive unit and an AC motor.
Changing Fluid
1. Run the truck for a few minutes to warm
the fluid.
2. Clean the area around the fluid fill and
drain plugs. See Figure 7-14. 7. Clean the area around the fluid fill and
drain plugs.
Figure 7-14. Drive Unit Plug Locations
8. Run the truck for several minutes. Check
Fill the fluid level again.
Plug
Drive Unit Removal
1. Park the lift truck on a level surface.
Engage the parking brake. Turn the key
switch OFF and disconnect the battery
connector.
Drain
Plug 2. Block the steerable wheels to prevent
truck movement.
3. Place a suitable container below the drain

plug.
4. Remove both the fill and the drain plugs. Use extreme care whenever the truck is
Allow the fluid to drain out completely. jacked up for any reason. Never block
the truck between the telescopic and the
5. Clean any ferrous residue from the floor. Use a suitable hoist to stabilize the
magnetic drain plug. Replace the drain mast. Keep hands and feet clear from
plug, torquing to 16 ft. lb. (22 Nm). beneath vehicle while jacking. Use jack
6. Use a flexible hose with either a syringe or stands or solid blocks to support truck.
a funnel to add new fluid (type ATF II D or Do not rely on the jack alone. See
equivalent) through the fill plug hole until “Jacking Safety” on page 2-8.
it starts overflowing (approx. 0.75 pints,
0.35 liter). See Figure 7-15. Install the fill 3. Jack the front of the truck.
plug. Torque to 16 ft. lb. (22 Nm). 4. Release the parking brake.
5. Drain the fluid (see “Changing Fluid”).
6. Remove the drive wheel.
7. Disconnect all hoses and cables connected
to the parking brake, service brake, and
traction motor.

Drive and Brake Drive Unit/Motor Assemblies
8. Remove the drive unit/motor assembly Drive Unit Installation

from the tractor as follows:
1. Carefully assemble the drive unit to the
a. Remove the upper front drive unit traction motor. Make sure the pinion and
mounting bolt and install an M14 x 30 spur gears mesh correctly.
threaded rod as shown in Figure 7-16
to support the drive unit/motor 2. Torque the motor to drive unit mounting
assembly. bolts to 17 ft. lb. (23 Nm).
Figure 7-16. Traction Motor/Drive Unit Removal 3. Install the drive unit/motor assembly into
the chassis in the reverse of removal.
4. Torque the drive unit to chassis mounting
bolts to 100 ft. lb. (135 Nm).
b. Remove the remaining five mounting

bolts. Slide the drive unit/motor
assembly out of the chassis.
c. If the traction motor is to be removed
from the drive unit, remove the three
bolts attaching the drive unit to the
motor. See Figure 7-17.
Figure 7-17. Traction Motor Mounting Bolt Location
Traction Motor
Mounting Bolts
When separating the motor from the

drive unit, do not damage the gears or
O-ring sealing surface in the housing.
Cover the opening of the drive unit to

prevent contamination while the motor
is removed.

Brake Service
NOTE: Replace the brake disk sets in both drive
units at the same time.
Figure 7-18. Exploded View of Drive Unit

Refer to Figure 7-18 for bracketed numbers • internal tooth disk [5]
referenced in this procedure. • external tooth disk [4]
Place the drive unit in a holding device or on the • internal tooth disk [5]
wheel bolts to perform the following steps. • external tooth disk [4]
1. Use an impact wrench to loosen the NOTE: Align the “high spots” on the internal
countersunk bolts in the cover [1]. tooth disks for maximum “spring”
action.
6. Insert the disk set into the ring gear [7].
Do not damage mating surfaces during 7. Put the internal disk carrier [3] into the
disassembly. correct fitting position. Slide the disks into
their correct position by slightly turning or
2. Carefully pry the cover [1] off the drive moving the internal disk carrier.
unit.
8. Carefully remove the internal disk carrier
NOTE: When the housing cover is removed, the from the fitting position. Make sure that
spur gear [2] remains connected to the the position of the disk is not changed.
internal disk carrier [3] as a single unit.
NOTE: If the wearable brass brake activation
3. Remove the disk set (four external tooth [4] pad [8] is replaced, make sure it is
and three internal tooth disks [5]) and positioned correctly. See Figure 7-20.
thrust washer [6] from the ring gear [7].
Figure 7-20. Brake Activation Pad
4. Lightly rub the new internal tooth disks
with a flat sanding block to visually
establish “high spots”. These “high spots”
must be in alignment when installed to
ensure correct braking. See Figure 7-19.
Figure 7-19. High Spots On Brake Disk
This hole must be

positioned toward
the bottom of the
drive unit
High Spot
Assembly
1. Thoroughly clean all the parts and remove
5. Assemble the new disk set in the following all residual thread-locking compound.
order:
2. Check brake disks for wear and damage.
• thrust washer [6] Replace if necessary.
• external tooth disk [4]
NOTE: Replace brakes in sets only.
• internal tooth disk [5]
3. Smooth the sealing surface with an
• external tooth disk [4] oilstone or a double-smooth file.

4. Replace all sealing elements using mastic 2. Drive a straight pin through both the cover
sealants (such as Loctite®). mount and the brake lever.
5. Assemble the cover to the drive unit. 3. Secure the straight pin with two snap
6. Check that silicone has been spread on rings.
the sealing surface of the cover. 4. Check the setting clearance (A).
7. Align the two 8 mm holes in the cover with
the two straight pins in the drive unit. Setting clearance (A) for the brake lever
should measure between 0.016 and
8. Drive the cover onto the drive unit. Move 0.039 in. (0.4 and 1.0 mm).
the cover lightly and tap on it with a
plastic hammer.
9. Use blue thread-locking compound
Storage
(P/N 1013829) to secure the countersunk • If no motor is attached, seal the drive unit
bolts that fasten the cover. Torque the to prevent contamination.
bolts to 6.6 ft. lb. (9 Nm).
• Fill the drive unit with oil. Turn the drive
shaft several times, then drain the oil.
Mounting Brake Actuator Lever to Drive Unit
Pack the drive unit in a closed plastic
1. Insert the brake lever into the cover container.
mount. Make sure the brake lever is
correctly positioned. See Figure 7-21.
Figure 7-21. Brake Actuation Lever Mounting
Snap Ring
Straight Pin
Brake
Actuator
A Lever

Single Traction Motor Trucks 4. Remove both the fill and drain plugs. Allow
fluid to drain out completely.
The drive unit/motor assembly consists of a 5. Clean any ferrous residue from the
planetary gear type drive unit and an AC motor. magnetic drain plug. Replace the drain
plug.
Drive units on trucks below S/N 10677 have a
6. Use a flexible hose with either a syringe or
automotive type shoe brake. See “Brake Service
a funnel to add new fluid through the fill
- S/Ns below 10677” on page 7-29. Drive units
plug hole until it is visible halfway up the
on trucks S/N 10677 and up have a internal
level window (approx. 2.6 qt./2.5 liter).
wet-brake system. See “Brake Service - S/Ns
Refer to "Lubrication Specification Chart"
10677 and up” on page 7-30.
on page A-2. Install the fill plug.
7. Clean the area around the fill and drain
Changing Fluid plugs.
S/Ns below 10677 8. Run the truck for several minutes. Check
fluid level again. Add fluid as necessary.
the fluid.
S/Ns 10677 and up
2. Clean the area around the fill and drain
NOTE: S/N trucks 10677 and up require a
plugs. See Figure 7-22.
specific break-in oil (P/N 990-603/SPL)
Figure 7-22. Drive Unit Plug Locations for the first 1500 hours of operation.
Fill
Plug the fluid.
2. Clean the area around the oil fill/oil level
Level plug and drain plugs. See Figure 7-23.
Window Figure 7-23. Drive Unit Plug Locations
Brake Bleeder
Oil Filler/Oil
Level Plug
Drain Oil Drain Plugs

Plug
3. Remove the oil fill/oil level plug. Remove
the sealing ring from the plug.
4. Place suitable container(s) below the drain
plugs.
5. Remove the drain plugs. Remove the
sealing rings from the plugs. Allow fluid to
drain out completely.
6. Clean any ferrous residue from the
3. Place a suitable container below the drain magnetic drain plugs. Install the drain
plug. plugs with new sealing rings.

7. Use a flexible hose with either a syringe or Figure 7-24. Accelerator Pedal Assembly
a funnel to add new fluid through the fill
hole until the oil level is at the bottom edge Pedal Assembly
of the fill hole/(approx. 1 gal./4 liters).
Refer to "Lubrication Specification Chart"
on page A-2. Install the fill plug with new
sealing rings.
8. Clean the area around the oil fill/oil level
plug and drain plugs.
9. Run the truck for several minutes. Check
fluid level again. Add fluid as necessary.
Drive Unit Removal Connector
1. Remove mast. See “Mast Removal and

Installation” on page 7-68. 7. Remove the upper and lower covers from
2. Block the steerable wheels to prevent the parking brake cable assembly.
truck movement. 8. Disconnect the parking brake cable.
9. Secure the drive unit using suitable hoist
straps placed around the flared flange
attaching the drive unit to the traction
Use extreme care whenever the truck is motor.
jacked up for any reason. Never block
10. Block the front of the traction motor.
floor. Use a suitable hoist to stabilize the 11. Remove the four bolts securing the
mast. Keep hands and feet clear from traction motor to the drive unit. Separate
beneath vehicle while jacking. Use jack the drive unit from the traction motor.
stands or solid blocks to support truck. NOTE: On drive units with automotive type
Do not rely on the jack alone. See shoe brakes, make sure the bolts are
“Jacking Safety” on page 2-8. removed from the large flared end of the
flange (closest to the traction motor). Do
3. Jack the front of the truck. Securely block not remove the six bolts on the small
the truck in position. end of the flange (closest to the drive
4. Remove and cap the hydraulic brake unit).
line(s).
12. Remove hardware securing the drive unit
5. Remove the floor plate from the operator to the chassis.
compartment.
13. Using a hoist, carefully roll drive unit
6. Disconnect the accelerator pot connector assembly forward and away from the
and remove the accelerator pedal chassis.
assembly. See Figure 7-24.
Drive Unit Installation
1. Secure the drive unit using suitable hoist
straps placed around the flared flange of
the drive unit.
2. Carefully assemble the drive unit to the
traction motor. Make sure the pinion and
spur gears mesh correctly.

3. Torque the four motor mounting bolts to

17 ft. lb. (23 Nm).
4. Reinstall the drive unit components in
reverse order of removal. Use extreme care whenever the truck is
5. Reinstall mast. See “Mast Removal and
Installation” on page 7-68.
floor. Use a suitable hoist to stabilize the
6. Bleed brakes. mast. Keep hands and feet clear from
beneath vehicle while jacking. Use jack
Brake Service - S/Ns below 10677 stands or solid blocks to support truck.
Do not rely on the jack alone. See
Replace the brake shoes when the braking “Jacking Safety” on page 2-8.
material thickness is <0.08 in. (2 mm).
4. Jack the front of the truck. Securely block
1. Park the lift truck on a level surface and
the truck in position.
engage the parking brake. Lower the
carriage completely. 5. Remove the drive wheels.
2. Turn the key switch OFF and disconnect 6. Remove the two hex head bolts securing
the battery connector. the hub cover to the brake drum. See
Figure 7-25.
3. Block the steerable wheels to prevent
truck movement. 7. Carefully remove the hub cover by driving
a screwdriver between the hub cover and
drum with a rubber hammer.
8. Wipe excess grease from the gear nut and
safety ring. Disengage safety ring tooth
from nut and remove.
9. Remove the roller bearing and brake
drum.
Figure 7-25. Shoe Brake Assembly Exploded View
Brake Drum Roller Bearing Safety Ring
Gear Nut
4
3 Hub Cover
2 1

10. Remove old brake shoes and install new

set.
11. Set the automatic adjustment mechanism New brakes must be engaged several
to allow clearance for the brake drum by times before they become “seated” with
turning the adjuster wheel clockwise. See the brake drum. Be careful when
Figure 7-26. “breaking in” new brakes.
Figure 7-26. Automatic Brake Adjustment Mechanism
15. Drive the truck backward in an open area
and engage the brake pedal several times
to set the automatic adjustment
mechanism.
Brake Service - S/Ns 10677 and up
The braking system is made up of seven discs in

an oil bath. Refer to Figure 7-27.
When the pedal brake is depressed, three

pistons apply pressure to the outer fixed disc,
Adjustment Mechanism compressing the disc group; six stationary discs
and seven inner toothed rotating discs.
When the parking brake lever is engaged,

pressure is applied to pins that mechanically
apply pressure to the outer fixed disc,
compressing the disc group.
12. Reassemble brake assembly in reverse
order of disassembly.
13. Remove truck from jack.
14. Reconnect the battery connector and turn
the key switch ON.
Figure 7-27. Braking System - S/Ns 10677 and Up
Brake Housing Fixed Discs (qty. 6) Brake Housing Parking Brake Pins
Rotating Discs (qty. 7) Outer Fixed Disc Brake Cover

Check Brake Disc Wear Figure 7-28. Reduction Gear Mounting Bolts
1. Disconnect the cable from the parking
brake lever on the drive unit.
2. Actuate brake lever by hand until
resistance is felt. Mark the position.
3. Apply a 370 ft. lb. (500 Nm) force to the
brake lever. Mark the position.
4. Measure the distance between the two
marks. If the distance exceeds 0.5 in.
(13 mm), the brake disc set should be
replaced.
Brake Disc Set Replacement

engage the parking brake. Lower the 9. Remove both reduction gears from the axle
carriage completely. housing. See Figure 7-29.
2. Turn the key switch OFF and disconnect Figure 7-29. Reduction Gear Removal
the battery connector.
truck movement.
Use extreme care whenever the truck is

floor. Use a suitable hoist to stabilize the
mast. Keep hands and feet clear from
beneath vehicle while jacking. Use jack
stands or solid blocks to support truck.
Do not rely on the jack alone. See
“Jacking Safety” on page 2-8. 10. Remove the flange bolts. See Figure 7-30.
4. Jack the front of the truck. Securely block Figure 7-30. Flange Mounting Bolts
the truck in position.
5. Remove the drive wheels.
6. Drain the fluid (refer to page 7-27).
7. Remove the drive unit. Refer to “Drive Unit
Removal” on page 7-28.
8. Remove the reduction gear mounting bolts
from both sides of the axle. See
Figure 7-28.

11. Install two eyebolts and lift flange from the Figure 7-33. Lower Brake Cover Mounting Bolts
axle housing. See Figure 7-31.
Figure 7-31. Separating Flange From Axle Housing
12. Remove the parking brake pins from the

brake cover. See Figure 7-32. 14. Remove the four remaining brake cover
mounting bolts. See Figure 7-34.
Figure 7-32. Parking Brake Pin Removal
Figure 7-34. Brake Cover Mounting Bolts
15. Remove the disc group. See Figure 7-35.

13. Remove the lower brake cover mounting
bolts. See Figure 7-33.


Figure 7-35. Disc Removal Figure 7-36. Expose Brake Pistons
Plug
Oil Inlets
17. Remove the three brake pistons. See

Figure 7-37. Replace the brake piston
seals.
Figure 7-37. Piston Removal
16. Plug one of the oil inlets on the brake cover 18. Reassemble in reverse order of
and blow low pressure compressed air into disassembly.
the other oil inlet to expose the brake
• torque the four brake cover mounting
pistons. See Figure 7-36.
bolts to 50 ft. lb. (68 Nm). See
Figure 7-34.
• torque the two lower brake cover
mounting bolts to 34 ft. lb. (46 Nm). See
Figure 7-33.
• torque the flange mounting bolts to
34 ft. lb. (46 Nm). See Figure 7-30.
• torque the reduction gear mounting
bolts to 207 ft. lb. (280 Nm). See
Figure 7-28.
19. Bleed service brake.
20. Remove truck from jack.

Brake Pedal Adjustment Drive and Brake
Brake Pedal Adjustment

Pedal clearance should measure 1.6 in. (40 mm)
from the floor when the pedal is in the neutral
position.
132 lb. (60 kg) maximum pressure is required

to fully depress the brake pedal.
Make sure that there is some clearance between

the end of the brake push rod and the master
cylinder piston face. The push rod should float
slightly in the piston as shown in Figure 7-38.
Figure 7-38. Brake Pedal Adjustment Points
132 lb. (60 kg)
1.6 in. (40 mm)

Drive and Brake Tire Replacement
Tire Replacement tire. The new tire must be placed in the

same position the old tire was installed on
hub. You can use a spacer (slightly smaller
in diameter than inside diameter of tire
insert and same thickness as depth of
Any misalignment of the tire and hub recess) to obtain correct amount of
while the tire is being pressed onto the recession.
hub can damage the hub. For this 4. Position hub assembly with old tire on top
reason, chamfers are provided on the of circular ram so outside of wheel is
outside edge of the hub and on the end positioned upward. The outside edge of
of the inside diameter of the tire’s metal hub has a chamfer to help guide new tire
insert. The chamfers help to center the onto wheel. The chamfered edge must
hub and tire during the pressing always be leading edge when a tire is
operations and reduce the possibility of pressed onto hub.
misalignment. To prevent damage, the
hub must be installed on the circular 5. Center hub assembly on top of ram and
ram with its chamfered side up. make sure that they mate squarely.
6. Position new tire with its chamfered insert
1. Check inside surface of metal insert on facing hub. Align new tire and hub so that
new tire. Use sandpaper to remove any they are concentric.
scaling or rust. Clean inside of metal 7. Begin pressing new tire onto hub and old
insert and lubricate it with a soap tire off wheel. Run press slowly for the first
solution. few inches of travel, because this is the
2. Place circular ram on the press table. See critical stage of the operation. If tire begins
Figure 7-39. The length of the ram must to cock to one side, stop press and realign
be longer than width of the old tire to allow tire. A sharp jar with soft-headed mallet
complete removal of old tire. The outside usually realigns tire on hub.
diameter of ram must be small enough to
NOTE: If new tire does not press on with a
fit loosely in the insert of tire but must be
minimum of 5 tons (68,947 kPa)
large enough to rest squarely on flat
pressure, replace hub.
surface on outer edge of hub.
8. Release press. Remove wheel, tire
Figure 7-39. Drive Tire Installation
assembly, and old tire from press table.
Inspect wheel and tire assembly.
3. If outside edge of hub is not flush with

edge of metal insert in the old tire,
measure how far hub is recessed inside

Tire Replacement Drive and Brake

Electrical Components
Electrical Components

Battery Procedures Electrical Components
Battery Procedures 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
Battery Exterior Cleaning the entire top of the battery with the soda
solution. Wait until all foaming stops,
1. Read, understand, and follow procedures,
indicating that the battery exterior is
recommendations, and specifications in
neutralized.
the battery and battery charger
manufacturer’s manuals. 8. Rinse the battery with clean water.
2. Wear personal protective equipment. See 9. Dry the battery completely before
“Battery Safety” on page 2-5. reinstalling it.
3. Turn the key switch OFF and disconnect 10. Reinstall the battery in the lift truck.
the battery connector. Remove the battery 11. Connect the battery connector. Close the
from the lift truck. battery cover and secure the latch.
4. Inspect the battery cables to make sure
they are not frayed or loose. Inspect the Testing, Charging, and
battery connector. Make sure there is no
foreign material inside the connector.
Maintenance
Make sure the filler plugs are tight and the
For information on testing, charging, and
vent holes in the filler plugs are not
maintaining your lift truck battery, consult the
plugged.
battery manufacturer’s specifications and
Figure 7-40. Battery Cable and Filler Plug instruction manual.
Battery Cable
Filler Plug
Vent Hole Never connect a battery charger directly
to the lift truck. This can cause severe
5. Keep the top of the battery clean and dry. damage to the lift truck’s electrical
Corrosion, dust, and moisture provide a system. Plug the charger into the battery
conducting path to short-circuit cells or connector only.
create shorts to ground.
Do not clean the top of the battery with

the soda solution while it is installed in
the lift truck. Water can seep into the
electrical components and cause serious
damage.
6. Wash dirty batteries (or any that have had

electrolyte spilled on them) with a solution

Electrical Components Power Cables
Power Cables Table 7-3. Cable Jacket Strip Length - Short Barrels
AWG Lug P/N Strip Length

Check power cables for: 1/0 1002215/001-004 11/16 in. (17 mm)
• evidence of overheating
2/0 1002215/005-008 13/16 in. (21 mm)
• burned spots in the cable
3/0 1002215/009-012 1 in. (25 mm)
• nicks in the insulation
• damaged or overheated terminal lugs 4/0 1002215/013-015 1-1/16 in. (27 mm)
• damaged mounting hardware or brackets

Table 7-4. Cable Jacket Strip Length - Long Barrels
Replace damaged cables or mounting hardware AWG Lug P/N Strip Length
as necessary.
1/0 1002217/001-003 1-9/16 in. (40 mm)
Power cables are marked near the terminal lug 2/0 1002217/004-006
with the location where they belong. If the
marking is missing or is not readable, remark 3/0 1002217/007-009
the cable with the correct information.
4/0 1002217/010-011 1-11/16 in. (43 mm)
NOTE: Terminal lugs may be replaced in the
field using the appropriate crimping 5. Insert cable into terminal.
tools. Crimping tool, lugs, and 6. Place cable and terminal into tool die and
heat-shrink are available through the crimp. Refer to Figures 7-41 and 7-42 for
Parts Distribution Center. Failure to use what a completed crimp should look like.
correct cables, terminal hardware, and
torque values can result in overheating Figure 7-41. Short Barrel Terminal
and damage to components.
Power Cable Repair

Traditional lug crimping techniques for power
cables on DC motors may not meet the higher
current requirements of AC motors. Use
Manual Crimp Tool (P/N 1069861) when
crimping power cables for all AC motors. This
tool may also be used to repair power cables for
DC motors.
1. Remove the bad cable(s).
2. Using the removed cable(s) for reference,
cut an appropriate amount of replacement
cable of the same gauge.
3. Set the adjustment screw on the manual
crimp tool head to match the cable gauge.
4. Strip the cable jacket to fit the terminal to
be crimped. Refer to Table 7-3 and
Table 7-4.

Power Cables Electrical Components

Figure 7-42. Long Barrel Terminals
7. Apply heat-shrink tubing (P/N 611-035) to

the terminal after crimping.
a. For short barrels, use 1.75 in. (45 mm)
of tubing. Apply 1 in. (25 mm) over the
jacket extending 0.75 in. (19 mm) over
the barrel.
b. For long barrels, use 2.5 in. (64 mm) of
tubing. Apply 1 in. (25 mm) over the
jacket extending 1.5 in. (38 mm) over
the barrel.

Electrical Components Wiring and Harness Connectors
Wiring and Harness • Use the appropriate tools to remove and

insert terminations at each connector.
Connectors • Remove damaged terminations and
discard. Never reuse a termination from a
wire.
General Repair Procedures • Do not cut away a terminal lug and reuse
the wire strands that were crimped into
See “Electrical Troubleshooting” on page 5-2.
the original lug.
Whenever working on the lift truck, use care • When stripping wire, use new wire strands
around wiring harnesses. for new terminations. Use a new wire with
extra length to allow for cutting and
• Carefully connect and disconnect all
stripping of the ends to install new
connections.
terminations.
• Do not pry connectors apart with
• Use a new wire that is the same gauge
unspecified tools.
(typically 18 gauge AWG), size, type, and
color as the wire it is replacing.
There should be a wire marker at each
termination. If the marker is missing or • Use a hand stripper capable of stripping
unreadable, remark the wire to allow easier by wire gauge number. Use care not to
identification. nick or cut any of the wire strands.
Discard and replace a wire with damaged
NOTE: It is normal to find unused connectors strands. Insert the wire strands the
for uninstalled options that have had correct length into termination before
heat shrink applied over them and have crimping.
been strapped to the harness.
Soldering Procedures
Repair
To prevent damage from excessive heat when
soldering small components in assemblies,
follow these guidelines.
Use correct electrostatic discharge
precautions. See “Static Precautions” on Make sure the soldering tip is clean. A dirty tip
page 2-7. does not transfer heat well and encourages long
dwell time and greater pressure. Apply light
When pulling a wire out through a bundle, cut pressure on the terminal.
off the pin or socket so it will not snag. When
replacing wires, in some cases you will be able • Flux: rosin base
to tape or solder one end of a new wire to one • Solder: 60/40 rosin core or equivalent
end of the failed wire. Then you can pull the old • Solder Iron: 55 watt max
wire out of the bundle and pull the new wire
into the bundle, all at the same time. Be sure to • Tip Size: 0.118 in. (3 mm) diameter by
disconnect the old wire from the new wire. 1.182 in. (30 mm) long screwdriver tip
• Tip Temperature: 500°F (260°C) max
In other cases, it is easier to secure a new wire • Terminal Contact Time: 6 seconds max
to the outside of the existing wire bundle with
straps of an appropriate size. The failed wire • After soldering, clean the terminals with a
can be left in the bundle, or can be pulled by brush dampened with an alcohol-based
one end to remove it from the bundle. cleaner (P/N 990-600/FOF). Do not allow
cleaner to seep into switches or
When replacing wires, follow these guidelines: potentiometers.

Wiring and Harness Connectors Electrical Components
NOTE: Components damaged due to solvent depressed far enough to clear the ridge in the
saturation are not covered under connector.
warranty.
Pin Extraction
Molex Connectors
To remove a pin from a Molex connector, use
Figure 7-43. Molex Connector, end view pin extraction tool P/N 950-026.
Socket 1. Insert the extraction tool over the pin and
push all the way into the connector. This
releases the locking ears on the pin. See
Pin Figure 7-44.
2. Pull the wire and pin from the connector.
Pin Insertion
To insert a pin into a Molex connector, insert

Locking Ears the pin into the back side of the connector and
push the wire all the way in until it clicks. The
locking ears have now engaged the connector.
For pin orientation of Molex connectors, see
Figure 5-2 on page 5-7. Molex connectors have
pins with locking ears that engage ridges in the
plastic connector body. To remove a pin from a
Molex connector, these locking ears must be
Figure 7-44. Pin Extraction
Top view
of Tool inserted over
connector pin
Locking Extraction
ears Tool
Side view
of
connector

AMP Harness/Harness
Connectors
AMP connectors provide water-resistant
connection by the use of seals between wires
and connectors and between the mating
connector halves.
To maintain the integrity of water-resistant

seals, use the following procedures when
working with AMP connectors.
Figure 7-45. AMP Water-Resistant Connector
Wire Seal
Interface
Seal
Contact
Cavity
Wire Seal Jack

Housing
Pin Contact
Pin Housing
Sealing Plug
Pin Extraction Figure 7-46. AMP pin extraction

Extraction Tool
To aid in separating AMP connectors, use
unlatching tool P/N 950-042. To remove a pin
from an AMP connector, use pin extraction tool
P/N 950-009.
1. While holding the wire seal, push the
selected wire forward, then insert the
extraction tool into the contact socket. See
Figure 7-46.
Locking
Lance
2. Pull the wire gently until you feel the
contact locking lances disengage.
3. Holding the wire seal and connector
housing together, rotate the wire while
pulling it through the wire seal. This

prevents damage to the seal. See Figure 7-49. Wire insertion

Figure 7-47.
Figure 7-47. Removing wire
Pin Contact
Rotate and Pull

Seals
1. Use a wire seal at the back (wire end) of
Pin Insertion each connector half. See Figure 7-48.
2. Plug unused pin positions with sealing
1. Make sure the connector has a wire seal plugs. See Figure 7-50.
attached to the connector back. See
Figure 7-48. Figure 7-50. Sealing Plug
Figure 7-48. Wire Seal Sealing Plug
Wire Seal
Pin Housing
2. If re-inserting a wire previously removed, a. Align the split tapered end of the
make sure the pin contact locking lances sealing plug with the unused opening
are extended to their original position. in the wire seal. Push the plug through
3. Grasp the wire close behind the contact the wire seal into the connector until it
insulation barrel and push the wire snaps into position.
straight through the wire seal into the b. Sealing plugs can be removed by
socket until it clicks. Pull back gently to pulling with needle-nose pliers while
make sure the contact is locked in place. grasping the wire seal and connector.
See Figure 7-49.
3. Use an interface seal between pin and jack
halves of the connector. To prevent
damage to the seal, use the matching
connector cap to slide the interface seal
over the contact silos on the pin housing.
See Figure 7-51.


Figure 7-51. Interface Seal
Interface
Seal
Pin Housing
4. When mating connectors, make sure the

polarized silos are correctly oriented. Push
pin and jack halves of the connector
together until locking latches engage. See
Figure 7-52.
Figure 7-52. Latching AMP connector
Locking Latch

AMP Harness/Power Amplifier

Connector
Connector Components
Figure 7-53. JPT1 Connector Components
(PT-1 on Traction Power

Amplifier)
(JT-1)
Disassembly (Contact Removal) Assembly

1. Insert a 4.8 mm screwdriver blade between
the mating seal and one of the red wedge Make sure the wedge lock is open.
lock tabs. See Figure 7-54. 1. To insert a contact, push it straight into
2. Pry open the wedge lock to the open the appropriate circuit cavity as far as it
position. will go. See Figure 7-55.
3. While rotating the wire back and forth over 2. Pull back on the contact wire with a force
a half turn (1/4 turn in each direction), of 1 or 2 lbs. to make sure the retention
gently pull the wire until the contact is fingers are holding the contact. See Figure
removed. 7-55 (c).
Figure 7-54. AMP JPT1 Connector


Figure 7-55. Contact Insertion
3. After all contacts have been inserted, the

wedge lock must be closed to its locked
position. Release the locking latches by
Be very careful when putting the wedge
squeezing them inward. See Figure 7-56.
lock in the locked position. Forcing the
Figure 7-56. Wedge Lock Latches wedge lock can cause damage to the
connector. Make sure the wedge lock is
aligned correctly. If resistance is felt,
slightly adjust the wedge lock until it
slides in freely.
4. Slide the wedge lock into the housing until

it is flush with the housing. See
Figure 7-57.


Figure 7-57. Wedge Lock Flush With Housing
Testing
Do not pierce wire insulation with a sharp point

while troubleshooting.
The wedge lock has slotted openings in the

forward (mating) end. These slots accommodate
circuit test tabs that are approx. 3.3 by 0.6 mm,
which prevent damage to the receptacle. For
circuit testing in the field, use a flat probe. Do
not use a probe with a sharp point.

Electrical Components Power Amplifiers
Power Amplifiers Table 7-5. Pump Power Amplifier Jumper Configuration
Model Jumper(s)
Before replacing a power amplifier, record the
470-C30 No jumpers required.
current performance parameters for reference
when setting parameters in the new amplifier. 470-C40 JBP-1 to JBP-2
470-C50HM JBP-1 to JBP-2

JEP-4 to JEP-5
Before removing a power amplifier, 470-C50 *JP2-1 to JP2-2

discharge the amplifier’s internal
470-C60
capacitor by jumpering the + and –
terminals with a 100 ohm 25W resistor. *Make sure this jumper is not present when power
amplifier is used as a traction amplifier.
Terminal Hardware
Do not attempt to repair power cable

terminal lugs without approved tools. If
a power cable has worn or damaged
lugs, replace the cable or refer to
“Power Cable Repair” on page 7-39. Do
not substitute other kinds of nuts for the
flanged nuts. Failure to use correct
cables, flanged nuts, and torque values
can result in overheating and damage to
components.
Whenever you connect power cables to a motor

or power amplifier, do not over-tighten nuts or
bolts. On motors with stud terminal securing
nuts, use a second wrench on the securing nut
to avoid twisting the stud. Torque power cable
terminal nuts to 11 ft. lb. (15 Nm).
Electrical Jumpers
Most Model 4700 pump power amplifiers are
configured with electrical jumpers. When
replacing a pump power amplifier on these
models, refer to Table 7-5.

