Maintenance Manual Models 4150/4250: Stand-Up Counterbalanced Lift Trucks With The ACR System

Maintenance Manual
Models 4150/4250
Stand-Up Counterbalanced Lift Trucks
With The ACR System ®
Models Serial Numbers

4150 42,000 and Up
4250 42,067 and Up
1193671B Issued: 13 Jun 2016

This publication, 1193671B, applies to the Stand-Up Counterbalanced Lift Truck Models 4150
(S/N 42,000 and up) and 4250 (S/N 42,067 and up), and to all subsequent releases of this
product until otherwise indicated in new editions or bulletins. Changes occur periodically to the
information in this publication.
If you need assistance with your lift truck, or need to order additional copies of this manual,
contact your local authorized Raymond Sales and Service Center. To locate your local
authorized Raymond Sales and Service Center, go to www.raymondcorp.com.
©2016 The Raymond Corporation.
The following terms are trademarks of The Raymond Corporation: Auto Power Off, The ACR
System, ComfortStance, iPORT, iALERT, iCONTROL, iBATTERY, Maintenance Minder, and
Raymond. All other brand and product names are trademarks or registered trademarks of their
respective companies.
Models 4150/4250 Maintenance Manual Table of Contents
Table of Contents
Document Revision History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Service Information List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
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
Safety Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Static Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Jacking Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Towing Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Lift Truck Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Truck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
FlashWare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Scheduled Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Maintenance Minder™ Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Initial 90 Day/250 Deadman Hours (HD) Maintenance . . . . . . . . . . . 4-5
Every 180 Days or 500 HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Every 360 Days or 2000 HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Contactor Tip Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Hydraulic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Symptom Tables: Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . 5-20
Symptom Tables: Drive Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Symptom Tables: Travel Functions . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Symptom Tables: Electrical Symptoms . . . . . . . . . . . . . . . . . . . . . . 5-26
Messages, Codes, and Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Summary List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Messages and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Analog Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Input Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73
Output Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-93
Publication: 1193671, Issued: 13 Jun 2016 i

Table of Contents Models 4150/4250 Maintenance Manual
Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

List of Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Component Locator Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Special Tools and Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Steering and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Drive and Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-97
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
System Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Traction System Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Steering System Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Lift/Lower System Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Pinout Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Lubrication Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Thread Adhesives, Sealants, and Lubricants . . . . . . . . . . . . . . . . . . . A-3
Component Specific Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Torque Chart - Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Torque Chart - Straight Thread Face Seal O-Rings . . . . . . . . . . . . . . A-7
Torque Chart - Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Torque Chart - Metric (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Torque Chart - Standard (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Torque Chart - Metric (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11
Torque Chart - Thread-Forming Screws . . . . . . . . . . . . . . . . . . . . . . A-12
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13
Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-15
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
ii Publication: 1193671, Issued: 13 Jun 2016

Models 4150/4250 Maintenance Manual Document Revision History
Document Revision History

Revision Date Description of Changes
A 15 May 2014 Initial Release
B 13 Jun 2016 Incorporated outstanding RSIs and add new mast content.
Publication: 1193671, Issued:13 Jun 2016 iii

Service Information List Models 4150/4250 Maintenance Manual
Service Information List

The following Raymond Service Information (RSI) documents have been incorporated into this
manual (use the blank rows to log Service Information documents when they are added to this
manual).
RSI Number Subject Issue Date
CTB-14-006 Quad Mast Flow Control Valve Removal and Installation August 19, 2014
CTB-14-008A Lift Chain Adjustment November 4, 2014
MUL-15-003 Fuse/Relay Card Troubleshooting April 7, 2015
MUL-15-004 Aux Motor Brush Inspection and Installation May 25, 2015
CTB-15-004 Drive Unit Updates July 27, 2015
MUL-15-007 Electrical Troubleshooting September 10, 2015
MUL-15-008 New Pump Spline Lubricant October 1, 2015
CTB-15-008 New Brake Assembly Available October 29, 2015
CTB-15-007 New Software Release October 30, 2015
iv Publication: 1193671, Issued:13 Jun 2016

Models 4150/4250 Maintenance Manual Section 1. How to Use This Manual
Section 1. How to Use This Manual
Publication: 1193671, Issued: 13 Jun 2016 1-1

Section 1. How to Use This Manual Models 4150/4250 Maintenance Manual
Manual Design
Manual Design • 7. Component Procedures contains

component locator photos and
step-by-step procedures for the testing,
This manual is designed to give personnel with removal, installation, and adjustment of
an expected level of expertise the technical individual truck components. Components
information necessary to maintain, trouble- are grouped by system. A detailed List of
shoot, and repair a Raymond product. Component Procedures can be found at
the beginning of the section.
The two-line header at the top of each page
• 8. Theory of Operation explains signal
contains the name of the manual, the title of the
flow within the electrical and hydraulic
current section, and the topic contained on the
systems for various conditions of lift truck
page.
operation. This section also contains a
detailed connection point table (Pinout
This manual consists of the following sections:
Matrix) designed to assist in testing and
• 1. How to Use This Manual explains the troubleshooting the truck.
manual format and design as well as
• Appendix contains reference information
abbreviations and symbols used.
such as torque values, lubricants, and
• 2. Safety explains warning and caution standard/metric conversions.
notes, gives general safety rules and (as
• Index alphabetically lists subject matter
applicable) specific safety rules for
with applicable page references.
batteries, static electricity, jacking, towing,
transport, and welding. • Schematics contains a power distribution
diagram, electrical, and hydraulic
• 3. Systems Overview includes general lift
schematics.
truck specifications, modes of operation,
and setup/configuration information.
• 4. Scheduled Maintenance identifies the
recommended maintenance tasks and
intervals necessary to keep the lift truck
working most efficiently.
• 5. Troubleshooting provides information
used to isolate a problem or failing
component based on the lift truck's
symptoms.
• 6. Messages, Codes, and Tests gives (as
applicable) operator messages, fault codes,
and procedures for running diagnostic
tests.
1-2 Publication: 1193671, Issued: 13 Jun 2016

Interactive Electronic Technical Manuals
Interactive Electronic
Technical Manuals
The electronic version of this document is an
Interactive Electronic Technical Manual (IETM).
IETMs provide quick access to specific service
and parts information and are available on
iManuals or from your local authorized
Raymond Sales and Service Center.
NOTE: IETMs require Adobe Reader 9.0 or
higher.
Blue text in the Maintenance Manual is linked

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

Abbreviations and Symbols
Abbreviations and
Symbols
The following abbreviations, acronyms, and symbols are used in this manual.
Term/Symbol Definition Term/Symbol Definition
A Ampere fpm feet per minute
Agnd analog ground FRC Fuse/Relay Card
amp Ampere or amplifier ft. foot or feet
APM Auxiliary Processing
Module gal. gallon or gallons
approx approximately Gnd ground
Assy assembly
Aux auxiliary HD hours on deadman
AWG American Wire Gauge Ht height
Hgt/Wgt Height/Weight
BDI Battery Discharge Indicator
BSM Battery Sensor Module in. inch or inches
BSOC Battery State-of-Charge ISS Integral Side Shifter
CAN Controller Area Network kg kilogram(s)

cc cubic centimeter kHz kilohertz
CCW counterclockwise km/h kilometers per hour
cm centimeter kPa kilo Pascal
COP Computer Operating
Program lb. pound or pounds
CW clockwise L/H Load Holding
CS cold storage L/L Lift/Lower
LPA Lift Power Amplifier
dim. dimension LPC Lift Power Contactor
Dgnd/D-GND digital ground lpm liters per minute
DMLL Deadman Lift/Lower LTPA Left Traction Power Amp
DMM Digital MultiMeter
DVM Digital Voltmeter mA milliampere
max maximum
EE UL Electric Truck Type min minute or minimum
Certification Rating where
electrical equipment is ml milliliter
completely enclosed mm millimeter
EMF ElectroMotive Force MM Maintenance Minder™
EPO Emergency Power Off mph miles per hour
ESD Electrostatic Discharge MS MicroSoft
ESDS Electrostatic Discharge mS millisecond or milliseconds
Sensitive mV millivolt or millivolts
mVAC millivolts - alternating
FF Forks-first current

Term/Symbol Definition Term/Symbol Definition

TS Traction Speed
NMT Network Management T/S troubleshoot
No. number TT Three-stage mast
NV non-volatile
NVM Non-Volatile Memory UL Underwriters Laboratories,
Nm newton meter Inc.
USB Universal Serial Bus
OACH Overall Collapsed Height
OD Operator Display V Version, Volt, or Volts
OI Operator Interface VDC Volts Direct Current
OSHA Occupational Safety and VM Vehicle Manager
Health Association
oz ounce wrt with respect to
Wt Weight
PC Personal Computer w/ with
prox proximity w/o without
pot potentiometer
psi pounds per square inch @ at
PTC Positive Temperature ™ trademark
Coefficient (Thermistors) © copyright
PWM Pulse Width Modulation + plus or positive
P/N Part Number – minus or negative
± plus or minus
rpm revolutions per minute ° degrees
R/R repair/replace °F degrees Fahrenheit
RTPA Right Traction Power Amp °C degrees Celsius/
Centigrade
SAE Society of Automotive < less than
Engineers > greater than
sec second % percent
SG specific gravity = equals
SOL Solenoid
spec specification
SW Switch
SWM Supplier Wireless Module
S/W Software
temp Temperature
TF Tractor-first or Two-stage
mast with full free lift
TML Traction Motor Left
TMR Traction Motor Right
TPA Traction Power Amplifier
TPC Traction Power Contactor


Models 4150/4250 Maintenance Manual Section 2. Safety
Section 2. Safety

Section 2. Safety Models 4150/4250 Maintenance Manual
Safety Definitions
Safety Definitions
Throughout this manual, you will see two kinds
of safety reminders:
Indicates a potentially hazardous

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

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

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

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

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

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

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

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

has leaked or spilled on the floor.
Do not park this lift truck in a cold storage area
overnight unless the lift truck is conditioned for
cold storage.
Always operate and park this lift truck indoors.

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

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

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

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

hydrogen gas concentration.
Wear personal protective equipment to protect

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

Battery Safety
Turn the key switch OFF before disconnecting Keep plugs, terminals, cables, and receptacles
the battery from the lift truck at the battery in good condition to avoid shorts and sparks.
connector. Do not break live circuits at the
battery terminals. A spark often occurs at the
point where a live circuit is broken.
Do not lay tools or metal objects on top of the

battery. A short circuit or explosion could
Keep filler plugs firmly in place at all times
result.
except when the electrolyte level is checked,
when water is added to the cells, or when the
specific gravity is checked.
Make sure the vent holes in the filler plugs are

open to allow the gas to escape from the cells.
Vent Hole
Keep batteries clean. Corrosion causes shorts

to the frame and possibly sparks.
Do not allow cleaning solution, dirt, or any

foreign matter to enter the cells.

Battery Safety
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 for more information.
Never plug a battery charger into the lift truck’s

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

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

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

components, follow these precautions:
• Wear an ESD wrist strap. The wrist strap
should be equipped with a 1 megohm
resistor to dissipate static charges slowly.
• Test the wrist strap and related
accessories before each use to make sure
they are working correctly.
• Connect the wrist strap plug to the ground
jack on the lift truck. See Figure 2-1. If
you cannot use the ground jack, connect
the ground clip to an unpainted, grounded
surface on the lift truck frame. Wrist straps (P/N 1-187-058/001) are also
available separately.
Figure 2-1. Ground Jack Location
Contact your local Raymond Sales and Service
Ground Jack Center for information.

Jacking Safety
Jacking Safety Figure 2-4. Jacking Tractor
Some maintenance procedures require the lift

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

Use extreme care when the lift truck is To jack the drive wheel:
jacked up. Never block the lift truck
1. Place the jack in the designated jacking
between the telescopic and the floor.
position. See Figure 2-3.
Attach a chain to the top of the mast and
an overhead hoist to stabilize the mast if 2. Jack the truck up just high enough to
jacking more than described in this raise the drive wheel off the floor.
procedure. Keep hands and feet clear 3. Place a block under the frame as shown in
while jacking the lift truck. After the lift Figure 2-3.
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 Jacking the Tractor
truck.
To jack the tractor:
5. Place the jack under the designated 1. Place the jack in the designated jacking
jacking points. See Figure 2-3 and position near the steerable wheel. See
Figure 2-4. Figure 2-4.
2. Jack the truck so that the steerable wheel
Figure 2-3. Jacking Drive Wheel
is off the floor no more than 1 in. (25 mm).
3. Block under the frame as shown in
Figure 2-4.
NOTE: After working on a vehicle, test all
controls and functions to verify correct
operation.

Towing Safety
Towing Safety
To safely tow this truck: When towing is complete, remove the
1. Lower the carriage and remove any load brake release bolts and return them to
from the forks. their stow location on the tractor frame.
2. Turn the key switch OFF and disconnect Failure to do so can cause serious injury.
3. Install the brake release bolts.
NOTE: The brake release bolts are stowed on
the tractor frame above the left traction
motor.
Figure 2-5. Brake Release Bolt Installation
4. Using a suitable towing vehicle, lift the

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

Welding Safety
Welding Safety
Disconnect the battery before you
attempt to inspect, service, or repair the
lift truck. Discharge all power amplifier’s
Flame cutting or welding on painted internal capacitor by jumpering the +
surfaces can produce potentially and – terminals with a 100 ohm 25W
harmful fumes, smoke, and vapors. resistor.
Before you do flame cutting or welding,
remove the coating in the area where
the operation will occur.
Coating removal can occur by

mechanical and/or chemical methods.
Perform flame cutting and/or welding
only in well ventilated areas.
Before working on this lift truck, make sure

that: • Test for shorts to frame. See “Shorts to
• Fire protection equipment is nearby. Frame Test” on page 5-3. If you find any
• You know where the nearest eyewash shorts, correct them before you weld.
station is. • 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. Do not attach the
ground cable to fasteners or other
removable components.
• Disconnect all electrical connectors from
circuit cards before doing any type of
electric resistance welding.
• Do not weld near electrical components.
• If you must weld near the battery
compartment, remove the battery from the
lift truck.

Welding Safety

Models 4150/4250 Maintenance Manual Section 3. Systems Overview
Section 3. Systems Overview

Section 3. Systems Overview Models 4150/4250 Maintenance Manual
Introduction
Introduction
This manual provides information for
maintenance and repair of Model 4150/4250
Stand-Up Counterbalanced lift trucks by
Raymond.
This manual contains the most current and

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

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

Lift Truck Specifications
Lift Truck Specifications

Specification Tag
This lift truck is rated for performance by load
center and load weight. Review the specification
tag for detailed load capacity and load center
information. See Figure 3-1.
Due to continuous product improvement,

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

Approximate weight
Serial number of lift truck with
battery installed,
Raymond Model # minus load and
operator
Nominal battery Approximate weight
voltage of lift truck minus
battery, load, and
operator
*Max battery weight
for this lift truck
*Min battery weight

for this lift truck
Max Battery
Max load capacity of Rated Capacity
this lift truck
*Battery weight must be

between the min and
max weight.
NOTE: The lift truck serial number can also be Load Capacity
found:
• on the mast specification tag on the Always refer to the specification tag on your lift
lower left mast upright truck for the correct ratings for your truck.
• stamped on tractor frame below top

console cover in operator
compartment

General Information
General Information Fluid Capacities

Drive Units (each) Hydraulic Reservoir
Model and Mast Designations 1.275 gal. Metal - 6 gal. (22.7 liters)
(4.82 liters) Plastic - 6.5 gal. (24.6 liters)
The model number includes the model and the
mast series designation.
Refer to “Lubrication Specification Chart” on
Max Load
Model Mast page A-2.
Forks Lowered
C30TF
3000 lb. (1360 kg)
C30TT
C35TF
4150 3500 lb. (1588 kg)
C35TT
C40TF
4000 lb. (1815 kg)
C40TT
C30TF
C30TT 3000 lb. (1360 kg)
C30QM
C35TF
C35TT 3500 lb. (1588 kg)
C35QM
4250
C40TF
C40TT 4000 lb. (1815 kg)
C40QM
C50TF
C50TT 5000 lb. (2268 kg)
C50QM
Battery Specifications
Weight Max
Width (in.) lb. (kg) Amp
Min Max Hours
13.75 1700 (771) 2050 (929) 800
16.5 1980 (898) 2250 (1022) 930
18.5 2300 (1043) 2600 (1180) 1085
21.25 2593 (1176) 2900 (1315) 1240
23.75 2700 (1226) 3250 (1474) 1395
UL note 583 specifies that a battery should

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

Truck Installation
Truck Installation
Installation must be performed by a Raymond
Certified Sales and Service Center Technician to
ensure warranty coverage.
During installation, a visual and functional

inspection must be performed. Refer to
Stand-Up Counterbalanced Lift Truck
Installation Guide P/N 1169847.

FlashWare
FlashWare • USB to USB - this method requires the

correct drivers to be installed on the
device. Typically, this type of connection is
Overview much faster than a serial connection. With
the key switch OFF, connect cable
FlashWare allows you to update software, view P/N 1120332/XXX to a USB port on the
options, and configure options on the lift truck device and the P3 connector on the
through the following features: manager. See Figure 3-2.
• Update Vehicle Manager software • Serial to Serial - this method requires a

surge protector (P/N 154-010-801) to be
• Clear Primary Memory connected in series with the cable to
• Clear Vehicle Manager protect the device. With the key switch
• Reset factory default settings OFF, connect cable P/N 610-809/201 to a
serial port on the device and the J9
• Update Power Amplifier Software connector on the manager. See Figure 3-2.
For more detailed FlashWare information, click Figure 3-2. Truck FlashWare Connections
on Help and select Help Topics from the
FlashWare menu bar. Serial connector (J9) USB connector (P3)
FlashWare can be installed on any MicroSoft

(MS) Windows compatible device. The device
communicates with the truck software via a
serial (9 pin) or USB port.
Installing FlashWare on a
Windows Compatible Device
If you are a customer service technician, obtain
FlashWare from your Raymond Sales and
Service Center. Starting FlashWare
1. With the key switch ON, double-click the
If you are a Raymond Sales and Service Center
FlashWare icon on the main desktop
technician, obtain FlashWare from the
screen or navigate via Start > Programs >
Raymond Portal software download site.
FlashWare. The Truck Opening Screen
appears. See Figure 3-3.
To install FlashWare on the device, double-click
the installation file and follow the instructions
Figure 3-3. Truck Opening Screen
on the screen. The software package is a
self-extracting executable file. Read the
“Readme” file in the software package for the
latest detailed installation instructions.
Connecting FlashWare to Truck

There are two methods available to connect the
device to a manager:

Starting FlashWare
NOTE: When entering or using FlashWare, it is

normal for a 50 Series Code to be
displayed.
2. From the menu bar, click
“Communications”, then select the
applicable connection type:
• COMx (9-pin Serial)
• COMx (USB)
NOTE: “x” numbers vary depending on the
computer configuration.
3. From the menu bar, click “Connect to
Truck”, then select “All Other Trucks”. If
the device is connected to a correctly
functioning Vehicle Manager, the Truck
Setup screen is displayed.
NOTE: Refer to FlashWare Help for specific
FlashWare related topics.

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

• Time and date
• Battery Discharge Indicator (BDI)
• Weight of load (option)
• VM Software version
• Attachment Selection function
• Hour meters (key hours [KH]), deadman
hours [HD], lift/aux hours [HL], total miles
[TM], and OCSS beam trip count
• Ambient temperature
• OCSS beam trip count
• Truck serial number
• Status/Fault messages
• Service required indicator
• Overtemperature indicator
• Lift-limit indicator (optional)
Figure 3-4. Operator Display
Up Button Down Button Key Switch
Display
Overtemperature
Indicator
Battery Discharge Service Required Enter Button Emergency
Indicator Indicator Power Off

Passwords
Passwords 2. Enter the password as follows:

NOTE: The default Maintenance Password is
Two levels of passwords are used on this truck; _ 2 _ _ _ _ _ _. The default Configuration
Configuration and Maintenance. Password is 1 _ _ _ _ _ _ _.
To illustrate this procedure, assume you
Configuration Mode Password are entering the default Maintenance
Password (_ 2 _ _ _ _ _ _). Look at the OD.
The Configuration Mode Password allows you to The flashing underscore is the active
enter Configure Mode (refer to “Configure Mode” character position. To move the active
on page 3-11). Configure Mode is intended for character position to the right, press the
customer use in setting performance ENTER button.
parameters within those features purchased To move the active character position to
with the truck. the left, hold down the ENTER button and
press the DOWN button. When the
character position you want to change is
Maintenance Mode Password active, release the buttons.
The Maintenance Mode Password allows you 3. Press the UP button. You will scroll up
enter Maintenance Mode. Maintenance Mode is through the numbers (0,1,2,3—7,8,9) and
intended to be used by qualified service letters (a,b,c—x,y,z).
technicians only. If you press the DOWN button, you will
scroll down through the letters
It is strongly recommended that the (z,y,x—c,b,a) and numbers (9,8,7—2,1,0).
Maintenance Mode Password be changed
during installation from the factory. This is to NOTE: If you push and hold the button, you
make sure that access to Maintenance Mode is will scroll very quickly.
restricted to qualified personnel only. If the Stop pressing the button when the letter
password is lost, changed, or forgotten, a reset or number you want appears in the
to the original factory password can be character position.
performed in FlashWare. In doing so, all
4. Move to the next character position you
settings are reset to the original factory default
want to change by:
parameters. Consequently, all variable settings
will need to be reconfigured. Configuration • Pressing the ENTER button to move the
settings should be documented for that truck active character position to the right.
before a reset is performed. • Holding down the ENTER button and
NOTE: Password recovery can be performed via pressing the DOWN button to move the
the Raymond Portal if FlashWare is not active character position to the left.
available. Within the Raymond Portal, 5. Repeat step 3 to change the letter or
select Service > Software > SuperWord number in this character position. Repeat
Recovery Passkey Program and follow steps 3 and 4 to enter the remaining
the procedure in the SuperWord_readme characters of the password.
file. 6. When the OD shows the correct password,
press the ENTER button. If the password
Entering a Password is correct, you are now in Maintenance
Mode.
NOTE: Press the ENTER button to access
7. If you make a mistake while entering a
Maintenance or Configure Mode after an
character, repeat steps 3 thru 6.
error code is displayed.
1. Press the ENTER button. The OD shows
an eight character field of underscores.

Electronic Key
Electronic Key
Electronic Key is a configurable software
feature that permits the customer to establish
an operator password.
When the key switch is turned ON, the operator

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

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

Modes of Operation
Modes of Operation Mode, the default mode of operation. Run Mode

is also entered when the truck exits Configure
or Maintenance Mode.
There are three modes of operation for this
truck:
Configure Mode
• RUN MODE - the standard working mode
for the truck. Configure Mode is used to change individual
• CONFIGURE MODE - used to change truck performance parameters for specific
truck operating parameters. customer requirements. Refer to Table 3-1.
• MAINTENANCE MODE - used to access
Learn Mode, perform various tests needed To enter Configure Mode, you must enter the
for troubleshooting, enable Active Configuration Mode password. See “Entering a
Maintenance Mode, view logged errors and Password” on page 3-9.
OCSS trip counter, and set sideshift and
tilt speeds. When Configure Mode is entered, the current
value selected is displayed first, followed by a
description of the setting being modified.
Run Mode
When the truck is powered ON and SelfTest is
completed, the truck automatically enters Run
Table 3-1. Configure Mode Menu

Configure Mode Menu (S/W V8.4)
Shaded rows are options that must be enabled in FlashWare
Menu Message Displayed and Parameter

Description
Item Selections Available
Quit "Exit Configuration Mode" Allows exit of Config Mode. Select Yes to save
Save?Yes changes. Select No to abandon changes before
Save? No leaving Configure Mode. If no changes were
made, session will exit at “Quit” prompt.
Default "Restore Factory Defaults" Restores all initial truck values established at the
Restor?N factory except travel speeds and passwords.
Restor?Y Current configuration settings should be
documented before restore is performed.

Configure Mode


Description
Travel "Set Forward Max Speed" Set maximum forward speed. Can be set as low
1.0 to 7.2 mph (1.6 to 11.5 km/h) as 1 mph (1.6 km/h), in increments of 0.1 mph
(Model 4150 - Default is 7.2 mph) (0.16 km/h).
1.0 to 8.0 mph (1.6 to 12.8 km/h)
(Model 4250 - Default is 8.0 mph)
"Set Reverse Max Speed" Set maximum reverse speed. Can be set as low
1.0 to 7.2 mph (1.6 to 11.5 km/h) as 1 mph (1.6 km/h), in increments of 0.1 mph
(Model 4150 - Default is 7.2 mph) (0.16 km/h).
1.0 to 8.0 mph (1.6 to 12.8 km/h)
(Model 4250 - Default is 8.0 mph)
"Set Travel Accel" Set travel acceleration rate. Useful when the
Soft truck operates in high or very low traffic
Medium (Default) environments.
Hard
"Set Corner Decel" Set the time (in seconds) it takes for the truck to
OFF (Default) decelerate to a target speed (configured
1.5 maximum speed minus 1.8 mph [2.9 km/h])
2.0 during a turn.
2.5
3.0
3.5
"Set Coast Distance" Set distance the truck travels when the control
Long (Default) handle is released and returns to the neutral
Medium position.
Short
Lift "Set Lift Accel" Set lift acceleration rate. Useful for limiting new
Soft operators, or when large loads are expected.
Medium
Hard (Default)
BSOC "Set Lift Cutout Point" Set the lowest state-of-charge the battery can
0 - 40% (Default is 20%) have and still lift. It is adjusted to keep from
over-discharging the battery. Value is a
percentage of BSOC and can be set in 5%
increments.
"Set Alternate Lift Cutout Point" Set the lift cutout setting on a Battery Sensor
0 - 40% (Factory Set at 20%) Module (BSM) equipped battery without using
FlashWare. Note: The preferred method to
change the BSM BSOC Cut-Out setting is via the
APM00 FlashWare screen.
"Set BSOC Display" Set which BSOC information is to appear on the

Truck (Default) Operator Display when a BSM equipped battery
iBattery is installed in the truck.
Password "Enter New Configuration Password" Set password used to enter Configure Mode.
(Default is 1 _ _ _ _ _ _ _) Refer to “Passwords” on page 3-9.

Configure Mode


Description
Units "Set Units for Messages" Specify unit of measure to be displayed on the
English (Default) Operator Display.
Metric
Mnt Mind "Setup Maintenance Minder" Enable/disable, configure, and reset

Quit MM "Exit MM" Maintenance Minder (MM).
Enable "Turn on MM"
*Setup
50 to 500FS (Factory Suggested)-> Set MM interval in 50 hr. increments.
Msg. Only----------------------------> Displays message when due.
L Cutout------------------------------> Displays message and disables lift when due.
*Reset
*Disable Note: Refer to page 4-3 for detailed information
*Displayed only when Maintenance Minder is enabled. on Maintenance Minder.
APOFF "Enter the Auto Power-Off Time" Enable (set time) or disable Auto Power-Off (sleep
Disabled (Default) mode). Disables truck power after the preset time
01Min of inactivity.
02Min
03Min
04Min
05Min
10Min
Clock "Set Time and Date" Set truck’s internal clock.

Quit Clk
24Hour "Enable/Disable 24 Hour Time
Display"
Y
N
Time
01:00PM or 1300
Date
mm/dd/yy
VM XX.X "Vehicle Manager Software Version"
VMB X.X "VM Boot Software Version"
TAXX.X "Left Traction Amp Software Version"
LTABX.XX "Left Traction Amp Boot Version"

Read only.
TAXX.X "Right Traction Amp Software Version"
RTABX.XX "Right Traction Amp Boot Version"
LA_XX.X "Lift Amp Software Version"
LPABX.XX "Lift Amp Boot Version"
Electronic "Enter New Electronic Key Password" Enter/change Electronic Key password. Requires
Key (Default is 3 _ _ _ _ _ _ _) entry of unique password before truck is
operational. Refer to “Passwords” on page 3-9.

Configure Mode


Description
Travel "Set Travel Alarm" Set desired action when the alarm sounds;
Alarm Forks during forks-first travel, tractor-first travel, both
Tractor directions, or not at all.
Both (Default)
None
Cust Out "Enter Customer Output Option Time" Enable (set time) or disable Customer Output
Disabled (Default) option. Disables output to JPC18-2.
0 to 120 seconds
HydOpt "Select Optional Hydraulic Attachment" Refer to “Attachment Control” on page 3-16.
Item Message Displayed Selections Available Description
QuitAtt "Exit Attachment Selection"
Attach 1 "Attachment 1 Setup"

None (Default) Select flow rate in
2-7 GPM (4150) 1 GPM increments.
2-11 GPM (4250)
Clamp
N = No (Default)
Y = Yes
QuitPsi
"Set Low Clamp Pressure(psi)" Low 750 (Default) Refer to Table 3-2,
"Set Med Clamp Pressure(psi)" Med 1000 (Default) “Attachment Setup,”
"Set High Clamp Pressure(psi)" Hi 1250 (Default) on page 3-16.
"Set Max Clamp Pressure(psi)" Max 2300 (Default)
"Set Clamp Open Pressure(psi)" Opn 2300 (Default) Lower psi = slower
unclamp speed.
Attach 2 "Attachment 2 Setup"
None (Default)
2-7 GPM (4150) Select flow rate in
2-11 GPM (4250) 1 GPM increments.
Spd Limit "Set the Speed Limit Switch Speed" Set speed when speed limit switch is activated.
1.0 to 6.0 mph (1.6 to 9.6 km/h) Can be set as low as 1 mph (1.6 km/h), in
(Default is 6.0 mph) increments of 0.1 mph (0.16 km/h).
LftLimit "Set the Lift Limit W/Bypass Type" Configure lift limit bypass option: No Bypass,
No Byp (Default) Standard Bypass, or Alternate Bypass.
Alt Byp
Std Byp
Bat Gate "Set the Battery Gate Action" Configure truck response when the battery gate
ON switch is activated (battery gate not correctly
OFF (Default) installed).
Weight "Select the Weight Sensor" Turn ON/OFF the weight sensor. When ON,
ON weight on forks is displayed on the Operator
OFF (Default) Display.

Configure Mode


Description
Sideshft "Enable Sideshift" Enable/disable sideshift function.

On (Default)
Off
TiltCntr "Enable tilt center" Enable/disable tilt centering function.

On
Off (Default)
BSOC "Set BSOC reset %" Set level at which the Battery Discharge Indicator
55 to 95% (Default is 75%) resets. Can be set in 5% increments.
iPORT Limit Mode Menu items - refer to iPORT Kit Installation and Maintenance Instructions P/N 1089339.

Attachment Control
Attachment Control SSL on the manifold. Sideshift must be disabled

in the Configure Mode Menu. The flow rates
associated with this connection are
Attachment 1 configurable under Attach 2 in the HydOpt
menu. Trucks with this configuration cannot be
If an attachment is added to the truck that
equipped with sideshift.
requires only one set of hoses, the hydraulic
lines are connected to ports AC and AR on the
hydraulic manifold. Flow rates associated with Setup and Operation
this connection are configurable under Attach 1
in the HydOpt menu. Refer to Table 3-2 for specific attachment setup
information. Refer to Table 3-3, “Attachment
Operation,” on page 3-17 for specific
Attachment 2 attachment operation information.
If the attachment requires two sets of hoses, the
second set of hoses are connected to SSR and
Table 3-2. Attachment Setup

Operator Display: Hydraulic Hose Adjustment Range
Function
Config or Maintenance Mode Menu Action Ports for Flow Rate
Sideshift Sideshift speed configurable via SSR (Sideshift Right) Set SS Speed - 60% to
“Maintenance Mode” menu item SS. See SSL (Sideshift Left) 90%
Table 3-4 on page 3-18.
Push/Pull Config Menu: Navigate to HydOpt and press AC (Aux Cap) Begin with 7 GPM and
Enter. AR (Aux Rod) adjust as needed or
_Select Attach 1 specified by
___Select flow rate manufacturer*.
_____Set clamp = N
Fork Config Menu: Navigate to HydOpt and press AC (Aux Cap) Begin with 2 GPM and
Positioner Enter. AR (Aux Rod) adjust as needed or
___Select flow rate manufacturer*.
_____Set clamp = N
Clamp Config Menu: Navigate to HydOpt and press AC (Aux Cap) Begin with 7 GPM and
Enter. AR (Aux Rod) adjust as needed or
__Select flow rate manufacturer*.
___Set clamp = Y (see Note 1)
____Set PSI (see Note 2)
Clamp with Config Menu: Navigate to HydOpt and press SSR (Sideshift Right) Begin with 3 GPM and
roll (see Enter. SSL (Sideshift Left) adjust as needed or
Note 3) _Select Attach 2 specified by
__Select flow rate manufacturer*.
*Flow rate can be adjusted in Configure Mode in 1 GPM increments; 2 to 7 (4150), 2 to 11 (4250).
Note 1: All clamp functions must be connected to AC and AR, never to SSR and SSL.
Note 2: Default values are Max = 2300, High = 1250, Med = 1000, Low = 750. Overall Range is 250 to 2300
psi, but values cannot overlap. Example, the highest setting for Low depends on what medium is set to. The
highest value for medium depends on what High is set to and so on.
Note 3: Use SSR and SSL for the roll function on the clamp with roll attachment.

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

(Push/Pull, Clamp) required to release load.
Attachment Function Attachment Switches, The input for the second function of the
added to the truck that Sideshift Left and Sideshift attachment requires the use of the sideshift input.
requires 2 functions Right
(Barrel Clamp with
Roll, Fork Positioner
with Sideshift)
Adjusting Attachment Pressure Figure 3-6. UP/DOWN Buttons on Operator Display

1. Press the top attachment button
momentarily to activate the clamp. See
Figure 3-5.
Figure 3-5. Top Attachment Button
NOTE: Low, Med, High, and Max pressure

settings are available.
2. The clamp pressure is shown on the

Operator Display.
3. To select another pressure, use the
UP/DOWN buttons on the Operator
Display. See Figure 3-6. The clamp
pressure you select remains active until
another pressure is selected; even if the lift
truck is turned OFF.

Maintenance Mode
Maintenance Mode
Maintenance Mode is used to test, cycle, and
troubleshoot functions on the truck. (Refer to
Table 3-4.)
To enter Maintenance Mode, you must enter the

maintenance password. See “Entering a
Password” on page 3-9.
Table 3-4. Maintenance Mode Menu

Menu Message Displayed
Description
Item and Parameter Selections Available
Quit "Exit Maintenance Mode" Allows exit of Maintenance Mode. Select

Save?Yes Yes to save changes. Select No to
Save? No abandon changes before leaving
Maintenance Mode. If no changes were
made, session will exit at “Quit” prompt.
Default "Restore Factory Defaults" Restores all initial truck values

Restor?N established at the factory (including
Restor?Y travel speeds and passwords). Current
configuration settings should be
documented before restore is performed.
Learn "Enter the Learn Mode" Perform Learn after replacing the VM,
Enter control handle, control handle pots, tilt
Quit "Exit Learn Mode" center pot, or optional weight transducer.
Weight "Learn Weight" (optional)
"Lower Carriage to Floor, then Lift 4 Inches.
Press Enter When Done"
Travel "Learn Travel"
"Return Control to Neutral, then Press Enter"
Lift "Learn Lift"
Tilt "Learn Tilt"
Sideshft "Learn Sideshift"
Reach "Learn Reach"
Retract "Learn Retract"
AutoTilt "Learn Auto-tilt"
Current "Enter New Maintenance Password" Set password used to enter Maintenance
Setting (Default is _ 2 _ _ _ _ _ _) Mode. Refer to “Passwords” on page 3-9.
D Inputs "Digital Inputs"

Quit "Exit Digital Inputs"
Refer to Input Tests beginning on page 6-73.----> Displays Input Test sub-menu. Allows an
individual Input test to be run.

Maintenance Mode
Menu Message Displayed

Description
Item and Parameter Selections Available
A Inputs "Analog Inputs"

Quit "Exit Analog Inputs"
Refer to Analog Tests beginning on page 6-31.--> Displays Analog Test sub-menu. Allows
an individual Analog test to be run.
Before performing an Output Test:
• Jack the lift truck so that the drive wheels are off the floor.
• Make sure the controls are in neutral.
• Make sure the lift truck is blocked to keep it from moving.
• Lower the forks all the way to the floor.
Outputs "Digital Outputs"
"Jack up drive wheels Ready?"-------------------> Press Enter.
Quit "Exit Digital Outputs"
Refer to Output Tests beginning on page 6-93.-> Displays Output Test sub-menu. Allows
an individual Output test to be run.
ActM Off "Active Maintenance Select" Allows menu to appear on the display to
ActM Off (Default) toggle between Analog and Input tests
ActM On while the truck is in Run Mode.
Erlog*## "Number of Errors Logged" *## = total number of error codes logged.
Quit "Exit Error Log Menu"
20 _ _-------------------------------------------------> Error code log number and associated
Clear "Press Enter to Clear Errors From the Log" code. Up to 20 error codes can be logged.
BTrip # "OCSS Beam Trip Count" Displays number of times the OCSS
Clear? "Press Enter to Clear Count" beam was blocked since it was last
cleared.
Current "Adjust Two Speed Tilt" Allows adjustment of tilt speed (based on
Setting 5 "Set Tilt Speed" percentage) when the
(4250 only) 4 carriage is above S12. The lower the
3 (Default) number, the faster the tilt speed. The
2 higher the number, the slower the tilt
1 speed. Default is 3 and represents no
speed adjustment.
Current "Set Tilt Speed" Set tilt speed. Value is a percentage and
Setting 60 - 90% (Default is 75%) can be set in 1% increments. The higher
the percentage, the faster the tilt speed.
Current "Set SS Speed" Select sideshift speed. Adjust sideshift

Setting 60 - 90% (Default is 75%) speed between 2 and 3.5 seconds (the
higher the percentage, the faster the
sideshift speed).

Storage
Storage Before returning the truck to service, drain the

reservoir and change the filter. Fill the reservoir
with new hydraulic fluid.
When storing the truck for any length of time,
cover the truck with canvas or plastic. Operate the hydraulic systems slowly at first to
allow lubrication of internal components.
If storing the truck for more than 30 days, jack
and block the truck up off the floor. NOTE: If the truck is going to be stored for more
than six months, spray hydraulic
components with a silicone protectant.
Do not let silicone protectant spray get
on circuit cards.
Use extreme care whenever the truck is
jacked up for any reason. Never block
the truck between the telescopic and the Hydraulic Cylinders
floor. Use a suitable hoist to stabilize the
mast. Keep hands and feet clear from Store the truck with the cylinder pistons
beneath vehicle while jacking. Use jack retracted. Coat all exposed chrome surfaces of
stands or solid blocks to support truck. the piston with hydraulic fluid.
Do Not rely on the jack alone. See
“Jacking Safety” on page 2-9. Lift Chains
Warranty Liberally lubricate all chains to prevent rust
and corrosion. Refer to “Lubrication
The Raymond Corporation must be contacted Specification Chart” on page A-2.
by an authorized Raymond Sales and Service
Center for the correct warranty procedures. Electronics
DC Motors Make sure all electronics stay dry.
The brushes in DC motors must be lifted away

from the commutator surface. When preparing
the truck for service, the surface must be
inspected and polished, if necessary, using a
rubber abrasive polish. Polishers are
specifically made for polishing commutators. Do
Not use a stone.
While in storage, periodically rotate the DC

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

Models 4150/4250 Maintenance Manual Section 4. Scheduled Maintenance
Section 4. Scheduled Maintenance

Section 4. Scheduled Maintenance Models 4150/4250 Maintenance Manual
Scheduled Maintenance Guidelines
Scheduled Maintenance
Guidelines
A successful scheduled maintenance program:
• promotes maximum truck performance
• prolongs truck life
• reduces costly down time
• prevents unnecessary repairs
Scheduled maintenance includes:

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

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

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

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

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

Option
Tool
The first time you enter the time interval menu,
Maintenance Minder Tool is a feature that the Factory Suggested setting, followed by the
allows a customer to be prompted when the letters FS, is displayed. Subsequently, when
truck is due for scheduled maintenance. you enter the time interval menu, the last used
setting is displayed. Values from 50 to 500
Maintenance Minder, when enabled, monitors hours, in increments of 50, are available. Scroll
the Hours on Deadman (HD) meter. When the to the desired time interval and press ENTER.
time interval for scheduled maintenance is
exceeded, the operator is informed in the Scroll to the desired action option and press
following ways: ENTER.
• One of two messages scrolls on the • MSG ONLY causes the Operator Display to
Operator Display for at least 30 seconds show SCHEDULED MAINTENANCE DUE
following the Daily Checklist message: when the scheduled maintenance time
interval is exceeded.
• Scheduled Maintenance Due
• L CUTOUT causes the Operator Display to
• Lift Cutout, Scheduled Maintenance Due show LIFT CUT OUT, SCHEDULED
• the wrench icon on the display flashes MAINTENANCE DUE when the scheduled
• The audible alarm sounds the high-low maintenance time interval is exceeded. Lift
tone for approx. five seconds. is disabled the next time the power circuits
are cycled.
Lift Cutout, when active, does not disable the
lift function until power to the control circuits is Scroll to QUIT MM from the sub-menu. Press
cycled (key switch OFF or battery ENTER.
disconnected).
From the Config Menu, exit by selecting QUIT
When the control circuit power is cycled, lift is CFG. You will be prompted to save changes.
disabled until Maintenance Minder is reset or
disabled, or the lift cutout option is turned OFF. Changing Time Interval or Action
Option
Enabling
When Maintenance Minder is active and you
MAINTENANCE MINDER is enabled and want to change the time interval or action
configured in the Configure Mode menu. The option, enter Configure Mode.
default factory setting is DISABLE. To enable
the feature, enter Configure Mode. With Configure Mode selected, scroll to MNT
MIND and press ENTER. When entered from an
NOTE: For instructions on selecting Modes of enabled state, Maintenance Minder offers a
Operation, see Modes of Operation on sub-menu with the options QUIT MM, RESET,
page 3-11. DISABLE, and SETUP. Scroll to SETUP, then
press ENTER. The current time interval is
With Configuration Mode selected, scroll to displayed (hours). Proceed as described under
display MAINTENANCE MINDER and press Setting Time Interval and Action Option.
ENTER. When entered from a disabled state,
Maintenance Minder offers a sub-menu with the
Resetting Maintenance Minder
options QUIT MM and ENABLE. Scroll to
ENABLE and press ENTER.
When Maintenance Minder is active and, after
you have performed scheduled maintenance,

Disabling
you want to reset the reminder prompt, enter

Configure Mode.
With Configure Mode selected, scroll to MNT

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

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

Initial 90 Day/250 Deadman Hours (HD) Maintenance
Initial 90 Day/250 Deadman Hours (HD)

Maintenance
Perform the following maintenance tasks 90 days or 250 HD after the lift truck was put into service,
whichever comes first.
Component What To Do
Drive Units Change fluid.
Hydraulic Reservoir Change fluid and filter.
Check/adjust roller bearings on trucks with TT masts S/N 50501 up. Refer to
Mast
Roller Bearing (Puck) Adjustment - TT Mast - S/N 50501 Up on page 7-106.
Power Amplifiers Torque power cable terminal bolts to 95 to 105 in. lb. (10.7 to 11.8 Nm).

Every 180 Days or 500 HD

NOTE: For Severe or Extreme operating condition service intervals, refer to Table 4-1, “Maintenance
Frequency,” on page 4-2.
Perform the following maintenance tasks every 180 days or 500 HD, whichever comes first.
Component Task
Check the weight stamped on the battery in the lift truck against the minimum
and maximum allowable weights on the spec for the lift truck. Report any lift
trucks that are running with batteries under the minimum or over the maximum
Battery
allowable weight. Inspect all battery connectors and leads for damage and cuts in
protective coatings. Make sure battery gates are in place and not damaged. Make
sure the battery has no more than 0.5 in. (13 mm) free play in any direction.
In an open area, measure stopping distance. Traveling 2 to 3 mph (3.2 to

4.8 km/h) empty, push the EPO switch; the empty lift truck should stop within 2
to 4 feet (0.6 to 1.2 m). During normal operation, with a rated load and traveling
at top speed, the lift truck should stop within approx. one and one-half truck
lengths. Stopping distance depends on the load, floor, and tire condition.
Examine for signs of oil on the friction disc. If oil is present, disassemble brake,
Brakes
clean rotor, and replace pads.
Measure for correct gap: Check the gap between the armature disc and the brake
coil. The gap should measure between 0.008 and 0.016 in. (0.2 and 0.4 mm). If
gap exceeds 0.016 in. (0.4 mm), remove and disassemble the brake assembly to
check components. Failure to keep brakes adjusted causes premature disc and
rotor wear and excessive motor heat. Refer to Brakes on page 7-46.
Inspect contactor tips for burnt or pitted surfaces. See Contactor Tip Inspection
on page 4-10. Failure to replace the tips may prevent the contactor from opening
Contactors or closing, causing unscheduled downtime. With the key switch OFF and the
battery disconnected, check the plunger for smooth operation with no binding. If
binding occurs, the lift truck may malfunction or exhibit intermittent fault codes.
Verify lift/lower function is smooth and controllable. Verify travel function is

smooth and responsive through full range of motion. Check for play in the center
Control Handle
position of lift or travel control; repair/replace control handle if necessary. Verify
function of all switches. Make sure nylon insert is in the lift knob set screw hole.
The deadman pedal must operate smoothly with no binding. Check for correct
Deadman Pedal
activation and deactivation of the deadman switch.
Beneath deadman pedal and in battery compartment - make sure the drain holes
Drain Holes
are not blocked by any debris.
Check oil level. See Adding Oil on page 7-35. Inspect for leaks. Check drive axle
Drive Units
for play.
Inspect all power cables for nicks or cuts. Replace any cable that is damaged or
shows signs of excessive heat. Failure to do so causes intermittent system
Electrical Cables shutdowns and/or electronic failures. Check the tension of the over-the-mast
pulley cables. Set tension so the cables just stay on the pulleys. Higher tension
causes premature failure.

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

Frame Checks
but not limited to, main frame and tractor.
Check bolt torque of major components (for example: motors, pumps, brake,
drive units, manifolds, mast-to-tractor mounting bolts, overhead guard mounting
Hardware bolts). On trucks equipped with the ComfortStance™ floor, check torque of pivot
block, tie rod, and strut mounting hardware. Tighten any loose hardware.
Replace any broken or missing hardware. Refer to “Appendix” for torque values.
Horn Check that horn sounds when activated. Check mounting bracket insulators.
Inspect all hydraulic hoses for leaks, nicks, cuts, chafing, and bulges. Replace
bad hoses as soon as possible. Inspect all fittings for leaks. Repair any leaks
Hydraulic Hoses
immediately. Inspect over-the-mast hoses for correct tension. Make sure
over-the-mast pulleys spin freely and show no signs of wear.
Hydraulic Reservoir Check fluid level.
Check adjustment. Inspect for excessive stretch or wear (Tool P/N 939-10606).
Lift Chains
Lubricate.
Lubricate steer wheel assembly, steer wheel axle, steer chain, sideshift carriage,
Lubrication
and fork position pins.
Wipe old grease off mast uprights and apply new grease. Examine mast bearings.
Inspect rails for abnormal wear, metal flakes, or shavings. Each pair of load
rollers should be shimmed so that the total side to side clearance in no greater
Mast
1/16 in. (1.5 mm) at the tightest point throughout the travel of the member. Pry
between the upright and load roller so that the opposite load roller is tight
against the upright. Measure the clearance for the pair of rollers.
AC - Check the cable lugs to make sure they are tight to the terminal studs.
Torque the inside and outside nut to the values listed on page 7-56. Replace any
cable that shows signs of excessive heat. Check sensor wires for sound
connection and condition. Blow out the inside of the motor with compressed air.
DC - Visually inspect brushes for excessive heat (discoloration of the pigtails). If

excessive heat is evident, inspect the armature circuit for loose connections.
Check condition of commutator per photos starting on page 5-14. Find the
Motors shortest brush in the holder. Remove the brush and check the overall dimension
per Table 7-6 on page 7-58. Inspect the brush for even wear over the full surface
of the brush. If the brush is not contacting the complete surface, replace the
brushes. Inspect the brush rigging for damage or loose brush holders. Make sure
the connections on the brush leads are tight. Check brush spring tension. Blow
out the inside of the motor with compressed air. Blow out impeller and cooling
fins. Check the cable lugs to make sure they are tight to the terminal studs.
Torque the inside and outside nut to the values listed on page 7-56. Replace any
cable that shows signs of excessive heat.

Component Task
Overhead Guard Inspect guard for physical damage. If structurally damaged, replace the guard.
Power Amplifiers Check torque on power amplifier connections.
Check for electrical shorts to frame. Refer to Shorts to Frame Test on page 5-3.
Shorts to Frame
Wipe compartments clean.
Lift-Tek ® Carriage - Check for loose or missing hardware, worn or damaged hoses
and hydraulic leaks. Inspect rollers and wear pads. If any wear pad surface is
worn to less than 0.1 in. (2.5 mm), replace all wear pads. Lubricate rollers. Refer
Sideshift/Fork to ISS Inspection on page 7-85.
Positioner Cascade™ Carriage - Check for loose or missing hardware, worn or damaged
hoses and hydraulic leaks. Tighten lower mounting hook capscrews to 165 ft. lb.
(225 Nm). Grease fork bearings, fork cylinder rod anchors, upper bearings and
lower flat bearings. Refer to Inspection on page 7-91.
Make sure static straps are not worn or broken. Clean debris from straps. Check
resistance of resistor in standoff. Resistance must measure between 200 and
Static Straps
250K ohm. EE Labeled lift trucks require a phosphor bronze static strap; do not
use steel braided cable on EE labeled lift trucks.
Check that steering system function is smooth and responsive. Inspect pivot
points and bearings in the steering assembly. Inspect the teeth on the steering
gear for wear. Inspect the steer chain for correct adjustment. Chain should flex
Steering
approximately 1/8 to 1/4 in. (1.6 to 3.2 mm). Inspect the wheel axle and bearings
for excessive wear. Check gap on steering prox switch [should be 0.060 +0.04/
–0.03 in. (1.5 +1.0/–0.7 mm)]. Inspect hoses and hydraulic motor for leaks.
Switches Check all switches for correct operation. Adjust as needed.
Make sure ventilation slots in the tractor frame/cover are clear of obstructions
Ventilation Slots
and debris.
Warning Decals Replace any illegible or damaged decals.
Wheels and Tires Examine for bond failure, chunking, and excessive or uneven wear.


Perform all 180 day/500 HD maintenance tasks plus the following every 360 Days or 2000 HD
Component What To Do
Drive Units Change fluid.
Hydraulic Reservoir Change fluid and filter.
Separate pump and motor. Apply lubricant (P/N 1223184) to the splines. Refer to
Pump Couplings
Lift Motor on page 7-64.

Contactor Tip Inspection
Contactor Tip Inspection

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

Lift Chains
Lift Chains
Inspection
Make sure chains are not damaged. Check the
chain for wear using a Chain Gauge
(P/N 939-10606).
Condition-Cause Chart
Condition Cause Maintenance Procedure
Use a chain gauge or lay the chain on a flat surface

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

Rust and corrosion Lubricate chain frequently.
new truck chains
Infrequent Oiling
Rust
Cracked plates Replace the chain.
Corrosion
Chain Fatigue
Bent pins or plates Replace the chain.

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

Fork Inspection
Fork Inspection 2. Multiply these numbers by 0.005 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. (51 mm) away from the heel of
• Tape Measure or Ruler
the fork. Measure any deviation and
• 24 in. Framing Square compare to the number calculated in
• 4 ft. Level step 2 for length of blade.
4. Place a straight edge on the shank of the
Do the following when performing Scheduled fork, 2 in. (51 mm) away from the heel of
Maintenance. the fork. Measure any deviation and
compare to the number calculated in
Surface Inspection step 2 for height of 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.
Straightness of Blade and Figure 4-3. Fork Angle
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
Shank Blade
Blade

Fork Tip Height
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 forks on the carriage, measure the 6. Compare this measurement to the
length of the blade. See Figure 4-2. maximum deviation.
• For forks 42 in. (106.7 cm) or less, max. 7. If the maximum deviation number is
deviation is 0.25 in. (6.3 mm). exceeded, remove the fork from service.
• If length of fork is greater than 42 in.
(106.7 cm), multiply length of blade by Wear
0.03.
Blade length _____in. x 0.03 = _____in.
Fork Blade and Shank
This is the maximum deviation.
2. Elevate forks approx. 4 ft. (1.2 m) off the 1. Remove the forks from the carriage.
floor. 2. Approximately half way up the shank, set
3. Place a 4 ft. level across the tips of the the front teeth of the jaws of the caliper on
forks. See Figure 4-4. the shank. Make sure the caliper is held
square across the shank to get an
4. Raise one end of the level to make it level.
accurate reading. The caliper is now set to
See Figure 4-4.
measure fork blade wear. Carefully remove
5. Measure the distance from the tip of the the caliper from the shank. See Figure 4-5.
fork. See Figure 4-4.