Fuses Electrical Components
Fuses Figure 7-60. Main Fuse Panel
For a complete list of fuses, amperage ratings,

and functional descriptions, refer to page 5-4.
Power Amplifier Fuses

Fuses for the Traction and Pump Power
Amplifiers are attached to their respective
power amplifier located in the right side
electrical compartment. See Figures 7-58 and
7-59.
Parts link:
C30, C40, C50HM
C50, C50HP, C50L. C60
Figure 7-58. Power Fuses - Dual Traction Motor Trucks
FP
+24V Fuse Panel

Fuses for +24V components are located on a
panel near the VM. On dual traction motor
trucks, the panel is located in the left side
electrical compartment. On single traction
motor trucks, the panel is located in the right
FT side electrical compartment on the fold-down
cover. See Figure 7-61.
Figure 7-59. Power Fuses - Single Traction Motor Trucks
FP FT
Main Fuses
Fuses for the key switch, DC/DC Converter,
Hydraulic Control Board, and optional
equipment terminal strip are located on the
Main Fuse Panel in the right side electrical
compartment. See Figure 7-60.

Electrical Components Fuses

Figure 7-61. +24V Fuse Panel Figure 7-62. Fuse Panel Near Hydraulic Control Board
DC/DC Converter Fuse

The DC/DC Converter on earlier trucks has a
12A fuse located on the end opposite the
connector.
Optional Fingertip Control Fuses

Fuses for optional fingertip controls are located
on the armrest mounting bracket near the
Hydraulic Control Board. See Figure 7-62.

Potentiometers Electrical Components
Potentiometers Travel Potentiometer (P2)

The travel pot is located in the right rear of the
Steer Potentiometer (P1) pedal assembly. See Figure 7-64.
Figure 7-64. Accelerator Pedal Assy. (single pedal shown)
The steer pot is located on the right side of the
steer axle (on dual traction motor trucks only).
See Figure 7-63.
Figure 7-63. Model 4700 Steer Pot
Travel Potentiometer
Removal
2. Unplug the wiring harness connector from
the steer pot and remove dust cap.
3. Remove the two screws and washers
securing the steer pot to the mounting
bracket. Removal
4. Carefully lift the steer pot straight off the 1. Turn the key switch OFF and disconnect
shaft. the battery connector.
2. Remove the operator compartment floor.
Installation 3. Unplug the wiring harness connectors to
1. Install the steer pot on the circular disk or the traction pot and switch(es).
bracket. 4. Remove the accelerator pedal assembly
2. Plug the wiring harness connector into the from the lift truck.
steer pot. 5. Remove the travel pot from the accelerator
3. Adjust steer pot to 5.5V with wheels pedal assembly.
straight per Pinout Matrix.
4. Run Learn for the steer pot in FlashWare. Installation
5. Secure the dust cap to the top of the steer 1. Install the new travel pot in the pedal
actuator. assembly.
2. Install the pedal assembly in the lift truck.

Electrical Components Potentiometers
3. Plug the wiring harness connectors into 1. Place the lift pot shaft through the hole in
the travel pot and switch(es). the control valve bracket. Align the locator
4. Run Learn for the travel pot in FlashWare. pin with the hole in the mounting plate.
2. Install the lock washer, nut, and washer
ring on the lift pot shaft. If the articulated
Lift Potentiometer (P3) joint is broken and/or the pot shaft slips
in the articulated joint bracket, replace the
Removal articulated joint.
1. Turn the key switch OFF and disconnect 3. Tighten the socket head screw in the shaft
the battery connector. clamp. Operate the lift/lower lever and
check for misalignment. The pot is
2. Remove the control valve cover.
sensitive to axial and side loading. If the
3. Unplug the wiring harness connector to shafts or pot mounting brackets are
the lift pot. misaligned, repair or replace. If there is
4. Loosen the socket head screw securing the excessive axial clearance, add a washer on
clamp on the lift pot shaft. the pivot shaft to reduce the axial
movement.
5. Remove the hardware securing the lift pot
to the bracket. 4. Verify resistance decreases linearly when
6. Remove the pot from the bracket. the lift lever is pulled.
5. Verify the lift microswitch operates
Figure 7-65. Lift Pot Location
correctly.
6. Run Learn for the lift pot in FlashWare.
Lift Pot
Installation
Before installing the new pot, connect a DVM

(set to resistance and 20,000 ohm range)
between the green and yellow wires on the pot
assembly. While rotating the pot shaft for one
full rotation, monitor the resistance of the pot.
There are two positions where the resistance
varies between 0 and approx. 5,000 ohms.
These positions are approx. 180° of shaft
rotation from each other. One location uses
approx. 20° of pot rotation and the other uses
less than 10° of rotation. Position the shaft in
the 20° location before installing pot.

Motor Encoder Bearing Electrical Components
Motor Encoder Bearing Figure 7-67. Snap Ring Removal
Parts link:
C30, C40, C50HM
C50, C50HP, C50L, C60
Removal
2. Disconnect all cables and connectors at
the motor and remove the motor.
3. Remove the four bolts that secure the top Snap
Ring
end bell to the bottom end bell. See
Figure 7-66.
Figure 7-66. Retaining Bolt Removal
7. With a spacer between the motor shaft and

bearing puller, remove the encoder
bearing. See Figure 7-68.
Figure 7-68. Encoder Bearing Removal
Retaining
Bolts
Spacer
4. Mark the position of the top end bell and

bottom end bell relative to the stator.
5. Remove top end bell.
6. Remove the snap ring. See Figure 7-67.
Installation
1. Lubricate motor shaft before installing
new encoder bearing. See Figure 7-69.

Electrical Components Motor Encoder Bearing

Figure 7-69. Lubricate Motor Shaft Figure 7-71. Driving Encoder Onto Motor Shaft
2. Drive the new encoder bearing onto the 4. Install the snap ring. See Figure 7-72.
motor shaft using an M8 screw, nut, and
washers. See Figure 7-70. Figure 7-72. Snap Ring Installation
Figure 7-70. Encoder Bearing Installation

M8 Screw
Nut
Washer
5. Install top end bell with the four bolts that

secure it to the bottom end bell.
Large Washer
6. Torque the end bell retaining bolts as
follows:
3. Slowly turn the nut until the bearing is Traction motor - 15 ft. lb. (20 Nm)
seated. See Figure 7-71. Pump motor - 8 ft. lb. (11 Nm)
7. Re-install motor.
8. Reconnect all connectors and power
cables. Torque motor cable securing nuts
to 18 ft. lb. (24 Nm).
the key switch ON.
10. Test truck operation.

Motor Temperature Switch Repair Electrical Components
Motor Temperature 3. Disconnect cables and motor harness

connections, making sure that you note
Switch Repair locations for reassembly later.
4. Separate the pump assembly from the lift
Temperature switches for the drive and pump pump motor and remove lift pump motor.
motors are integral to the motor. When a motor 5. Remove the four bolts that secure the top
temperature switch fails, it can be replaced end bell to the bottom end bell.
using the procedures that follow. 6. Remove the top end bell. Use care that the
bearing remains in the bottom end bell to
Traction Motor reduce the chance of damaging the
bearing.
7. Install a new temperature sensor using the
high temperature silicone (neutral curing)
2. Disconnect all cables and connectors at supplied with the temperature switch.
the motor. Mount the sensor close to the location of
3. Mark the position of the top end bell and the original. Secure the cable with a cable
bottom end bell relative to the stator, then tie to one of the power leads.
remove the snap ring. 8. Carefully press the top end bell to the
4. Remove the four bolts that secure the top stator. Do not pinch the cables or allow
end bell to the bottom end bell. contact with the rotor. Verify correct stator
installation.
5. Remove the top end bell. Use care that the
encoder bearing remains in the bottom 9. Secure the top end bell to the bottom end
end bell to reduce the chance of damaging bell using the four bolts previously
the bearing. removed.
6. Install a new temperature switch using the 10. Reinstall pump motor to the pump
high temperature silicone (neutral curing) assembly.
supplied with the temperature sensor. 11. Reconnect connector and power cables.
Mount the sensor close to the location of
the original. Secure the cable with a cable 12. Reconnect the battery connector and turn
tie to one of the power leads. the key switch ON.
7. Install the top end bell in the position that

was previously marked. Verify correct
stator installation and install snap ring.
8. Secure the top end bell to the bottom end
bell using the four bolts previously
removed.
9. Reconnect all connectors and power
cables. Torque motor cable securing nuts
to 18 ft. lb. (24 Nm).
the key switch ON.
Pump Motor
2. Disconnect the temperature switch
connector.

Electrical Components Cold Storage Conditioning
Cold Storage
Conditioning
NOTE: Conversion of lift trucks for cold storage
operation requires prior Raymond
approval via Form S207.
Lift trucks operated in a cold storage

environment require the following:
• All-weather hydraulic fluid (P/N 1017238)
NOTE: Do not add any additive to this hydraulic
fluid.
• Sealed seat switch (P/N 312347-000).
• Sealed electrical connectors. See
“Connector Sealing”.
Connector Sealing
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.
NOTE: Self-sealing AMP connectors (reference
page 7-43) do not need sealing
treatment.
Corrosion Inhibitor Coating

Coat or spray bare metal surfaces listed below
with Corrosion Inhibitor Coating (P/N 990-644):
• Reach cylinder cotter pins
• Main and free lift chain pulleys and shafts
• Main and free lift chain anchors and
threaded pins

Cold Storage Conditioning Electrical Components

Hydraulic Components
Hydraulic Components

Hydraulic Fluid Hydraulic Components
Hydraulic Fluid • Remove a hydraulic pump

• Remove the hydraulic reservoir
Changing Fluid TF and TT Masts

To change the hydraulic fluid, park the truck on 1. Reconnect the battery connector and turn
a flat surface with the mast tilted back and the the key switch ON. Sit on the seat and lift
forks lowered. Set the parking brake. the forks 6 to 12 in. (150 to 300 mm) off
the ground.
1. Disconnect one of the outboard hoses that
feeds the auxiliary functions. 2. Free Lift Cylinders - Loosen (do not
2. Direct the hose into a waste container with remove) the bleed screw on the lift cylinder
a capacity >5.5 gallons (21 liters). To drain to let any air escape. Hold a shop rag close
to and beneath the bleed screw to keep
the reservoir, operate an auxiliary function
any hydraulic fluid from spraying out.
until you hear air in the system.
When all of the air has escaped and
hydraulic fluid starts coming out of the
bleed screw hole, securely tighten the
Operating the pump with the system bleed screw.
drained can damage the pump. NOTE: Main Lift Cylinders are self-bleeding. Lift
and lower the forks several times.
the battery connector. 3. Lower the forks all the way to the floor.
4. Remove the floor of the operator NOTE: When bleeding the hydraulic system,
compartment to access the reservoir and bleed all cylinders.
filter.
4. Bleed the auxiliary system:
5. Remove cap with filter. Remove the filter
a. Tilt the mast all the way forward and
from the cap.
backward several times.
6. Install a new filter on the cap.
b. If the lift truck has sideshift, shift the
7. Reconnect the outboard hose. carriage all the way to the left and right
8. Fill the reservoir with new, clean hydraulic several times.
fluid. Refer to "Lubrication Specification 5. Check the hydraulic fluid level. Add
Chart" on page A-2. Install cap with filter. hydraulic fluid as needed.
9. Install the operator compartment floor.
10. Test to make sure the hydraulic system is Quad Masts
functioning correctly.
1. Without a load, extend the free lift cylinder
11. Check to make sure there are no fluid and continue to extend the main lift
leaks. cylinders to 90% of full stroke. Retract all
cylinders completely. Repeat three times.
Bleeding the Hydraulic System 2. Extend the cylinders without a load at
50% lift speed, then build full system
You must bleed the hydraulic system whenever pressure at the end of the main lift
you: cylinder stroke. Retract cylinders. Repeat
• Change the hydraulic fluid and filter four times.
• Change a hydraulic hose 3. Cycle the mast with a half load (50% mast
rated capacity) through full cylinder
• Disconnect a hydraulic fitting extension several times. The cylinders
• Notice that the load is bouncing should extend smoothly. Repeat the steps
• Remove a hydraulic cylinder if cylinder extension is not smooth.

Hydraulic Components Hydraulic Pressure Adjustment
Hydraulic Pressure
Adjustment
Lift and auxiliary function pressures are
adjusted at the control valve. On trucks with
lever controls, the lift, tilt, sideshift, and 4th
aux functions have individual adjustment
points on the control valve. On trucks with
optional fingertip controls, only the lift pressure
is adjustable. See Figures 7-73 and 7-74.
Figure 7-73. Pressure Adjustment Points - Lever Controls
4th Aux Lift
Sideshift Tilt
Tilt Forward
Sideshift Left Lift

4th Aux
4th Aux
Sideshift
4th Aux
Tilt
Sideshift Right
Tilt Backward
Lift
OLDER MODELS
NEWER MODELS
1. Loosen retaining nut.
2. Turn pressure adjusting screw:
clockwise to increase pressure
counterclockwise to decrease pressure
3. Tighten retaining nut.

Hydraulic Pressure Adjustment Hydraulic Components

Figure 7-74. Pressure Adjustment Points - Fingertip Controls
EVP Proportional Valve
EV7 - 4th Aux EV8 - 4th Aux
EV6 - Right Sideshift

EV5 - Left Sideshift
EV3 - Tilt Forward
EV4 - Tilt Backward
Lower
Lift
Pressure Adjusting Screw
Turn pressure adjusting screw:

clockwise to increase pressure
counterclockwise to decrease pressure Valve Tightening Torque - 22 ft. lb. (30 Nm)
Lift Pressure Adjustment Figure 7-75. Pressure Port - Dual Traction Motor Trucks
1. Lower the carriage completely.

3. Remove the cover to gain access to the
pump pressure port. Remove protective
cap.
4. Using Metric Pressure Fitting Adapter Pressure port
capable of reading at least 5000 psi
(34,470 kPa) at the pump pressure port.
See Figures 7-75 and 7-76.

Hydraulic Components Hydraulic Pressure Adjustment

Figure 7-76. Pressure Port - Single Traction Motor Trucks Auxiliary Function Pressure
Adjustment
Pressure port 1. Lower the carriage completely.
3. Remove the cover to gain access to the
pump pressure port and the hydraulic
control valve cover.
4. Using Metric Pressure Fitting Adapter
at the pump pressure port.
5. Reconnect the battery connector and turn the key switch ON.
the key switch ON.
6. Activate an auxiliary function to bypass.
6. Place the maximum rated load on the
forks. NOTE: Loosen the locking nut for the function
requiring adjustment and turn the
7. Elevate the carriage past free lift (when the
pressure adjustment screw clockwise to
telescopics begin to lift). Record the
increase pressure, counterclockwise to
pressure required to lift the load.
decrease the pressure.
8. Lower the carriage and remove the load.
7. Check the pressure. Adjust the
9. Elevate the carriage in a safe area until the corresponding pressure adjustment screw
upper limit is reached (lift bypass). to 2300 psi (16000 kPa) max (see
NOTE: Loosen the locking nut and turn the lift Figure 7-73).
pressure adjustment screw clockwise to 8. Tighten the locking nut.
increase pressure, counterclockwise to
decrease the pressure.
10. Continue trying to lift. Turn the lift 10. Remove pressure gauge from the pump
pressure adjusting screw (see Figure 7-73) pressure port and replace cap.
to obtain a pressure reading 200 psi
(1379 kPa) greater than the pressure 11. Reinstall covers.
required to lift the maximum rated load
(the value recorded in step 7).
11. Check the pressure again. Repeat this
procedure until the correct pressure
reading is obtained. Tighten the locking
nut.
13. Remove pressure gauge and adapter from
the pump pressure port and replace
protective cap.
14. Reinstall covers.

Hydraulic Pump and Motor Hydraulic Components
Hydraulic Pump and

Motor
If the pump is to be removed, disconnect hoses.
If motor only is to be removed, leave the hoses
attached to the pump.
Parts link:
C30
C40, C50, C50HM, C50HP, C50L, C60
Separating Pump and Motor

There are four bolts on the end of the pump.
Two bolts are shorter and hold the pump
together. The other two bolts are longer and
thread into the end bell of the motor. See
Figure 7-77.
Figure 7-77. Pump Mounting Bolts
Pump
Mounting
Bolts
Apply molybdenum anti-seize compound

(P/N 990-638) to the pump shaft splines before
reassembly.
After reassembly, torque the pump mounting

bolts to 33 ±4 ft. lb. (45 ±5 Nm).

Hydraulic Components Quad Mast Cylinder Service
Quad Mast Cylinder 2. Use a strap wrench and 400-grit emery

cloth to secure the plunger while turning
Service the piston with a pin type spanner wrench.
See Figure 7-78.
Figure 7-78. Piston Removal
Main or Free Lift Cylinders
Hole
1. Remove the cylinder from the mast. See
“Cylinder Removal and Installation” on
page 7-84.
2. Use a claw-type spanner wrench to remove
the retainer from the shell.
3. Remove the plunger/piston assembly from
the shell.
MA0677 eps
4. Inspect all components for nicks or burrs. 3. Turn the piston until the snap wire end is
Minor nicks or burrs can be removed with visible through the hole. Use a screwdriver
400-grit emery cloth. to start the wire end out the hole. Turn the
NOTE: Minor nicks are those that will not piston to feed the wire out.
bypass oil when under pressure. If they 4. Pull the piston from the plunger.
cannot be removed with emery cloth,
5. For reassembly, reverse the removal
replace the part. If the piston requires
procedure. Install a new snap wire when
replacement, refer to “Piston Removal”.
installing the piston.
5. Replace the retainer and piston seals,
back-up rings, O-rings, and bearing. Check Valve Inspection
Lubricate the new seals with petroleum
jelly prior to installation. Note correct seal Some Quad masts may experience drift if the
direction. The seal lip always points toward check valve(s) in the right side main lift cylinder
the pressure side of cylinder. The cylinder become loose.
will not operate correctly if the seals are
installed backwards. 1. Remove the right side main lift cylinder.
6. Main Lift Cylinder - Install the plunger 2. Remove piston.
retainer on the plunger. Install the 3. Remove check valve. See Figure 7-79.
plunger/piston assembly into the cylinder
Figure 7-79. Quad Mast Check Valves
shell. Using the claw spanner and strap
wrenches, tighten the retainer to 95 to
125 ft. lb. (129 to 169 Nm).
Free Lift Cylinder - Install the plunger

retainer on the plunger. Install the
plunger/piston assembly into the cylinder
shell. Pour 1/2 cup (120 ml) hydraulic oil
into the cylinder cavity between the shell
and rod. Using the claw spanner and strap
wrenches, tighten the retainer to 95 to
125 ft. lb. (129 to 169 Nm).
Piston Removal
1. Remove the plunger/piston assembly from
the cylinder shell.

Quad Mast Cylinder Service Hydraulic Components
4. Inspect check valve. If the O-ring is

missing or damaged, replace the check
valve. Refer to Parts Manual.
5. Clean check valve and apply Replacing the valve cartridge with a
thread-locking compound (P/N 990-403) different part number may cause the
to circumference of check valve. mast to malfunction.
6. Re-install check valve and torque to
4. Install new valve cartridge.
50 in. lb. (5.65 Nm).
5. Connect supply hose.
7. Repeat steps 3 thru 6 for remaining two
check valves.
8. Reassemble cylinder and install in mast.
Valve Cartridge Replacement

1. Lower mast completely.
2. Remove supply hose from the valve
cartridge. Plug the hose. See Figure 7-80.
Figure 7-80. Valve Cartridge Replacement
Valve
Cartridge
Supply Hose
3. Remove the valve cartridge from the

lowering control valve. Note the stamped
part number on the cartridge when
ordering a replacement.

Mast
Mast

Mast Removal and Installation Mast
Mast Removal and 9. Disconnect the main hydraulic hose at the

base of the mast.
Installation 10. Remove the screws, lock washers, and
plate securing the pins through the tilt
cylinder yoke and mast mounting
Dual Traction Motor Trucks brackets. Remove the cylinder mounting
pins. See Figure 7-82.
The base of the mast is attached to the tractor
Figure 7-82. Mast-to-Tilt Cylinder Mounting
frame near the traction motors and to the tilt
cylinders.
Removal
engage the parking brake. Lower the
carriage completely.
2. Tilt the mast completely forward.
truck movement.
5. Remove forks.
6. Double wrap a sling around the top of the 11. Lift the mast away from the lift truck
mast. Attach a suitable lifting device to the slowly until you have enough room to
mast and lift until the sling is snug. reach the bleeder hose. Disconnect the
7. Remove the lower bearing caps and bolts bleeder hose, then continue moving the
clamping the base of the mast to the mast away from the lift truck.
chassis. See Figure 7-81. 12. Slowly lower the mast until it lays flat on
the floor.
Figure 7-81. Mast-to-Frame Mounting Points
Installation
Mounting Points 1. Double wrap a sling around the top of the
mast. Attach a suitable lifting device to the
mast and slowly lift the mast to vertical.
2. Slowly move the mast toward the lift truck,
aligning the mast mounts.
3. Before the mast is fully in position,
connect the bleeder hose to the reservoir.
4. Finish aligning the mast on the mast
mounts.
5. Place the pins through the tilt cylinder
yoke and mast mounting brackets.
NOTE: The bearing caps are machined. Mark
each bearing cap so that it is returned to NOTE: Make sure the bearing caps are
the correct side during mast returned to the correct side during mast
installation. installation.
8. Disconnect the auxiliary supply hoses at 6. Install the lower bearing caps and bolts
the sides of the mast. securing the base of the mast to the

Mast Mast Removal and Installation
chassis. Torque the mast to chassis Figure 7-83. Mast Base Hardware
securing bolts to 36 ft. lb. (49 Nm).
Mast Base Hardware
7. Connect the main hydraulic hose at the
base of the mast.
8. Connect the auxiliary supply hoses at the
sides of the mast.
9. Install the screws, lock washers, and plate
securing the pins through the tilt cylinder
yoke and mast mounting brackets.
10. Jack the truck enough to remove the
blocks, then lower to the floor.
11. Remove the sling from the top of the mast.
12. Grease the mast mounting points at the
tilt cylinder and the frame.
13. Install forks. 7. Remove and cap the main hydraulic hose
attached at the base of the mast. See
14. Reconnect the battery connector and turn Figure 7-84.
the key switch ON.
Figure 7-84. Disconnect Hose
15. Bleed the hydraulic system. Refer to
“Bleeding the Hydraulic System” on
page 7-60.
16. Test the operation of the lift truck before
returning the lift truck to service.
Single Traction Motor Trucks

Removal
engage the parking brake. Lower the Hydraulic Hose
carriage completely.
the battery connector. 8. Remove pins securing mast to tilt
3. Block the steerable wheels to prevent cylinders. See Figure 7-85.
truck movement.
4. Remove forks.
5. Double wrap a sling around the top of the
mast and lift until the sling is snug.
6. Tilt the mast forward to access the
hardware securing the base of the mast to
the drive unit. Remove hardware. See
Figure 7-83.

Mast Removal and Installation Mast

Figure 7-85. Tilt Cylinder Pins
Tilt Cylinder Pins
9. Slowly lift the mast away from the truck.

10. Slowly lower the mast until it lays flat on
the floor.
Installation
1. Double wrap a sling around the top of the
mast and slowly lift the mast to vertical.
2. Slowly move the mast toward the lift truck,
aligning the mast mounts.
3. Tilt the mast forward to access the mast
base and drive unit. Secure the mast base
to the drive unit.
4. Connect the main hydraulic hose at the
base of the mast.
5. Install pins securing mast to tilt cylinders.
6. Jack the truck enough to remove the
blocks, then lower to the floor.
7. Remove the sling from the top of the mast.
8. Grease the mast mounting points at the
tilt cylinder and the frame.
the key switch ON.
10. Bleed the hydraulic system. Refer to
“Bleeding the Hydraulic System” on
page 7-60.
11. Test the operation of the lift truck before
returning the lift truck to service.

Mast Guide Shoe (Puck) Adjustment - TF/TT Mast
Guide Shoe (Puck)

Adjustment - TF/TT Mast
Adjust mast guide shoe clearance to 0.008 to
0.016 in. (0.2 to 0.4 mm). See Figure 7-86.
Figure 7-86. Guide Shoe Adjustment
Adjustment
Screw
0.008 to 0.016 in.

(0.2 to 0.4 mm)
clearance

Fork Carriage - TF/TT Mast Mast
Fork Carriage - TF/TT 7. Loosen the center hose cover bracket to

allow the hoses to move back.
Mast 8. Use a 19 mm wrench to remove the
carriage chain anchor nuts. With the
chain anchor nuts removed, use the hoist
Removal to lower the carriage to the floor.
1. Elevate the carriage above the free lift NOTE: Only the rollers hold the carriage to the
cylinders to gain access to the upper and telescopics at this time. Secure the
lower carriage stop bolts. See Figure 7-87. carriage so it does not fall when the
Figure 7-87. Fork Carriage Stop Bolts inner telescopic is lifted up.
9. Use the lift truck’s hydraulic system to
elevate the telescopics until the inner
telescopic is lifted off the carriage. Once
the carriage is free from the inner
telescopic, back the truck away from the
carriage.
OR
Lift the carriage out of the top of the mast.

With the strap and hoist attached to the
carriage, and the chain anchor nuts
removed, move the hoses and chains out
of the way. Use the hoist to lift the carriage
2. Secure the carriage to a hoist with straps out of the top of the mast, then lower the
so it does not fall. See Figure 7-88. carriage to the floor. See Figure 7-89.
Figure 7-88. Secure Carriage to Hoist Figure 7-89. Carriage Removal/Installation Through Top
of Mast
3. Remove the four carriage stop bolts. See

Figure 7-87.
4. Remove the hose retaining clamps (if Installation
present).
5. Remove the attachment hose reel and Install the carriage through either the top or the
hoses (if present). bottom of the mast.
6. Disconnect and plug the sideshift hoses.

Mast Fork Carriage - TF/TT Mast
Top Installation
1. Align the carriage rollers with the inner
telescopic rails.
2. Slowly lower the carriage through the
inner telescopics to a convenient work
height.
3. Loosely install the chain anchor nuts.
4. Install the fork carriage stop bolts.
5. Reconnect all hoses and hose retaining
clamps.
6. Adjust the fork carriage height and
securely tighten the chain anchor nuts.
Bottom Installation
1. Place the carriage on the floor beneath the
inner telescopics.
2. Either use a hoist or the truck’s hydraulic
system to slowly lower the inner telescopic
over the carriage rollers.
3. Loosely install the chain anchor nuts.
4. Install the fork carriage stop bolts.
5. Reconnect all hoses and hose retaining
clamps.
6. Adjust the fork carriage height. Securely
tighten the chain anchor nuts.

Fork Carriage with Sideshift - TF/TT Mast Mast
Fork Carriage with Figure 7-91. Carriage Frame Partially Removed
Sideshift - TF/TT Mast

Removal
1. Remove the load backrest, if installed.
2. Remove the forks.
3. Elevate the carriage to a convenient work
height.
5. Remove the four socket head cap screws
holding the side plate from either side of 7. Wrap a strap around the middle of the
the carriage. See Figure 7-90. carriage frame. Attach the strap to an
overhead hoist. See Figure 7-92.
Figure 7-90. Example of Side Plate Bolt Removal
Figure 7-92. Example of Carriage Frame Attached to Hoist
6. Pull the carriage frame to the side until

half of the carriage overhangs the sideshift
mechanism. See Figure 7-91.
8. With the hoist supporting the carriage

frame, continue pulling the carriage to the
side until the sideshift mechanism is
cleared. See Figure 7-93.

Mast Fork Carriage with Sideshift - TF/TT Mast

Figure 7-93. Carriage Frame Removal 4. Apply thread-locking compound to the
four socket head cap screws. Secure the
side plate to the carriage. See Figure 7-95.
Figure 7-95. Side Plate Mounting Bolts
NOTE: The lower carriage shims and slider may

fall out when the carriage is pulled to
the side. The carriage shims and slider
are installed between the lower sideshift 5. Slowly sideshift in both directions to make
ram housing and the carriage frame. sure the rams are touching both sides of
the frame.
Installation 6. Maximum sideshift in both directions to
check that there is no binding or excessive
1. Attach a safety strap to the middle of the
play, and that the carriage moves
carriage frame.
smoothly in both directions.
2. Suspend the carriage frame beside the
7. Install the forks on the sideshift carriage.
sideshift mechanism.
8. Install the load backrest, if present.
NOTE: Confirm that all shims and sliders are in
position as the sideshift frame is
installed.
3. Carefully slide the carriage frame onto the
sideshift mechanism. Remove the strap
when it begins to interfere with
reinstalling the carriage frame. See
Figure 7-94.
Figure 7-94. Carriage Frame Installation

Free Lift Cylinder Jacking Bolt Adjustment - TF/TT Mast Mast
Free Lift Cylinder Jacking

Bolt Adjustment - TF/TT
Mast
Jacking bolts at the bottom of the free lift
cylinders must be adjusted to ensure the
cylinder is fully captured in the locking collar at
the top of the cylinder.
Raise/lower free lift cylinders to their correct

position by adjusting the jacking bolts located
at the base of the lift cylinder.
Figure 7-96. Free Lift Cylinder Jacking Bolt
Notched Washer
Jacking Bolt
While holding the notched washer with a

spanner wrench, screw the jacking bolt in or
out as necessary to raise or lower the cylinder.
NOTE: The flat washer under the head of the
jacking bolt can be loose.
Do not use this procedure to adjust lift chain

tension.

Mast Lift Chains
Lift Chains 5. Remove cotter pins at both chain anchors

to separate the chain from the anchors.
6. Inspect the chain. See “Lift Chain
Adjustment Inspection” on page 4-9. Replace both
chains when either is worn.
1. Lower the fork carriage fully.
2. Tilt the mast so the forks are parallel with
the floor.
Installation
3. Measure from the floor to the top of the 1. On a work bench or floor, attach the
fork. adjustable chain anchor to the chain using
a new master link.
4. Elevate the fork carriage to gain access to
the chain anchors. Block the fork carriage 2. Install cotter pins (for each anchor)
and mast to prevent lowering while through both pins and bend to secure.
working on the lift truck. 3. With carriage lowered, key switch OFF,
5. Turn the key switch OFF and disconnect and battery connector disconnected, insert
the battery connector. the chain anchor (with chain attached)
over the sheave and into the chain anchor
6. Adjust the anchor nuts equally until the
block.
forks are 2 in. (51 mm) off the floor, when
measured to the top surface of the fork at 4. Thread on the lock nut by hand to hold the
the fork bend. chain in place.
NOTE: Make sure the forks are parallel with the 5. Insert the opposite end of the chain
floor. between the fork carriage and the lift
cylinder. The end of the chain should be
7. Repeat the preceding steps until you near the main frame chain anchor.
obtain the correct lowered height.
6. Fasten the chain to the anchor with a
8. Liberally apply oil to each chain. See master link and secure with a cotter pin.
“Lubrication Specification Chart” on
7. Repeat steps 1-6 for the other chain.
page A-2.
8. Holding the chain anchor with locking
9. Test operation.
pliers, tighten the chain anchor nuts until
1 in. (25.4 mm) of thread is visible below
Removal the nut.
the key switch ON.
10. Slowly raise the carriage, using the lift
Use extreme care when blocking the lever, until the carriage is raised off the
mast for any reason. blocking.
11. Remove the blocking, then slowly lower the
1. Lower the fork carriage onto wooden carriage all the way down.
blocks to slacken the chains.
NOTE: The carriage may rest on the floor with
2. Turn the key switch OFF and disconnect slack in the chains.
12. Keeping equal tension on the chains,
3. Remove the master links at the carriage
adjust the chain anchor nuts so the
chain anchors.
carriage is slightly off the floor.
4. Remove the chain and chain anchors by
13. Tilt the mast so the forks are parallel with
unscrewing the nuts on the adjustable
the floor.
chain anchors.
14. With the forks level with the floor and the
key switch OFF, adjust the anchor nuts

Lift Chains Mast
equally until the forks are 2 in. (51 mm) off

the floor, when measured to the top
surface of the fork at the fork bend.
15. Liberally apply oil to each chain. See
page A-2.
16. Test the operation of the lift chains.
Lift Chain Anchor Bolts

Make sure the lift chain anchor bolts are not
damaged and that the adjusting nuts are locked
by a cotter pin. See Figure 7-97.
Figure 7-97. Chain Anchor Bolts
Cotter Pin

Mast Quad Mast Service
Quad Mast Service 1. Remove the internal hose reeving from the
mast while it is on the truck.
2. Remove the mast assembly from the truck.
Mast Inspection Refer to “Mast Removal and Installation”
on page 7-68.
During normal scheduled maintenance checks, 3. Remove the main lift cylinders from the
pry between the upright and load roller so the mast. Refer to “Cylinder Removal and
opposite load roller is tight against the upright. Installation” on page 7-84.
Measure the clearance for the pair of rollers at
XXX shown in Figure 7-98. 4. Using an overhead chain hoist, turn the
mast over (face up).
Figure 7-98. Load Roller Clearances
5. Remove the free lift cylinder from the
Pry Here mast. Refer to “Free Lift Cylinder Removal
Load Roller
- Mast on Floor” on page 7-85.
6. Remove the carriage from the mast. Refer
to “Removal - Mast on Floor” on page 7-84.
7. Remove the free lift chain anchors and
X
X
chains from the inner upright center cross
X
member and tag for reassembly.
8. Disconnect the free lift cylinder hose from
the tube and remove the stop/hose
bracket/tube assembly.
9. Disconnect the inner main chain anchors
.06 in. from the lower end of the inner upright
(1.5 mm)
Max. and the upper end of the outer
intermediate upright.
10. Move the inner upright downward. Remove
the free lift hose sheave, hose, and main
chain sheaves at the top of the inner
NOTE: Raise the lower end of the inner upright
slightly to clear the inner intermediate
upright lower cross member.
11. Remove the inner main lift chains and tag
Each pair of load rollers on the uprights and
for reassembly.
carriage should be shimmed so that a total side
to side clearance no greater than 0.06 in. 12. Remove the load rollers from the lower end
(1.5 mm) occurs at the tightest point of the inner upright. Remove the load
throughout the travel of the member. rollers and thrust plugs from the upper
end of the inner intermediate upright. Note
the number of shims behind each for
Disassembly reassembly.
NOTE: Quad Mast uprights require complete 13. Attach an overhead hoist to the inner
disassembly in order to service load upright and remove it through the top end
rollers, thrust plugs/blocks, and of the inner intermediate upright.
chain/hose sheaves.
NOTE: The stub shafts on the lower end of the
inner upright come out of the inner
Refer to Figure 7-99.
intermediate upright between the rail
cutout and the stub shaft.

Quad Mast Service Mast
14. Remove the outer main lift chain anchors 18. Attach an overhead hoist to the inner
from the lower end of the inner intermediate upright and remove it
intermediate upright and the top end of through the top end of the outer
the outer upright. Set the chains aside and intermediate upright.
tag for reassembly. 19. Roll the outer intermediate upright
15. Remove the lower stop from the outer downward and remove the lower rollers.
intermediate upright. Remove the upper rollers and thrust
16. Remove the chain sheaves from the outer blocks from the outer upright. Note the
intermediate upright. number of shims behind each roller and
thrust block for reassembly.
17. Roll the inner intermediate upright
downward and remove the lower rollers. 20. Attach an overhead hoist to the outer
Remove the upper rollers and thrust plugs intermediate upright and remove it
from the outer intermediate upright. Note through the top end of the outer upright.
the number of shims behind each roller for
reassembly.
Figure 7-99. Quad Mast Disassembly
8 Inner 12 12
Intermediate
Upright
9
10 Thrust
Plug
7 10 Thrust
Plug
Shim
Inner
Main Lift
Chains
11
10
10
MA0244.eps
12 9
7 12
Free Lift
Chains
MA0078.eps
Note: Bubbled numbers refer to
steps in associated procedure.
Reassembly the top of the outer upright. Position it out

the lower end of the outer upright approx.
1. Lubricate the full length of the outer 6 in. (15 cm).
upright rails. See “Lubrication
3. Assemble shims, load rollers, and thrust
Specification Chart” on page A-2.
blocks to the upper end of the outer
2. Attach an overhead hoist to the outer upright. Assemble shims and load rollers
intermediate upright and install it through

to the lower end of the outer intermediate 4. Lubricate the full length of the outer
upright. intermediate upright rails. See
• Roller Shimming - Install shims to “Lubrication Specification Chart” on
provide a total side-to-side clearance of page A-2 and Figure 7-100.
0.06 in. (1.5 mm) max. at the tightest 5. Attach an overhead hoist to the inner
point throughout the travel of the intermediate upright and install it through
upright. See Figure 7-100. Pry between the top end of the outer intermediate
the upright and the load roller so that upright. Position it out the lower end of the
the opposite load roller is tight against outer intermediate upright approx. 6 in.
the upright. Measure the clearance for (15 cm).
the pair of rollers at the XXX shown in 6. Install shims and load rollers to the lower
Figure 7-100. Use an equal number of end of the inner intermediate upright.
shims on each side. Install shims, load rollers, and thrust
NOTE: Roll the uprights past installed thrust plugs to the upper end of the outer
plugs/blocks before checking load roller intermediate upright. Refer to step 3 for
clearance. roller shimming and thrust plug clearance
measurement.
• Thrust Plug/Block Replacement - Install
thrust plugs/blocks to provide a 7. Install the chain sheaves to the upper end
clearance of 0.06 in. (1.5 mm) max. of the outer intermediate upright. Install
between an upright and its the outer main lift chain anchors and
corresponding thrust plug/block. See chains over the outer intermediate upright
Figure 7-101. Pry between the upright chain sheaves.
upper cross members. Measure the
clearance at the XXX shown to
determine which thickness thrust
plug/block to use. Thrust plugs/blocks
may be shimmed as required.
Figure 7-100. Load Roller Clearance/Channel Lubrication
1 4 Lube
Upright
Rails
Upright
Rail
Shim
Load
Rollers
3
.06 in.
(1.5 mm)
Max. MA0259.eps



Figure 7-101. Outer Intermediate Upright Installation
3
Thrust Thrust
Plugs Block
2
.06 in.
(1.5 mm)
Max.
2 Thrust
Block
Inside
of Rail
Outer
3 Upright
MA0246.eps
Outer
Intermediate
Note: Bubbled numbers refer to Upright
8. Install the outer main lift chain anchors upper end of the inner intermediate
(long anchors) to the lower end of the inner upright. Refer to step 3 for roller shimming
intermediate upright. and thrust plug clearance measurement.
9. Install the lower stop on the outer 15. Install the inner main lift chain anchors
intermediate upright. Torque the cap (long anchors) on the back side, lower end
screw to 81 to 88 ft. lb. (110 to 120 Nm). of the inner upright. Connect the inner
10. Install the main chain sheaves, free lift main lift chains.
sheaves, and hose in the inner 16. Install the stop/hose bracket/tube
intermediate upright. Torque the retainer assembly on the lower end of the inner
cap screws to 26 to 30 ft. lb. (35 to 40 Nm). upright. Torque the cap screws to 81 to
11. Install the upper inner main chain 88 ft. lb. (110 to 120 Nm).
anchors to the outer intermediate upright.
Install the free lift hose bracket and tube.
12. Lubricate the inner intermediate upright
rails. See “Lubrication Specification Chart”
on page A-2.
13. Attach an overhead hoist to the inner
upright and install through the top of the
inner intermediate upright. Position it out
the lower end of the inner intermediate
upright approx. 6 in. (25 cm).
14. Assemble shims and load roller to the
lower end of the inner upright. Assemble
shims, load rollers, and thrust plugs to the


Figure 7-102. Inner Upright Installation
14
13 Thrust
Plug
15 Thrust
13 Plug
Shim
MA0269.eps
14
14
Inner
Upright
16 Note: Bubbled numbers refer to

MA0251.eps
17. Install the free lift chain anchors (short re-blocked in a level position. See
anchors) and chains to the inner upright Figure 7-103.
center cross member.
Figure 7-103. Blocking Uprights Before Turning Mast Over
18. Install the free lift cylinder supply hose to
the free lift cylinder tube. Leave the tubing
clamp loose.
22 21
19. Install the carriage. See “Installation -
Mast on Floor”.
20. Install the free lift cylinder. See “Free Lift
Cylinder Installation - Mast on Floor” on
page 7-85. Connect the tube to the
MA0254.eps
cylinder fitting and tighten the tubing
clamp. Note: Bubbled numbers refer to
21. Place a 2 x 4 in. (5 x 10 cm) wood block
between the outer and outer intermediate 23. Install main lift cylinders. See “Main Lift
lower cross members to prevent upright Cylinder Installation - Mast on Floor” on
movement. page 7-85.
22. Turn the mast over (face down), rotating it 24. Install the Mast. Refer to “Mast Removal
on its lower end. Make sure the mast is and Installation” on page 7-68.

25. Install the internal hose reeving. See to decrease clearance. See Figure 7-104.
“Reeving” on page 7-86. Torque the cap screws to 79 to 80 ft. lb.
26. Adjust the main and free lift chains. (95 to 110 Nm).
27. Check the mast for skewing. Figure 7-104. Carriage Side Thrust Rollers
Carriage
Removal - Mast on Floor
1. Remove mast from truck. See “Mast
Removal and Installation” on page 7-68.
2. Remove the pins fastening the free lift
chains to the carriage chain anchors.
3. Disconnect the internal reeving hoses from
the carriage fittings (if equipped). Plug the
hose ends.
4. Remove the socket head stops on the inner
upright lower cross member. For
reassembly, tighten to 80 ft. lb. (110 Nm).
5. Roll the carriage to the bottom end of the
mast.
6. Attach an overhead hoist to the carriage
side bars and remove the carriage through 5. Check and adjust the free lift chains.
the bottom end of the mast. 6. Adjust mast tilt. See “Mast Tilt
7. Remove the load rollers, noting the Adjustment” on page 7-90.
number of shims behind each roller for
reassembly. Cylinder Removal and
Installation
Installation - Mast on Floor
Main Lift Cylinder Removal - Mast on
Reverse the removal procedure and do the
Floor
following:
1. Inspect the carriage. 1. Remove the mast from the truck. See
“Mast Removal and Installation” on
2. Lubricate the inner upright rails. Refer to
page 7-68.
page A-2. 2. Insert a 2 x 4 in. (5 x10 cm) wood block
between the lower cross members of the
3. Assemble shims and load rollers on the
outer upright and outer intermediate
carriage stub shafts. The shims should be
upright to prevent uprights from moving
installed to provide a total side to side
out the bottom of the mast.
clearance no looser than 0.06 in. (1.5 mm)
at the tightest point throughout the travel 3. Lay the mast face-down on wood blocks.
of the carriage. Use an equal amount of Block under each end of the outer upright
shims on each side. so the mast is level and the inner uprights
and carriage are free to move.
4. Adjust the carriage side thrust rollers for
unrestricted clearance along the travel of 4. Using a 1 in. wrench, disconnect the
the carriage. Turn the eccentric mount cylinder supply hoses from the cylinder
base of each roller toward the upright rail inlet ports. Using a 1 in. socket, remove

the special long fittings from the cylinder Free Lift Cylinder Installation - Mast
ports and install plugs. on Floor
5. Remove the snap ring from the top of the
left hand cylinder rod, the tube, and fitting For installation, reverse the Removal procedure.
from the top of the right hand cylinder rod. Bleed the system. See “Bleeding the Hydraulic
Plug the cylinder port. System” on page 7-60.
6. Roll the uprights through the top of the
mast 1 to 2 ft. (30 to 60 cm) and disengage Free Lift Cylinder Supply Hose -
the cylinder rods from the outer Tracking and Adjustment
7. Lift the cylinder from its base mounting 1. Make sure the cylinder supply hose is not
boss in the outer upright and angle twisted, and that it travels evenly in the
inward. Remove the cylinders through the hose sheave.
sides of the uprights. 2. Check the hose to make sure it is not
8. Note the number of shims (if equipped) on scuffing.
each cylinder rod. 3. Adjust the hose by loosening the hose
clamp on the outer upright as shown in
Main Lift Cylinder Installation - Mast Figure 7-105 and twisting the hose.
on Floor Figure 7-105. Free Lift Cylinder Supply Hose Adjustment
For installation, reverse the Removal procedure.

Bleed the system. See “Bleeding the Hydraulic
System” on page 7-60.
Free Lift Cylinder Removal - Mast on

Floor
1. Remove the mast from the truck. See Free Lift
“Mast Removal and Installation” on Hose Clamp
page 7-68.
2. Lay the mast face-up, blocking under the
lower mounts so the mast is level.
3. Roll the carriage upward to allow slack in
the free lift chains and internal reeving.
4. Remove the snap ring fastening the
crosshead to the cylinder rod.
5. Pull the crosshead with chains and hoses 4. Tighten the clamp while holding the hose
of the cylinder rod. in place.
Tension on the hose can be adjusted by sliding the hose through the loosened clamp as required.
6. Roll the carriage above the free lift

NOTE: The hose and the clamp must be dry of
cylinder.
oil and water before inserting the hose
7. Using a 1 in. wrench, disconnect the tube into the clamp.
from the cylinder fitting. Cap the cylinder
fitting and plug the tube. 5. After inserting the hose through the loose
clamp and tensioning the hose, snugly
8. Using a 5 mm Allen wrench, remove the tighten the two clamp bolts, then tighten
cylinder strap. to 5.9 ft. lb. (8 Nm) with a torque wrench.
9. Remove the cylinder from the mast.

Reeving 3. Install the fittings on the bracket. See

Figure 7-108.
Internal Reeving • Single Function - Install the fittings to
the left or right side location. Tighten
1. Install the shaft, sheave, and hose guards the fittings finger tight.
to the crosshead center plate. See
• Double Function - Install the fittings to
Figure 7-106. Leave the cap screw and nut
the left and right side location. Tighten
finger tight to allow for hose installation.
the fittings finger tight.
Figure 7-106. Crosshead Center Plate Assembly
Figure 7-108. Fitting Installation
OR
1 3
SINGLE DOUBLE
FUNCTION FUNCTION
Note: Bubbled numbers refer to MA0256.eps
4. Make up two hose assemblies by

MA0222.eps connecting the two hoses to the two long
hoses. See Figure 7-110.
5. Install the shaft, sheave(s), shim, and
hardware to the inner intermediate
2. Install the carriage hose bracket to the
upright chain sheave shaft. See
center tab on the lower carriage bar. See
Figure 7-109. Torque the cap screw to
Figure 7-107.
37 ft. lb. (50 Nm).
Figure 7-107. Carriage Hose Bracket Installation
6. Route the hose ends over the inner
intermediate upright sheave(s) down to the
inner upright bracket.
NOTE: The short hose routes over the cylinder
crosshead.
7. Position the hoses with the tabs on the
inner upright bracket as shown in
Figure 7-110.
8. Loosen the crosshead cover plate cap
screw. Route the hoses up over the
crosshead rollers.

MA0255.eps


Figure 7-109. Hose Reeving Hardware Installation on Uprights
13
Outer
Outer 14
Upright
Intermediate
Upright
Inner
Intermediate
Upright
Upper
Hose
14 Guide
5 Double
Function 14
Single
Function
11
10
Lower
Hose
Guide
MA0225.eps

9. Completely lower the carriage. Route the Tighten clamp cap screws enough to stop
hoses down behind the carriage bar to the hose movement.
carriage bracket fittings. Connect the hose 13. Install the upper hose guide to the outer
ends to the fittings leaving the hose ends upright. Tighten the cap screw to 37 ft. lb.
finger tight. (50 Nm).
10. Install the hose clamps to the lower hose 14. Install the hose clamps to the upper hose
guide. Leave the cap screws finger tight. guide. Leave the cap screws finger tight.
11. Install the lower hose guide and spacer to
the outer intermediate upright. Tighten
the cap screws to a torque of 37 ft. lb.
(50 Nm).
12. Route hoses down to the lower hose guide.
Place hoses under the hose clamp at the
top of the lower hose guide. Pull downward
on the hoses with 20 lbs. (9 kg) force.


Figure 7-110. Hose Reeving Installation
16
6
8
Inner
Intermediate
Upright Sheave
SINGLE DOUBLE
FUNCTION FUNCTION
Long
Hose
Upper
8 12 Hose
Short Guide
Hose
15
17
7 Lower
Hose
Guide
Connect
4 hoses
SINGLE DOUBLE
FUNCTION FUNCTION
FRONT VIEW
Inner
Upright
Bracket
7 MA0257.eps
9
Carriage
Bracket
Fittings
SINGLE DOUBLE
FUNCTION FUNCTION
SINGLE DOUBLE
FUNCTION FUNCTION BACK VIEW


15. Route the hoses up into the upper hose Figure 7-111. Hose Reeving Installation - continued
guide.
4
16. Route the hoses under the hose clamps at 21
the top of the upper hose guide. Tighten
the cap screws finger tight.
17. Route the hoses under the hose clamps at 4
21
the bottom of the upper hose guide. Do not
tighten the clamp cap screws.
18. Tighten the crosshead cover plate cap
screw to 30 to 33 ft. lb. (40 to 45 Nm).
19. Align the hoses by twisting the hose ends
to travel centered in the crosshead on the
natural curve of the hose. The hoses
Upper
should travel parallel to each other. Hold Hose
the hoses while tightening the fittings to Guide
keep the hoses from twisting.
20. Loosen the hose clamps at the top of the
lower hose guide. Pull down on the hoses 18
1
with 40 lbs. (18 kg) of force. Tighten the
hose clamp cap screws to 7 to 11 ft. lb. (10 20
3 4
21
to 15 Nm).
Crosshead
21. Loosen the hose clamps on the upper hose
guide. Adjust the hoses to the natural
hose bend and align evenly spaced in the
guide rails. Tighten the hose clamp cap
screws to 7 to 11 ft. lb. (10 to 15 Nm).
22. Raise and lower the mast slowly through
several cycles and check for correct hose 20
3
alignment, clearances and hose tracking
in the guides.
Lower
Hose
Guide
19
2
MA0258.eps


Mast Tilt Adjustment Mast
Mast Tilt Adjustment 3. Place a square on the mast 39.4 in.

(1 meter) below where the plumb line is
attached and measure the distance
Perform the following procedure when adjusting between the face of the mast and the
mast tilt. plumb line.
1. Attach a plumb line to the mast. See 4. Repeat steps 1 thru 3 using the back of
Figure 7-112. the mast main frame for backward tilt.
Figure 7-112. Measuring Mast Tilt 5. Adjust the stroke of the tilt cylinders as
necessary to achieve the correct mast tilt.
Refer to Figure 7-112 and Table 7-6.
Table 7-6. Mast Tilt Parameters
Tilt Fwd Tilt Back Tilt

Mast
Type Angle Dim. A Angle Dim. A
TT 4.1 in.
39.4 in. 6°
TF 2 in. (105 mm)
(1 meter) Std 3°
(52 mm) 2.7 in.
Quad 4°
(70 mm)
TT 3.4 in.
Optional 5°
TF (87 mm) 4.1 in.
6°
Bottler’s 6.2 in. (105 mm)
TT 9°
Tilt (156 mm)
Mast Tilt Position Switch

Adjustment (Bottler’s Tilt Only)
Trucks equipped with the Bottler’s Tilt option
require mast mounted switches (S11 and S18)
for the VM to determine carriage and mast
position.
Mast Adjust the Mast Tilt Position Switch (S18) so

Face that it opens when the mast is tilted beyond 3°
forward.
39.4 in. (1 meter) Plumb
from plumb line 1. Attach a plumb line to the mast. See
attach point Line
Figure 7-112.
2. Place a square on the mast 39.4 in.
(1 meter) below where the plumb line is
attached and tilt the mast forward 3°
(2 in./52 mm at Dim. A in Figure 7-112).
3. Adjust Mast Tilt Position Switch (S18)
bracket so that the switch opens when the
Dim. A mast is tilted further forward.
2. Tilt the mast forward completely.

Model 4700 Maintenance Manual Section 8. Theory of Operation
Section 8. Theory of Operation

Section 8. Theory of Operation Model 4700 Maintenance Manual
System Architecture
System Architecture
This truck can be configured to accept either a
36V or 48V battery. The truck uses AC drive
and lift technology. The standard truck uses
conventional hydraulic controls via lever
operated spool valves mounted on the right side
console. An optional configuration uses
fingertip controls mounted on an armrest to the
right of the operators seat. A DC/DC converter
provides 24V to the cooling fans, brake, tail,
rotating, and work lights.
The electrical control system consists of the

components listed in Table 8-1.
Table 8-1. Electrical Control System Components
Component Function
*Vehicle Manager Serves as an interface for all control signals and performs
analog/digital signal conversions. Manages tail and brake light
operation based on traction motor encoder input. Shares primary
memory with the Operator Display.
*Traction Power Amplifier (TPA) Powers the traction motors
*Pump Power Amplifier (PPA) Powers the pump motor
DC/DC Converter Converts battery voltage to required DC voltage
*Operator Display (OD) Displays truck systems information. Shares primary memory with
the VM.
*Armrest Board Optional Fingertip Controls/VM interface
*Hydraulic Control Board Coil driver board for hydraulic solenoids. Required for optional
Fingertip Controls
Contactor 1 (CT1) Provides B+ to the DC/DC Converter and Hydraulic Control Board
(for optional Fingertip Controls)
Contactor 2 (CT2) Provides B+ to the PPA
Contactor 3 (CT3) Provides B+ to the TPA
*Electrical control system components communicate via a Control Area Network (CAN-Bus).

Systems Overview System Architecture
Systems Overview direction and speed with regard to steer wheel

angle. It stores the learned value for the steer
This section is an overview of the components potentiometer. Motor parameters such as
that make up the control systems of the truck. acceleration, speed limiting, motor braking,
See “Pinout Matrix” beginning on page 8-14 for motor current, and creep speed can be
specific input, output, and voltage information. configured with FlashWare and are stored in
the TPA. The TPA also stores the learned values
for the steer potentiometer. The Master and
Vehicle Manager Slave are capable of generating error codes. See
“Codes” on page 6-4.
The Vehicle Manager (VM) provides several
functions. It interfaces with the travel direction Single Traction Motor Trucks
switches and travel potentiometer. The VM
stores the learned values for the travel and lift
The Traction Power Amplifier (TPA) is an AC
potentiometers. It also stores the learned values
Motor Controller. Requests for travel direction
for the lift and travel potentiometers as well as
and speed are communicated from the VM via
default configuration values. With the standard
the CAN-Bus. The TPA generates a command
spool valve hydraulic controls, lift/lower,
voltage to the traction motor to comply with the
sideshift, tilt, 4th, and 5th auxiliary function
travel request. It then monitors motor operation
switch/potentiometer requests are input
and adjusts the RPM request to the motor to
directly to the VM. The VM distributes 24V
maintain motor performance equal to the
power to the operational and working lights on
request. Motor parameters such as
the truck. It also contains the circuits that
acceleration, speed limiting, motor braking,
activate the brake and tail lights based on
motor current, and creep speed can be
inputs from the TPA. Refer to “Hydraulic
configured with FlashWare and are stored in
System” on page 8-8 for specific information on
the TPA. The TPA is capable of generating error
the operation of standard and optional
codes. See “Codes” on page 6-4.
hydraulic systems.
Pump Power Amplifier

Traction Power Amplifier
The Pump Power Amplifier (PPA) is an AC motor
controller that controls the motor used to
provide hydraulic power for all hydraulic
The Traction Power Amplifier (TPA) is a Dual AC
functions. The PPA communicates with other
Motor Controller. The TPA contains two
devices via the CAN-Bus. Requests for all
separate controllers within a single unit with
hydraulic functions (including steering) are
outputs for two separate AC motors. The
communicated to the PPA via the CAN-Bus from
controllers are designated as Master and Slave.
the VM or from the Armrest Board (fingertip
The Master controls the right traction motor
control configurations). The PPA then generates
and the Slave controls the left traction motor.
an RPM request to the pump motor. Pump
The Master and Slave communicate with each
motor operating parameters may be different for
other internally as well as externally with other
the various hydraulic functions. Parameters
devices connected to the CAN-Bus. Requests for
such as delay, maximum speed, and maximum
travel direction and speed are communicated
motor current can be configured with
from the VM via the CAN-Bus. The TPA
FlashWare and are stored in the PPA. The PPA
generates an RPM request to the traction
is capable of generating error codes. See
motors to comply with the travel request. It
“Codes” on page 6-4.
then monitors motor operation and adjusts the
command voltage to the motors to maintain
motor performance equal to the request. The Amplifier Fan
TPA receives an input from the steer
potentiometer and regulates traction motor The truck is equipped with a cooling fan for the
TPA and PPA. This fan should energize within

System Architecture Systems Overview
about one minute of turning the key ON. This is Hydraulic Control Board
accomplished by a drive signal from the VM to
the fan. If this fails to occur, the TPA and PPA The Hydraulic Control Board is a hydraulic
could overheat. driver board that receives commands via the
CAN-Bus from the Armrest Board. It contains
DC/DC Converter coil drivers for the hydraulic solenoids and is
required for the optional Fingertip controls. The
A DC/DC converter provides 24V to the lights, Armrest Board communicates hydraulic
cooling fan, solenoid valves, and so on. It also function requests to the Hydraulic Control
provides 24V to the Hydraulic Control Board on Board, which energizes the solenoids. The
trucks with the Fingertip Controls option. A parameters regarding the operation of the
dedicated 12A fuse is located on the end solenoid valves that the Hydraulic Control
opposite the connector. Board controls can be adjusted and set in
FlashWare. The Hydraulic Control Board can
initiate error codes in the coil circuits that it
Operator Display
controls. See “Codes” on page 6-4.
The Operator Display (OD) receives
communications from the CAN-Bus and 24V CT1
power from the VM. Various icons illuminate to
inform the operator of the status of the truck. CT1 provides B+ to the DC/DC Converter and
The OD also displays hour meters and Battery Hydraulic Control Board (for optional Fingertip
State-of-Charge (BSOC), however BSOC is Controls). The CT1 contactor coil is designed to
calculated by the Master TPA. The OD also operate on approx. 36V. Because these trucks
contains a two position alphanumeric display accept both 36V and 48V batteries, voltage to
that provides error and status code CT1 from a 48V battery must be reduced. This
information. See “Operator Display Messages” is accomplished via a control relay (RL1) that is
on page 6-2. energized when the key switch is turned ON.
When a 48V battery is installed in a truck

Armrest Board
configured (via FlashWare) for a 48V battery,
RL1 is energized. The RL1 contact tips open,
The truck can be equipped with optional
redirecting current through a 56 ohm resistor
Fingertip hydraulic controls that are located on
wired in parallel with the RL1 contact tips. The
the armrest on the right side of the operator’s
56 ohm resistor reduces the voltage approx. 8V,
seat. The Armrest Board receives inputs from
thus providing approx. 40V to the CT1
the fingertip hydraulic function controls based
contactor coil.
on operator input. Hydraulic output flow is
controlled by proportional and solenoid valves
When a 36V battery is installed in a truck
instead of the spool valves used on the standard
configured (via FlashWare) for a 36V battery,
hydraulic system. The Armrest Board processes
RL1 is not energized. The RL1 contact tips
the request and informs the Hydraulic Control
remain closed, causing current to bypass a
Board which solenoids to energize and the PPA
56 ohm resistor wired in parallel with the RL1
to energize the pump motor, providing the
contact tips, thus providing B– to the CT1
hydraulic flow necessary for the given function.
contactor coil.
The Armrest Board can also initiate error codes
for the components (potentiometers and
switches) that it interfaces with. See “Codes” on CT2
page 6-4.
CT2 provides B+ to the PPA. This is a 36/48V
contactor which is supplied 24V PWM.

Systems Overview System Architecture
CT3
CT3 provides B+ to the TPA. This is a 36/48V

contactor which is supplied 24V PWM.

Traction System Pre-Operational Checks (SelfTest)
Traction System Hand Direction Lever
Moving the lever from the neutral position

Pre-Operational Checks toward the mast closes Forward switch (SW9).
(SelfTest) Moving the lever from the neutral position away
from the mast closes Reverse switch (SW10).
These directional inputs are sent to the VM. The
Before the truck can be operational, the VM
VM monitors the Enable switch (SW8) and the
performs the following checks:
Travel Pot (P2). When the operator pedal is
• Seat switch (SW2) - CLOSED (operator depressed, the Enable switch (SW8) closes. This
seated) informs the VM to recognize the Hand Direction
• Battery Interlock switch (SW30) (optional) Lever switch (SW9 or SW10) inputs. Output
- CLOSED voltage from Travel Pot (P2) is compared to the
previously Learned value and the VM converts
• Parking Brake switch (SW7) - OPEN
the voltage value into a percentage-of-request.
(parking brake released)
The VM converts travel direction and the
percentage of the request into a message that is
If truck is equipped with a Hand Direction
sent via the CAN-Bus to the Traction Power
Lever, the lever must be in the neutral position.
Amplifier (TPA) and Operator Display (OD). The
TPA sends the RPM request to the Traction
Travel Motor(s) to satisfy the direction and speed
request received by the VM. The TPA monitors
After SelfTest is complete and no codes are the Encoder(s) (EN1 for single traction motor
displayed on the Operator Display, travel is trucks; EN1 and EN2 for dual traction motor
allowed. Travel can be requested via one of two trucks) to verify that actual travel direction and
configurations. speed matches what was requested. The VM
constantly monitors the travel request and
Standard configurations utilize a hand updates the information to the TPA as changes
activated direction lever located on the steering occur. All operational parameters that affect
column. The lever is moved forward (toward the motor torque and speed are controlled by the
mast) for forward travel and back (away from TPA. The TPA also monitors the Temperature
the mast) for reverse travel. It is used in switch(es) (TS1 for single traction motor trucks;
conjunction with a single foot activated travel TS1 and TS2 for dual traction motor trucks).
pedal located on the floor of the operator The temperature switch(es) are normally closed.
compartment to the right of the brake pedal. They open when an overtemperature condition
Travel speed is based on how far the pedal is exists in the motor, causing a reduction in
depressed. The further down the pedal is travel speed to allow the motor to cool. An icon
depressed, the faster the truck travels. on the Operator Display is also illuminated to
alert the operator.
An optional configuration utilizes two pedals
located on the floor of the operator Two Pedal Configuration
compartment, to the right of the brake pedal.
The left pedal is depressed for forward travel
The Forward and Reverse travel direction
and the right pedal for reverse travel. Travel
pedals are located to the right of the brake
speed is based on how far either pedal is
pedal on the operator compartment floor. The
depressed. The further down the pedal is
left pedal is depressed for forward travel and
depressed, the faster the truck travels.
the right pedal for reverse travel. When either
NOTE: For two-pedal configuration, a jumper pedal is depressed, the corresponding Forward
must be installed between J33-4 and switch (SW4) or Reverse switch (SW5) closes,
J33-5. sending an input to the VM as a request for
forward or reverse travel. The VM monitors the
Travel Pot (P2). Output voltage from P2 is

Travel Traction System
compared to its previously Learned value and

the VM converts the voltage value into a
percentage-of-request. The VM converts travel
direction and percentage-of-request into a
message that is sent via the CAN-Bus to the
Traction Power Amplifier (TPA) and Operator
Display (OD). The TPA sends the RPM request
to the Traction Motor(s) to satisfy the direction
and speed request received by the VM. The TPA
monitors the Encoder(s) (EN1 for single traction
motor trucks; EN1 and EN2 for dual traction
motor trucks) to verify that actual travel
direction and speed matches what was
requested. The VM constantly monitors the
travel request and updates the information to
the TPA as changes occur. All operational
parameters that affect motor torque and speed
are controlled by the TPA. The TPA also
monitors the Temperature switch(es) (TS1 for
single traction motor trucks; TS1 and TS2 for
dual traction motor trucks). The temperature
switch(es) are normally closed. They open when
an overtemperature condition exists in the
motor, causing a reduction in travel speed to
allow the motor to cool. An icon on the Operator
Display is also illuminated to alert the operator.
When the truck is moving and the travel pedal

is released or travel direction is reversed, the
same sequence of events takes place. The VM
does not request plugging or regeneration: it
just requests travel in the opposite direction at
a particular speed. The VM communicates this
information to the TPA via the CAN-Bus. The
TPA calculates both direction and speed and
determines whether the request from the VM
must be met with a travel, a plug, or a
regeneration control output to the traction
motor. The VM energizes the Braking Lights.
The brake pedal may be depressed to apply the
hydraulic brake, aiding in slowing the truck.
NOTE: The Braking Lights are not energized
just by depressing the brake pedal
alone. The lights are energized when the
truck is traveling and a change in
requested direction is sensed by the TPA
and relayed to the VM via the CAN-Bus.