Wear
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 Fork Hooks
the fork.
1. Remove the forks from the carriage.
4. Place the caliper over the flanks of the fork
2. Determine the fork mounting class.
arm blade at this 2 in. (50 mm) point. See
Figure 4-6. a. Measure the height of the carriage or
the distance between the hooks. See
Figure 4-6. Measuring Fork Blade Wear 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

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

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

Wear
4. Slide the extruded edge up into the hook

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.

Wear

Models 4150/4250 Maintenance Manual Section 5. Troubleshooting
Section 5. Troubleshooting

Section 5. Troubleshooting Models 4150/4250 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 • Before replacing an electrical component,
disconnect and clean all jack/pin
connectors on the component(s) with
contact cleaner (P/N 996-600/CC2).
Reconnect and retest truck.
Block the lift truck so that the drive tires
are off the floor whenever a
troubleshooting procedure requires Shorts to Frame
turning the key switch ON. This prevents
accidents caused by unexpected lift Shorts to frame is an industry term for
truck travel. unintentional current leakage paths between
normally isolated electrical circuits and their
Unless otherwise directed, disconnect metal enclosures.
the battery connector when you check
electrical circuits or components with an Shorts to frame may be metallic connections,
ohmmeter. Electrical current can damage such as a wire conductor contacting metal
an ohmmeter. through worn insulation. More often, shorts to
frame are resistive “leakage” paths caused by
Before removing a power amplifier, contamination and/or moisture.
discharge the amplifier’s internal
capacitor by jumpering the + and – These leakage paths can result in unwanted
terminals with a 100 ohm 25W resistor. electrical noise on the metallic lift truck
structure and can cause incorrect operation.
• Many problems can be caused by a dirty
battery. Make sure the battery is clean. Shorts to frame are caused by:
Refer to Battery Exterior Cleaning on page • Accumulation of dirt
7-53.
• Battery electrolyte leakage
• Save time and trouble by looking for
• Motor brush dust
simple causes first.
• Motor brush leads touching the housing
• Use a Digital MultiMeter (DMM), such as a
Fluke meter, for all measurements. Analog • Breakdown in insulation
meters can give inaccurate readings and • Bare wires
load down sensitive electronic circuits
• Pinched wiring harness
enough to cause failure. Make sure meter
cables are connected to the correct meter • Incorrect mounting of circuit cards
jacks and that the correct function and
scale are selected. Shorts to frame can occur at numerous
locations on a lift truck, including:
• Printed circuit boards are conformal
coated. Make sure meter leads make a • Batteries
good electrical connection with test points. • Motors
• When measuring voltage, connect the • Cables, wiring, and harnesses
positive meter lead to the connector or
• Heatsinks
probe point marked (+) in the test.
Connect the negative meter lead to the • Bus bars
connector or probe point marked (–). • Solenoids

Shorts to Frame
• Contactors 4. With the battery disconnected (or removed

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

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

Battery State-of-Charge
to frame in the travel circuit, travel must Battery State-of-Charge

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

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

below 95% charge will not change the
Operator Display. Older batteries or
applications providing inadequate
charging time could require a lower
configured value for BSOC since older
batteries might be unable to reach a
higher percent charge. Therefore, some
batteries could require BSOC configured
as low as 55% before lift cutout resets and
the Operator Display shows the charge of
the replacement battery.
Lift Cutout Adjustment

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

Fuses
Fuses
Test/Inspection
Examine the fuse for signs of overheating,

discoloration, cracking, or other physical
damage. Replace as necessary.
To test a fuse, remove it from the lift truck. The

resistance should be less than 1 ohm.
Table 5-1 lists the fuses for a lift truck with all
available options. Not all trucks will have all of
the fuses listed.
Table 5-1. Fuse Chart

Fuse Function Location Amps
FU1 Power Fuse for Steer Motor 100
FU2 Power Fuse for Traction Power Amplifiers Contactor Panel 750
FU3 Power Fuse for Lift Pump Motor 500
FU5 Control Fuse for Vehicle Manager B+ 15
FU6 Control Fuse for Vehicle Manager B– Fuse/Relay Card 15
FU7 Control Fuse for Aux Power B+ (See page 5-10.) 15/5
FU8 Control Fuse for Aux Power B– 15/5
FU11 Control Fuse for Strobe and Warning Light (Optional) In-line Wiring 1.5
FU12 Control Fuse for Operator’s Cooling Fan (Optional) In-line Wiring 1.5
FU17 Control Fuse for OCSS (Optional) Photo-Eye Heater In-line Wiring 2
FU35 iPORT Supplier Wireless Module In-line Wiring 2

Electrical Connector Locations
Electrical Connector Locations 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
Terminology 1, 2, and 3 raised ridges at pin numbers 1, 2,
and 3. See Figure 5-1.
The term “connector JPx” means a mated
connector having two connector halves. One Figure 5-1. Molex Jack and Pin Connector
half has male connectors, or pins (P); the other
half has female connectors, or jacks (J). Pin Identifier Lines
(black lines added for clarity)
When you disconnect a mated JP connector,
you have two connector halves. The individual
connector halves are specified by “Jx” and “Px.”
If you cannot find a connector designated “Jx”
or “Px,” look for “JPx,” and vice versa.
For example, connector JP1 is the mated main

Operator Display connector. J1 represents the
Jack Pins
jack connections (in the harness). P1 represents
the pin connections (on the Operator Display).
Table 5-2. Electrical Connector Locations and Functions
Connector Function or Routing Location

H2 Travel Alarm Forward of Battery Connector
JPA Ambient Temperature Sensor Forward of Fuse/Relay Card
JPB1 Power Amp Fans Near Power Amps
JPB3 Left Side Brake Near Left Traction Motor
JPB4 Right Side Brake Near Right Traction Motor
JPC3 USB
JPC4 Optional Lever #1 Connector
JPC6 Display Inputs and Outputs
JPC9 FlashWare
JPC10 CAN Digital Inputs/Outputs
JPC12 Handle
JPC12A Lever Option Harness Vehicle Manager
JPC12B Lever Option Harness
JPC14 Bus+ and Bus– CAN Communications
JPC18 Some Coils, Horn, and Travel Alarm
JPC20 Proportional Coils
JPC22 Digital Inputs
JPC24 Inputs from Display, Battery, and Temp Sensor
JPD1 Display
Operator Display
JPD2 Display
JPDS Deadman Pedal Left Side of Operator Compartment

Connector Function or Routing Location

JPF1 B– Aux Power, B+ Power Amp (B+K3)
JPF2 B+ Connector (B+K1, B+K2, B+K4)
Fuse/Relay Card
JPF3 B– Connector on Fuse Relay Card
JPF4 Key Switch, EPO, Battery Sense
JPH1 Control Handle Control Handle
JPH2 Mast mounted solenoids Mast
JPL1 Lift Power Amp Lift Power Amp
JPL2 Lift Encoder
Near Lift Motor
JPL3 Lift Motor Temperature Sensor
JPL4AC Lift Power Contactor Configuration (Model 4250)
Near Fuse/Relay Card
JPL4DC Lift Power Contactor Configuration (Model 4150)
JPS1 Contactor Panel Interface Near Contactor Panel
JPS2 Steering Position Sensor Near Steering Hub
JPS5 High Speed Limit Option
JPS6 Lift Limit Switch Option
Forward of Fuse/Relay Card
JPS13 Right Battery Gate Switch
JPS14 Left Battery Gate Switch
JPT1 Mast Tilt Sensing Option Near Lift Motor
JPTL1 Left Traction Amp Left Traction Amp
JPTL2 Left Traction Motor Encoder
Near Left Traction Motor
JPTL3 Left Traction Motor Temperature Sensor
JPTR1 Right Traction Amp Right Traction Amp
JPTR2 Right Traction Motor Encoder
Near Right Traction Motor
JPTR3 Right Traction Motor Temperature Sensor
JPW1 OCSS - Upper Left Emitter Near Steering Hub
JPW2 OCSS - Upper Right Detector
Right Side of Operator Compartment
JPW3 OCSS - Lower Right Emitter
JPW4 OCSS - Lower Left Detector Near Steering Hub
JPW5 Warning Light Near Warning Light
JPWL1
JPWL2
JPWL3 Working Light Option Near Working Light
JPWL4
JPWL5
JPY1 Weight Pressure Sensor Option Near Hydraulic Manifold
TS1 Terminal Strip for Optional Equipment To Right of Control Handle

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

Fuse/Relay Card Connectors

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

necessary.
Troubleshooting
Refer to Fuse/Relay Card Connectors on
page 5-10 for Fuse/Relay Card component and
connector location information.
4. Measure the resistance between circuits 2
Fuses and 3. Welded tips will have a resistance
less than 0.5 ohm. Otherwise, there
Fuses for system power (FU5 and 6) and Aux should be an open circuit. Replace as
power (FU7 and 8) are present on the necessary.
Fuse/Relay Card. Refer to page 5-6 for
inspection and testing of fuses. Removal and Replacement
Relays Remove relays by carefully cutting the strap

securing them to the socket. Pull relay out
straight to avoid bending or damaging the pins.
Relays should be checked when indicated by a
Install relay by aligning pins with the
test or when troubleshooting any of the
corresponding sockets. Firmly press the relay
symptoms listed in the following table.
straight into the socket until fully seated.
Secure the relay with a new strap.
Relay Circuit Possible Symptoms
Key-ON Key-ON options do not
K1
Aux Power power up with truck. Capacitor and FGND
Subsystem Contactors, solenoids,
Problems with the filter capacitors (C1, C2, or
K2 Power brake, horn, or fans do not
operate.
C3) are most frequently observed on trucks
equipped with an RF scanner unit. Visually
Amp Amps do not power up or inspect the capacitors for any sign of damage.
*K3 Power have stopped
The capacitors may be physically different from
communicating.
the one pictured. Inspect mounting screw in the
Keep Alive Keep-alive accessories for upper left mounting hole of the Fuse/Relay
K4 Power Cold Storage do not Card (marked FGND). If necessary, clean or
function.
replace this screw to ensure a solid connection
*B+ power for amplifiers may come from K2 to the frame.
(JPF1-6) or K3 (JPF1-3). Refer to schematic.
Inspection
Visually inspect relay and socket for

discoloration, melting, or other signs of heating.
Replace as necessary. If socket is melted or
damaged, replace the Fuse/Relay Card.
Test
1. Perform Test O32 - Toggle Relay Enable
(page 6-110).
2. Turn the key switch OFF and remove relay
(refer to Removal and Replacement).
3. Measure the resistance across pins 1-A
and 1-B. Resistance should measure

Fuse/Relay Card Troubleshooting
To test, measure the resistance from the FGND Inrush Protection

screw to any piece of bare metal on the frame
with a DMM. Resistance should be less than A resettable fuse protects the VM battery sense
0.5 ohm. circuit and can be reset by turning the truck
OFF momentarily. Opening of the fuse will
frequently manifest as an FH code along with
other F-series codes.
NOTE: This test should be performed after the
truck has had a chance to come to room
temperature.
To test, remove JPF4 from the Fuse/Relay

Card. Measure the resistance from PF4-1 to
PF4-7. Resistance should be approximately
1.3 ohms. Replace the Fuse/Relay Card as
necessary.
Input Diodes
NOTE: Remove connectors JP1 thru JP4 before
performing this test.
To test the relay coil input diodes, locate CR5

and CR6 on the Fuse/Relay Card. Using a DMM
set to the “diode” function, measure the voltage
by putting the black probe on the banded (right)
side of the diode and the red probe on the
non-banded (left) side. Voltage should be
approximately 0.5V across each diode. An open
circuit will be displayed if the diodes are tested
in the reverse direction. Replace the Fuse/Relay
Card as necessary.

DC Motors
DC Motors The commutator must be smooth and clean to

provide maximum brush wear. When
commutators are not correctly maintained,
Types of DC Motors carbon dust can collect in the grooves between
the segments. This can lead to a short circuit in
There are two primary types of DC Motors (refer
the armature.
to Figure 5-2):
• A series-wound motor has only two Remove the brushes from their box. Inspect the
external connections because the contact surface and brush length. If brush
armature and field windings are connected surface has grooves or pit marks, it indicates a
internally. burr on the commutator surface.
• A permanent magnet motor has two
external connections. The field is produced Good commutation is indicated by a dark
by an internal magnet. brown polished commutator and an evenly
polished brush wearing surface. See Table 5-3,
NOTE: Field connections may be labeled A or S. “Commutator Surfaces.”
Series wound motor field connections
may be labeled D. If the commutator appears rough, pitted, or has
signs of burning or heavy arcing between the
Figure 5-2. Motor Circuits
commutator bars, remove the motor for
Series-Wound Motor servicing.
Permanent Magnet
S/D Motor
MS+
Servicing
A2
Some conditions identified in Table 5-3 may be
MS resolved by cleaning the commutator with a
special polishing stone. Polishing the
MP commutator should only be attempted for these
A1
MS– specified conditions. Refer to Polishing the
Commutator on page 7-58.
A
Some conditions can be resolved by recutting
Inspection the commutator on a lathe. This requires
special equipment and training and should only
Inspect commutator for surface condition and be performed at a qualified DC motor repair
high mica. Most armatures have the mica facility.
undercut. If the armature on your motor does
not, do not attempt to cut it.
Figure 5-3. Mica Undercutting

Mica Segment
NORMAL
UNDERCUT
High Mica
HIGH MICA

DC Motors
Table 5-3. Commutator Surfaces
Condition Probable Cause Commutator Surface
Good Condition-Light Film Uniform coloring indicates satisfactory operation

of machine and brushes. Acceptable film color
may vary from light to dark due to film thickness.
Satisfactory This condition can appear in alternating bars as

Condition-Light and Dark shown or every 3rd or 4th bar. This is caused by
Pattern imbalances in the windings or other motor
variances and is not an indication of commutator
problems. The motor should have no issues
running, however this condition may indicate a
need for more frequent inspections.
Unsatisfactory Threading or streaked film on the commutator

Condition-Streaky Film surface. May also notice rattling or loud
with No Commutator Wear operation. Frequently due to incorrect brush
grade. Environmental conditions such as freezer
operation or low humidity can be a contributing
factor. May be repaired with a polishing stone if
caught soon enough. Refer to Polishing the
Commutator on page 7-58.
Unsatisfactory Patchy colors of varying densities and shape.

Condition-Uneven Film Generally due to unclean operating conditions
and does not indicate damage to the commutator.
Clean commutator with a polishing stone (refer to
Polishing the Commutator on page 7-58) and
compressed air. Consider more frequent
scheduled maintenance intervals.
Unsatisfactory Condition- Dark areas can be isolated or regular. Indicates

Film with Dark Areas the commutator is out-of-round. Continued use
may result in failure and damage to other
systems. Motor should be replaced or recut at a
qualified repair facility.
Unsatisfactory Bars are low on entry and leaving edges causing

Condition-Example of Poor brushes to rub on the middle of the bars.
Commutator Machining Continued use may result in failure and damage
to other systems. Motor should be replaced or
recut at a qualified repair facility. Consider more
frequent scheduled maintenance intervals.
Unsatisfactory Bars are low in the middle causing brushes to

Condition-Example of Poor ride on entry and leaving bar edges. Continued
Commutator Machining use may result in failure and damage to other
systems. Motor should be replaced or recut at a
qualified repair facility. Consider more frequent
scheduled maintenance intervals.

DC Motors
Condition Probable Cause Commutator Surface
Unsatisfactory This is a further development of the third

Condition-Streaky Film example. Earlier corrective action should have
with Commutator Wear been taken. Continued use may result in failure
and damage to other systems. Motor should be
replaced or recut at a qualified repair facility.
Consider more frequent scheduled maintenance
intervals.
Unsatisfactory Darkening of commutator in sequences two pole

Condition-Double Pole pitches apart. May result from an armature fault
Pitch or some other fault. Continued use may result in
failure and damage to other systems. Motor
should be replaced or recut at a qualified repair
facility.
Unsatisfactory May result from storage of machine with brushes

Condition-Brush Contact in position for long periods. May also result from
Mark operation in prolonged stall conditions. Storage
marks are easily removed with a polishing stone
(refer to Polishing the Commutator on page 7-58).
Stall marks should be cleaned and inspected for
damage or shorts. Motor should be replaced if
damage has occurred.
Unsatisfactory Condition is caused by high mica in every slot

Condition-Bar Edge and can be caused by incorrect or excessive
Burning-Cause High Mica stoning. Same effect can occur on one bar only.
May also notice chattering or loud operation.
Continued operation will result in increased
brush wear and may result in commutator
damage. Motor should be replaced or recut at a
Unsatisfactory Due to sparking under brush. This is caused by

Condition-Small Bright overloaded machines or low brush pressure.
Spots Check brush spring tension (refer to Motor Brush
Spring Tension Inspection on page 7-58). If not
corrected, will result in damage to commutator.
May be repaired with a polishing stone (refer to
Polishing the Commutator on page 7-58) if
caught early and no scoring has occurred. If
damaged, motor should be replaced or recut at a
Open Circuit Motor Test To test a motor for an open circuit:

1. Isolate the motor from the lift truck circuit
An open circuit is an electrical circuit within the by removing the power cables. Use two
motor that is broken. This can be caused by: wrenches to avoid twisting the terminal
• bad brushes or brush springs stud.
• a broken wire in the field or armature 2. With the motor at room temperature,
winding connect the leads of a digital ohmmeter to
the + and – terminals of the motor. The
• loose or bad connections
meter should read less than 1 ohm of
resistance.

AC Motors
3. If the meter indicates high resistance, Short Circuited Winding

check the condition of the brushes before
replacing the motor. A short circuited winding is one where the
NOTE: If you find an open circuit in a insulation on the field or armature has broken
series-wound motor, the motor must be down at two or more points. The breakdown
disassembled by a motor rebuilding creates a low resistance path that allows
facility to isolate the problem to the field current to flow from one turn of the coil to
or armature circuit. another adjacent coil turn, without actually
flowing through the coil wire. The result is a
decrease in total resistance of the motor
Grounded Motor Test winding and an increase in the current flow.
The severity of the short circuit depends on its
In a grounded motor, an electrical circuit exists location.
between the current-carrying conductors and
the motor housing. This can be caused either by A shorted motor may be indicated by:
direct contact or through conductive foreign
material. • slow or sluggish operation
• running faster than normal
The ground may be caused by: • overheating
• insulation breakdown • blowing a power fuse
• brush leads touching the motor housing • burning of brush wires
• build-up of carbon dust or other materials • severe burning or discoloration on one or
more commutator segments every 90° of
To test for a grounded motor: rotation
1. Isolate the motor from the lift truck circuit
by removing the power cables. Use two These symptoms can be caused by problems
wrenches to avoid twisting the terminal other than the motor itself, such as binding in
studs. an attached pump, hose, or solenoid valve.
2. Attach one lead of a megohm meter or
digital ohmmeter to a motor terminal and Testing a motor for short circuited windings
the other lead to an unpainted surface of requires special equipment at a motor
the motor housing. Set the ohmmeter to rebuilding facility.
the highest scale.
3. If the ohmmeter indicates resistance of AC Motors
less than 100,000 ohms, the motor is
grounded. Clean, repair, or replace the AC motors used on this lift truck are brushless,
motor as necessary. 3-phase, internally delta-connected, variable
speed motors.
Short Circuited Armature
The AC motor has a rotor (in place of the DC
armature) and a stator (in place of the DC field).
A short circuit in the armature causes heat that
There is no electrical connection to the rotor;
could result in burning of the:
current is induced in the rotor. The stator has
• armature coil three windings staggered 120° apart, and three
• brush wires external connections labeled U, V, and W. See
Figure 5-4.
• commutator segments

AC Motors
Figure 5-4. AC Motor Circuitry
AC
3φ
V W
Open Winding
If the AC motor fails with an open winding, the

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

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

motor moves erratically, as if hunting/
searching, and there is a high-pitched sound.
Use a clamping ammeter to measure current in

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

Communication Error Code Troubleshooting
Communication Error Code

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

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

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

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

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

Plugging
If lift truck is equipped with optional travel

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

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

Is Turned ON
Troubleshoot per code on display using Test I23

- CAN Communication Test (page 6-82).

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

Symptom Tables: Hydraulic Functions
Symptom Tables:
Hydraulic Functions
NOTE: If it is determined that a component
failed as a result of hydraulic fluid
contamination, replace the failed
component and flush, fill, and bleed the
hydraulic system.
Intermittent Lift/Lower
Possible Cause Action
Bad wiring Check wiring harnesses between valves and VM.
Hydraulic contamination (can Replace damaged component and flush, fill, and bleed the
cause binding proportional hydraulic system.
valve or load holding solenoid)
Lift Function
No Lift - Lift motor does not run
Bad optional lift limit switch Run “Test I05 - Lift Limit (S12)”.
No Lift - Lift motor runs

Priority Bypass Solenoid Run “Test A81 - Priority Bypass Current (SOL4)”. Check for
(SOL4) not energizing contamination. If contamination is present, flush, fill, and bleed
the hydraulic system.
Dump Solenoid (SOL3) not Run “Test O09 - Lift Relief Solenoid (SOL3)”. Check for
energizing contamination. If contamination is present, flush, fill, and bleed
Lift/Lower Solenoid (SOL2) Run “Test A34 - Lift/Lower Current (SOL2)”. Check for
open contamination. If contamination is present, flush, fill, and bleed
Bad Lift Pump Replace Lift Pump.
Slow Lift - Lift motor runs

Bad battery Adjust lift cutout as necessary. See Lift Cutout Adjustment on
page 5-5. Replace battery with fully-charged battery. Test battery
for bad cells.
Bad proportional lift/lower Inspect for binding. Run “Test O12 - Lift/Lower Solenoid (SOL2)”.
valve
Relief valve SOL3 stuck open Test system pressure. Check for contamination. If contamination is
present, replace valve. Flush, fill, and bleed the hydraulic system.
Run “Test O09 - Lift Relief Solenoid (SOL3)”.

Lower Function

Plugged or malfunctioning Check for contamination in valve. If contamination is present,
flow control valve in lift replace the flow control valves. Flush, fill, and bleed the hydraulic
cylinder system.
Bad lift pump Test system pressure.
Binding in the mast Inspect the mast and bearings for signs of binding.
Bad lift motor 4150 DC Lift Trucks: Test lift motor. See DC Motors on page 5-13.
Check amp draw.
4250 AC Lift Trucks: Run “Test O28 - Ramp Lift Motor (AC Lift)”
and/or “Test I20 - Lift RPM (AC Lift only)”.
Bad lift motor encoder Run “Test I20 - Lift RPM (AC Lift only)”.
Unable to Pick Up a Load

Battery problems Adjust lift cutout as necessary.
Replace battery with fully-charged battery.
Test battery for bad cells. See Battery Procedures on page 7-52.
Incorrect lift pressure Check and adjust lift pressure setting.
adjustment
Bad lift pump Test system pressure.
Bad lift motor 4150 DC Lift Trucks: Test lift motor. See DC Motors on page 5-13.
Check amp draw.
4250 AC Lift Trucks: Run “Test O28 - Ramp Lift Motor (AC Lift)”
and/or “Test I20 - Lift RPM (AC Lift only)”.
Binding in the mast Inspect mast and bearings for signs of binding.
Lower Function
Slow Lower
Binding proportional valve Check valve operation. Run “Test O12 - Lift/Lower Solenoid
(SOL2)”.
Binding in the mast Inspect the mast and bearings for signs of binding.
Plugged or malfunctioning Check for contamination in valve. If contamination is present,
flow control valve flush, fill, and bleed the hydraulic system. If no contamination is
found, replace the flow control valves in the main lift cylinders.
Intermittent Lower
Bad load hold solenoid Run “Test O11 - Load Hold Solenoid (SOL1)”.
Binding proportional valve Check valve operation. Run “Test O12 - Lift/Lower Solenoid
(SOL2)”.
Plugged or malfunctioning If still slow, remove and inspect. Check for contamination in valve.
flow control valve If contamination is present, flush, fill, and bleed the hydraulic
system. If no contamination is found, replace the flow control
valves in the main lift cylinders.

Auxiliary Functions
Load Drifting/Settling
Load holding solenoid Run “Test O11 - Load Hold Solenoid (SOL1)”. Check for
contamination in valve. If contamination is present, replace relief
valve. Flush, fill, and bleed the hydraulic system.
Auxiliary Functions
No Aux Functions
SOL4 not functioning Perform “Test O36 - Priority Bypass Solenoid (SOL4)”.
correctly
Aux Functions in One Direction Only

SOL6 not functioning Perform “Test O04 - Aux. Direction Solenoid (SOL6)”.
correctly
No Sideshift
No input Perform “Test A73 - Sideshift Right (S9)” and “Test A74 - Sideshift
Left (S8)” or “Test A74 - Sideshift Left/Right (SW4) (Optional
Handle)”.
SOL9L/9R not functioning Perform “Test O08 - Sideshift Solenoid (SOL9L, SOL9R)”.
correctly
Configuration Make sure Sideshift is enabled in FlashWare. Check the selected
percentage for Sideshift speed. Refer to Maintenance Mode on
page 3-18.
No Tilt
No input Perform “Test A71 - Tilt Down (S7)” and “Test A72 - Tilt Up (S6)”, or
“Test A72 - Tilt Up/Down (SW4) (Optional Handle)”.
SOL10 not functioning Perform “Test O07 - Tilt Solenoid (SOL10)”.
correctly
Unrequested Tilt
SOL10 stuck ON Perform “Test O07 - Tilt Solenoid (SOL10)”.

Symptom Tables: Drive Units
Symptom Tables: Drive

Units
See Drive Units on page 7-34 for standard drive
unit repair procedures.
Oil Leaks
Damaged sealing rings Replace sealing rings, bearing shims, and drive
shaft bearings, if needed.
Worn or damaged drive shaft Replace sealing rings, bearing shims, drive shaft
bearings, and drive shaft.
Housing/cover joint Reseal.
Worn or damaged housing Replace drive unit.
Drive Wheel Wobbles

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

Symptom Tables: Travel Functions
Symptom Tables: Travel

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

Sluggish or No Steering
Sluggish or No Steering
Pump Check working pressure (may need to install fitting to access and
test pressure). Working pressure should be approximately 1000 psi
(6895 kPa).
Pressure relief set too low Check relief (bypass) pressure (may need to install fitting to access
and test pressure). Relief pressure should be 1550 psi (12410 kPa).
If necessary, adjust relief pressure (relief pressure adjustment
screw is located on steering valve - under plastic plug).
Pressure Test Fitting Relief Pressure Adjustment Screw

(under plastic plug)
Motor Check amperage, inspect brushes and holders, and motor cables.
Mechanical Check steer chain, pump coupling, and steerable wheel bearings.

Symptom Tables: Electrical Symptoms
Symptom Tables:
Electrical Symptoms
NOTE: For intermittent issues with optional
devices such as RF units, check the
Fuse/Relay Card “Capacitor and
FGND”. Refer to page 5-11.
Electrical Motors
Motor Arcing (DC Motors only)
Worn brushes or incorrect Replace brushes and brush springs.
brush tension
Partially shorted motor Replace motor.
armature or field
Rough or pitted motor Replace motor.
commutator
Motor Overheating
Dragging brake Replace brake or worn brake parts (see note). See Drive Units on
page 7-34.
Application exceeds designed Check with Service Manager to verify application.
workload -- short runs with
plugging/acceleration or
heavy-duty lifting cycles
Bad battery Check voltage, both open circuit and under load. Replace with
fully-charged good battery if necessary.
Incorrect BSOC Cutout value Check battery specific gravity at cutout, after battery has
stabilized. Compare to battery manufacturer specifications for
discharged battery. Adjust BSOC Cutout as needed.
Cable, terminal, or wiring Replace wiring or cables as necessary.
problems. Look for discolored Check cable connection torque.
terminals, loose or damaged
crimps
Worn, damaged, or bad Inspect motor brushes.
brushes or springs (DC Check brush spring tension.
Motors only)
Binding gearbox or pump Check gearbox or pump for binding (see note for traction motors;
check amp draw for lift motor). Clean, repair/replace as necessary.
Hydraulic fluid viscosity too Replace hydraulic fluid with correct fluid. See Lubrication
high or too low Specification Chart on page A-2.
Pressure relief too high Adjust SOL3.
Note: Perform “Test A11 - Left Traction Current” and “Test A67 - Right Traction Current” with the
traction tires off the floor and the truck correctly blocked. At full travel speed, readings should be
drive unit.

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

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

Dead Lift Truck

Models 4150/4250 Maintenance Manual Section 6. Messages, Codes, and Tests
Section 6. Messages, Codes, and Tests

Summary List
Summary List
Messages
Step Off the Deadman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . 6-7
Release Control Handle to Resume Operation . . . . . . . . . . . . . . . . . .. . .. . . 6-7
Lift CutOut Pending... Low battery . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . 6-7
EPO Depressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . 6-7
Scheduled Maintenance Due . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . 6-7
Lift Cutout, Scheduled Maintenance Due . . . . . . . . . . . . . . . . . . . . . .. . .. . . 6-8
Battery Low, No Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . 6-8
Speed Limited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . 6-8
Press Bypass Switch to Continue Lifting . . . . . . . . . . . . . . . . . . . . . .. . .. . . 6-8
Release Bypass Switch to Continue Lifting . . . . . . . . . . . . . . . . . . . . .. . .. . . 6-8
Stalled, Release Control Handle to Resume Operation . . . . . . . . . . . .. . .. . . 6-9
Release Handle Button to Resume Operation . . . . . . . . . . . . . . . . . . .. . .. . . 6-9
Release Lift to Resume Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . 6-9
Release Tilt to Resume Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . 6-9
Release Side Shift to Resume Operation . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-10
Release Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-10
Press TILT BACK to Unclamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-10
Lower Mast or Tilt Back to Resume Travel and Lift . . . . . . . . . . . . . . .. . .. . 6-10
Lower Below Limit Switch To Initialize Bypass Functions . . . . . . . . . .. . .. . 6-10
Lift Stalled, Re-key to Resume Operation . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-10
Check Battery Gates/Speed Limited . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-11
Entrance Beam Blocked. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-11
Invalid Option Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-11
View SWM Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-11
Loss of Connection to the SWM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-11
Log In to Enable Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-11
Codes
Code 1H: Overheated, Allow Time to Cool. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Code 2A: Left Traction Motor Approaching Overtemp . . . . . . . . . . . . . . . . . . 6-12
Code 2E: Left Traction Motor Temp Sensor Out-of-Range . . . . . . . . . . . . . . . 6-12
Code 2G: Phase Open on Left Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Code 2H: Failure Detected in Left Traction Motor Speed Feedback Encoder . 6-13
Code 2M: Left TPA Pre-Charge Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Code 2T: Left TPA Current Calibration Error . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Code 2U: Left TPA Overcurrent or Short Circuit . . . . . . . . . . . . . . . . . . . . . . 6-13
Code 2V: Left TPA High DC Bus Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Code 2W: Left TPA Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 2X: Left TPA Power Supply Out-of-Range. . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 2Y: Incorrect Left TPA Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 42: LPC Detected Closed When Commanded Open . . . . . . . . . . . . . . . 6-14
Code 43: LPC Detected Open When Commanded Closed . . . . . . . . . . . . . . . 6-14
Code 4B: Steer Contactor Detected Closed When Commanded Open . . . . . . 6-15
Code 4C: Steer Contactor Detected Open When Commanded Closed . . . . . . 6-15
Code 4F: TPC Detected Closed When Commanded Open . . . . . . . . . . . . . . . 6-15
Code 4G: TPC Detected Open When Commanded Closed . . . . . . . . . . . . . . . 6-15

Section 6. Messages, Codes, and Tests Models 4150/4250 Maintenance Manual
Codes
Code 4J: TPC Contactor Coil Open or Shorted TPC . . . . . . . . . . . . . . . . . . . 6-15

Code 4K: LPC Contactor Coil Open or Shorted . . . . . . . . . . . . . . . . . . . . . . . 6-15
Code 59: CAN Transmission Buffer Error. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 5A: CAN-Bus Error Overflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 5B: CAN Transmission Buffer Error . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 5F: No Communications Received by VM from Right TPA . . . . . . . . . . 6-16
Code 5G: No Communications Received by VM from Left TPA . . . . . . . . . . . 6-16
Code 5J: No Communications Received by VM from LPA . . . . . . . . . . . . . . . 6-16
Code 5M: Left TPA NMT Start Timeout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 5P: LPA NMT Start Timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 5U: Right TPA NMT Start Timeout. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 5Y: Incorrect Right TPA Installed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 61: Mast Switch Not Sensed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 6D: Pressure Sensor Output Voltage Out-of-Range . . . . . . . . . . . . . . . 6-17
Code 7A: Lift Motor Overtemp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 7E: Lift Motor Temperature Sensor Out-of-Range . . . . . . . . . . . . . . . . 6-18
Code 7F: LPA Overtemp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 7G: LPA Motor Phase Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 7H: Lift Motor Feedback Encoder Failure Detected . . . . . . . . . . . . . . . 6-18
Code 7M: LPA Failed to Precharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 7T: LPA Current Sensor Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 7U: LPA Overcurrent or Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 7V: LPA High Voltage on DC Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 7W: LPA Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 7X: LPA Power Supply Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 7Y: Incorrect LPA Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 80: Throttle Potentiometer (VR1) Voltage Out-of-Range . . . . . . . . . . . . 6-20
Code 81: Lift/Lower Potentiometer (VR2) Voltage Out-of-Range . . . . . . . . . . 6-20
Code 82: Handle Heater Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 83: Throttle Potentiometer (VR1) Out-of-Neutral . . . . . . . . . . . . . . . . . 6-20
Code 84: Brakes Inoperable - Not Applied . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Code 87: Mast Tilt Centering Pot (VR6) Out-of-Range. . . . . . . . . . . . . . . . . . 6-21
Code 88: 5V Power Supply Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code 8A: OCSS Photo Sensor Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code 8F: Lift/Lower Potentiometer Out-of-Neutral . . . . . . . . . . . . . . . . . . . . 6-21
Code 8J: Ambient Temperature Sensor Out-of-Range . . . . . . . . . . . . . . . . . 6-21
Code 8L: Brake Feedback Current Out-of-Range . . . . . . . . . . . . . . . . . . . . . 6-21
Code 8M: Internal Handle Heater Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code 8P: Tilt Potentiometer Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code 8R: Tilt Out-of-Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code 8S: Sideshift Potentiometer Out-of-Range . . . . . . . . . . . . . . . . . . . . . . 6-22
Code 8T: Sideshift Out-of-Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code 8U: Attachment Function 1 Out-of-Range . . . . . . . . . . . . . . . . . . . . . . 6-22
Code 8V: Attachment Function 1 Out-of-Neutral . . . . . . . . . . . . . . . . . . . . . 6-23
Code 8W: Attachment Function 2 Out-of-Range. . . . . . . . . . . . . . . . . . . . . . 6-23
Code 8X: Attachment Function 2 Out-of-Neutral . . . . . . . . . . . . . . . . . . . . . 6-23
Code 8Z: Drive Train Error Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code A0: Incorrect Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code A2: Software Compatibility Issue with VM and Left TPA . . . . . . . . . . . 6-24
Code A3: Software Compatibility Issue with VM and Right TPA . . . . . . . . . . 6-24
Code A4: Software Compatibility Issue with VM and LPA . . . . . . . . . . . . . . . 6-24
Code AG: Communications To/From Operator Display Failed . . . . . . . . . . . 6-24

Analog Tests
Code AH: Bad Operator Display Checksum . . . . . . . . . . . . . . . . . . . .. . . . . 6-24

Code AL: VM Battery Backed Up RAM Failed . . . . . . . . . . . . . . . . . . .. . . . . 6-24
Code AP: Left TPA Software Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-25
Code AR: Right TPA Software Fault . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-25
Code AT: LPA Software Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-25
Code EC: COP Not Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-25
Code FE: Internal VM Circuit for BSOC Not Calibrated . . . . . . . . . . .. . . . . 6-25
Code FG: +5V Reference Voltage and +12V Power Supply Failure . . . .. . . . . 6-26
Code FH: Battery Voltage Out-of-Range . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-26
Code FN: Relays Did Not Open at Power Off . . . . . . . . . . . . . . . . . . . .. . . . . 6-26
Code FT: VM Internal Software Error . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-26
Code G2: Bad Steer Position Reference Input . . . . . . . . . . . . . . . . . . .. . . . . 6-26
Code HA: Right Traction Motor Overtemp. . . . . . . . . . . . . . . . . . . . . .. . . . . 6-27
Code HE: Right Traction Motor Temperature Sensor Out-of-Range. . .. . . . . 6-27
Code HF: Right TPA Overtemp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-27
Code HG: Right Traction Motor Phase Open . . . . . . . . . . . . . . . . . . . .. . . . . 6-27
Code HH: Right Traction Motor Feedback Encoder Failure . . . . . . . . .. . . . . 6-27
Code HM: Right TPA Pre-Charge Failed . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-28
Code HT: Right TPA Current Sensor Fault . . . . . . . . . . . . . . . . . . . . .. . . . . 6-28
Code HU: Right TPA Overcurrent or Short Circuit . . . . . . . . . . . . . . .. . . . . 6-28
Code HV: Right TPA High DC Bus Voltage . . . . . . . . . . . . . . . . . . . . .. . . . . 6-28
Code HW: Right TPA Software Error . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 6-28
Code HX: Right TPA Power Supply Out-of-Range . . . . . . . . . . . . . . . .. . . . . 6-29
Code M9: Lift Limited... Installed Battery is Too Light . . . . . . . . . . . .. . . . . 6-29
Code T0: Aux Relief SOL5 Open Circuit or Constant Low . . . . . . . . . .. . . . . 6-29
Code T3: Proportional Lower SOL2 Open Circuit or Constant Low . . .. . . . . 6-29
Code T4: Priority Bypass SOL4 Open Circuit or Constant Low . . . . . .. . . . . 6-29
Code VC: Internal Error in VM Communications . . . . . . . . . . . . . . . .. . . . . 6-30
Analog Tests
Test A04 - Travel Pot (VR1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Test A05 - Lift/Lower Pot (VR2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Test A08 - Left Traction Motor Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Test A09 - Lift Motor Temp (AC Lift only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Test A10 - Left Traction Power Amp Temp . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Test A11 - Left Traction Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Test A13 - Weight Sensor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Test A14 - Ext. Supply Sense (12VDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Test A15 - Battery Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Test A19 - Lift Power Amp Temp (AC Lift only) . . . . . . . . . . . . . . . . . . . . . . . 6-41
Test A20 - Lift Current (AC Lift only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Test A22 - Traction Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Test A23 - Lift Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
Test A26 - Pot Supply (5VDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
Test A34 - Lift/Lower Current (SOL2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Test A35 - Brake Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Test A36 - Ambient Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Test A40 - Handle Heater Reference Voltage (optional) . . . . . . . . . . . . . . . . . 6-49
Test A65 - Right Traction Power Amp Temp . . . . . . . . . . . . . . . . . . . . . . . . 6-50
Test A67 - Right Traction Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
Test A68 - Right Traction Motor Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52

Input Tests
Test A69 - Mast Tilt Centering Pot (VR6) . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-53

Test A71 - Tilt Down (S7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-54
Test A72 - Tilt Up (S6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-55
Test A72 - Tilt Up/Down (SW4) (Optional Handle) . . . . . . . . . . . . . . .. . .. . 6-56
Test A73 - Sideshift Right (S9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-57
Test A74 - Sideshift Left (S8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-58
Test A74 - Sideshift Left/Right (SW4) (Optional Handle) . . . . . . . . . .. . .. . 6-59
Test A75 - Attach Fcn 1 (S4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-60
Test A75 - Attach Fcn 1 (SW3) (Optional Handle) . . . . . . . . . . . . . . .. . .. . 6-61
Test A76 - Attach Fcn 2 (S5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-62
Test A76 - Attach Fcn 2 (SW2) (Optional Handle) . . . . . . . . . . . . . . .. . .. . 6-63
Test A77 - EPO (S21) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-64
Test A80 - Aux Select Current (SOL6) . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-65
Test A81 - Priority Bypass Current (SOL4) . . . . . . . . . . . . . . . . . . . .. . .. . 6-66
Test A82 - Aux. Relief Current (SOL5) . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-67
Test A96 - BSM Curr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-68
Test A97 - BSM Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-69
Test A98 - BSM Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-70
Test A99 - H2O Snse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-71
Test A100 - BSM Comm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-72
Input Tests
Test I00 - Deadman (S2) . . . . . . . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-74
Test I02 - Mast Tilt Speed Reduction (S11) ........ . .. .. . .. . . . . . . . . . 6-75
Test I05 - Lift Limit (S12) . . . . . . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-76
Test I13 - Lift Contactor (DC Lift) . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-77
Test I14 - Steer Contactor . . . . . . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-78
Test I15 - Horn (S3, SW1) . . . . . . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-79
Test I19 - Left Traction RPM . . . . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-80
Test I20 - Lift RPM (AC Lift only) . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-81
Test I23 - CAN Communication Test . . . . . ........ . .. .. . .. . . . . . . . . . 6-82
Test I65 - Tilt Position SW (S18) . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-84
Test I80 - OCSS - Low . . . . . . . . . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-85
Test I81 - OCSS - High . . . . . . . . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-86
Test I82 - Right Traction RPM . . . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-87
Test I87 - Battery Gate 1 . . . . . . . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-88
Test I88 - Battery Gate 2 . . . . . . . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-89
Test I89 - Steer Position Sensor . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-90
Test I91 - iPort Communication . . . . . . . . ........ . .. .. . .. . . . . . . . . . 6-91
Output Tests
Test O00 - TPC Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-94
Test O01 - Steer Contactor (STR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-95
Test O02 - Lift Power Contactor (LPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96
Test O04 - Aux. Direction Solenoid (SOL6) . . . . . . . . . . . . . . . . . . . . . . . . . 6-97
Test O07 - Tilt Solenoid (SOL10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-98
Test O08 - Sideshift Solenoid (SOL9L, SOL9R) . . . . . . . . . . . . . . . . . . . . . . 6-99
Test O09 - Lift Relief Solenoid (SOL3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-100
Test O11 - Load Hold Solenoid (SOL1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-101
Test O12 - Lift/Lower Solenoid (SOL2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-102

Output Tests
Test O18 - Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-103

Test O19 - Ramp Sounder . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-104
Test O20 - Travel Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-105
Test O23 - Toggle Amplifier Fan . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-106
Test O28 - Ramp Lift Motor (AC Lift) . . . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-107
Test O29 - Ramp Traction Motors . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-108
Test O30 - Electric Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-109
Test O32 - Toggle Relay Enable . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-110
Test O33 - Handle Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-111
Test O36 - Priority Bypass Solenoid (SOL4) . . . . . . . . . . . . . . .. . .. .. . . . 6-112
Test O37 - Aux. Relief Solenoid (SOL5) . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-113
Test O45 - HSA1 Solenoid (SOL7C, SOL7R) . . . . . . . . . . . . . .. . .. .. . . . 6-114
Test O47 - Customer Output . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . 6-115

Messages and Codes
Messages and Codes

Section 6. Messages, Codes, and Tests
Messages
Message Displayed: Step Off the Deadman
Icon Code Title/Reason Tests to Run Notes/Corrective Action
Step Off the Deadman Test I00 - Deadman (S2) Release deadman.
Deadman (S2) is activated while lift (Page 6-74)
truck is trying to perform SelfTest.
Message Displayed: Release Control Handle to Resume Operation

Release Control Handle to Resume Test A04 - Travel Pot (VR1) Release throttle, step on
Operation (Page 6-32) deadman, resume travel.
Control handle moved before deadman
pressed.
Message Displayed: Lift CutOut Pending...Low battery

Lift CutOut Pending... Low battery None Message is displayed for

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

EPO Depressed Test A77 - EPO (S21) Lift EPO Button and cycle
VM senses the EPO switch is open (IN). (Page 6-64) key switch to clear.
Message Displayed: Scheduled Maintenance Due

Scheduled Maintenance Due None Perform scheduled

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

Messages
Message Displayed: Lift Cutout, Scheduled Maintenance Due

Lift Cutout, Scheduled Maintenance None Lift is disabled. Perform

Due scheduled maintenance.
This message occurs when scheduled Reset Maintenance Minder
maintenance is due and Maintenance in Configure Mode.
Minder is enabled in Configure Mode.
Message Displayed: Battery Low, No Lift

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

Lift interrupt has occurred due to the battery does not clear the Charge/change battery.
battery state-of-charge. message, run Test A15 -
Battery Volts (Page 6-40)
Message Displayed: Speed Limited

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

An overtemperature condition was Motor Temp (Page 6-34) reduced when a traction
detected. Test A09 - Lift Motor Temp motor or the lift motor
(AC Lift only) (Page 6-35) becomes overheated. Allow
Test A10 - Left Traction time for lift truck to cool.
Power Amp Temp
(Page 6-36)
Test A19 - Lift Power Amp
Temp (AC Lift only)
(Page 6-41)
Test A65 - Right Traction
Power Amp Temp
(Page 6-50)
Motor Temp (Page 6-52)
Message Displayed: Press Bypass Switch (^) To Continue Lifting

Press Bypass Switch to Continue Test I05 - Lift Limit (S12) Lift is disabled unless
Lifting (Page 6-76) bypass switch (UP button)
Lift Inhibit Switch (S24) was crossed. is activated. Lower carriage
below lift inhibit switch.
Message Displayed: Release Bypass Switch (^) To Continue Lifting

Release Bypass Switch to Continue None Release UP arrow on

Lifting Operator Display.

Messages
Message Displayed: Stalled, Release Control Handle to Resume Operation

Stalled, Release Control Handle to Test I19 - Left Traction Travel or lift speed is
Resume Operation RPM (Page 6-80) limited when the
No encoder pulses are received by Test I82 - Right Traction corresponding power amp
Power Amplifiers. RPM (Page 6-87) is not receiving encoder
Test I20 - Lift RPM (AC Lift pulses. Cycle key switch to
only) (Page 6-81) clear.
Message Displayed: Release Handle Button to Resume Operation

Release Handle Button to Resume Test I15 - Horn (S3, SW1) This message appears prior
Operation (Page 6-79) to an out-of-range code
Digital input from handle activated at Test A71 - Tilt Down (S7) being displayed.
startup. (Page 6-54)
Test A72 - Tilt Up (S6)
(Page 6-55)
Test A72 - Tilt Up/Down
(SW4) (Optional Handle)
(Page 6-56)
Test A73 - Sideshift Right
(S9) (Page 6-57)
Test A74 - Sideshift Left
(S8) (Page 6-58)
Test A74 - Sideshift
Left/Right (SW4) (Optional
Handle) (Page 6-59)
Test A75 - Attach Fcn 1
(S4) (Page 6-60)
(S5) (Page 6-62)
Message Displayed: Release Lift to Resume Operation

Release Lift to Resume Operation Test A05 - Lift/Lower Pot Release lift, step on
Lift pot out of Learned neutral position (VR2) (Page 6-33) deadman pedal.
at startup.
Message Displayed: Release Tilt to Resume Operation

Release Tilt to Resume Operation Test A72 - Tilt Up/Down Release tilt control.
Applies to trucks equipped with (SW4) (Optional Handle)
optional handle. Tilt control out of (Page 6-56)
Learned neutral at startup.

Messages
Message Displayed: Release Side Shift to Resume Operation

Release Side Shift to Resume Test A74 - Sideshift Release sideshift control.
Operation Left/Right (SW4) (Optional
Applies to trucks equipped with Handle) (Page 6-59)
optional handle. Sideshift control out of
Learned neutral at startup.
Message Displayed: Release Horn Button

Release Horn Button Test I15 - Horn (S3, SW1) Release horn button.
Digital input from handle activated (Page 6-79)
longer than ten seconds.
Message Displayed: Press TILT BACK to Unclamp

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

Informational message to advise (SW4) (Optional Handle)
operator to activate Tilt Back button (Page 6-56)
when the lift truck is equipped with a
clamp.
Message Displayed: Lower Mast or Tilt Back to Resume Travel and Lift
Lower Mast or Tilt Back to Resume Test I02 - Mast Tilt Speed Follow instructions on
Travel and Lift Reduction (S11) display. If message still
Informational message for trucks (Page 6-75) scrolls, perform tests.
equipped with bottler’s tilt. Test I65 - Tilt Position SW
(S18) (Page 6-84)
Message Displayed: Lower Below Limit Switch To Initialize Bypass Functions

Lower Below Limit Switch To None Lower below the lift limit
Initialize Bypass Functions switch.
Message Displayed: Lift Stalled, Re-key to Resume Operation

Lift Stalled, Re-key to Resume Test I20 - Lift RPM (AC Lift Lift speed is limited. Cycle
Operation only) (Page 6-81) key switch to clear.
LPA is not receiving encoder pulses.

Messages
Message Displayed: Check Battery Gates/Speed Limited

Check Battery Gates/Speed Limited Test I87 - Battery Gate 1 Travel speed limited to
Battery Gate Switch open. (Page 6-88) 1.0 mph (1.6 km/h). Clear
Test I88 - Battery Gate 2 condition.
(Page 6-89)
Message Displayed: Entrance Beam Blocked

Entrance Beam Blocked Test I80 - OCSS - Low Clear Condition. Clean
Optional OCSS beam blocked. (Page 6-85) photo eyes.
Test I81 - OCSS - High
(Page 6-86)
Message Displayed: Invalid Option Enabled

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

View SWM Display iPORT related message. Refer to iPORT Kit Installation
and Maintenance Instructions.
Message Displayed: Loss of connection to the SWM

Loss of Connection to the SWM iPORT related message. Refer to iPORT Kit Installation
Communication between the SWM and and Maintenance Instructions.
VM has been interrupted.
Message Displayed: Log in to enable truck

Log In to Enable Truck iPORT related message. Refer to iPORT Kit Installation
Operator not logged on to SWM. and Maintenance Instructions.

Codes
Codes
NOTE: Codes C46 and C47 are iPORT related
codes. Refer to iPORT Kit Installation
and Maintenance Instructions. All "M"
Series codes are iBATTERY related error
codes. Refer to iBATTERY Battery
Monitoring System Installation and
Maintenance Instructions.
Message Displayed: CODE 1H Overheated, Allow Time to Cool

Code 1H: Overheated, Allow Time to Test A10 - Left Traction Cycle key switch to clear
Cool Power Amp Temp after TPA has cooled.
The left TPA has reported its internal (Page 6-36)
temperature is less than –40°F (–40°C) Test I89 - Steer Position
or greater than +203°F (+95°C). Sensor (Page 6-90)
Message Displayed: CODE 2A Overheated, Allow Time to Cool

Code 2A: Left Traction Motor Test A08 - Left Traction Travel speed is linearly
Approaching Overtemp Motor Temp (Page 6-34) derated starting at 266°F
The TPA senses that the Traction Motor Test I89 - Steer Position (130°C). Travel speed is
is approaching overtemperature. Sensor (Page 6-90) limited to 1 mph
Traction performance is limited. (1.6 km/h) at 300°F
(149°C). Cycle key switch
to clear after Traction
Motor has cooled.
Message Displayed: CODE 2E Inform Service

Code 2E: Left Traction Motor Temp Test A08 - Left Traction Travel is limited to 6.5 mph
Sensor Out-of-Range Motor Temp (Page 6-34) (10.4 km/h). Clears when
The Traction Motor temperature sensor reason for fault is
is open or shorted. corrected.
Message Displayed: CODE 2G Inform Service

Code 2G: Phase Open on Left Test O29 - Ramp Traction Travel is disabled. Cycle
Traction Motor Motors (Page 6-108) key switch to clear.
The TPA has detected no current draw
in one of the three phases of the motor.

Codes
Message Displayed: CODE 2H Inform Service

Code 2H: Failure Detected in Left Test I19 - Left Traction Travel is limited to 1 mph
Traction Motor Speed Feedback RPM (Page 6-80) (1.6 km/h). If a single
Encoder channel is bad, this code is
displayed during Run. If
one or both channels are
bad at SelfTest, STALLED
is displayed. Cycle key
switch to clear.
Message Displayed: CODE 2M Inform Service

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

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

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

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

Code 2V: Left TPA High DC Bus None Travel is disabled. Cycle
Voltage key switch to clear. Test
The left TPA has detected an voltage at left TPA+. If OK,
overvoltage condition at the + terminal. replace left TPA. The VM
cannot cause this code.