Hydraulic System Lift/Lower
Hydraulic System the reservoir. The rate of lower is dependent on

the position of the lever, but is restricted to a
maximum rate of 115 ft./min. by a flow
Lift/Lower restrictor valve located in the distribution
manifold at the base of the main frame, between
NOTE: A priority valve is used to ensure the lift cylinders. Flow controls in each cylinder
adequate hydraulic pressure to the restrict lowering speed.
steering system at all times. If adequate
flow is not available for steering, the Optional Fingertip Controls
priority valve diverts fluid from any
other requested function.
Lift
Standard Lever Controls The Armrest Board monitors the lift switch
(SW17) and the voltage from the wiper of
Lift lift/lower pot (P4). When lift is requested, SW17
closes. This is sensed by the Armrest Board.
The VM monitors the lift control lever switch The Armrest Board encodes the lift request into
(SW11) and the voltage from the wiper of the lift a digital message and communicates it to the
pot (P3). When lift is requested, SW11 closes, VM via the CAN-Bus. The VM checks the
which is sensed by the VM. The VM checks battery voltage (for lift reduction) and the Lift
battery voltage (for lift reduction) and the Lift Limit option, which could prevent the activation
Limit option that could prevent activation of the of the lift system. Output voltage from P4 is
lift system. Output voltage from the lift pot is interpreted by the Armrest Board. The Armrest
also sensed by the VM. It is compared to the Board converts the voltage value into a
previously Learned value of the pot and the VM percentage of total request. The PPA receives
converts the voltage value into a percentage of the lift request via the CAN-Bus. The PPA
total request. The Pump Power Amplifier (PPA) generates the correct voltage to the pump motor
receives the lift request via the CAN-Bus. The to run the pump at the requested RPM. From
PPA generates the correct voltage to the pump the pump, fluid flows first to the priority valve.
motor to run the pump at the requested RPM.
From the pump, fluid flows first to the priority The lift request is also sent to the Hydraulic
valve. Control Board. The Hydraulic Control Board
interprets the message and provides controlling
When the lift/lower valve is in the neutral voltage to the lifting solenoid EV2, causing EV2
position, fluid bypasses the lift/lower valve and to open, providing fluid to the lift cylinders. The
is either available for other functions or Hydraulic Control Board also energizes the
returned to the reservoir. proportional solenoid valve, EVP. This valve
opens proportionally to the lift request from P4
When lift is requested, fluid flows to the lift and provides a path back to the reservoir for the
cylinders. Lift motor RPM is determined by the fluid not used by the lift cylinders. For
position of the lift lever, which determines the maximum lift, EVP is fully energized.
output voltage of P3. The center cylinders
elevate first because less pressure is required. When the lift solenoid valve is de-energized,
Once the inner cylinders reach the stops, the fluid bypasses the lift/lower valve and is either
pressure increases enough to start elevating the available for other functions or returned to the
outer cylinders. reservoir through the proportional lift solenoid
valve (EVP).
Lower
Motor RPM and position of the EVP are
When lower is requested, there is no electrical determined by the position of the fingertip
response from the truck. When the valve is control, which determines the output of P4. The
stroked to the lower position, fluid returns to center cylinders elevate first because less

Emergency Lower Hydraulic System
pressure is required. Once the inner cylinders Figure 8-1. Emergency Lower Valve
reach the stops, the pressure increases enough 8DSCN0283.JPG
to start elevating the outer cylinders.
Lower
The Armrest Board monitors the lower switch

(SW18) and the voltage from the wiper of
lift/lower pot (P4). When lower is requested,
SW18 closes and P4 voltage changes, which is
sensed by the Armrest Board. The lower request
is encoded into a digital message that is Emergency Lower Valve
communicated to the Hydraulic Control Board
via the CAN-Bus. The Hydraulic Control Board
interprets the message and provides controlling
voltage to the lowering solenoid EVP1. This
causes EVP1 to open proportionally to the When the emergency lower valve is opened,
request and allows fluid from the cylinders to hydraulic fluid is allowed to pass through the
return to the reservoir. The rate of lower is emergency lower valve at a constant rate.
dependent on the position of the fingertip
control, which determines the output of P4, but
is restricted to a maximum rate of 115 ft./min.
by a flow restrictor valve located in the
distribution manifold at the base of the main
frame, between the lift cylinders. Flow controls
in each cylinder restrict lowering speed.
Emergency Lower
An emergency lower valve, located at the base of
the solenoid valve assembly, allows the carriage
to be lowered in the event of a loss of power to
the truck. See Figure 8-1.

Auxiliary Functions Standard Lever Controls
Auxiliary Functions Sideshift
When sideshift is requested, the sideshift

NOTE: A priority valve is used to ensure
switch (SW13) closes, which is sensed by the
adequate hydraulic pressure to the
VM. The Pump Power Amplifier (PPA) receives
steering system at all times. If adequate
the RPM request via the CAN-Bus. The pump
flow is not available for steering, the
motor operates at a fixed RPM that is
priority valve diverts fluid from any
configurable using the FlashWare program.
other requested function.
Oil is pumped through the activated side of the
Auxiliary functions are activated by the
sideshift valve to the sideshift cylinders. Return
operator moving one of the auxiliary function
oil flows from the cylinders, through the
levers or optional fingertip controls. Tilt and
sideshift valve, and back to the reservoir.
Sideshift are discussed below for both
configurations. Operational theory for the 4th
When sideshift is not requested, all fluid
function is similar to tilt and sideshift.
bypasses the sideshift valve and is either
available for use by other functions or returned
Standard Lever Controls to the reservoir.
Tilt Optional Fingertip Controls

When tilt is requested, the tilt switch (SW12)
closes, which is sensed by the VM. The Pump
Tilt
Power Amplifier (PPA) receives the RPM request
via the CAN-Bus. The pump motor operates at a When tilt is requested, the tilt switch (SW19 or
fixed RPM that is configurable using the S20) closes, which is sensed by the Armrest
FlashWare program. Board. Output voltage from the tilt pot (P5) is
also sensed by the Armrest Board. The Armrest
Oil is pumped through the activated side of the Board encodes the tilt request into a digital
tilt valve to the tilt cylinders. Return oil flows message and communicates it to the Hydraulic
from the other side of the cylinders through the Control Board via the CAN-Bus. The Hydraulic
tilt valve, and back to the reservoir. Control Board relays the RPM to the PPA. The
PPA generates the correct voltage to the pump
When tilt is not requested, all fluid bypasses the motor to run the pump.
tilt valve and is either available for use by other
functions or returned to the reservoir. The Hydraulic Control Board interprets the
message and provides controlling voltage to the
There are two flow controls in the tilt system. tilt solenoids (EV3 or EV4) from a coil driver
One flow control, located in the spool valve, located on the board.
provides the correct flow rate.
A flow control valve (V2) between the tilt
The second flow control (V2) is located in the solenoid valves and tilt cylinders prevents
adapter fitting on the control valve assembly. excessive forward tilt speed when lift and tilt are
V2 controls fluid flow in the return circuit when requested simultaneously. This valve also keeps
tilting forward. If fluid flow in the return circuit the forks from drifting when the tilt command is
is excessive (for example: the tilt system is removed from the tilt solenoid.
supplied with fluid at the lift system delivery
rate), the control restricts the return flow to When tilt is not requested, all fluid bypasses the
reduce forward tilt speed. tilt valve and is either available for use by other
functions or returned to the reservoir.

Optional Fingertip Controls Auxiliary Functions
Sideshift
When sideshift is requested, the sideshift

switch (SW21 or SW22) closes, which is sensed
by the Armrest Board. Output voltage from the
sideshift pot (P6) is also sensed by the Armrest
Board. The Armrest Board encodes the sideshift
request into a digital message and
communicates it to the Hydraulic Control Board
via the CAN-Bus. The Hydraulic Control Board
relays the RPM to the PPA. The PPA generates
the correct voltage to the pump motor to run
the pump.
The Hydraulic Control Board interprets the

message and provides controlling voltage to the
sideshift solenoids (EV5 or EV6) from a coil
driver located on the board.
Oil is pumped through the energized sideshift

solenoid (EV5 or EV6) to the sideshift cylinders.
A flow restrictor in the solenoid valve provides
correct flow for sideshift.
When sideshift is not requested, all fluid

bypasses the sideshift valve and is either
available for use by other functions or returned
to the reservoir.

Steering System System Components
Steering System The pump motor starts when travel is

requested, providing hydraulic flow to the
steering system. Depressing the service brake
System Components pedal also causes the pump motor to run.
• Steer Orbitrol – Hydraulically couples

operator request (from steer tiller) to the
Functional Description
steering axle.
A forward or reverse travel request is received
• Pump Power Amplifier (PPA) – Controls the by the VM and is encoded into a digital message
speed of the pump motor. Receives input that is sent to the PPA. The PPA generates the
from the brake switch (SW6) or accelerator correct voltage to the pump motor to run the
potentiometer (P2), VM, and TPA via the pump.
CAN-Bus.
• AC Pump Motor – Drives the hydraulic When the Service Brake pedal is depressed,
pump. SW6 closes and GND is removed from the VM.
• Priority Valve – Routes hydraulic fluid from The VM encodes this into a digital message that
the pump to the steering, lift, and is sent to the PPA. The PPA generates the rpm
auxiliary systems. Ensures the steering request to the pump motor to run the pump.
system receives priority over lift and aux
functions. The priority valve ensures adequate hydraulic
pressure to the steering system at all times,
• Hydraulic Pump – Provides fluid to the regardless of other hydraulic demands on the
Steer Orbitrol via the Priority Valve. system.
• Steer Potentiometer (P1) – Provides steer
wheel position feedback to the TPA Master. When the pump motor starts, fluid is delivered
P1 also provides input to the steer wheel to the orbitrol through port CF of the priority
position indicator on the Operator Display. valve. As pressure builds in the steering
system, the pilot moves the priority valve
NOTE: Steer Potentiometer (P1) is present on
against spring tension, dividing the fluid flow
dual traction motor trucks only.
and delivering a restricted flow to the steering
system (through CF) and an unrestricted flow to
System Overview the lift and auxiliary functions (through EF).
The steering system is a hydraulically activated When the orbitrol is rotated, the pressure at LS
system. A steer request is generated when the increases, assisting the spring to move the
operator rotates the steering wheel in either a priority valve toward the steering only position.
clockwise or counterclockwise direction. The Fluid is directed to the steer cylinder.
steering system uses the same hydraulic fluid
as the lift and auxiliary systems by means of a Steer Position Feedback is provided to the TPA
priority valve. Because steering takes priority from the Steer Pot (P1) located on the right side
over all other hydraulic functions, the priority steer axle.
valve ensures that sufficient oil flow to the
steering system is always present.
Fluid capacity is checked by the Priority Valve.

Excess oil is sent to the Control valve for other
functions. When the steering wheel is turned,
the orbitrol measures a volume of oil
proportional to the movement of the steering
wheel and sends it to the steer cylinder.

Standard Lever Controls Options
Options de-energizes EV12, blocking fluid to the lift

cylinders. To continue lifting, PB9 must be
depressed and the lift request resumed.
Standard Lever Controls
Finger Tip Controls
Bottler’s Tilt
Bottler’s Tilt
Bottler’s Tilt allows the mast to be tilted further
forward when under free lift mast height. The Same as for a lever controlled truck with the
limit is 9° forward, 6° backward. The option is exception of the Tilt Limit Solenoid. When the
controlled by two switches, a Blocking Solenoid VM senses a change in state at the switches
(EV12), and a Tilt Limit Solenoid (EV13). that limit lift or tilt, the VM sends a
communication message to the Hydraulic
When the forks are fully lowered and the mast Control Board. The Hydraulic Control Board
is centered, the End of Free Lift switch (SW16) then removes the request for the requested
and the Angle Tilt Proximity switch (SW30) are function.
normally closed. When tilt is requested, tilt
functions as normal. However, when the forks
Lift-Limit with Bypass
are elevated above free lift, SW16 opens,
causing a change in state to be seen at the VM.
Same as for a lever controlled truck with the
If tilt is then requested, the VM allows forward
exception of the Blocking Solenoid (EV12).
Tilt until it sees a change in state of SW30. If
When the VM senses a change in state at the
the VM sees SW16 and SW30 open, it
switches that limit lift, the VM sends a
commands the Tilt Limit Solenoid (EV13) to
communication message to the Hydraulic
activate, stopping return flow from the tilt
Control Board. The Hydraulic Control Board
cylinders and preventing further forward tilt. If
then removes the request for the requested
the mast is then lowered until SW16 closes, tilt
function.
forward is allowed.
If lift is requested while the mast is tilted fully

forward, lift is allowed until the End of Free Lift
switch opens. When the VM again sees SW30
and SW16 open, it de-energizes the Blocking
Solenoid (EV12), blocking flow to the lift
cylinders. When the mast is tilted back until
SW30 closes, EV12 is energized, allowing flow
to the lift cylinders.
Lift-Limit with Bypass
Lift-Limit with Bypass consists of a switch

placed on the mast that prevents lift past a
certain height. To lift beyond this height, the
operator must activate a switch.
This is accomplished by having a Mast Height

switch (SW31), Lift-Limit Push Button switch
(PB9), and a Blocking Solenoid (EV12).
If switch SW31 is opened during a lift request,

the VM sees the change of state and

Pinout Matrix All Dual Traction Motor Trucks and Single Traction Motor Trucks <S/N 10677
Pinout Matrix • Theory of Operation: detailed description

of the signal carried on the wire. If the
signal is variable, the state of a related
The pinout matrix chart lists functions and component that causes the signal to vary
normal voltages of terminals and harness is indicated. Also identifies possible causes
connector pins. The matrix columns have the for lack of correct signal.
following meanings:
• Normal Level: the approximate voltage that
• Item: sequential number to aid in must be seen on that wire for the state
reference. indicated. Unless otherwise indicated,
• Connection: actual connector/wire voltages are measured with respect to (wrt)
designation or component as identified on B–.
the electrical schematic (listed • Signal Source: the device or connection
alpha-numerically). that supplies the signal directly to the
• Function Description: brief definition of wire.
the signal carried on the wire. • Signal User: the device or connection
where the wire directly delivers the signal.
All Dual Traction Motor Trucks and Single Traction Motor Trucks
<S/N 10677
Function Signal Signal
Item Connection Theory of Operation Normal Level
Description Source User
1 JAM NOT USED
2 JAP NOT USED
3 JAT-1 CAN H Communication line between the N/A TPA, VM TPA, VM

TPA and VM (at connection J34-35).
4 JAT-2 and 3 NOT USED
5 JAT-4 CAN L OUT Communication line between the N/A TPA, PPA TPA, PPA
TPA and PPA (JCP-1).
6 JAT-5 NOT USED
7 JAT-6 CAN L Communication line between the N/A TPA, VM TPA, VM

TPA and VM (J34-23).
8 JAT-7 CAN H OUT Communication line between the N/A TPA, PPA TPA, PPA
9 JAT-8 NOT USED
10 JBP-1 B– Jumper between JBP-1 and JBP-2 if Battery voltage PPA PPA
TSA200-180 pump motor wrt BT1+ if no
configuration is present. jumper installed;
12V with jumper
11 JBP-2 CONF. Jumper between JBP-1 and JBP-2 if 12V PPA PPA
TSA200-180 pump motor
configuration is present.
12 JBT NOT USED

All Dual Traction Motor Trucks and Single Traction Motor Trucks <S/N 10677 Pinout Matrix

13 JCM-1 LOW Voltage from the HCB to turn on the Approx. 2-12V HCB EVP1
Lowering Solenoid (EVP1). If not wrt B+ (approx.
present, check the HCB, wiring, and 18 ohms across
connections. coil)
14 JCM-2 +V Voltage from the HCB to the B+ HCB EV2, EVP1

Lowering (EVP1) and Lifting (EV2)
Solenoids. If not present, check the
HCB, wiring, and connections.
Note: This voltage is common to
both solenoids. If this voltage is lost,
neither solenoid will work.
15 JCM-3 LIFT Voltage from the HCB to turn on the Lifting: Approx. HCB EV2
Lifting Solenoid (EV2). If not present, 24V wrt B+
check the HCB, wiring, and (approx. 27 ohms
connections. across coil)
16 JCM-4 TILT FW Voltage from the HCB to turn on the Approx. 15V wrt HCB EV3
Tilt Forward Solenoid (EV3). If not B+ (approx.
connections. coil)
17 JCM-5 +V Voltage from the HCB to the Tilt B+ HCB EV3, EV4
Forward (EV3) and Tilt Backward
(EV4) Solenoids. If not present,
check the HCB, wiring, and
connections.
18 JCM-6 TILT BW Voltage from the HCB to turn on the Approx. 15V wrt HCB EV4
Tilt Backward Solenoid (EV4). If not B+ (approx.
connections. coil)
19 JCM-7 L SIDESHIFT Voltage from the HCB to turn on the Approx. 18V wrt HCB EV5
Left Sideshift Solenoid (EV5). If not B+ (approx.
connections. coil)
20 JCM-8 +V Voltage from the HCB to the Left B+ HCB EV5, EV6
(EV5) and Right (EV6) Sideshift
21 JCM-9 thru 11 NOT USED
22 JCM-12 4th FUNCTION Voltage from the HCB to turn on the Approx. 18V wrt HCB EV7
4th Function Solenoid (EV7). If not B+ (approx.
connections. coil)


23 JCM-13 +V Voltage from the HCB to the 4th B+ HCB EV7, EV8
Function (EV7 and EV8) Solenoids.
If not present, check the HCB,
wiring, and connections.
connections. coil)
25 JCM-15 R SIDESHIFT Voltage from the HCB to turn on the Approx. 18V wrt HCB EV6
Right Sideshift Solenoid (EV6). If not B+ (approx.
connections. coil)
27 JCM-19 DRAIN Voltage from the HCB to turn on the Approx. 2 to 13V HCB EVP
Drain Solenoid (EVP). If not present, wrt B+ when
check the HCB, wiring, and requesting lift
connections. and/or any aux
function. (approx.
18 ohms across
coil)
28 JCM-20 +V Voltage from the HCB to the Drain B+ HCB EVP

Solenoid (EVP). If not present, check
the HCB, wiring, and connections.
29 JCM-21 and 22 NOT USED
30 JCM-23 GND B– supply to optional HCB. This B– Battery voltage B– at J1– HCB
is shared by many components wrt BT1+
prior to and after the VM. If not
present, follow back towards B–
until loss can be determined.
31 JCP-1 CAN L Communication between the PPA N/A TPA, PPA TPA, PPA
and the TPA (JAT-4).
32 JCP-2 NOT USED
33 JCP-3 CAN H Communication between the PPA N/A TPA, PPA TPA, PPA
and the TPA (JAT-7).
34 JCP-4 NOT USED
35 JCT-1 +12V +12V to the Right Traction Motor +12V TPA EN1
(RTM) encoder (EN1). If not present,
check the TPA, wiring, and
connections.
36 JCT-2 GND Ground to the Right Traction Motor Battery voltage TPA EN1
(RTM) encoder (EN1). If not present, wrt BT1+
connections.


37 JCT-3 +V KEY B+ from Key switch (SW1). Used by B+ SW1 TPA

the TPA to determine BSOC. If not
present, check the Key switch,
38 JCT-4 +V OUT B+ from TPA to Seat switch (SW2) B+ TPA TPA

and optional Battery Interlock switch
(SW30). If not present, check the
TPA, wiring, and connections.
39 JCT-5 SEAT Input from the Seat switch (SW2). If B+ SW2 TPA
not present, check the seat switch,
battery interlock switch (SW30),
jumper, wiring, and connections.
40 JCT-6 thru 10 NOT USED
41 JCT-11 +12V +12V to the Left Traction Motor +12V TPA EN2
(LTM) encoder (EN2). If not present,
connections.
42 JCT-12 GND Ground to the Left Traction Motor Battery voltage TPA EN2
(LTM) encoder (EN2). If not present, wrt BT1+
connections.
43 JCT-13 RTM ENCODER Channel A from the Right Traction Approx. 5V EN1 TPA
CHANNEL A Motor (RTM) encoder (EN1). If not running; 0V or
present, check voltage to the 10V static
encoder, wiring, and connections.
44 JCT-14 RTM ENCODER Channel B from the Right Traction Approx. 5V EN1 TPA
CHANNEL B Motor (RTM) encoder (EN1). If not running; 0V or
45 JCT-15 GND POT Ground from the TPA to the Steer Battery voltage TPA P1
pot (P1). If not present, check the wrt BT1+
46 JCT-16 +V POT +12V from the TPA to the Steer pot +12V TPA P1
(P1). If not present, check the TPA,
47 JCT-17 C POT Input from the Steer pot (P1) to the Approx. 1.5V P1 TPA
TPA. If not present, check the Steer steered left; 5.5V
pot (P1), wiring, and connections. centered; 10V
steered right
49 JCT-22 LTM ENCODER Channel A from the Left Traction Approx. 5V EN2 TPA
CHANNEL A Motor (LTM) encoder (EN2). If not running; 0V or


50 JCT-23 LTM ENCODER Channel B from the Left Traction Approx. 5V EN2 TPA
CHANNEL B Motor (LTM) encoder (EN2). If not running; 0V or
51 JCT-24 and 25 NOT USED
52 JCT-26 –V COIL Voltage from the TPA to CT3 coil Approx. B+ to TPA CT3
(J50-8). If not present, check the energize coil;
TPA, wiring, and connections. drops to approx.
Approx. 32 ohms across coil. 14V for holding
wrt B+
53 JCT-27 +V COIL Voltage from the TPA to CT3 coil B+ TPA CT3
(J50-7). If not present, check the
Approx. 32 ohms across coil.
54 JCT-28 and 29 NOT USED
55 JCT-30 +V AUX COIL Voltage from the TPA to Relay 1 (RL1 0V with 36V TPA RL1
at J51-1) coil. If 36V battery, RL1 battery; 24V with
stays de-energized. If 48V battery, 48V battery wrt
RL1 is energized to allow 12V drop JCT-31
across R3, providing 36V to CT1. If
not present, check the TPA, wiring,
and connections. Approx. 1K ohm
across coil.
56 JCT-31 –V AUX COIL Voltage from the TPA to RL1 coil 0V with 36V TPA RL1
(J51-5). If not present, check the battery; 24V with
TPA, wiring, and connections. 48V battery wrt
Approx. 1K ohm across coil. B+
58 JDP-1 +12V +12V to the Pump Motor (PM) +12V PPA EN3
encoder (EN3). If not present, check
the PPA, wiring, and connections.
59 JDP-2 GND Ground to the Pump Motor (PM) Battery voltage PPA EN3
encoder (EN3). If not present, check wrt BT1+
60 JDP-3 PM ENCODER Channel A from the Pump Motor Approx. 5V EN3 PPA
CHANNEL A (PM) encoder (EN3). If not present, running; 0V or
check voltage to the encoder, 10V static
61 JDP-4 NOT USED
62 JDP-5 PM ENCODER Channel B from the Pump Motor Approx. 5V EN3 PPA
CHANNEL B (PM) encoder (EN3). If not present, running; 0V or
63 JDP-6 NOT USED
64 JEP-1 thru 3 NOT USED


65 JEP-4 +V OUT Jumper between JEP-4 and JEP-5 if B+ PPA PPA

TSA200-180 pump motor with 14cc
hydraulic motor configuration
present.
66 JEP-5 CONF. Jumper between JEP-4 and JEP-5 if B+ if jumper in PPA PPA
TSA200-180 pump motor with 14cc place. 0V - no
hydraulic motor configuration jumper.
present.
67 JEP-6 thru 14 NOT USED
68 JFP-1 +V KEY B+ from Key switch (SW1). If not B+ SW1 PPA

present, check Key switch, wiring,
and connections.
69 JFP-2 +V COIL Voltage from the PPA to CT2 coil B+ PPA CT2
PPA, wiring, and connections.
70 JFP-3 and 4 NOT USED
71 JFP-5 SAFETY/ B– from JFP-11 on the PPA. If Battery voltage PPA PPA
AMPLIFIER voltage is >1V (wrt B–) check wrt BT1+
ENABLE jumper from JFP-11. If jumper is OK,
check B– to PPA.
72 JFP-6 PM TEMP Input to the PPA from the Pump Approx. 0V TS3 PPA
Motor (PM) temperature switch closed; 9V open
(TS3). Input will be low under
normal operating conditions. If
overtemp condition exists [>266°F
(130°C)], input will be high. Allow
to cool. If still open (high), check
switch, wiring, and connections.
73 JFP-7 NOT USED
74 JFP-8 –V COIL Voltage from the PPA to CT2 coil Approx. B+ to PPA CT2
(J50-5). If not present, check the energize coil;
PPA, wiring, and connections. drops to approx.
Approx. 32 ohms across coil. 14V for holding
wrt B+
75 JFP-9 and 10 NOT USED
76 JFP-11 B– Ties the Amplifier Enable (SAFETY) Battery voltage PPA PPA
input (JFP-5) to low. If not present, wrt BT1+
check B– to the PPA.
77 JFP-12 TERM Ground from the PPA to the Pump Battery voltage PPA TS3
Motor (PM) temperature switch wrt BT1+
(TS3). If not present, check B– to the
78 JP2-1 B– Configuration jumper installed on B– PPA PPA

single traction motor trucks only.


79 JP2-2 CONFIG Configuration jumper installed on B– if jumper. No PPA PPA

JUMPER single traction motor trucks only. jumper: high
80 JP4-1 CAN L Communication between the PPA N/A TPA, PPA TPA, PPA
and the TPA (JT4-2).
81 JP4-2 NOT USED
82 JP4-3 CAN H Communication between the PPA N/A TPA, PPA TPA, PPA
and the TPA (JT4-4).
83 JP4-4 NOT USED
84 JP6-1 +12V +12V to the Pump Motor (PM) +12V PPA EN3
85 JP6-2 GND Ground to the Pump Motor (PM) Battery voltage PPA EN3
86 JP6-3 PM ENCODER Channel A from the Pump Motor Approx. 5V EN3 PPA
87 JP6-4 NOT USED
88 JP6-5 PM ENCODER Channel B from the Pump Motor Approx. 5V EN3 PPA
89 JP6-6 NOT USED
90 JP8 NOT USED
91 JP12-1 +V KEY B+ from Key switch (SW1). If not B+ SW1 PPA

and connections.
92 JP12-2 +V COIL Voltage from the PPA to CT2 coil Approx. B+ PPA CT2
93 JP12-3 NOT USED
94 JP12-4 SEAT Input from the Seat switch (SW2). If B+ SW2 TPA, PPA
not present, check seat switch,
95 JP12-5 AMPLIFIER B– from JP12-11 on the PPA. If Battery voltage PPA PPA
ENABLE voltage is >1V (wrt B–), check the wrt BT1+
jumper from JP12-11. If jumper is
OK, check B– to the PPA.
96 JP12-6 NOT USED


97 JP12-7 +V OUT Voltage to SW30 and SW2. If not B+ PPA SW30,

present, check PPA, wiring, and SW2
connections.
98 JP12-8 –V COIL Voltage from the PPA to CT2 coil Approx. B+ to PPA CT2
(J50-6). If not present, check PPA, energize coil;
wiring, and connections. Approx. drops to approx.
32 ohms across coil. 14V for holding
wrt B+
99 JP12-9 OUT B– from PPA to TPA (JT12-5). Battery voltage PPA TPA
wrt BT1+
100 JP12-10 NOT USED
101 JP12-11 B– Ties the AMPLIFIER ENABLE input to Battery voltage PPA PPA
JP12-5 low. If not low, check the wrt BT1+
PPA.
102 JP12-12 NOT USED
103 JP14 NOT USED
104 JT2-1 and 2 NOT USED
105 JT4-1 CAN L Communication line between the N/A TPA, VM TPA, VM
106 JT4-2 CAN L OUT Communication line between the N/A TPA, PPA PPA
TPA and PPA (JP4-1).
107 JT4-3 CAN H Communication line between the N/A TPA, VM TPA, VM
108 JT4-4 CAN H OUT Communication line between the N/A TPA, PPA PPA
TPA and PPA (JP4-3).
109 JT6-1 +12V +12V to the Traction Motor (TM) +12V TPA EN1
110 JT6-2 GND Ground to the Traction Motor (TM) Battery voltage TPA EN1
111 JT6-3 TM ENCODER Channel A from the Traction Motor Approx. 5V EN1 TPA
CHANNEL A (TM) encoder (EN1). If not present, running; 0V or
112 JT6-4 NOT USED
113 JT6-5 TM ENCODER Channel B from the Traction Motor Approx. 5V EN1 TPA
CHANNEL B (TM) encoder (EN1). If not present, running; 0V or
114 JT6-6 NOT USED
115 JT8 NOT USED


116 JT12-1 +V KEY B+ from Key switch (SW1). If not B+ SW1 TPA
and connections.
117 JT12-2 +V COIL Voltage from the TPA to CT3 coil. If B+ TPA CT3
and connections. Approx. 32 ohms
across coil.
118 JT12-3 +V AUX COIL Voltage from the TPA to Relay 1 (RL1 0V with 36V TPA RL1
RL1 is energized to allow 12V drop JT12-9
not present, check TPA, wiring, and
connections. Approx. 1K ohm
across coil.
119 JT12-4 SEAT Input from the Seat switch (SW2). If B+ SW2 TPA
associated wiring, and connections.
120 JT12-5 SAFETY B– from PPA (JP12-9) to TPA. Battery voltage PPA TPA
wrt BT1+
121 JT12-6 and 7 NOT USED
122 JT12-8 –V COIL Voltage from the TPA to CT3 coil. If Approx. B+ to TPA CT4
not present, check TPA, wiring, and energize coil;
connections. Approx. 32 ohms drops to approx.
across coil. 14V for holding
wrt B+
123 JT12-9 –V AUX COIL Voltage from the TPA to RL1 coil 0V with 36V TPA RL1
(J51-5). If not present, check TPA, battery; 24V with
wiring, and connections. Approx. 48V battery wrt
1K ohm across coil. JT12-3
124 JT12-10 thru 12 NOT USED
125 JT14 NOT USED
126 J1+ B+ B+ from the positive battery B+ BT1 CT1, CT2,

terminal. If not present, make sure CT3 tips,
battery is connected and check F1 and F4
associated wiring.
127 J1– B– B– from the negative battery Battery voltage BT1 Entire truck
terminal. If not present, make sure wrt BT1+
battery is connected and check
associated wiring.
128 J4 OIL BRAKE Provides input to the VM (J34-17) Approx. 5V open; B– VM

from Low Brake Fluid Sensor (SW3). 0V closed
If not present, check switch, fluid,


129 J8-1 GND Ground to Horn push button switch Battery voltage VM PB4
(PB4) from VM (J34-6). If not wrt BT1+
present, check VM, wiring, and
connections.
130 J8-2 HORN IN Horn push button (PB4) input to VM Approx. 5V open; PB4 VM
(J34-16). If not present, check 0V closed
131 J8-3 and 4 NOT USED
132 J11– HR 1 GND B– to the Horn (HR1). If not present, Battery voltage B– Horn
check wiring and connections. wrt BT1+
133 J11 IN HORN OUT Control voltage to Horn (HR1) from +24V normal VM Horn
the VM (J34-9). If not present, check goes to 0V when
VM, switch, wiring, and horn button
connections. depressed
134 J11+ +24V +24V to the Horn (HR1) from the +24V DC/DC Horn
DC/DC Converter. If not present, Converter
check fuse F6, wiring, and
connections. Approx. 65 ohms
across coil (J11+ to J11–).
135 J13-1 +12V +12V to the Pump Motor (PM) +12V PPA EN3
136 J13-2 GND Ground to the Pump Motor (PM) Battery voltage PPA EN3
137 J13-3 PM ENCODER Channel A from the Pump Motor Approx. 5V EN3 PPA
138 J13-4 PM ENCODER Channel B from the Pump Motor Approx. 5V EN3 PPA
139 J13-5 TERM Dual Traction Motor Truck - Battery voltage PPA TS3
Ground from the PPA to the Pump wrt BT1+
Motor (PM) temperature switch
(TS3). If not present, check the PPA,
140 J13-5 TERM Single Traction Motor Truck - Battery voltage PPA TS2
Ground from the VM (J34-6) to the wrt BT1+
Pump Motor (PM) temperature
switch (TS2). If not present, check


141 J13-6 PM TEMP Dual Traction Motor Truck - Approx. 0V TS3 PPA
Input to the PPA (JFP-6) from the closed; 9V open
switch (TS3). Input will be low under
142 J13-6 PM TEMP Single Traction Motor Truck - Approx. 0V TS2 PPA
Input to the VM (J34-26) from the closed; 9V open
143 J13-7 thru 9 NOT USED
144 J14-A C POT Input from the Steer pot (P1) to the Approx. 1.5V P1 TPA
TPA (JCT-17). If not present, check steered left; 5.5V
the Steer pot (P1), wiring, and centered; 10V
connections. steered right
145 J14-B GND POT Ground from the TPA (JCT-15) to the Battery voltage TPA P1
Steer pot (P1). If not present, check wrt BT1+
the TPA, wiring, and connections.
146 J14-C +V POT +12V from the TPA (JCT-16) to the +12V TPA P1
Steer pot (P1). If not present, check
the TPA, wiring, and connections.
Approx. 1.8K ohms across pot
J14-B to J14-C.
147 J15-1 +12V Dual Traction Motor Truck - +12V TPA EN1
+12V to the Right Traction Motor
(RTM) encoder (EN1) from the TPA
(JCT-1). If not present, check the
148 J15-1 +12V Single Traction Motor Truck - +12V TPA EN1
+12V to the Traction Motor (TM)
encoder (EN1) from the TPA (JT6-1).
If not present, check the TPA, wiring,
and connections.
149 J15-2 GND Dual Traction Motor Truck - Battery voltage TPA EN1
Ground to the Right Traction Motor wrt BT1+
(RTM) encoder (EN1) from the TPA


150 J15-2 GND Single Traction Motor Truck - Battery voltage TPA EN1
Ground to the Traction Motor (TM) wrt BT1+
encoder (EN1) from the TPA (JT6-2).
and connections.
151 J15-3 RTM ENCODER Dual Traction Motor Truck - Approx. 5V EN1 TPA
CHANNEL B Channel B from the Right Traction running; 0V or
Motor (RTM) encoder (EN1) to the 10V static
TPA (JCT-14). If not present, check
voltage to the encoder, wiring, and
connections.
152 J15-3 TM ENCODER Single Traction Motor Truck - Approx. 5V EN1 TPA
CHANNEL B Channel B from the Traction Motor running; 0V or
(TM) encoder (EN1) to the TPA 10V static
(JT6-5). If not present, check voltage
to the encoder, wiring, and
connections.
153 J15-4 RTM ENCODER Dual Traction Motor Truck - Approx. 5V EN1 TPA
CHANNEL A Channel A from the Right Traction running; 0V or
Motor (RTM) encoder (EN1) to the 10V static
TPA (JCT-13). If not present, check
connections.
154 J15-4 TM ENCODER Single Traction Motor Truck - Approx. 5V EN1 TPA
CHANNEL A Channel A from the Traction Motor running; 0V or
(TM) encoder (EN1) to the TPA 10V static
(JT6-3). If not present, check voltage
connections.
155 J15-5 GND Ground from the VM (J34-6) to the Battery voltage VM TS1
TM temperature switch (TS1). If not wrt BT1+
present, check the VM, wiring, and
connections.
156 J15-6 RTM TEMP SW Dual Traction Motor Truck - Approx. 0V TS1 VM
(TS1) Input to the VM (J34-26) from the closed; 5V open
RTM temperature switch (TS1). Input
will be low under normal operating
conditions. If overtemp condition
exists [>266°F (130°C)], input will
be high. Allow to cool. If still open
(high), check the switch, wiring, and
connections.
157 J15-6 TM TEMP SW Single Traction Motor Truck - Approx. 0V TS1 VM

(TS1) Input to the VM (J34-27) from the closed; 5V open
TM temperature switch (TS1). Input
connections.