Codes
Message Displayed: CODE 2W Inform Service

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

Code 2X: Left TPA Power Supply None Travel restricted to 1 mph
Out-of-Range (1.6 km/h). Cycle key
The power supply output in the left TPA switch to clear. Disconnect
is less than 4.5V, greater than 5.5V, or (+) wire to temp and speed
too much current is being drawn by an sensors. If code changes,
external component. troubleshoot wires and
sensors. If not OK, replace
TPA. The VM cannot cause
this code.
Message Displayed: CODE 2Y Inform Service

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

Code 42: LPC Detected Closed When Test I13 - Lift Contactor Lift is disabled. Cycle key
Commanded Open (DC Lift) (Page 6-77) switch to clear.
AC Lift - the LPA has detected an Test O02 - Lift Power
incorrect voltage at the B+ terminal on Contactor (LPC)
the amplifier. (Page 6-96)
DC Lift - the VM has detected an
incorrect voltage at JPC22-20.

Code 43: LPC Detected Open When Test I13 - Lift Contactor Cycle key switch to clear.
Commanded Closed (DC Lift) (Page 6-77)
AC Lift - the LPA has detected an Test O02 - Lift Power
incorrect voltage at the B+ terminal on Contactor (LPC)
the amplifier. (Page 6-96)
DC Lift - the VM has detected an
incorrect voltage at JPC22-20.

Codes
Message Displayed: CODE 4B Inform Service

Code 4B: Steer Contactor Detected Test I14 - Steer Contactor Cycle key switch to clear.
Closed When Commanded Open (Page 6-78)
The VM measured greater than Test O01 - Steer Contactor
+10VDC at JPC22-19 when the STR (STR) (Page 6-95)
coil was de-energized.
Message Displayed: CODE 4C Inform Service

Code 4C: Steer Contactor Detected Test I14 - Steer Contactor Cycle key switch to clear.
Open When Commanded Closed (Page 6-78)
The VM measured less than +10VDC at Test O01 - Steer Contactor
JPC22-19 when the STR coil was (STR) (Page 6-95)
commanded closed.
Message Displayed: CODE 4F Inform Service

Code 4F: TPC Detected Closed When Test O00 - TPC Contactor Travel is disabled. Cycle
Commanded Open (Page 6-94) key switch to clear.
The right TPA has detected an incorrect
voltage at the B+ terminal on the
amplifier.

Code 4G: TPC Detected Open When Test O00 - TPC Contactor Travel is disabled. Cycle
Commanded Closed (Page 6-94) key switch to clear.
The TPA has detected the TPC open
after power-up.
Message Displayed: CODE 4J Inform Service

Code 4J: TPC Contactor Coil Open or Test O00 - TPC Contactor Travel is disabled. Cycle
Shorted TPC (Page 6-94) key switch to clear.
TPC contactor coil is open or shorted.
Message Displayed: CODE 4K Inform Service

Code 4K: LPC Contactor Coil Open or Test O02 - Lift Power Lift is disabled. Cycle key
Shorted Contactor (LPC) switch to clear.
The LPC contactor coil is open or (Page 6-96)
shorted.

Codes

Code 59: CAN Transmission Buffer Test I23 - CAN All functions disabled.
Error Communication Test Cycle key switch to clear.
The VM has detected a CAN (Page 6-82)
transmission buffer error.
Message Displayed: CODE 5A Inform Service

Code 5A: CAN-Bus Error Overflow Test I23 - CAN All functions disabled.
CAN-Bus error overflow detected by Communication Test Cycle key switch to clear.
VM. (Page 6-82)
Message Displayed: CODE 5B Inform Service

Code 5B: CAN Transmission Buffer Test I23 - CAN Cycle key switch to clear.
Error Communication Test
CAN transmission buffer error. (Page 6-82)

Code 5F: No Communications Test I23 - CAN Travel is disabled. Cycle

Received by VM from Right TPA Communication Test key switch to clear.
The VM has not received CAN (Page 6-82)
communications from the right TPA.

Code 5G: No Communications Test I23 - CAN Travel is disabled. Cycle

Received by VM from Left TPA Communication Test key switch to clear.
The VM has not received CAN (Page 6-82)
communications from the left TPA.

Code 5J: No Communications Test I23 - CAN Lift is disabled. Cycle key
Received by VM from LPA Communication Test switch to clear.
AC lift only. The VM has not received (Page 6-82)
CAN communications from the LPA.

Codes

Code 5M: Left TPA NMT Start Test I23 - CAN If code does not clear,
Timeout Communication Test replace left TPA.
No communications received from left (Page 6-82)
TPA within one minute.
Message Displayed: CODE 5P Inform Service

Code 5P: LPA NMT Start Timeout Test I23 - CAN If code does not clear,
AC Lift only. No communications Communication Test replace LPA.
received from LPA within one minute. (Page 6-82)

Code 5U: Right TPA NMT Start Test I23 - CAN If code does not clear,
Timeout Communication Test replace the right TPA.
No communications received from right (Page 6-82)
TPA within one minute.

Code 5Y: Incorrect Right TPA None Replace with correct power
Installed amp.
Incorrect right traction power amplifier
installed. Should be 500A, 400A was
installed.

Code 61: Mast Switch Not Sensed Test I02 - Mast Tilt Speed Travel is limited to 2.5 mph
Mast Switch change of state not Reduction (S11) (4.0 km/h). Clears when
detected within allotted lift request (Page 6-75) switch change of state is
time. Test O12 - Lift/Lower detected.
Solenoid (SOL2)
(Page 6-102)
Message Displayed: CODE 6D Inform Service

Code 6D: Pressure Sensor Output Test A13 - Weight Sensor A high number is displayed
Voltage Out-of-Range Voltage (Page 6-38) for weight.
The VM has determined that the
pressure sensor voltage has exceeded
the programmed limits.

Codes
Message Displayed: CODE 7A Overheated, Allow Time to Cool

Code 7A: Lift Motor Overtemp Test A09 - Lift Motor Temp Lift is disabled. Allow time
AC Lift only. Lift motor temperature has (AC Lift only) (Page 6-35) to cool. Cycle key switch to
exceeded 300°F (149°C). clear.
Message Displayed: CODE 7E Inform Service

Code 7E: Lift Motor Temperature Test A09 - Lift Motor Temp Lift performance is
Sensor Out-of-Range (AC Lift only) (Page 6-35) disabled by LPA. Cycle key
AC Lift only. Lift motor temperature switch to clear.
sensor voltage is out-of-range.
Message Displayed: CODE 7F Overheated, Allow Time to Cool

Code 7F: LPA Overtemp Test A19 - Lift Power Amp Lift is disabled. Cycle key
AC Lift only. The LPA has reported its Temp (AC Lift only) switch to clear.
internal temperature is less than –40°F (Page 6-41)
(–40°C) or greater than +203°F (+95°C).

Code 7G: LPA Motor Phase Open Test O28 - Ramp Lift Motor Lift is disabled. Cycle key
AC Lift only. The LPA has detected no (AC Lift) (Page 6-107) switch to clear.
current draw in one of the three phases
of the motor.
Message Displayed: CODE 7H Inform Service

Code 7H: Lift Motor Feedback Test I20 - Lift RPM (AC Lift Lift is limited to approx.
Encoder Failure Detected only) (Page 6-81) 10 fpm (3 m/min). Cycle
AC Lift only. The LPA has detected key switch to clear.
incorrect pulses from the lift motor
encoder.

Code 7M: LPA Failed to Precharge None Lift is disabled. Check for
AC Lift only. The LPA failed to B+ at the LPA+ terminal.
precharge. Cycle key switch to clear. If
code does not clear, replace
LPA. The VM cannot cause
this code.

Codes

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

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

Code 7V: LPA High Voltage on DC Bus None Lift is disabled. Cycle key
AC Lift only. The LPA has detected that switch to clear. Test voltage
the voltage at the + terminal is at LPA+. If OK, replace LPA.
overvoltage. The VM cannot cause this
code.

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

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

Codes

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

Code 80: Throttle Potentiometer Test A04 - Travel Pot (VR1) Travel is disabled. Cycle
(VR1) Voltage Out-of-Range (Page 6-32) key switch to clear.

Code 81: Lift/Lower Potentiometer Test A05 - Lift/Lower Pot Lift is disabled. Cycle key
(VR2) Voltage Out-of-Range (VR2) (Page 6-33) switch to clear.

Code 82: Handle Heater Open Test A40 - Handle Heater Cycle key switch to clear.
The circuit for the optional heater in the Reference Voltage
control handle is open. (optional) (Page 6-49)

Code 83: Throttle Potentiometer Test A04 - Travel Pot (VR1) Travel is disabled. Return
(VR1) Out-of-Neutral (Page 6-32) control handle to neutral.
Throttle potentiometer (VR1) out of Cycle key switch to clear.
Learned neutral value.

Code 84: Brakes Inoperable - Not Test O30 - Electric Brakes Travel disabled at startup.
Applied (Page 6-109) Make sure brake release
The traction motor bearing encoder bolts are removed from
indicated movement during SelfTest. brake assembly. Cycle key
switch to clear.

Codes
Message Displayed: CODE 87 Incorrect mast tilt pot reading...Tilt-Centering disabled

Code 87: Mast Tilt Centering Pot Test A69 - Mast Tilt Cycle key switch to clear.
(VR6) Out-of-Range Centering Pot (VR6)
(Page 6-53)

Code 88: 5V Power Supply Test A26 - Pot Supply Cycle key switch to clear.
Out-of-Range (5VDC) (Page 6-45)
Control handle 5V power supply located
in VM out-of-range.
Message Displayed: CODE 8A Inform Service

Code 8A: OCSS Photo Sensor Fault Test I80 - OCSS - Low Cycle key switch to clear.
The VM senses the beams are ON with (Page 6-85)
the deadman pedal up. Test I81 - OCSS - High
(Page 6-86)

Code 8F: Lift/Lower Potentiometer Test A05 - Lift/Lower Pot Lift and lower disabled.
Out-of-Neutral (VR2) (Page 6-33) Return control handle to
Lift/Lower potentiometer (VR2) out of neutral. Cycle key switch to
Learned neutral value. clear.

Code 8J: Ambient Temperature Test A36 - Ambient Cycle key switch to clear.
Sensor Out-of-Range Temperature (Page 6-48)
Message Displayed: CODE 8L Inform Service

Code 8L: Brake Feedback Current Test O30 - Electric Brakes Cycle key switch to clear.
Out-of-Range (Page 6-109) Note: The brake is fully
The current measured in the brake engaged or fully disengaged
feedback circuit is zero, or outside the when this code is present.
reference range.

Codes

Code 8M: Internal Handle Heater Test A40 - Handle Heater Self resetting.
Failure Reference Voltage
The internal heater in the control (optional) (Page 6-49)
handle has malfunctioned.
Message Displayed: CODE 8P Inform Service

Code 8P: Tilt Potentiometer Test A72 - Tilt Up/Down Cycle key switch to clear.
Out-of-Range (SW4) (Optional Handle) Check for correct handle
(Page 6-56) configuration in
FlashWare.
Message Displayed: CODE 8R Inform Service

Code 8R: Tilt Out-of-Neutral Test A72 - Tilt Up (S6) Return switch to neutral
Tilt potentiometer out-of-neutral or (Page 6-55) and cycle key switch to
switch detected closed at startup. Test A72 - Tilt Up/Down clear.
(Page 6-56)
Message Displayed: CODE 8S Inform Service

Code 8S: Sideshift Potentiometer Test A74 - Sideshift Cycle key switch to clear.
Out-of-Range Left/Right (SW4) (Optional Check for correct handle
Handle) (Page 6-59) configuration in
FlashWare.

Code 8T: Sideshift Out-of-Neutral Test A74 - Sideshift Left Return switch to neutral
Sideshift potentiometer out-of-neutral (S8) (Page 6-58) and cycle key switch to
or switch detected closed at startup. Test A74 - Sideshift clear.
Left/Right (SW4) (Optional
Handle) (Page 6-59)

Code 8U: Attachment Function 1 Test A75 - Attach Fcn 1 Cycle key switch to clear.
Out-of-Range (S4) (Page 6-60) Check for correct handle
configuration in
FlashWare.

Codes

Code 8V: Attachment Function 1 Test A75 - Attach Fcn 1 Return switch to neutral
Out-of-Neutral (S4) (Page 6-60) and cycle key switch to
Function 1 potentiometer Test A75 - Attach Fcn 1 clear.
out-of-neutral or switch detected closed (SW3) (Optional Handle)
at startup. (Page 6-61)

Code 8W: Attachment Function 2 Test A76 - Attach Fcn 2 Cycle key switch to clear.
Out-of-Range (SW2) (Optional Handle) Check for correct handle
(Page 6-63) configuration in
FlashWare.

Code 8X: Attachment Function 2 Test A76 - Attach Fcn 2 Return switch to neutral
Out-of-Neutral (S5) (Page 6-62) and cycle key switch to
Function 2 potentiometer Test A76 - Attach Fcn 2 clear.
out-of-neutral or switch detected closed (SW2) (Optional Handle)
at startup. (Page 6-63)
Message Displayed: CODE 8Z Inform Service

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

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

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

Codes

Code A2: Software Compatibility None Travel disabled. Cycle key

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

Code A3: Software Compatibility None Travel disabled. Cycle key

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

Code A4: Software Compatibility None Lift disabled. Cycle key

Issue with VM and LPA switch to clear. If this code
AC lift only. appears, upgrade the
using FlashWare.
Message Displayed: CODE AG Inform Service

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

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

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

Code AL: VM Battery Backed Up RAM None Cycle key switch to clear. If
Failed code does not clear, replace
VM.

Codes
Message Displayed: CODE AP Inform Service

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

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

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

Code EC: COP Not Enabled None Cycle key switch to clear. If
code does not clear, replace
VM.
Message Displayed: CODE FE Inform Service

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

BSOC Not Calibrated seconds. Cycle key switch
to clear. If intermittent, test
the "Inrush Protection"
circuit. Refer to page 5-12.
If code does not clear,
replace VM.

Codes
Message Displayed: CODE FG Inform Service

Code FG: +5V Reference Voltage and Test A14 - Ext. Supply Travel, lift, and lower
+12V Power Supply Failure Sense (12VDC) (Page 6-39) disabled. Brake engages.
Cycle key switch to clear. If
intermittent, test the
"Inrush Protection" circuit.
Refer to page 5-12.
Message Displayed: CODE FH Inform Service

Code FH: Battery Voltage Test A15 - Battery Volts Brake remains engaged.
Out-of-Range (Page 6-40) Cycle key switch to clear. If
Wrong voltage battery or voltage intermittent, test the
out-of-range. "Inrush Protection" circuit.
Refer to page 5-12.
Message Displayed: CODE FN Inform Service

Code FN: Relays Did Not Open at Test O32 - Toggle Relay Brake engages. Cycle key
Power Off Enable (Page 6-110) switch to clear. If
intermittent, test the
"Inrush Protection" circuit.
Refer to page 5-12.
Message Displayed: CODE FT Inform Service

Code FT: VM Internal Software Error None Travel, lift, and lower
disabled. Brake remains
engaged. Cycle key switch
to clear. If intermittent, test
the "Inrush Protection"
circuit. Refer to page 5-12.
If code does not clear,
Flash VM with latest
software.
Message Displayed: CODE G2 Inform Service

Code G2: Bad Steer Position Test I89 - Steer Position Cycle key switch to clear.
Reference Input Sensor (Page 6-90)

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

Code HA: Right Traction Motor Test A68 - Right Traction Travel speed is linearly
Overtemp Motor Temp (Page 6-52) derated starting at 266°F
(130°C). Travel speed is
limited to 1 mph
(1.6 km/h) at 300°F
(149°C). Cycle key switch
to clear after traction motor
has cooled.
Message Displayed: CODE HE Inform Service

Code HE: Right Traction Motor Test A68 - Right Traction Travel is limited to 6.5 mph
Temperature Sensor Out-of-Range Motor Temp (Page 6-52) (10.4 km/h). Clears when
reason for fault is
corrected.
Message Displayed: CODE HF Overheated, Allow Time to Cool

Code HF: Right TPA Overtemp Test A65 - Right Traction Cycle key switch to clear
The right TPA has reported its internal Power Amp Temp after TPA has cooled.
temperature is less than –40°F (–40°C) (Page 6-50)
or greater than +203°F (+95°C).
Message Displayed: CODE HG Inform Service

Code HG: Right Traction Motor Test A67 - Right Traction Travel is disabled. Cycle
Phase Open Current (Page 6-51) key switch to clear.
Message Displayed: CODE HH Inform Service

Code HH: Right Traction Motor Test I82 - Right Traction Travel is limited to 1 mph
Feedback Encoder Failure RPM (Page 6-87) (1.6 km/h). If a single
Failure detected in traction motor channel is bad, this code is
speed feedback encoder. displayed during operation.
If one or both channels are
bad at SelfTest, STALLED
is displayed. Cycle key
switch to clear.

Codes
Message Displayed: CODE HM Inform Service

Code HM: Right TPA Pre-Charge None Travel is disabled. Check

Failed for B+ at the right TPA+
TPA failed to precharge correctly. terminal. Cycle key switch
to clear. If code does not
clear, replace right TPA.
code.
Message Displayed: CODE HT Inform Service

Code HT: Right TPA Current Sensor None Travel is limited to 2.5 mph
Fault (4.0 km/h). Cycle key
The right TPA has sensed a current switch to clear. If code does
calibration error. not clear, replace right TPA.
code.
Message Displayed: CODE HU Inform Service

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

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

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

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

Codes
Message Displayed: CODE HX Inform Service

Code HX: Right TPA Power Supply None Travel restricted to 1 mph
Out-of-Range (1.6 km/h). Cycle key
The power supply output in the right switch to clear. Disconnect
TPA is less than 4.5V, greater than (+) wire to temp and speed
5.5V, or too much current is being sensors. If code changes,
drawn by an external component. troubleshoot wires and
sensors. If not OK, replace
TPA. The VM cannot cause
this code.
Message Displayed: CODE M9 Lift limited...Installed battery is too light

Code M9: Lift Limited... Installed iBATTERY related message. Refer to iBATTERY Battery
Battery is Too Light Monitoring System Installation and Maintenance
Battery installed in truck is below the Instructions.
minimum rated weight.
Message Displayed: CODE T0 Inform Service

Code T0: Aux Relief SOL5 Open Test A82 - Aux. Relief Cycle key switch to clear.
Circuit or Constant Low Current (SOL5) (Page 6-67)

Code T3: Proportional Lower SOL2 Test A34 - Lift/Lower Cycle key switch to clear.
Open Circuit or Constant Low Current (SOL2) (Page 6-46)

Code T4: Priority Bypass SOL4 Open Test A81 - Priority Bypass Cycle key switch to clear.
Circuit or Constant Low Current (SOL4) (Page 6-66)

Codes
Message Displayed: CODE VC Inform Service

Code VC: Internal Error in VM None Cycle key switch to clear. If

Communications code does not clear, replace
VM.

Models 4150/4250 Maintenance Manual Section 6. Messages, Codes and Tests
Analog Tests
Analog Tests
Section 6. Messages, Codes and Tests
A Diagnosis and Repair table is provided for

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

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

Action/
Step (+) Lead (–) Lead Expected Results Step Passed Step Failed
Meter Setting
This column identifies

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

identifies the required
setting on the meter
for this step.

Section 6. Messages, Codes and Tests Models 4150/4250 Maintenance Manual
Test A04 - Travel Pot (VR1) Analog Tests
Test A04 - Travel Pot Run test:

(VR1) The test is a success if the voltage displayed is
within these limits:
This test displays the voltage the VM produces
based on input from the control handle travel Throttle Position Value Displayed
potentiometer VR1. Full Tractor-First (TF) 0.16 to 0.90V
NOTE: Run Learn when the throttle (travel)
Neutral Position 0.9 to 1.4V
assembly is replaced, repaired, or
adjusted. See “Maintenance Mode” on Full Forks-First (FF) 1.25 to 2.00V
page 3-18.
NOTE: If code 83 is displayed, check the handle If the voltage reading is outside these limits or
spring for excessive movement. does not change in a smooth, linear fashion, the
test has failed. Any voltage fluctuation indicates
a bad cable or potentiometer VR1.
The voltage reading should decrease when the

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

Action/
Step Meter (+) Lead (–) Lead Expected Results Step Passed Step Failed
Setting
Approx. 5V.
JPC12
If missing, no other
1 Disconnected PC12-1 PC12-12 Perform step 2 Replace VM
control handle
/DCV
functions work.
T/S the control

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

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

(VR2) The test is a success if the voltage displayed is
This test displays the voltage the VM produces
based on input from the control handle Lift/Lower
Value Displayed
lift/lower pot VR2. Control Position
NOTE: Run Learn when the lift/lower pot is Full Lift Position 0.21 to 0.95V
replaced, repaired, or adjusted. See Neutral Position 0.8 to 1.4V
“Maintenance Mode” on page 3-18.
Full Lower Position 1.35 to 2.19V
NOTE: If code 8F is displayed, check the handle
spring for excessive movement.
If the voltage reading is outside these limits or
does not change in a smooth, linear fashion, the
test has failed. Any voltage fluctuation indicates
The voltage reading should decrease when the

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

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

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

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

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

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

temperature from the temperature sensor. Heat
the lift truck up by driving it hard for approx.
30 minutes. As the motor heats, the
temperature increases.
NOTE: For more information on how to use
Maintenance Mode, refer to page 3-18.

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

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

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

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

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

Power Amp Temp
This test displays the temperature of the left
Traction Power Amplifier.
Limits
• Normal operation: ambient to 175°F (79°C)
• Starting at 176°F (80°C), speed is linearly
reduced by the TPA to 0.0 mph at 239°F
(115°C), when traction is disabled
• Temperature icon lights at 185°F (85°C)
• Fault Code 1H is displayed at 203°F (95°C)
NOTE: Also check “Test I89 - Steer Position
Sensor” on page 6-90.
Run test:
The Operator Display shows the heatsink
temperature that the Traction Power Amplifier
reads.
From ambient temperature, as drive is

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

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

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

2 N/A N/A Replace TPA
cool. code and connections

Analog Tests Test A11 - Left Traction Current
Test A11 - Left Traction Diagnosis and Repair

Current 1. If any one phase differs significantly from
the other two, check power cable
continuity. Replace cables as necessary.
This test displays the current in the left See “Power Cable Terminals” on
Traction Motor power circuit. page 7-56.
• If power cable continuity is OK, T/S the
Limits: traction motor. See “AC Motors” on
page 5-16.
• Above 266°F (130°C) current is reduced
linearly • If all phases give high readings, the
drive unit may be binding. Check drive
• Maximum current up to 540A when
unit.
deadman pedal is released, unaffected and
unreduced by temperature 2. The power amplifier may be bad. Run
“Test O29 - Ramp Traction Motors” on
NOTE: For best results, run this test in Active page 6-108.
Maintenance Mode.
For more information on how to use

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

phase, the test may not always reveal a
current problem.
NOTE: Check all motor and power amplifier
connections for tightness and corrosion.
Check individual phase currents with a

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

test has failed.

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

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

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

display is inaccurate, the test has failed.

Action/
Meter Setting
1 JPC24-13 JPC24-10 Perform step 2 Replace VM

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

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

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

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

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

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

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

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

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

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

Action/
Setting
Check battery water level

and specific gravity.
1 TP1 Perform step 2
Check battery cables.
Replace battery
DCV TP4 B+ T/S harness TP1 to

2 JPF4-1 Perform step 3
JPF4-1
3 JPF4-7 Perform step 4 T/S Fuse/Relay Card
T/S harness from

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

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

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

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

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

Test A20 - Lift Current (AC Lift only) Analog Tests
Test A20 - Lift Current Diagnosis and Repair

(AC Lift only) 1. If any one phase differs significantly from
This test displays Lift Motor current through
• If power cable continuity is OK,
the Lift Power Amplifier.
troubleshoot the lift motor. See “AC
NOTE: For best results, run this test in Active Motors” on page 5-16.
Maintenance Mode. • If all phases give high readings, the lift
pump may be binding.
Maintenance Mode, refer to page 3-18. 2. The power amplifier may be bad. Run
“Test O28 - Ramp Lift Motor (AC Lift)” on
page 6-107.
The lift carriage and forks will move

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

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

evenly as the lift accelerates and decelerates.
Phase currents must be approximately equal.
Gross differences indicate a problem.

test has failed.

Analog Tests Test A22 - Traction Request
Test A22 - Traction

Request
This test displays the percentage of traction
throttle request from control handle travel pot
VR1 being read by the VM.
Run test:
NOTE: Run Learn after you replace, repair, or
adjust the throttle assembly. See
“Maintenance Mode” on page 3-18.
The Operator Display shows the percentage of

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

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

the test has failed.
NOTE: Any travel limiting conditions will result
in less than 100% shown on display.

Action/
Meter Setting
Test should pass. Check traction

Run “Test A04 - Compare Test A04 system for speed
Travel Pot results with the limits due to motor
1 N/A N/A Replace TPA
(VR1)” on results from A22. temperature, limit
page 6-32 Max throw should switches, or
show max values. configured speed

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

This test displays the percentage of lift throttle
request from control handle lift/lower pot VR2
being read by the VM.
Run test:
NOTE: Run Learn after you replace, repair, or
adjust the lift/lower potentiometer VR2.
See “Maintenance Mode” on page 3-18.
The Operator Display shows the percentage of

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

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

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

Action/
Meter Setting
Compare Test A05

Run “Test A05 - Check lift system
results with the
Lift/Lower Pot for limits due to
1 N/A N/A results from A23. Replace the LPA
(VR2)” on motor temperature
Max throw should
page 6-33 or switches
show max values

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

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

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

Action/
Meter Setting
T/S the control

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

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

Current (SOL2)
This test displays the current the proportional
lift/lower solenoid coil (SOL2) is drawing.
NOTE: For best results, run this test in Active
Maintenance Mode.

Run test:
State Value Displayed
Neutral Approx. 0.0A
Full Lower Approx. 1.15A
If these results are not observed, the test has

failed.

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

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

Analog Tests Test A35 - Brake Armature
Test A35 - Brake

Armature
This test displays the voltage the VM measures
across the brake coil driver.
Maintenance Mode.

Run test:
Deadman Pedal Value Displayed
Up B+
0V for 1 second; increases to

Down
12 to 14V

failed.

If the voltage is not specified, replace the VM. If
the voltage is as specified, Run “Test O30 -
Electric Brakes” on page 6-109.

Test A36 - Ambient Temperature Analog Tests
Test A36 - Ambient

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

Action/
Meter Setting
JPC24-3 & 11
1 Disconnected/ JPC24-23 JPC24-11 Approx. 5V Perform step 2 Replace VM
DCV
2 JPC24-23 JPA-1 Replace temp T/S wires as

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

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

Heater Reference
Voltage (optional)
This test displays the voltage the Vehicle
Manager sees going through the internal
control handle heater (HTR6).
NOTE: Heater operation requires ambient
temperature sensor to be activated.
Heaters then turn on at 40°F (4.4°C).
Run Test
Heater OFF Heater ON
0V Approx. 6.0V
If the values displayed do not match the values

given in the table, the test has failed. Verify
option is turned ON. Refer to Diagnosis and
Repair.

Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
Check cable
wiring. If OK,
Disconnect Approx.
1 JC12-7 JC12-12 Perform step 2 replace handle
JPC12/Ohms 12 Ohms
or internal
heater
Heater ON:
Disconnect PC12-7 PC12-12
2 approx. 4.4V Perform step 1 Replace VM
JPC12/DCV on VM on VM
Heater OFF: 0V

Test A65 - Right Traction Power Amp Temp Analog Tests

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

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

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

1 Hot to touch Perform step 2
hot to touch? TPA
N/A N/A
Allow time to Not hot to touch, no Check cables
2 Replace TPA
cool. code and connections

Analog Tests Test A67 - Right Traction Current
Test A67 - Right Traction Diagnosis and Repair

Current • If any one phase differs significantly from
This test displays the current in the right See “Power Cable Terminals” on
Traction Motor power circuits. page 7-56.
• If power cable continuity is OK, T/S the
Limits: traction motor. See “AC Motors” on
page 5-16.
• Above 266°F (130°C) current is reduced
linearly • If all phases give high readings, the drive
unit may be binding. Check drive unit.
• Maximum current up to 540A when
deadman pedal is released, unaffected and NOTE: The power amplifier may be bad. Run
unreduced by temperature “Test O29 - Ramp Traction Motors” on
page 6-108.
Maintenance Mode.

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

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

evenly as the lift truck accelerates and
decelerates. Phase currents must be
approximately equal. Gross differences indicate
a problem.

test has failed.

Test A68 - Right Traction Motor Temp Analog Tests
Test A68 - Right Traction Run test:

Motor Temp 1. With the lift truck at rest and at ambient
temperature, compare the temperatures
obtained using Active Maintenance Mode
This test displays the temperature of the right to the ambient temperature.
Traction Motor.
2. If the temperatures are not within several
degrees, the test has failed.
Limits 3. If the lift truck is not at ambient
• Normal operation: ambient to 258°F temperature, use the diagnosis and repair
(125°C) chart to isolate the cause.
• Between 266°F (130°C) and 300°F (149°C),
speed is linearly reduced to 1.0 mph
(1.6 km/h)
(130°C)
• Fault Code 2A is displayed and travel is
While operating, the VM continually monitors

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

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

Action/
Meter Setting
JPTR1
Replace right
1 Disconnected/ JTR1-8 JTR1-7 Perform step 2
<1200 ohms if traction TPA
Ohms
motor is cool;
JPTR3 >1200 ohms if hot T/S Traction Replace
2 Disconnected/ JTR3-2 JTR3-1 Motor temp Traction Motor
Ohms sensor wires temp sensor

Analog Tests Test A69 - Mast Tilt Centering Pot (VR6)
Test A69 - Mast Tilt If the voltage reading is outside these limits or
does not change in a smooth, linear fashion, the
Centering Pot (VR6) test has failed. Any voltage fluctuation indicates
This test displays the voltage the VM produces The voltage reading should decrease when
based on input from the mast tilt centering pot tilting forward and increase when tilting back. If
(VR6). these results are not observed, the test has
NOTE: Run Learn after you replace, repair, or failed.
adjust VR6. See “Maintenance Mode” on
page 3-18.
Run test:
NOTE: Perform this test in Active Maintenance
Mode.
The test is a success if the voltage displayed is

Mast Tilt Position Value Displayed
Full Tilt Forward Position 1.0 to 1.6V
Neutral Position 2.0 to 2.4V
Full Tilt Back Position 2.7 to 3.3V

Action/
Meter Setting
1 JPC20-5 JPC24-5 10.5 to 13V Perform step 2 Replace VM
T/S wiring from

VM to 5V power
2 JPT5-3 JPT5-4 4.5 to 5.5V Perform step 3 supply. If OK,
replace power
DCV supply.
Neutral: 2.0 to 2.4V

T/S wiring from
Full tilt forward: 1.0 to
JPC24-22 to
3 JPC24-22 JPC24-5 1.6V Replace VM
JPT1-4. If OK,
Full tilt back: 2.7 to
replace pot.
3.3V

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

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

failed.

Action/
Meter Setting
Note: A breakout cable or box is required to measure control handle voltages.
JPC12
1 >4V Perform step 2 Replace VM
Disconnected/DCV
JPC12-6 JPC12-12 Repair or replace

S7 open: >4V control handle,
2 DCV Replace VM
S7 closed: <1V cable, or S7 (in
handle)

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

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

failed.

Action/
Meter Setting
JPC12
Disconnected/DCV

S6 open: >4V control handle,
2 DCV Replace VM
S6 closed: <1V cable, or S6 (in
handle)

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

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

does not change linearly, the test has failed.
Any voltage fluctuation indicates a bad cable or
switch.

Action/
Meter Setting
Neutral: approx.
2.44V Repair or replace
Full Tilt Down: control handle,
1 DCV JPC12-8 JPC12-12 Replace VM
approx. 0.6V cable, or SW4 (in
Full Tilt Up: approx. handle)
4.36V

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

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

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

change, the test has failed.

Action/
Meter Setting
JPC12
Disconnected/DCV
JPC12-9 JPC12-12 Repair or

S9 Open: >4V replace control
2 DCV Replace VM
S9 Closed: <1V handle, cable, or
S9 (in handle)

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

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

Approx. 0.0V
Activated


Action/
Meter Setting
JPC12 Perform
1 >4V Replace VM
Disconnected/DCV step 2
S8 Open: >4V
2 DCV Replace VM control handle, cable,
S8 Closed: <1V
or S8 (in handle)

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

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

change linearly, the test has failed.

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

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

Test A75 - Attach Fcn 1 (S4) Analog Tests

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


Action/
Meter Setting
JPC12 Perform
1 JPC12-12 >4V Replace VM
Disconnected/DCV step 2
JPC12-4 Repair or replace

De-activated: approx. 5V control handle,
2 DCV TP4 Replace VM
Activated: <1V cable, or S4 (in
handle)

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

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


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

Test A76 - Attach Fcn 2 (S5) Analog Tests

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


Action/
Meter Setting
JPC12
1 Disconnected/ JPC12-12 >4V Perform step 2 Replace VM
DCV
JPC12-11 Repair or replace
De-activated: approx. 5V control handle,
2 DCV TP4 Replace VM
Activated: <1V cable, or S5 (in
handle)

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

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


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

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

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

failed.

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

1 DCV JPC22-21 TP4 Replace VM
Open: <0.5V and connections

Analog Tests Test A80 - Aux Select Current (SOL6)
Test A80 - Aux Select

Current (SOL6)
This test displays the current at the Aux Select
Solenoid (SOL6).
Run test:
Sideshift Left
1.4A
Tilt Forward

failed.
NOTE: If "CNTR ON" is displayed, disable
TiltCntr in Configure Mode Menu.

Action/
Setting
JPC18 &
JPC20 Dis-
1 JPC18-1 Approx. 18 ohms Perform step 2 T/S wires and coil
connected
/Ohms
JC20-13
No function
Check SOL6 for
requested: B+
2 DCV TP4 mechanical binding. Replace VM
Tilt Forward: approx.
Replace SOL6
10V

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

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

Sideshift percentage.

failed.

Action/
Setting
JPC20
T/S wires
1 Disconnected PC20-17 PC20-18 Approx. 20 ohms Perform step 2
and coil
/Ohms
OFF: B+
Check valve for
Test Tilting Fwd: ramps to approx. Replace VM
mechanical
3 Activated/ JPC20-18 B– 26V
binding/
DCV Tilting Back: approx. 1V less
contamination
Sideshifting: approx. 25V

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

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

Approx. 0.45A
Attachments

failed.

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

Test A96 - BSM Curr Analog Tests
Test A96 - BSM Curr

Real time current as seen by the Battery Sensor
Module (BSM). Displays in whole amps (for
example: 150 A).

Analog Tests Test A97 - BSM Volt
Test A97 - BSM Volt

Real time voltage as seen by the Battery Sensor
Module (BSM). Displays in tenths of a volt (for
example: 37.8V).

Test A98 - BSM Temp Analog Tests
Test A98 - BSM Temp

Battery temperature as seen by the Battery
Sensor Module (BSM). Displays in whole
degrees centigrade (for example: 23°C).

Analog Tests Test A99 - H2O Snse
Test A99 - H2O Snse

Battery water sensed by the Battery Sensor
Module (BSM). Displays as True or False. False
indicates water level is low.

Test A100 - BSM Comm Analog Tests
Test A100 - BSM Comm

Communication level indicator between the
iBattery™ Auxiliary Processing Module (APM)
and Battery Sensor Module (BSM). This is
represented with 0 to 4 bars: 4 bars indicates
excellent communication, 0 bars indicates no
communication.

Input Tests
Input Tests

and Repair table.

table below.

Action/
Meter Setting

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

for this step.

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

This test shows what the VM is reading from
Deadman S2.
Run test:
The state of Deadman S2 is displayed:
Deadman Pedal Value Displayed
Up Off
Down On

failed.

Action/
Setting
Note: With the deadman pedal fully pressed, the gap between the proximity switch and flag should be
0.05 to 0.07 in. (1.3 to 1.8 mm).
Deadman UP: approx. 5V

1 JPC22-8 Replace VM Perform step 2
Deadman DOWN: <1V
DCV JPC22-11
T/S switch, wiring,
2 JPC10-1 Approx. 12V Replace VM
and connection

Input Tests Test I02 - Mast Tilt Speed Reduction (S11)
Test I02 - Mast Tilt Speed

Reduction (S11)
This test monitors the state of the Mast Tilt
Speed Reduction switch (S11) on trucks above
S/N 50500 and displays what the VM is reading
from the switch.
NOTE: S11 is also used for the Hi-Speed Limit
function of the Bottler’s Tilt option.
Run test:
When the test is run, observe the following
results:
High Speed Limit Switch

Value Displayed
Sensor
Near Metal Belw
Away From Metal Abve

failed.
NOTE: Correct gap for switch is 0.11 ±0.04 in.
(2.79 ±1 mm).

Action/
Setting

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

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

This test monitors the state of the optional Lift
Limit switch (S12) and displays what the VM is
reading from the switch.
NOTE: Trucks below S/N 50501 with a Quad
mast use S12 for Mast Tilt Speed
Reduction.
Run test:
results:
Mast Value Displayed
Below Switch (closed) Belw
Above Switch (open) Abve

failed.
(2.79 ±1 mm).

Action/
Setting
T/S wiring &

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

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

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

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

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

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

failed. Check fuse FU3 and the LPC Contactor
tips.

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

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

Test I14 - Steer Contactor Input Tests
Test I14 - Steer Contactor

This test reports the absence or presence of
voltage to the load side of the STR contactor.
Run test:
NOTE: Must be in Active Maintenance Mode to
perform this test.


results:
STR Contactor Value Displayed
Open Out
Closed In

failed.
Check fuse FU1 and the STR Contactor tips.

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

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

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

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

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

failed.

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

1 JC12-10 PH1-10 0 ohms Perform step 2
/Ohms connectors
Button pressed: <1V T/S control

2 DCV JPC12-10 JPC12-12 Button released: Replace VM handle wiring &
approx. 5V switch

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

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

obstructions with ample room for
maneuvering.

Maintenance Mode.

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

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

4.5 to 5.5V T/S or replace
2 JPTL2-1 JPTL2-4 Perform step 3
harness
3 JPTL1-31 JPTL1-7; Perform step 4 Perform step 5

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

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

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

obstructions with ample room for lifting.

Maintenance Mode.

Run test:

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

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

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

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

Communication Test
This test verifies the VM is communicating with
the Left Traction Power Amplifier, Right
Traction Power Amplifier, and (4250 Only) Lift
Power Amplifier.
If the fault code is intermittent, the cause could

be a bad cable or connection. It could also be
caused by a static discharge. Check the static
straps, the terminating resistor, or wiring on
the Left Traction Amp JTL1-21 and JTL1-34.
Additionally, it can be caused by an optional
device or bad DC motor brushes.
Run test:
The Operator Display (OD) shows:
• V if VM is communicating with any
amplifier
• L if the left side TPA is communicating
with the VM
• R if the right side TPA is communicating
with the VM
• P (4250 only) if the LPA is communicating
with the VM
If V, L, R, or P (4250 only) are not displayed, the

test has failed.

Input Tests Diagnosis and Repair

Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Setting Results
If all letters are missing (not displayed):
T/S B+ from K2 or K3
1 DCV JPTL1-1 B– B+ Perform step 2
Relay
2 JPTL1 & JPC14 JPL1-23 JPC14-11 Perform step 3

Disconnected/ 0 Ohms R/R harness
3 Ohms JPTL1-35 JPC14-35 Replace VM
If letter P is missing (4250 Only):
1 JPL1-1 Perform step 2

DCV B– (On Amp) B+
2 JPL1-11 Perform step 3
R/R harness
3 JPTL1 & JPC14 JPL1-23 JPC14-11 Perform step 4
Disconnected/ 0 Ohms
4 Ohms JPL1-35 JPC14-4 Replace LPA
If letter L is missing:
1 JPTL1-1 Perform step 2

DCV B– (On Amp) B+
2 JPTL1-12 Perform step 3
R/R harness
3 JPTL1 & JPC14 JPTL1-23 JPC14-11 Perform step 4
4 Ohms JPTL1-35 JPC14-4 Replace LTPA
If letter R is missing:
1 JPTR1-1 Perform step 2
2 DCV JPTR1-11 B– (On Amp) B+ Perform step 3
3 JPTR1-12 Perform step 4 R/R harness

4 JPTR1 & JPC14 JPTR1-23 JPC14-11 Perform step 5
5 Ohms JPTR1-35 JPC14-4 Replace RTPA

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

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

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

failed.
Check that the tilt position switch has the

correct clearance; adjust the switch so that it
deactivates when the mast is tilted past 3°
forward. See “Mast Tilt Position Switch
Adjustment” on page 7-141.

Action/
Meter Setting
T/S wiring &

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

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

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

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

Maintenance Mode, refer to page 3-18. Down On
Up Off

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

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

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

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

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

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

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

Maintenance Mode, refer to page 3-18. Down On
Up Off

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

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

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

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

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

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

obstructions with ample room for
maneuvering.

Maintenance Mode.

Run test:

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

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

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

Test I87 - Battery Gate 1 Input Tests
Test I87 - Battery Gate 1

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

(2.79 ±1.00 mm).

Action/
Setting

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

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

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

(2.79 ±1.00 mm).

Action/
Setting

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

Test I89 - Steer Position Sensor Input Tests
Test I89 - Steer Position NOTE: Adjust the prox. switch position if the
results are erratic. The gap between the
Sensor bottom face of the sensor and the upper
surface of the steer plate should
measure 0.060 +0.04/–0.03 in.
This test observes feedback from the Steer (1.5 +1.0/–0.7 mm) (Alignment Tool,
Position Sensor. P/N 939-350/ALT, is available from the
Parts Distribution Center).

obstructions with ample room for Steer Tire Value Steer Tone
(when in Active
maneuvering. Position Displayed Maintenance Mode)
NOTE: Steer tire rotation is opposite that of the 90° (full clockwise)
101 High
to 67°
steer tiller.
67° to 41° 100 Medium
Run test: 41° to 18° 000 Low
NOTE: Audible "Steer Tones" are enabled when 18° to –18° (wheels
this test is run in Active Maintenance 001 None
centered)
Mode.
–18° to –41° 011 Low
As the steer tire rotates, the numbers listed in –41° to –67° 010 Medium
the table appear on the display. If they do not
change or are erratic, the test has failed. –90° (full
110 High
clockwise) to –67°
Make sure the steer position proximity switch is
Error Condition 111
not damaged. Replace components as
necessary.

Action/
Meter Setting
JPC24
1 Disconnected/ JPC24-1 Perform step 2 Replace VM
DCV 10.5 to 13V
2 JPS2-1 Perform step 3

TP4
3 JPC24-17 Perform step 4 T/S wiring &
DCV Over metal: <2V
4 JPC24-20 Perform step 5 sensor
Not over metal: >7V
5 JPC22-9 Replace VM

Input Tests Test I91 - iPort Communication
Test I91 - iPort

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

Test I91 - iPort Communication Input Tests

Output Tests
Output Tests

and Repair table.

table below.

Action/
Meter Setting

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

for this step.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Action/
Setting
Model 4150
JPF2 &
T/S wires,
JPC18
1 JF2-1 JPC18-9 Approx. 18 ohms Perform step 2 connections, and
Disconnected
contactor coil
/Ohms
T/S K2 Relay
2 JPF2-1 TP4 B+ Perform step 3 and Fuse/Relay
Card
DCV
Check
TP1 (B+) JPC18-9 Test ON: approx. 23V
3 contactor for Replace VM
or LPC-X or LPC-Y Test OFF: 0V
binding
Model 4250
T/S wires,
JPL1 connections
1 Disconnected JL1-13 JL1-6 Approx. 37 ohms Perform step 2 (including JPL4),
/Ohms and the
contactor coil
2 JPL1-13 TP4 B+ Perform step 3
DCV Check Replace LPA

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

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

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

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

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

Action/
Setting
JPF2 T/S wiring,

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

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

Output Tests Test O08 - Sideshift Solenoid (SOL9L, SOL9R)
Test O08 - Sideshift 5. Turn the key switch OFF and disconnect
Solenoid (SOL9L, SOL9R) 6. Disconnect wire from the right Sideshift
Solenoid at SOL9R-1.
This test toggles the sideshift solenoids (SOL9L, 7. Connect an ammeter in series with the
SOL9R) ON and OFF. right Sideshift Solenoid as follows:
• (–) lead to terminal of SOL9R-1
Run test: • (+) lead to wire removed from SOL9R-1
1. Turn the key switch OFF and disconnect 8. Reconnect the battery connector and turn
the battery connector. the key switch ON. Start test.
2. Disconnect wire from the left Sideshift
Solenoid at SOL9L-1.
3. Connect an ammeter in series with the left 0.500 to 1.000A ON
Sideshift Solenoid as follows: 0.000 to 0.020A OFF
• (–) lead to terminal of SOL9L-1
• (+) lead to wire removed from SOL9L-1 If these results are not observed, the test has
failed. Reconnect wire to SOL9R-1.
the key switch ON. Start test. NOTE: Individual coils are approx. 29 ohms.
0.500 to 1.000A ON
0.000 to 0.020A OFF
If these results are not observed, the test

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

Action/
Setting
JPC18 T/S wiring,

1 Disconnected JPC18-14 JF2-8 Approx. 14 ohms Perform step 2 coils, and
/Ohms connections
T/S wiring and

2 SOL9L-2 connections.
Check for binding. Perform step 3
DCV JPC18-14 Approx. 22V
Replace solenoid T/S wiring and
3 SOL9R-2 connections.
Replace VM

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

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

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

Solenoid ON and OFF.
0.000 to 0.020A OFF

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

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

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

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

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

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

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

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

Action/
Setting
JPC20
1 Disconnected JPC20-16 JPC20-15 Approx. 16 ohms Perform step 2 T/S wires and coil
/Ohms
2 DCV JPC20-15 B+ Perform step 3
Solenoid OFF: B+
Test TP4 Replace VM
Solenoid ON: Check for binding/
3 Activated JPC20-16
approx. 21V when contamination
/DCV
full power

Output Tests Test O18 - Horn
Test O18 - Horn

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

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

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

Test O19 - Ramp Sounder Output Tests
Test O19 - Ramp

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

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

Action/
Setting
T/S wiring. If good,

1 DCV JPD1-1 JPC24-2 Test ON: voltage ramps up Replace VM
replace Operator Display

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

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

from shorting to any components.

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

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

Test O23 - Toggle Amplifier Fan Output Tests
Test O23 - Toggle

Amplifier Fan
On trucks equipped with an optional cooling
fan, this test toggles the power amplifier cooling
fan ON and OFF.
A successful test proves the fan, wiring, and

related circuitry in the VM are working
correctly.
NOTE: The cooling fan turns ON when the
internal temperature of the LTPA, RTPA,
or LPA reaches 134°F (56.7°C).
Run test:
Fan Value Displayed
On PWM 100%
Off PWM 0%

failed.

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

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

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

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

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

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

0 and exit the test.

Action/
Setting
If current does not ramp

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

Test O29 - Ramp Traction Motors Output Tests
Test O29 - Ramp Traction Run test:

Motors 1. Step on the deadman pedal and run test.
2. Press ENTER once to run motors in
reverse. Press a second time to run motors
This test ramps the Traction Motors by
in forward. The requested percent of ON
gradually increasing the command to the
time is displayed.
Traction Power Amplifiers via the CAN Bus.
This test verifies that the TPAs can generate 3. Use the UP button to increase RPM in
current and drive the Traction Motors. increments of 15%, from 0 to 90%.
4. Press DOWN button to decrease the
request to 0, and exit the test.
Running this test for an extended period 5. Observe both traction motors; they both
of time can cause damage to the should be moving close to the same rate of
Traction Motors, Traction Power speed.
Amplifiers, or wiring.
If one motor is faster than the other, refer to
Diagnosis and Repair below.
The Traction Motors will rotate during

this test. Jack the drive wheels off the
floor. Use extreme care whenever the lift
truck is jacked up for any reason. Never
block the lift truck between the
telescopic and the floor. Use a suitable
hoist to stabilize the mast. Keep hands
and feet clear from beneath vehicle
while jacking. Use jack stands or solid
blocks to support truck. DO NOT rely on
the jack alone. See “Jacking Safety” on
page 2-9.

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

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

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

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

test.

failed.

Action/
Setting
JPF2 & Right Side:

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

Test O32 - Toggle Relay Enable Output Tests
Test O32 - Toggle Relay NOTE: Removing K1 will disable any key-power
accessories installed on the truck.
Enable If results do not match the preceding table, the
test has failed. Refer to Diagnosis and Repair.
This test toggles Fuse/Relay Card relays K1,
K2, K3, and K4 ON and OFF.
Run test:
NOTE: OFF is displayed when entering the test
even if the relays are closed.
Press the ENTER button to toggle the test.
The following table gives the expected value at

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

swapping K1 or K4 with the suspected relay
and performing the test again. Refer to relay
troubleshooting procedures on page 5-11.

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

Output Tests Test O33 - Handle Heater
Test O33 - Handle

Heater
This test proves the control handle heater is
working correctly.
Run Test
The Operator Display shows 25% if the voltage
from the VM to the handle heater is correct.
The test is a success if the displayed value is

correct.
Test OFF Test ON
0 25%
If not, the test has failed. Refer to Diagnosis and

Repair.

Action/
Meter Scale
Test OFF: 0V
Disconnect
1 PC12-7 PC12-12 Test ON: approx. Perform step 2 Replace VM
JPC12/DCV
1.1V
2 JP12-12 Open Circuit Perform step 3

Disconnect JP12-7 Replace cable from
3 JPC12 and JH1-7 Perform step 4
0 Ohms VM to handle
JH1/Ohms
4 JP12-12 JH1-13 Replace handle

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

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

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

A successful test proves the wiring and related

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

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

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

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

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

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

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

Test O45 - HSA1 Solenoid (SOL7C, SOL7R) Output Tests
Test O45 - HSA1 4. Reconnect the battery connector and turn

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

Action/
Meter Setting
JPT18 & JPF2

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

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

Output Tests Test O47 - Customer Output
Test O47 - Customer

Output
NOTE: This test only applies to trucks with the
Customer Output option enabled.
This test toggles the device ON and OFF.
Run test:
Use the ENTER button to toggle the test ON and
OFF. The Operator Display shows ON or OFF.

Action/
Meter Setting
Test ON: B+
1 Device– Replace device Perform step 2
Device+ Test OFF: 0V
2 TP4 B+ Perform step 3 T/S B+ to device

DCV
Verify option is
Test ON: B+ T/S wiring to enabled with
3 TP1
Test OFF: 0V device from VM FlashWare.
Replace VM.

Diagnosis and Repair Output Tests

Models 4150/4250 Maintenance Manual Section 7. Component Procedures
Section 7. Component Procedures

Section 7. Component Procedures Models 4150/4250 Maintenance Manual
List of Component Procedures
List of Component Drive and Brake . . . . . . . . . . . . . . . . .

Drive Units . . . . . . . . . . . . . . . . . . . . .
7-33
7-34
Procedures Removal . . . . . . . . . . . . . . . . . . . . . .
Installation. . . . . . . . . . . . . . . . . . . .
7-34
7-35
Adding Oil . . . . . . . . . . . . . . . . . . . . 7-35
Component Locator Photos . . . . . . . . . . 7-5 Repair . . . . . . . . . . . . . . . . . . . . . . . 7-36
Models 4150/4250 . . . . . . . . . . . . . . . 7-5 Drive Tire Pressing. . . . . . . . . . . . . . . . 7-45
Models 4150/4250 Rear View . . . . . . . 7-6 Brakes. . . . . . . . . . . . . . . . . . . . . . . . . 7-46
Major Components - Brake Assembly P/N 1043541 . . . . . 7-46
Upper Tractor Compartment . . . . . . 7-7 Brake Assembly P/N 1094113 . . . . . 7-47
Major Components -
Lower Tractor Compartment . . . . . . 7-8 Electrical Components . . . . . . . . . . . . 7-51
Major Components - Tractor Front . . . 7-9 Battery Procedures . . . . . . . . . . . . . . . 7-52
Power Cables . . . . . . . . . . . . . . . . . . . . 7-54
Special Tools and Decals . . . . . . . . . . . 7-11 Motors . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
Special Tools . . . . . . . . . . . . . . . . . . . . 7-12 General . . . . . . . . . . . . . . . . . . . . . . 7-56
Decals ands Tags . . . . . . . . . . . . . . . . . 7-13 DC Motor Service . . . . . . . . . . . . . . . 7-56
Polishing the Commutator . . . . . . . . 7-58
Steering and Controls . . . . . . . . . . . . . 7-17 AC Motor Service . . . . . . . . . . . . . . . 7-59
Steer Caster Assembly . . . . . . . . . . . . . 7-18 Traction Motors . . . . . . . . . . . . . . . . . . 7-62
Wheel Removal . . . . . . . . . . . . . . . . . 7-18 Lift Motor. . . . . . . . . . . . . . . . . . . . . . . 7-64
Wheel Installation . . . . . . . . . . . . . . . 7-18 Power Amplifiers . . . . . . . . . . . . . . . . . 7-65
Steer Caster Removal . . . . . . . . . . . . 7-18 Deadman Pedal . . . . . . . . . . . . . . . . . . 7-66
Steer Caster Installation . . . . . . . . . . 7-21 Wiring and Harness Connectors. . . . . . 7-67
Steer Caster Disassembly . . . . . . . . . 7-21 General Connector Repair Procedures 7-67
Service . . . . . . . . . . . . . . . . . . . . . . . 7-22 Soldering Procedures . . . . . . . . . . . . 7-67
Reassembly. . . . . . . . . . . . . . . . . . . . 7-22 Molex Connectors. . . . . . . . . . . . . . . 7-68
ComfortStance Floor. . . . . . . . . . . . . . . 7-23 AMP Water-Resistant Connectors . . . 7-69
Floor Plate. . . . . . . . . . . . . . . . . . . . . 7-23 AMP Harness/Traction
Strut Removal . . . . . . . . . . . . . . . . . . 7-24 Power Amplifier Connector . . . . . . 7-72
Pivot Plate Bearing Replacement . . . . 7-24 Cold Storage . . . . . . . . . . . . . . . . . . . . 7-75
Control Handle -
Standard/Cold Storage . . . . . . . . . . 7-25 Hydraulic Components . . . . . . . . . . . . 7-77
Removal . . . . . . . . . . . . . . . . . . . . . . 7-25 Manifold Solenoids, Fittings,
Handle Disassembly . . . . . . . . . . . . . 7-25 and Attachments . . . . . . . . . . . . . . 7-78
Handle Assembly . . . . . . . . . . . . . . . 7-25 Hydraulic Fluid . . . . . . . . . . . . . . . . . . 7-82
Installation . . . . . . . . . . . . . . . . . . . . 7-26 Fluid Level . . . . . . . . . . . . . . . . . . . . 7-82
Inspection . . . . . . . . . . . . . . . . . . . . . 7-26 Selecting Hydraulic Fluid Type . . . . . 7-82
Hand Soldering Procedures . . . . . . . . 7-26 Bleeding the Hydraulic System . . . . . 7-82
Control Handle - Pressure Relief Valve . . . . . . . . . . . . . . 7-83
Optional Variable Flow . . . . . . . . . . 7-28 Measuring System Pressure . . . . . . . 7-83
Return Spring Replacement. . . . . . . . 7-28 Adjusting Pressure . . . . . . . . . . . . . . 7-83
Handle Removal . . . . . . . . . . . . . . . . 7-28 Proportional Lowering Valve Adjustment 7-84
Disassembly . . . . . . . . . . . . . . . . . . . 7-28 Carriage Service - Lift-Tek ® . . . . . . . . . 7-85
Lift/Lower Potentiometer (VR2) ISS Removal - Mast on Truck . . . . . . 7-85
Replacement. . . . . . . . . . . . . . . . . 7-28 ISS Removal - Mast on Floor. . . . . . . 7-85
Travel Potentiometer (VR1) ISS Inspection . . . . . . . . . . . . . . . . . 7-85
Replacement. . . . . . . . . . . . . . . . . 7-30 Cylinder Seal Replacement . . . . . . . . 7-85
Sideshift/Tilt Switch Rubber Boot ISS Installation. . . . . . . . . . . . . . . . . 7-87
Replacement. . . . . . . . . . . . . . . . . 7-30
Assembly . . . . . . . . . . . . . . . . . . . . . 7-30
Installation . . . . . . . . . . . . . . . . . . . . 7-31

Carriage Service - Cascade™. . . . . . . . . 7-88 Flow Control Valve Replacement . . . 7-140

Sideshift Cylinder Seal Replacement . 7-88 Mast Tilt Adjustment . . . . . . . . . . . . . 7-141
Fork Positioner . . . . . . . . . . . . . . . . . 7-88 Mast Tilt Position Switch
Service . . . . . . . . . . . . . . . . . . . . . . . 7-90 Adjustment . . . . . . . . . . . . . . . . 7-141
Lift Cylinder Service . . . . . . . . . . . . . . . 7-93
All except Model 4250 TT Masts
S/N 50501 Up . . . . . . . . . . . . . . . 7-93
Model 4250 TT Masts S/N 50501 Up . 7-93
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . 7-97
Mast Removal and Installation . . . . . . . 7-98
Partial Removal . . . . . . . . . . . . . . . . . 7-98
Installation after Partial Removal . . . . 7-98
Complete Mast Removal . . . . . . . . . . 7-99
Installation after Complete Removal. 7-100
Lift Chains . . . . . . . . . . . . . . . . . . . . . 7-101
Main Lift Chain Adjustment. . . . . . . 7-101
Main Lift Chain Service . . . . . . . . . . 7-102
Free Lift Chain Adjustment . . . . . . . 7-104
Free Lift Chain Service. . . . . . . . . . . 7-105
Roller Bearing (Puck) Adjustment -
TT Mast - S/N 50501 Up . . . . . . . . 7-106
Mast Skewing . . . . . . . . . . . . . . . . . . . 7-107
All except Model 4250
TT Masts S/N 50501 Up . . . . . . . 7-107
Model 4250 TT Masts S/N 50501 Up 7-108
2-Stage (TF) Mast Service . . . . . . . . . . 7-109
Disassembly . . . . . . . . . . . . . . . . . . 7-109
Inspection . . . . . . . . . . . . . . . . . . . . 7-110
Reassembly . . . . . . . . . . . . . . . . . . . 7-110
Cylinder Removal and Installation . . 7-111
Internal Reeving Installation . . . . . . 7-115
3-Stage (TT) Mast Service -
below S/N 50501 . . . . . . . . . . . . . 7-116
Disassembly . . . . . . . . . . . . . . . . . . 7-116
Inspection . . . . . . . . . . . . . . . . . . . . 7-116
Reassembly . . . . . . . . . . . . . . . . . . . 7-117
3-Stage (TT) Mast Service -
S/N 50501 Up. . . . . . . . . . . . . . . . 7-122
Disassembly . . . . . . . . . . . . . . . . . . 7-122
Inspection . . . . . . . . . . . . . . . . . . . . 7-122
Reassembly . . . . . . . . . . . . . . . . . . . 7-122
Quad Mast Service . . . . . . . . . . . . . . . 7-130
Disassembly . . . . . . . . . . . . . . . . . . 7-130
Inspection . . . . . . . . . . . . . . . . . . . . 7-131
Reassembly . . . . . . . . . . . . . . . . . . . 7-131


Component Locator Photos

Models 4150/4250
Overhead Guard
Mast
Battery
Connector Tilt Cylinder
Load Backrest
Carriage
Battery Gate
Forks
Right Traction Tire

Models 4150/4250 Rear View
Control Handle
Operator
Display
Steer Tiller
Deadman Pedal
Steerable Wheel

Major Components - Upper Tractor Compartment

Vehicle Operator Fuse/Relay Hydraulic Contactor
Manager Display Horn Card Manifold Panel
Right Traction
Power Amp
Lift Power Amp

(4250 Only)
Left Traction
Power Amp
Steering Valve
FU8
FU6 FU1
FU3
FU7 FU2
FU5
Fuse/Relay Card
Contactor Panel
Operator Display Key Switch EPO

Major Components - Lower Tractor Compartment
Hydraulic Steer Motor
Steer Proximity
Sensor
Strut
(ComfortStance Floor only)
Steerable Wheel
Assembly
Deadman
Pedal
Steer Tire ComfortStance

Floor

Major Components - Tractor Front

Steer Motor Brake Release
and Pump Bolts
Tilt Cylinder Tilt Cylinder
Right Traction Lift Motor Left Traction

Motor and Brake and Pump Motor and Brake


Special Tools and Decals
Special Tools and Decals


Special Tools and Decals Special Tools
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
Set gap between the bottom face of the steer position

Alignment Tool 939-350/ACT
proximity sensor and the upper surface of the steer plate.
Anti-static Field Kit 1-187-059

ESD Protection
Anti-static Wrist Straps 1-187-058/001
Axle Puller 950-350/AXLEPL Steer wheel axle removal
Chain Gauge 939-10606 Lift chain inspection
Connector Unlatching 950-042 Separate AMP connectors
Crimp Tool 1069861 Crimp power cable lugs
Cylinder Head Cap Tool 1217957/72 Removal of cylinder head cap on carriage cylinders for Model
4250 TT masts S/N 50501 Up
Cylinder Retainer 1217957/71 Removal of retainer on carriage cylinders for Model 4250 TT
Socket masts S/N 50501 Up
Model 4150 TF/TT mast main and free lift cylinder end cap
End Cap 1090761/003
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
ESD/voltage surge protection for serial type FlashWare

Surge Protector 154-010-801
connections
USB/CAN Interface 230489-001 FlashWare connection to truck

Decals ands Tags Special Tools and Decals
Decals ands Tags

Table 7-2. Decal and Tag Location Chart
Decal and Specification Locations
Identifier Description
1 Raymond (2 places)
2 ACR (2 places)
3 Warning Decal (2 places)
4 Mast Specification Tag
5 Manual Replacement
6 Manual Location
7 EE Compliance (optional)
8 Battery Removal Warning (2 places)
9 No Riding
10 Overhead Guard ANSI/ITSDF conformance
11 Warning Decal (<S/N 50501 - 2 places; >S/N 50500 - 4 places)
12 Operator General Safety Decal
13 Specification Tag
14 Attachment Tag
15 Approved Lubricants
Note: Items in italics are safety decals.

Special Tools and Decals Decals ands Tags

Figure 7-1. Decal and Specification Tag Locations
3
8
10
2
9
4
7
Shown with mast on trucks below S/N 50501
WARNING
11 Keep
Hands
Clear
311563-000
Mast on trucks above S/N 50500

Decals ands Tags Special Tools and Decals

Figure 7-1 (Cont.). Decal and Specification Tag Locations
11
WARNING
Keep
Hands
Clear
311563-000
11
WARNING
Keep
Hands
Clear
311563-000

Special Tools and Decals Decals ands Tags

Figure 7-2. Decal and Specification Tag Locations
13
12
14
6 15

Steering and Controls
Steering and Controls


Steering and Controls Steer Caster Assembly
Steer Caster Assembly Steer Caster Removal

Wheel Removal
2. Remove the Steer Compartment Cover.
1. Position the steerable wheel so the axle
3. On trucks equipped with the
nut is visible.
ComfortStance™ Floor system, remove
2. Turn the key switch OFF and disconnect strut. Refer to “Strut Removal” on
the battery connector. page 7-24.
4. Take the steer chain off the steer plate by
removing the outer nut on the threaded
end of the chain anchor. See Figure 7-2.
Use extreme care whenever the truck is
jacked up. Never block the truck Figure 7-2. Removing Steering Plate Chain Nut
between the telescopic and the floor.
Use a suitable hoist to stabilize the mast. Steer Plate
Keep hands and feet clear from vehicle
while jacking the truck. After the truck is
jacked, place solid blocks beneath it to Steer
support it. Do not rely on the jack alone Motor
to support the truck. See “Jacking
Safety” on page 2-9.
3. Jack and block the truck so the steerable Steer

wheel is off the floor. Chain
Chain Anchor Nut
4. Remove the axle nut.
5. Using a drift pin, drive the axle
approximately 0.5 in. (13 mm) toward the
battery compartment. 5. Disengage the steer chain from the steer
motor assembly. Leave chain attached to
6. Rotate the steerable wheel so the opposite
the other side of the steer plate.
end of the axle is visible.
6. Remove the two screws that hold the steer
7. Remove the axle. Axle Puller
position proximity sensor bracket in place,
P/N 950-350/AXLEPL is available from
then remove the bracket. See Figure 7-3.
the Parts Distribution Center.
8. With the axle removed, remove the wheels. Figure 7-3. Removing Steering Position Sensor
Sensor
Wheel Installation Ring
Proximity
Sensor
1. Place the wheel assemblies under the
truck and position them in the steer pivot.
2. Carefully insert the axle in the steer pivot
and wheels. Do not damage the bearing
seals.
3. Install the axle nut. Tighten the axle nut
until the wheels start to bind when turned
by hand. Loosen the axle nut 1/4 turn.
4. Lower truck to the floor.
Steer
Plate

Steer Caster Assembly Steering and Controls
7. Remove the three flat head screws that Figure 7-6. Removing Steering Plate Bolts
hold the steer sensor ring to the top of the
steer plate, then remove the ring. See
Figure 7-4.
Figure 7-4. Removing Steering Sensor Ring
Flat Head Screws
10. Remove the six mounting bolts holding the

steerable wheel assembly to the lift truck
frame. See Figure 7-7.
Figure 7-7. Steering Wheel Mounting Bolts
8. Scribe a mark from the top of the steer

hub onto the steer plate. (Realign these
marks later to ensure the steer plate is
installed in the correct position). See
Figure 7-5.
Figure 7-5. Scribing a Mark from Hub to Steer Plate Mounting Bolts
Scribed Mark On Plate
Scribed Mark On Hub

11. Place chocks in front of the drive wheels.
12. Reinstall one of the steer plate bolts. Wrap
a piece of heavy wire around this screw to
use as a temporary support. You will use
this temporary support to lower the steer
assembly to the floor when the lift truck is
9. Remove the four bolts that hold the steer jacked up. See Figure 7-8.
plate in place, then remove the steer plate.
See Figure 7-6.


Figure 7-8. Temporary Support for Steerable Wheel Figure 7-9. Wheel Hub Shown Flush with Lift Truck Frame
Heavy Wire and

Steer Plate Bolt
Wire and Bolt

Jack
Block
The steerable wheel assembly is heavy.

Use extreme care whenever the truck is Use a suitable lifting device if necessary.
jacked up. Never block the truck
between the telescopic and the floor. 15. While holding the wire, slowly move the
Use a suitable hoist to stabilize the mast. steerable wheel assembly out from under
Keep hands and feet clear from vehicle the truck.
while jacking the truck. After the truck is 16. As the wheels come out, lower the casting
jacked, place solid blocks beneath it to to the floor.
support it. Do not rely on the jack alone
17. Move the steerable wheel assembly down
to support the truck. See “Jacking
and out from beneath the truck. See
Safety” on page 2-9.
Figure 7-10.
13. Jack the rear of the truck. As the lift truck
Figure 7-10. Steerable Wheel Removed
is jacked, the steerable wheel assembly
separates from the tractor frame.
NOTE: Removing the steerable wheels from the
steer pivot yoke reduces the jacking
height.
14. Continue to jack the lift truck until the
pivot hub on the steerable wheel is flush
with the tractor frame. Block the lift truck
in this position. See Figure 7-9.

Steer Caster Assembly Steering and Controls
Steer Caster Installation 17. Test the steering function. If OK, return lift
truck to service.
Position the steerable wheel assembly within
the tractor frame. Steer Caster Disassembly
1. While holding the steer wheel assembly
1. Remove the nut that holds the upper steer
upright, lower the tractor until it is near
hub to the steer pivot. See Figure 7-11.
the mounting flange.
2. Remove the wire and bolt from the steer Figure 7-11. Steerable Wheel Components
plate. Position the stop correctly.
Lock Upper
3. Install the mounting bolts. Refer to Nut Steer
“Component Specific Torque Chart” on Hub
page A-4.
Pivot
4. Install the steer plate. Align the scribe Key Hub
marks, made during disassembly, between
the hub and the steer plate. Grease
5. Install the four mounting bolts and Fitting
Bearings
tighten. Steer
6. Install the steer sensing ring on top of the Pivot
steer plate.
7. Install the steer position proximity sensor
bracket. The gap between the bottom face
of the sensor and the upper surface of the
steer plate should measure 0.060
+0.04/–0.03 in. (1.5 +1.0/–0.7 mm).
(Alignment Tool, P/N 939-350/ACT, is Bearings
available from the Parts Distribution
Center)
8. Reinstall and adjust the steer chain. Chain
should flex approx. 1/8 to 1/4 in. (1.6 to
3.2 mm).
9. On trucks equipped with the
ComfortStance™ Floor system, install
strut. Perform step 6 in "Installation" on
page 7-24.
the key switch ON. 2. Use a three-arm puller to remove the
11. Run "Test I89 - Steer Position Sensor". upper steer hub.
This verifies the steer position proximity 3. Pull the steer pivot out of the pivot hub.
sensor is adjusted correctly. See Figure 7-12.
13. Remove any blocks supporting the truck.
14. Lower the lift truck to the floor.
15. Install the steer compartment cover.
the key switch ON.


Figure 7-12. Steerable Wheel Shown Unassembled
Pivot Hub
Steer Hub
Steer Pivot and Lock Nut
and Wheel
Service
1. Clean the inside of the pivot hub.
2. Clean and inspect the bearings. Replace
any worn components.
3. Remove, clean, and inspect the keys.
Clean and inspect the keyways.
4. Pack the bearings with grease. Refer to
“Lubrication Specification Chart” on
page A-2. Add additional grease to the
pivot spindle and hub so that when the
unit is assembled, it is 50-75% full of
grease.
5. Slide the steer pivot into the pivot hub.
6. Coat the keys and keyways with
thread-locking compound (P/N 990-536).
Reassembly
1. Install the upper steer hub.
2. Install the nut.
3. Tighten the nut while rotating the pivot
hub that mounts to the tractor frame.
4. Continue to tighten the nut until the pivot
hub just starts to resist rotation.

ComfortStance Floor Steering and Controls
ComfortStance Floor
The ComfortStance Floor system consists of a
two piece floor (floor plate and pivot plate), two
pivot bearing blocks, a strut, and a tie rod. See
Figure 7-13.
Figure 7-13. ComfortStance Floor Components
Strut
3/4-10
(for lifting eye bolt)
8.5 in. (22 cm)
3 in. (7.6 cm)

Pivot Plate
Bearing
Floor Plate
Block
Bump Stop
Tie Rod
Bearings
Bearing
Block
Floor Plate 3. Remove bolt securing deadman switch

cable. Unplug deadman switch and
Removal remove deadman pedal.
1. Turn the key switch OFF and disconnect 4. Remove bolt securing tie rod to the floor
the battery connector. plate (located under truck at the right rear
side).
2. Remove the steer compartment and
console covers. 5. Remove floor pad and pad over deadman
pedal.

Steering and Controls ComfortStance Floor
6. Install a 4 in. lifting eye bolt into the NOTE: If removing the strut only, attach a 4 in.
threaded hole in the floor plate. lifting eye bolt to the floor plate and lift
slightly to relieve pressure on the strut.
NOTE: The bottom bolt that secures the strut to
The floor plate weighs approx. 320 lb. the lower mounting bracket is accessible
(145 kg). through a hole in the battery
compartment wall.
7. Use a suitable lift strap/chain and
overhead hoist to lift floor plate. Slightly Pivot Plate Bearing
lift to remove slack in strap/chain. Replacement
8. Carefully remove the three bolts securing
the floor plate to the pivot plate. 1. Remove steerable wheel assembly. Refer to
“Steer Caster Assembly” on page 7-18.
9. Remove floor plate.
2. Remove four bearing block mounting
bolts. See Figure 7-13.
Installation
3. Remove pivot plate.
1. Install strut to lower bracket.
4. Remove bearing blocks and spacers from
2. Apply thread-locking compound pivot plate.
(P/N 990-536) to the three bolts that
5. Remove bearings from pivot block casting.
secure floor plate to the pivot plate and
install floor plate. Leave eye bolt attached 6. Install new bearings.
to floor plate and lower until approx. level. 7. Reinstall bearing blocks and spacers.
3. Install tie rod. Refer to “Component NOTE: Use a M12 x 1.75 tap to chase the
Specific Torque Chart” on page A-4. threads of the four bearing block
4. Install deadman pedal and cable. mounting holes.
5. Attach strut to upper bracket. NOTE: Position the bearing blocks with the
6. Lower floor plate completely. When settled, counter-bore facing down.
the floor plate height should measure 8. Reinstall the pivot plate with new
approx. 9 3/8 in. (238 mm) from the top of mounting bolts. Apply thread-locking
the floor pad to the warehouse floor. If not, compound (P/N 990-536).
lift floor plate slightly and adjust strut in
the upper slotted bracket until correct 9. Reinstall steerable wheel assembly. Refer
dimension is obtained. Torque strut to “Steer Caster Installation” on page 7-21.
mounting bolts. Refer to “Component
Specific Torque Chart” on page A-4.
Remove hoist and eye bolt.
7. Install deadman pedal cover, floor pad,
and truck covers.
8. Test operation and return to service.
Strut Removal
Remove the bolts securing the strut to the
upper and lower mounting brackets and remove
strut.

Control Handle - Standard/Cold Storage Steering and Controls
Control Handle - 3. Position the thumb control return spring

onto the control handle. Make sure that
Standard/Cold Storage the ears of the spring are positioned
correctly. See Figure 7-14.
Removal Figure 7-14. Correct Positioning of Spring Ears

2. Remove the console cover.
Use correct ESD precautions. See “Static

Precautions” on page 2-8.
3. Unplug the control handle wiring harness

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

Steering and Controls Control Handle - Standard/Cold Storage
2. Install the lift knob on the potentiometer 6. Reconnect the battery connector and turn
shaft. Do not tighten the set screws yet. the key switch ON.
3. Rotate the lift knob fully CCW and tighten 7. Enter Maintenance Mode and perform
the set screws. Learn. See “Maintenance Mode” on
4. Verify the lift potentiometer voltages. page 3-18.
5. Install the nylon screw inserts over the set 8. Reinstall the console cover.
screws.
Inspection
Whenever the control handle is disassembled,
The solid state potentiometers used in perform the checks defined in the following
this handle are ESD sensitive. table.
6. When installing the wire harness, a service Part Check for:
loop is required.
Horn button Cracks or deformation
7. Install the handle and route the harness
assembly
last, after all the other wires are routed
through this area. Routing should occur Lift/lower pot Cracks, deformation, loose dowel
toward the left side of the truck, then bracket pin, over-round or oversized
forward and around the front of the VM. shaft hole
Connect the handle from the right side of
Travel pot Cracks, loose spirol pin, stripped
the VM. enclosure threads, deformation or indents
on external stops
Handle halves Cracks, damage or deformation

Make sure all other wires are tied back or indents on external stops
and away from the handle harness
Lift/lower Cracks, deformation, stripped
service loop. Do not route through any
knob threads, loose dowel pin
components.
Other Stripped threads. All screw
8. Test the motion of the service loop by hardware threads must be cleaned.
cycling the handle. The entire length of the
loop should absorb the twist. Make sure
that the loop does not hang up on adjacent Hand Soldering Procedures
wires, cable ties, or structures.
When hand soldering is performed on solid
state potentiometers, the following is
Installation recommended:
1. Insert the shaft of the control handle • Flux - rosin base
assembly into the mounting bracket.
• Solder - 60/40 rosin core or equivalent
2. Apply thread-locking compound
• Solder Iron - 55 watt max.
(P/N 1013829) to threads of the screw.
• Tip Size - 0.118 in. (3 mm) dia. x 1.182 in.
3. Hold the control handle in place, aligning
(30 mm) long screwdriver
the hole in the shaft with the hole in the
bracket. Torque the set screw to 14 ft. lb. • Tip Temperature - 500°F (260°C) max.
(19 Nm). • Terminal Contact Time - 6 seconds max.
4. Route the control handle wiring harness NOTE: Apply light soldering iron pressure on
and plug into the VM at JPC12. the terminal. Make sure the tip is clean.
5. Make sure cable extends out of the handle A dirty tip does not transfer heat well,
as straight as possible to avoid kinking.

Control Handle - Standard/Cold Storage Steering and Controls
therefore requiring longer dwell time

and greater tip pressure.
Contact contamination can occur if

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

dampened with an alcohol-based cleaner. Make
sure cleaner does not seep into the electrical
component.
Components damaged due to solvent saturation

are not covered under warranty.

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

pot.
Optional Variable Flow 4. Slide the lift/lower potentiometer bracket
over the potentiometer shaft, engaging the
metal tab of potentiometer in the slot in
Return Spring Replacement the side of the bracket. See Figure 7-15.
The lift/lower knob return spring can be Figure 7-15. Lift/Lower Pot Bracket Installation
replaced without removing and disassembling
the control handle. Metal Tab
When replacing a return spring, coat the inside

of the spring lightly with lithium grease Bracket
(P/N 990-635).
Handle Removal
2. Remove the console cover.
3. Disconnect cable from the control handle.
5. Insert the lift/lower pot assembly into the
4. Loosen control handle set screw and right control handle shell.
remove handle from pivot.
6. Connect PCH2.
7. Adhere heater pad section of flexible
Disassembly circuit to back of pot.
NOTE: A fixture (P/N 828-009-213) is available 8. Reassemble and reinstall the control
to hold the handle in position while handle. See "Assembly" and “Installation”
disassembled. Note the orientation of on page 7-31.
switches, potentiometers, routing of
cables and wires for reassembly.
the key switch ON.
1. Remove nylon plug from the lift/lower 10. Enter Maintenance Mode and perform
knob to expose set screw underneath. Learn. See “Maintenance Mode” on
Loosen set screw and remove lift/lower page 3-18.
knob.
11. In Run Mode, test the lift/lower function
2. Remove six socket head screws securing for correct operation.
the handle shell halves together.
3. Carefully remove the left half of the handle
shell.
Lift/Lower Potentiometer (VR2)

Replacement
1. Remove the lift/lower potentiometer
bracket and potentiometer from the
handle shell. Slide the bracket off the
potentiometer. See Figure 7-16 on
page 7-29.
2. Disconnect PCH2.

Control Handle - Optional Variable Flow Steering and Controls

Figure 7-16. Optional Control Handle
Sideshift/Tilt Switch Rubber Boot
Lift/Lower Pot Bracket

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

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

replacement boot inside out, install the
Replacement replacement boot and verify that the tabs
1. Lift up gently on the pivot shaft to free the are aligned and that the boot is seated
travel pot assembly from the handle. See correctly. Stretch the boot over the joystick
Figure 7-16 on page 7-29. housing. See Figure 7-17.
2. Slide the travel pot out of the pivot shaft
Figure 7-17. Boot Installation
assembly.
3. Disconnect PCH1.
4. Install double-sided tape to back of new
pot.
5. Install pot in the pivot shaft assembly,
aligning the flat on the pot shaft with the
flat inside the positioner.
6. Install the travel pot assembly in the
handle shell. The tab of the throttle pot
must engage the slot in the handle shell
(straight down). Align the composite Boot (turned inside out)
bushings with the molded holders in the
handle. 5. Reassemble and re-install the control
7. Connect PCH1. handle.
8. Adhere heater pad section of flexible
circuit to back of pot. Assembly
9. Reassemble and reinstall the control
1. Check flexible circuit and wires for correct
handle. See "Assembly" and "Installation".
routing.
2. Orient the VR1 return spring ears straight
the key switch ON.
up in the right half of the handle.
11. Enter Maintenance Mode and perform
3. Install the left half of the handle shell. The
Learn. See “Maintenance Mode” on
pin in the left side handle shell must fit
page 3-18.
between the ears of the VR1 throttle pot
12. In Run Mode, test the travel function for return spring. The wires from the VR2
correct operation. lift/lower pot must fit between the tabs in
the handle shell. Make sure the tabs do
Sideshift/Tilt Switch Rubber not crush any of these wires.
Boot Replacement 4. If using a fixture, loosen the thumb screw
and remove the handle from the fixture.
1. Move the lift/lower pot and bracket out of
5. Install the two socket head screws to hold
the way in order to access the tilt and
the handle halves together.
sideshift joystick boot.
6. Insert a screwdriver in the handle shaft
2. While activating the switch in the tilt
mounting hole to hold the shaft in place.
position, tilt back and rotate the assembly
out of the handle half. 7. Rotate the control handle from neutral to
maximum forward, then maximum
3. Remove the boot assembly.
backward, then to neutral. The handle
NOTE: The joystick assembly has locating should move freely with no binding.
indentations and the replacement boot Correct any binding before proceeding
has corresponding tabs. further.

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

screws in the handle and torque to 15 to
20 in. lb. (1.7 to 2.25 Nm).
9. Rotate the lift/lower potentiometer shaft
so the flat on the shaft is parallel to the
return spring pin on the potentiometer
bracket. If the potentiometer shaft has no
flat, rotate the shaft to the center of its
travel.
10. Install the lift/lower knob. The pin on the
knob must fit between the ears of the
potentiometer return spring.
11. Install and tighten set screw and nylon
plug in the knob. Check the potentiometer
for correct rotation and spring return to
neutral. Correct any binding.
Installation
1. Install the control handle on to the pivot.
(P/N 1013829) to the control handle set
screw.
3. Install the set screw and tighten.
4. Form a loop in the control handle cable
harness as it leaves the handle. Do not
route through or under any components.
Route the cable to the VM and connect
JPC12.
5. Make sure that all other wires are tied
back and away from the handle harness
service loop.
6. Test the motion of the service loop by
rotating the handle. The entire length of
the loop should absorb the twist. Make
sure the loop does not hang up on nearby
wires, cable ties, or structures.
7. Install covers.


Drive and Brake
Drive and Brake


Drive and Brake Drive Units
Drive Units
Removal Use extreme caution whenever the lift
truck is jacked up. Never block the lift
truck between the telescopic and the
floor. Use a suitable hoist to stabilize the
Drive unit weighs approximately 175 lb. mast. Keep hands and feet clear from
(79 kg). Use a suitable lifting device if beneath vehicle while jacking the lift
necessary. Have additional help truck. After the lift truck is jacked up,
available when removing or installing place solid blocks or jack stands
the drive unit. beneath it to support it. DO NOT rely on
the jack alone to support the lift truck.
1. Turn the key switch OFF and disconnect See “Jacking Safety” on page 2-9.
8. Jack the side of the lift truck to remove the
2. Remove the mast from the lift truck. See
drive unit. Place blocks beneath the lift
“Mast Removal and Installation” on
truck to support it. See Figure 7-19.
page 7-98.
3. Drain all the gear oil out of the drive unit. Figure 7-19. Drive Wheel Removal
Use a drain pan that is approximately 1.5
gal. (5.7 liters). See Figure 7-18.
Figure 7-18. Draining Drive Unit
9. Remove the eight bolts that secure the

wheel and tire assembly to the drive unit.
10. Remove the six bolts securing the drive
unit to the lift truck frame. See
Figure 7-20.
4. Remove the brake assembly.

5. Remove the traction motor.
6. Install a lifting eye hook into one of the
traction motor mounting holes.
7. Loosen, but do not remove, the eight bolts
that secure the wheel and tire assembly to
the drive unit.

Drive Units Drive and Brake

Figure 7-20. Drive Unit Mounting Bolts Adding Oil
NOTE: The drive unit must be installed before
filling the drive unit with oil.
1. Remove the oil level check screw.
2. Remove the fill screw.
3. Refer to “Lubrication Specification Chart”
on page A-2 to determine the correct type
of gear lubricant (or oil for cold storage lift
trucks).
4. Slowly pour the lubricant in the fill hole.
Watch the oil level check screw hole. When
the lubricant is level with the bottom of the
screw hole, stop pouring. Allow all excess
oil to drain out.
Installation
5. Reinstall the oil level check screw and fill
1. Make sure the drain plug is installed in screw.
the drive unit.
(P/N 1013829) to the two locating pins.
Install the locating pins into the drive unit
casting.
3. Position the drive unit in place. Align the
bolt holes in the mounting flange with the
bolt holes in the tractor frame.
(P/N 1013829) to the six mounting bolts
and install. Torque to 180 ft. lb. (244 Nm).
5. Install the drive wheel and tire assembly.
Install the wheel mounting bolts.
6. Lower the lift truck to the floor and torque
drive wheel mounting bolts in a star
pattern to 110 ft. lb. (151 Nm).
7. Apply silicone sealant (P/N 990-659) to the
joint between the drive unit and traction
motor. Reinstall the traction motor. Torque
mounting screws to 28 ft. lb. (38 Nm).
8. Reinstall the brake assembly. Make sure
to remove the brake release bolts from the
brakes.
9. Refill the drive unit with gear oil until the
fluid is even with the bottom of the fluid
check hole located on the side of the drive
unit.
10. Install the mast.

Repair
Refer to Figure 7-21 for all bracketed [ ] item
number references in this procedure.
Figure 7-21. Drive Unit Exploded View

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

Disassembly Figure 7-24. Fill Level Plug Removal
Refer to Figure 7-21 on page 7-36 for all

bracketed [ ] item number references in this
procedure.
Clean the outside of the drive unit thoroughly

and drain any remaining oil from the drive unit.
Visually inspect the outside of the housing [1]

for damage, wear, or cracks. Pay particular
attention to the area where hub wear may be
evident, the mast pivot area, motor area, and 3. Remove the Main Cover screws [15].
around all bolts. 4. Pry the cover [16] or tap with a mallet to
loosen the cover’s seal to the housing.
Figure 7-22. Hub Wear Inspection
5. Remove the cover from the housing.
6. Inspect inside cover for damage or wear.
Axle Shaft and Ring Gear Removal

1. Loosen the set screw locking the axle shaft
clamp nut [13].
Figure 7-25. Axle Shaft Clamp Nut Set Screw
Main Cover Removal

1. Remove the drain plug [17].
Figure 7-23. Drain Plug Removal
2. Use a screwdriver in the clamp nut slot to

turn the clamp nut off.
Figure 7-26. Clamp Nut Removal
2. Remove the fill level plug.
3. Remove thrust washer [10].

4. Lift the ring gear from the housing. Figure 7-29. Spiral Pinion Removal
5. Remove thrust washer, shim, and spacer
[10, 11, and 12].
6. Drive the axle from the housing using a
rubber mallet.
Spiral Gear and Helical Gear Removal

1. Remove the set screw locking the helical
gear clamp nut [14].
Figure 7-27. Clamp Nut Set Screw Removal
4. Lift the helical gear [3], spacer, and

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

NOTE: The bearing cups and cones are usually
2. Use a screwdriver in the clamp nut slot to damaged during removal. They must be
turn the clamp nut off. (The gear may need replaced as sets.
to be wedged to keep it from turning.)
Inspect the clamp nut for damage. 1. Use a mallet and a long punch to drive the
lower pinion bearing cup [7] from the
Figure 7-28. Remove Clamp Nut housing.
NOTE: If axle and pinion bearing seat
dimensions are not recorded (stamped)
on the inside of the drive unit housing,
save the shims to use for reference at
reassembly.
Figure 7-30. Lower Pinion Bearing Cup Removal
3. Use a rubber mallet to drive the spiral

pinion [4] from the housing.
reassembly.
2. Use a mallet and punch to drive the upper
pinion bearing cup [2] from housing.


Figure 7-31. Upper Pinion Bearing Cup Removal 5. Visually inspect the housing bores and
sealing surfaces for damage or wear.
Housing Cleaning and Inspection
Thoroughly degrease the housing. Visually

inspect the entire housing again for damage,
cracks, or wear.
Axle Shaft Disassembly
3. Remove the outer axle bearing cup [8]

Always watch for pinch points when
(toward the axle) and axle seal [5] from the
using a press or pressing tools.
housing using the punch and mallet.
Figure 7-32. Axle Shaft Bearing Cup Removal 1. Place a bearing puller clamp beneath the
outer axle bearing cone [8].
2. Press the bearing from the axle using a
bearing press and a 6 in. tube.
Figure 7-34. Press Bearing from Axle
4. Use a mallet and punch to drive the inner

axle bearing cup [9] (toward the ring gear)
from the housing.
3. Inspect the axle for damage or wear.
Pinion Gear Shaft Disassembly
reassembly. 1. Place a bearing puller clamp beneath the
bearing cone [7] on the spiral gear.
Figure 7-33. Inner Axle Bearing Cup Removal


Figure 7-35. Lower Pinion Bearing Removal a. Record axle bearing seat dimension
from housing.
b. Record mounting distance etched on
ring gear.
c. Determine shim thickness required for
ring gear.
Example Ring Gear Shim Calculation

Bearing seat dim. from housing 3.7175 in.
Mounting distance from ring gear –1.8120 in.
Minimum bearing height –1.1875 in.
Minimum thickness of spacer –0.4630 in.
2. Press the bearing from the pinion gear Minimum thickness of washer –0.2175 in.
shaft.
Starting Shim Thickness Req’d 0.0375 in.
Assembly Actual Ring Gear Shim Calculation

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

1. Determine pinion shim starting thickness. 1. Press upper pinion bearing cup [2] into
a. Record pinion bearing seat dimension housing. Place the spiral gear shims
from housing. (0.015 in. [0.38 mm] thickness) in the
b. Record mounting distance etched on housing, then place the bearing cup [7] in
pinion shaft. the housing.
c. Determine shim thickness required for Figure 7-36. Upper Pinion Bearing Cup Installation
pinion.
Example Pinion Shim Calculation

Bearing seat dim. from housing 5.9020 in.
Mounting distance from pinion –4.9380 in.
Minimum bearing height –0.9375 in.
Shim Thickness Required 0.0265 in.
Actual Pinion Shim Calculation

Bearing seat dim. from housing _______ in.
Mounting distance from pinion –_______ in. 2. Turn the drive unit housing over. Insert
Minimum bearing height –0.9375 in. correct shim thickness (calculated - refer
Shim Thickness Required _______ in.
to “Shim Calculation”) into lower pinion
bearing seat.
2. Determine ring gear shim thickness. 3. Press the lower pinion bearing cup [7] in
the housing.

NOTE: A setup bearing can be made by having Figure 7-39. Outer Axle Bearing Cup Installation
the outside of the cup turned down to
2.6130 in. so pressing and pulling it is
not required during the setup process.
Figure 7-37. Lower Pinion Bearing Cup Installation
Spiral Pinion and Ring Gear Installation

NOTE: The Spiral Pinion and Ring gears are a
matched set [4]. Their alignment is
4. Install the inner axle bearing cup [9] in the critical. Do not replace them separately.
housing bore using a press or mallet.
Figure 7-38. Inner Axle Bearing Cup Installation
Bearing can become extremely hot. Use

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

shaft bearing cones [2 and 7] to 300ºF
(150ºC) maximum.
Figure 7-40. Preheating Bearing Cone
NOTE: Wipe away any chips or excess metal

pieces resulting from installation.
5. Install the outer axle bearing cup [8] in the
housing using a mallet or press.
NOTE: Steps 2 thru 5 must be completed before

the bearing cools.
2. Slide a preheated pinion shaft bearing
cone [7] onto the spiral pinion gear shaft.
3. Gather helical gear and pinion clamp nut.
NOTE: Handle helical gear with care during the
entire assembly process. Do not allow
the gear teeth to be nicked or damaged.
4. Place second preheated pinion bearing
cone into the top bearing cup [2] (traction

motor flange on housing must be facing NOTE: If necessary, loosen the pinion nut and
up). strike the pinion gear with a punch in
the drill center to slide the bearing cone
Figure 7-41. Upper Pinion Bearing Cone Installation on the pinion gear to loosen the rolling
torque. Retighten the pinion nut as
required.
(P/N 990-669) to clamp nut and locking
screw threads after shimming is correct
and final assembly is completed.
10. Tighten the clamp nut to 23 ft. lb.
(31.2 Nm) and tighten the locking screw to
128 in. lb. (14.5 Nm). Make sure the open
ends of the pinion clamp nut do not touch
after the locking screw is torqued down.
5. Place helical gear [3] onto top pinion 11. Check the rolling torque. The rolling
bearing cone [2]. torque must be 5 to 8 in. lb.
(0.6 to 0.9 Nm).
NOTE: Install helical gear with the word “UP”
stamped on the gear facing up. The gear 12. Tighten or loosen the pinion nut, as
hub face that is flush with the outside necessary, to attain the correct rolling
surface of the gear should face down torque.
and touch the bearing. NOTE: Less than 1/16 of a turn on the pinion
6. Insert pinion gear up from bottom of nut will have an affect on the rolling
housing, through pinion bearing cone and torque.
helical gear.
Axle Assembly/Installation
7. Install helical gear clamp nut onto spiral
pinion shaft. Rotate the helical gear 1. Use a bearing heater to preheat axle
incrementally, bringing the clamp nut bearing cones [8 and 9] to 300ºF (150ºC)
torque to 35 ft. lb. (47.5 Nm) to seat the maximum.
pinion bearings and the helical gear. 2. Apply thread-locking compound
(P/N 990-543) to the OD of the axle seal
Figure 7-42. Install Clamp Nut [5] and install into housing.
Bearing can become extremely hot. Use

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

the bearing cools.
3. Press outer axle bearing cup [8] onto axle
shaft [6].
4. Gather axle bearing cone [9], spacer [12],
8. Check rolling torque of pinion gear. Rolling shim stack [11] (calculated - refer to “Shim
torque must be 5 to 8 in. lb. (0.6 to Calculation” on page 7-40), thrust washer
0.9 Nm). Tighten or loosen the clamp nut, [10], ring gear [4], thrust washer [10], and
as necessary, to attain the correct rolling axle shaft clamp nut [13].
torque.

5. Rotate unit so ring gear cavity is facing up. NOTE: Backlash may increase up to 0.003 in.
Lightly oil axle bearing cone [9] and set (0.076 mm) after the heated bearings
into cup that is already pressed into the cool.
housing. Place spacer [12] on axle bearing,
10. Apply marking compound to the ring gear
then shim stack [11], and thrust washer
and check the contact pattern. See
[10], in that order. Insert ring gear [4]
Figure 7-43. Add or remove shims as
under pinion gear. Make sure tooth marked
required. After shimming is corrected,
“X” on pinion gear is between two teeth
verify backlash is still within tolerance per
marked “X-X” on ring gear.
Step 9.
6. Insert axle shaft [6] up through bottom of
housing, through spacer, shims, thrust Figure 7-43. Ring Gear Contact Patterns
washer, and ring gear. Install second
thrust washer [10] and axle shaft clamp
nut [13] onto axle.
NOTE: Do not use thread-locking compound on
clamp nut until shimming is correct.
7. Clamp helical gear to keep gear assembly
from rotating. Torque axle shaft clamp nut
[13] to 125 ft. lb. (170 Nm). Additional
torque may be required to pull axle up
through heated bearing. Re-adjust to
correct torque setting. Remove clamp, then
using torque wrench on axle shaft clamp
nut, rotate gear assembly 11 times to
Ideal
re-align “X” on pinion gear with “X-X” on
Contact
ring gear (to seat bearings). Replace clamp Pattern
and re-torque axle shaft clamp nut.
8. Make sure “X” on pinion gear is aligned to
“X-X” on ring gear. Using a dial indicator,
check backlash at the large spiral bevel
ring gear, by firmly rotating the large spiral
bevel ring gear back and forth, making
certain that the pinion gear is held
motionless. Rotate gear to the tightest
backlash location as determined by the
assembler and check backlash again.
NOTE: Clamp helical gear to achieve a more
accurate backlash reading.
9. If the lowest backlash reading is within
tolerance [0.004 to 0.010 in. (0.1 to
0.25 mm)], proceed to Step 10. If backlash 11. Disassemble the components and return
is not within tolerance, disassemble axle to Step 2 of “Bearing Cup Installation” on
ring gear assembly. Check for errors in page 7-40. Follow procedures for
assembly of components or reassembly.
contamination. If backlash is still not 12. Apply thread-locking compound
within tolerance, repeat steps 8 thru 11, (P/N 990-669) to axle shaft clamp nut and
adding or subtracting shims as necessary locking screw threads. Install clamp nut
until backlash is within tolerance. onto axle and torque to 125 ft. lb.
(170 Nm). Apply thread-locking compound

(P/N 1013829) to locking screw and

torque to 128 in. lb. (14.5 Nm). Make sure
the open ends of the axle clamp nut do not
touch after the locking screw is torqued.
Check the axle gap (distance between axle
and housing). This is an indication that
the bearings are correctly seated. Gap
should measure approx. 0.195 in.
(4.95 mm).
13. Check that the mounting surface of the
cover plate and housing are free of paint,
dirt, and debris. Clean both surfaces with
isopropyl alcohol and allow surfaces to
dry. Apply RTV silicone gasket-forming
compound (P/N 990-659) to housing
surface. Install cover plate onto housing,
making sure drain hole in cover is on the
opposite side of the pinion gear. Install
screws (qty. 10) and torque to 7 ft. lb.
(9.4 Nm).
14. Install magnetic drain plug into cover plate
using gasket sealant compound
(P/N 990-556). Install “Check Level” plug
into housing finger tight and without
sealant.
15. Install dowel pins using thread-locking
compound (P/N 1013829).

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

Drive and Brake Brakes
Brakes Figure 7-44. Brake Release Bolt Installation
Brake Assembly P/N 1043541

Inspection
Check the gap between the brake coil and

armature disc. The gap should measure 0.008
and 0.016 in. (0.2 and 0.4 mm). If gap exceeds
0.016 in. (0.4 mm), remove and disassemble the
brake assembly to check components.
A drive tire fender kit is available for trucks that

operate in dusty or dirty environments. Refer to
the Parts Manual.
Removal
1. Lower the forks all the way and tilt the
mast forward.
3. Remove the front covers. 6. Remove nut and washer from motor shaft.
NOTE: Note location of cable ties for correct 7. Remove the three bolts that hold the brake
installation later. assembly to the motor. Lift the brake
assembly off the traction motor.
4. Cut the cable ties joining the brake coil
harness and the speed feedback sensor
harness and temperature sensors. Disassembly
Disconnect the brake coil assembly 1. Remove the three bolts that hold the lower
electrical connector JPB4 or JPB3 from friction plate to the brake coil.
the lift truck’s harness.
2. Remove and inspect the brake friction
5. Install the brake release bolts. Tighten to disc.
release the brake.
3. Clamp brake assembly in vise or use “C”
clamps.
4. Remove the brake release bolts and top
friction plate from the brake coil.
NOTE: When removing the top friction plate
from the brake coil, hold the coil
inverted so the brake springs remain in
the coil assembly.
5. Check the thickness of the friction disc. If
the thickness is less than 0.235 in.
(6 mm), replace the friction disc.
6. Check the top and bottom friction plates.
Replace them if worn more than 0.003 in.
(0.08 mm).

Brakes Drive and Brake
Assembly Press the EPO button. The truck should

stop within one and one half truck
1. Place the springs evenly in the holes in the lengths. This distance varies depending on
brake coil. (There may be fewer springs floor and tire conditions.
used than there are holes.)
2. Place the top friction plate over springs. Brake Assembly P/N 1094113
3. Carefully clamp assembly together.
4. Install the two brake release bolts and Inspection
tighten.
5. Center the friction disc on the upper the battery connector.
friction plate.
2. Remove front covers.
6. Place the three bolts previously removed
through the brake coil assembly. 3. Check air gap between the armature and
armature plate near all three spacers. See
7. Secure the brake coil assembly to the Figure 7-45. If air gap exceeds 0.040 in.
lower friction plate assembly. Torque to (1 mm), replace the brake pads. Refer to
70 in. lb. (7.9 Nm). “Pad Replacement”.
Installation Figure 7-45. Checking Brake Air Gap
1. Install the brake assembly onto the

traction motor. Make sure the friction disc
Motor
fits over the splined hub. Refer to Shaft
“Component Specific Torque Chart” on
page A-4. Brake
2. Install nut and washer on motor shaft and Mounting
torque. Refer to “Component Specific Bolt (qty. 3)
Torque Chart” on page A-4.
3. Remove the brake release bolts and stow
Armature
in their correct location on the tractor
frame.
Armature
Plate
Adapter Spacer
Make sure that all the brake release Plate
bolts are removed before using the lift
truck. The brake will not work if the
brake release bolts are not removed. Removal
4. Plug the wiring harness connector from the battery connector.
the brake coil into the connector from the
VM (JPB4 for the right brake coil; JPB3 for 2. Block the drive tires to prevent movement.
the left brake coil). Install cable ties as 3. Remove front covers.
necessary. 4. Disconnect the brake armature lead
5. Re-install the front covers. connection.
6. Reconnect the battery connector and turn 5. Loosen one of the locking bolts and obtain
the key switch ON. a spacer approx. 0.005 to 0.015 in.
7. Check the operation of the brake. Travel (0.12 to 0.38 mm) thicker than the
forks-first at full speed with a rated load. measured total air gap (non-energized).
Insert spacer between the armature plate

and the coil body. Tighten the locking bolt Figure 7-47. Pad Replacement
just enough to prevent rotation of the
Small Flange Carrier
motor shaft.
(large flange
6. Remove the retaining nut and washer from opposite side)
the motor shaft. See Figure 7-45.
7. Remove the three brake mounting bolts.
8. Use a brake puller to remove the brake
assembly from the motor.
Pad Replacement
1. Install the brake release bolts.
NOTE: Do not overtighten the brake release Pad (qty. 6)
bolts.
2. Turn the brake assembly over and remove 5. Install adapter plate. Torque adapter plate
the three bolts securing the adapter plate. bolts to 6 ft. lb. (8.6 Nm).
See Figure 7-46. NOTE: Leave the brake release bolts installed
for reassembly to motor.
Figure 7-46. Adapter Plate Removal
Coil Replacement
1. If installed, carefully remove the brake
release bolts. Separate the coil from the
armature plate.
NOTE: The brake release bolts are under
tension from the springs inside the coil
body.
2. With the coil inverted, make sure all six
springs are inserted into the cavities.
NOTE: On coils with ten spring cavities, the two
empty cavities must be 180° apart.
3. Place the thin washer shaped spacer over
the springs.
Adapter
Plate Bolts 4. Note the orientation and place the inverted
armature plate on the coil directly over the
spacer.
3. Remove the adapter plate. Inspect spacers 5. Assemble the armature and coil:
and replace if damaged.
a. Using a clamp, mate the armature plate
4. Remove old pads from carrier and install to the coil. Make sure the thin washer
new pads. See Figure 7-47. is correctly aligned.
b. Install the brake release bolts through
the coil and armature plate and tighten.
6. Install carrier, pads, and adapter plate.
Torque adapter plate bolts to 6 ft. lb.
(8.6 Nm).

Brakes Drive and Brake
Installation
1. Correctly position the brake assembly on
motor. Make sure the keyways on the
motor shaft and carrier are correctly
aligned.
2. Gently tap the carrier flange onto motor
shaft until seated.
(P/N 990-536) and install the three brake
mounting bolts. Torque to 16 ft. lb.
(21.7 Nm).
4. Remove brake release bolts and install in
their storage locations.
5. Loosen one of the retainer bolts and insert
a 0.030 to 0.040 in. (0.76 to 1 mm) spacer
between the armature plate and coil body.
Tighten the retainer bolt just enough to
prevent rotation of the motor shaft as the
retaining nut is torqued.
6. Install retaining nut and a new washer to
motor shaft. Torque retaining nut to 150
ft. lb. (203 Nm).
7. Loosen the retainer bolt and remove the
spacer.
8. Unblock the drive tires. Reconnect the
battery connector and turn the key switch
ON.
9. Make sure brake operates correctly.


Electrical Components
Electrical Components

Electrical Components Battery Procedures
Battery Procedures touching and causing a short circuit.

Do not allow the metal cable end to
touch the battery. Use insulated tools
and avoid contact with battery case or
cable ends.
Before working on the battery, review
1. To remove a cable from the connector,
“Battery Safety”, beginning on
push the retainer down while pulling the
page 2-5. Batteries for this lift truck
battery cable towards the rear and out of
weigh between 1980 and 3250 lb. (898
the connector. See Figure 7-48 and
to 1475 kg). Use extreme care during
Figure 7-49.
replacement. Use a suitable battery
moving device or hoist for lifting. Do not Figure 7-48. Battery Cable and Connector
extend a battery more than 1/3 of its
length outside the battery compartment
without being attached to a
battery-moving device.
Battery Connector/Cables
Inspection
2. Check the battery connector for damaged
cables.
3. Check to see if battery cables are pulling Figure 7-49. Battery Cable Removal from Connector
out of the connector.
4. Check the cables at the battery terminals.
Connections should be tight, with no
corrosion.
5. Look inside the connector. Check all
internal contacts for damage, dirt, or
corrosion. Do not use a metal object to
clean the connector.
NOTE: Some degreasers and parts cleaners
cause the connector shell to
disintegrate. Avoid contacting battery
connectors with solvents.
2. Do not attempt to repair battery cables by
Removal, Replacement, and crimping new terminals. Replace the
Installation cable.
The cables to either half of the connector have a

lip on their forward end. This lip snaps over a
spring-loaded retainer that is part of the
connector.
NOTE: When replacing battery cable ends,
remove only one end at a time from the
connector, to avoid the cable ends

Battery Procedures Electrical Components
Battery Exterior Cleaning 6. Wash dirty batteries (or any that have had
electrolyte spilled on them) with a solution
1. Read, understand, and follow procedures, of 1 lb. (0.45 kg) of baking soda added to
recommendations and specifications in the 0.5 gal. (1.9 liters) of hot water.
battery and battery charger
manufacturer’s manuals. 7. Use a brush with flexible bristles to clean
the entire top of the battery with the soda
solution. Wait until all foaming stops,
indicating that the battery exterior is
neutralized.
8. Rinse the battery with clean water.
9. Dry the battery completely before
reinstalling it.
10. Reinstall the battery in the lift truck, using
a suitable battery moving device.
2. Wear personal protective equipment. See Reconnect the battery connector.
“Battery Safety” on page 2-5.
3. Turn the key switch OFF and disconnect Testing, Charging, and Maintenance
the battery connector. Remove the battery
from the lift truck. For information on testing, charging, and
maintaining your lift truck battery, consult the
4. Inspect the battery cables to make sure battery manufacturer’s specifications and
they are not frayed or loose. Inspect the instruction manual.
battery connector to make sure there is no
foreign material inside the connector. NOTE: Never plug the battery charger into the
Make sure the filler plugs are tight and the lift truck. This severely damages the lift
vent holes in the filler plugs are open. truck’s electrical system. Plug the
charger only into the connector from the
Figure 7-50. Battery Cable and Filler Plug battery.
Battery Cable
Filler Plug Battery State-of-Charge

Vent Hole
Battery State-of-Charge (BSOC) is a feature that
5. Keep the top of the battery clean and dry. monitors and remembers the charge level of the
Corrosion, dust, and moisture provide a battery connected to the lift truck and prevents
conducting path to short-circuit cells or excessive discharging of that battery. Operating
create shorts to ground. a lift truck using a discharged battery can
NOTE: Do not clean the top of the battery with damage both the battery and the electrical
the soda solution while it is installed in components of the lift truck. See page 5-4 for a
the lift truck. Water can seep into the detailed description of how BSOC works and
electrical components and cause serious the procedure for setting BSOC Cutout.
damage.