159 J16-1 +12V +12V to the Left Traction Motor +12V TPA EN2
(LTM) encoder (EN2) from the TPA
160 J16-2 GND Ground to the Left Traction Motor Battery voltage TPA EN2
(LTM) encoder (EN2) from the TPA wrt BT1+
161 J16-3 LTM ENCODER Channel B from the Left Traction Approx. 5V EN2 TPA
CHANNEL B Motor (LTM) encoder (EN2) to the running; 0V or
TPA (JCT-23). If not present, check 10V static
connections.
162 J16-4 LTM ENCODER Channel A from the Left Traction Approx. 5V EN2 TPA
CHANNEL A Motor (LTM) encoder (EN2) to the running; 0V or
TPA (JCT-22). If not present, check 10V static
connections.
LTM temperature switch (TS2). If not wrt BT1+
connections.
164 J16-6 LTM TEMP SW Input to the VM (J34-27) from the Approx. 0V TS2 VM
(TS2) LTM temperature switch (TS2). Input closed; 5V open
connections.
166 J20-1 SEAT Input from the Seat switch (SW2). If B+ SW2 TPA
jumper at J22-A3 and J22-A4,
167 J20-2 NOT USED
168 J20-3 +V OUT B+ from TPA to Seat switch (SW2). B+ TPA TPA
If not present, check the seat switch,
battery interlock switch (SW30),
169 J23-1 +V OUT Dual Traction Motor Truck - B+ TPA SW30,

Voltage from TPA to Battery Interlock SW2
switch (SW30). If not present, check
TPA, switch, wiring, and
connections.


170 J23-1 +V OUT Single Traction Motor Truck - B+ PPA SW30,

Voltage from PPA to Battery Interlock SW2
PPA, switch, wiring, and
connections.
171 J23-2 +V OUT Voltage from Battery Interlock switch B+ PPA or TPA SW30,
(SW30) to Seat switch (SW2). SW2
Provides input to amplifiers to allow
operation. If not present, check PPA
or TPA (as applicable), switch,
172 J30-1 GND Ground to the Parking Brake switch Battery voltage VM SW7
(SW7) from the VM (J34-6). If not wrt BT1+
present, check wiring and
connections.
173 J30-2 NOT USED
174 J30-3 PARK Input to the VM (J34-14) from the Approx. 5V brake SW7 VM
Parking Brake switch (SW7). If not set; 0V brake
present, check switch, wiring, and released
connections.
175 J31-1 GND Ground to the Brake Pedal switch Battery voltage VM SW6
connections.
176 J31-2 BRAKE Input to the VM (J34-15) from the Approx. 5V pedal SW6 VM
Brake Pedal switch (SW6). If not not depressed;
present, check switch, wiring, and approx. 0V pedal
177 J31-3 NOT USED
178 J32-1 C POT Input from the wiper of the Travel Approx. 2V P2 VM
pot (P2) to the VM (J34-3). If not difference
present check pot, wiring, and between neutral
connections. The pot may need to and pedal
be re-learned. depressed
Note: To check pot, unplug
connector and measure resistance
between pins 2 and 3. Approx.
4.6K ohms should be read (J32-2 to
J32-3).
179 J32-2 N POT Ground to Travel pot (P2) from the Battery voltage VM P2
VM (J34-2). If not present check wrt BT1+
VM, wiring, and connections.
180 J32-3 VCC Voltage to Travel pot (P2) from VM Approx. +10V VM P2
(J34-5). If not present, check VM,


181 J32-4 GND Ground to Travel Enable switch Battery voltage VM SW8
connections. (Single Pedal Only)
182 J32-5 EN. Input from the Travel Enable switch Approx. 5V pedal SW8 VM
(SW8) to the VM (J34-32). If not released; 0V
present, check switch, wiring, and pedal depressed
183 J32-6 /EN. Input from the Travel Enable switch Approx. 0V pedal SW8 VM
present check switch, wiring, and pedal depressed
184 J33-1 GND Ground to Forward Pedal switch Battery voltage VM SW4
connections. (Dual Pedal
System)
185 J33-2 FW Input from the Forward Pedal switch Approx. 5V pedal SW4 VM
System)
186 J33-3 /FW Input from the Forward Pedal switch Approx. 0V pedal SW4 VM
System)
187 J33-4 GND Ground from the VM (J34-6). If not Battery voltage VM VM
present, check VM, wiring, and wrt BT1+
System)
188 J33-5 CONFIG. Configuration input to the VM Approx. 0V VM VM

(J34-25). This input allows VM to w/dual pedals;
recognize Dual Pedal. If not approx. 5V
present, check jumper, wiring, and without dual
connections. (Dual Pedal pedals
System)
189 J33-6 NOT USED
190 J33-7 GND Ground to Reverse Pedal switch Battery voltage VM SW5
System)
191 J33-8 BW Input from the Reverse Pedal switch Approx. 5V pedal SW5 VM
(SW5) to the VM (J34-19). If not released; approx.
present, check switch, wiring, and 0V pedal
connections. (Dual Pedal depressed
System)


192 J33-9 /BW Input from the Reverse Pedal switch Approx. 0V pedal SW5 VM
connections. (Dual Pedal depressed
System)
193 J33-10 thru12 NOT USED
194 J34-1 TAIL LIGHT Output from VM to the Tail Lights +24V VM LP2, LP4
(LP2 and LP4). If not present, check
195 J34-2 N POT Negative reference for the Travel Battery voltage VM P2
pot (P2). If this reference is lost or wrt BT1+
intermittent, the travel pot will not
function correctly and possibly will
throw codes. If not present, check
196 J34-3 C POT Wiper input from the Travel pot Approx. 2V P2 VM
(P2). Voltage will vary depending difference
on travel request. The pot may need between neutral
to be re-learned. If not present, and pedal
check pot, wiring, and connections. depressed
J34-3).
197 J34-4 NOT USED
198 J34-5 VCC Voltage to Travel pot (P2). If not Approx. 10V wrt VM P2
present check VM, wiring, and J34-2
connections.
199 J34-6 GND One of the grounds supplied by the Battery voltage VM SW3 thru
VM to multiple components. If wrt BT1+ 10, 16,
ground is not present at this 30, PB2,
connection check for B– coming into PB3, PB4,
the VM at (J34-7, 8, 10) and PB9, TS1,
(J40-17). TS2
200 J34-7 GND B– supply to the VM. This B– is Battery voltage B– at J1– VM
shared by many components prior wrt BT1+
to and after the VM. If not present,
follow back towards B– until loss
can be determined.
can be determined.


202 J34-9 HORN OUT Output from the VM to activate the +24V; 0V VM HR1
Horn (HR1 at J11-IN). If not present, activated
check VM, horn push button, and
wiring.
can be determined.
204 J34-11 +24V +24V input to VM from DC/DC +24V DC/DC VM

converter (J96-4). If not present, Converter
check converter, wiring, and
connections.
205 J34-12 +24V CAN +24V output from the VM to Armrest +24V VM Armrest
Board (J139-5) and Operator Board, OD
Display (J137-5). If not present,
check VM, wiring, and connections.
206 J34-13 BRAKE LIGHT +24V output from VM to the Brake +24V VM Brake
Lights (LP1 and LP3) when traveling Lights
and changing direction or traveling
and pressing brake pedal. If not
connections.
207 J34-14 PARK Input to the VM from Parking Brake Approx. 5V brake SW7 VM
switch (SW7 at J30-3). If not set; 0V brake
connections.
208 J34-15 BRAKE Input to the VM from the Brake Approx. 5V pedal SW6 VM
Pedal switch (SW6 at J31-2). If not not depressed;
209 J34-16 HORN IN Input to VM from Horn switch (PB4 Approx. 5V when PB4 VM
at J8-2). If not present, check horn switch is open; 0V
switch, wiring, and connections. when switch is
activated
210 J34-17 OIL BRAKE Input to VM from Low Brake Fluid Approx. 5V open; SW3 VM
Sensor (SW3). If not present, check 0V switch closed
211 J34-18 /BW Input to VM from Reverse Pedal Approx. 0V open; SW5 VM
switch (SW5 at J33-9). If not approx. 5V switch
present, check switch, wiring, and closed
System)
212 J34-19 BW Input to VM from Reverse Hand Approx. 5V SW5, VM

Direction switch (SW10 at J39-7) or switch open; SW10
Reverse Foot Pedal switch (SW5 at approx. 0V switch
J33-8). If not present, check closed
switches, wiring, and connections.


213 J34-20 /FW Input to VM from Forward Foot Approx. 0V SW4 VM

Pedal switch (SW4 at J33-3). If not switch open;
present, check switch, wiring, and approx. 5V switch
connections. (Dual Pedal closed
System)
214 J34-21 CAN L Communication line between VM, N/A VM, OD VM, OD,
Operator Display (J137-1), and CAN-Bus
CAN-Bus Interface (J132-2). Interface
215 J34-22 CAN L Communication line between VM N/A VM Armrest

and Armrest Board (J131-1). Board
216 J34-23 CAN L Communication line between VM N/A VM, TPA VM, TPA
and TPA (Dual Traction Motor
truck: JAT-6) (Single Traction
Motor truck: JT4-1)

connections.
218 J34-25 CONFIG Input to the VM to identify the type Approx. 5V J33-5 VM
of directional controls on the truck w/Hand Direction
(standard Hand Direction Lever or Lever; Approx. 0V
optional Dual Pedal System). If truck w/Dual Pedal
has the standard Hand Direction System
Lever, the input will be high. If the
truck has the optional Dual Pedal
System, the input will be low.
219 J34-26 R-TR.TEMP.SW Dual Traction Motor Truck - Approx. 0V when TS1 VM
Input to VM from Right TM Temp OK; approx. 5V
Switch (TS1 at J15-6). When the when open
switch opens, an error code is (overheated)
displayed. If not present, check TS1,
220 J34-26 PUMP.TEMP.SW Single Traction Motor Truck - Approx. 0V when TS2 VM
Input to VM from PM temperature OK; approx. 5V
switch (TS2 at J13-6). When the when open
221 J34-27 L-TR.TEMP.SW Dual Traction Motor Truck - Approx. 0V when TS2 VM
Input to VM from Left TM Temp OK; approx. 5V
Switch (TS2 at J16-6). When the when open


222 J34-27 TR.TEMP.SW Single Traction Motor Truck - Approx. 0V when TS1 VM
Input to VM from TM temperature OK; approx. 5V
switch (TS1 at J15-6). When the overtemp
switch opens, an error code is
223 J34-28 LPH Input to the VM from the LPH switch Approx. 0V when PB3 VM
(PB3 at J36-2). If not present, check PB3 closed;
switch, wiring, and connections. approx. 5V open
224 J34-29 SP. RED. Input to VM from the Speed Approx. 0V when PB2 VM
Reduction switch (PB2 at J37-3). If PB2 closed;
not present, check switch, wiring, approx. 5V open
and connections.
225 J34-30 FW Input to VM from Forward Hand 5V switch open; SW4, VM

Direction switch (SW9 at J39-5) or 0V switch closed SW9
Forward Foot Pedal switch (SW4 at
J33-2). If not present, check
226 J34-31 /EN. Input to the VM from Travel Enable Approx. 0V SW8 VM
switch (SW8 at J32-6). Used in w/pedal
conjunction with Travel pot (P2) for released; approx.
trucks configured with Hand 5V w/pedal
Direction Lever. If not present, check depressed
227 J34-32 EN. Input to the VM from Travel Enable Approx. 5V SW8 VM
228 J34-33 CAN H Communication line between VM, N/A VM, OD VM, OD,
229 J34-34 CAN H Communication line between VM N/A VM Fingertip

and Fingertip Armrest Board Armrest
(J131-2). Board
230 J34-35 CAN H Communication line between VM N/A VM, TPA VM, TPA
and TPA (Dual Traction Motor
Truck: JAT-6) (Single Traction
Motor truck: JT4-3)
231 J36-1 GND Ground to LPH switch (PB3) from the Battery voltage VM PB3
VM (J34-6). If not present, check wrt BT1+
232 J36-2 LPH Provides input to VM (J34-28) from Approx. 0V when PB3 VM
the LPH switch (PB3). If not present, PB3 closed;
check switch, wiring, and approx. 5V open
connections.


233 J37-1 GND Ground to Speed Reduction switch Battery voltage VM PB2
(PB2) from the VM (J34-6). If not wrt BT1+
connections.
234 J37-2 NOT USED
235 J37-3 SP. RED. Provides input to VM (J34-29) from Approx. 0V when PB2 VM
(TURTLE) the Speed Reduction switch (PB2). If PB2 closed;
and connections.
236 J39-1 GND Ground to Forward Hand Direction Battery voltage VM SW9
switch (SW9) from the VM (J34-6). wrt BT1+
If not present, check VM, wiring,
and connections.
237 J39-2 GND Ground to Reverse Hand Direction Battery voltage VM SW10
and connections.
239 J39-5 FW Provides input to VM (J34-30) from Approx. 5V SW9 VM

Forward Hand Direction switch switch open; 0V
(SW9). If not present, check switch, switch closed
240 J39-6 NOT USED
241 J39-7 BW Provides input to VM (J34-19) from Approx. 5V SW10 VM

Reverse Hand Direction switch switch open; 0V
(SW10). If not present, check switch closed
242 J39-8 NOT USED
243 J40-1 LIFTING Input to VM from Lifting switch Approx. 5V open; SW11 VM
(SW11 at J42-3). If not present, 0V closed
check switch, wiring, and
connections.
244 J40-2 FAN DRIVE Output from the VM to the Power Approx. 5V ON; VM FN1
Amp Fan (FN1 at J71-3). If not 0V OFF
connections. Should be present
within a minute of turning Key
switch ON.
245 J40-3 SIDESHIFT Input to VM from Sideshift switch Approx. 5V open; SW13 VM
connections.
246 J40-4 4TH Input to VM from 4th Function Approx. 5V open; SW14 VM
switch (SW14 at J45-3). If not 0V closed
present, check switch, wiring, and
connections.


247 J40-5 NOT USED
VM to multiple components. If wrt BT1+ 15
ground is not present at this
connection check for B– coming into
the VM at (J34-7, 8, 10) and
(J40-17).
249 J40-7 VCC Supply voltage to the Lift pot (P3 at Approx. 5V VM P3
J41-1) from the VM. If not present,
250 J40-8 CAN L Communication line between the N/A VM HCB

VM and optional HCB (J140-4). If
option is not present, a jumper with
terminating resistor is installed
between J48-8 and J48-15.
251 J40-9 N POT Negative reference for the Lift pot Battery voltage VM P3
(P3 at J41-3). If this reference is lost wrt BT1+
or intermittent, the lift pot will not
Note: Check P3 by disconnecting it
from the circuit and reading across
it. Approx. 4K ohm should be read
across J41-1 and 3.
252 J40-10 TILT Input to VM from Tilt switch (SW12 Approx. 5V open; SW12 VM
at J43-3). If not present, check 0V closed
253 J40-11 C POT Wiper input from the Lift pot (P3 at Approx. 2.5V in P3 VM
J41-2). Voltage will vary depending neutral; approx.
on lift request. The pot may need to 5V w/full lift
be re-learned. If not present, check requested
pot, wiring, and connections.
254 J40-12 AUX IN 3 Input to VM from the optional Approx. 5V open; VM SW28
Forward Working Lights switch 0V closed
(SW28 at J99). If not present, check
255 J40-13 AUX IN 1 Input to VM from the Lowering Approx. 5V open; SW15 VM
connections.
256 J40-14 AUX IN 2 Input to VM from J95 (jumper). If not Approx. 5V open; VM VM
present, check wiring and 0V closed
connections.


257 J40-15 CAN H Communication line between the N/A VM HCB

258 J40-16 AUX OUT 1 +24V output from VM, through fuse +24V VM BZ1
F10, to the optional Travel Alarm
(BZ1 at J70+). If not present, check
Note: Option must be enabled in
FlashWare.
259 J40-17 GND B– supply to VM. This B– is shared Battery voltage B– at J1– VM
by many components prior to and wrt BT1+
after the VM. If not present, follow
back towards B– until loss can be
determined.
260 J40-18 AUX IN 4 Input to the VM from the optional Approx. 5V open; SW29 VM
Reverse Working lights switch 0V closed
(SW29 at J94). If not present, check
261 J40-19 AUX OUT 2 +24V output from the VM, through +24V VM LP5
fuse F11, to Warning light (LP5 at
J97).
262 J40-20 +24V AUX +24V input to VM from DC/DC +24V DC/DC VM
connections.
connections.
264 J40-22 AUX OUT 3 +24V output from the VM, through +24V VM LP7
fuse F12, to Forward Left Work light
(LP7 at J104).
265 J40-23 AUX OUT 4 +24V output, through fuse F13, to +24V VM LP8, LP9
Reverse Working lights (LP8 at J106
and LP9 at J105).
266 J41-1 VCC Supply voltage to the Lift pot (P3) Approx. 5V VM P3
from the VM (J40-7). If not present,
267 J41-2 C POT Wiper input from the Lift pot (P3) to Approx. 2.5V in P3 VM
VM (J40-11). Voltage will vary neutral; approx.
depending on lift request. The pot 5V w/full lift
may need to be re-learned. If not requested
present, check pot, wiring, and
connections.


(P3) from the VM (J40-9). If this wrt BT1+
reference is lost or intermittent, the
lift pot will not function correctly and
possibly will throw codes. If not
connections.
across J41-1 and 3.
269 J42-1 GND One of the grounds supplied by the Battery voltage VM SW11
VM (J40-6) to Lift switch (SW11). If wrt BT1+
not present, check VM, wiring, and
connections.
270 J42-2 NOT USED
271 J42-3 LIFTING Input to VM (J40-1) from the Lift Approx. 5V open; SW11 VM
switch (SW11). If not present, check 0V closed
VM (J40-6) to Tilt switch (SW12). If wrt BT1+
connections.
273 J43-2 NOT USED
274 J43-3 TILT Input to VM (J40-10) from the Tilt Approx. 5V open; SW12 VM
VM (J40-6) to Sideshift switch wrt BT1+
(SW13). If not present, check VM,
276 J44-2 NOT USED
277 J44-3 SIDESHIFT Input to VM (J40-3) from the Approx. 5V open; SW13 VM
Sideshift switch (SW13). If not 0V closed
connections.
VM (J40-6) to 4th Function switch wrt BT1+
279 J45-2 NOT USED
280 J45-3 4th FUNCTION Input to VM (J40-4) from the 4th Approx. 5V open; SW14 VM
Function switch (SW14). If not 0V closed
connections.


281 J46-1 +24V +24V to optional 5th Function +24V DC/DC PB5
switch (PB5) from fuse F7. If not Converter
present, check fuse, wiring, and
connections.
282 J46-2 5TH When switch (PB5) is closed, +24V PB5 EV11
SOLENOID voltage is allowed to pass to
(optional) optional 5th Solenoid Valve (EV11).
If not present, check switch, wiring,
and connections.
VM (J40-6) to Lowering switch wrt BT1+
284 J47-2 NOT USED
285 J47-3 AUX IN 1 Input to VM (J40-13) from the Approx. 5V open; SW15 VM
Lowering switch (SW15). If not 0V closed
connections.
286 J47-4 NOT USED
287 J70+ AUX OUT 1 Output from VM (J40-16), through +24V VM BZ1
fuse F10, to the optional Travel
Alarm (BZ1). If not present, check
VM, fuse, wiring, and connections.
FlashWare.
288 J70– GND B– supply to optional Travel Alarm Battery voltage B– at J1– BZ1
(BZ1). This B– is shared by many wrt BT1+
components prior to and after the
VM. If not present, follow back
towards B– until loss can be
determined.
289 J71-1 GND B– supply to Power Amplifier Fan. Battery voltage B– at J1– Power
This B– is shared by many wrt BT1+ Amp Fan
fan. If not present, follow back
determined.
290 J71-2 +24V +24V to the Power Amplifier Fan +24V DC/DC Power
from fuse F5. If not present, check Converter Amp Fan
fuse, wiring, and connections.
291 J71-3 FAN DRIVE Output from the VM (J40-2) to the Approx. 5V On; VM Power
Power Amp Fan (FN1). If not 0V Off Amp Fan
switch ON.
292 J71-4 NOT USED


293 J91-1 GND B– to the Left Brake Light (LP3) and Battery voltage BT1 LP3, LP4
Left Tail Light (LP4). If not present, wrt BT1+
can be determined.
294 J91-2 TAIL LIGHT Output from the VM (J34-1) to the +24V ON; VM Left Tail
Left Tail Light (LP4). If not present, 0V OFF Light
295 J91-3 TAIL LIGHT Output from VM (J34-1) to the Tail +24V ON; VM Tail Lights
Lights (LP2 and LP4). If not present 0V OFF
296 J91-4 BRAKE LIGHT Output from the VM (J34-13) to the +24V ON; VM Left Brake
Left Brake Light (LP3) when traveling 0V OFF Lights
connections.
297 J91-5 BRAKE LIGHT Output from VM (J34-13) to the +24V ON; VM Right Brake
Right Brake Light (LP1) when 0V OFF Lights
traveling and changing direction or
traveling and pressing brake pedal.
If not present check VM, wiring, and
connections.
298 J91-6 NOT USED
J96 6-Pin Config. on Dual Traction Motor Trucks <S/N 29999 and Single Traction Motor Trucks <S/N 10677
299 J96-1 B– B– to DC/DC converter. If not Battery voltage B– DC/DC

present, make sure battery is wrt BT1+ Converter
connected. Check wiring and
connections. A jumper is installed to
J96-6.
300 J96-2 B+ B+ to DC/DC converter when CT1 B+ CT1 DC/DC

coil is energized. If not present, Converter
check F2, SW1, CT1 coil, CT1 tips,
301 J96-3 NOT USED
302 J96-4 +24V +24V from DC/DC converter to +24V DC/DC +24V
24V circuit. If not present, check for Converter Circuits
power and ground to converter.
303 J96-5 NOT USED

J96-1.


J96 5-Pin Config. on Dual Traction Motor Trucks S/N 29999 and up


J96-6.
307 J96-3 NOT USED

J96-1.
310 J97 AG+, N– Connection for optional Warning +24V ON; VM LP5
Light (LP5). 0V OFF
311 J100-1 B+ B+ to auxiliary power strip from B+ BT1 Aux Power

J50-11. If not present, check fuse
F4, wiring, and connections.
312 J100-2 NOT USED
313 J100-3 B– B– to auxiliary power strip. If not Battery voltage B– Aux Power
present, make sure battery is wrt BT1+
connections.
314 J101 L, CH input Connection for optional Lift-Limit 24V ON; 0V OFF VM EV12
Push Button Switch (PB9).
315 J102-1 GND B– supply from Battery. This B– is Battery voltage BT1 LP1 and
used by LP1 and LP2. If not present, wrt BT1+ LP2
can be determined.
316 J102-2 TAIL LIGHT Output from VM (J34-1) to the Right +24V VM Tail Lights
Tail Light (LP2). If not present, check
317 J102-3 TAIL LIGHT Tied to J102-2. +24V VM Tail Lights
318 J102-4 TAIL LIGHT Output from VM (J34-1) to the Right +24V VM Brake Light
Brake Light (LP1) when traveling
connections.


319 J102-5 BRAKE LIGHT Tied to J102-4. +24V VM Tail Lights
320 J102-6 NOT USED
321 J103 AC+, N– Connection for optional Forward +24V ON VM LP6

Right Work Light (LP6).
FlashWare. Verify jumper is
installed under dash if no switch is
installed.

Left Work Light (LP7).
installed.
323 J105 AH+, N– Connection for optional Backward +24V ON VM LP9

installed.

installed.
325 J107-1 +V Voltage from the HCB (JCM-2) to the B+ HCB EVP1
Lowering (EVP1) Solenoid. If not
present, check the HCB, fuse F15,
326 J107-2 LOW Voltage from the HCB (JCM-1) to Approx. 2 to 11V HCB EVP1
turn on the Lowering Solenoid wrt B+ (approx.
(EVP1). If not present, check the 18 ohms across
HCB, wiring, and connections. coil)
327 J108-1 +V Voltage from the HCB (JCM-2) to the B+ HCB EV2
Lifting Solenoid (EV2). If not present,
check the HCB, fuse F15, wiring,
and connections.
328 J108-2 LIFT Voltage from the HCB (JCM-3) to Approx. 24V wrt HCB EV2
turn on the Lifting Solenoid (EV2). If B+ (approx.
not present, check the HCB, wiring, 27 ohms across
and connections. coil)
Tilt Forward Solenoid (EV3). If not


330 J109-2 TILT FW Voltage from the HCB (JCM-4) to Approx. 15V wrt HCB EV3
turn on the Tilt Forward Solenoid B+ (approx.
(EV3). If not present, check the HCB, 18 ohms across
wiring, and connections. coil)
Tilt Backward Solenoid (EV4). If not
332 J110-2 TILT BW Voltage from the HCB (JCM-6) to Approx. 15V wrt HCB EV4
turn on the Tilt Backward Solenoid B+ (approx.
Left Sideshift Solenoid (EV5). If not
334 J111-2 L SIDESHIFT Voltage from the HCB (JCM-7) to Approx. 18V wrt HCB EV5
turn on the Left Sideshift Solenoid B+ (approx.
Right Sideshift Solenoid (EV6). If not
336 J112-2 R SIDESHIFT Voltage from the HCB (JCM-15) to Approx. 18V wrt HCB EV6
turn on the Right Sideshift Solenoid B+ (approx.
337 J113-1 +V Voltage from the HCB (JCM-13) to B+ HCB EV7

the 4th Function Solenoid (EV7). If
not present, check the HCB, fuse
338 J113-2 4th FUNCTION Voltage from the HCB (JCM-12) to Approx. 18V wrt HCB EV7
turn on the 4th Function Solenoid B+ (approx.