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
4/0 1002215/013-015 1-1/16 in. (27 mm)
• damaged or overheated terminal lugs
• 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
Power cables are marked on the terminal lug 2/0 1002217/004-006 1-9/16 in. (40 mm)
with the location where they belong. If the
3/0 1002217/007-009
marking is missing or is not readable, remark
the cable with the correct information. 4/0 1002217/010-011 1-11/16 in. (43 mm)
NOTE: Terminal lugs may be replaced in the
field using the appropriate crimping 5. Insert 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 7-51 and 7-52.
Parts Distribution Center. Failure to use
correct cables, terminal hardware, and Figure 7-51. Short Barrel Terminal
torque values can result in overheating
and damage to components.
Power Cable Repair

Traditional lug crimping techniques for power
cables on DC motors may not meet the higher
current requirements of AC motors. Use
Manual Crimp Tool (P/N 1069861) when
crimping power cables for all AC motors. This
tool may also be used to repair power cables for
DC motors.
1. Remove the bad cable(s).
2. Using the removed cable(s) for reference,
cut an appropriate amount of replacement
cable of the same gauge.
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 7-52. 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 Motors
Motors DC Motor Service

Motor Brushes
General
Inspection
Power Cable Terminals
Figure 7-53. Motor Brush Location
Table 7-5. Power Cable Terminal Torques
Location/Stud
Torque
Size/Type
Traction Motors Top Nut: 12.5 to 18.4 ft. lb.

(23 to 25 Nm)
Lift Motor - AC Bottom Nut: 10.7 to 11 ft. lb.
(14.5 to 15 Nm)
Top Nut: 7.5 to 9.2 ft. lb.

(10.2 to 12.4 Nm)
Lift Motor - DC
Bottom Nut: 9.2 to 11.6 ft. lb.
(12.4 to 15.8 Nm)
Top Nut: 7.5 to 9.2 ft. lb.

(10.2 to 12.5 Nm)
Steer Motor
Bottom Nut: 9.2 to 11.7 ft. lb.
(12.5 to 15.9 Nm)
95 to 105 in. lb.

Power Amplifiers
(10.7 to 11.8 Nm)
Conduct a partial inspection of the motor
Contactor - M6 during scheduled maintenance. If the truck is
50 in. lb. (5.6 Nm)
steel
operated in a severe or caustic environment or
Contactor - M8 is used in an extended duty cycle application,
180 in. lb. (20.3 Nm) inspect the motor more frequently.
steel
Contactor - M8 Set up and rigidly adhere to a strict inspection

70 in. lb. (7.8 Nm)
brass/copper
schedule to obtain the maximum efficiency
from the electrical equipment.
DC Motor Troubleshooting Each partial inspection of the motor must
include:
See “DC Motors” on page 5-13.
1. Inspect the brushes for wear and for
correct contact with the commutator.
AC Motor Troubleshooting Record the level of wear on the brushes.
This history provides an indication of
See “AC Motors” on page 5-16.
whether a brush must be changed or if it
can wait until the next inspection. Refer to
Table 7-6 on page 7-58 for acceptable
brush length.
NOTE: Overloading a unit is ultimately reflected
in the motor and brush wear; therefore,
you must take this into account when
considering brush replacement.

Motors Electrical Components
2. Check brush spring tension. Refer to 4. Remove the sandpaper.

“Motor Brush Spring Tension”. 5. Blow any dust out of the motor with clean,
3. Clean brushes and holders. Wipe the compressed air at a maximum of 30 psi
commutator with a dry, lint-free cloth. Do (207 kPa).
not use lubricants of any kind on or
around the commutator. Aux Motor Brush Replacement
4. Check brush holders for a solid connection
1. Remove the worn brushes. Inspect each
to the mounting support. Tighten the
brush holder and spring. The spring
mounting screws as necessary.
should be tight and rest against the brush
5. Check the cap screws that hold the brush holder. If spring is bent or damaged,
cross-connectors to the brush holder replace spring set. Make sure the rivets
body. attaching the brush housing to the brush
6. Make sure the motor terminals are board are not loose. If there are loose
secured tightly to the motor frame. Use rivets or damage to any part of the brush
care not to strip the threads or crush the housing assembly, the motor should be
insulating parts. See “Power Cable replaced.
Terminals” on page 7-56. 2. Slide the brush into the brush housing.
7. Check all the cap screws around the frame Make sure the brush wire is facing down
for tightness. towards the motor. Verify the brushes
8. Keep the outside frame of the motor clean move freely inside the brush holders. If a
and free from dirt. Maintain a free air brush hangs up or is tight, remove brush
passage around the motor to permit heat and inspect the brush holder for damage.
radiation. Verify the brushes being installed are the
correct part number.
Replacement 3. Verify the brushes are in full contact with
the commutator and the brush springs are
NOTE: If one brush needs replacement, always
correctly installed, applying pressure to
replace the entire set of brushes.
the center of the brushes.
Use only genuine Raymond brushes. Using 4. Check brush spring tension. Refer to
another type of brush could cause damage to Table 7-6, “Minimum Brush Length and
the commutator or cause excessive brush wear Spring Tension,” on page 7-58.
and voids your warranty. 5. Attach the brush wire terminal to the
brush holder assembly. The terminal on
If the end of the brush is not already contoured the leads should point to the 3 o’clock
to fit the commutator, seat the brush to the position. Tighten the retaining screws
commutator: until snug, do not over tighten and strip
NOTE: If the motor commutator is not threads.
accessible, form the brush contour 6. Position the brush lead so that it is
using a brush seating stone. straight behind the brush. Pull excess wire
up towards the screw terminal to allow
1. Move the motor brush springs out of your
proper installation of the covers. Do not
way.
tuck the leads to the side or inward toward
2. Wrap a piece of 00 sandpaper around the the commutator. Failure to correctly
commutator. Do not use emery cloth to position the leads will result in the
seat brushes. brushes hanging up and losing contact
3. Move the brushes back down into their with the commutator.
holders. Rotate the armature until the face 7. Reassemble the motor and test for correct
of the brushes are contoured to match the operation.
curve of the commutator.

Motor Brush Spring Tension 9. Refer to Table 7-6 for correct spring
tension.
Inspection
Table 7-6. Minimum Brush Length and Spring Tension
the battery connector. Min.
Motor Brush Spring Tension
2. Remove the operator compartment covers.
Length
3. Slide the brush up slightly in its holder.
Lift 0.62 in. 40 to 65 oz.
4. Insert a paper strip between the brush (4150 only) (15.7 mm) (1134 to 1842 grams)
face and the commutator. See Figure 7-54.
0.50 in. 12 to 30 oz.
Steer (Aux)
Figure 7-54. Motor Brush Spring Tension Inspection (13 mm) (340 to 850 grams)
Spring 10. Repeat steps 3 thru 9 for the remaining

Scale
brushes.
Polishing the Commutator

NOTE: Use a narrow masking tape (1/2 to
3/4 in. wide) and wrap the stone in a
spiral configuration, leaving only
enough stone exposed to make contact
with the commutator. As the length of
Leather
Loop the stone becomes shorter with use, peel
back and remove portions of the tape.
Make sure loose clothing is tied back.

Paper
Do not wear jewelry. Wear insulated
gloves.
1. If the motor has 4 or more brushes,

remove an accessible brush from the
Rotation motor with the motor still installed in the
Pull paper in direction of rotation truck. If the motor only has 2 brushes or
the commutator is not accessible with the
5. Place a small leather loop around the coil stone, the armature will have to be
spring for the brush. If the brush spring installed in a lathe or replaced. If so, go to
has a loop at the brush, hook the spring step 4.
scale directly to the spring.
2. Activate the motor.
6. Attach a 5 lb. (2.27 kilogram) spring scale
3. With the motor turning, carefully insert
to the leather loop.
the commutator stone into the brush box
7. While gently pulling the scale outward, area.
slowly pull the paper strip in the direction
4. With minimal pressure, run the stone
that the commutator normally rotates.
back and forth across the commutator
8. When the paper strip begins to move until it is polished. Do not pass stone over
freely, the spring scale will read the brush the ends of the commutator segments.
spring tension.
5. Thoroughly blow out the motor with
compressed air.

6. Inspect commutator. Reinstall the brush supplied with the temperature sensor.
or armature and cover. Mount the sensor close to the location of
7. Check operation. the original. Secure the cable with a cable
tie to one of the power leads for stress
relief.
AC Motor Service 11. Install the top end bell in the position that
was previously marked. Verify correct
AC traction and lift motor service is limited to
stator installation and install snap ring.
Speed and Temperature Sensor replacement.
12. Secure the top end bell to the bottom end
bell using the four bolts previously
AC Motor Temperature Sensor
removed.
Temperature sensors in the AC traction and lift 13. Install the brake mounting motor flange
motors are integral to the motor. When a motor with new mounting bolts.
temperature sensor fails, it can be replaced 14. Re-install the brake assembly including
using the procedures below. the rotor hub mount and rotor hub.
15. Install the terminal board, reconnect
Traction Motor Temp Sensor Replacement
JPTA3 and power cables. Refer to
1. Turn the key switch OFF and disconnect “Component Specific Torque Chart” on
the battery connector. page A-4.
2. Remove the brake assembly including the 16. Reconnect the battery connector and turn
rotor hub nut and rotor hub. Note the the key switch ON.
number of spacers used.
3. Disconnect the temperature sensor Lift Motor Temp Sensor Replacement
connector JPTA3. 1. Turn the key switch OFF and disconnect
4. Disconnect power cables. Note locations the battery connector.
for reassembly later. 2. Disconnect the temperature sensor
5. Remove the terminal board. connector JPLA3.
3. Disconnect cables and motor harness
connections, making sure that you note
locations for reassembly later.
Use correct electrostatic discharge
precautions. See “Static Precautions” on 4. Separate the pump assembly from the lift
page 2-8. pump motor and remove lift pump motor.
5. Remove the four bolts that secure the top
6. Mark the position of the top end bell and end bell to the bottom end bell.
bottom end bell relative to the stator, then 6. Remove the top end bell. Use care that the
remove the snap ring. bearing remains in the bottom end bell to
7. Remove the brake mounting motor flange. reduce the chance of damaging the
bearing.
NOTE: Use new flange mounting bolts when
reassembling. 7. Install a new temperature sensor using the
high temperature silicone (neutral curing)
8. Remove the four bolts that secure the top supplied with the temperature sensor.
end bell to the bottom end bell. Mount the sensor close to the location of
9. Remove the top end bell using a puller. the original. Secure the cable with a cable
Use care that the encoder bearing remains tie to one of the power leads for stress
in the bottom end bell to reduce the relief.
chance of damaging the bearing. 8. Carefully press the top end bell to the
10. Install a new temperature sensor using the stator. Do not pinch the cables or allow
high temperature silicone (neutral curing)

contact with the rotor. Verify correct stator 12. Remove the four bolts that secure the top
installation. end bell to the bottom end bell.
9. Secure the top end bell to the bottom end 13. Remove the top end bell and bottom end
bell using the four bolts previously bell using a puller.
removed. 14. Remove the clamps that secure the
10. Reinstall lift motor to the pump assembly. encoder bearing cable.
11. Reconnect JPLA3 and power cables. 15. Remove the encoder bearing from the rotor
12. Reconnect the battery connector and turn using a suitable puller, pulling on the
the key switch ON. outer race only.
16. Remove the oil seal to allow pressing of the
AC Motor Bearing Encoder bottom end bell to the stator for later
reassembly.
Traction Motor Encoder Replacement 17. Make sure that the O-ring and wave
1. Turn the key switch OFF and disconnect washer are correctly positioned in the
the battery connector. bottom bell bearing pocket.
2. Remove the brake assembly including the 18. Position the new encoder bearing in the
rotor hub nut and rotor hub. Note the bottom end bell with the cable oriented in
number of spacers used. the middle of the notch in the side of the
bearing pocket.
3. Disconnect the temperature sensor
connector JPTA3. 19. Use an assembly bushing on the outer
race and press the bearing into place. Do
4. Disconnect the bearing encoder connector not press on the encoder part of the
JPTA2. bearing.
5. Disconnect power cables. Note locations 20. Re-install encoder bearing cable clamps.
for reassembly later.
21. Install the top end bell in the position that
6. Remove the terminal board. was previously marked. Verify correct
stator installation and install snap ring.
22. Carefully press the bottom end bell to the
Use correct electrostatic discharge stator.
precautions. See “Static Precautions” on 23. Secure the top end bell to the bottom end
page 2-8. bell using the four bolts previously
removed. Re-install oil seal.
7. Remove the steering position reference
24. Install key, pinion gear, and nut to the
bracket.
bottom of the traction motor. Re-install
8. Remove the traction motor. See “Removal” traction motor. See “Installation” on
on page 7-62. page 7-62.
9. Remove the nut that secures the pinion 25. Install the brake mounting motor flange
gear. Remove the gear and key using a with new mounting bolts.
suitable puller.
26. Re-install the brake assembly including
10. Mark the position of the top end bell and the rotor hub mount and rotor hub. See
bottom end bell relative to the stator, then “Brakes” on page 7-46.
remove the snap ring.
27. Install the terminal board, reconnect
11. Remove the brake mounting motor flange. JPTA2, JPTA3, and power cables. Refer to
NOTE: Use new flange mounting bolts when “Component Specific Torque Chart” on
reassembling. page A-4.

28. Re-install steering position reference

bracket and filler tube if previously
removed.
the key switch ON.
Lift Motor Encoder Replacement


precautions. See “Static Precautions” on
page 2-8.
2. Disconnect connectors JPLA2, JPLA3,

cables, and motor harness connections,
making sure that you note locations for
reassembly later.
3. Separate the pump assembly from the lift
pump motor and remove lift pump motor.
4. Remove the four bolts that secure the top
end bell to the bottom end bell.
5. Remove the top end bell using a suitable
puller.
6. Remove the encoder bearing from the
rotor, pulling on the outer race only.
7. Install the new encoder bearing by
applying steady pressure to the inner ring.
8. Carefully press the top end bell to the
stator. Do not pinch the cables or allow
contact with the rotor. Verify correct stator
installation.
9. Secure the top end bell to the bottom end
bell using the four bolts previously
removed.
10. Install lift motor and reconnect lift pump
assembly. See “Lift Motor” on page 7-64.
11. Reconnect JPLA2, JPLA3, and power
cables.
the key switch ON.

Electrical Components Traction Motors
Traction Motors c. As you turn the bolts, the traction

motor pushes upward, breaking its seal
to the drive unit. See Figure 7-56.
Removal Figure 7-56. Traction Motor Removal, Breaking Seal
the battery connector. Traction Motor
2. Remove the three front covers.

3. Remove the mast.
4. Remove the brake assembly.
5. Remove the friction plate retaining nut.
6. Remove the friction plate.
7. Disconnect the three power cables from
the terminals on the traction motor and Bolt in “Blind” Hole
label for later installation. Use two Drive Unit
wrenches to avoid twisting the terminal
studs.
8. Disconnect JPTL2 (left) or JPTR2 (right)
and JPTL3 (left) or JPTR3 (right). The traction motor is heavy. Use a
suitable lifting device to move it if
9. Place a drain pan beneath the drive unit.
necessary.
Remove the drain plug and drain approx.
two pints (one liter) of drive unit oil. This
12. Lift the traction motor off the drive unit.
prevents oil from spilling when the traction
motor is removed. See Figure 7-55. 13. If you are not reinstalling a traction motor,
use plastic film and masking tape to seal
Figure 7-55. Drive Unit Drain Plug the opening for the traction motor so that
no debris can fall into the drive unit.
14. Remove the pinion gear from the traction
motor shaft.
Installation
1. Thoroughly clean the mating areas on the
traction motor shaft and pinion gear.
2. Correctly install the pinion gear on the
traction motor shaft (taper correctly
oriented). Apply thread-locking compound
(P/N 1013829) and install nut. Torque to
10. Remove the four bolts that attach the 45 ft. lb. (61 Nm).
traction motor to the top of the drive unit. 3. Thoroughly clean the mating areas on the
11. To break the seal between the traction top of the drive unit and the bottom of the
motor and drive unit: traction motor mounting flange.
a. Install two of the bolts you removed in 4. Apply a coat of gasket cement
step 10 into the two “blind” holes on the (P/N 990-556) to the mating surface on
traction motor mounting flange. the top of the drive unit. A gasket
(P/N 828-013-978) may be used instead of
b. Evenly turn each bolt clockwise. the gasket cement.

Traction Motors Electrical Components
5. Position the traction motor on top of the

drive unit and align the mounting holes.
6. Refer to “Component Specific Torque
Chart” on page A-4 and install the bolts.
7. Install the brake assembly.
8. Reconnect the cables to the terminals on
the traction motor. Use two wrenches to
avoid twisting the terminal studs. Refer to
page A-4.
9. Reconnect the harnesses to the traction
speed feedback sensors and temperature
sensors.
10. Add gear oil to the drive unit through the
filler plug hole.
11. Install the mast.
12. Install the front covers.
the key switch ON.

Electrical Components Lift Motor
Lift Motor Installation

(P/N 1013829) to the lift motor mounting
studs.
Discharge the power amplifiers energy 2. Carefully place the lift motor on the
storage capacitors before removing any mounting bolts on the frame. Support the
large fuse or motor cable for service. To motor on the wood blocks used during
discharge, turn the key switch OFF, removal.
disconnect the battery, and manually
3. Install washers and mounting nuts and
push in the plungers on all three
tighten.
contactors.
4. Fill the motor cavity (including the space
below the splines) with lubricant
Removal (P/N 1223184) to within 0.5 in. (12.7 mm)
1. Remove the mast. of the top of the cavity.
2. Turn the key switch OFF and disconnect 5. Mate the lift/aux pump to the lift motor.
the battery connector. Apply thread-locking compound
(P/N 1013829) to the mounting bolts and
3. Remove the three front covers. install. Reconnect hoses.
4. Remove the power cables, labeling if 6. Reconnect the power cables to the motor.
necessary for reinstallation. Use two Use two wrenches to avoid twisting the
wrenches to avoid twisting the terminal terminal studs. Refer to “Component
studs. Specific Torque Chart” on page A-4.
5. Model 4250 only: Disconnect speed sensor 7. Model 4250 only: Reconnect speed sensor
(JPL2) and temperature sensor (JPL3). (JPL2) and temperature sensor (JPL3).
6. Remove the two bolts securing the front 8. Remove the wood block from beneath the
cover mounting bracket to the reservoir. motor.
7. Using caution not to get oil in motor, 9. Reinstall the front cover mounting
remove the lift pump from the lift motor. It bracket.
may be necessary to disconnect the lift
pump hoses. 10. Install the mast.
8. Place wood blocks beneath the lift motor to 11. Reconnect the battery connector and turn
help support it during removal. Leave no the key switch ON.
more than a 1/2 in. (13 mm) gap between 12. Test lift/lower functions. Check for
the top of the wood blocks and the bottom hydraulic leaks where mast hoses were
bell of the lift motor. disconnected.
The lift motor is heavy. Use a suitable 14. Install the front covers.
lifting device if necessary.
9. Remove the mounting nuts that hold the

lift motor to the frame.
10. Carefully slide the lift motor off the
mounting studs.

Power Amplifiers Electrical Components
Power Amplifiers NOTE: When correctly torqued, the cable and

terminal can rotate up to 5° in either
direction.
Removal 5. Reconnect JT1.
the key switch ON.
Before removing a power amplifier,

discharge the amplifier’s internal
capacitor by jumpering the + and –
terminals with a 100 ohm 25W resistor.

2. Disconnect JT1 from the power amplifier.
3. Disconnect the power cables and the B–
bus bar from the power amplifier.
4. Remove the four mounting screws.
5. Lift the power amplifier off the mounting
plate.
Installation
1. Install new thermal conductive material
between the base of the power amplifier
and the heatsink.
2. Position the power amplifier and install the
four mounting screws.
3. Tighten the mounting screws to 7.4 ft. lb.
(10 Nm).
Do not attempt to repair power cable

terminal lugs without approved tools. If
a power cable has worn or damaged
lugs, either replace the cable or replace
the lugs. Refer to “Power Cable Repair”
on page 7-54. Failure to use correct
cables, flanged nuts, and torque values
can result in overheating and damage to
components.
4. Reinstall the bus bar and reconnect the

power cables to the correct terminals.
Torque to 95 to 105 in. lb. (10.7 to
11.8 Nm).

Electrical Components Deadman Pedal
Deadman Pedal
If switch does not activate when pedal is fully
pressed or if switch has failed, perform the
following procedure.
2. Remove pad over the deadman pedal.
3. Remove bolt securing deadman switch
cable clamp to floor. Leave deadman
switch plugged in and remove deadman
pedal.
4. Measure gap between the proximity sensor
and the indicator flag.
a. Fully press the pedal. The gap between
the proximity sensor and the indicator
flag should be between 0.05 and 0.07
in. (1.2 to 1.7 mm). Adjust as
necessary. See Figure 7-57.
Figure 7-57. Deadman Pedal Adjustment

PEDAL DEPRESSED
Indicator Flag
0.05 to 0.07 in. Proximity Sensor

(1.2 to 1.7 mm) gap
b. If gap is OK or sensor does not activate

after adjustment, replace proximity
sensor.
5. Run Test I00 - Deadman (S2) (Page 6-74).
6. Reinstall deadman pedal in floor. Refer to
page A-4.
7. Reinstall pad over deadman pedal.
NOTE: If pad was previously glued, apply glue
(P/N 990-569/102) in locations
originally glued.

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

• Use the appropriate tools to remove and
Connectors insert terminations at each connector.
• Remove damaged terminations and
discard. Never reuse a termination from a
General Connector Repair wire.
Procedures
• Do not cut away a terminal lug and reuse
the wire strands that were crimped into
Inspection the original lug.
Whenever working on the lift truck, use care • When stripping wire, use new wire strands
around wiring harnesses. for new terminations. Make sure to use a
new wire with extra length to allow for
• Carefully connect and disconnect all cutting and stripping of the ends to install
connections. new terminations.
• Do not pry connectors apart with • Use a new wire that is the same gauge
unspecified tools. (typically gauge 18 AWG), size, type, and
color as the wire it is replacing.
There should be a wire marker at each
termination. If the marker is missing or • Use a hand stripper capable of stripping
unreadable, remark the wire to allow easier by wire gauge number. Use care not to
identification. nick or cut any of the wire strands.
Discard and replace a wire with damaged
NOTE: It is normal to find unused connectors strands. Insert the wire strands the
for uninstalled options that have had correct length into termination before
heat shrink applied over them and have crimping.
been strapped to the harness.
Soldering Procedures
Repair
To prevent damage from excessive heat when
soldering small components in assemblies,
follow these guidelines:
• Make sure the soldering tip is clean. A
precautions. See “Static Precautions” on
dirty tip does not transfer heat well and
page 2-8.
encourages long dwell time and greater
pressure. Apply light pressure on the
When pulling a wire out through a bundle, cut
terminal.
off the pin or socket so it does not snag. When
replacing wires, in some cases you can tape or • Flux: rosin base
solder one end of a new wire to one end of the • Solder: 60/40 rosin core or equivalent
failed wire. Then you can pull the old wire out of
• Solder Iron: 15-25 watt “pencil-type”
the bundle and pull the new wire into the
maximum
bundle, all at the same time. Make sure to
disconnect the old wire from the new wire. • Tip Size: 3 mm (0.118 in.) diameter x
30 mm (1.182 in.) long screwdriver tip.
In other cases, it is easier to secure a new wire Make sure the tip is clean.
to the outside of the existing wire bundle with • After soldering, clean the terminals with a
cable ties of an appropriate size. The failed wire brush dampened with an alcohol-based
can be left in the bundle, or can be pulled by cleaner (P/N 990-600/FOF). Do not allow
one end to remove it from the bundle. any cleaner to seep into the switches or
potentiometers, or contact contamination
may occur.

Electrical Components Wiring and Harness Connectors
Molex Connectors Pin Extraction
Molex connectors have pins with locking ears To remove a pin from a Molex connector, use
that engage ridges in the plastic connector pin extraction tool P/N 950-026. See
body. See Figure 7-58. Figure 7-59.
1. Insert the extraction tool over the pin and
Figure 7-58. Molex Connectors - End View
push all the way into the connector. This
Pin releases the locking ears on the pin.
2. Pull the wire and pin from the connector.
Socket Pin Insertion

1. To insert a pin into a Molex connector,
insert the pin into the back side of the
connector and push the wire all the way in
until it clicks.
Locking Ears
2. The locking ears have now engaged the
connector.
To remove a pin from a Molex connector, these
locking ears must be pressed far enough to
clear the ridge in the connector.
Figure 7-59. Pin Extraction Tool
Tool Inserted Over Pin

Top View
Locking Ears
Extraction Tool
Side View

AMP Water-Resistant
Connectors
AMP connectors provide water-resistant
connection by the use of seals between wires
and connectors and between the mating
connector halves. See Figure 7-60.
Figure 7-60. AMP Water-Resistant Connector

Wire Seal
Interface
Seal
Contact
Cavity
Wire Seal Jack

Housing
Pin Contact
Pin Housing
Sealing Plug
To maintain the integrity of water-resistant Figure 7-61. AMP Pin Extraction

seals, use the following procedures when Extraction Tool
working with AMP connectors.
Pin Extraction
To aid in separating AMP connectors, use

unlatching tool Raymond P/N 950-042. To
remove a pin from an AMP connector, use pin
extraction tool Raymond P/N 950-009.
1. While holding the wire seal, push the
selected wire forward, then insert the
extraction tool into the contact socket. See Locking
Lance
Figure 7-61.
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 7-62.


Figure 7-62. Removing Wire Figure 7-64. Wire Insertion
Rotate and Pull

Pin Contact
Pin Insertion Seals

1. Make sure the connector has a wire seal 1. Use a wire seal at the back (wire end) of
attached to the connector back. See each connector half. See Figure 7-63.
Figure 7-63. 2. Plug unused pin positions with sealing
plugs. See Figure 7-65.
Figure 7-63. Wire Seal
3. Align the split tapered end of the sealing
Wire Seal
plug with the unused opening in the wire
seal. Push the plug through the wire seal
into the connector until it snaps into
position.
4. Remove sealing plugs by pulling with
needle-nose pliers while grasping the wire
seal and connector.
Pin Housing
Figure 7-65. Sealing Plug
2. If re-inserting a wire previously removed, Sealing Plug
check the pin contact locking lances to
make sure they are extended to their
original position.
3. Grasp the wire close behind the contact
insulation barrel and push the wire
straight through the wire seal into the
socket until it clicks. Pull back gently to
make sure the contact is locked in place.
See Figure 7-64.
5. Use an interface seal between pin and jack

halves of the connector. To prevent
damage to the seal, use the matching
connector cap to slide the interface seal
over the contact silos on the pin housing.
See Figure 7-66.


Figure 7-66. Interface Seal
Interface
Seal
Pin Housing
6. When mating connectors, make sure

polarized silos are correctly oriented. Push
pin and jack halves of the connector
together until locking latches engage. See
Figure 7-67.
Figure 7-67. Latching AMP Connector
Locking
Latches

AMP Harness/Traction Power

Amplifier Connector
Connector Components
Figure 7-68. Power Amp Connector Components
(PT-1 on Traction Power

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

1. Insert a 4.8 mm screwdriver blade between
The axial concentricity of the crimped contact
the mating seal and one of the red wedge
must fall into an area defined by a 2 mm
lock tabs. See Figure 7-68.
diameter cylinder whose center is the centerline
2. Pry the wedge lock to the open position. of the contact front end. See Figure 7-70.
3. While rotating the wire back and forth over
a half turn (1/4 turn in each direction), Assembly
gently pull the wire until the contact is
removed. See Figure 7-69. Make sure the wedge lock is open.
1. To insert a contact, push it straight into
Figure 7-69. AMP JPT1 Connector
the appropriate circuit cavity as far as it
goes. See Figure 7-70. (a) and (b).
2. Pull back on the contact wire with a force
of 1 or 2 lbs. to make sure the retention
fingers are holding the contact. See
Figure 7-70. (c).


Figure 7-70. Contact Insertion
3. After all contacts are inserted, close the

wedge lock to its locked position. Release
the locking latches by squeezing them
Be very careful when putting the wedge
inward. See Figure 7-71.
lock in the locked position. Forcing the
Figure 7-71. 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 7-72.


Figure 7-72. Wedge Lock Flush With Housing
Testing
Do not pierce wire insulation with a sharp point

while troubleshooting.
The wedge lock has slotted openings in the

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

Cold Storage Electrical Components
Cold Storage • all terminals on the horn

• terminals of the key switch and EPO
switch
Cold Storage (CS) is an option that enables
truck operation in temperatures of –20°F • terminals on lift motor
(–28.86°C) to 40°F (4°C). • terminals on the steer motor
• terminals on both traction motors
On cold storage trucks, the electrical panel on
the tractor is completely enclosed to contain 4. Install the recommended hydraulic fluid
heat. and gear case oil. Refer to “Lubrication
Specification Chart” on page A-2.
Cold Storage Conditioning
Perform Cold Storage conditioning with the
items listed below:
Description Part Number
Silicone Grease 990-445
Sealing Compound 990-542
LPS3 Spray 990-644
NOTE: Optional Handle is Cold Storage ready.

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

Electrical Components Cold Storage

Hydraulic Components
Hydraulic Components

Hydraulic Components Manifold Solenoids, Fittings, and Attachments
Manifold Solenoids,
Fittings, and
Attachments
Table 7-7 provides torque specifications for
manifold components.
Table 7-7. Main Manifold Torque Specifications

Valve/Fitting Torque Coil Nut Torque
Component Function
ft. lb. (Nm) ft. lb. (Nm)
SOL1 Load Hold 35 (48) 5 (6.8)
SOL2 Lift/Lower 100 (135)

Finger Tight
SOL3 Lift Relief
37 (50)
SOL4 Priority Bypass 12 (16)
SOL5 Aux Proportional Relief 25 (35) 5 (6.8)
SOL6 Aux Select 60 (80) 10 (14)
SOL7C/7R HSA (4250 Only)
SOL9L/9R L/R Sideshift 27 (37) 7 (9)
SOL10 Tilt
CV1 Check Valve 35 (47)
N/A Filter Plug N/A

30 (40)
CB1, CB2 Counterbalanced Check Valve

Manifold Solenoids, Fittings, and Attachments Hydraulic Components

Figure 7-73. Hydraulic Manifold (1 of 3)
SOL7R SOL9L SOL9R SSR Hydraulic Filter and Plug
SOL6
G2
SOL10 SOL7C AC CB1 CB2 SOL2
Expansion
Plugs
Bottom
View
CV1

Hydraulic Components Manifold Solenoids, Fittings, and Attachments

SOL9L SOL9R
SOL7R SOL10 SOL7C
P1 SSL SSR
AA
G1
CYL
AUX-P TC TR AR

Manifold Solenoids, Fittings, and Attachments Hydraulic Components

SOL5
SOL4
SOL1
SOL3
TANK CYL-P

Hydraulic Components Hydraulic Fluid
Hydraulic Fluid All except Model 4250 TT Masts

S/N 50501 Up
Fluid Level 1. Without a load, extend the free lift cylinder

and continue to extend the main lift
cylinders to 90% of full stroke. Retract all
To check the level of the hydraulic fluid in the
cylinders completely. Repeat three times.
system:
1. Lower the forks to the floor. 2. Extend the cylinders without a load at
50% lift speed, then build full system
2. Remove the fill cap from the hydraulic pressure at the end of the main lift
reservoir. The hydraulic fluid should be cylinder stroke. Retract cylinders. Repeat
1/2 to 1 in. (13 to 25.4 mm) above the four times.
filler screen. See Figure 7-76.
3. Cycle the mast with a half load (50% mast
NOTE: Reservoir capacity is approx. 6 gal. rated capacity) through full cylinder
(22.7 liters) for metal reservoir and 6.5 extension several times. The cylinders
gal. (24.6 liters) for plastic reservoir. should extend smoothly. Repeat the steps
if cylinder extension is not smooth.
Figure 7-76. Hydraulic Fluid Filler Screen
Model 4250 TT Masts S/N 50501 Up
1. Lift the forks 6 to 12 in. (150 to 300 mm)
off the floor.
2. Main Lift Cylinders - Loosen (do not
remove) the bleed screw on the lift cylinder
to let any air escape. Hold a shop rag close
to and beneath the bleed screw to keep
any hydraulic fluid from spraying out.
When all of the air has escaped and
hydraulic fluid starts coming out of the
bleed screw hole, securely tighten the
bleed screw.
NOTE: Free Lift Cylinders are self-bleeding. Lift
and lower the forks several times.
Selecting Hydraulic Fluid Type
3. Lower the forks all the way to the floor.
See Lubrication Specification Chart on NOTE: When bleeding the hydraulic system,
page A-2. bleed all cylinders.
4. Bleed the auxiliary system:
Bleeding the Hydraulic System
a. Tilt the mast all the way forward and
You must bleed the hydraulic system whenever backward several times.
you: b. If the lift truck has sideshift and/or
• Change the hydraulic fluid and filter fork positioning, shift the carriage
and/or forks all the way to the left and
• Change a hydraulic hose right several times.
• Disconnect a hydraulic fitting
5. Check the hydraulic fluid level. Add
• Notice that the load is bouncing hydraulic fluid as needed.
• Remove a hydraulic cylinder
• Remove a hydraulic pump
• Remove the hydraulic reservoir

Pressure Relief Valve Hydraulic Components
Pressure Relief Valve Figure 7-77. Uninstalled Circlip
Measuring System Pressure

NOTE: To measure the system pressure, you
need a calibrated pressure gauge
capable of measuring 3000 psi (20684
kPa) at mid-range and the coupler to
attach to the manifold.
2. Remove the front covers.
3. Connect the pressure gauge to the test
port (G1) on the main hydraulic manifold.
the key switch ON. 2. Elevate the forks until the upper limit is
reached.
5. Place a maximum rated load (or heaviest
load available) on the forks. 3. Continue to try to elevate. Using a 5/64
hex key, push in and turn the lift pressure
6. Elevate the forks. Record the pressure adjusting screw to obtain a pressure
required to lift the load. Make sure the reading 10% greater than that previously
load is elevated near the maximum rated recorded, ±50 psi (344 kPa).
height for that load when taking the
pressure reading. NOTE: A 5K lift truck may need +50 psi
(344 kPa) over the 10% value.
7. Lower the forks and remove the load.
NOTE: Make sure to push the adjuster in when
turning.
Adjusting Pressure
NOTE: The adjuster is very sensitive, and
changes pressure very quickly with very
little movement.
Do not lose the retaining circlip on SOL3. 4. Turn the adjusting screw clockwise to
increase pressure; counterclockwise to
1. Use a jeweler’s screwdriver or other small decrease pressure.
tool to remove the retaining circlip on
SOL3. See Figure 7-77. Save the clip to 5. Reinstall the circlip.
reinstall after pressure is set. 6. Check the pressure again. If the value has
changed, repeat this procedure until the
correct pressure reading is obtained.
8. Remove the pressure gauge.
9. Reinstall the front covers.

Hydraulic Components Proportional Lowering Valve Adjustment
Proportional Lowering
Valve Adjustment
If the carriage hesitates when being lowered, or
cannot be feathered, adjust the proportional
valve using the following procedure.
1. Raise the fork carriage to eye level.
3. Remove the top cover.
4. Remove one of the coil wires from SOL2.
Refer to Figure 7-73 on page 7-79. Loosen
the jam nut and lock nut holding the
adjusting screw on the proportional valve.
the key switch ON.
6. Energize the Load Holding Solenoid by
requesting Lower.
7. Slowly rotate the adjusting screw
clockwise until the carriage just starts to
creep downward. Turn the screw
counterclockwise until the carriage stops.
Repeat several times in order to refine the
adjustment point. When adjustment is
complete, tighten the lock nut and jam
nut.
9. Reconnect the coil wire previously
removed.
the key switch ON.
11. Check for correct lowering while empty
and loaded using Test A23 in Active
Maintenance Mode. Carriage movement
should start at approx. 9 to 10% request.
12. Reinstall the top cover.

Carriage Service - Lift-Tek ® Hydraulic Components
Carriage Service - ISS Removal - Mast on Floor

Lift-Tek ® 1. Remove mast from truck. Refer to
“Complete Mast Removal” on page 7-99.
2. Remove the chain anchor nuts and
The following procedures apply to all carriages
discard. Remove the chain anchors from
except those installed on a Model 4250 above
the carriage with the chains attached.
S/N 50500 with a TT Mast.
3. Disconnect the internal reeving hoses from
The Integral Side Shifter (ISS) travels within the the ISS fittings (if equipped). Plug the hose
rails of the mast inner upright on six rollers. ends.
Only the bottom four rollers are shim 4. Roll the ISS to the bottom of the mast.
adjustable. The top rollers are not shim
5. Attach an overhead hoist to the ISS bars.
adjustable. They are held in place by a retainer
Remove the ISS through the bottom of the
plate. The upper and lower load rollers are
mast.
interchangeable. The middle rollers are slightly
smaller in diameter. 6. Note the number of shims behind each
load roller for reassembly.
On TF and Quad masts, there are four side
thrust rollers to transfer ISS side loading to the ISS Inspection
inner rails. These rollers are eccentrically
adjustable. 1. Inspect the rollers for excessive wear or
damage. Rollers with visible flat spots or
cracks should be replaced.
ISS Removal - Mast on Truck
2. Turn the rollers on their shafts. Rollers
1. Remove load backrest. with roughness or noticeable restrictions
NOTE: If carriage has a Quick Disconnect to turning should be replaced.
assembly, remove/replace while 3. Inspect all welds between the ISS side
carriage is on mast. plates and the ISS fork bars. If any welds
are cracked, replace the ISS.
2. Raise the mast high enough to place a 20
in. (50 cm) long, 4 x 4 in. (10 x 10 cm) 4. Inspect the roller stub shafts. Small burrs
wood block between the intermediate or scratches can be repaired with emery
lower cross member and the ground. cloth. If they are damaged or if there are
Lower the ISS to be even with the bottom cracks at the base of the stub shafts, the
of the inner upright (the Free Lift cylinder ISS must be replaced or repaired.
will be completely retracted).
3. Attach an overhead hoist to the ISS. Raise Cylinder Seal Replacement
the ISS to slacken the carriage chains.
1. Remove forks from the carriage.
4. Remove the chain anchor nuts and
2. Raise carriage to eye level and center
discard. Remove the chain anchors from
sideshift. Turn key switch OFF and
the carriage with the chains attached.
disconnect battery connector.
5. Disconnect the internal reeving hoses from
3. Remove the six lower carriage claw bolts,
the ISS fittings (if equipped). Plug the hose
claws, and shims (if used - note their
ends.
position for reassembly).
6. Using the overhead hoist, lower the ISS to
4. Lower carriage completely.
the bottom of the mast to remove.
5. Remove the front sideshift frame and
7. Note the number of shims behind each
backrest assembly by lifting it out and
load roller for reassembly.
upward.

Hydraulic Components Carriage Service - Lift-Tek ®
6. Place clean rags on the lower bar directly your fingers. Make sure the raised portion
under the two sideshift cylinder hydraulic of the wiper is facing outward.
fittings. Loosen the fittings (1/2 to 1 full 16. Lightly lubricate the wiper with hydraulic
turn) to allow removal of the sideshift rods. oil.
7. Remove the two sideshift rods by grasping 17. Identify the tapered end with the cylinder
and pulling them straight out from their rod groove. This end will be inserted into
bores and gland nuts. the cylinder assembly. Carefully clean any
8. Use a pick to remove the rod wiper (black dust or dirt from the rod using a lint free
rubber) and the energized poly pack seals cloth. Lubricate the outside of the rod
(cream colored) from both sides of the lightly but completely with hydraulic oil.
cylinder assembly. See Figure 7-78. Spinning the cylinder rod will help to
correctly engage the cylinder rod into the
Figure 7-78. Sideshift Cylinder Seal Replacement wiper. Carefully insert the rod into the
cylinder gland nut, through the wiper seal,
and further to engage the main seal.
Install by pressing the rod into the
cylinder in a slow and smooth manner;
using a hammer or other abrupt motion
will damage the seals. Verify the wiper
does not become inverted when inserting
the cylinder rods. If any portion of the
9. Clean and verify the cleanliness of the wiper is inverted, carefully slide the
inside bore of the gland nut. Make cylinder rods in an outward direction to
absolutely certain that the two grooves for restore the seal to a correct, non-inverted
the seals do not contain any foreign position.
matter.
18. Tighten both hydraulic fittings to 21 ft. lb.
10. Apply hydraulic fluid to the main seal (28.5 Nm).
groove (farthest from the open end) within
the gland nut with a small brush. 19. Verify wear pads are installed correctly.
11. Install the seal into the second slot from 20. Install the frame and backrest assembly
the unthreaded side of the cylinder head onto spine. Slide frame from side to side to
with the groove in the seal facing the disperse grease. Clean excess grease from
inside of the cylinder. ends of spine bars. Apply thread-locking
compound (P/N 1013829) to the six holes
12. Use one thumb to guide the seal into the located at rear of frame lower bar.
groove and the other to apply force. Roll
the seal around the groove using both 21. Install claws to rear of frame lower bar.
thumbs until the seal snaps into the Install hex screws and torque to
groove. Make sure that the O-ring in the 44 ±5 ft. lb. (60 ±6.8 Nm). Install the forks.
seal does not come out of the seal groove 22. Reconnect battery connector and turn key
during installation. switch ON. Lift forks off floor. Cycle the
13. Inspect the seal inside diameter. Make side shifter from left to right several times
sure the seal has seated correctly in the to purge any air from the hydraulic
groove without distortion. system. After all air has been purged, test
for smooth operation of the side shifter.
14. Lubricate the wiper seal groove with
hydraulic fluid using a small brush.
15. Install the wiper seal into the groove
located just inside the gland nut
assemblies. Squeeze and insert the wide
edge of the seal into the groove and work
the remaining seal into the groove with

Carriage Service - Lift-Tek ® Hydraulic Components
ISS Installation
For installation, reverse the removal procedure
and do the following:
• Inspect the carriage.
• Lubricate the upright inner rails.
• Assemble shims and load rollers on the
stub shafts. The shims should be installed
(except on the top rollers) to provide a total
side to side clearance no greater than
1/16 in. (1.5 mm) at the tightest point
throughout the travel of the ISS. Use an
equal amount of shims on each side.
• Torque the upper bearing retainer plate
screws to 6.5 ft. lb. (9 Nm).
• On TF and Quad masts, adjust the side
thrust rollers for unrestricted clearance
along the travel of the ISS. The rollers have
eccentric mount bases. Turn the base of
the roller toward the upright rail to
decrease clearance. Tighten the cap
screws to 70 to 80 ft. lb. (95 to 110 Nm).
• Attach the chain anchors to the carriage
using a new self-locking nut.
• Check and adjust the free lift chains. Refer
to “Free Lift Chain Adjustment” on
page 7-104.

Hydraulic Components Carriage Service - Cascade™
Carriage Service - Figure 7-79. Fork Removal

Fork Carrier
Outer Section
Cascade™ Fork Carrier
Inner Section
Fork Carrier
Capscrews
The following procedures apply to carriages on

a Model 4250 above S/N 50500 with a TT Mast.
Sideshift Cylinder Seal

Replacement
NOTE: Rod seal carriers are the only
serviceable parts on the cylinder and are
supplied with the seals loaded. The
cylinder must be removed from the FP1123.eps
carriage to replace the seals.

1. Remove cylinder from the carriage.
2. Place the cylinder in a soft jawed vice.
2. If necessary, remove backrest to provide

access to Fork Positioner mounting cap
Do not clamp on the cylinder shell.
screws.
Clamp on the ends of the cylinder only.
3. Unscrew the seal carrier from each end of

the cylinder and slide out the cylinder rod.
4. Remove any sharp edges on the cylinder Before removing any hoses, relieve
with 400 grit emery cloth and clean with pressure in the hydraulic system. With
solvent. the truck OFF, open the truck auxiliary
control valve(s) several times in both
5. Make sure seals and O-rings are in place. directions.
Apply a thick film of petroleum jelly to the
interior bore. Carefully slide the seal 3. Disconnect supply hoses from Fork
carrier onto the cylinder rod and screw Positioner manifold and for reassembly.
into the cylinder retainer. Tighten to See Figure 7-80.
240 ft. lb. (325 Nm).
Figure 7-80. Hose Connections
6. Reinstall cylinder in the carriage.
Fork Positioner CLOSE OPEN
Assembly Forks Forks
Fork Positioner
Removal/Replacement
1. Remove cap screws fastening inner fork
carriers and remove forks. See
Figure 7-79.
Make sure locking pins are removed

from the forks. Forks must slide freely FP0858.eps
on sideshifter frame or carriage bars. Manifold

Carriage Service - Cascade™ Hydraulic Components
4. Remove cap screws fastening Fork Figure 7-81. Flow Restrictor Adjustment
Positioner to sideshifter frame and remove
unit through front. Keep track of shims.
For reassembly, shim as necessary, with a
maximum of 4 shims per side. Tighten
mounting cap screws to 50 ft. lb. (65 Nm).
FP0760.eps
Maximum difference in number of shims

Flow Restrictor (each side)
per side is 2 and the total allowable gap
a. Loosen jam nuts and screw both flow
before tightening cap screws is 0.020 in.
restrictors in until they bottom.
(0.5 mm).
b. Fully open and close forks. Look for
5. For installation, reverse the previous steps unequal fork movement.
with the following exceptions: c. Adjust the flow restrictor for the faster
• Service Fork Positioner as required. fork by screwing the flow restrictor
• If necessary, adjust flow restrictors for inward, CW, 1/2 turn and test again.
equal fork movement as follows: d. Repeat procedure until fork movement
is equal. Positioning speed should be
3 in. (75 mm)/second. Tighten jam
nuts.
Figure 7-82. Fork Positioner Removal/Install
Capscrews –
Use lockwashers
and tighten to
Sideshifter 50 ft.-lbs. (65 Nm).
Fork Positioner
Shims –
Maximum 4 per side to reduce
FRONT total allowable gap is .020 in.
(0.5 mm) maximum.
Recommended Torque Sequence
A LH side top
B RH side bottom A
FP1125.eps C RH side top
D LH side bottom D
LH Side
Confirm fork carriers are

RH Side behind face of carriage
FRONT using a straight edge.
C
B Fork Carriers
FP1416.eps

Service 2. Remove cylinder rod anchor plug. Move

fork carrier toward manifold and remove
half-ring keepers. Move cylinder rod to
Disassembly fully retracted position. See Figure 7-83.
1. Use C-clamps to clamp Fork Positioner 3. Unscrew cylinder retainer using Cylinder
face down onto a bench top as shown. Use Retainer Socket Tool P/N 1217957/71 to
2 x 4 in. (5 x 10 cm) wood blocks for remove cylinder assembly from manifold.
clearance and to keep parts in alignment.
See Figure 7-83.
Figure 7-83. Fork Positioner Disassembly
Tool
Anchor 1217957/72
Plug
Cylinder
Rod Cylinder
Shell
Keepers
FP1189.eps
FP1190.eps
Tool Fork Carrier

1217957/71
Cylinder
Shell
Piston/ Rod
Assembly
Cylinder
Retainer
4. Disconnect hydraulic tubes at manifold.

Remove C-clamp and remove cylinder/fork
carrier assembly.
Do not scratch seal grooves. Use brass
NOTE: If tubes are removed from cylinder head seal removal tools to pry items from
end, reinstall prior to installation of grooves.
cylinder/fork carrier assembly to
manifold. Do not bend tubes. 7. If required, unscrew cylinder shell from
head end using Cylinder Head Cap Tool
5. Slide fork carrier from cylinder shell.
P/N 1217957/72. For reassembly, replace
Remove piston/rod assembly from
cylinder head end O-ring and apply
cylinder shell.
thread-locking compound (P/N 1013829)
6. Remove all seals, O-rings, wear rings, and to threads. Clamp head end in vise and
bearings from components. tighten shell to 200 ft. lb. (270 Nm).
NOTE: Cap screw (M25 x 1.5 x 60 mm L) and
Jam Nut (M25 x 1.5) may also be used.

Carriage Service - Cascade™ Hydraulic Components
Inspection Reassembly
NOTE: If bending damage is found, Fork 1. Lubricate new seals, O-rings, and wear
Positioner/Sideshifter assembly should rings with O-ring lube, hydraulic fluid, or
be replaced as a complete unit. petroleum jelly.
• Inspect rod, piston and retainer for nicks 2. If necessary, use 400-grit emery cloth to
and burrs. Remove minor imperfections break any sharp edges on the piston,
using 400 grit emery cloth. retainer and cylinder shell chamfer angles,
and threads to prevent seal damage.
• Inspect cylinder bore for minor nicks and
burrs. Remove minor imperfections with a 3. Install new seals, O-rings, wear rings, and
hone (butterfly). fork carrier bearings. See Figure 7-84.
Refer to Figure 7-85 for retainer seal
• Inspect cylinder shells for deformities,
loading technique.
cracks that could impair performance or
cause leaks under pressure. NOTE: Fork carrier bearings snap into their
• Inspect fork carrier bearings for wear and respective grooves. Bronze bearings
replace as necessary. consist of three separate segments.
Figure 7-84. Fork Positioner Reassembly

U-Cup Pressure Seal
Note Seal Direction
Two-Piece
O-rings Wiper seal Wear Ring Pressure Seal Wipers Composite or Bronze Bearings
Retainer Piston Fork Carrier
External
Spacer
(if required)
O-ring
FP0703.eps
Head End/
Retainer Manifold Cylinder Cylinder Inner Fork Outer Fork Internal Fork Carrier Mounting Foot
Shell Rod Carrier Carrier Spacer Capscrews
(if required)
Back (Driver's) View – RH Side


Figure 7-85. Retainer Seal Loading Technique 8. Tighten retainer to 120 ft. lb. (165 Nm).
Tighten hydraulic tubes at manifold and
Twist seal into 'figure 8' or cylinder head end.
'half-circle' shape to
Lubricate seal and force
insert into retainer.
partially into groove.
Note Seal Direction.
3/8 in. (10 mm)
pin punch –
no sharp edge
1/2 in. (12-15 mm)

diameter rod
located flush with
bottom of seal
groove.
Use flat brass

O-ring tool to seat
seals fully into groove. FP0829.eps
4. Install piston/rod assembly into cylinder

shell. Push rod fully into cylinder.
Make sure piston seal is not damaged

by cylinder shell threads during
reassembly.
5. Slide fork carrier onto cylinder shell with

the cap screw heads facing outwards. See
Figure 7-84.
6. Align cylinder assembly to manifold and
engage opposite cylinder rod into fork
carrier. See Figure 7-84.
NOTE: Install external spacer on cylinder rod, if
required. Install cylinder retainer
through opposite side of manifold and
screw partially into cylinder shell.
7. Make sure cylinder is correctly oriented
with restrictor fittings on backside. Engage
tubes and screw retainer fully into shell.
Reclamp assembly to bench.

Lift Cylinder Service Hydraulic Components
Lift Cylinder Service 8. Install the plunger retainer on the plunger.