341 J117-1 DRAIN Voltage from the HCB (JCM-19) to Approx. 2.5V HCB EVP
turn on the Drain Solenoid (EVP). If static; Approx. 2
not present, check the HCB, wiring, to 13V wrt J117-2
and connections. when lifting or
performing an
aux function
(approx. 18 ohms
across coil)
342 J117-2 +V Voltage from the HCB (JCM-20) to Approx. B+ when HCB EVP
turn on the Drain Solenoid (EVP). If lifting or
not present, check the HCB, fuse performing an
F21, wiring, and connections. aux function
343 J119-1 +V Voltage is supplied to the optional +24V SW16, EV12

Lift Limit Bypass solenoid when PB9
SW16 is normally closed. When
SW16 opens, the Lift-Limit Bypass
button PB9 must be depressed to
allow lift. If not present, check
wiring, fuse, switches, and
connections.
344 J119-2 B– B– supply from Battery. This B– is Battery voltage BT1 EV12
used by the optional Lift-Limit Bypass wrt BT1+
Valve (EV12). If not present, follow
determined.
345 J137-1 CAN L Communication line between N/A VM Operator

Operator Display and VM (J34-21). Display
346 J137-2 CAN H Communication line between N/A VM Operator

347 J137-3 GND B– supply from Battery. This B– is Battery voltage BT1 Operator
used by the Operator Display. If not wrt BT1+ Display
348 J137-4 NOT USED
349 J137-5 +V +24V supply to Operator Display +24V VM Operator

from the VM (J34-12). If not present, Display
connections.
350 J137-6 GND B– supply from Battery to the Battery voltage BT1 Operator
Operator Display. This connection wrt BT1+ Display
supplies B– to the CAN-Bus
Interface by use of a jumper. If not


351 J138-1 GND B– supply from Battery. This B– is Battery voltage BT1 Fingertip
used by the optional Fingertip wrt BT1+ Armrest
Armrest Board. If not present, follow Board
determined.
352 J138-2 CAN L Communication line between PPA N/A PPA Fingertip
and optional Fingertip Armrest Armrest
Board (JCAN-2). Board
determined.
354 J138-4 CAN H Communication line between PPA N/A PPA Fingertip
355 J138-5 +24V CAN +24V supply to Fingertip Armrest +24V VM Fingertip
Board (JCAN-5) from VM (J34-12). Armrest
If not present, check fuse F23, Board
357 J140-1 B+ B+ to HCB. If voltage is not present, B+ F3 HCB

connections.

connections.
359 J140-3 B– B– supply from Battery. This B– is Battery voltage BT1 HCB
used by the optional HCB. If not wrt BT1+
360 J140-4 CAN L Communication line between HCB N/A VM HCB

and VM (J40-8).
362 J140-13 CAN H Communication line between HCB N/A VM HCB

and VM (J40-15).
363 J140-14 NOT USED
364 J406-A NOT USED
365 J406-B +V POT Voltage to the Lifting/Lowering pot Approx. 5V Armrest Lifting/
(P4). If not present, check the Board Lowering
Armrest Board, wiring, and Fingertip
connections. Module


366 J406-C C POT Output from the Lifting/Lowering Approx. 2.5V in Lifting/ Armrest
pot (P4) wiper to the Armrest Board. neutral; range 0V Lowering Board
If not present, check P4, wiring, and to 5V Fingertip
connections. Module
it. Approx. 4K ohms should be read
across J400-1 and 4.
367 J406-D GND POT Ground to the Lifting/Lowering pot Battery voltage Armrest Lifting/
(P4). If not present, check the wrt BT1+ Board Lowering
connections. Module
368 J406-E MICRO Input from Lifting/Lowering Approx. 5V Lifting/ Armrest

directional switch (SW17). If not closed; 0V open Lowering Board
present, check switch, wiring, and Fingertip
connections. Module
369 J406-F MICRO Input from Lifting/Lowering Approx. 5V Lifting/ Armrest

connections. Module
370 J406-G GND Ground to Lifting/Lowering Battery voltage Armrest Lifting/

directional switches (SW17 and wrt BT1+ Board Lowering
SW18). If not present, check the Fingertip
Armrest Board, wiring, and Module
connections.
371 J407-A NOT USED
372 J407-B +V POT Voltage to the Tilt pot (P5). If not Approx. 5V Armrest Tilt
present, check the Armrest Board, Board Fingertip
wiring, and connections. Module
373 J407-C C POT Output from the Tilt pot (P5) wiper to Approx. 2.5V in Tilt Armrest
the Armrest Board. If not present, neutral; range 0V Fingertip Board
check P5, wiring, and connections. to 5V Module
374 J407-D GND POT Ground to the Tilt pot (P5). If not Battery voltage Armrest Tilt
present, check the Armrest Board, wrt BT1+ Board Fingertip
375 J407-E MICRO Input from Tilt pot directional switch Approx. 5V Tilt Armrest
(SW19). If not present, check closed; 0V open Fingertip Board
switch, wiring, and connections. Module
376 J407-F MICRO Input from Tilt pot directional switch Approx. 5V Tilt Armrest


377 J407-G GND Ground to Tilt directional switches Battery voltage Armrest Tilt
(SW19 and SW20). If not present, wrt BT1+ Board Fingertip
check the Armrest Board, wiring, Module
and connections.
378 J408-A NOT USED
379 J408-B +V POT Voltage to the Sideshift pot (P6). If Approx. 5V Armrest Sideshift
not present, check the Armrest Board Fingertip
Board, wiring, and connections. Module
Note: This switch is internal to the
Fingertip Module. If switch is bad,
replace the module.
380 J408-C C POT Output from the Sideshift pot (P6) Approx. 2.5V in Sideshift Armrest
wiper to the Armrest Board. If not neutral; range 0V Fingertip Board
present, check P6, wiring, and to 5V Module
connections.
381 J408-D GND POT Ground to the Sideshift pot (P6). If Battery voltage Armrest Sideshift
not present, check the Armrest wrt BT1+ Board Fingertip
382 J408-E MICRO Input from Sideshift pot directional Approx. 5V Sideshift Armrest
switch (SW21). If not present, check closed; 0V open Fingertip Board
383 J408-F MICRO Input from Sideshift pot directional Approx. 5V Sideshift Armrest
384 J408-G GND Ground to Sideshift directional Battery voltage Armrest Sideshift
switches (SW21 and SW22). If not wrt BT1+ Board Fingertip
present, check the Armrest Board, Module
385 J409-A NOT USED
386 J409-B +V POT Voltage to the 4th Aux pot (P7). If Approx. 5V Armrest 4th Aux
replace the module.
387 J409-C C POT Output from the 4th Aux pot (P7) Approx. 2.5V in 4th Aux Armrest
connections.


388 J409-D GND POT Ground to the 4th Aux pot (P7). If Battery voltage Armrest 4th Aux
389 J409-E MICRO Input from 4th Aux pot (P7) Approx. 5V 4th Aux Armrest
directional switch (SW23). If not closed; 0V open Fingertip Board
present, check switch, wiring, and Module
connections.
390 J409-F MICRO Input from 4th Aux pot (P7) Approx. 5V 4th Aux Armrest
connections.
391 J409-G GND Ground to 4th Aux pot (P7) Battery voltage Armrest 4th Aux
directional switches (SW23 and wrt BT1+ Board Fingertip
SW24). If not present, check the Module
Armrest Board, wiring, and
connections.
392 J411-1 GND Ground to the Horn switch (PB12) Approx. 5V Armrest PB12
on the Armrest Board. If not present, Board
check the switch, armrest board,
393 J411-2 HORN Input from the Horn switch (PB12) to Approx. 0V PB12 Armrest
the Armrest Board when pushed. If closed; 5V open Board
not present, check the switch,
394 J412-1 GND Optional voltage from Armrest B– Armrest Armrest

Board to PB13. Board Board
395 J412-2 NOT USED
396 J412-3 LIFT LIMIT Optional input to Armrest Board Approx. 0V Armrest Armrest
BYPASS from PB13. closed; 5V open Board Board
397 PPA B+ B+ B+ from the battery to the PPA B+ J1+ PPA

through fuse FP. If not present, make
sure the battery is connected. Check
398 PPA B– B– B– from the battery to the PPA. If not Battery voltage BT1 PPA
present, make sure the battery is wrt BT1+
connections.
399 PPA (U) PPA (U) One of three phases from the PPA to 0 to approx. PPA PM
the Pump Motor. Voltage is 20VAC; Approx.
measured between any two phases. 200A ramping;
If not present, check the PPA, Approx. 250A full
wiring, and connections. lift
400 PPA (V) PPA (V) One of three phases from the PPA to 0 to approx. PPA PM
the Pump Motor. Voltage is 20VAC; approx.
If not present, check the PPA, approx. 250A full


401 PPA (W) PPA (W) One of three phases from the PPA to 0 to approx. PPA PM
402 TPA B+ B+ B+ from the battery to the TPA B+ J1+ TPA

through fuse FT. If not present, make
403 TPA B– B– B– from the battery to the TPA. If not Battery voltage BT1 TPA
connected. Check the wiring and
connections.
404 TPA (U) TPA (U) One of three phases from the TPA to 0 to approx. TPA Traction
the Traction Motor. Voltage is 20VAC; approx. Motor
If not present, check the TPA, wiring, approx. 35A full
and connections. speed on jack
405 TPA (V) TPA (V) One of three phases from the TPA to 0 to approx. TPA Traction
406 TPA (W) TPA (W) One of three phases from the TPA to 0 to approx. TPA Traction
407 TPA (UM) TPA (UM) One of three phases from the 0 to approx. TPA Right
Master TPA to the Right Traction 20VAC; approx. Traction
Motor. Voltage is measured 50A ramping; Motor
between any two phases. If not approx. 35A full
present, check the TPA, wiring, and speed on jack
connections.
408 TPA (VM) TPA (VM) One of three phases from the 0 to approx. TPA Right
connections.
409 TPA (WM) TPA (WM) One of three phases from the 0 to approx. TPA Right
connections.


410 TPA (US) TPA (US) One of three phases from the Slave 0 to approx. TPA Left
TPA to the Left Traction Motor. 20VAC; approx. Traction
Voltage is measured between any 50A ramping; Motor
two phases. If not present, check the approx. 35A full
TPA, wiring, and connections. speed on jack
411 TPA (VS) TPA (VS) One of three phases from the Slave 0 to approx. TPA Left
412 TPA (WS) TPA (WS) One of three phases from the Slave 0 to approx. TPA Left

Single Traction Motor Trucks >S/N 10676 Pinout Matrix
Single Traction Motor Trucks >S/N 10676

1 JAM NOT USED
2 JAP-1 thru 3 NOT USED
3 JAP-4 +V OUT Output to optional Mast Height B+ VM SW31

wiring and connections.
4 JAP-5 NOT USED
5 JAP-6 IN Input to VM from optional Mast Switch closed: B+ SW31 VM

Height switch (SW31). If not open: 0V
connections.
6 JAP-7 thru 14 NOT USED
7 JAT-1 thru 3 NOT USED
8 JAT-4 +V OUT +V Out to the configuration B+ VM VM

jumper(s) designating Model C60,
EE, or both.
9 JAT-5 CONF. Input to VM (configuration jumper) Open/+V Key if VM VM

for Model C60, standard and EE. jumpered
10 JAT-6 CONF. Input to VM (configuration jumper) Open/+V Key if VM VM

for all EE models. jumpered
11 JAT-7 thru 14 NOT USED
12 JBP-1 +V KEY B+ from Key switch (SW1). If not B+ SW1 PPA

and connections.
13 JBP-2 +V COIL Voltage from the PPA to CT2 coil B+ PPA CT2
14 JBP-3 NOT USED
15 JBP-4 SEAT Input from the Seat switch (SW2). If B+ SW2 TPA, PPA
16 JBP-5 SAFETY/ B– from JBP-11 on the PPA. If Battery voltage PPA PPA
AMPLIFIER voltage is >1V (wrt B–), check the wrt BT1+
ENABLE jumper from JBP-11. If jumper is OK,
check B– to the PPA.
17 JBP-6 NOT USED
18 JBP-7 +V OUT Voltage to SW30 and SW2. If not B+ PPA SW30,

present, check PPA, wiring, and SW2
connections.

Pinout Matrix Single Traction Motor Trucks >S/N 10676

19 JBP-8 –V COIL Voltage from the PPA to CT2 coil Approx. B+ to PPA CT2
(J50-6). If not present, check PPA, energize coil;
wiring, and connections. Approx. drops to approx.
32 ohms across coil. 14V for holding
wrt B+
20 JBP-9 OUT B– from PPA to TPA (JBT-5). Battery voltage PPA TPA
wrt BT1+
21 JBP-10 NOT USED
22 JBP-11 B– Ties the SAFETY/AMPLIFIER Battery voltage PPA PPA

ENABLE input to JBP-5 low. If not wrt BT1+
low, check the PPA.
23 JBP-12 NOT USED
24 JBT-1 +V KEY B+ from Key switch (SW1). If not B+ SW1 TPA

and connections. This is used by the
TPA to determine BSOC.
25 JBT-2 +V COIL Voltage from the TPA to CT3 coil. If B+ TPA CT3
and connections. Approx. 32 ohms
across coil.
26 JBT-3 +V AUX COIL Voltage from the TPA to Relay 1 (RL1 0V with 36V TPA RL1
RL1 is energized to allow 12V drop JBT-9
not present, check TPA, wiring, and
connections. Approx. 1K ohm
across coil.
27 JBT-4 SEAT Input from the Seat switch (SW2). If B+ SW2 TPA
28 JBT-5 SAFETY B– from PPA (JBP-9) to TPA. Battery voltage PPA TPA
wrt BT1+
29 JBT-6 NOT USED
30 JBT-7 +V Out Voltage from the TPA to the optional B+ TPA Speed
Speed Reduction switch. If not Reduction
present, check TPA, wiring, and switch
connections. Jumpered if no switch.
31 JBT-8 –V COIL Voltage from the TPA to CT3 coil. If Approx. B+ to TPA CT3
not present, check TPA, wiring, and energize coil;
connections. Approx. 32 ohms drops to approx.
across coil. 14V for holding
wrt B+


32 JBT-9 –V AUX COIL Voltage from the TPA to RL1 coil 0V with 36V TPA RL1
(J51-5). If not present, check TPA, battery; 24V with
wiring, and connections. Approx. 48V battery wrt
1K ohm across coil. JBT-3
33 JBT-10 SPEED Input from optional Speed Reduction Jumpered: B+ Speed TPA
REDUCTION switch to TPA. If not present, check Switch closed: 0V Reduction
TPA, switch wiring, and Switch
connections.
34 JBT-11 and 12 NOT USED
35 JCM-1 LOW Voltage from the HCB to turn on the Approx. 2 to 12V HCB EVP1
Lowering Solenoid (EVP1). If not wrt B+ (approx.
connections. coil)
36 JCM-2 +V Voltage from the HCB to the B+ HCB EV2, EVP1

Lowering (EVP1) and Lifting (EV2)
37 JCM-3 LIFT Voltage from the HCB to turn on the Lifting: Approx. HCB EV2
Lifting Solenoid (EV2). If not present, 24V wrt B+
check the HCB, wiring, and (approx. 27 ohms
connections. across coil)
38 JCM-4 TILT FW Voltage from the HCB to turn on the Approx. 15V wrt HCB EV3
Tilt Forward Solenoid (EV3). If not B+ (approx.
connections. coil)
39 JCM-5 +V Voltage from the HCB to the Tilt B+ HCB EV3, EV4
Forward (EV3) and Tilt Backward
(EV4) Solenoids. If not present,
check the HCB, wiring, and
connections.
40 JCM-6 TILT BW Voltage from the HCB to turn on the Approx. 15V wrt HCB EV4
Tilt Backward Solenoid (EV4). If not B+ (approx.
connections. coil)
41 JCM-7 L SIDESHIFT Voltage from the HCB to turn on the Approx. 18V wrt HCB EV5
Left Sideshift Solenoid (EV5). If not B+ (approx.
connections. coil)


42 JCM-8 +V Voltage from the HCB to the Left B+ HCB EV5, EV6
(EV5) and Right (EV6) Sideshift
connections. coil)
45 JCM-13 +V Voltage from the HCB to the 4th B+ HCB EV7, EV8
Function (EV7 and EV8) Solenoids.
If not present, check the HCB,
connections. coil)
47 JCM-15 R SIDESHIFT Voltage from the HCB to turn on the Approx. 18V wrt HCB EV6
Right Sideshift Solenoid (EV6). If not B+ (approx.
connections. coil)
49 JCM-19 DRAIN Voltage from the HCB to turn on the Approx. 2-13V HCB EVP
Drain Solenoid (EVP). If not present, wrt B+ when
check the HCB, wiring, and requesting lift
connections. and/or any aux
function. (approx.
18 ohms across
coil)
50 JCM-20 +V Voltage from the HCB to the Drain B+ HCB EVP

Solenoid (EVP). If not present, check
the HCB, wiring, and connections.
51 JCM-21 and 22 NOT USED
52 JCM-23 GND B– supply to optional HCB. This B– Battery voltage B– at J1– HCB
is shared by many components wrt BT1+
prior to and after the VM. If not
53 JCP-1 CAN L Communication between the PPA N/A TPA, PPA TPA, PPA
and the TPA (JCT-2).
54 JCP-2 NOT USED


55 JCP-3 CAN H Communication between the PPA N/A TPA, PPA TPA, PPA
and the TPA (JCT-4).
56 JCP-4 NOT USED
57 JCT-1 CAN L Communication line between the N/A TPA, VM TPA, VM

58 JCT-2 CAN L OUT Communication line between the N/A TPA, PPA PPA
59 JCT-3 CAN H Communication line between the N/A TPA, VM TPA, VM

60 JCT-4 CAN H OUT Communication line between the N/A TPA, PPA PPA
61 JDP-1 Jumper
62 JDP-2 Jumper
63 JDT-1 and 2 NOT USED
64 JEP-1 +12V +12V to the Pump Motor (PM) +12V PPA EN3
65 JEP-2 GND Ground to the Pump Motor (PM) Battery voltage PPA EN3
66 JEP-3 PM ENCODER Channel A from the Pump Motor Approx. 5V EN3 PPA
67 JEP-4 NOT USED
68 JEP-5 PM ENCODER Channel B from the Pump Motor Approx. 5V EN3 PPA
69 JEP-6 NOT USED
70 JET-1 +12V +12V to the Traction Motor (TM) +12V TPA EN1
71 JET-2 GND Ground to the Traction Motor (TM) Battery voltage TPA EN1
72 JET-3 TM ENCODER Channel A from the Traction Motor Approx. 5V EN1 TPA
CHANNEL A (TM) encoder (EN1). If not present, running; 0V or
73 JET-4 NOT USED


74 JET-5 TM ENCODER Channel B from the Traction Motor Approx. 5V EN1 TPA
CHANNEL B (TM) encoder (EN1). If not present, running; 0V or
75 JET-6 NOT USED
76 J1+ B+ B+ from the positive battery B+ BT1 CT1, CT2,

terminal. If not present, make sure CT3 tips,
battery is connected and check F1 and F4
associated wiring.
77 J1– B– B– from the negative battery Battery voltage BT1 Entire truck
terminal. If not present, make sure wrt BT1+
battery is connected and check
associated wiring.
78 J4 OIL BRAKE Provides input to the VM (J34-17) Approx. 5V open; B– VM

from Low Brake Fluid Sensor (SW3). 0V closed
If not present, check switch, fluid,
79 J8-1 GND Ground to Horn push button switch Battery voltage VM PB4
(PB4) from VM (J34-6). If not wrt BT1+
connections.
80 J8-2 HORN IN Horn push button (PB4) input to VM Approx. 5V open; PB4 VM
(J34-16). If not present, check 0V closed
82 J11– HR 1 GND B– to the Horn (HR1). If not present, Battery voltage B– Horn
check wiring and connections. wrt BT1+
83 J11 IN HORN OUT Control voltage to Horn (HR1) from +24V normal VM Horn
the VM (J34-9). If not present, check goes to 0V when
VM, switch, wiring, and horn button
84 J11+ +24V +24V to the Horn (HR1) from the +24V DC/DC Horn
DC/DC Converter. If not present, Converter
connections. Approx. 65 ohms
across coil (J11+ to J11–).
85 J13-1 +12V +12V to the Pump Motor (PM) +12V PPA EN3
86 J13-2 GND Ground to the Pump Motor (PM) Battery voltage PPA EN3
87 J13-3 PM ENCODER Channel A from the Pump Motor Approx. 5V EN3 PPA


88 J13-4 PM ENCODER Channel B from the Pump Motor Approx. 5V EN3 PPA
89 J13-5 TERM Ground from the VM (J34-6) to the Battery voltage PPA TS2
Pump Motor (PM) temperature wrt BT1+
switch (TS2). If not present, check
90 J13-6 PM TEMP Input to the VM (J34-26) from the Approx. 0V TS2 PPA
Pump Motor (PM) temperature closed; 9V open
92 J15-1 +12V +12V to the Traction Motor (TM) +12V TPA EN1
encoder (EN1) from the TPA (JET-1).
and connections.
93 J15-2 GND Ground to the Traction Motor (TM) Battery voltage TPA EN1
encoder (EN1) from the TPA (JET-2). wrt BT1+
and connections.
94 J15-3 TM ENCODER Channel B from the Traction Motor Approx. 5V EN1 TPA
CHANNEL B (TM) encoder (EN1) to the TPA running; 0V or
(JET-5). If not present, check voltage 10V static
connections.
95 J15-4 TM ENCODER Channel A from the Traction Motor Approx. 5V EN1 TPA
CHANNEL A (TM) encoder (EN1) to the TPA running; 0V or
(JET-3). If not present, check voltage 10V static
connections.
TM temperature switch (TS1). If not wrt BT1+
connections.
97 J15-6 TM TEMP SW Input to the VM (J34-27) from the Approx. 0V TS1 VM

(TS1) TM temperature switch (TS1). Input closed; 5V open
connections.


99 J20-1 SEAT Input from the Seat switch (SW2). If B+ SW2 TPA
100 J20-2 NOT USED
101 J20-3 +V OUT B+ from TPA to Seat switch (SW2). B+ TPA TPA
If not present, check the seat switch,
battery interlock, jumper at J22-A3
and J22-A4, wiring, and
connections.
102 J23-1 +V OUT Voltage from PPA to Battery Interlock B+ PPA SW30,
switch (SW30). If not present, check SW2
PPA, switch, wiring, and
connections.
103 J23-2 +V OUT Voltage from Battery Interlock switch B+ SW30, PPA or TPA
(SW30) to Seat switch (SW2) SW2
Provides input to amplifiers to allow
operation. If not present, check PPA
or TPA (as applicable), switch,
104 J30-1 GND Ground to the Parking Brake switch Battery voltage VM SW7
connections.
105 J30-2 NOT USED
106 J30-3 PARK Input to the VM (J34-14) from the Approx. 5V brake SW7 VM
Parking Brake switch (SW7). If not set; 0V brake
connections.
107 J31-1 GND Ground to the Brake Pedal switch Battery voltage VM SW6
connections.
108 J31-2 BRAKE Input to the VM (J34-15) from the Approx. 5V pedal SW6 VM
Brake Pedal switch (SW6). If not not depressed;
109 J31-3 NOT USED
110 J32-1 C POT Input from the wiper of the Travel Approx. 2V P2 VM
pot (P2) to the VM (J34-3). If not difference
present check pot, wiring, and between neutral
connections. The pot may need to and pedal
be re-learned. depressed
J32-3).


111 J32-2 N POT Ground to Travel pot (P2) from the Battery voltage VM P2
VM (J34-2). If not present check wrt BT1+
112 J32-3 VCC Voltage to Travel pot (P2) from VM Approx. +10V VM P2
(J34-5). If not present, check VM,
113 J32-4 GND Ground to Travel Enable switch Battery voltage VM SW8
114 J32-5 EN. Input from the Travel Enable switch Approx. 5V pedal SW8 VM
115 J32-6 /EN. Input from the Travel Enable switch Approx. 0V pedal SW8 VM
116 J33-1 GND Ground to Forward Pedal switch Battery voltage VM SW4
connections.
(Dual Pedal System)
117 J33-2 FW Input from the Forward Pedal switch Approx. 5V pedal SW4 VM
connections.
(Dual Pedal System)
118 J33-3 /FW Input from the Forward Pedal switch Approx. 0V pedal SW4 VM
connections.
(Dual Pedal System)
119 J33-4 GND Ground from the VM (J34-6). If not Battery voltage VM VM
present, check VM, wiring, and wrt BT1+
connections.
(Dual Pedal System)
120 J33-5 CONFIG. Configuration input to the VM Approx. 0V VM VM

(J34-25). This input allows VM to w/dual pedals;
recognize Dual Pedal. If not approx. 5V
present, check jumper, wiring, and without dual
connections. pedals
(Dual Pedal System)
121 J33-6 NOT USED


122 J33-7 GND Ground to Reverse Pedal switch Battery voltage VM SW5
connections.
(Dual Pedal System)
123 J33-8 BW Input from the Reverse Pedal switch Approx. 5V pedal SW5 VM
(Dual Pedal System)
124 J33-9 /BW Input from the Reverse Pedal switch Approx. 0V pedal SW5 VM
(Dual Pedal System)
125 J33-10 thru12 NOT USED
126 J34-1 TAIL LIGHT Output from VM to the Tail Lights +24V VM LP2, LP4
(LP2 and LP4). If not present, check
127 J34-2 N POT Negative reference for the Travel Battery voltage VM P2
pot (P2). If this reference is lost or wrt BT1+
intermittent, the travel pot will not
128 J34-3 C POT Wiper input from the Travel pot Approx. 2V P2 VM
(P2). Voltage will vary depending difference
on travel request. The pot may need between neutral
to be re-learned. If not present, and pedal
check pot, wiring, and connections. depressed
J34-3).
129 J34-4 NOT USED
130 J34-5 VCC Voltage to Travel pot (P2). If not Approx. 10V wrt VM P2
present check VM, wiring, and J34-2
connections.
VM to multiple components. If wrt BT1+ 10, 16,
ground is not present at this 30, PB2,
connection check for B– coming into PB3, PB4,
the VM at (J34-7, 8, 10) and PB9, TS1,
(J40-17). TS2


can be determined.
can be determined.
134 J34-9 HORN OUT Output from the VM to activate the +24V; 0V VM HR1
Horn (HR1 at J11-IN). If not present, activated
check VM, horn push button, and
wiring.
can be determined.

check converter, wiring and
connections.
137 J34-12 +24V CAN +24V output from the VM to Armrest +24V VM Armrest
Board (J139-5) and Operator Board, OD
Display (J137-5). If not present,
138 J34-13 BRAKE LIGHT +24V output from VM to the Brake +24V VM Brake
Lights (LP1 and LP3) when traveling Lights
connections.
139 J34-14 PARK Input to the VM from Parking Brake Approx. 5V brake SW7 VM
switch (SW7 at J30-3). If not set; 0V brake
connections.
140 J34-15 BRAKE Input to the VM from the Brake Approx. 5V pedal SW6 VM
Pedal switch (SW6 at J31-2). If not not depressed;
141 J34-16 HORN IN Input to VM from Horn switch (PB4 Approx. 5V open; PB4 VM
at J8-2). If not present, check horn 0V switch closed
142 J34-17 OIL BRAKE Input to VM from Low Brake Fluid Approx. 5V open; SW3 VM
Sensor (SW3). If not present, check 0V switch closed


143 J34-18 /BW Input to VM from Reverse Foot Pedal Approx. 0V open; SW5 VM
switch (SW5 at J33-9). If not approx. 5V switch
present, check switch, wiring, and closed
System)
144 J34-19 BW Input to VM from Reverse Hand Approx. 5V SW5, VM

Direction switch (SW10 at J39-7) or switch open; SW10
Reverse Foot Pedal switch (SW5 at approx. 0V switch
J33-8). If not present, check closed
145 J34-20 /FW Input to VM from Forward Foot Approx. 0V SW4 VM

Pedal switch (SW4 at J33-3). If not switch open;
present, check switch, wiring, and approx. 5V switch
connections. (Dual Pedal closed
System)
146 J34-21 CAN L Communication line between VM, N/A VM, OD VM, OD,
147 J34-22 CAN L Communication line between VM N/A VM Armrest

and Armrest Board (J131-1). Board
148 J34-23 CAN L Communication line between VM N/A VM, TPA VM, TPA
and TPA (JCT-1)

connections.
150 J34-25 CONFIG Input to the VM to identify the type Approx. 5V J33-5 VM
of directional controls on the truck w/Hand Direction
(standard Hand Direction Lever or Lever; Approx. 0V
optional Dual Pedal System). If truck w/Dual Pedal
has the standard Hand Direction System
Lever, the input will be high. If the
truck has the optional Dual Pedal
System, the input will be low.
151 J34-26 PUMP.TEMP.SW Input to VM from PM temperature Approx. 0V when TS2 VM

switch (TS2 at J13-6). When the OK; approx. 5V
switch opens, an error code is when open
displayed. If not present, check TS2, (overheated)
152 J34-27 TR.TEMP.SW Input to VM from TM temperature Approx. 0V when TS1 VM

switch (TS1 at J15-6). When the OK; approx. 5V
switch opens, an error code is overtemp
153 J34-28 LPH Input to the VM from the LPH switch Approx. 0V when PB3 VM
(PB3 at J36-2). If not present, check PB3 closed;
switch, wiring, and connections. approx. 5V open


154 J34-29 SP. RED. Input to VM from the Speed Approx. 0V when PB2 VM
Reduction switch (PB2 at J37-3). If PB2 closed;
and connections.
155 J34-30 FW Input to VM from Forward Hand 5V switch open; SW4, VM

Direction switch (SW9 at J39-5) or 0V switch closed SW9
Forward Foot Pedal switch (SW4 at
J33-2). If not present, check
156 J34-31 /EN. Input to the VM from Travel Enable Approx. 0V SW8 VM
157 J34-32 EN. Input to the VM from Travel Enable Approx. 5V SW8 VM
158 J34-33 CAN H Communication line between VM, N/A VM, OD VM, OD,
159 J34-34 CAN H Communication line between VM N/A VM Fingertip

and Fingertip Armrest Board Armrest
(J131-2). Board
160 J34-35 CAN H Communication line between VM N/A VM, TPA VM, TPA
and TPA (JCT-3).
161 J36-1 GND Ground to LPH switch (PB3) from the Battery voltage VM PB3
VM (J34-6). If not present, check wrt BT1+
162 J36-2 LPH Provides input to VM (J34-28) from Approx. 0V when PB3 VM
the LPH switch (PB3). If not present, PB3 closed;
check switch, wiring, and approx. 5V open
connections.
163 J37-1 GND Ground to Speed Reduction switch Battery voltage VM PB2
(PB2) from the VM (J34-6). If not wrt BT1+
connections.
164 J37-2 NOT USED
165 J37-3 SP. RED. Provides input to VM (J34-29) from Approx. 0V when PB2 VM
(TURTLE) the Speed Reduction switch (PB2). If PB2 closed;
and connections.


166 J39-1 GND Ground to Forward Hand Direction Battery voltage VM SW9
and connections.
167 J39-2 GND Ground to Reverse Hand Direction Battery voltage VM SW10
and connections.
169 J39-5 FW Provides input to VM (J34-30) from Approx. 5V SW9 VM

Forward Hand Direction switch switch open; 0V
(SW9). If not present, check switch, switch closed
170 J39-6 NOT USED
171 J39-7 BW Provides input to VM (J34-19) from Approx. 5V SW10 VM

Reverse Hand Direction switch switch open; 0V
(SW10). If not present, check switch closed
172 J39-8 NOT USED
173 J40-1 LIFTING Input to VM from Lifting switch Approx. 5V open; SW11 VM
connections.
174 J40-2 FAN DRIVE Output from the VM to the Power Approx. 5V ON; VM FN1
Amp Fan (FN1 at J71-3). If not 0V OFF
switch ON.
175 J40-3 SIDESHIFT Input to VM from Sideshift switch Approx. 5V open; SW13 VM
connections.
176 J40-4 4TH Input to VM from 4th Function Approx. 5V open; SW14 VM
connections.
177 J40-5 NOT USED
VM to multiple components. If wrt BT1+ 15
ground is not present at this
connection check for B– coming into
the VM at (J34-7, 8, 10) and
(J40-17).


179 J40-7 VCC Supply voltage to the Lift pot (P3 at Approx. 5V VM P3
J41-1) from the VM. If not present,
180 J40-8 CAN L Communication line between the N/A VM HCB

(P3 at J41-3). If this reference is lost wrt BT1+
or intermittent, the lift pot will not
across J41-1 and 3.
182 J40-10 TILT Input to VM from Tilt switch (SW12 Approx. 5V open; SW12 VM
at J43-3). If not present, check 0V closed
183 J40-11 C POT Wiper input from the Lift pot (P3 at Approx. 2.5V in P3 VM
J41-2). Voltage will vary depending neutral; approx.
on lift request. The pot may need to 5V w/full lift
be re-learned. If not present, check requested
pot, wiring, and connections.
184 J40-12 AUX IN 3 Input to VM from the optional End-of Approx. 5V open; SW16 VM
Free Lift switch (SW16). If not 0V closed
connections.
185 J40-13 AUX IN 1 Input to VM from the Lowering Approx. 5V open; SW15 VM
connections.
186 J40-14 AUX IN 2 Input to VM from Tilt Angle Prox Approx. 5V open; SW32 VM
switch, wiring and connections.
187 J40-15 CAN H Communication line between the N/A VM HCB

188 J40-16 AUX OUT 1 +24V output from VM, through fuse +24V VM BZ1
F13, to the optional Travel Alarm
(BZ1 at J70+). If not present, check


189 J40-17 GND B– supply to VM. This B– is shared Battery voltage B– at J1– VM
by many components prior to and wrt BT1+
after the VM. If not present, follow
determined.
190 J40-18 AUX IN 4 Input to the VM from the optional Approx. 5V open; PB9 VM
Lift-Limit with Bypass switch (PB9). If 0V closed
not present, check switch, wiring,
and connections.
191 J40-19 AUX OUT 2 +24V output from the VM, through +24V VM EV13
fuse F23, to the Tilt Limit Solenoid
(EV13). If not present, check VM.
connections.
connections.
194 J40-22 AUX OUT 3 +24V output from the VM, through +24V VM EV12
fuse F22, to the Lift-Limit Solenoid
(EV12). If not present, check VM,
fuse F22, wiring, and connections.
195 J40-23 NOT USED
196 J41-1 VCC Supply voltage to the Lift pot (P3) Approx. 5V VM P3
from the VM (J40-7). If not present,
197 J41-2 C POT Wiper input from the Lift pot (P3) to Approx. 2.5V in P3 VM
VM (J40-11). Voltage will vary neutral; approx.
depending on lift request. The pot 5V w/full lift
may need to be re-learned. If not requested
present, check pot, wiring, and
connections.
(P3) from the VM (J40-9). If this wrt BT1+
reference is lost or intermittent, the
lift pot will not function correctly and
possibly will throw codes. If not
connections.
across J41-1 and 3.