Install the plunger/piston assembly into
the cylinder housing.
9. Free Lift Cylinder only - Pour 1/2 cup
S/N 50501 Up (120 ml) hydraulic oil into the cylinder
1. Remove the cylinder from the mast. Refer cavity between the housing and rod.
to the applicable cylinder removal 10. Tighten the retainer using the claw
procedure in “Mast” on page 7-97. spanner wrench and a strap wrench.
2. Remove the retainer using a claw type Torque per the following table.
spanner wrench.
Mast Torque
3. Remove the plunger/piston assembly from
the housing. 2-Stage (TF) 225 to 250 ft. lb. (305 to 340 Nm)
4. TF and TT Masts only - Remove the 3 Stage (TT) 275 to 300 ft. lb. (375 to 405 Nm)
Hydraulic Fuse components.
Quad 95 to 125 ft. lb. (129 to 169 Nm)
5. Inspect all components for nicks or burrs.
Minor nicks or burrs can be removed with
400 grit emery cloth.
Model 4250 TT Masts
NOTE: Minor nicks are those that do not S/N 50501 Up
bypass oil when under pressure. If they
cannot be removed with emery cloth, 1. Remove cylinder from mast. Refer to the
replace the part. applicable cylinder removal procedure in
“Mast” on page 7-97.
6. Replace the retainer and piston seals,
backup rings, O-rings, and bearing. 2. Place cylinder in a soft jawed vice or other
Lubricate the new seals with petroleum fixturing method to hold the cylinder
jelly prior to installation. during disassembly.
3. Use a claw type spanner wrench to remove
NOTE: Note the orientation of the piston seals
the retainer. Pull the plunger/piston
when removing them. Install the seals in
assembly from the shell.
the correct direction. The cylinder will
not operate correctly if the seals are 4. Carefully remove the seals from the piston
installed backwards. and retainer, using a screwdriver with
smooth edges. See Figures 7-87 and 7-88.
7. TF Mast Free Lift and TT Mast Lift
Cylinders only - When replacing the piston
check valve O-ring, make sure the check
valve is reinstalled with the arrow pointing Do not scratch seal grooves.
in the correct direction.
Figure 7-86. Check Valve Direction

Hydraulic Components Lift Cylinder Service

Figure 7-87. Piston Seal Removal by the washer, retaining rings, and
cushioning sleeve (main lift cylinder only).
NOTE: Make sure the arrow on the check valve
is pointing in the correct direction.
Figure 7-89. Check Valve O-Ring Replacement

7pumpbolts.jpg
Figure 7-88. Retainer Seal Removal
Check Valve
O-Ring
Washer
Retaining Ring
Free Lift
Cushion Sleeve
5. Clean the plunger, piston, retainer, and
cylinder bore, then inspect for nicks and
burrs. Minor nicks and burrs can be Retaining Ring
removed with 400 grit emery cloth. Main Lift
NOTE: If nicks can be felt with a fingernail after 8. Place the guide tool (supplied with seal kit)
using emery cloth, replace the part. in the cylinder shell. The guide tool must
cover all the threads, but not contact the
6. Replace the seals, backup rings, O-rings, thread relief chamfer. See Figure 7-90.
and wear ring.
Figure 7-90. Guide Tool
NOTE: Note the orientation of the seals when 7pumpbolts.jpg
removing them. Install the seals in the

correct direction. The cylinder will not
operate properly if the seals are installed Guide Tool
backwards.
7. To replace the O-ring on the internal Shell
check valve, first remove the retaining
Do not allow lower
rings, cushioning sleeve (main lift cylinder
edge of guide tool
only), and washer. Use a hook or screw-
to contact thread
driver to remove the check valve from the relief chamfer.
piston. Replace the O-ring and insert the
check valve back into the piston, followed

Lift Cylinder Service Hydraulic Components
9. Apply a film of clean hydraulic oil to the

cylinder bore, loader, and piston seals.
Insert the plunger/piston assembly
through the guide tool and into the
cylinder shell. If resistance is encountered,
tap the plunger with a rubber mallet.
Remove the guide tool and make sure the
plunger is fully inserted.
10. Install the retainer. Torque to
160 to 180 ft. lb. (217 to 244 Nm).
11. Reinstall cylinder in mast. Bleed cylinder.

Hydraulic Components Lift Cylinder Service

Mast
Mast

Mast Mast Removal and Installation
Mast Removal and

Installation Tilting the mast too far forward will
cause the bottom of the mast upright to
damage the drive unit cover plate.
Partial Removal
NOTE: For this procedure, you will need a hoist 10. Using the hoist or lift truck, carefully tilt
or lift truck with a capacity of at least the mast forward until it is tilted no more
five tons. than 45° from the vertical position. See
Figure 7-92.
the battery connector. Figure 7-92. Mast Partial Removal (Detail)
2. Remove the console and front covers. Drive Unit
3. Remove the forks.
4. Verify that the mast is in a vertical
position. Mast Drive
Wheel
5. Position the truck beneath the hoist or lift
truck.
7. Wrap a chain or lifting strap around the
top of the mast. Attach the chains or
straps to a hoist or lift truck.
8. Lift the hoist just enough to take the slack
out of the chain or strap.
9. Remove the tilt pin assembly retaining Avoid Contact
bolts and tilt pin assemblies. Carefully Between Mast
remove the pivot blocks from each tilt and Drive Unit
cylinder clevis, allowing the tilt cylinder to Cover Plate
rest on the brake assemblies.
Figure 7-91. Tilt Cylinder Removal from Mast

Installation after Partial
Removal
Tilt Pin Assembly
NOTE: For this procedure, you will need a hoist
or lift truck of suitable capacity.
1. With the mast securely held by a strap and
chain, carefully raise the mast until it is
vertical.
Tilt Cylinder
the key switch ON.
3. Slowly extend the tilt cylinders until you
Retaining Bolt are able to install the tilt cylinder pivot
blocks into each clevis. Tighten the jam
nuts snug against the pivot blocks.
4. Install the tilt pin assemblies to secure the
pivot blocks to the mast. Install the
retaining bolts.

Mast Removal and Installation Mast
5. Remove the lifting device and any 9. Position the truck beneath the hoist.
chains/straps used to lift the mast. 10. Turn the key switch OFF and disconnect
6. Install the forks. the battery connector.
7. Install the covers. 11. Wrap a chain or lifting strap around the
top of the mast. Attach the chains or
straps to a hoist.
Complete Mast Removal
12. Lift the hoist just enough to take the slack
NOTE: See also “Partial Removal” procedure out the chain or strap.
which precedes for an alternative means
13. Remove the tilt pin assembly retaining
of gaining access to motors and pumps.
bolts and tilt pin assemblies. Carefully
remove the pivot blocks from each tilt
For this procedure, you will need a hoist or lift
cylinder clevis, allowing the tilt cylinder to
truck of suitable capacity.
rest on the brake assemblies.
the battery connector. Figure 7-94. Tilt Cylinder Removal from Mast
2. Remove the console and front covers. Tilt Pin Assembly
3. Remove the forks.
the key switch ON. Elevate the fork
carriage about 18 in. (450 mm). Place
blocks under the fork carriage. Lower the
fork carriage onto the blocks.
Tilt Cylinder
Figure 7-93. Mast Pivot Bearing Caps
Retaining Bolt
14. Disconnect the hose from the lift/lower

manifold. Be careful not to spill hydraulic
fluid. Plug/cap each fitting to prevent
contamination from entering the hydraulic
system.
Figure 7-95. Mast Hydraulic Hose Disconnection
Lower Mounting Bolts

6. Remove the lower mounting bolt only from
each mast bearing cap. Do not remove
the upper bolt.
the key switch ON. Elevate the fork
carriage, remove the blocking, and lower
the fork carriage all the way to the floor.
8. Verify that the mast is in a vertical
position.

Mast Mast Removal and Installation
15. Remove the upper mounting bolt securing 7. Place the mast pivot bearing caps over
the mast pivot bearing cap on each drive both mast pivot bearings. Install the upper
unit. Remove the mast pivot bearing cap. mounting bolt in both mast pivot bearing
caps.
Figure 7-96. Mast Pivot Bearing Parts
8. Reconnect the hydraulic hose at the main
Drive Unit manifold.
Shims
Drive Wheel the key switch ON.
Mast 10. Slowly extend the tilt cylinders until you
are able to install the tilt cylinder pivot
blocks into each clevis. Tighten the jam
nuts snug against the pivot blocks.
11. Install the tilt pin assemblies to secure the
pivot blocks to the mast. Install the
Pivot retaining bolts.
Oilite Bearing Cap
Bearing 12. Remove the lifting device and any
chains/straps used to lift the mast.
16. Use the hoist or other lift truck to lift the 13. Elevate the fork carriage about 18 in.
mast just enough to allow it to be moved (450 mm). Place blocks under the fork
away from the tractor. carriage. Lower the fork carriage onto the
17. Using tie wraps, attach the hose to the lift blocks.
chain to keep it in place. 14. Turn the key switch OFF and disconnect
18. Have wood blocks positioned to support the battery connector.
the mast off the floor. 15. Apply thread-locking compound
19. Carefully lower the mast onto the support (P/N 1013829) to the lower mast pivot
blocks with the fork carriage facing down. bearing cap mounting bolts and torque to
20. Note the number of shims between the 43 ft. lb. (60 Nm).
Oilite bearings and mast. 16. Remove the upper mast pivot bearing cap
mounting bolts. Apply thread-locking
compound (P/N 1013829) to the bolts and
Installation after Complete torque to 43 ft. lb. (60 Nm).
Removal
NOTE: For this procedure, you will need a hoist the key switch ON.
or lift truck of suitable capacity. 18. Elevate the fork carriage and remove any
1. Make sure the pivot bearings are shimmed blocking.
as they were when the mast was removed. 19. Install the forks.
2. Wrap a chain or lifting strap around the 20. Bleed the hydraulic system. See Bleeding
top of the mast. Attach the chains or the Hydraulic System on page 7-82.
straps to the lifting device.
21. Install the covers.
3. Slowly lift the mast up and off the wooden
blocks.
4. Slowly move the mast towards the truck.
5. Position the lower pivot bearings on the
mast at the same height as the pivot yokes
on the drive units.
6. Carefully engage the mast pivot bearings
with the yokes on the drive unit.

Lift Chains Mast
Lift Chains Model 4250 TT Masts S/N 50501 Up

1. Raise the inner upright 3 ft. (90 cm). Place
a 3 ft. (90 cm) block under the free lift
Main Lift Chain Adjustment cylinder support blocks. The main lift
chain anchors are now accessible.
The main lift chains should be adjusted so that
when the unloaded mast is fully lowered, the 2. Adjust one chain to achieve the correct
uprights are flush at the bottom. upright position when fully lowered.
3. Adjust the other chain to achieve equal
All TT Masts except Model 4250 chain tension.
S/N 50501 Up 4. Raise and lower the mast several times to
confirm the adjustments.
1. Adjust one chain to achieve the correct
upright position when fully lowered. Figure 7-98. Main Lift Chain Anchors - TT Masts
2. Adjust the other chain to achieve equal S/N 50501 Up
chain tension. Tighten the nuts together to
a torque of 50 to 70 ft. lb. (68 to 95 Nm).
3. Raise and lower the mast several times to
Figure 7-97. Main Lift Chain Anchors - TT Masts

S/N 42000 thru 50500

Mast Lift Chains
Quad Mast Main Lift Chain Service

1. Locate the four main lift threaded chain
anchors on the back side top of the outer TT Mast
and outer intermediate uprights, on each
side of the main lift cylinders.
Figure 7-99. Main Lift Chain Anchors - Quad Mast

Block the intermediate upright.
1. Raise the inner upright 3 ft. (90 cm). Place

a 3 ft. (90 cm) block under the free lift
cylinder support casting, then lower the
cylinder support onto the block. The main
Outer Main lift chains should be slack.
Inner Main Lift Chain
Lift Chain Adjusting Nuts Figure 7-100.TT Mast Blocking (below S/N 50501)
Adjusting
Nuts
Free Lift Chain

Adjusting Nuts
Important: The chain anchor

nuts must be installed as shown
for correct operation.
2. Adjust one anchor of the outer main lift

chain pair first to achieve a flush inner Block
intermediate upright position with the

mast outer uprights.
3. Adjust the other anchor of the pair to
achieve equal chain tension. Repeat steps
1 and 2 for the inner main lift chain pair to
achieve a flush inner upright position with
the mast intermediate uprights.
4. Tighten the nuts together to a torque of 50
to 70 ft. lb. (68 to 95 Nm).

Lift Chains Mast

Figure 7-101.TT Mast Blocking (above S/N 50500) onto the blocks. The outer main lift chains
should be slack.
Figure 7-102.Outer Main Lift Chain Replacement - Quad

Mast
Upper Chain
Anchor on
Outer Upright
Outer Main
Lift Chains (2) Lower Chain
Anchor on Inner
Intermediate
Upright
2. Remove the cotter pins and pins from the

chain anchors. Remove the chains.
3. Inspect the chain anchors for cracks.
Replace as required.
4. For reassembly, reverse the disassembly 2. Remove the cotter pins and pins from the
procedure. Adjust the chains. chain anchors. Remove the chains.
3. Inspect the chain anchors for wear or
cracks. Replace as required.
If chain anchor is secured with a nylon 4. For reassembly, reverse the disassembly
lock nut, install a new lock nut when it is procedure. Adjust the chains.
necessary to loosen the chain or remove
the anchor. Inner Main Lift Chain Replacement
Quad Mast
Outer Main Lift Chain Replacement Block the inner upright.
1. Raise the inner upright and place a 2 ft.

(60 cm) long block under the free lift
Block the inner intermediate upright. cylinder support casting. Lower the
upright onto the block. The inner main lift
1. Raise the inner intermediate upright and chains should be slack.
place a 2 ft. (60 cm) long block under each
of the upright’s rails. Lower the upright

Mast Lift Chains

Figure 7-103.Inner Main Lift Chain Replacement - Quad Free Lift Chain Adjustment
Mast
The free lift chains should be adjusted so that
when the mast is vertical and the carriage is
fully lowered, the forks are positioned as
specified in the table below.
Fork Type Distance Above Floor
2 in. (5 cm) measured from top of

Standard
fork at the heel
0.12 to 0.25 in. (3 to 6.4 mm)

Chisel measured from the bottom of the fork
at the heel
Upper Chain
Anchor on
Outer Intermediate
Inner
Main Lift
Upright
Chains (2)
Lower Chain
S/N 50501 Up
Anchor on Inner
Upright 1. Locate the threaded chain anchors on the
front side of the cylinder. Adjust one chain
to achieve the correct fork height.
2. Adjust the other chain to achieve equal
chain tension. Tighten the nuts together to
a torque of 50 to 70 ft. lb. (68 to 95 Nm).

2. Remove the cotter pins and pins from the 1. Locate the threaded chain anchors on the
chain anchors. Remove the chains. front side of the inner upright cross
member in front of both cylinders. Adjust
3. Inspect the chain anchors for wear or one chain to achieve the correct carriage
cracks. Replace as required. position when fully lowered.
4. For reassembly, reverse the disassembly 2. Adjust the other chain to achieve equal
procedure. Adjust the chains. chain tension.

Lift Chains Mast
Free Lift Chain Service

1. Raise the carriage enough to place a 12 in.
(300 mm) block under the carriage, then
lower the carriage onto the block. The free
lift chains should be slack.
Block the carriage.
Figure 7-104.Blocking the Carriage
2. Remove the cotter pins and pins from the

chain anchors. Remove the chains.
3. Inspect the chain anchors for cracks.
Replace as required.
4. For reassembly, reverse the disassembly
procedure. Adjust the chains.
If chain anchor is secured with a nylon

lock nut, install a new lock nut when it is
necessary to loosen the chain or remove
the anchor.

Mast Roller Bearing (Puck) Adjustment - TT Mast - S/N 50501 Up
Roller Bearing (Puck)

Adjustment - TT Mast
- S/N 50501 Up
Adjust the roller bearing wear pad spacing as

shown. See Figure 7-105.
Figure 7-105.Roller Bearing Adjustment
0.2 to 0.4 in.

(0.008 to 0.016 mm)
Clearance

Mast Skewing Mast
Mast Skewing members. Lower the cross member onto

the block. See Figure 7-108.
Raise the mast to full height: Figure 7-107.Mast Cylinder Shim Installation
Snap Ring
• If the mast kicks to the right at full
extension, the right hand main lift cylinder
rod must be shimmed.
Shim
• If the mast kicks to the left at full
extension, the left hand main lift cylinder
rod must be shimmed.
Figure 7-106.Mast Skewing (2-Stage shown) Angle Iron
TF Mast
TT Mast
Quad Mast - Place a 4 x 4 x 20 in. (10 x 10 x 50 cm) wood block between the outer intermediate and outer upright cross members. Lower the cross member onto the block.
Figure 7-108.Quad Mast Cylinder Shim Installation

Inner uprights must be blocked or
supported as shown.
All except Model 4250 TT Masts Snap

S/N 50501 Up Ring
1. TF and TT Masts - Place a 6 in. (15 cm)

long, 2 x 2 in. (5 x 5 cm) angle iron
Shim
between the top of the main lift cylinder
and the cross member. Do not contact the
cylinder rod seal. Lower the cross member
onto the angle iron. See Figure 7-107.
Quad Mast - Place a 4 x 4 x 20 in. (10 x 10

x 50 cm) wood block between the outer
intermediate and outer upright cross

Mast Mast Skewing
2. Remove the snap ring from the cylinder to Reinstall the outer and inner sleeves,
be adjusted. Activate the lower control to screw, and cap.
allow the cylinder rod to retract and 5. Repeat steps 1 thru 4 until skewing has
disengage the cross member. been removed.
3. Install shim(s) as necessary.
4. Slowly activate the lift control to allow the
cylinder rod to engage the cross member.
Reinstall the snap ring.
5. Repeat steps 1 thru 4 until skewing has
been removed.

1. Place a 4 x 4 x 12 in. (10 x 10 x 30 cm)
wood block between the intermediate
weldment and the outer weldment cross
members. Lower the cross member onto
the block. See Figure 7-109.
Figure 7-109.Model 4250 TT Mast (S/N 50501 Up)

Cylinder Shim Installation
2. Remove the cap, screw, inner and outer

sleeves from the cylinder to be adjusted.
Activate the lower control to allow the
cylinder rod to retract and disengage the
cross member.
3. Install shim(s) as necessary.
4. Slowly activate the lift control to allow the
cylinder rod to engage the cross member.

2-Stage (TF) Mast Service Mast
2-Stage (TF) Mast Service 4. Remove internal hose reeving sheave and
hoses.
5. Remove the free lift cylinder from the
Bubbled items in figures correspond to steps in
mast. Refer to Free Lift Cylinder Removal -
the associated procedure.
Mast on Floor on page 7-112.
6. Remove the ISS from the mast. Refer to
Disassembly ISS Removal - Mast on Floor on page 7-85.
Refer to Figure 7-110. 7. Remove the pins fastening the free lift
chains to the inner upright chain anchors.
1. Remove the mast assembly from the truck.
Refer to Complete Mast Removal on page 8. Attach an overhead hoist to the inner
7-99. upright cross member as shown.
2. Remove the main lift cylinders from the 9. Roll the inner upright downward to expose
mast. Refer to Main Lift Cylinder Removal the upper and lower load rollers. Remove
- Mast on Floor on page 7-111. the load rollers. Note the number of shims
behind each load roller.
3. Using an overhead chain hoist, turn the
mast over (face up). 10. Attach an overhead hoist to the inner
upright and remove it through the top of
the outer upright.
Figure 7-110.2-Stage Mast Disassembly

Mast 2-Stage (TF) Mast Service
Inspection 9. Install the internal hose reeving hoses.

Refer to Internal Reeving Installation on
1. Inspect the load rollers for excessive wear page 7-115.
or damage. Rollers with visible flat spots or
10. Install mast on truck. Refer to Installation
cracks should be replaced.
after Complete Removal on page 7-100.
2. Inspect the load roller bearings by turning
11. Adjust the free lift chains. Refer to Free
the rollers on their shafts. Rollers with
Lift Chain Adjustment on page 7-104.
roughness or noticeable restrictions to
turning should be replaced. 12. Check for mast skewing. Refer to Mast
Skewing on page 7-107.
3. Inspect the load roller stub shafts. If they
are damaged or have cracks at the base,
the upright must be replaced or repaired.
4. Check gap between uprights and thrust
plugs. If gap is greater than 0.060 in.
(1.5 mm), add shims or replace thrust
plug.
5. Inspect the lift chains.
Reassembly
Refer to Figure 7-111.
1. Lubricate the outer rails. See Lubrication
Specification Chart on page A-2.
2. Attach an overhead hoist to the inner
upright. Install the inner upright through
the top of the outer upright.
3. Install load rollers on the stub shafts
using the correct number of shims. The
shims should be installed to provide a
total side to side clearance no greater than
throughout the travel in the upright. Use
an equal number of shims on each side.
NOTE: Roll the inner upright past the wear
pads before checking roller clearances.
4. Install the free lift chains to the inner
upright cross member chain anchors.
5. Install the free lift cylinder. Refer to Free
Lift Cylinder Installation - Mast on Floor
on page 7-113.
6. Install the ISS. Refer to ISS Installation on
page 7-87.
7. Turn the mast over.
8. Install the main lift cylinders. Refer to
Main Lift Cylinder Installation - Mast on
Floor on page 7-112.


Figure 7-111.2-Stage Mast Reassembly
Upright
Rails
LUBRICATE ONLY WHERE INDICATED

BY THE HEAVY LINE FOR THE FULL
LENGTH OF EACH UPRIGHT
Cylinder Removal and 3. Disconnect the cylinder supply hoses from

the cylinder inlet ports. Remove the special
Installation long fittings from the cylinder ports and
install plugs.
Refer to page 7-93 for cylinder service.
4. Disconnect the hose and tube from the
cylinder plungers.
Main Lift Cylinder Removal - Mast on
Floor 5. Remove the snap rings fastening the
cylinder rods to the inner upright.
Refer to Figure 7-112. 6. Pull the inner upright outward 2 ft.
1. Remove the mast from the truck. See (60 cm).
Complete Mast Removal on page 7-99. 7. Lift the cylinder from the base mount and
2. Lay the mast face-down on wood blocks as angle it inward to remove through the gap
shown. Block under the outer upright so at the top of the uprights.
the inner upright is free to move. The ISS 8. Note the number of shims (if equipped) on
must be positioned between the blocks each cylinder rod.
and free to move.


Figure 7-112.2-Stage Mast Main Lift Cylinder Removal
Main Lift Cylinder Installation - Mast 8. Remove the cylinder from the mast.
on Floor
For installation, reverse the Removal procedure.

Bleed the system. See Bleeding the Hydraulic
System on page 7-82.
Free Lift Cylinder Removal - Mast on

Floor

1. Remove the mast from the truck. See
Complete Mast Removal on page 7-99.
2. Lay the mast down as shown.
3. Roll the carriage toward the center of the
cylinder to slacken the chains and internal
reeving hoses.
4. Disconnect the tube from the cylinder
fitting. Cap the fitting and plug the tube.
5. Remove the snap rings fastening the
crosshead to the cylinder rod.
6. Pull the crosshead with chains and hoses
off the cylinder rod.
7. Remove the cylinder strap and nylon
segments.


Figure 7-113.2-Stage Mast Free Lift Cylinder Removal - Mast on Floor
Free Lift Cylinder Installation - Mast wood block between the lower carriage bar
on Floor and the floor.
3. Disconnect the tube from the cylinder
For installation, reverse the Removal procedure. fitting. Cap the fitting and plug the tube.
Bleed the system. See Bleeding the Hydraulic 4. Remove the snap ring fastening the
System on page 7-82. crosshead to the cylinder rod.
Free Lift Cylinder Removal - Mast on off the cylinder rod.
Truck
6. Remove the cylinder strap and nylon
segments.
7. Remove the cylinder from the mast.
1. Completely lower the carriage. Remove
forks or attachment. Attach an overhead
hoist to the top carriage bar.
The carriage must be supported by a

block while removing the cylinder to
avoid possible injury.
2. Raise the carriage to the center of the

reeving hoses. Block the carriage in place
using a 4 x 4 x 24 in. (10 x 10 x 60 cm)


Figure 7-114.2-Stage Mast Free Lift Cylinder Removal - Mast
on Truck
Free Lift Cylinder Installation - Mast

on Truck


Internal Reeving Installation 12. Raise and lower mast several times to
make sure the hoses are tracking correctly
Refer to Figure 7-115. in the guide brackets. Use white line on
the hoses to detect twisting. Adjusting the
1. Install the fittings on the carriage bracket.
hose ends with a slight amount of twist
2. Install front hose guide bracket to back may improve hose tracking in the guides.
side of the inner upright cross member.
Tighten cap screws to 48 to 52 ft. lb. (65 to Figure 7-115.Hose Reeving Installation - 2-Stage Mast
70 Nm).
3. Install rear hose bracket to outer upright
by inserting the round bar at the end of 4
the bracket into the hole in the upper
3 Hoses must
outer chain anchor mounting block.
not contact
4. Attach lower end of bracket to inside of bottom of chain
anchor mount.
outer upright chain anchor mounting,
leaving a gap between the top of the
bracket and chain anchor mount. Bracket
should be parallel with upright. Tighten
cap screw to 48 to 52 ft. lb. (65 to 70 Nm). 9
5. Remove existing cap screw and guard from
one side of the cylinder crosshead. Install Rear Hose
hose sheave and guard. Tighten cap screw Guide Bracket
to 48 to 52 ft. lb. (65 to 70 Nm).
6. Install hoses to the carriage fittings with
white line facing outward.
7. Feed hoses between the crosshead guard
and sheave. Raise carriage just above free 7
lift. Route hoses under the front hose
10
guide bracket. Install hose clamp. Pull on
hoses to remove slack. Tighten cap screw 4
to 25 to 30 ft. lb. (35 to 40 Nm). 5 2 8
Completely lower the carriage.
11
8. Route hoses to the rear guide bracket. The
loop in the hoses should be 4 in. (101 mm)
±1 in. (25 mm) below the bottom of the
rear bracket.
9. Install hose clamps at the top of the rear
guide bracket. Make sure the loop is the
same for both hoses. Tighten cap screws
to 25 to 30 ft. lb. (35 to 40 Nm). Check and
adjust hose clearances.
10. Install bulkhead fittings to the bracket
with the securing nuts located on the top
side. Install hose ends to the fittings. 6
1
11. Move the lowering control valve and
bracket to the back side of the center cross
member. Tighten the cap screws to 25 to
30 ft. lb. (35 to 40 Nm). Check and adjust
hose clearances.

Mast 3-Stage (TT) Mast Service - below S/N 50501
3-Stage (TT) Mast Service 12. Attach an overhead hoist to the inner
upright. Remove the inner upright through
- below S/N 50501 the top of the intermediate upright.
13. Remove the main lift chain anchors (long
Bubbled items in figures correspond to steps in anchors) and chains from the outer
the associated procedure. upright cross member. the anchors for
reassembly.
Disassembly 14. Roll the intermediate upright downward to
expose the intermediate and outer upright
Refer to Figure 7-116. load rollers. Remove the load rollers. Note
1. Remove the mast assembly from the truck. the number of shims behind each load
Refer to Complete Mast Removal on page roller.
7-99. 15. Attach an overhead hoist to the
2. Remove the main lift cylinders from the intermediate upright and remove it
mast. Refer to Main Lift Cylinder Removal through the top of the outer upright.
- Mast on Floor on page 7-119.
Figure 7-116.3-Stage Mast Disassembly
3. Using an overhead chain hoist, turn the
mast over (face up).
4. Remove the free lift cylinder from the
mast. Refer to Free Lift Cylinder Removal -
Mast on Floor on page 7-119.
5. Remove the ISS from the mast. Refer to
ISS Removal - Mast on Floor on page 7-85.
6. Remove internal hose reeving sheave and
hoses.
7. Remove the pins fastening the main lift
chains to the inner upright chain anchors.
Pull the main lift chains back through the
chain sheaves.
Discard used chain anchor nuts. Install

new chain anchor nuts during
reassembly.
8. Remove the main lift chain anchors (long

anchors) from the inner upright lower Inspection
back side. the anchors for reassembly.
1. Inspect the load rollers for excessive wear
9. Remove the pins fastening the free lift or damage. Rollers with visible flat spots or
chains to the inner upright chain anchors. cracks should be replaced.
10. Remove the free lift cylinder supply hose 2. Inspect the load roller bearings by turning
and sheave. Remove the main lift chain the rollers on their shafts. Rollers with
sheaves. roughness or noticeable restrictions to
11. Roll the inner upright downward to expose turning should be replaced.
the inner and intermediate upright load 3. Inspect the load roller stub shafts. If they
rollers. Remove the load rollers. Note the are damaged or have cracks at the base,
number of shims behind each load roller. the upright must be replaced or repaired.

3-Stage (TT) Mast Service - below S/N 50501 Mast
4. Check gap between uprights and thrust 8. Install the chain anchors (long anchors) to
plugs. If gap is greater than 0.060 in. the back side of the inner upright lower
(1.5 mm), add shims or replace thrust cross member. Refer to Figure 7-117.
plug. 9. Pull the main lift chains over the chain
5. Inspect the lift chains. sheaves and attach to the lower inner
upright chain anchors.
Reassembly 10. Install the free lift chain anchors (short
anchors) and chains to the inner upright
Refer to Figure 7-117. center cross member. Refer to
Figure 7-117.
1. Lubricate the outer rails. See Lubrication
Specification Chart on page A-2. 11. Install the free lift cylinder supply hose
through the hole in the outer upright top
2. Attach an overhead hoist to the
cross member and over the sheave on the
intermediate upright. Install the
intermediate top upright.
intermediate upright through the top of
the outer upright. 12. Install the ISS. Refer to ISS Installation on
page 7-87.
3. Install load rollers on the outer and lower
intermediate upright stub shafts using the 13. Install the free lift cylinder. Refer to Free
correct number of shims. The shims Lift Cylinder Installation - Mast on Floor
should be installed to provide a total side on page 7-119.
to side clearance no greater than 1/16 in. 14. Install the internal reeving sheaves and
(1.5 mm) at the tightest point throughout hoses. Refer to Internal Reeving
the travel in the upright. Use an equal Installation on page 7-120.
number of shims on each side.
15. Turn the mast over.
NOTE: Roll the upright past the wear pads 16. Install the main lift cylinders. Refer to
before checking roller clearances. Main Lift Cylinder Installation - Mast on
4. Lubricate the intermediate upright rails. Floor on page 7-125.
See Lubrication Specification Chart on 17. Install mast on truck. Refer to Installation
page A-2. Attach an overhead hoist to the after Complete Removal on page 7-100.
inner upright. Install the inner upright
18. Adjust the main and free lift chains. Refer
through the top of the intermediate
to Main Lift Chain Adjustment on page
upright.
7-101 and Free Lift Chain Adjustment on
5. Install load rollers on the intermediate page 7-104.
upright top and inner upright lower stub
19. Check for mast skewing. Refer to Mast
shafts using the correct number of shims.
Skewing on page 7-107.
The shims should be installed to provide a
total side to side clearance no greater than
throughout the travel in the upright. Use
an equal number of shims on each side.
NOTE: Roll the upright past the wear pads
before checking roller clearances.
6. Install the chain sheave and free lift hose
sheave to the intermediate upright.
Tighten the cap screw to 26 to 30 ft. lb. (35
to 40 Nm).
7. Install the main lift chain anchors (long
anchors) and chains.


Figure 7-117.3-Stage Mast Reassembly

Cylinder Removal and 4. Disconnect the hose from the cylinder 45°
fitting. Cap the fitting and plug the hose.
Installation
5. Remove the snap ring fastening the
Refer to page 7-93 for cylinder service. crosshead to the cylinder rod.
Main Lift Cylinder Removal - Mast on (if equipped) off the cylinder rod.
Floor 7. Remove the cylinder retainer cap screws.
1. Remove the mast from the truck. See 8. Remove the cylinder from the mast.
2. Lay the mast face-down on wood blocks. Free Lift Cylinder Installation - Mast
Block under the outer upright so the inner on Floor
upright is free to move. The ISS must be
positioned between the blocks and free to For installation, reverse the Removal procedure.
move. Bleed the system. See Bleeding the Hydraulic
3. Disconnect the cylinder supply hoses from System on page 7-82.
long fittings from the cylinder ports and Free Lift Cylinder Removal - Mast on
install plugs. Truck
NOTE: Each internal fuse piston holds a
compressed spring in place.
4. Remove the snap rings fastening the forks or attachment. Make sure the free lift
cylinder rods to the intermediate upright. cylinder is completely retracted. Attach an
5. Pull the inner and intermediate upright overhead hoist to the top carriage bar.
outward 2 ft. (60 cm).
6. Lift the cylinder from the base mount and
angle it inward to remove through the gap
at the top of the uprights. The carriage must be supported by a
7. Note the number of shims (if equipped) on block while removing the cylinder to
each cylinder rod. avoid possible injury.
Main Lift Cylinder Installation - Mast 2. Raise the carriage to the center of the
on Floor
using a 4 x 4 x 24 in. (10 x 10 x 60 cm)
wood block between the lower carriage bar
and the floor.
3. Remove the cylinder retainer bolts.
Free Lift Cylinder Removal - Mast on 4. Remove the snap ring fastening the
Floor crosshead to the cylinder rod.
1. Remove the mast from the truck. See (if equipped) off the cylinder rod and lay
Complete Mast Removal on page 7-99. over upper carriage bar.
2. Lay the mast down. 6. Pry the cylinder up out of the support
3. Roll the carriage toward the center of the casting to gain access to the cylinder hose
cylinder to slacken the chains and internal fitting. Remove the hose from the 45°
reeving hoses. fitting. Cap the fitting and plug the hose.

7. Remove the cylinder from the mast. carriage bracket fittings. Connect the hose
fittings to the carriage fittings and tighten.
Free Lift Cylinder Installation - Mast 6. Loosen the crosshead cover plate cap
on Truck screw. Route the hoses up over the
crosshead sheaves. Orient the hoses with
For installation, reverse the Removal procedure. the natural curve over the sheaves.
Bleed the system. See Bleeding the Hydraulic 7. Route the hoses down between the free lift
System on page 7-82. cylinder and middle inner cross member to
the bracket behind the free lift cylinder.
Figure 7-118.3-Stage Mast Free Lift Cylinder Removal - Mast The hoses route through the wire loop,
on Truck
then underneath the lower inner cross
member. Assemble the clamp and hoses,
then pull down on the hoses with 80 lbs.
(36 kg) of force to remove slack. Tighten
the clamp cap screws to 8 ft. lb. (11 Nm).
8. Route the hoses under the lower inner
cross member to loop up to the lower hose
bracket. Install the hose clamps, leaving
the cap screws finger tight. Align the hoses
under the cross member and into the
clamp. Tighten the clamp cap screws to
8 ft. lb. (11 Nm).
9. Route the hoses up to and over the upper
hose sheaves and then down to the upper
hose bracket. Assemble the clamp and
hoses to the upper bracket, leaving the cap
screws finger tight. Starting with the outer
hose, pull down on the hoses with 80 lbs.
(36 kg) of force to remove slack, then
tighten the clamp cap screws to 8 ft. lb.
(11 Nm).
10. Attach the hose ends to the center hose
Internal Reeving Installation bracket, aligning the hoses with their
natural curve. Tighten the clamp cap
Refer to Figure 7-119. screws to 8 ft. lb. (11 Nm).
1. Install the shafts, sheaves, and hose 11. Attach the left cylinder supply hose and
guards to the crosshead center plate. clamp to the outer upright center cross
Leave the cap screw and nut finger tight to member. Tighten the clamp cap screw to
allow hose installation. 8 ft. lb. (11 Nm).
2. Install the ISS bracket to the tabs between 12. Tighten the crosshead cover plate cap
the ISS side plates. Leave the cap screws screw to 51 ft. lb. (70 Nm).
finger tight. 13. Tighten the carriage bracket cap screws to
3. Install fittings to the left or right side of 46 ft. lb. (63 Nm).
bracket. Tighten the fittings finger tight. 14. Raise and lower the mast slowly through
4. Install the brackets, hose clamps, and several cycles, checking for correct hose
sheaves to the uprights. Tighten the alignment, clearances, and hose tracking.
bracket cap screws to 38 ft. lb. (51 Nm).
5. Completely lower the ISS. Route the hoses
down behind the top carriage bar to the


Figure 7-119.Hose Reeving Installation - 3-Stage Mast

Mast 3-Stage (TT) Mast Service - S/N 50501 Up
3-Stage (TT) Mast Service Figure 7-120.Mast Disassembly
Intermediate Upright
- S/N 50501 Up
Inner Upright
the associated procedure.
Disassembly
1. Remove the mast assembly from the truck.
Refer to Complete Mast Removal on page
7-99. Outer Upright
2. Reverse the Internal Reeving Installation

on page 7-128 from step 13 to step 2.
3. Remove the free lift cylinders. Refer to Free
Lift Cylinder Removal - Mast on Floor on
Inspection
page 7-125. 1. Inspect the pucks for excessive wear or
4. Disconnect the free lift chains from the damage. Pucks with visible flat spots or
carriage. cracks should be replaced.
5. Disconnect the auxiliary hoses from the 2. Inspect the roller bearings by turning
carriage bulkheads and plug all fittings. them on their shafts. Roller bearings with
roughness or noticeable restrictions to
6. Remove the carriage by sliding it out of the
turning should be replaced.
bottom of the inner upright.
3. Inspect the bearing roller stub shafts. If
7. Remove the main lift chain. Refer to Main
they are damaged or have cracks at the
Lift Chain Service on page 7-102.
base, the upright must be replaced or
8. Remove main lift chain sheave. repaired.
9. Remove fittings and hoses between the 4. Inspect the lift chains.
mast manifold and main lift cylinders.
5. Inspect the outer upright chain anchors.
10. Remove the main lift cylinders. Refer to
6. Inspect the inner upright chain anchors.
Main Lift Cylinder Removal - Mast on Floor
on page 7-125.
11. Remove the mast manifold.
Reassembly
12. Using an overhead hoist, turn the mast Refer to Figure 7-121.
over (cross members facing down).
1. Install small and large roller bearing
13. Attach an overhead hoist to the inner assemblies in the locations specified.
upright. Remove the inner upright through Pucks should be pushed in as far as they
the top of the intermediate upright. can go. Set screws should be started but
14. Attach an overhead hoist to the should not be installed far enough to start
intermediate upright and remove it forcing the puck out of the roller stud.
through the top of the outer upright. 2. Lubricate the roller bearing surfaces on
15. Remove bearing assemblies (if necessary). the outer, intermediate, and inner
uprights. See Lubrication Specification
Chart on page A-2.
3. Attach an overhead hoist to the
intermediate upright. Install the

3-Stage (TT) Mast Service - S/N 50501 Up Mast
intermediate upright through the top of 15. Connect auxiliary hoses to the carriage
the outer upright. bulkheads in the correct orientation.
4. Adjust the puck spacing on the roller 16. Connect the free lift chains to the carriage.
bearings positioned on the top of the outer Refer to Free Lift Chain Service on page
upright and at the bottom of the 7-105.
intermediate upright. This adjustment is 17. Install free lift cylinders. Refer to Free Lift
made by driving in the adjusting set screw. Cylinder Installation - Mast on Floor on
Spacing between the pucks and the rails page 7-126.
should be between 0.008 and 0.016 in.
(0.2 and 0.4 mm) on both sides. The 18. Adjust the chains by securing the carriage
intermediate upright should be centered at the specified dimension from the bottom
within the outer upright. of the inner upright with C-clamps
clamped on the upright flange. Adjust both
5. Attach an overhead hoist to the inner chain anchors until they have equal
upright. Install the inner upright through tension with the carriage in the correct
the top of the intermediate upright. position (minor adjustments will need to
6. Adjust the puck spacing on the roller be made once the mast is upright). Leave
bearings positioned on the top of the the carriage in this position with the
intermediate upright and at the bottom of C-clamps in place.
the inner upright. This adjustment is 19. Route the auxiliary and lift hoses. Refer to
made by driving in the adjusting set screw. Internal Reeving Installation on page
Spacing between the pucks and the rails 7-128.
should be between 0.008 and 0.016 in.
(0.2 and 0.4 mm) on both sides. The inner
upright should be centered within the
intermediate upright.
7. Using an overhead hoist, turn the mast
over (cross members facing up).
8. Install the mast manifold as shown.
9. Install the main lift cylinders. Refer to
Main Lift Cylinder Installation - Mast on
Floor on page 7-125.
10. Install fittings and hoses between the mast
manifold and main lift cylinders as shown.
11. Install the main lift chain sheave.
12. Install the main lift chain. Refer to Main
Lift Chain Service on page 7-102.
13. Install the carriage by sliding it into the
bottom of the inner upright.
14. Adjust the puck spacing on the roller
bearings positioned on either side of the
carriage. This adjustment is made by
driving in the adjusting set screw. Spacing
between the pucks and the rails should be
between 0.008 and 0.016 in. (0.2 and
0.4 mm) on both sides. The carriage
should be centered within the inner
upright.


Figure 7-121.Mast Reassembly

Cylinder Removal and 5. Remove the two screws securing the

cylinder retaining bracket.
Installation
6. Remove the cylinder retaining bolt at the
Refer to page 7-93 for cylinder service. bottom of the cylinder.
7. Remove main lift cylinder.
Main Lift Cylinder Removal - Mast on
Floor Main Lift Cylinder Installation - Mast
on Floor
2. Lay the mast face-down on wood blocks. In addition:
Block under the outer upright so the inner
• Torque the screw at the top of the cylinder
upright is free to move. The ISS must be
to 55 ft. lb. (74.5 Nm).
positioned between the blocks and free to
move. • Bleed the system. See Bleeding the
Hydraulic System on page 7-82.
3. Disconnect the cylinder supply hoses from
long fittings from the cylinder ports and Free Lift Cylinder Removal - Mast on
install plugs. Floor
NOTE: Each internal fuse piston holds a
compressed spring in place.
4. Remove the cap, screw, inner sleeve, outer Complete Mast Removal on page 7-99.
sleeve, and shims (if present). See
Figure 7-122. 2. Lay the mast down.
3. Roll the carriage toward the center of the
Figure 7-122.Main Lift Cylinder Removal cylinder to slacken the chains and internal
reeving hoses.
4. Disconnect the cross-over tube and
fittings from the cylinders. Cap the fittings
and plug the hose.
5. Remove the free lift hose assembly from
the free lift chain sheave assembly by
removing the two bolts.
6. Remove the chain and nut from the free lift
chain anchor.
7. Remove the free lift chain sheave assembly
from the cylinder.
8. Remove the bolts connecting the cylinder
to the lower mounting blocks.
9. Remove the chain anchor and remove the
cylinder from the mast.


on Floor
For installation, reverse the Removal procedure. The carriage must be supported by a
Bleed the system. See Bleeding the Hydraulic block while removing the cylinder to
System on page 7-82. avoid possible injury.
Figure 7-123.Free Lift Cylinder Removal - Mast on Floor 2. Raise the carriage to the center of the
using a 4 x 4 x 24 in. (10 x 10 x 60 cm)
wood block between the lower carriage bar
and the floor.
3. Remove the bolts connecting the cylinders
to the lower mounting blocks.
4. Remove the free lift hose assembly.
5. Remove the chain and nut from the free lift
chain anchor.
6. Remove the free lift chain sheave assembly
from the cylinder.
7. Disconnect the cross-over tube and
fittings from the cylinders. Cap the fittings
and plug the hose.
8. Remove the chain anchors.

on Truck

Free Lift Cylinder Removal - Mast on
Truck

forks or attachment. Make sure the free lift
cylinder is completely retracted. Attach an
overhead hoist to the top carriage bar.


Figure 7-124.Free Lift Cylinder Removal - Mast on Truck

Internal Reeving Installation 12. Attach the lift hose to the mast manifold.
13. Secure the two auxiliary hoses to the
Refer to Figure 7-125. fitting on the mast manifold with a cable
1. Install auxiliary hoses at the carriage tie.
fittings. 14. Raise and lower the mast several times.
2. Route auxiliary hoses over the free lift Make sure the hoses track over the pulleys
cylinder and through the hose pulley correctly. The hose pulley assembly
assembly. Attach hose pulley assembly to attached to the free lift cylinder should be
the free lift chain sheave assembly. aligned front to back. If it looks like it is
twisting as the free lift cylinder is raised,
3. Route auxiliary hoses down the free lift
perform the following adjustment
cylinder to the hose clamp. Install hose
procedure:
clamp components around auxiliary hoses
and bolt clamps to the cross-member. Do a. Slightly loosen the aux hose fittings at
not tighten. the carriage, allowing the swivel fitting
to correct the twist in the hose.
4. With carriage at its lowest position, pull
slack out of the two aux hoses. Mark the b. Tighten the fittings and check the hose
hoses at the bottom of the clamp. Pull the pulley assembly for alignment. If
hoses until the distance between the line necessary, adjust the hose ends with a
and the clamp is 1.5 ±0.5 in. (38 ±12 mm). slight amount of twist to improve the
Tighten the clamp. alignment of the hose pulley assembly.
5. Route the auxiliary hoses as shown,
clamping them at the positions specified
with the hose clamps.
6. Attach lift hose to the cross-over tube
between the free lift cylinders.
7. Clamp the lift hose and auxiliary hoses
into the hose clamp. Make sure the plastic
clamps are arranged as shown. Torque the
screws to 50 in. lb. (6 Nm).
8. Route the lift and aux hoses up to the
upper hose pulley assembly. Install the
hoses on the pulleys, then push the
pulleys into position so the shaft can
engage both pulleys.
9. Assemble the upper hose clamp as shown
with the hoses in the clamps, do not
tighten.
10. With the mast fully collapsed, pull slack
out of the lift hose and two aux hoses.
Mark the hoses at the bottom of the clamp.
Pull the hoses until the distance between
the line and the clamp is 1.5 ±0.5 in.
(38 ±12 mm). Tighten the clamp to hold
the hoses. Torque the screws to 50 in. lb.
(6 Nm).
11. Route hoses as shown over to the main lift
cylinder and clamp at equal distances in 3
places on the main lift cylinder.


Figure 7-125.Internal Reeving Installation

Mast Quad Mast Service
Quad Mast Service 11. Remove the inner main lift chains and for
reassembly.
12. Remove the load rollers from the lower end
of the inner upright. Remove the load
associated procedure.
rollers and thrust plugs from the upper
end of the inner intermediate upright. Note
Disassembly the number of shims behind each for
reassembly.
NOTE: Quad Mast uprights require complete
disassembly in order to service load 13. Attach an overhead hoist to the inner
rollers, thrust plugs/blocks, and upright and remove it through the top end
chain/hose sheaves. of the inner intermediate upright.
NOTE: The stub shafts on the lower end of the
Refer to Figure 7-126. inner upright come out of the inner
1. Remove the internal hose reeving from the intermediate upright between the rail
mast while it is on the truck. cutout and the stub shaft.
2. Remove the mast assembly from the truck. 14. Remove the outer main lift chain anchors
Refer to Complete Mast Removal on page from the lower end of the inner
7-99. intermediate upright and the top end of
3. Remove the main lift cylinders from the the outer upright. Set the chains aside and
mast. Refer to Main Lift Cylinder Removal for reassembly.
- Mast on Floor on page 7-135. 15. Remove the lower stop from the outer
4. Using an overhead chain hoist, turn the intermediate upright.
mast over (face up). 16. Remove the chain sheaves from the outer
5. Remove the free lift cylinder from the intermediate upright.
mast. Refer to Free Lift Cylinder Removal - 17. Roll the inner intermediate upright
Mast on Floor on page 7-135. downward and remove the lower rollers.
6. Remove the ISS from the mast. Refer to Remove the upper rollers and thrust plugs
ISS Removal - Mast on Floor on page 7-85. from the outer intermediate upright. Note
the number of shims behind each roller for
7. Remove the free lift chain anchors and
reassembly.
chains from the inner upright center cross
member and for reassembly. 18. Attach an overhead hoist to the inner
intermediate upright and remove it
8. Disconnect the free lift cylinder hose from
through the top end of the outer
the tube and remove the stop/hose
bracket/tube assembly.
19. Roll the outer intermediate upright
9. Disconnect the inner main chain anchors
downward and remove the lower rollers.
from the lower end of the inner upright
Remove the upper rollers and thrust
and the upper end of the outer
blocks from the outer upright. Note the
number of shims behind each roller and
10. Move the inner upright downward. Remove thrust block for reassembly.
the free lift hose sheave, hose, and main
20. Attach an overhead hoist to the outer
chain sheaves at the top of the inner
intermediate upright and remove it
through the top end of the outer upright.
NOTE: The lower end of the inner upright must
be raised slightly to clear the inner
intermediate upright lower cross
member.

Quad Mast Service Mast

Figure 7-126.Quad Mast Disassembly
Inner 12 12
Intermediate
Upright
8 Thrust
Plug
9 10 Thrust
10 Plug
Shim
7
Inner
Main Lift
Chains
11 10
10
MA0244.eps
12 9
7 12
Free Lift
Chains
MA0078.eps
Inspection Reassembly
1. Inspect the load rollers for excessive wear 1. Lubricate the full length of the outer
or damage. Rollers with visible flat spots or upright rails. See Lubrication Specification
cracks should be replaced. Chart on page A-2.
2. Inspect the load roller bearings by turning 2. Attach an overhead hoist to the outer
the rollers on their shafts. Rollers with intermediate upright and install it through
roughness or noticeable restrictions to the top of the outer upright. Position it out
turning should be replaced. the lower end of the outer upright approx.
3. Inspect the load roller stub shafts. If they 6 in. (15 cm).
are damaged or have cracks at the base, 3. Assemble shims, load rollers, and thrust
the upright must be replaced or repaired. blocks to the upper end of the outer
4. Check gap between uprights and thrust upright. Assemble shims and load rollers
plugs. If gap is greater than 0.060 in. to the lower end of the outer intermediate
(1.5 mm), add shims or replace thrust upright.
plug.
5. Inspect the lift chains.

• Roller Shimming - Install shims to 4. Lubricate the full length of the outer
provide a total side-to-side clearance of intermediate upright rails. See Lubrication
0.06 in. (1.5 mm) max. at the tightest Specification Chart on page A-2.
point throughout the travel of the 5. Attach an overhead hoist to the inner
upright. Pry between the upright and intermediate upright and install it through
the load roller so that the opposite load the top end of the outer intermediate
roller is tight against the upright. upright. Position it out the lower end of the
Measure the clearance for the pair of outer intermediate upright approx. 6 in.
rollers at the XXX shown in (15 cm).
Figure 7-127. Use an equal number of
shims on each side. 6. Install shims and load rollers to the lower
end of the inner intermediate upright.
Figure 7-127.Load Roller Clearance/Channel Lubrication Install shims, load rollers, and thrust
plugs to the upper end of the outer
1 4 Lube
intermediate upright. Refer to step 3 for
roller shimming and thrust plug clearance
Upright measurement.
Rails
7. Install the chain sheaves to the upper end
of the outer intermediate upright. Install
the outer main lift chain anchors and
chains over the outer intermediate upright
chain sheaves.
8. Install the outer main lift chain anchors
(long anchors) to the lower end of the inner
Upright
Rail 9. Install the lower stop on the outer
intermediate upright. Torque the cap
Shim
screw to 81 to 88 ft. lb. (110 to 120 Nm).
Load 10. Install the main chain sheaves, free lift
Rollers
sheaves, and hose in the inner
intermediate upright. Torque the retainer
cap screws to 26 to 30 ft. lb. (35 to 40 Nm).
3 11. Install the upper inner main chain
.06 in.
(1.5 mm) anchors to the outer intermediate upright.
Max. MA0259.eps Install the free lift hose bracket and tube.
NOTE: Roll the uprights past installed thrust
plugs/blocks before checking load roller
clearance.
• Thrust Plug/Block Replacement - Install
thrust plugs/blocks to provide a
clearance of 0.06 in. (1.5 mm) max.
between an upright and its
corresponding thrust plug/block. Pry
between the upright upper cross
members. Measure the clearance at the
XXX shown to determine the thickness
of thrust plug/block to use. Thrust
plugs/blocks may be shimmed as
required.