VM (J40-6) to Lift switch (SW11). If wrt BT1+
connections.
200 J42-2 NOT USED
201 J42-3 LIFTING Input to VM (J40-1) from the Lift Approx. 5V open; SW11 VM
VM (J40-6) to Tilt switch (SW12). If wrt BT1+
connections.
203 J43-2 NOT USED
204 J43-3 TILT Input to VM (J40-10) from the Tilt Approx. 5V open; SW12 VM
VM (J40-6) to Sideshift switch wrt BT1+
206 J44-2 NOT USED
207 J44-3 SIDESHIFT Input to VM (J40-3) from the Approx. 5V open; SW13 VM
Sideshift switch (SW13). If not 0V closed
connections.
VM (J40-6) to 4th Function switch wrt BT1+
209 J45-2 NOT USED
210 J45-3 4th FUNCTION Input to VM (J40-4) from the 4th Approx. 5V open; SW14 VM
Function switch (SW14). If not 0V closed
connections.
211 J46-1 +24V +24V to optional 5th Function +24V DC/DC PB5
switch (PB5) from fuse F7. If not Converter
present, check fuse, wiring, and
connections.
212 J46-2 5TH When switch (PB5) is closed, +24V PB5 EV11
SOLENOID voltage is allowed to pass to
(optional) optional 5th Solenoid Valve (EV11).
If not present, check switch, wiring,
and connections.


VM (J40-6) to Lowering switch wrt BT1+
214 J47-2 NOT USED
215 J47-3 AUX IN 1 Input to VM (J40-13) from the Approx. 5V open; SW15 VM
Lowering switch (SW15). If not 0V closed
connections.
216 J47-4 NOT USED
217 J70+ AUX OUT 1 Output from VM (J40-16), through +24V VM BZ1
fuse F13, to the optional Travel
Alarm (BZ1). If not present, check
VM, fuse, wiring, and connections.
FlashWare.
218 J70– GND B– supply to optional Travel Alarm Battery voltage B– at J1– BZ1
(BZ1). This B– is shared by many wrt BT1+
VM. If not present, follow back
determined.
219 J71-1 GND B– supply to Power Amplifier Fan. Battery voltage B– at J1– Power
This B– is shared by many wrt BT1+ Amp Fan
fan. If not present, follow back
determined.
220 J71-2 +24V +24V to the Power Amplifier Fan +24V DC/DC Power
from fuse F5. If not present, check Converter Amp Fan
221 J71-3 FAN DRIVE Output from the VM (J40-2) to the Approx. 5V ON; VM Power
Power Amp Fan (FN1). If not 0V OFF Amp Fan
switch ON.
222 J71-4 NOT USED
223 J91-1 GND B– to the Left Brake Light (LP3) and Battery voltage BT1 LP3, LP4
Left Tail Light (LP4). If not present, wrt BT1+
can be determined.
224 J91-2 TAIL LIGHT Output from the VM (J34-1) to the +24V ON; 0V VM Left Tail
Left Tail Light (LP4). If not present, OFF Light


225 J91-3 TAIL LIGHT Output from VM (J34-1) to the Tail +24V ON; 0V VM Tail Lights
Lights (LP2 and LP4). If not present OFF
226 J91-4 BRAKE LIGHT Output from the VM (J34-13) to the +24V ON; 0V VM Brake
Left Brake Light (LP3) when traveling OFF Lights
connections.
227 J91-5 BRAKE LIGHT Output from VM (J34-13) to the +24V ON; 0V VM Brake
Right Brake Light (LP1) when OFF Lights
traveling and changing direction or
traveling and pressing brake pedal.
If not present check VM, wiring, and
connections.
228 J91-6 NOT USED
229 J92-1 GND B– to the Forward Right Working Battery voltage BT1 LP6
Light (LP6). If not present, follow wrt BT1+
determined.
230 J92-2 LP6+ +24V to the optional Forward Right +24V SW28 LP6
Working Light (LP6) from SW28. If
not present, check fuse F11, wiring,
and connections.
installed.
231 J93-1 LP5+ +24V to the optional Rotating Lamp +24V SW27 LP5
(LP5) from SW27. If not present,
connections.
installed.
232 J93-2 LP7+ +24V to the optional Forward Left +24V SW28 LP7
Working Light (LP7) from SW28. If
not present, check fuse F11, wiring,
and connections.
installed.


233 J93-3 LP8+ and LP9+ +24V to the optional Reverse +24V SW29 LP8, LP9
Working Lights (LP8 and LP9) from
SW29. If not present, check fuse
installed.
234 J93-4 GND B– to LP5, LP7, LP8, and LP9. If not Battery voltage BT1 LP5, LP7,
present, follow back towards B– wrt BT1+ LP8, LP9


J96-6.
238 J96-3 NOT USED

J96-1.
241 J97 AG+, N– Connection for optional Warning +24V ON; 0V VM LP5
Light (LP5). OFF
installed.
242 J100-1 B+ B+ to auxiliary power strip from B+ BT1 Aux Power

J50-11. If not present, check fuse
243 J100-2 NOT USED
244 J100-3 B– B– to auxiliary power strip. If not Battery voltage B– Aux Power
present, make sure battery is wrt BT1+
connections.
245 J101 L, CH input Connection for optional Lift-Limit 24V ON; 0V OFF VM EV12
Push Button Switch (PB9).


246 J102-1 GND B– supply from Battery. This B– is Battery voltage BT1 LP1 and
used by LP1 and LP2. If not present, wrt BT1+ LP2
can be determined.
247 J102-2 TAIL LIGHT Output from VM (J34-1) to the Right +24V VM Tail Lights
Tail Light (LP2). If not present, check
248 J102-3 TAIL LIGHT Tied to J102-2. +24V VM Tail Lights
249 J102-4 TAIL LIGHT Output from VM (J34-1) to the Right +24V VM Brake Light
Brake Light (LP1) when traveling
connections.
250 J102-5 BRAKE LIGHT Tied to J102-4. +24V VM Tail Lights
251 J102-6 NOT USED




256 J107-1 +V Voltage from the HCB (JCM-2) to the B+ HCB EVP1
Lowering (EVP1) Solenoid. If not
257 J107-2 LOW Voltage from the HCB (JCM-1) to Approx. 2-11V HCB EVP1
turn on the Lowering Solenoid wrt B+ (approx.
(EVP1). If not present, check the 18 ohms across
HCB, wiring, and connections. coil)
Lifting Solenoid (EV2). If not present,
check the HCB, fuse F15, wiring,
and connections.
259 J108-2 LIFT Voltage from the HCB (JCM-3) to Approx. 24V wrt HCB EV2
turn on the Lifting Solenoid (EV2). If B+ (approx.
not present, check the HCB, wiring, 27 ohms across
and connections. coil)
Tilt Forward Solenoid (EV3). If not


261 J109-2 TILT FW Voltage from the Hydraulic Control Approx. 15V wrt HCB EV3
Board (JCM-4) to turn on the Tilt B+ (approx.
Forward Solenoid (EV3). If not 18 ohms across
present, check the Hydraulic Control coil)
Board, wiring, and connections.
Tilt Backward Solenoid (EV4). If not
263 J110-2 TILT BW Voltage from the HCB (JCM-6) to Approx. 15V wrt HCB EV4
turn on the Tilt Backward Solenoid B+ (approx.
Left Sideshift Solenoid (EV5). If not
265 J111-2 L SIDESHIFT Voltage from the HCB (JCM-7) to Approx. 18V wrt HCB EV5
turn on the Left Sideshift Solenoid B+ (approx.
Right Sideshift Solenoid (EV6). If not
267 J112-2 R SIDESHIFT Voltage from the HCB (JCM-15) to Approx. 18V wrt HCB EV6
turn on the Right Sideshift Solenoid B+ (approx.




272 J117-1 DRAIN Voltage from the HCB (JCM-19) to Approx. 2.5V HCB EVP
turn on the Drain Solenoid (EVP). If static; Approx. 2
not present, check the HCB, wiring, to 13V wrt J117-2
and connections. when lifting or
performing an
aux function
(approx. 18 ohms
across coil)
273 J117-2 +V Voltage from the HCB (JCM-20) to Approx. B+ when HCB EVP
turn on the Drain Solenoid (EVP). If lifting or
not present, check the HCB, fuse performing an
F21, wiring, and connections. aux function
274 J119-1 +V Voltage is supplied to the optional +24V SW16, EV12

Lift Limit Bypass solenoid when PB9
SW16 is normally closed. When
SW16 opens, the Lift-Limit Bypass
button PB9 must be depressed to
allow lift. If not present, check
wiring, fuse, switches, and
connections.
275 J119-2 B– B– supply from Battery. This B– is Battery voltage BT1 EV12
used by the optional Lift-Limit Bypass wrt BT1+
Valve (EV12). If not present, follow
determined.
276 J137-1 CAN L Communication line between N/A VM Operator

277 J137-2 CAN H Communication line between N/A VM Operator

278 J137-3 GND B– supply from Battery. This B– is Battery voltage BT1 Operator
used by the Operator Display. If not wrt BT1+ Display
279 J137-4 NOT USED
280 J137-5 +V +24V supply to Operator Display +24V VM Operator

from the VM (J34-12). If not present, Display
connections.
281 J137-6 GND B– supply from Battery to the Battery voltage BT1 Operator
Operator Display. This connection wrt BT1+ Display
supplies B– to the CAN-Bus
Interface by use of a jumper. If not


determined.
283 J138-2 CAN L Communication line between PPA N/A PPA Fingertip
determined.
285 J138-4 CAN H Communication line between PPA N/A PPA Fingertip
286 J138-5 +24V CAN +24V supply to Armrest Board +24V VM Armrest
(JCAN-5) from VM (J34-12). If not Board
present, check fuse F23, wiring,
and connections.

connections.

connections.
290 J140-3 B– B– supply from Battery. This B– is Battery voltage BT1 HCB
used by the optional HCB. If not wrt BT1+
291 J140-4 CAN L Communication line between HCB N/A VM HCB

and VM (J40-8).
293 J140-13 CAN H Communication line between HCB N/A VM HCB

and VM (J40-15).
294 J140-14 NOT USED
295 J141-1 GND Optional voltage from Armrest B– Armrest Armrest

Board to PB13. Board Board
296 J141-2 NOT USED
297 J141-3 LIFT LIMIT Optional input to Armrest Board Approx. 0V Armrest Armrest
BYPASS from PB13. closed; 5V open Board Board


298 J142-1 GND Ground to the Horn switch (PB12) Approx. 5V Armrest PB12
on the Armrest Board. If not present, Board
check the switch, armrest board,
299 J142-2 HORN Input from the Horn switch (PB12) to Approx. 0V PB12 Armrest
the Armrest Board when pushed. If closed; 5V open Board
not present, check the switch,
300 J406-A NOT USED
301 J406-B +V POT Voltage to the Lifting/Lowering pot Approx. 5V Armrest Lifting/
(P4). If not present, check the Board Lowering
connections. Module
302 J406-C C POT Output from the Lifting/Lowering Approx. 2.5V in Lifting/ Armrest
pot (P4) wiper to the Armrest Board. neutral; range 0V Lowering Board
If not present, check P4, wiring, and to 5V Fingertip
connections. Module
across JSOLL-1 and 4.
303 J406-D GND POT Ground to the Lifting/Lowering pot Battery voltage Armrest Lifting/
(P4). If not present, check the wrt BT1+ Board Lowering
connections. Module
304 J406-E MICRO Input from Lifting/Lowering Approx. 5V Lifting/ Armrest

connections. Module
305 J406-F MICRO Input from Lifting/Lowering Approx. 5V Lifting/ Armrest

connections. Module
306 J406-G GND Ground to Lifting/Lowering Battery voltage Armrest Lifting/

directional switches (SW17 and wrt BT1+ Board Lowering
SW18). If not present, check the Fingertip
Armrest Board, wiring, and Module
connections.
307 J407-A NOT USED
308 J407-B +V POT Voltage to the Tilt pot (P5). If not Approx. 5V Armrest Tilt
present, check the Armrest Board, Board Fingertip


309 J407-C C POT Output from the Tilt pot (P5) wiper to Approx. 2.5V in Tilt Armrest
the Armrest Board. If not present, neutral; range 0V Fingertip Board
check P5, wiring, and connections. to 5V Module
across JBRA-1 and 4.
310 J407-D GND POT Ground to the Tilt pot (P5). If not Battery voltage Armrest Tilt
present, check the Armrest Board, wrt BT1+ Board Fingertip
311 J407-E MICRO Input from Tilt pot directional switch Approx. 5V Tilt Armrest
312 J407-F MICRO Input from Tilt pot directional switch Approx. 5V Tilt Armrest
313 J407-G GND Ground to Tilt directional switches Battery voltage Armrest Tilt
(SW19 and SW20). If not present, wrt BT1+ Board Fingertip
check the Armrest Board, wiring, Module
and connections.
314 J408-A NOT USED
315 J408-B +V POT Voltage to the Sideshift pot (P6). If Approx. 5V Armrest Sideshift
replace the module.
316 J408-C C POT Output from the Sideshift pot (P6) Approx. 2.5V in Sideshift Armrest
connections.
across JTRA-1 and 4.
317 J408-D GND POT Ground to the Sideshift pot (P6). If Battery voltage Armrest Sideshift
318 J408-E MICRO Input from Sideshift pot directional Approx. 5V Sideshift Armrest
319 J408-F MICRO Input from Sideshift pot directional Approx. 5V Sideshift Armrest
320 J408-G GND Ground to Sideshift directional Battery voltage Armrest Sideshift
switches (SW21 and SW22). If not wrt BT1+ Board Fingertip
present, check the Armrest Board, Module


321 J409-A NOT USED
322 J409-B +V POT Voltage to the 4th Aux pot (P7). If Approx. 5V Armrest 4th Aux
replace the module.
323 J409-C C POT Output from the 4th Aux pot (P7) Approx. 2.5V in 4th Aux Armrest
connections.
across JIV-1 and 4.
324 J409-D GND POT Ground to the 4th Aux pot (P7). If Battery voltage Armrest 4th Aux
325 J409-E MICRO Input from 4th Aux pot (P7) Approx. 5V 4th Aux Armrest
connections.
326 J409-F MICRO Input from 4th Aux pot (P7) Approx. 5V 4th Aux Armrest
connections.
327 J409-G GND Ground to 4th Aux pot (P7) Battery voltage Armrest 4th Aux
directional switches (SW23 and wrt BT1+ Board Fingertip
SW24). If not present, check the Module
Armrest Board, wiring, and
connections.
328 PPA B+ B+ B+ from the battery to the PPA B+ J1+ PPA

through fuse FP. If not present, make
329 PPA B– B– B– from the battery to the PPA. If not Battery voltage BT1 PPA
connections.
330 PPA (U) PPA (U) One of three phases from the PPA to 0 to approx. PPA PM
the Pump Motor. Voltage is 20VAC; Approx.
If not present, check the PPA, Approx. 250A full


331 PPA (V) PPA (V) One of three phases from the PPA to 0 to approx. PPA PM
332 PPA (W) PPA (W) One of three phases from the PPA to 0 to approx. PPA PM
333 TPA B+ B+ B+ from the battery to the TPA B+ J1+ TPA

through fuse FT. If not present, make
334 TPA B– B– B– from the battery to the TPA. If not Battery voltage BT1 TPA
connected. Check the wiring and
connections.
335 TPA (U) TPA (U) One of three phases from the TPA to 0 to approx. TPA Traction
336 TPA (V) TPA (V) One of three phases from the TPA to 0 to approx. TPA Traction
337 TPA (W) TPA (W) One of three phases from the TPA to 0 to approx. TPA Traction

Model 4700 Maintenance Manual Section A. Appendix
Section A. Appendix
Publication 1160093, Issued: 20 May 2013 A-1

Section A. Appendix Model 4700 Maintenance Manual
Lubrication Specification Chart
Lubrication Specification
Chart
Approved Raymond Lubricants
Where Used Type Specification Raymond Part Number
Drive Unit Gear Case - Transmission ATF II Type A suffix A 990-623/001 (1 gal/3.8 liters)
dual traction motor trucks Fluid 990-623/004 (1 qt./0.9 liter)
Drive Unit Gear Case - Gear 75W-90 Synthetic Gear 990-655/001 (1 qt./0.9 liter)
single traction motor trucks Lubricant Oil 990-655/003 (1 gal/3.8 liters)
below S/N 10677 API Service GL-5
Drive Unit Gear Case - Oil 10W-30 Motor Oil Break-in (first 1500 hrs. -
single traction motor trucks API Service CE, CD, CC, 990-603/SPL (1.1 gal/4.2 liters)
S/N 10677 and up SG, SF
After break-in - 990-603/470
Hydraulic Brake Brake Fluid BLACK RESERVOIR CAP - 990-DOT/004

SAE J1730-JAN80
DOT-4
GREEN RESERVOIR CAP - 990-603/470 (Mobilfluid 424)

Mineral oil
Hydraulic Reservoir Hydraulic ISO 46 990-616/04 (1 qt./0.9 liter)

(Non-CS trucks Fluid Anti-Wear Hydraulic 990-616/01 (1 gal/3.8 liters)
(+50 to +120°F) Fluid 990-616/03 (5 gal/18.9 liters)
(+10 to +49°C)
Hydraulic Reservoir Hydraulic MIL-H-5606E 990-618/01 (1 gal/3.8 liters)

(CS trucks) Fluid
(–20 to 0°F)
(–29 to –18°C)
(confined to freezer)
Hydraulic Reservoir Hydraulic IS0 VG32 1017238 (5 gal/18.9 liters)

(CS trucks) Fluid 1017238/01 (55 gal/208 liters)
(0 to +50°F)
(–18 to +10°C)
(in and out of freezer)
Lift Chains Teflon Grease Aerosol 1151877/001 (Rexoil)

1151877/002 (Rocol)
Mast Uprights, Bearings Grease NLGI Grade 2 1012992/01

(10 cartridges/case)
1012992/02 (5 gal/18.9 liters)
A-2 Publication 1160093, Issued: 20 May 2013

Thread Adhesives, Sealants, and Lubricants
Thread Adhesives,
Sealants, and Lubricants
Loctite*
Raymond P/N Application
Number/Color
990-403 Thread-locking 1/4 in. and below 222/Purple
990-445 Cold Storage Silicone Sealing Compound
990-452 Anti-Seize Lubricant, Heavy Duty High Temperature
990-463 Thread-locking 1 in. and under, contamination tolerant 603/Green
990-533 Thread-locking Primer T7471
990-544 Thread-locking 1 in. and under 271/Red
990-552 Hydraulic Sealant 569
990-571 Thread-locking 1 in. and over 277/Red
990-638 Molybdenum Anti-Seize Compound (Molykote) Silver
990-644 Corrosion Inhibitor Coating
990-659 RTV Silicone Sealant 5900/Black
990-666 Thread-locking Primer 7649 (19269)
990-669 Thread-locking, primerless high strength 2760
1013829 Thread-locking 1/4 to 3/4 in. medium strength 243 or 2440

7242 (Cyberbond)
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 Torque/Information Chart
Component Specific
Torque/Information
Chart
Component Thread-Locking
Sub-Component(s) Torque to:
Compound
Counterweight mounting bolts N/A 200 ft. lb. (300 Nm)
Drive Unit fluid fill and drain plugs N/A 16 ft. lb. (22 Nm)
dual traction motor trucks mounting bolts to chassis N/A 100 ft. lb. (135 Nm)
Hydraulic Pump mounting bolts to motor 1013829 33 ft. lb. (45 Nm)
Mast bearing cap bolts (secures N/A 36 ft. lb. (49 Nm)
dual traction motor trucks mast base to chassis)
Power Amplifiers power cables N/A 8.8 to 11 ft. lb
(12 to 15 Nm)
Pump Motor end bell retaining bolts N/A 8 ft. lb. (11 Nm)
power cables N/A 18 ft. lb. (24 Nm)
Quad Mast Cylinders check valves (right side 990-403 50 in. lb (5.65 Nm)
main lift cylinder)
lift cylinder piston N/A 95 to 125 ft. lb
retainer (129 to 169 Nm)
Static Strap mounting hardware 1013829 15 ft. lb. (21 Nm)
Steer Axle mounting bolts N/A 96 ft. lb. (130 Nm)
Steer Cylinder mounting bolts 1013829 95 to 105 ft. lb
(120 to 144 Nm)
Steer Wheels lug nuts N/A 133 ft. lb. (180 Nm)
Traction Motor power cables N/A 18 ft. lb. (24 Nm)
end bell retaining bolts 15 ft. lb. (21 Nm)
mounting bolts to drive N/A 17 ft. lb. (23 Nm)
unit
Traction Wheels lug nuts N/A 103 ft. lb. (140 Nm)
Tire Replacement A minimum pressure of 5 tons (4536 kg) is required to press on a new tire. If the
minimum pressure is not met, replace the hub.

Torque Chart - Standard (Ferrous)
Torque Chart - Standard

(Ferrous)
Grade
Identification None
Marking
SAE Grade 2 Bolts SAE Grade 5 Bolts SAE Grade 7 Bolts SAE Grade 8 Bolts
Tightening Torque Tightening Torque Tightening Torque Tightening Torque
Size
Dry Oiled* Dry Oiled* Dry Oiled* Dry Oiled*
in. lb. in. lb. in. lb. in. lb. in. lb. in. lb. in. lb. in. lb.
4-40 5 4 8 6 11 8 12 9
4-48 6 5 9 7 12 9 13 10
6-32 10 8 16 12 20 15 23 17
6-40 12 9 18 13 22 17 25 19
8-32 19 14 29 22 36 27 41 31
8-36 20 15 31 23 38 29 44 33
10-24 27 21 42 32 52 39 60 45
10-32 31 24 48 36 60 45 68 51
1/4-20 66 49 100 76 125 94 143 107
1/4-28 75 56 120 87 143 107 164 123
ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb.
5/16-18 11 8 17 13 21 16 25 18
5/16-24 12 9 19 14 24 18 25 20
3/8-16 20 15 30 23 40 30 45 35
3/8-24 23 17 35 25 45 30 50 35
7/16-14 32 24 50 35 60 45 70 55
7/16-20 35 25 55 40 70 50 80 60
1/2-13 50 35 75 55 95 70 110 80
1/2-20 55 40 85 65 105 80 120 90
9/16-12 70 50 110 80 135 100 150 110
9/16-18 80 60 120 90 150 110 170 130
5/8-11 95 70 150 110 190 140 220 170
5/8-18 110 85 170 130 210 160 240 180
3/4-10 170 130 260 200 330 240 380 280
3/4-16 190 140 300 220 370 280 420 320
7/8-9 170 125 430 320 530 400 600 460
7/8-14 185 140 470 350 580 440 660 500
1-8 250 190 650 480 800 600 900 680
1-12 275 205 700 520 860 660 1000 740
1 1/8-7 350 270 800 600 1120 840 1280 960
1 1/8-12 400 300 880 660 1260 940 1440 1080
1 1/4-7 500 375 1120 840 1580 1200 1820 1360
1 1/4-12 550 420 1240 920 1760 1320 2000 1500
1 3/8-6 650 490 1460 1100 2080 1560 2380 1780
1 3/8-12 750 560 1680 1260 2380 1780 2720 2040
1 1/2-6 870 650 1940 1460 2780 2080 3160 2360
1 1/2-12 980 730 2200 1640 3100 2340 3560 2660
NOTE: *Use “oiled” values for bolts with thread-locking compound.

Torque Charts - Metric
Torque Charts - Metric

Ferrous Metric Bolts, Coarse Thread
(The grade rating is stamped on the head of the bolt.)
Grade 8.8 Grade 10.9 Grade 12.9
Size Dry Oiled* Dry Oiled* Dry Oiled*
ft. lb. Nm ft. lb. Nm ft. lb. Nm ft. lb. Nm ft. lb. Nm ft. lb. Nm
M6-1 8 10.9 6 8.2 11 15.1 8 11.3 13 17.6 10 13.2
M8-1.25 19 26 15 20 27 37 20 27 31 43 24 32
M10-1.25 41 56 30 41 56 76 42 57 66 90 49 67
M12-1.25 75 102 55 75 100 136 75 102 120 163 90 122
M16-1.5 175 238 130 177 245 333 185 252 280 381 215 292
M20-1.5 360 490 255 367 500 680 375 510 580 789 440 598
M24-2 610 830 435 626 850 1156 640 870 1000 1360 740 1006
NOTE: *Use “oiled” values for bolts with thread-locking compound.
Brass MS63 Metric Bolts, Coarse Thread

Torque (with bolts oiled*)
Diameter (mm)
in. lb. Nm
2 1.2 0.14
2.5 2.5 0.29
3 4.4 0.5
3.5 7.0 0.79
4 10 1.2
5 19 2.2
6 34 3.9
8 79 9
10 150 17
NOTE: * Use ”oiled” values for bolts with
thread-locking compound.

Torque Chart - Thread-Forming Screws
Torque Chart -
Thread-Forming Screws
Standard Thread-Forming Screws
Torque
Size
in. lb. Nm
4-40 10 1.1
5-40 16 1.8
6-32 20 2.3
8-32 36 4
10-24 51 5.76
10-32 59 6.7
12-24 81 9.1
1/4-20 123 13.9
5/16-18 253 28.6
3/8-16 450 50.8
7/16-14 736 83.1
1/2-13 1000 113
Metric Thread-Forming Screws

Diameter Torque
(mm) in. lb. Nm
2.5 7 0.8
3 14 1.6
3.5 22 2.5
4 33 3.7
5 47 5.3
6 113 12.7
6.3 147 16.6
7 198 22.3
8 280 31.7
10 554 62.6
12 981 110.9

Torque Chart - Hydraulic Fittings
Torque Chart - Hydraulic

Fittings
JIC SAE Straight Thread Steel Plugs

SAE
Thread (37° Flare Thread)
Dash Hollow Hex Head Plug HP50N Hex Head Plug P50N
Size
Size
ft. lb. Nm ft. lb. Nm ft. lb. Nm
-2 5/16-24 3 ±1 4 ±1 3 ±0.5 4 ±0.6 7.5 ±0.5 10 ±0.6
-3 3/8-24 6 ±1 8 ±1 5 ±0.5 7 ±0.6 14 ±1 19 ±1
-4 7/16-20 12 ±1 16 ±1 11 ±1 15 ±1 18 ±1 24 ±1
-5 1/2-20 15 ±1 20 ±1 15 ±1 20 ±1 22 ±1 30 ±1
-6 9/16-18 21 ±1 28 ±1 18 ±1 24 ±1 27 ±2 37 ±3
-8 3/4-16 45 ±2 61 ±3 46 ±2 62 ±3 48 ±2 65 ±3
-10 7/8-14 60 ±5 81 ±7 75 ±5 102 ±7 90 ±5 122 ±7
-12 1 1/16-12 85 ±5 115 ±7 85 ±5 115 ±7 110 ±5 149 ±7
-14 1 3/16-12 105 ±5 142 ±7 130 ±6 176 ±8 145 ±6 197 ±8
-16 1 5/16-12 120 ±5 163 ±7 135 ±6 183 ±8 160 ±6 217 ±8
-20 1 5/8-12 170 ±10 230 ±14 225 ±12 305 ±16 225 ±12 305 ±16
-24 1 7/8-12 200 ±15 271 ±20 250 ±12 339 ±16 250 ±12 339 ±16
-32 2 1/2-12 270 ±20 366 ±27 325 ±15 441 ±20 325 ±15 441 ±20

Torque Chart - Straight Thread Face Seal O-Rings
Torque Chart - Straight

Thread Face Seal
O-Rings
SAE Dash Tube Size

ft. lb. Nm
Size Thread Size
-4 9/16-18 18 ±1 24 ±1
-6 11/16-18 27 ±2 37 ±3
-8 13/16-16 40 ±2 54 ±3
-10 1-14 63 ±3 85 ±4
-12 1 3/16-12 90 ±4 122 ±5
-14 1 5/16-32 95 ±6 129 ±8
-16 1 7/16-12 120 ±8 163 ±11
-20 1 11/16-12 140 ±8 190 ±11
-24 2-12 165 ±8 224 ±11
-32 2 1/2-12 360 ±10 488 ±14

Decimal Equivalent Chart

To 3 To 2
4ths 8ths 16ths 32nds 64ths “mm” Equivalent
Places Places
1/64 .016 .02 0.397
1/32 .031 .03 0.794
3/64 .047 .05 1.191
1/16 .062 .06 1.587
5/64 .078 .08 1.984
3/32 .094 .09 2.381
7/64 .109 .11 2.778
1/8 .125 .12 3.175
9/64 .141 .14 3.572
5/32 .156 .16 3.969
11/64 .172 .17 4.366
3/16 .188 .19 4.762
13/64 .203 .20 5.159
7/32 .219 .22 5.556
15/64 .234 .23 5.593
1/4 .250 .25 6.350
17/64 .266 .27 6.747
9/32 .281 .28 7.144
19/64 .297 .30 7.540
5/16 .312 .31 7.937
21/64 .328 .33 8.334
11/32 .344 .34 8.731
23/64 .359 .36 9.128
3/8 .375 .38 9.525
25/64 .391 .39 9.922
13/32 .406 .41 10.319
27/64 .422 .42 10.716
7/16 .438 .44 11.112
29/64 .453 .45 11.509
15/32 .469 .47 11.906
31/64 .484 .48 12.303
1/2 .500 .50 12.700

To 3 To 2
4ths 8ths 16ths 32nds 64ths “mm” Equivalent
Places Places
33/64 .516 .52 13.097
17/32 .531 .53 13.494
35/64 .547 .55 13.891
9/16 .562 .56 14.288
37/64 .578 .58 14.684
19/32 .594 .59 15.081
39/64 .609 .61 15.478
5/8 .625 .62 15.875
41/64 .641 .64 16.272
21/32 .665 .66 16.669
43/64 .672 .67 17.065
11/16 .688 .69 17.462
45/64 .703 .70 17.859
23/32 .719 .72 18.256
47/64 .734 .73 18.653
3/4 .750 .75 19.050
49/64 .766 .77 19.447
25/32 .781 .78 19.844
51/64 .797 .80 20.241
13/16 .812 .81 20.637
53/64 .828 .83 21.034
27/32 .844 .84 21.431
55/64 .859 .86 21.828
7/8 .875 .88 22.225
57/64 .891 .89 22.622
29/32 .906 .91 23.019
59/64 .922 .92 23.416
15/16 .938 .94 23.812
61/64 .953 .95 24.209
31/32 .969 .97 24.606
63/64 .984 .98 25.003
1.000 1.00 25.400

Standard/Metric Conversions
Standard/Metric Conversions
To Convert... Multiply, Add, or Subtract...
Area
Square Inches to Square Centimeters Square Inches x 6.452
Square Centimeters to Square Inches Square Centimeters x 0.155
Square Feet to Square Meters Square Feet x 0.093
Square Meters to Square Feet Square Meters x 10.753
Square Yards to Square Meters Square Yards x 0.836
Square Meters to Square Yards Square Meters x 1.196
Distance
Inches to Millimeters Inches x 25.4
Millimeters to Inches Millimeters x 0.039
Inches to Centimeters Inches x 2.54
Centimeters to Inches Centimeters x 0.394
Feet to Meters Feet x 0.305
Meters to Feet Meters x 3.281
Yards to Meters Yards x 0.914
Meters to Yards Meters x 1.094
Miles to Kilometers Miles x 1.609
Kilometers to Miles Kilometers x 0.621
Mass
Ounces to Grams Ounces x 28.35
Grams to Ounces Ounces x 0.035
Ounces to Kilograms Ounces x 0.028
Kilograms to Ounces Kilograms x 35.27
Pounds to Kilograms Pounds x 0.454
Kilograms to Pounds Kilograms x 2.2
Pressure
Pounds per Square Inch (psi) to kiloPascals PSI x 6.894
kiloPascals to Pounds per Square Inch (psi) kiloPascals x 0.145
Speed
Miles per hour to Kilometers per hour Miles per hour x 1.609
Kilometers per hour to Miles per hour Kilometers per hour x 0.6214
Temperature
Fahrenheit to Celsius (°F minus 32) x 0.555
Celsius to Fahrenheit (°C x 1.8) plus 32
Torque
Inch Pounds (in. lb.) to Newton Meters (Nm) Inch Pounds x 0.113
Newton Meters (Nm) to Inch Pounds (in. lbs.) Newton Meters x 8.85
Foot Pounds (ft. lb.) to Newton Meters (Nm) Foot Pounds x 1.3568
Newton Meters (Nm) to Foot Pounds (ft. lbs.) Newton Meters x 0.737
Volume
Pints to Liters Pints x 0.473
Liters to Pints Liters x 2.113
Quarts to Liters Quarts x 0.946
Liters to Quarts Liters x 1.057
Gallons to Liters Gallons x 3.785
Liters to Gallons Liters x 0.26