Figure 7-128.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
Upright
12. Lubricate the inner intermediate upright upright. Torque the cap screws to 81 to
rails. See Lubrication Specification Chart 88 ft. lb. (110 to 120 Nm).
on page A-2. 17. Install the free lift chain anchors (short
13. Attach an overhead hoist to the inner anchors) and chains to the inner upright
upright and install through the top of the center cross member.
inner intermediate upright. Position it out 18. Install the free lift cylinder supply hose to
the lower end of the inner intermediate the free lift cylinder tube. Leave the tubing
upright approx. 6 in. (25 cm). clamp loose.
14. Assemble shims and load roller to the 19. Install the ISS. See ISS Installation on
lower end of the inner upright. Assemble page 7-87.
shims, load rollers, and thrust plugs to the
upper end of the inner intermediate 20. Install the free lift cylinder. Connect the
upright. Refer to step 3 for roller shimming tube to the cylinder fitting and tighten the
and thrust plug clearance measurement. tubing clamp.
15. Install the inner main lift chain anchors

(long anchors) on the back side, lower end
of the inner upright. Connect the inner
main lift chains.
16. Install the stop/hose bracket/tube
assembly on the lower end of the inner


Figure 7-129.Inner Upright Installation
14
13
Thrust
Plug
15 Thrust
13 Plug
Shim
MA0269.eps
14
14
Inner
Upright
16
MA0251.eps
21. Place a 2 x 4 in. (5 x 10 cm) wood block 23. Install main lift cylinders.
between the outer and outer intermediate 24. Install the Mast. Refer to Installation after
lower cross members to prevent upright Complete Removal on page 7-100.
movement.
25. Install the internal hose reeving. See
22. Turn the mast over (face down), rotating it Internal Reeving Installation on
on its lower end. Make sure the mast is page 7-136.
re-blocked in a level position.
26. Adjust the main and free lift chains.
Figure 7-130.Blocking Uprights Before Turning Mast Over 27. Check the mast for skewing.
22 21
MA0254.eps

Cylinder Removal and Check Valve Inspection

Installation
Some Quad masts may experience drift if the
Refer to page 7-93 for cylinder service. check valve(s) in the right side main lift cylinder
become loose.
Main Lift Cylinder Removal - Mast on 1. Remove the right side main lift cylinder.
Floor 2. Remove piston.
3. Remove check valve. See Figure 7-131.
Figure 7-131.Quad Mast Check Valves
2. Insert a 2 x 4 in. (5 x 10 cm) wood block
between the lower cross members of the
outer upright and outer intermediate
upright to prevent uprights from moving
out the bottom of the mast.
3. Lay the mast face-down on wood blocks.
Block under each end of the outer upright
so the mast is level and the inner uprights
and carriage are free to move.
4. Using a 1 in. wrench, disconnect the
cylinder supply hoses from the cylinder
inlet ports. Using a 1 in. socket, remove
the special long fittings from the cylinder
ports and install plugs.
5. Remove the snap ring from the top of the 4. Inspect check valve. If the O-ring is
left hand cylinder rod. Remove the tube missing or damaged, replace the check
and fitting from the top of the right hand valve. Refer to Parts Manual.
cylinder rod. Plug the cylinder port.
5. Clean check valve and apply
6. Roll the uprights through the top of the thread-locking compound (P/N 990-403)
mast 1 to 2 ft. (30 to 60 cm) and disengage to circumference of check valve.
the cylinder rods from the outer
6. Re-install check valve and torque to 50 in.
lb. (5.65 Nm).
7. Lift the cylinder from its base mounting
7. Repeat steps 3 thru 6 for remaining two
boss in the outer upright and angle it
check valves.
inward. Remove the cylinders through the
sides of the uprights. 8. Reassemble cylinder and install in mast.
8. Note the number of shims (if equipped) on
each cylinder rod. Free Lift Cylinder Removal - Mast on
Floor
Main Lift Cylinder Installation - Mast 1. Remove the mast from the truck. See
on Floor Complete Mast Removal on page 7-99.
2. Lay the mast face-up, blocking under the
For installation, reverse the Removal procedure. lower mounts so the mast is level.
System on page 7-82. 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 Figure 7-133.Carriage Hose Bracket Installation
off the cylinder rod.
6. Roll the carriage above the free lift
cylinder.
7. Using a 1 in. wrench, disconnect the tube
from the cylinder fitting. Cap the cylinder
fitting and plug the tube.
8. Using a 5 mm hex head wrench, remove
the cylinder strap.
3
on Floor 2

System on page 7-82. 3. Install the fittings on the bracket.
• Single Function - Install the fittings to
the left or right side location. Tighten
Internal Reeving Installation the fittings finger tight.
1. Install the shaft, sheave, and hose guards • Double Function - Install the fittings to
to the crosshead center plate. Leave the the left and right side location. Tighten
cap screw and nut finger tight to allow for the fittings finger tight.
hose installation.
Figure 7-134.Fitting Installation
Figure 7-132.Crosshead Center Assembly
OR
3
1
SINGLE DOUBLE
FUNCTION FUNCTION
MA0256.eps
4. Install the lower internal hose reeving

bracket and plastic inserts to the block at
the bottom of the inner upright weldment.
Torque the cap screw to 52 ft. lb. (71 Nm).
2. Install the carriage hose bracket to the 5. Install the shaft and hardware to the inner
center tab on the lower carriage bar. intermediate upright chain sheave shaft.
Torque the cap screw to 52 ft. lb. (71 Nm).
6. Install the lower hose guide to the outer
intermediate upright. Torque the cap
screw to 30 ft. lb. (41 Nm).
7. Install hose clamps to lower guide. Leave
cap screws finger tight.


Figure 7-135.Hose Reeving Hardware Installation on Uprights
2XWHU
8SSHU+RVH*XLGH 8SULJKW
2XWHU
,QWHUPHGLDWH
8SULJKW

,QQHU
,QWHUPHGLDWH
8SULJKW

,QQHU
8SULJKW
&URVVKHDG
0$HSV &RPSRQHQWV
/RZHU*XLGHV

/RZHU,QQHU

&RPSRQHQWV &DUULDJH
&RPSRQHQWV
8. Completely lower the carriage. Route the 11. Connect the long hoses to the short hoses
short hoses down behind the carriage bar behind the free lift cylinder. The outside
to the carriage bracket fittings. Connect hose(s) is approx. 4 in. (102 mm) shorter
the hose ends to the fittings, leaving the than the inside hose(s). See Figure 7-136.
hose ends finger tight. 12. Pull down on the hoses with approx.
NOTE: For Double Function, the No. 4 hoses 30 lbs. (14 kg) of force. Clamp the hoses to
connect to the two right fittings (viewed the lower bracket attached to the inner
from the operator’s compartment). upright cross member. Torque the cap
9. Route the hoses over the crosshead
sheaves. 13. Position the hoses with the tabs on the
inner upright bracket as shown in
10. Route the hoses down between the free lift Figure 7-136.
cylinder and cross member. Position the
hoses in their natural curve over the 14. Install the lower internal hose reeving
crosshead sheaves. Tighten the hose ends cover plate and hardware. Tighten the cap
at the carriage bracket. screws to 30 ft. lb. (41 Nm).


Figure 7-136.Hose Reeving Installation

,QQHU
,QWHUPHGLDWH
8SULJKW6KHDYH 6,1*/( '28%/(
/RQJ )81&7,21 )81&7,21
+RVH

6KRUW
+RVH
/RQJ 6KRUW 6KRUW

+RVH +RVH +RVHV
/RQJ /RZHU
/RQJ
+RVH +RVH
+RVH
*XLGH
0$HSV
6,1*/( '28%/(
)81&7,21 )81&7,21 &RQQHFW
%$&.9,(:
KRVHV
,QQHU
8SULJKW
%UDFNHW

&DUULDJH
%UDFNHW
)LWWLQJV
6,1*/( '28%/(
)81&7,21 )81&7,21
0$HSV
6,1*/( '28%/(
)81&7,21 )81&7,21
%$&.9,(:


Figure 7-137.Hose Reeving Installation - continued top of the lower hose guide. Pull downward
on the hoses with 20 lbs. (9 kg) force.

Tighten clamp cap screws enough to stop
hose movement.
17. Install the upper hose guide to the outer
upright. Tighten the cap screw to 30 ft. lb.
(41 Nm).
18. Loop the hoses approx. 5 in. (125 mm)
below the bottom of the lower hose clamp
and route upward into the upper hose
guide.
19. Install the hose clamps to the upper hose
guide. Leave cap screws finger tight.
8SSHU
+RVH 20. Route the hoses under the hose clamps at
*XLGH the top of the upper hose guide. Tighten
the cap screws finger tight.
21. Route the hoses under the hose clamps at
the bottom of the upper hose guide. Do not
tighten the clamp cap screws.
22. Torque the crosshead cover plate cap
&URVVKHDG screw to 52 ft. lb. (71 Nm).

23. Align the hoses by twisting the hose ends
to travel centered in the crosshead on the
/RZHU
+RVH
natural curve of the hose. The hoses
*XLGH should travel parallel to each other. Hold
the hoses while tightening the fittings to
keep the hoses from twisting.
24. Loosen the hose clamps at the top of the
lower hose guide. Pull down on the hoses
with 40 lbs. (18 kg) of force. Tighten the
hose clamp cap screws to 7 to 11 ft. lb. (10
to 15 Nm).
25. Loosen the hose clamps on the upper hose
guide. Adjust the hoses to the natural
hose bend and align evenly spaced in the
guide rails. Tighten the hose clamp cap
26. Raise and lower the mast slowly through
several cycles and check for correct hose
alignment, clearances, and hose tracking
15. Route the hoses up toward the top of the
in the guides.
mast following the inner lift chains. Bend
the hoses over the inner intermediate
upright sheave and install the sheave on
the shaft bolted to the intermediate
upright. Install washer and retaining ring
to shaft.
16. Route hoses down to the lower hose guide.
Place hoses under the hose clamp at the

Flow Control Valve

Replacement
1. Tilt mast forward completely.
2. Lower carriage completely.
4. Place a small pan under the Flow Control
Valve.
Figure 7-138.Quad Mast Flow Control Valve

7MA0258.eps
5. Remove the hose attached to the Flow

Control Valve.
6. Remove the Flow Control Valve, noting
direction of the arrow on the valve body.
7. Install new valve with arrow on the body in
the same direction as removed valve.
Torque to 44 to 48 ft. lb. (60 to 65 Nm).
8. Reattach hose and torque to 44 to 48 ft. lb.
(60 to 65 Nm).
9. Bleed the hydraulic system.
10. Test lift function and check for leaks.

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 7-139. the mast main frame for backward tilt.
Figure 7-139.Measuring Mast Tilt 5. Adjust the stroke of the tilt cylinders as
necessary to achieve the correct mast tilt.
Refer to Figure 7-139 and Table 7-8.
Table 7-8. Mast Tilt Parameters

Tilt Fwd Tilt Back Tilt
Type Angle Dim. A Angle Dim. A
Standard 3° 2.05 in. 5° 3.4 in.
(52 mm) (87 mm)
39.4 in.
(1 meter) Optional 5° 3.4 in. 3° 2.05 in.
(87 mm) (52 mm)
Bottler’s 10° 6.8 in.
(173 mm)
Mast Tilt Position Switch

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

adjusted so that it opens when the mast is tilted
beyond 3° forward.
Mast 1. Attach a plumb line to the mast. See
Face Figure 7-139.
39.4 in. (1 meter) Plumb 2. Place a square on the mast 39.4 in.
from plumb line
attach point Line (1 meter) below where the plumb line is
attached and tilt the mast forward 3°
(2.05 in./52 mm at Dim. A in
Figure 7-139).
3. Adjust Mast Tilt Position Switch (S18)
bracket so that the switch opens when the
mast is tilted further forward.
Dim. A
2. Tilt the mast forward completely.

Mast Mast Tilt Adjustment

Models 4150/4250 Maintenance Manual Section 8. Theory of Operation
Section 8. Theory of Operation

Section 8. Theory of Operation Models 4150/4250 Maintenance Manual
System Architecture
System Architecture
Table 8-1 identifies the electronic components
found on Model 4150/4250 lift trucks and their
function. Table 8-2 identifies where memory is
stored.
Table 8-1. Electrical System Components
Component Function Ident

Vehicle Manager Controlling Manager for the truck. VM
Right Traction Power Amp Controls the traction motor on the right-hand side. RTPA
Left Traction Power Amp Controls the traction motor on the left-hand side. LTPA
Lift Power Amplifier Controls the pump motor. Used for 4250 hydraulic systems. LPA
Fuse/Relay Card Distributes B+/– to the truck. Houses the B+/– control fuses, and FRC
the relays.
Contactor/Fuse Panel Contactors and power fuses are located on this panel.
Standard Handle Assembly Contains Solid State pots for Lift/Lower and Travel. Contains
mechanical type switches for Horn, Sideshift, Tilt, and Aux
functions.
Optional Handle Assembly Contains Solid State pots for Lift/Lower, Travel, Sideshift, Tilt, and
Aux functions. Contains Hall Effect switch for Horn.
Operator Display Card Displays information and fault codes to operator. Contains the
vehicle identity (Primary Memory) and stores hour meter
information.
Steer Position Sensor Used by the VM to determine the steering position for correct control
of the traction motors.
Table 8-2. Stored Value Location
Value Location
Primary Memory Primary Memory is stored in the Operator Display. There is a backup copy in
the VM.
• If the Operator Display is blank or has corrupted memory, the VM sends a
copy to the Display if they can communicate.
• If both cards are valid, but different, the Operator Display overwrites the
VM.
Configure Mode Settings Configure Mode settings are stored in the VM.
Learn Mode Values Learn Mode values are stored in the VM.
Date and Time Date and Time are calculated and stored in the VM.
Hour Meters Hour Meters (Hours Deadman, Hours Lifting, Key Hours, and Traction Miles)
are stored in the Operator Display.

Systems Overview
Systems Overview operator requests. The VM calculates the

steering position based on the three channels in
the steering position sensor. The VM reduces
The Model 4150/4250 control system uses up the travel speed (or changes the direction of
to four “intelligent” devices working together to rotation) of each individual motor if necessary
control the lift truck and respond to operator due to the steering position. It also may cause
requests. These devices pass information to speed reduction due to traction motor
each other via the Controller Area Network temperature. The VM contains a backup copy of
(CAN) Bus. The devices are: the primary memory (see Operator Display
• Vehicle Manager (VM) Card). The VM contains a power supply that
provides a regulated +12V and +5V. The VM
• Right Traction Power Amplifier (RTPA)
also determines that the correct battery is
• Left Traction Power Amplifier (LTPA) connected, and determines the Battery
• Lift Power Amplifier (LPA) (4250 only) State-of-Charge (BSOC) from the voltage
measured at BATTERY_SENSE_IN.
The system uses other “non-intelligent” devices.
• Operator Display Card Traction Power Amplifiers
• Fuse/Relay Card
The Traction Power Amplifiers (TPAs)
• Contactors communicate only with the VM, from where
• Steer Position Sensor they receive all requests regarding travel
direction and speed. The TPAs monitor the
traction motor encoders and temperature
Intelligent Devices sensors. They determine, based on the encoder
feedback and the travel request, if the lift truck
BUS+/– Communications should be traveling, plugging, or regenerative
braking, and determine if the performance has
BUS+/– are the communication lines that the achieved the travel request from the VM. If it
intelligent modules use to communicate with has not, the TPA adjusts the motor control
one another. BUS+ is a digital, serial voltage or sends a fault code to the VM, as
communication line. BUS– is a digital, serial appropriate. The TPAs are solely responsible for
communication line that is a mirror image of controlling traction motor current. The TPAs
BUS+. Using communication lines in this send the traction motor temperature status to
fashion limits noise problems associated with the VM. The VM then alters the travel request, if
long communication lines operating in a noisy necessary, depending on the traction motor
environment. temperature. The TPAs monitor their internal
temperature and limit current or travel speed as
Vehicle Manager required by their internal programming. The
TPAs also check the charging of the amplifiers
The Vehicle Manager (VM) controls the system. and various internal operating parameters.
It communicates with all other devices that are They also send fault codes to the VM if anything
on the communications BUS. It receives all is operating incorrectly. The right-hand side
requests for travel, auxiliary, and lift. The VM TPA monitors and controls the TPC (Traction
receives information on the status of all Power Contactor).
switches such as the Deadman, Horn, Steer
Position Sensor, and EPO. It also receives Lift Power Amplifier (Model 4250)
traction motor speed, direction, and
temperature information from the Traction The Lift Power Amplifier (LPA) is used for all
Power Amplifiers, and lift motor speed and hydraulic functions except steering. The LPA
temperature information from the Lift Power only communicates with the VM, from where it
Amplifier (LPA). The VM determines allowable receives all requests regarding motor rotation
vehicle operation based on those inputs and speed. The LPA monitors both the lift motor

Non-intelligent Devices
encoder and temperature sensor. Motor speed TPC Contactor

may be fixed or varied based on different types
of requests (such as tilt versus sideshift versus The TPC Contactor provides B+ to the power
high speed clamp). It determines if the motor side of both traction amplifiers. It is controlled
has achieved the requested speed (from the by the Right Traction Power Amplifier (RTPA).
encoder feedback). The LPA is solely responsible
for controlling lift motor current. It sends the
STR Contactor
lift motor temperature status to the VM. The
VM then determines if the motor must be
The STR Contactor provides B+ to the power
shut-down due to motor temperature. The LPA
side of the Steer Motor (SM). It is controlled by
monitors its internal temperature and limits
the VM.
current or lift speed as required by its internal
programming. The LPA also checks the
operation of the LPC, the charging of the Steer Position Sensor
amplifiers, and various internal operating
parameters. It also sends fault codes to the VM Consists of three independent Steer Feedback
if anything is operating incorrectly. Proximity Sensors located in one potted
assembly. The steering hub has a mounted on it
that changes the activation sequence of the
Non-intelligent Devices sensors when the steering hub is rotated. The
VM uses this to determine the steerable wheel
Operator Display Card position for correct control of the traction
motors.
The Operator Display Card is connected to the
VM. Messages and codes are displayed on it.
The Display contains the Primary Memory,
Hydraulic Devices
which includes Model Number, Serial Number,
The lift system consists of single acting
Date of Manufacture, Hour Meters, and a list of
hydraulic cylinders. During a lift from floor
enabled Options. The keypad containing the
level, the free lift cylinders elevate the carriage
data entry push buttons connects to the
before the telescopic is extended by the lift
Operator Display.
action of the main cylinders.
Fuse/Relay Card Lift/Aux Pump (P1)

The Fuse/Relay Card is the control power
Pump P1 is a positive displacement gear pump
distribution board. It contains the B+ and B–
that rotates clockwise from the shaft end. P1 is
control fuses and the K1 thru K4 relays. It
used for all lift and aux functions.
provides B+ and B– to the VM, TPC, LPC, and
STR. It also supplies B+ and B– to optional
equipment. Sideshift Cylinders
The sideshift cylinder is a double-acting

LPC Contactor
hydraulic cylinder used to shift the load left and
right with respect to the mast. It is an integral
In the Model 4250, this contactor is used to
part of the sideshift carriage.
supply B+ to the power side of the Lift Power
Amplifier.
Tilt Cylinders
In the Model 4150, this contactor is used to
supply B+ to the DC Lift Motor. The tilt cylinders are double-acting hydraulic
cylinders used to tilt the mast forward and
back.

Hydraulic Devices
Load Hold Valve (SOL1) Attachment Solenoids (SOL7C/R)
The load hold valve is a normally closed SOL7C/R are normally closed solenoid valves
solenoid valve used to hold the carriage in an used to block (de-energized) or allow (energized)
elevated position. fluid flow to and from the attachment cylinders.
Lift/Lower Valve (SOL2) Sideshift Solenoids (SOL9R/L)
The proportional lower valve is a pressure SOL9R/L are normally closed solenoid valves
compensated flow control solenoid valve used to used to block (de-energized) or allow (energized)
lower the carriage. As the voltage to the valve fluid flow to and from the sideshift cylinders.
increases, the flow through the valve increases,
regardless of the pressure. The Model 4150 Tilt Solenoid (SOL10)
uses SOL2 for feathering lift as well.
SOL10 is a normally closed solenoid valve used
Dump Valve (SOL3) to block (de-energized) or allow (energized) fluid
flow to and from the tilt cylinders.
SOL3 is a solenoid used as a lift system relief.
In addition, SOL3 is used to divert oil from P1 Steer Valve
back to the reservoir after a lift is stopped and
the pump is still spinning. It also acts as a valve The steer valve is an orbitrol type rotary flow
to port excess oil back to the reservoir when valve with an auxiliary port. When no steering
performing auxiliary functions. is requested, fluid flows through the auxiliary
port (E). When steering is requested, fluid flows
Priority Bypass (SOL4) first through the steer valve, hydraulic motor,
and the steer return port (T). Any excess flow
SOL4 is a normally open proportional pressure exits out the auxiliary port.
compensated priority flow valve. It regulates
flow to the auxiliary system by the voltage to the Counterbalance Check Valves (CB1,
coil, regardless of the system working pressure.
CB2)
Increasing the voltage decreases the flow to the
auxiliary system.
Counterbalanced check valves are used to hold
the tilt cylinders in place when a tilt request is
Prop Relief (SOL5) no longer present.
SOL5 is a proportional solenoid used as an

Check Valve (CV1)
auxiliary system relief. Voltage is used to adjust
the relief pressure [24V = 3000 psi (20684 kPa);
Check valve is used to make sure the fluid
0V = 100 psi (689 kPa)]. The voltage to this
exiting the lift cylinders during a lower
valve varies when different pressure settings
command is routed through SOL2.
are chosen on the display for auxiliary
attachments.
Hydraulic Filter
Aux Select (SOL6)
The hydraulic system has a filter in the main
manifold. Its purpose is to filter impurities from
SOL6 is a directional solenoid valve providing
the hydraulic system. It filters oil on the return
directional control to the tilt, sideshift, or
to the reservoir from the lift system. It has no
auxiliary functions. When SOL6 is energized,
internal bypass.
flow direction is reversed for tilt, sideshift, or
auxiliary functions.

Traction System Theory
Traction System Theory memory. See “Maintenance Mode” on

page 3-18. During normal use, the VM learns
the extreme values for full forward/reverse and
Key ON full lift/lower. These values are also stored in
memory in the VM. See “Configure Mode” on
When the key is turned ON, the Vehicle page 3-11. For Travel or Lift/Lower, the VM
Manager powers up and proceeds with SelfTest. compares the pot position information to the
If the BATTERY_SENSE_IN (JPC24-24) voltage values that it stored when it learned the pots.
is between 28 and 45V, a circuit is turned ON in
the VM that provides B– to the RELAY_ENABLE When the control handle is moved from neutral,
(JPC14-6) in order to energize the relays. After the VM detects a different voltage at JPC12-3
this, the BATTERY_SENSE_IN voltage is used to from VR1. To release the brake, the VM must
determine BSOC. When K1, K2, K3, and K4 are know the deadman switch is operational and
energized, K2 or K3 provides B+ to the control that the control handle has moved. The VM
side of the power amplifiers. The TPC and LPC then provides B– to JPC20-14 (Brake) that
contactors provide the precharge. energizes the brake coils and releases the
brakes. The lift truck is equipped with two
NOTE: B+ power for the amplifiers may come traction motors, each with its own brake. Both
from K2 (JPF1-6) or K3 (JPF1-3). brakes are controlled by the same circuit from
the VM.
The VM establishes communication to the
amplifiers. After successful communication has When the VM receives a request to travel by
been established, the VM requests the RTPA to seeing the VR1 voltage change (control handle
activate the TPC contactor and check its status. moved), it compares that voltage to the learned
For the 4250, the VM requests the LPA to value for VR1 to determine the direction and
activate the LPC contactor and check its status. magnitude of the travel request. The VM then
For the 4150, the VM activates the LPC looks at all speed limiting inputs such as motor
contactor via pin LPC_CTRL (JPC18-9) and temperature, height, weight, steering angle, and
verifies by LPC_SENSE (JPC22-20). The LPC fault codes to determine if the requested speed
and TPC are de-energized after approximately is allowable. The VM then initiates a request for
2.5 minutes of inactivity. the appropriate direction and speed to the TPAs
over the communications BUS. The VM
Deadman Pedal Pressed constantly updates the travel request to the
TPAs.
When the Deadman Pedal is pressed, S2
(Deadman Switch) is closed. The switch is an When the TPA receives a travel request from the
input at JPC22-8 to the VM. When S2 closes, it VM, it produces an output to the traction motor.
switches Deadman Switch voltage from a high All operational parameters that affect traction
state (greater than 4.5VDC) to a low state (less motor torque and speed are controlled
than 0.7VDC). exclusively by the TPA. It monitors motor
current, voltage, and RPM, and from them, can
When the VM receives that voltage, it activates determine motor performance. The TPA alters
a circuit in the VM that provides B– to its output to the traction motor to match the
JPC18-11, energizing the STR contactor coil motor performance to the travel request from
and the steer motor is powered up. the VM. As the travel request from the control
handle changes, so does the travel request from
the VM to the TPA. That in turn, alters motor
Travel Theory operation. To track the travel request from the
operator, the TPA monitors the speed sensor.
During Learn, the VM learns the neutral The TPA also monitors traction motor
position for the travel (VR1) and lift (VR2) temperature and the internal temperature of
potentiometers and stores those values in the amplifier and can alter travel based on the

Travel Theory
TPA temperature. The TPA sends motor The TPA calculates both direction and speed,
temperature to the VM, and the VM alters the then determines whether the travel request
travel request based on traction motor from the VM must be met with a travel, a plug,
temperature. or a regeneration control output to the traction
motor.
When the lift truck is moving and the travel
control handle is moved to request the opposite The VM constantly monitors the steering
direction, the same sequence of events takes position sensor for reduction in speed to a
place. particular traction motor, cut power to a
particular traction motor, or cause the motor to
The VM does not request plugging or reverse the direction of travel even if the travel
regeneration; it just requests travel in the control direction request did not change.
opposite direction.
This allows the vehicle to corner correctly with
the dual drive system.
Table 8-3. Steering Parameters
Operator
Steer Tiller
Steer Tire Position Effect On System Display
Position
Message
90° (full CW) to 67° Reverse direction in 1 motor Left 101
67° to 41° One motor power cut Left 100
41° to 18° Reduced throttle percentage Left 000
18° to –18° (wheels centered) Full Speed Centered 001
–18° to –41° Reduced throttle percentage Right 011
–41° to –67° One motor power cut Right 010
–90° (full CCW) to –67° Reverse direction in 1 motor Right 110

Steering System Theory
Steering System Theory

With the key switch ON, the deadman pedal
pressed, and the EPO switch closed, Relay K2 is
energized, sending B+K2 from the Fuse/Relay
Card at JPF2-1 to SPL9.
From SPL9, the voltage goes to the STR

contactor X terminal. The VM supplies the
negative component (JPC18-11) to energize the
steering contactor coil. When the coil is
energized, the steer contactor tips close,
supplying battery voltage to the steer motor.
With the steer motor running, oil is sent

through the steering orbitrol and back to the
hydraulic reservoir. When steering is requested,
oil is sent through the orbitrol to the hydraulic
steer motor to rotate (steer) the drive unit.

Lift/Lower System Theory
Lift/Lower System motor to determine that the lift motor has

stopped spinning. As long as the VM senses
Theory voltage on the P Sense line, it provides voltage
to the Priority Bypass (SOL4) and lift/lower
proportional (SOL2) coil, keeping the valve(s)
Model 4150 open to allow the fluid from the pump to return
to tank. This ensures the cylinders do not
continue lifting after the request has ended.
Lift System
Once the lift motor has completely stopped
spinning, the VM removes voltage to the Priority
The VM constantly monitors the output voltage
Bypass (SOL4) and lift/lower proportional
of VR2. The VM compares this voltage to the
(SOL2) coil, closing the Priority Bypass (SOL4)
voltages stored during the Learn process. The
and lift/lower proportional valve.
VM checks the battery voltage (for lift cutout),
and all enabled options and switches that could
prevent the activation of the lift system. When Lower System
satisfied that no criteria are present to prevent
lift, it then determines the requested percentage The following description is based on a lower
of full speed lift. It then activates Priority request from a full speed lift situation.
Bypass (SOL4). The lift/lower proportional valve
(SOL2) fully opens and closes the lift pump VR2 passes through neutral to a full speed
contactor (LPC) by taking the coils to B–. lower request. The VM recognizes the change
and realizes full speed lower is required. All
Opening the lift/lower valve fully prevents enabled options and switches that can prohibit
sudden movement when the lift pump is first lower are checked.
activated by allowing the fluid to return to the
tank. As soon as the command to close the P Once the VM is satisfied that lower is allowed, it
contactor is activated, the VM looks at the monitors the LPC_Sense line to determine the
LPC_Sense input, verifying the contactor closed condition of the P contactor (open or closed) and
as commanded. It then slowly reduces the PWM verifies the lift motor is not still spinning by
(Pulse Width Modulation) output to the coil for checking for back ElectroMotive Force (EMF).
the lift/lower proportional valve to match the As long as the VM senses voltage on the
percentage of lift speed requested. As the LPC_Sense line, it provides voltage to the
lift/lower proportional valve closes, hydraulic Priority Bypass (SOL4) and lift/lower
fluid passes through the CV1 check valve, the proportional coil, keeping the valve(s) open to
normally closed check valve in the load holding allow the fluid from the pump to return to tank.
valve, to the flow limiter on the crosstie, to the This ensures the cylinders do not continue
flow limiters at the bottom of the lift cylinders. lifting after the request has ended.
The flow limiter in the cylinder allows
unrestricted fluid flow to the center lift ram. The Once the lift motor has completely stopped
free lift cylinder elevates first because less spinning, the VM removes voltage to the
pressure is required. Once the carriage hits the lift/lower coil, closing the lift/lower
stops on the inner telescopic, the pressure proportional valve. The Load Holding solenoid
increases enough to start elevating the main lift (SOL1) is activated by the VM, opening the
cylinder(s). valve. The VM then gradually opens the
lift/lower solenoid (SOL2) to the percentage of
The VM monitors the LPC_Sense line to requested lower. This allows the oil to flow from
determine the condition of the LPC contactor the cylinders, the load holding valve, the
and verify the lift motor is spinning. When a lift lift/lower proportional valve, the filter, and back
request has finished (VR2 has either returned to the reservoir. The telescopics lower first due
to neutral or through neutral to a lower to the greater weight of the telescopics. Once
request), the VM monitors the LPC_Sense line the telescopics are fully lowered, the center
for back ElectroMotive Force (EMF) from the cylinder begins to lower.

Model 4250
Model 4250 Lower System
Lift System With the key switch ON and the deadman

pressed, rotating the lift/lower control VR2 to
the lower position sends a change in voltage to
All inputs and outputs related to the lift/lower
the VM on JPC12-2 (the voltage is an increasing
system are controlled by the Vehicle Manager
voltage).
(VM). The VM determines what actions are
required based on inputs from the operator and
The VM senses the request for lower and sends
from system feedback.
the negative to the load holding solenoid (SOL1)
at JPC18-10 to energize its coil.
When VR2 is moved to request lift, a voltage is
sent to the VM at JPC12-2. The VM sees a
After the load holding solenoid opens, the
voltage different from the “learned” neutral
proportional lower solenoid (SOL3) opens to
voltage, and sends a request to the lift power
allow fluid to flow back to the reservoir by
amplifier via BUS+/– (JPC14-11 and JPC14-4
controlling the negative to the coil. This
on the VM to JPL1-23 and JPL1-35 on the Lift
negative comes from the VM at JPC20-16. SOL3
Amp). To lift, voltage from VR2 decreases; when
opens proportionally to the amount that VR2 is
it is moved to lower, the voltage from VR2
moved from neutral during lower.
increases.
Voltage across the proportional lower solenoid
Lift speed varies directly with lift motor RPM.
varies, depending on the position of the
The voltage supplied to the lift motor is
lift/lower control (VR2):
proportional to the amount of lift request from
VR2, faster lift = higher motor voltage. • Low voltage = slow lowering
Frequency is also manipulated to perform the • High voltage = fast lowering
operator’s request.
The lift power amplifier internally supplies B+ Auxiliary Functions

and B– to the lift contactor coil (LPC coil) at
JPL1-13 and JPL1-6 respectively. B– is Sideshift
controlled to close the normally open contactor
tips. When the lift contactor coil is energized, With the key switch ON and the deadman pedal
the contactor tips close, allowing B+ to the pressed, the following occurs to activate the
power side of the LPA. The LPA supplies voltage sideshift function.
to the lift motor.
Moving the sideshift control on the standard
Prior to requesting a lift, all valves are in the handle closes SS Left switch (S8), which
de-energized state. supplies DGND to the VM at JPC12-8, or SS
Right switch (S9), which supplies DGND to the
SOL4 receives oil flow at port 1 placing pressure VM at JPC12-9. Moving the sideshift control on
on the pilot line of the valve. This pressure the optional handle varies the output voltage of
moves the spool in the valve to allow flow out of the sideshift pot. SS Right decreases voltage
port 2 and down to CV-1. Then the oil flows and SS Left increases voltage. This voltage goes
through the de-energized load holding solenoid to the VM at JPC12-5. The VM sees a voltage
(SOL1), through the mast mounted flow limiter change at the respective connection and sends
to the flow limiters in the base of the lift a request to the LPA via BUS+/– (JPC14-11 and
cylinders, and into the lift cylinders producing JPC14-4 to JPL1-23 and JPL1-35).
lift.
The LPA internally supplies B– to the lift
When the lift knob is returned to neutral, the contactor coil (LPC) at JPL1-6, closing the
lift motor is ramped down. SOL3 is opened to normally open contactor tips.
relieve any pressure spikes in the system.

Auxiliary Functions
When the lift contactor coil is energized, the When the lift contactor coil is energized, the
contactor tips close, allowing B+ to the power contactor tips close, allowing B+ to be supplied
side of the LPA. The LPA supplies voltage to the to the power side of the lift power amplifier. This
lift motor. The motor turns at a speed supplies voltage to the lift motor to make it
predetermined by software. rotate. The motor turns at a speed
predetermined by software.
SOL4 receives oil flow at port 1 that flows
through the valve and out port 3 to SOL6, the SOL4 receives oil flow at port 1, that flows
directional solenoid. When energized, SOL6 through the valve and out port 3 to SOL6, the
reverses the direction of the Aux functions. directional solenoid. When energized, SOL6
reverses the direction of the Aux functions.
Oil flow then goes to solenoid 9R or 9L. Solenoid
9R and 9L must be energized for Sideshift to Oil flow then goes to SOL10. SOL10 must be
work in either direction. From SOL9, the oil energized for Tilt to work in either direction.
flows through the over-the-mast hoses to the
Sideshift cylinders. From SOL10, the oil flows through CB-1 or 2,
depending on the requested tilt direction. The
From the Maintenance Menu, the user can oil then flows through the hoses to the Tilt
establish sideshift speed. See Table 3-4, cylinders.
“Maintenance Mode Menu,” on page 3-18.
During a lift and aux function at the same time,
This is used to adjust sideshift speed between 3 SOL4 becomes energized to allow the correct oil
and 4.5 seconds. It is also used to set the flow to the Aux functions.
correct speed of an attachment that has a
second AUX function. The VM varies the voltage Bottler’s Tilt (Optional)
to SOL4 in order to create the differing sideshift
speeds. Bottler’s Tilt allows additional forward mast tilt
while in free lift, and may limit the lift height
Tilt depending on the tilt position.
With the key switch ON and the deadman pedal To accomplish this, there are modifications to
pressed, the following occurs to activate the Tilt the lift truck and the option must be enabled in
function. FlashWare. See Table 3-1, “Configure Mode
Menu,” on page 3-11.
Moving the tilt control on the standard handle
closes Tilt Up switch (S6), which supplies When the mast is fully lowered and vertical, the
DGND to the VM at JPC12-5 or Tilt Down High Speed Limit Switch (SW11) and Mast Tilt
switch (S7), which supplies DGND to the VM at Switch (SW18) are normally closed.
JPC12-6. Moving the tilt control on the optional
handle varies the output voltage of the tilt pot. When tilt is requested, greater than 3° tilt
Tilt Down decreases voltage and Tilt Up forward is possible.
increases voltage. This voltage goes to the VM at
JPC12-8. The VM sees a voltage change at the When the lift truck is elevated above free lift,
respective connection and sends a request to SW11 opens, causing a change in state to be
the LPA via BUS+/– (JPC14-11 and JPC14-4 to seen at the VM.
JPL1-23 and JPL1-35).
The VM does not allow tilt forward to go more
The LPA internally supplies B– to the lift than 3° as seen by SW18.
contactor coil (LPC) at JPL1-6, closing the
normally open contactor tips. When the mast is tilted more than 3° while in
free lift, and lift is requested, lift stops when
switch SW11 is deactivated.

Auxiliary Functions

Pinout Matrix
Pinout Matrix
Section 8. Theory of Operation
The pinout matrix chart lists functions and • Normal Level: the approximate voltage that
normal voltages of terminals and harness must be seen on that wire for the state
connector pins. The matrix columns have the indicated. Unless otherwise indicated,
following meanings: voltages are measured with respect to (wrt)
• Item: sequential number to aid in B– at TP4.
reference. • Signal Source: the device or connection
• Connector: the actual wire numbers or that supplies the signal directly to the
component abbreviations on the electrical wire.
schematic. • Signal User: the device or connection
• Function Description: brief definition of where the wire directly delivers the signal.
the signal carried on the wire.
• Theory of Operation: a detailed description
of the signal carried on the wire. If the
signal can be variable, the state of a
related component that will cause the
signal to vary is indicated. Identifies
possible causes for lack of correct signal.
Functional Signal Signal

Item Connector Theory of Operation Normal Level
Description Source User
1 JPC3-1 VBUS Voltage Supply for USB.
2 JPC3-2 D– Used for USB Communication.
3 JPC3-3 D+ Used for USB Communication.
4 JPC3-4 DGND B– for USB. <0.5V
5 JPC6-2 DATA_OUT No usable data can be obtained.
6 JPC6-4 DGND This is the negative path for the <0.5V VM OD

Operator Display circuits.
7 JPC6-5 SHIFT_CLOCK No usable data can be obtained.
8 JPC6-6 +12V This is the positive path for the 12V 10.8 to 13V VM OD
supply to the Operator Display.
9 JPC9-2 TXD Connector for FlashWare.
10 JPC9-3 RXD Connector for FlashWare.
11 JPC9-5 DGND Connector for FlashWare.
12 JPC10-1 +12VP 12V supply to Deadman Switch (S2). 10.8 to 13V VM S2
13 JPC10-3 ENABLE Connection for VM to enable Key ON: 12V VM OCSS

Emitters for OCSS after the Deadman down: Emitters
Deadman pedal is pressed. <1V
14 JPC12-1 +5VP 5V supply from VM used for VR1 5V VM VR1, VR2

std. handle (Travel) and VR2 (Lift/Lower) pots.

Pinout Matrix

15 JPC12-1 +5VP 5V supply from VM used for switches 5V VM Optional

opt. handle in optional handle. handle
switches
16 JPC12-2 LIFT Input to VM from VR2. Neutral: 1.17V VR2 VM

Full Lift: 0.62V
Full Lwr: 1.68V
17 JPC12-3 TRAVEL Input to VM from VR1. Neutral: 1.0V VR1 VM

Full TF: 0.52V
Full FF: 1.60V
18 JPC12-4 FUNCTION 1 Input to VM from SW3. De-activated: SW3 VM

opt. handle 4.32V
Variable down to
0.597V fully
activated
19 JPC12-4 FUNCTION 1 Input to VM from S4. De-activated: 5V S4 VM

std. handle Activated: <1V
20 JPC12-5 SSHIFT Input to VM from SW4. Neutral: 2.44V SW4 VM

opt. handle Full SS Right: 0.6V
Full SS Left: 4.36V
21 JPC12-5 TILT_UP Input to VM from S6. De-activated: 5V S6 VM

22 JPC12-6 TILT_Down Input to VM from S7. De-activated: 5V S7 VM

23 JPC12-7 H_HTR 8V to the heater in the optional Linear based on VM HTR6

opt. handle control handle. ambient temp.
0V @ 97°F,
8V @ 50°F
24 JPC12-8 TILT Input to VM from SW4. Neutral: 2.44V SW4 VM

opt. handle Full Tilt Dn: 0.6V
Full Tilt Up: 4.36V
25 JPC12-8 SSHIFT_LEFT Input to VM from S8. De-activated: 5V S8 VM

26 JPC12-9 SSHIFT_RIGHT Input to VM from S9. De-activated: 5V S9 VM

27 JPC12-10 HORN Input to VM from SW1. De-activated: 5V SW1 VM

opt. handle Activated: <1V
28 JPC12-10 HORN Input to VM from S3. De-activated: 5V S3 VM

29 JPC12-11 FUNCTION 2 Input to VM from SW2. De-activated: SW2 VM

opt. handle 4.32V
Variable down to
0.597V fully
activated
30 JPC12-11 FUNCTION 2 Input to VM from S5. De-activated: 5V S5 VM


Pinout Matrix

31 JPC12-12 DGND B– to control handle. <0.5V VM Handle

switches
32 JPC14-1 B–F B–F for the VM. <0.5V TP4 VM
33 JPC14-2 DGND B–F for DGND on the VM. <0.5V TP4 VM
35 JPC14-4 BUS– The wire that carries the negative 2.185V VM VM,
component of the digital Power
communications between the VM Amps
and power amplifiers.
36 JPC14-6 RELAY_ENABLE Control path for K1, K2, K3, & K4 B+ w/Key Switch VM K1, K2,
on the Fuse/Relay Card. After S1 is ON and all relays K3, & K4
closed, all relays are energized de-energized;
simultaneously during SelfTest if the <0.5V w/Key
voltage at Battery_Sense_In is Switch OFF or ON
between 28 and 45V. If the vehicle and any relay
is equipped with optional heaters, energized
the VM may keep this circuit active
at B– even with the Key Switch OFF
(JPC14-7) to allow the heaters to run
based on the ambient temperature
sensor reading.
37 JPC14-7 B+K4 This is used for a circuit in the VM. If B+ w/Key Switch VM K4
the lift truck is equipped with the ON (B+ w/Key
optional heater assembly, the VM Switch OFF if truck
looks at the Ambient Temperature is equipped with
Sensor (JPC24-23) input to Cold Storage and
determine if the Relay Enable circuit ambient temp.
should remain activated in order to requires heaters to
have power remaining to the VM remain ON)
power supply.
41 JPC14-11 BUS+ The wire that carries the positive 2.8V VM VM,
component of the digital Power
communications between the VM Amps
and power amplifiers.
42 JPC14-12 B+KEY B+ that is switched by the Key Switch B+ S1 VM

(S1) to power functions on the VM
that are initiated after S1 is closed
and are not affected by the EPO.
This includes the VM power supplies,
the operation of the microprocessor,
and execution of the firmware.
43 JPC14-13 B+K2 B+ provided to the VM when the K2 B+ K2 VM

relay tips are closed. They are
de-energized when the EPO is open.

Pinout Matrix

44 JPC14-14 B+K2 B+ provided to the VM when the K2 B+ K2 VM

relay tips are closed. They are
de-energized when the EPO is open.
45 JPC18-1 AUX SELECT Control path for SOL6. Voltage Neutral: B+ VM SOL6
varies with different functions and SS Left: 8.0V
also depends on selection of SS Rt: 23V
sideshift percentage in Configure Tilt Up: 8.0V
Mode. Tilt Dn: 30V
46 JPC18-2 CUST OUT Customer Output 10.8 to 13V VM Customer

Output
Switch
47 JPC18-5 DGND DGND for optional OCSS Lower Left <0.5V VM Lower Left
Detector. Detector
48 JPC18-6 DGND DGND for optional OCSS Upper <0.5V VM Upper

Right Detector. Right
Detector
49 JPC18-9 LPC_CTRL Control path for LPC Contactor. De-energized: B+ VM LPC Coil
(4150 only) Energized: 12.7V
50 JPC18-10 LOAD HOLD Control path for SOL1. De-energized: B+ VM SOL1

Energized: 13V
51 JPC18-11 STR_CONTACTOR Control path for Steering Contactor. De-energized: B+ VM Steering

Energized: 11.3V Contactor
Coil
52 JPC18-12 HSA1 Control path for SOL7R and SOL7C. De-energized: B+ VM SOL7R,
Energized: 12.7V SOL7C
53 JPC18-14 SIDESHIFT Control path for SOL9R and SOL9L. De-energized: B+ VM SOL9R,
Energized: 11.9V SOL9L
54 JPC18-15 TILT Control path for SOL10. De-energized: B+ VM SOL10

Energized: 10.6V
55 JPC18-16 HORN Control path for Horn. De-energized: B+ VM Horn

Energized: 0.1V
56 JPC18-18 TRAV/LIFT ALARM Control path for Trav/Lift Alarm. De-energized: B+ VM Trav/Lift
Energized: 0.09V Alarm
57 JPC20-1 +12VP 12V supply to optional OCSS Upper 10.8 to 13V VM Upper Left
Left Emitter. Emitter
58 JPC20-2 +12VP 12V supply to optional OCSS Lower 10.8 to 13V VM Lower Left
Left Detector. Detector
59 JPC20-3 +12VP 12V supply to optional Left Battery 10.8 to 13V VM S22A
Gate (S22A).
60 JPC20-4 +12VP 12V supply to optional Right Battery 10.8 to 13V VM S22B
Gate (S22B).

Pinout Matrix

61 JPC20-5 +12VP 12V supply to optional Mast Tilt 10.8 to 13V VM S18 or
(Bottler’s Tilt) Switch (S18) or Mini Mini
Power Supply for Tilt Centering Power
option. Supply
S/N <50501 with Quad Mast: 12V

supply to the Mast Tilt Speed
JPC20-6 Reduction Switch (S12).
62 +12VP 10.8 to 13V VM S12
(4250 only)
12V supply to the optional Lift Limit
Switch (S12).
S/N >50500 with TT or Quad Mast:

12V supply to the Mast Tilt Speed
63 +12VP 10.8 to 13V VM S11
(4250 only)
12V supply to the optional Hi-Speed
Limit Switch (S11) (Bottler’s Tilt).
64 JPC20-9 +12VP 12V supply to optional OCSS Lower 10.8 to 13V VM Lower
Right Emitter. Right
Emitter
65 JPC20-10 +12VP 12V supply to optional OCSS Upper 10.8 to 13V VM Upper
Right Detector. Right
Detector
66 JPC20-12 DUMP Control path for SOL3. No request: B+ VM SOL3

Feather Lift: 9.0V
Full Lift: 8.1V
Full Lift & Aux
Request: 7.0V
67 JPC20-13 ISENSE5(K2) B+ from the K2 relay to the SOL6 B+ VM SOL6

coil. This is also used to sense the
current drawn by SOL6.
68 JPC20-14 BRAKES Control path for the Brake coils. B+ without request VM Brakes
Brakes are released after a throttle and Key Switch
command has been initiated, and ON; Initial brake
are applied when travel has stopped release: 0.4V, then
or EPO is pressed. 13V
69 JPC20-15 ISENSE2(K2) B+ Supply from the K2 relay to the B+ VM SOL2

SOL2 coil. This is also used to sense
the current drawn by SOL2.
70 JPC20-16 LIFT/LOWER Control path for proportional SOL2. De-energized: B+ VR2 VM

(4150 only) Voltage should vary depending on Lift: 21 to 34V
the position of Lift Pot (VR2). Lower: 35 to 19V
71 JPC20-16 LIFT/LOWER Control path for proportional SOL2. De-energized: B+ VR2 VM

(4250 only) Voltage should vary depending on Lower: 35 to 19V
the position of Lift Pot (VR2).
72 JPC20-17 ISENSE3(K2) B+ from the K2 relay to SOL4 coil. B+ VM SOL4

This is also used to sense the current
drawn by SOL4.

Pinout Matrix

73 JPC20-18 PRIORITY BYPASS Control path for SOL4. (Normal Key ON: B+ VM SOL4
std. handle voltages are approximate Sideshift: 22.75V
(4150 only) depending on sideshift setting in Tilt: 23.9V
Maintenance Mode.)
74 JPC20-18 PRIORITY BYPASS Control path for SOL4. (Normal Key ON: B+ VM SOL4
opt. handle voltages are approximate Feather Lift: 12.4V
(4250 only) depending on sideshift setting in Full Lift: 10V
Maintenance Mode.) Tilt: 20V
Tilt & Lift: 15V
75 JPC20-19 ISENSE4(K2) B+ from the K2 relay to the SOL5 B+ VM SOL5

coil. This is also used to sense the
current drawn by SOL5.
76 JPC20-20 PROP RELIEF Control path for SOL5. Lift: 32V VM SOL5
std. handle Aux: 18V
77 JPC20-20 PROP RELIEF Control path for SOL5. Lift: 32V VM SOL5
opt. handle Tilt & SS: 18V
Tilt & Lift: 12 to
18V
78 JPC22-3 GATE_L Input to the VM from the optional left Activated: approx. S22A VM
Battery Gate Switch (S22A). 0V
Not activated: 5V
79 JPC22-4 GATE_R Input to the VM from the optional Activated: approx. S22B VM
right Battery Gate Switch (S22B). 0V
Not activated: 5V
80 JPC22-5 TILT_DN Input to the VM from the optional Activated: approx. S18 VM
Mast Tilt Switch (S18) (Bottler’s Tilt). 0V
Not activated: 5V
S/N <50501 with Quad Mast: Input

to the VM from the Mast Tilt Speed Activated: approx.
81 LIFT_LIM 0V S12 VM
(4250 only)
Input to the VM from the optional Lift Not activated: 5V
Limit Switch (S12).
82 JPC22-8 ON DEADMAN Input to the VM from the Deadman S2 open: approx. S2 VM

Switch (S2). 5V;
S2 closed: 0V
83 JPC22-9 POS C POS C input to the VM from the Activated: 1.36V Steer VM
Steer Position Sensor. Not activated: Position
8.12V Sensor
84 JPC22-10 DISP_MISO No usable data can be obtained.
85 JPC22-11 DGND DGND for Deadman Switch (S2). <0.5V VM S2
86 JPC22-13 BEAM_L Input to the VM from the optional Clear: <1V Lower Left VM
Lower Left OCSS Detector (Deadman Blocked: 5V Detector
pressed).

Pinout Matrix

87 JPC22-14 BEAM_R Input to the VM from the optional Clear: <1V Upper VM
Upper Right OCSS Detector Blocked: 5V Right
(Deadman pressed). Detector
88 JPC22-19 STR_SENSE Sense wire used by the VM to Contactor STR VM

determine the state of the Steer De-energized: Contactor
Contactor and FU1. <0.5V
Energized: B+
89 JPC22-20 LPC_SENSE Sense wire used by the VM to Contactor LPC VM

(4150 only) determine the state of the LPC De-energized: Contactor
Contactor and FU3. <0.5V
Energized: B+
90 JPC22-21 EPO_SENSE Sense wire used by the VM to EPO Closed: B+ S21 VM

determine when the EPO (S21) is Open: <0.5V
open. This is used to initiate braking
and display a message.

Input to the VM from the Mast Tilt
Speed Reduction Switch (S11). Activated: approx.
JPC22-22
91 HIGH_SPD 0V S11 VM
(4250 only) Input to the VM from the optional Not activated: 5V
Hi-Speed Limit Switch (S11) (Bottler’s
Tilt).
92 JPC24-1 +12VP 12V supply to the Steer Position 10.8 to 13V VM Steer
Sensor from the VM. Position
Sensor
93 JPC24-3 DGND DGND for left Battery Gate Switch <0.5V VM S22A
(S22A).
94 JPC24-4 DGND DGND for right Battery Gate Switch <0.5V VM S22B
(S22B).
95 JPC24-5 DGND DGND for Mast Tilt Switch (S18) or <0.5V VM S18 or
Mini Power Supply for Tilt Centering Mini
option. Power
Supply
S/N <50501 with Quad Mast:

DGND for Mast Tilt Speed Reduction
JPC24-6 Switch (S12).
96 DGND <0.5V VM S12
(4250 only)
DGND for optional Lift Limit Switch
(S12).
97 JPC24-7 DGND DGND for Ambient Temperature <0.5V VM Ambient

Sensor. Temp
Sensor

DGND for Mast Tilt Speed Reduction
JPC24-8 Switch (S11).
98 DGND <0.5V VM S11
(4250 only)
DGND for optional Hi-Speed Limit
Switch (S11) (Bottler’s Tilt).