Model 4700 Maintenance Manual Section I. Index
Section I. Index
Numerics Service
Dual Traction Motor Truck . . . 7-25
24V Converter . . . . . . . . . . . . . . . . . . . 8-4 Single Traction Motor
(below S/N 10677) . . . . . . . 7-29
Single Traction Motor
A (S/N 10677 up) . . . . . . . . . 7-30
Bulletins, Service . . . . . . . . . . . . . . . . . . iv
Adjustment
Lift/Aux Pressure . . . . . . . . . . . . 7-61
C
Steer Pressure . . . . . . . . . . . . . . . 7-20
AMP Connectors . . . . . . . . . . . . . . . . 7-43
Amplifier Cable
Fan . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Soldering Procedures . . . . . . . . . . 7-41
Pump . . . . . . . . . . . . . . . . . . . . . . 8-3 Cables, Power . . . . . . . . . . . . . . . . . . . 7-39
Traction . . . . . . . . . . . . . . . . . . . . . 8-3 Carriage, Fork . . . . . . . . . . . . . . . . . . 7-72
Armrest Board Installation . . . . . . . . . . . . . 7-72, 7-75
Theory . . . . . . . . . . . . . . . . . . . . . . 8-4 Removal . . . . . . . . . . . . . . . 7-72, 7-74
Auxiliary Functions Chain, Lift
Pressure Adjustment . . . . . . . . . . 7-63 Anchor Bolts . . . . . . . . . . . . . . . . . 7-78
Theory . . . . . . . . . . . . . . . . . . . . . 8-10 Installation . . . . . . . . . . . . . . . . . . 7-77
Theory, Fingertip Controls . . . . . . 8-10 Removal . . . . . . . . . . . . . . . . . . . . 7-77
Theory, Lever Controls . . . . . . . . . 8-10 Chains
Condition-Cause Chart . . . . . . . . . . 4-9
Maintenance . . . . . . . . . . . . . . . . . . 4-9
B Charging, Battery . . . . . . . . . . . . . . . . 7-38
Charts
Battery Decimal Equivalent . . . . . . . . . . . . . A-8
Change Voltage . . . . . . . . . ... . . 3-10 Torque
Charge Indicator . . . . . . . . ... . . . 6-2 Component Specific . . . . . . . . . . A-4
Charging . . . . . . . . . . . . . . ... . . 7-38 Metric . . . . . . . . . . . . . . . . . . . . A-6
Checks . . . . . . . . . . . . . . . ... . . . 4-4 Standard - Brass . . . . . . . . . . . . A-7
Cleaning, Exterior . . . . . . . ... . . 7-38 Standard (Ferrous) . . . . . . . . . . A-5
Maintenance . . . . . . . . . . . ... . . 7-38 Checks
Procedures . . . . . . . . . . . . ... . . 7-38 Battery . . . . . . . . . . . . . . . . . . . . . . 4-4
Safety . . . . . . . . . . . . . . . . ... . . . 2-5 Brakes . . . . . . . . . . . . . . . . . . . . . . 4-4
Testing . . . . . . . . . . . . . . . ... . . 7-38 Drive Unit . . . . . . . . . . . . . . . . . . . . 4-4
Brake Forks . . . . . . . . . . . . . . . . . . . . . . . 4-4
Checks . . . . . . . . . . . . . . . . . . . . . 4-4 Power Amplifier . . . . . . . . . . . . . . . . 4-5
Disc Replacement Pre-Operational (Self-Test) . . . . . . . 8-6
Single Traction Motor Codes
(S/N 10677 up) . . . . . . . . 7-31 Communication . . . . . . . . . . . . . . . 6-4
Disc Wear Check Display . . . . . . . . . . . . . . . . . . . . . . 6-3
Single Traction Motor Error . . . . . . . . . . . . . . . . . . . . . . . 6-4
(S/N 10677 up) . . . . . . . . 7-31 Intermittent . . . . . . . . . . . . . . . . . . 6-4
Fluid Level Indicator . . . . . . . . . . . 6-2 Multiple . . . . . . . . . . . . . . . . . . . . . 6-4
Parking . . . . . . . . . . . . . . . . . . . . . 6-2 Cold Storage Conditioning . . . . . . . . . 7-57
Pedal Adjustment . . . . . . . . . . . . 7-34 Components
Electrical System . . . . . . . . . . . . . . 8-2
Publication 1160093, Issued: 20 May 2013 I-1

Section I. Index Model 4700 Maintenance Manual
Connectors Drive Unit, Single

AMP . . . . . . . . . . . . . . . . . . 7-43, 7-46 Fluid Replacement -
Molex . . . . . . . . . . . . . . . . . . 5-7, 7-42 below S/N 10677 . . . . . . . . . . 7-27
Contactor 1 . . . . . . . . . . . . . . . . . . . . . .8-4 Fluid Replacement -
Contactor 2 . . . . . . . . . . . . . . . . . . . . . .8-4 S/N 10677 up . . . . . . . . . . . . . 7-27
Contactor 3 . . . . . . . . . . . . . . . . . . . . . .8-5 Installation . . . . . . . . . . . . . . . . . . 7-28
Contactors, Inspection . . . . . . . . . . . . .4-4 Removal . . . . . . . . . . . . . . . . . . . . 7-28
Controls
Fingertip, Theory . . . . . . . . . . 8-8, 8-10 E
Lever, Theory . . . . . . . . . . . . . 8-8, 8-10
Controls, Operator . . . . . . . . . . . . . . . .3-4
Electrical
Conversions, Standard/Metric . . . . . .A-10
Connections . . . . . . . . . . . . . . . . . . 5-7
Converter, 24V . . . . . . . . . . . . . . . . . . .8-4
System Components . . . . . . . . . . . . 8-2
Corrosion Inhibitor, Cold Storage . . . . 7-57
Emergency Lower
CT1 . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4
Theory . . . . . . . . . . . . . . . . . . . . . . 8-9
CT2 . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4
Encoder Bearing Replacement . . . . . . 7-54
CT3 . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5
Error Codes . . . . . . . . . . . . . . . . . . . . . 6-4
Cylinder
Display . . . . . . . . . . . . . . . . . . . . . . 6-3
Quad Mast
Free Lift
Installation . . . . . . . . . . . . 7-85 F
Removal . . . . . . . . . . . . . . . 7-85
Main Fan, Amplifier . . . . . . . . . . . . . . . . . . . 8-3
Installation . . . . . . . . . . . . 7-85 Finger Tip Controls
Removal . . . . . . . . . . . . . . . 7-84 Theory of Operation . . . . . . . . . . . 8-13
Piston Removal . . . . . . . 7-65, 7-66 Fingertip Controls
Service . . . . . . . . . . . . . . . . . . 7-65 Auxiliary Functions Theory . . . . . . 8-10
Lift/Lower Theory . . . . . . . . . . . . . . 8-8
D Solenoid Driver Board . . . . . . . . . . 8-4
FlashWare
Connection to Truck . . . . . . . . . . . . 3-6
DC/DC Converter
Installation . . . . . . . . . . . . . . . . . . . 3-6
Theory . . . . . . . . . . . . . . . . . . . . . . .8-4
Program . . . . . . . . . . . . . . . . . . . . . 3-6
Decals and Plates . . . . . . . . . . 7-15 to 7-18
Requirements . . . . . . . . . . . . . . . . . 3-6
Decimal to Fraction Conversion . . . . . .A-8
Start . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Definitions, Safety . . . . . . . . . . . . . . . . .2-2
Fluid
Direction Lever
Brake, Level Indicator . . . . . . . . . . . 6-2
Hand . . . . . . . . . . . . . . . . . . . . . . . .8-6
Replacement
Direction Pedals . . . . . . . . . . . . . . . . . .8-6
Drive Unit, Dual . . . . . . . . . . . 7-22
Direction, Travel . . . . . . . . . . . . . . . . . .6-3
Drive Unit, Single below
Display . . . . . . . . . . . . . . . . . . . . . . . . .6-2
S/N 10677 . . . . . . . . . . . . 7-27
Error Codes . . . . . . . . . . . . . . . . . . .6-3
Drive Unit, Single
Operator . . . . . . . . . . . . . . . . . . . . .8-4
S/N 10677 up . . . . . . . . . . 7-27
Drive Motor
Hydraulic . . . . . . . . . . . . . . . . 7-60
Terminal Nuts . . . . . . . . . . . . . . . . 7-49
Drive Unit Checks . . . . . . . . . . . . . . . . .4-4
Drive Unit, Dual
Assembly . . . . . . . . . . . . . . . . . . . 7-25
Fluid Replacement . . . . . . . . . . . . 7-22
Installation . . . . . . . . . . . . . . . . . . 7-23
Removal . . . . . . . . . . . . . . . . . . . . 7-22
Storage . . . . . . . . . . . . . . . . . . . . . 7-26
I-2 Publication 1160093, Issued: 20 May 2013

Fork Inspection
Angle . . . . . . . . . . . . . . . . . . . . . . 4-10 Quad Mast . . . . . . . . . . . . . . . . . . 7-79
Carriage . . . . . . . . . . . . . . . . . . . 7-72 Quad Mast Check Valve . . . . . . . . 7-65
Installation . . . . . . . . . . 7-72, 7-75 Interactive Electronic
Removal . . . . . . . . . . . . . 7-72, 7-74 Technical Manuals . . . . . . . . . . . . . 1-3
Checks . . . . . . . . . . . . . . . . . . . . . 4-4
Hooks . . . . . . . . . . . . . . . . . . . . . 4-12 J
Inspection . . . . . . . . . . . . . . . . . . 4-10
Markings . . . . . . . . . . . . . . . . . . . 4-13
Jacking Safety . . . . . . . . . . . . . . . . . . . 2-8
Positioning Locks . . . . . . . . . . . . . 4-11
Jumpers
Straightness . . . . . . . . . . . . . . . . 4-10
Pump Power Amplifier . . . . . . . . . . 7-49
Tip Height . . . . . . . . . . . . . . . . . . 4-11
Jumpers, Electrical . . . . . . . . . . . . . . 7-49
Wear . . . . . . . . . . . . . . . . . . . . . . 4-11
Fraction to Decimal Conversion . . . . . . A-8
Free Lift Cylinder L
Adjustment . . . . . . . . . . . . . . . . . 7-77
Lever Controls
G Auxiliary Function Theory . . . . . . . 8-10
Lift/Lower Theory . . . . . . . . . . . . . . 8-8
Theory of Operation . . . . . . . . . . . 8-13
General Safety . . . . . . . . . . . . . . . . . . . 2-3
Lever, Direction
Guide Shoe Adjustment (TF/TT) . . . . 7-71
Theory . . . . . . . . . . . . . . . . . . . . . . 8-6
Lift
H Inhibit . . . . . . . . . . . . . . . . . . . . . . 6-2
Potentiometer . . . . . . . . . . . . . . . . 7-53
Harness Pressure Adjustment . . . . . . . . . . 7-62
Repair . . . . . . . . . . . . . . . . . . . . . 7-41 Lift Chains
Soldering Procedures . . . . . . . . . . 7-41 Anchor Bolts . . . . . . . . . . . . . . . . . 7-78
Hose Reeving Checks . . . . . . . . . . . . . . . . . . . . . . 4-5
Quad Mast . . . . . . . . . . . . . . . . . 7-86 Inspection . . . . . . . . . . . . . . . . . . . . 4-9
Hour Meter . . . . . . . . . . . . . . . . . . . . . 6-3 Installation . . . . . . . . . . . . . . . . . . 7-77
Hydraulic Removal . . . . . . . . . . . . . . . . . . . . 7-77
Cylinder Service Lift Cylinder
Quad Mast . . . . . . . . . . . . . . . 7-65 Jacking Bolt Adjust . . . . . . . . . . . . 7-77
Fluid Replacement . . . . . . . . . . . . 7-60 Quad Mast
Pump . . . . . . . . . . . . . . . . . . . . . 7-64 Piston Removal . . . . . . . 7-65, 7-66
Troubleshooting . . . . . . . . . . . . . 5-13 Service
Hydraulic Control Board Quad Mast . . . . . . . . . . . . . . . 7-65
Theory . . . . . . . . . . . . . . . . . . . . . . 8-4 Lift Limit w/Bypass Theory . . . . . . . . . 8-13
Hydraulic System Lift Pressure Adjustment . . . . . . . . . . 7-61
Theory . . . . . . . . . . . . . . . . . . . . . . 8-8 Lift Pump
Checks . . . . . . . . . . . . . . . . . . . . . . 4-8
I Lift/Lower
Theory . . . . . . . . . . . . . . . . . . . . . . 8-8
Theory, Fingertip Controls . . . . . . . 8-8
IETM . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Theory, Lever Controls . . . . . . . . . . 8-8
Indicator
Lower
Battery Charge . . . . . . . . . . . . . . . 6-2
Emergency, Theory . . . . . . . . . . . . . 8-9
LPH . . . . . . . . . . . . . . . . . . . . . . . . 6-3
LPH . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Steer Wheel Position . . . . . . . . . . . 6-3
Indicator . . . . . . . . . . . . . . . . . . . . . 6-3
Travel Direction . . . . . . . . . . . . . . . 6-3
Lubrication
Specification Chart . . . . . . . . . . . . . A-2

M Operator
Controls . . . . . . . . . . . . . . ... ... . 3-4
Maintenance, Battery . . . . . . . . . . . . . 7-38 Display . . . . . . . . . . . . . . . ... ... . 6-2
Mast Theory . . . . . . . . . . . . ... ... . 8-4
Checks . . . . . . . . . . . . . . . . . . . . . .4-5 Options, Theory of Operation . ... ... 8-13
Guide Shoe (Puck) Overtemperature
Adjustment (TF/TT) . . . . . . . . . 7-71 Pump Motor . . . . . . . . . . . . . . . . . . 6-3
Installation Traction Motor . . . . . . . . . . . . 6-2, 6-3
Dual Traction Motor Trucks . . 7-68
Single Traction Motor Trucks . . 7-70 P
Quad
Check Valve . . . . . . . . . . . . . . . 7-65 P1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
Hose Reeving . . . . . . . . . . . . . . 7-86 P2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
Hose Replacement . . . . . . . . . . 7-86 P3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53
Reassembly . . . . . . . . . . . . . . . 7-80 Parking Brake . . . . . . . . . . . . . . . . . . . 6-2
Removal Pedal
Dual Traction Motor Trucks . . 7-68 Brake, Adjustment . . . . . . . . . . . . 7-34
Single Traction Motor Trucks . . 7-69 Pedals, Direction
Messages . . . . . . . . . . . . . . . . . . . . . . .6-2 Theory . . . . . . . . . . . . . . . . . . . . . . 8-6
Meter, Hour . . . . . . . . . . . . . . . . . . . . .6-3 Performance
Modes Mode Indicator . . . . . . . . . . . . . . . . 6-3
Performance . . . . . . . . . . . . . . . . . .3-5 Modes . . . . . . . . . . . . . . . . . . . . . . 3-5
Performance Reduction . . . . . . . . . .3-5 Reduction Mode . . . . . . . . . . . . . . . 6-3
Turtle . . . . . . . . . . . . . . . . . . . . . . .3-5 Performance Mode, Reduced . . . . . . . . 3-5
Molex Connectors . . . . . . . . . . . . 5-7, 7-42 Pin Extraction
Motor AMP Connectors . . . . . . . . . . . . . . 7-43
Checks . . . . . . . . . . . . . . . . . . . . . .4-5 Pin Extraction/Insertion
Open Winding . . . . . . . . . . . . . . . . .5-6 Molex Connectors . . . . . . . . . . . . . 7-42
Pump . . . . . . . . . . . . . . . . . . . . . . 7-64 Pinout Matrix . . . . . . . . . . . . . 8-14 to 8-74
Overtemperature . . . . . . . . . . . .6-3 Model 4700 Dual Traction/
Shorted Winding . . . . . . . . . . . . . . .5-6 Single Traction Motor . . . . . . . 8-14
Traction Model 4700 Single Traction
Installation, Dual . . . . . . . . . . . 7-23 Motor >S/N 10676 . . . . . . . . . 8-48
Removal . . . . . . . . . . . . . . . . . 7-22 Potentiometers
Troubleshooting . . . . . . . . . . . . . . .5-6 Lift . . . . . . . . . . . . . . . . . . . . . . . . 7-53
Motor Encoder . . . . . . . . . . . . . . . . . . 7-54 Steer . . . . . . . . . . . . . . . . . . . . . . 7-52
Motors Travel . . . . . . . . . . . . . . . . . . . . . . 7-52
Drive Power Amplifier
Terminal Nuts . . . . . . . . . . . . . 7-49 Checks . . . . . . . . . . . . . . . . . . . . . . 4-5
Power Cable Nut Torques . . . . . . . 7-49 Connector . . . . . . . . . . . . . . . . . . 7-46
Pump Discharging Internal Capacitor . . . . 5-2
Terminal Nuts . . . . . . . . . . . . . 7-49 Jumpers . . . . . . . . . . . . . . . . . . . . 7-49
Pump . . . . . . . . . . . . . . . . . . . . . . 7-49
O Traction . . . . . . . . . . . . . . . . . . . . 7-49
Power Cable Nut Torques . . . . . . . . . . 7-49
Open Winding . . . . . . . . . . . . . . . . . . . .5-6 Power Cables . . . . . . . . . . . . . . . . . . . 7-39
Operating Conditions . . . . . . . . . . . . . .4-2 PPA see Pump Power Amplifier
Operation of Truck . . . . . . . . . . . . . . . .3-4

Pressure Adjustment Scheduled Maintenance

Auxiliary Functions . . . . . . . . . . . 7-63 120 Day . . . . . . . . . . . . . . . . . . . . . 4-4
Lift . . . . . . . . . . . . . . . . . . . 7-61, 7-62 180 Day . . . . . . . . . . . . . . . . . . . . . 4-4
Sideshift . . . . . . . . . . . . . . . . . . . 7-61 360 Day . . . . . . . . . . . . . . . . . . . . . 4-8
Steering . . . . . . . . . . . . . . . . . . . . 7-20 Chains . . . . . . . . . . . . . . . . . . . . . . 4-9
Tilt . . . . . . . . . . . . . . . . . . . . . . . 7-61 Scheduled Maintenance Guidelines . . . 4-2
Puck Adjustment (TF/TT) . . . . . . . . . 7-71 Sealants . . . . . . . . . . . . . . . . . . . . . . . . A-3
Pump Motor . . . . . . . . . . . . . . . . . . . 7-64 Seat Switch . . . . . . . . . . . . . . . . . . . . . 6-2
Encoder Bearing Replacement . . . 7-54 Self-Test . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Overtemperature . . . . . . . . . . . . . . 6-3 Service Bulletins . . . . . . . . . . . . . . . . . . . iv
Temperature Sensor Repair . . . . . 7-56 Service Frequency . . . . . . . . . . . . . . . . 4-2
Terminal Nuts . . . . . . . . . . . . . . . 7-49 Shorted Winding . . . . . . . . . . . . . . . . . . 5-6
Pump Power Amplifier Sideshift . . . . . . . . . . . . . . . . . . . . . . . 7-74
Contactor . . . . . . . . . . . . . . . . . . . 8-4 Theory . . . . . . . . . . . . . . . . 8-10, 8-11
Jumpers . . . . . . . . . . . . . . . . . . . 7-49 Sideshift Pressure Adjustment . . . . . . 7-61
Theory . . . . . . . . . . . . . . . . . . . . . . 8-3 Soldering Procedures . . . . . . . . . . . . . 7-41
Pump, Hydraulic . . . . . . . . . . . . . . . . 7-64 Solenoid Driver Board . . . . . . . . . . . . . 8-4
Spec Plate . . . . . . . . . . . . . . . . . . . . . . 3-3
Q Special Tools . . . . . . . . . . . . . . . . . . . 7-14
Specifications, Lift Truck . . . . . . . . . . . 3-3
Standard/Metric Conversions . . . . . . . A-10
Quad Mast
Static Precautions . . . . . . . . . . . . . . . . 2-7
Check Valve . . . . . . . . . . . . . . . . . 7-65
Steer Potentiometer . . . . . . . . . . . . . . 7-52
Inspection . . . . . . . . . . . . . . . 7-65
Steering
Free Lift Cylinder
Functional Description . . . . . . . . . 8-12
Installation . . . . . . . . . ... . . 7-85
Inspection . . . . . . . . . . . . . . . . . . . . 4-8
Removal . . . . . . . . . . . . ... . . 7-85
Pressure Adjustment . . . . . . . . . . 7-20
Hose Replacement . . . . . . . ... . . 7-86
System Components . . . . . . . . . . . 8-12
Inspection . . . . . . . . . . . . . ... . . 7-79
System Overview . . . . . . . . . . . . . . 8-12
Main Cylinder
Theory . . . . . . . . . . . . . . . . . . . . . 8-12
Installation . . . . . . . . . . . . . . 7-85
Wheel Position Indicator . . . . . . . . . 6-3
Removal . . . . . . . . . . . . . . . . . 7-84
Switch
Quad Mast Cylinder Service . . . . . . . 7-65
Motor Temperature . . . . . . . . . . . . 7-56
Seat . . . . . . . . . . . . . . . . . . . . . . . . 6-2
R Symptom Tables
Troubleshooting . . . . . . . . . . . . . . 5-14
Reduced Performance . . . . . . . . . . . . . 6-3 System
Architecture . . . . . . . . . . . . . . . . . . 8-2
S Control, Overview . . . . . . . . . . . . . . 8-3
Hydraulic . . . . . . . . . . . . . . . . . . . . 8-8
Steering . . . . . . . . . . . . . . . . . . . . 8-12
Safety
Steering, Functional Description . . 8-12
Battery . . . . . . . . . . . . . . . . . . . . . 2-5
Traction . . . . . . . . . . . . . . . . . . . . . 8-6
Decals . . . . . . . . . . . . . . . 7-15 to 7-18
Systems
Definitions . . . . . . . . . . . . . . . . . . . 2-2
Electrical . . . . . . . . . . . . . . . . . . . . 8-2
General . . . . . . . . . . . . . . . . . . . . . 2-3
Systems Overview
Jacking . . . . . . . . . . . . . . . . . . . . . 2-8
General . . . . . . . . . . . . . . . . . . . . . . 3-2
Static . . . . . . . . . . . . . . . . . . . . . . . 2-7
Welding . . . . . . . . . . . . . . . . . . . . . 2-9

T Torque Chart
Component Specific . . . . . . . . . . . . A-4
Temperature Sensor Repair Metric . . . . . . . . . . . . . . . . . . . . . . . A-6
Pump Motor . . . . . . . . . . . . . . . . . 7-56 Standard (Brass) . . . . . . . . . . . . . . A-7
Traction Motor . . . . . . . . . . . . . . . 7-56 Standard (Ferrous) . . . . . . . . . . . . . A-5
Terminal hardware . . . . . . . . . . . . . . . 7-49 Terminal Nuts . . . . . . . . . . . . . . . 7-49
Testing, Battery . . . . . . . . . . . . . . . . . 7-38 TPA see Traction Power Amplifier
Theory of Operation Traction Motor
Armrest Board . . . . . . . . . . . . . . . .8-4 Encoder Rearing Replacement . . . 7-54
Auxiliary Functions . . . . . . . . . . . . 8-10 Installation, Dual . . . . . . . . . . . . . 7-23
CT1 . . . . . . . . . . . . . . . . . . . . . . . . .8-4 Overtemperature . . . . . . . . . . 6-2, 6-3
CT2 . . . . . . . . . . . . . . . . . . . . . . . . .8-4 Temperature Sensor Repair . . . . . 7-56
CT3 . . . . . . . . . . . . . . . . . . . . . . . . .8-5 Traction Motor Removal, Dual . . . . . . 7-22
DC/DC Converter . . . . . . . . . . . . . .8-4 Traction Power Amplifier
Directional Lever . . . . . . . . . . . . . . .8-6 Contactor . . . . . . . . . . . . . . . . . . . . 8-5
Directional Pedals . . . . . . . . . . . . . .8-6 Power Cable Mounting Bolts . . . . . 7-49
Emergency Lower . . . . . . . . . . . . . .8-9 Theory . . . . . . . . . . . . . . . . . . . . . . 8-3
Finger Tip Controls . . . . . . . . . . . . 8-13 Traction System Theory . . . . . . . . . . . . 8-6
Fingertip Controls Travel Direction Indicator . . . . . . . . . . . 6-3
Auxiliary Functions . . . . . . . . . 8-10 Travel Potentiometer . . . . . . . . . . . . . 7-52
Lift/Lower . . . . . . . . . . . . . . . . .8-8 Travel Theory . . . . . . . . . . . . . . . . . . . . 8-6
Hydraulic Control Board . . . . . . . . .8-4 Troubleshooting
Hydraulic System . . . . . . . . . . . . . .8-8 Chains . . . . . . . . . . . . . . . . . . . . . . 4-9
Lever Controls . . . . . . . . . . . . . . . . 8-13 Electrical . . . . . . . . . . . . . . . . . . . . 5-2
Auxiliary Functions . . . . . . . . . 8-10 Error Codes . . . . . . . . . . . . . . . . . . 6-4
Lift/Lower . . . . . . . . . . . . . . . . .8-8 Hydraulic . . . . . . . . . . . . . . . . . . . 5-13
Lift . . . . . . . . . . . . . . . . . . . . . . . . .8-8 Hydraulic Functions . . . . . . . . . . . 5-15
Lift Limit w/Bypass . . . . . . . . . . . . 8-13 Motors . . . . . . . . . . . . . . . . . . . . . . 5-6
Lift/Lower . . . . . . . . . . . . . . . . . . . .8-8 Pinout Matrix . . . . . . . . . . 8-14 to 8-74
Lower . . . . . . . . . . . . . . . . . . . . . . .8-8 Symptom Tables . . . . . . . . . . . . . . 5-14
Operator Display . . . . . . . . . . . . . . .8-4 Travel Functions . . . . . . . . . . . . . 5-14
Options . . . . . . . . . . . . . . . . . . . . . 8-13 Truck Controls . . . . . . . . . . . . . . . . . . . 3-4
Pinout Matrix . . . . . . . . . . 8-14 to 8-74 Turtle Mode . . . . . . . . . . . . . . . . . 3-5, 6-3
Pump Power Amplifier . . . . . . . . . . .8-3
Self-Test . . . . . . . . . . . . . . . . . . . . .8-6 V
Sideshift . . . . . . . . . . . . . . . 8-10, 8-11
Tilt . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Valve, Check
Traction Power Amplifier . . . . . . . . .8-3 Quad Mast . . . . . . . . . . . . . . . . . . 7-65
Traction System . . . . . . . . . . . . . . .8-6 Vehicle Manager (VM) Theory . . . . . . . . 8-3
Travel . . . . . . . . . . . . . . . . . . . . . . .8-6 Voltage
Vehicle Manager . . . . . . . . . . . . . . .8-3 Change Battery Voltage . . . . . . . . 3-10
Thread Adhesives . . . . . . . . . . . . . . . . .A-3
Thread Lubricants . . . . . . . . . . . . . . . .A-3
W
Tilt
Pressure Adjustment . . . . . . . . . . . 7-61
Theory . . . . . . . . . . . . . . . . . . . . . . 8-10 Welding Safety . . . . . . . . . . . . . . . . . . . 2-9
Tire Replacement . . . . . . . . . . . . . . . . 7-35 Wiring
Tools, Special . . . . . . . . . . . . . . . . . . . 7-14 Repair . . . . . . . . . . . . . . . . . . . . . 7-41
Soldering Procedures . . . . . . . . . . 7-41

Publication No. 1160093A
Printed by the Digital Print Center
The Raymond Corporation, Greene, NY

Schematics
Model Serial Numbers

4700 C30/C40/C50HM 470-06-XX00001 and up This publication applies to the all subsequent releases of this product until
4700 C50 otherwise indicated in new editions or bulletins. Changes occur periodically to
the information in this publication.
4700 C50L
If you need assistance with your lift truck, or to order additional copies of this
4700 C60 document, contact your local authorized Raymond Dealer. To locate your local
authorized Raymond Dealer, go to www.raymondcorp.com.
Publication: 1160095A Issued: 20 May 2013 Use with Maintenance Manual 1160093A
©2013 The Raymond Corporation.

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Publication: 1160095A, Issued: 20 May 2013 3

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Figure 10. Electrical Schematic - Dual Traction Motor Trucks >S/N 29998 (Sheet 1 of 6)

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Figure 16. Electrical Schematic - Single Traction Motor Trucks >S/N 10676 (Sheet 1 of 7)

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Figure 23. Hydraulic Schematic - Lever Controls (Dual Traction Motor Trucks)
Model 4700
Lever Controls
Figure 24. Hydraulic Schematic - Lever Controls (Single Traction Motor Trucks)
Model 4700
Lever Controls
Single Traction Motor Trucks
Figure 25. Hydraulic Schematic - Fingertip Controls
Model 4700
Fingertip Controls
Figure 26. Hydraulic Schematic - Bottler’s Tilt
Bottler’s Tilt

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What is the purpose of this manual?

What is the purpose of this manual?

What safety precautions are outlined in the manual?

What safety precautions are outlined in the manual?

Maintenance Manual

Model 4700 Sit-Down Counterbalanced Lift

Model Serial No.

1160093A Issued: 20 May 2013

For revision information, see “Page Revision Page” on page iii.

©2013 The Raymond Corporation.

Publication 1160093, Issued: 20 May 2013 i

Pinout Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

ii Publication 1160093, Issued: 20 May 2013

Document Revision History

Revision Date Description of Changes

Publication 1160093, Issued: 20 May 2013 iii

Service Information List

Document Number Subject Date

iv Publication 1160093, Issued: 20 May 2013

Section 1. How to Use This Manual

Publication 1160093, Issued: 20 May 2013 1-1

Manual Design • 7. Component Procedures gives

1-2 Publication 1160093, Issued: 20 May 2013

Interactive Electronic Technical Manuals

Blue colored text in the Maintenance Manual is

Green colored text in the Maintenance Manual

Publication 1160093, Issued: 20 May 2013 1-3

Abbreviations and Symbols

Term/Symbol Definition Term/Symbol Definition

CAN Controller Area Network No. number

1-4 Publication 1160093, Issued: 20 May 2013

Abbreviations and Symbols

Publication 1160093, Issued: 20 May 2013 1-5

Abbreviations and Symbols

1-6 Publication 1160093, Issued: 20 May 2013

Publication 1160093, Issued: 20 May 2013 2-1

Warning means a potentially hazardous

Caution means a potentially hazardous

2-2 Publication 1160093, Issued: 20 May 2013

Do not operate or work on this lift truck unless

Before working on this lift truck, always turn

Know the lift truck’s controls and what they do.

Do not wear watches, rings, or jewelry when

Follow the scheduled lubrication, maintenance,

Publication 1160093, Issued: 20 May 2013 2-3

Do not wash this lift truck with a hose.

Do not add to or modify this lift truck until you

Clean up any hydraulic fluid, oil, or grease that

2-4 Publication 1160093, Issued: 20 May 2013

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

As a battery is being charged, an

Battery electrolyte is a solution of

Publication 1160093, Issued: 20 May 2013 2-5

Do not lay tools or metal objects on top of the

Do not allow cleaning solution, dirt, or any

Make sure you install the correct size battery. A

Keep batteries clean. Corrosion causes shorts

Keep plugs, terminals, cables, and receptacles

Never plug a battery charger into the lift truck’s