Pinout Matrix

99 JPC24-10 DGND DGND for Pressure (Weight) Sensor. <0.5V VM Pressure

Sensor
100 JPC24-12 DATA_LATCH No usable data can be obtained.
101 JPC24-13 +12VP 12V supply to the optional Pressure 10.8 to 13V VM Pressure
Sensor from the VM. Sensor
102 JPC24-14 ADDR_LATCH No usable data can be obtained.
103 JPC24-17 POS A POS A input to the VM from the Activated: 1.36V Steer VM
Steer Position Sensor. Not activated: Position
8.12V Sensor
104 JPC24-18 PRESSURE_AIN Input to the VM from the optional 0 to 5V Based on Pressure VM
Pressure Sensor. weight on forks Sensor
105 JPC24-20 POS B POS B input to the VM from the Steer Activated: 1.36V Steer VM
Position Sensor. Not activated: Position
8.12V Sensor
106 JPC24-22 TILT_AIN Input to the VM from the Tilt Tilted Fwd: VR6 VM
Centering Pot (VR6). approx. 2V;
Centered:
approx 3V; Tilted
Back: approx. 4V
107 JPC24-23 AMBIENT Input to the VM from the optional 0 to 5V Based on Ambient VM
Ambient Temperature Sensor. ambient temp. Temp
Sensor
108 JPC24-24 BATTERY_SENSE_IN B+ present when the battery is B+ (there should TP1 VM
plugged in. It is supplied through a be no voltage
thermistor on the Fuse/Relay Panel. drop)
This is used by the VM to determine
that the correct battery is connected.
It accepts between 28 and 45V. If
the correct battery is sensed, Relay
Enable is energized during startup.
After startup, this voltage is used to
determine BSOC.
109 JPF1-1 B– B– for FU8 (15A/5A) Fuse for <0.5V TP4 Accessory
optional Accessory Power. Power
110 JPF1-2 B– B– for FU8 (15A/5A) Fuse for <0.5V TP4 Accessory
optional Accessory Power. Power
111 JPF1-3 B+F Provides B+F to B+K3 on the Power K3 Energized: B+ K3 Power
Amplifiers. B+K3 is used to power Amplifiers
the control circuits of the LPA, LTPA,
and RTPA.
Note: B+ power for amplifiers may
come from K2 (JPF1-6) or K3
(JPF1-3). Refer to schematic.
112 JPF1-4 B–F B– from FU8 (15A/5A) Fuse for <0.5V TP4 TS1-1 & 2
optional Accessory Power.

Pinout Matrix

113 JPF1-5 ID0, ID1 Provides B+F to B+ID’s on the TPAs. K3 Energized: B+ K3 Power
At startup, the K3 coil is energized Amplifiers
and this is used to identify amplifiers.
114 JPF1-6 B+F Provides B+F to B+K2 on the Power K2 Energized: B+ K2 Power
Amplifiers. B+K2 is used to power Amplifiers
the control circuits of the LPA, LTPA,
and RTPA.
115 JPF2-1 B+K2 B+ supplied to the Steer Contactor, K2 Energized: B+ K2 tips STR, LPC
LPC Contactor (4150), and optional CNTR and
Power Amp Fan. optional
Power
Amp Fan
116 JPF2-2 B+K2 B+K2 to power the Horn and K2 Energized: B+ K2 tips Horn and
Travel/Lift Alarm. Travel/Lift
Alarm
117 JPF2-3 B+K2 B+ Supply from the K2 relay to the K2 Energized: B+ K2 tips Right
Right Brake Coil. Brake Coil
118 JPF2-4 B+K4 Supply input to the VM that allows K4 Energized: B+ K4 tips VM
the VM to remain powered up with
the Key Switch OFF. This is used in
cold storage applications to allow
the handle heater circuit to work
based on input from the Ambient
Temperature Sensor.
119 JPF2-5 B+K2 B+ from the K2 relay to the Left K2 Energized: B+ K2 tips Left Brake
Brake Coil. Coil
120 JPF2-6 B+K2 B+ from the K2 relay to VM. K2 Energized: B+ K2 tips VM
121 JPF2-7 B+K2 B+ from the K2 relay to VM. K2 Energized: B+ K2 tips VM
122 JPF2-8 B+K2 B+ Supply from the K2 relay to K2 Energized: B+ K2 tips SOL1, 3,
SOL1, 3, 7R, 7C, 9R, 9L, and 7R, 7C,
optional SOL11. 9R, 9L, &
SOL11
123 JPF2-9 B+Key B+ from the K1 relay to be used for K1 Energized: B+ K1 tips TS1-5 & 6
Accessory Power after the Key
Switch is activated.
124 JPF3-1 B– B– for FU6 that provides B– to the <0.5V TP4 VM

VM.
125 JPF3-2 B– B– for FU6 that provides B– to the <0.5V TP4 VM

VM.
126 JPF3-3 DGND B–F for DGND on the VM. <0.5V FU6 VM
127 JPF3-4 DGND B–F for DGND on the VM. <0.5V FU6 VM
128 JPF3-5 B–F B–F for the VM. <0.5V FU6 VM

Pinout Matrix

131 JPF4-1 B+ B+ from TP1 to FU5 to supply K4 coil B+ TP1 K2, K4,
and the K2, K4 relay tips. Also VM
supplies BATTERY_SENSE_IN to the
VM.
132 JPF4-2 B+ B+ from TP1 to FU5 to supply the K4 B+ TP1 K2, K4,
coil and the K2, K4 relay tips. Also VM
supplies BATTERY_SENSE_IN to the
VM.
133 JPF4-3 B+ B+ from TP1 to FU7 and K1 tips to B+ TP1 FU7 &
supply Accessory Power option. Accessory
Power
Option
134 JPF4-4 B+ B+ from TP1 to FU7 and K1 tips to B+ TP1 FU7 and
supply Accessory Power option. Accessory
Power
Option
135 JPF4-5 B+EPO B+ supply from EPO to K1, K2, and EPO Closed: B+ EPO K1, K2,
K3. All functions associated with Open: 0.05V K3
these relays are inoperable when the
EPO is open.
136 JPF4-7 BATTERY_SENSE_IN B+ present when the battery is B+ (there should TP1 VM
plugged in. It is supplied through a be no voltage
thermistor on the Fuse/Relay Panel. drop)
This is used by the VM to determine
that the correct battery is connected.
It accepts between 28 and 45V. If
the correct battery is sensed, Relay
Enable is energized during startup.
After startup, this voltage is used to
determine BSOC.
137 JPF4-8 BRAKES Control path for the Brake Coils. B+ without request VM Brakes
Brakes are released after a throttle and Key Switch
command is initiated, and are ON;
applied when travel is stopped or Initial brake
EPO is pressed. release: 0.4V, then
16V
138 JPF4-10 B+F B+ to the Key Switch. B+ FU5 S1
139 JPF4-11 BRAKES (Left) Control path for the Left Brake Coil. B+ without request VM Brakes
Brake is released after a throttle and Key Switch
command is initiated, and is applied ON;
when travel is stopped or EPO is Initial brake
pressed. release: 0.4V, then
16V

Pinout Matrix

140 JPF4-12 BRAKES (Right) Control path for the Right Brake Coil. B+ without request VM Brakes
Brake is released after a throttle and Key Switch
command is initiated, and is applied ON;
when travel is stopped or EPO is Initial brake
pressed. release: 0.4V, then
16V
141 JPF4-13 RELAY_ENABLE Control path for K1, K2, K3, and K4 B+ w/Key Switch VM K1, K2,
on the Fuse/Relay Card. After S1 is ON and all relays K3, & K4
closed, all relays are energized de-energized;
simultaneously during SelfTest if the <0.5 w/Key
voltage at BATTERY_SENSE_IN is Switch OFF or ON
between 28 and 45V. If the vehicle and any relay
is equipped with optional heaters, energized
the VM may keep this circuit active
at B– even with the Key Switch OFF
(JPC14-7) to allow the heaters to run
based on the ambient temperature
sensor input.
142 JPL1-1 B+K2 (or K3) B+ to the LPA. Present when K2 (or K2 (or K3) K2 (or K3) LPA
K3) is energized. Energized: B+
143 JPL1-6 LPC Control path for the LPC. The Lift LPC De-energized: LPA LPC
Power Amplifier supplies a path for B+
B– for the contactor by the way of Energized: 14.7V
the B– terminal.
144 JPL1-7 L VEL SENSOR– Return path for the encoder in the Lift <0.5V LPA Lift
Motor. Encoder
145 JPL1-8 T TEMP+ Temp Sensor input to the LPA. Approx. 1V @ Lift Motor LPA
(4250 only) Analog voltage that varies with the 75ºF (24ºC) Temp
Lift Motor temperature. Sensor
146 JPL1-11 ID0 B+ present at the amp with the K3 K3 Energized: K3 LPA
tips activated. It is used as an approx. B+
identifier.
147 JPL1-12 ID1 Not Used
148 JPL1-13 B+K2 (or K3) B+ for the LPC. The Lift Power Key Switch ON: LPA LPC Coil
(4250 only) Amplifier supplies B+ for the LPC. B+
149 JPL1-23 BUS+ Positive component of the digital 2.8V VM VM,

communications (CAN Bus) between Power
the VM and Power Amplifiers. Amps
150 JPL1-26 L VEL SENSOR+ 5V to the Encoder on the Lift Motor. 4.95V LPA Lift
Encoder

Pinout Matrix

151 JPL1-31 L VEL PHASE A Input to LPA from Lift Motor Encoder. Motor Stationary: Lift Motor LPA
It is a square wave that is either high 4.06 or 0.03V Encoder
(>3V) or low (<1V). The frequency Turning: 2.3V
varies directly with motor speed.
Identical to L VEL Phase B except for
phase. The LPA uses the relationship
between phases to determine lift
speed.
152 JPL1-32 L VEL PHASE B Input to LPA from Lift Motor Encoder. Motor Stationary: Lift Motor LPA
It is a square wave that is either high 4.06 or 0.03V Encoder
Identical to L VEL Phase A except for
phase. The LPA uses the relationship
between phases to determine lift
speed.
153 JPL1-33 BUS– Negative component of the digital 2.185V VM VM,

154 JPTL1-1 B+K2 (or K3) B+ to LTPA. Present when K2 (or K3) K2 (or K3) K2 (or K3) LTPA
is energized. Energized: B+
155 JPTL1-7 T VEL SENSOR– Return path for the Encoder in the <0.5V LTPA TML
Left Traction Motor (TML). Encoder
156 JPTL1-8 T TEMP+ TML Temp Sensor input to the LTPA. Approx 1V @ 75ºF TML Temp LTPA
Analog voltage that varies with (24ºC) Sensor
motor temperature.
157 JPTL1-11 NOT USED
158 JPTL1-12 ID1 B+ present at the amp with the K3 K3 Energized: B+ K3 LTPA
tips activated. It is used as an De-energized: –1V
identifier.
159 JPTL1-21 CAN TERM H Connection used to terminate the K2 Energized: LTPA LTPA
BUS+, BUS– communication. 2.96V
160 JPTL1-23 BUS+ Positive component of the digital 2.8V VM VM,

161 JPTL1-26 T VEL SENSOR+ 5V supply to the TML Encoder. 4.95V LTPA TML
Encoder
162 JPTL1-31 T VEL PHASE A Input from TML Encoder to LTPA. It is Motor Stationary: TML LTPA
a square wave that is either high 4.06V or 0.03V Encoder
Identical to T VEL Phase B except for
phase. The LTPA uses the relationship
between phase A and B to determine
travel speed and direction.

Pinout Matrix

163 JPTL1-32 T VEL PHASE B Input from TML Encoder to LTPA. It is Motor Stationary: TML LTPA
a square wave that is either high 4.06 or 0.03V Encoder
Identical to T VEL Phase A except for
phase. The LTPA uses the relationship
between phase A and B to determine
travel speed and direction.
164 JPTL1-33 BUS– Negative component of the digital 2.185V VM VM,

165 JPTL1-34 CAN TERM L Connection used to terminate the K2 (or K3) LTPA LTPA
BUS+, BUS– communication. Energized: 2.96V
166 JPTR1-1 B+K2 (or K3) B+ to RTPA. Present when K2 (or K3) K2 (or K3) K2 (or K3) RTPA
is energized. Energized: B+
167 JPTR1-6 TPC Control path for the TPC. The RTPA TPC De-energized: RTPA TPC
supplies a path for B– for the B+
Contactor. Energized: 14.7V
168 JPTR1-7 T VEL SENSOR– Return path for the Encoder in the <0.5V RTPA TMR
Right Traction Motor (TMR). Encoder
169 JPTR1-8 T TEMP+ TMR Temp Sensor input to the RTPA. Approx 1V @ 75ºF TMR Temp RTPA
Analog voltage that varies with (24ºC) Sensor
motor temperature.
170 JPTR1-11 ID0 B+ present at the amp with the K3 K3 Energized: K3 VM

identifier. De-energized: –1V
171 JPTR1-12 ID1 B+ present at the amp with the K3 K3 Energized: K3 VM

identifier. De-energized: –1V
172 JPTR1-13 B+K2 (or K3) B+ to the TPC from the RTPA. Key Switch ON: TPA TPC Coil
B+
173 JPTR1-23 BUS+ Positive component of the digital 2.8V VM VM,

the VM and Power Amps. Amps
174 JPTR1-26 T VEL SENSOR+ 5V supply to the TMR Encoder. 4.95V RTPA TMR
Encoder

Pinout Matrix

175 JPTR1-31 T VEL PHASE A Input from TMR Encoder to RTPA. It is Motor Stationary: TMR RTPA
Identical to T VEL Phase B except for
phase. The RTPA uses the
relationship between phase A and B
to determine travel speed and
direction.
176 JPTR1-32 T VEL PHASE B Input from TMR Encoder to RTPA. It is Motor Stationary: TMR RTPA
Identical to T VEL Phase A except for
phase. The RTPA uses the
relationship between phase A and B
to determine travel speed and
direction.
177 JPTR1-33 BUS– Negative component of the digital 2.185V VM VM,


Models 4150/4250 Maintenance Manual Section A. Appendix
Section A. Appendix
Publication: 1193671, Issued: 13 Jun 2016 A-1

Section A. Appendix Models 4150/4250 Maintenance Manual
Lubrication Specification Chart
Lubrication Specification Chart

Approved Raymond Lubricants
Where Used Type Specification Raymond Part Number
75W-90 Synthetic
Drive Unit Gear Case Gear 990-655/001 (1 qt./0.9 liters)
Gear Oil
(all applications) Lubricant 990-655/003 (1 gal./3.8 liters)
API Service GL-5
Hydraulic Reservoir 990-616/04 (1 qt./0.9 liter)

(Non-CS trucks) 990-616/01 (1 gal./3.8 liters)
Hydraulic Fluid ISO VG 46
+50° to +120°F 990-616/02 (2 gal./7.6 liters)
(+10° to +49°C) 990-616/03 (5 gal./18.9 liters)
Hydraulic Reservoir 1017238

(CS trucks - in and out of Note: Do not mix with any other
freezer) Hydraulic Fluid ISO VG 32 type of hydraulic fluid. Install
0° to +50°F decal (P/N 1074515) on the
(–18° to +10°C) hydraulic unit.
Hydraulic Reservoir
(CS trucks - confined to
990-618/TX1 (1 gal./3.8 liters)
freezer) Hydraulic Fluid MIL-H-5606E
990-618/01 (1 gal./3.8 liters)
–20° to 0°F
(–29° to –18°C)
Mast Uprights, Bearings,

and so forth
(all-weather) Grease NLGI 2 1012992
–20° to +120°F
(–29° to +49°C)
High Performance/
1151877/001 (Rexoil)
Lift Chains High Load Chain Aerosol
1151877/002 (Rocol)
Spray
A-2 Publication: 1193671, Issued: 13 Jun 2016

Thread Adhesives, Sealants, and Lubricants
Thread Adhesives, Sealants, and Lubricants

Loctite (Supplier)
Description/Application Part Number
Number/Color
Adhesive (floor pad installation) 990-569/102
Cleaner - alcohol based 990-600/FOF
Contact cleaner 996-600/CC2
Corrosion inhibitor coating 990-644 LPS3 Spray
Gasket Sealant Compound 990-556
Lubricant (Spline Shaft) 1223184
Sealing compound (cold storage conditioning) 990-542
Silicone grease (cold storage conditioning) 990-445
Silicone sealant 990-659
Thread-locking compound primerless 990-669 2760
Thread-locking compound1/4 in. and below 990-403 222/Purple
Thread-locking compound1/4 to 3/4 in. dia. contamination

1013829 243/Blue
tolerant
*Loctite is a registered trademark of the Loctite Corporation. Brand endorsement is not implied here, but
listed only as a commonly identified product.

Component Specific Torque Chart

Thread-Locking Torque to: (use Dry value for pre-applied
Component Sub-Component(s) Compound thread-locking compound)
P/N 1013829 Lubricated Dry
gear (top of motor) 120 ft. lb. (162.7 Nm)
assembly to traction Yes N/A
Brake 15 ft. lb. (20.3 Nm)
motor
coil to lower friction plate No N/A 70 in. lb. (7.9 Nm)
mounting bracket to
20 ft. lb. (27.1 Nm) 27 ft. lb. (36.6 Nm)
tractor deck screws Yes
Control Handle shaft set screw 14 ft. lb. (19 Nm) N/A
15 to 20 in. lb.
assembly screws
No N/A (1.7 to 2.3 Nm)
cover screws 7 ft. lb. (9.4 Nm)
Drive Unit
tractor frame mtg. bolts Yes 180 ft. lb. (244 Nm) N/A
Drive Wheels mounting bolts No N/A 108 ft. lb. (146 Nm)
strut bracket bolts Yes 50 ft. lb. (67.8 Nm) 65 ft. lb. (88 Nm)
strut mounting bolts No N/A 100 ft. lb. (135.5 Nm)
floor plate to pivot plate
Floor 80 ft. lb. (108.5 Nm) 110 ft. lb. (149.1 Nm)
mounting bolts
(ComfortStance)
pivot plate bearing block
90 ft. lb. (122 Nm) 100 ft. lb. (135.5 Nm)
mounting bolts Yes
tie-rod mounting bolts 35 ft. lb. (47.5 Nm) 45 ft. lb. (61 Nm)
Hydraulic Steer sprocket set screws 13 ft. lb. (18.2 Nm) N/A
Motor mounting bolts 40 ft. lb. (54.2 Nm) 53 ft. lb. (71.8 Nm)
Top Nut:
203 to 221 in. lb.
(23 to 25 Nm)
Lift Motor - AC
Bottom Nut:
128 to 132 in. lb.
(14.5 to 15 Nm)
cable securing nut (top) No N/A
Top Nut:
90 to 110 in. lb.
(10.2 to 12.4 Nm)
Lift Motor - DC
Bottom Nut:
110 to 140 in. lb.
(12.4 to 15.8 Nm)
Manifold, Main mounting bolts 20 ft. lb. (27 Nm) 27 ft. lb. (36.6 Nm)
mounting (pivot bearing
Mast 43 ft. lb. (58.3 Nm) N/A
cap) bolts Yes
Overhead
mounting bolts 170 ft. lb. (230.5 Nm) 230 ft. lb. (312 Nm)
Guard

Thread-Locking Torque to: (use Dry value for pre-applied

Component Sub-Component(s) Compound thread-locking compound)
P/N 1013829 Lubricated Dry
mounting bolts Yes 8 ft. lb. (10.8 Nm) 11 ft. lb. (14.9 Nm)
Power
Amplifiers 95 to 105 in. lb.
power cables
(10.7 to 11.8 Nm)
Top Nut:
40 to 50 in. lb.
(4.5 to 5.6 Nm)
power cables No N/A
Bottom Nut:
Steer Motor 50 to 60 in. lb.
(5.6 to 6.8 Nm)
mounting lock nuts 11 to 13 ft. lb.
(qty. 4) (15 to 17.5 Nm)
Steerable Wheel
mounting bolts (qty. 6)
Assembly 50 ft. lb. (67.8 Nm) N/A
Yes
brake sprocket nut
mounting bolts 21 ft. lb. (28 Nm) 28 ft. lb. (38 Nm)
Top Nut:
203 to 221 in. lb.
Traction Motors (23 to 25 Nm)
power cables No N/A
Bottom Nut:
128 to 132 in. lb.
(14.5 to 15 Nm)
pinion gear nut (drive end) Yes 45 ft. lb. (63 Nm) N/A

Torque Chart - Hydraulic Fittings
Torque Chart - Hydraulic Fittings

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

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

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

Torque Chart - Standard (Ferrous)
Torque Chart - Standard (Ferrous)
Grade
None
Marking
SAE Grade 2 Bolts SAE Grade 5 Bolts SAE Grade 7 Bolts SAE Grade 8 Bolts
Tightening Torque Tightening Torque Tightening Torque Tightening Torque
Size
Dry** Oiled* Dry** Oiled* Dry** Oiled* Dry** Oiled*
in. lb Nm in. lb Nm in. lb Nm in. lb Nm in. lb Nm in. lb Nm in. lb Nm in. lb Nm
4-40 5 0.56 4 0.45 8 0.9 6 0.68 11 1.5 8 0.9 12 1.4 9 1.0
4-48 6 0.68 5 0.56 9 1.0 7 0.8 12 1.4 9 1.0 13 1.5 10 1.1
6-32 10 1.1 8 0.9 16 1.8 12 1.4 20 2.2 15 1.7 23 2.6 17 1.9
6-40 12 1.4 9 1.0 18 2.0 13 1.5 22 2.5 17 1.9 25 2.8 19 2.1
8-32 19 2.1 14 1.6 29 3.3 22 2.5 36 4.1 27 3.0 41 4.6 31 3.5
8-36 20 2.2 15 1.7 31 3.5 23 2.6 38 4.3 29 3.3 44 5.0 33 3.7
10-24 27 3.0 21 2.4 42 4.8 32 3.6 52 5.9 39 4.4 60 6.8 45 5.1
10-32 31 3.5 24 2.7 48 5.4 36 4.1 60 6.8 45 5.1 68 7.7 51 5.8
1/4-20 66 7.5 49 5.5 100 11.3 76 8.6 125 14.1 94 10.6 143 16.2 107 12.1
1/4-28 75 8.5 56 6.3 120 13.6 87 9.8 143 16.2 107 12.1 164 18.5 123 13.9
ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm ft. lb Nm
5/16-18 11 15.1 8 10.9 17 23.0 13 18 21 29 16 22 25 34 18 24
5/16-24 12 16.3 9 12.2 19 26 14 19 24 33 18 24 25 34 20 27
3/8-16 20 27 15 20 30 41 23 31 40 54 30 41 45 61 35 47
3/8-24 23 31 17 23 35 47 25 34 45 61 30 41 50 68 35 47
7/16-14 32 43 24 33 50 68 35 47 60 81 45 61 70 95 55 75
7/16-20 35 47 25 34 55 75 40 54 70 95 50 68 80 109 60 81
1/2-13 50 68 35 47 75 102 55 75 95 129 70 95 110 150 80 109
1/2-20 55 75 40 54 85 115 65 88 105 143 80 109 120 163 90 122
9/16-12 70 95 50 68 110 150 80 109 135 183 100 136 150 203 110 150
9/16-18 80 109 60 81 120 163 90 122 150 203 110 150 170 231 130 177
5/8-11 95 129 70 95 150 203 110 150 190 258 140 190 220 298 170 231
5/8-18 110 150 85 115 170 231 130 177 210 285 160 217 240 326 180 244
3/4-10 170 231 130 177 260 353 200 272 330 448 240 326 380 515 280 381
3/4-16 190 258 140 190 300 407 220 298 370 502 280 381 420 569 320 434
7/8-9 170 231 125 169 430 583 320 434 530 719 400 544 600 813 460 624
7/8-14 185 252 140 190 470 637 350 475 580 786 440 598 660 895 500 680
1-8 250 339 190 258 650 881 480 651 800 1085 600 813 900 1224 680 925
1-12 275 373 205 278 700 949 520 705 860 1166 660 895 1000 1360 740 1003
1 1/8-7 350 475 270 366 800 1085 600 813 1120 1519 840 1139 1280 1136 960 1302
1 1/8-12 400 544 300 407 880 1193 660 895 1260 1708 940 1274 1440 1952 1080 1464
1 1/4-7 500 680 375 509 1120 1523 840 1139 1580 2142 1200 1627 1820 2468 1360 1884
1 1/4-12 550 746 420 569 1240 1681 920 1247 1760 2386 1320 1790 2000 2720 1500 2034
1 3/8-6 650 881 490 664 1460 1980 1100 1491 2080 2820 1560 2115 2380 3227 1780 2413
1 3/8-12 750 1017 560 759 1680 2278 1260 1708 2380 3227 1780 2413 2720 3688 2040 2766
1 1/2-6 870 1180 650 881 1940 2630 1460 1980 2780 3769 2080 2820 3160 4298 2360 3200
1 1/2-12 980 1329 730 990 2200 2983 1640 2224 3100 4203 2340 3173 3560 4857 2660 3606
NOTE: * Use “oiled” values for bolts with liquid thread-locking compound applied at point of use.
NOTE: ** Use “dry” values for bolts with pre-applied, chemical thread-locking compound.

Torque Chart - Metric (Ferrous)
Torque Chart - Metric (Ferrous)

Ferrous Metric Bolts, Coarse Thread
(The grade rating is stamped on the head of the bolt.)
Grade 4.8 Grade 8.8 Grade 10.9 Grade 12.9
Size Dry** Oiled* Dry** Oiled* Dry** Oiled* Dry** Oiled*
in. lb. Nm in. lb. Nm in. lb. Nm in. lb. Nm in. lb. Nm in. lb. Nm in. lb. Nm in. lb. Nm
M1.6-0.35 0.8 0.09 0.6 0.07 1.6 0.18 1.2 0.14 2.2 0.25 1.7 0.19 2.6 0.30 2.0 0.22
M2-0.40 1.7 0.19 1.3 0.14 3.3 0.37 2.5 0.28 4.6 0.52 3.4 0.39 5.3 0.60 4.0 0.45
M2.5-0.45 3.5 0.40 2.6 0.30 6.7 0.76 5.1 0.57 9.3 1.1 7.0 0.79 11 1.2 8.2 0.93
M3-0.5 6.2 0.70 4.7 0.53 12 1.4 9 1.0 17 1.9 12 1.4 19 2.2 15 1.7
M3.5-0.6 9.8 1.1 7.3 0.83 19 2.1 14 1.6 26 3.0 20 2.2 31 3.5 23 2.6
M4-0.7 14 1.6 11 1.5 28 3.2 21 2.4 39 4.4 29 3.3 45 5.1 34 3.8
M5-0.8 29 3.3 22 2.5 57 6.4 42 4.8 78 8.9 59 6.6 91 10.4 69 7.8
ft. lb. Nm ft. lb. Nm ft. lb. Nm ft. lb. Nm ft. lb. Nm ft. lb. Nm ft. lb. Nm ft. lb. Nm
M6-1 – – – – 8 10.9 6 8.2 11 15.1 8 11.3 13 17.6 10 13.2

M8-1.25 – – – – 19 26 15 20 27 37 20 27 31 43 24 32
M8-1 – – – – 21 29 16 22 29 39 22 30 34 6 25 34
M10-1.5 – – – – 38 52 29 39 53 72 40 54 62 85 47 63
M10-1.25 – – – – 41 56 30 41 56 76 42 57 66 90 49 67
M12-1.75 – – – – 65 88 50 68 90 122 70 95 110 150 80 109
M12-1.25 – – – – 75 102 55 75 100 136 75 102 120 163 90 122
M14-2 – – – – 105 143 80 109 150 204 110 150 175 238 130 177
M14-1.5 – – – – 115 156 85 116 160 218 120 163 190 258 140 190
M16-2 – – – – 165 224 125 170 230 313 170 231 270 367 200 272
M16-1.5 – – – – 175 238 130 177 245 333 185 252 280 381 215 292
M20-2.5 – – – – 325 442 240 326 450 612 340 462 520 707 400 544
M20-1.5 – – – – 360 490 270 367 500 680 375 510 580 789 440 598
M24-3 – – – – 560 762 420 571 780 1061 580 789 900 1224 680 925
M24-2 – – – – 610 830 460 626 850 1156 640 870 1000 1360 740 1006
M30-3.5 – – – – 1120 1523 840 1142 1550 2108 1160 1578 1800 2448 1350 1836
M30-2 – – – – 1240 1686 920 1251 1700 2312 1280 1741 2000 2720 1500 2040
M36-4 – – – – 1950 2652 1460 1986 2700 3671 2000 2720 3160 4298 2350 3196
M36-2 – – – – 2200 2992 1640 2230 3000 4080 2250 3060 3500 4760 2650 3604
NOTE: * Use “oiled” values for bolts with liquid thread-locking compound applied at point of use.
NOTE: ** Use “dry” values for bolts with pre-applied, chemical thread-locking compound.

Torque Chart - Standard (Brass)
Torque Chart - Standard (Brass)

Brass MS63 Standard Bolts, Coarse Thread
Torque (with bolts oiled*)
Size
in. lb. Nm
0-80 0.5 0.05
1-64 0.9 0.10
1-72 1.0 0.11
2-56 1.5 0.17
2-64 1.6 0.18
3-48 2.3 0.26
3-56 2.5 0.28
4-40 3.3 0.37
4-48 3.6 0.40
5-40 4.8 0.54
5-44 5.3 0.60
6-32 6.1 0.69
6-40 6.8 0.77
8-32 11 1.24
8-36 11 1.24
10-24 14 1.58
10-32 17 1.92
12-24 23 2.59
12-28 25 2.82
1/4-20 35 3.96
1/4-28 40 4.52
5/16-18 73 8.25
5/16-24 81 9.15
3/8-16 130 14.69
3/8-24 147 16.61
NOTE: *Use “oiled” values for bolts with
thread-locking compound.

Torque Chart - Metric (Brass)
Torque Chart - Metric (Brass)

Brass MS63 Metric Bolts, Coarse Thread
Diameter Torque (bolts oiled)

(in millimeters) 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 1.1
5 19 2.1
6 34 3.8
8 79 9
10 150 17
NOTE: *Use “oiled” values for bolts with

thread-locking compound.

Torque Chart - Thread-Forming Screws
Torque Chart - Thread-Forming Screws

Standard Thread-Forming Screws Metric Thread-Forming Screws
Nearest Plate Torque Nearest Plate Torque
Size
Thickness (in.) in. lb. Nm Size Thickness
0.0469 4 0.5 in. (mm) in. lb. Nm
2-56 0.0625 4 0.5 0.039 (1) 9 1.0
0.0938 5 0.6 M3 x 0.5 0.079 (2) 9 1.0
0.0625 6 0.7
0.118 (3) 14 1.6
3-48 0.0938 7 0.8
0.079 (2) 16 1.8
0.1250 7 0.8
0.0312 6 0.7 M4 x 0.7 0.118 (3) 29 3.3
4-40 0.0625 9 1.0 0.157 (4) 38 4.3
0.0938 11 1.2 0.098 (2.5) 25 2.8
0.0625 12 1.4 M5 x 0.8 0.138 (3.5) 53 6.0
5-40 0.0938 18 2.0 0.197 (5) 62 7.0
0.1250 20 2.3
0.118 (3) 44 5.0
0.0625 14 1.6
M6 x 1.0 0.177 (4.5) 89 10.0
6-32 0.0938 20 2.3
0.1250 22 2.5 0.236 (6) 89 10.0
0.0938 30 3.4 0.157 (4) 177 20.0
8-32 0.1250 45 5.1 M8 x 1.25 0.236 (6) 248 28.0
0.1875 45 5.1 0.315 (8) 266 30.0
0.0938 35 4.0
0.197 (5) 266 30.0
10-24 0.1250 45 5.1
M10 x 1.5 0.315 (8) 398 45.0
0.1875 55 6.2
0.0938 35 4.0 0.394 (10) 487 55.0
10-32 0.1250 50 5.6 0.236 (6) 531 60.0
0.1875 70 7.9 M12 x 1.75 0.354 (9) 575 65.0
0.1250 65 7.3 0.472 (12) 885 100.0
12-24 0.1875 75 8.5
0.2500 85 9.6
0.1250 85 9.6
1/4-20 0.1875 125 14.1
0.2500 125 14.1
0.1875 160 18.1
5/16-18 0.2500 225 25.4
0.3125 250 28.2
0.2500 350 39.5
3/8-16 0.3125 400 45.2
0.3750 450 50.8
0.3125 500 56.5
7/16-14 0.3750 600 67.8
0.5000 700 79.1
0.2500 500 56.5
1/2-13 0.3750 850 96.0
0.5000 1000 113.0

Decimal Equivalent Chart

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
1/64 .016 .02 .397
1/32 .031 .03 .794
3/64 .047 .05 1.191
1/16 .062 .06 1.587
5/64 .078 .08 1.984
3/32 .094 .09 2.381
7/64 .109 .11 2.778
1/8 .125 .12 3.175
9/64 .141 .14 3.572
5/32 .156 .16 3.969
11/64 .172 .17 4.366
3/16 .188 .19 4.762
13/64 .203 .20 5.159
7/32 .219 .22 5.556
15/64 .234 .23 5.593
1/4 .250 .25 6.350
17/64 .266 .27 6.747
9/32 .281 .28 7.144
19/64 .297 .30 7.540
5/16 .312 .31 7.937
21/64 .328 .33 8.334
11/32 .344 .34 8.731
23/64 .359 .36 9.128
3/8 .375 .38 9.525
25/64 .391 .39 9.922
13/32 .406 .41 10.319
27/64 .422 .42 10.716
7/16 .438 .44 11.112
29/64 .453 .45 11.509
15/32 .469 .47 11.906
31/64 .484 .48 12.303
1/2 .500 .50 12.700
33/64 .516 .52 13.097
17/32 .531 .53 13.494
35/64 .547 .55 13.891
9/16 .562 .56 14.288
37/64 .578 .58 14.684
19/32 .594 .59 15.081
39/64 .609 .61 15.478
5/8 .625 .62 15.875
41/64 .641 .64 16.272

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
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
To Convert... Multiply, Add, or Subtract...
Area
Square Inches to Square Centimeters Square Inches x 6.452
Square Centimeters to Square Inches Square Centimeters x 0.155
Square Feet to Square Meters Square Feet x 0.093
Square Meters to Square Feet Square Meters x 10.753
Square Yards to Square Meters Square Yards x 0.836
Square Meters to Square Yards Square Meters x 1.196
Distance
Inches to Millimeters Inches x 25.4
Millimeters to Inches Millimeters x 0.039
Inches to Centimeters Inches x 2.54
Centimeters to Inches Centimeters x 0.394
Feet to Meters Feet x 0.305
Meters to Feet Meters x 3.281
Yards to Meters Yards x 0.914
Meters to Yards Meters x 1.094
Miles to Kilometers Miles x 1.609
Kilometers to Miles Kilometers x 0.621
Mass
Ounces to Grams Ounces x 28.35
Grams to Ounces Ounces x 0.035
Ounces to Kilograms Ounces x 0.028
Kilograms to Ounces Kilograms x 35.27
Pounds to Kilograms Pounds x 0.454
Kilograms to Pounds Kilograms x 2.2
Pressure
Pounds per Square Inch (PSI) to kiloPascals PSI x 6.894
kiloPascals to Pounds per Square Inch (PSI) kiloPascals x 0.145
Speed
Miles per hour to Kilometers per hour Miles per hour x 1.609
Kilometers per hour to Miles per hour Kilometers per hour x 0.6214
Temperature
Fahrenheit to Celsius (°F minus 32) x 0.555
Celsius to Fahrenheit (°C x 1.8) plus 32
Torque
Inch Pounds (in. lb.) to Newton Meters (Nm) Inch Pounds x 0.113
Newton Meters (Nm) to Inch Pounds (in. lb.) Newton Meters x 8.85
Foot Pounds (ft. lb.) to Newton Meters (Nm) Foot Pounds x 1.3568
Newton Meters (Nm) to Foot Pounds (ft. lb.) Newton Meters x 0.737
Volume
Pints to Liters Pints x 0.473
Liters to Pints Liters x 2.113
Quarts to Liters Quarts x 0.946
Liters to Quarts Liters x 1.057
Gallons to Liters Gallons x 3.785
Liters to Gallons Liters x 0.26


Models 4150/4250 Maintenance Manual Section I. Index
Section I. Index
Numerics Aux Prop Valve SOL5 . . . . . . . . . . . . . 7-78
Aux Select (SOL6) . . . . . . . . . . . . . . . . . 8-5
2-Stage Mast
Disassembly . . . . . . . . . . . . . . . .7-109 B
Free Lift Cylinder
Installation . . . . . . . . 7-113, 7-114 Battery
Removal . . . . . . . . . . . 7-112, 7-113 Cables . . . . . . . . . . . . . . . . . . . . . 7-52
Inspection . . . . . . . . . . . . . . . . . .7-110 Charging . . . . . . . . . . . . . . . . . . . . 7-53
Main Lift Cylinder Cleaning Exterior . . . . . . . . . . . . . 7-53
Installation . . . . . . . . . . . . . .7-112 Maintenance . . . . . . . . . . . . . . . . . 7-53
Removal . . . . . . . . . . . . . . . . .7-111 Safety . . . . . . . . . . . . . . . . . . . . . . . 2-5
Reassembly . . . . . . . . . . . . . . . . .7-110 State-of-Charge (BSOC) . . . . . 5-4, 7-53
Reeving . . . . . . . . . . . . . . . . . . . .7-115 Testing . . . . . . . . . . . . . . . . . . . . . 7-53
3-Stage Mast below S/N 50501 Battery Specifications . . . . . . . . . . . . . . 3-4
Disassembly . . . . . . . . . . . . . . . .7-116 Bleeding Hydraulic System . . . . . . . . . 7-82
Free Lift Cylinder Brake
Installation . . . . . . . . 7-119, 7-120 Floating Disc . . . . . . . . . . . . . . . . . 7-47
Removal . . . . . . . . . . . . . . . . .7-119 Floating Disk
Inspection . . . . . . . . . . . . . . . . . .7-116 Coil Replacement . . . . . . . . . . 7-48
Main Lift Cylinder Installation . . . . . . . . . . . . . . . 7-49
Installation . . . . . . . . . . . . . .7-119 Pad Replacement . . . . . . . . . . . 7-48
Removal . . . . . . . . . . . . . . . . .7-119 Removal . . . . . . . . . . . . . . . . . 7-47
Reassembly . . . . . . . . . . . . . . . . .7-117 Brakes . . . . . . . . . . . . . . . . . . . . . . . . 7-46
Reeving . . . . . . . . . . . . . . . . . . . .7-120 Disassembly . . . . . . . . . . . . . . . . . 7-46
3-Stage Mast S/N 50501 Up Installation . . . . . . . . . . . . . . . . . . 7-47
Disassembly . . . . . . . . . . . . . . . .7-122 Brushes . . . . . . . . . . . . . . . . . . . . . . . 7-56
Free Lift Cylinder BSOC (Battery State-of-Charge) . 5-4, 7-53
Installation . . . . . . . . . . . . . .7-126 Setting BSOC Cutout . . . . . . . . . . . 5-5
Removal . . . . . . . . . . . 7-125, 7-126
Inspection . . . . . . . . . . . . . . . . . .7-122
C
Main Lift Cylinder
Installation . . . . . . . . . . . . . .7-125
Removal . . . . . . . . . . . . . . . . .7-125 Cable, Terminology . . . . . . . . . . . . . . . . 5-7
Reassembly . . . . . . . . . . . . . . . . .7-122 Cables, Power . . . . . . . . . . . . . . . . . . . 7-54
Reeving . . . . . . . . . . . . . . . . . . . .7-128 CAN Bus
Test . . . . . . . . . . . . . . . . . . . . . . . 6-82
Theory of Ops . . . . . . . . . . . . . . . . . 8-3
A Caster, Steer
Disassembly . . . . . . . . . . . . . . . . . 7-21
AC Motors . . . . . . . . . . . . . . . . . . . . . 5-16 Installation . . . . . . . . . . . . . . . . . . 7-21
Adjustment Reassembly . . . . . . . . . . . . . . . . . . 7-22
Attachment Pressure . . . . . . . . . . 3-17 Removal . . . . . . . . . . . . . . . . . . . . 7-18
Mast Tilt . . . . . . . . . . . . . . . . . . .7-141 Service . . . . . . . . . . . . . . . . . . . . . 7-22
System Pressure . . . . . . . . . . . . . 7-83 Chain
AMP Connectors . . . . . . . . . . . . . . . . 7-69 Inspection . . . . . . . . . . . . . . . . . . . 4-11
Attachment Control . . . . . . . . . . . . . . 3-16 Main Lift . . . . . . . . . . . . . . . . . . . 7-101
Attachment Solenoids (SOL7C/R) . . . . 8-5 Maintenance . . . . . . . . . . . . . . . . . 4-11
Attachments Service . . . . . . . . . . . . . . . . . . . . . 4-11
Setup and Operation . . . . . . . . . . 3-16 Storage Preparation . . . . . . . . . . . 3-20
Publication: 1193671, Issued: 13 Jun 2016 I-1

Section I. Index Models 4150/4250 Maintenance Manual
Charts, Torque Cylinder

Component Specific . . . . . . . . . . . . .A-4 Free Lift
Face Seal O-Rings . . . . . . . . . . . . . .A-7 2-Stage Mast
Ferrous, Metric . . . . . . . . . . . . . . . .A-9 Installation . . . . . .7-113, 7-114
Ferrous, Standard . . . . . . . . . . . . . .A-8 Removal . . . . . . . .7-112, 7-113
Hydraulic Fittings . . . . . . . . . . . . . .A-6 3-Stage Mast below S/N 50501
Metric, Brass . . . . . . . . . . . . . . . . .A-11 Installation . . . . . .7-119, 7-120
Standard, Brass . . . . . . . . . . . . . .A-10 Removal . . . . . . . . . . . . . 7-119
Check Valve (CV1) . . . . . . . . . . . . 7-78, 8-5 3-Stage Mast S/N 50501 Up
Checking Hydraulic Oil Level, see Oil . 7-82 Installation . . . . . . . . . . . 7-126
Codes . . . . . . . . . . . . . . . . . . . 6-12 to 6-30 Removal . . . . . . . .7-125, 7-126
Cold Storage . . . . . . . . . . . . . . . . . . . . 7-75 Quad Mast
Conditioning . . . . . . . . . . . . . . . . . 7-75 Installation . . . . . . . . . . . 7-136
ComfortStance Floor . . . . . . . . . . . . . . 7-23 Removal . . . . . . . . . . . . . 7-135
Communication Error Code Main Lift
Troubleshooting . . . . . . . . . . . . . . 5-18 2-Stage Mast
Configure Mode . . . . . . . . . . . . . . . . . . 3-11 Installation . . . . . . . . . . . 7-112
Configure Mode Menu . . . . . . . . . . . . . 3-11 Removal . . . . . . . . . . . . . 7-111
Connectors 3-Stage Mast below S/N 50501
AMP . . . . . . . . . . . . . . . . . . 7-68, 7-69 Installation . . . . . . . . . . . 7-119
Battery . . . . . . . . . . . . . . . . . . . . . 7-52 Removal . . . . . . . . . . . . . 7-119
General . . . . . . . . . . . . . . . . . . . . . 7-67 3-Stage Mast S/N 50501 Up
Molex . . . . . . . . . . . . . . . . . . . . . . 7-68 Installation . . . . . . . . . . . 7-125
Power Amp . . . . . . . . . . . . . . . . . . 7-72 Removal . . . . . . . . . . . . . 7-125
Repair . . . . . . . . . . . . . . . . . . . . . . 7-67 Quad Mast
Contactors . . . . . . . . . . . . . . . . . . . . . 4-10 Installation . . . . . . . . . . . 7-135
LPC . . . . . . . . . . . . . . . . . . . . . . . . .8-4 Removal . . . . . . . . . . . . . 7-135
STR . . . . . . . . . . . . . . . . . . . . . . . . .8-4 Service (except TT Mast
Tests S/N 50501 Up) . . . . . . . . . . . . 7-93
LPC . . . . . . . . . . . . . . . . . . . . . 6-96 Service (TT Mast S/N 50501 Up) . . 7-93
Steer . . . . . . . . . . . . . . . . . . . . 6-95 Sideshift
TPC . . . . . . . . . . . . . . . . . . . . . 6-94 Seal Replacement (Cascade) . . 7-88
TPC . . . . . . . . . . . . . . . . . . . . . . . . .8-4 Seal Replacement (Lift-Tek) . . . 7-85
Control Handle Storage Preparation . . . . . . . . . . . 3-20
Optional . . . . . . . . . . . . . . . . . . . . 7-28
Soldering Procedures . . . . . . . . . . . 7-26 D
Standard . . . . . . . . . . . . . . . . . . . . 7-25
Conversion
DC Motor
Decimal to Fraction . . . . . . . . . . . .A-13
Brushes . . . . . . . . . . . . . . . . . . . . 7-56
Fraction to Decimal . . . . . . . . . . . .A-13
Troubleshooting . . . . . . . . . . . . . . 5-13
Standard/Metric . . . . . . . . . . . . . .A-15
DC Motor Test . . . . . . . . . . . . . . . . . . 5-16
Counterbalance Check Valves
Deadman Pedal Adjustment . . . . . . . . 7-66
(CB-1, CB-2) . . . . . . . . . . . . . . . . . .8-5
Decals and Plates . . . . . . . . . . . . . . . . 7-13
Customer Output
Decimal to Fraction Conversion . . . . . A-13
Test O47 . . . . . . . . . . . . . . . . . . . 6-115
Default Passwords, see Passwords . . . . 3-9
CV1 Check Valve . . . . . . . . . . . . . . . . . 7-78
Display Messages . . . . . . . . . . . . . . . . . 3-8
Drive Motor, see Motors . . . . . . . . . . . 7-62
Drive Tire Pressing . . . . . . . . . . . . . . . 7-45
Drive Unit
Adding Oil . . . . . . . . . . . . . . . . . . 7-35
Assembly Procedures . . . . . . . . . . 7-40
Axle Shaft Assembly . . . . . . . . . . . 7-42
I-2 Publication: 1193671, Issued: 13 Jun 2016

Bearing Installation Fuse/Relay Card

Shim Calculation . . . . . . . . . . 7-40 Theory of Ops . . . . . . . . . . . . . . . . . 8-4
Bearing Removal . . . . . . . . . . . . . 7-38 Troubleshooting . . . . . . . . . . . . . . 5-11
Disassembly Procedure . . . . . . . . 7-37 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Exploded View . . . . . . . . . . . . . . . 7-36
Housing Disassembly H
Helical Gear . . . . . . . . . . . . . . 7-38
Spiral Gear . . . . . . . . . . . . . . 7-38
Harness
Drive Units . . . . . . . . . . . . . . . . . . . . 7-34
Connectors . . . . . . . . . . . . . . . . . . 7-67
Dump Valve (SOL3) . . . . . . . . . . . . . . . 8-5
Soldering Procedures . . . . . . . . . . 7-67
Terminology . . . . . . . . . . . . . . . . . . 5-7
E Horn
Test . . . . . . . . . . . . . . . . . . . . . . 6-103
Electrostatic Discharge . . . . . . . . . . . . 2-8 Hydraulic
ESD Components . . . . . . . . . . . . . . . . . 7-78
Precautions . . . . . . . . . . . . . . . . . . 2-8 Filter . . . . . . . . . . . . . . . . . . . 7-78, 8-5
Fluid Capacity . . . . . . . . . . . . . . . . 3-4
F Fluid, see Oil . . . . . . . . . . . . . . . . 7-82
Oil, Selecting, see Oil . . . . . . . . . . 7-82
System
Filter, Hydraulic . . . . . . . . . . . . . . . . 7-78
Bleeding . . . . . . . . . . . . . . . . . 7-82
FlashWare
Storage Preparation . . . . . . . . . 3-20
Program . . . . . . . . . . . . . . . . . . . . 3-6
Starting . . . . . . . . . . . . . . . . . . . . . 3-6
Floor, ComfortStance . . . . . . . . . . . . . 7-23 I
Fluid Capacities . . . . . . . . . . . . . . . . . 3-4
Fluids, see Oil . . . . . . . . . . . . . . . . . . 7-82 IETM . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Fork Inspection
Inspection . . . . . . . . . . . . . . . . . . 4-12 Battery Connector . . . . . . . . . . . . . 7-52
Positioner Brakes . . . . . . . . . . . . . . . . . . . . . 7-46
Removal/Replacement Contactors . . . . . . . . . . . . . . . . . . 4-10
(Cascade Carriage) . . . . . . 7-88 Control Handle . . . . . . . . . . . . . . . 7-26
Fraction to Decimal Conversion . . . . . A-13 Forks . . . . . . . . . . . . . . . . . . . . . . 4-12
Free Lift Fuses . . . . . . . . . . . . . . . . . . . . . . . 5-6
Chain Motor Brushes . . . . . . . . . . . . . . . 7-56
Adjustment . . . . . . . . . . . . . .7-104 Quad Mast Check Valve . . . . . . . 7-135
Service . . . . . . . . . . . . . . . . . .7-105 Wiring/Harness . . . . . . . . . . . . . . 7-67
Free Lift Cylinder Installation, Truck . . . . . . . . . . . . . . . . 3-5
2-Stage Mast Interactive Electronic Technical
Installation . . . . . . . . 7-113, 7-114 Manuals . . . . . . . . . . . . . . . . . . . . . 1-3
Removal . . . . . . . . . . . 7-112, 7-113
3-Stage Mast below S/N 50501 L
Installation . . . . . . . . 7-119, 7-120
Removal . . . . . . . . . . . . . . . . .7-119
L/L Pot Test . . . . . . . . . . . . . . . . . . . . 6-33
3-Stage Mast S/N 50501 Up
Lift
Installation . . . . . . . . . . . . . .7-126
Chain
Removal . . . . . . . . . . . 7-125, 7-126
Maintenance . . . . . . . . . . . . . . 4-11
Quad Mast
Storage Preparation . . . . . . . . . 3-20
Installation . . . . . . . . . . . . . .7-136
Cylinder
Removal . . . . . . . . . . . . . . . . .7-135
Service (TT Mast
S/N 50501 Up) . . . . . . . . . 7-93
Motor, see Motors . . . . . . . . . . . . . 7-64

Power Amplifier . . . . . . . . . . . . . . . 7-65 2-Stage

Power Amplifier, Theory of Ops . . . .8-3 Disassembly . . . . . . . . . . . . . 7-109
Lift Chain Free Lift Cylinder
Free Lift Installation . . . . . . . . . . . 7-113
Adjustment . . . . . . . . . . . . . . 7-104 Removal . . . . . . . . . . . . . 7-112
Service . . . . . . . . . . . . . . . . . 7-105 Inspection . . . . . . . . . . . . . . . 7-110
Main Lift Main Lift Cylinder
Adjustment . . . . . . . . . . . . . . 7-101 Installation . . . . . . . . . . . 7-112
Service . . . . . . . . . . . . . . . . . 7-102 Removal . . . . . . . . . . . . . 7-111
Lift/Aux Pump (P1) . . . . . . . . . . . . . . . .8-4 Reassembly . . . . . . . . . . . . . . 7-110
Lift/Lower Reeving . . . . . . . . . . . . . . . . . 7-115
Potentiometer . . . . . . . . . . . . . . . . 7-28 3-Stage below S/N 50501
Theory of Ops . . . . . . . . . . . . 8-9, 8-11 Disassembly . . . . . . . . . . . . . 7-116
Valve (SOL2) . . . . . . . . . . . . . . . . . .8-5 Free Lift Cylinder
Lights Installation . . . . . . . . . . . 7-119
Steering Indicator . . . . . . . . . . . . . .3-8 Removal . . . . . . . . . . . . . 7-119
Load Holding Valve (SOL1) . . . . . 7-78, 8-5 Inspection . . . . . . . . . . . . . . . 7-116
Loctite® Main Lift Cylinder
See Thread Adhesives Installation . . . . . . . . . . . 7-119
LPC Contactor . . . . . . . . . . . . . . . . . . .8-4 Removal . . . . . . . . . . . . . 7-119
Lubrication Specification Chart . . . . . . .A-2 Reassembly . . . . . . . . . . . . . . 7-117
3-Stage S/N 50501 Up
M Disassembly . . . . . . . . . . . . . 7-122
Free Lift Cylinder
Installation . . . . . . . . . . . 7-126
Main Lift
Removal . . . . . . . .7-125, 7-126
Chain
Inspection . . . . . . . . . . . . . . . 7-122
Adjustment . . . . . . . . . . . . . . 7-101
Main Lift Cylinder
Service . . . . . . . . . . . . . . . . . 7-102
Installation . . . . . . . . . . . 7-125
Main Lift Cylinder
Removal . . . . . . . . . . . . . 7-125
2-Stage Mast
Reassembly . . . . . . . . . . . . . . 7-122
Installation . . . . . . . . . . . . . . 7-112
Reeving . . . . . . . . . . . . . . . . . 7-128
Removal . . . . . . . . . . . . . . . . 7-111
Installation
3-Stage Mast below S/N 50501
After Complete Removal . . . . 7-100
Installation . . . . . . . . . . . . . . 7-119
After Partial Removal . . . . . . . 7-98
Removal . . . . . . . . . . . . . . . . 7-119
Quad
3-Stage Mast S/N 50501 Up
Check Valve . . . . . . . . . . . . . 7-135
Installation . . . . . . . . . . . . . . 7-125
Disassembly . . . . . . . . . . . . . 7-130
Removal . . . . . . . . . . . . . . . . 7-125
Flow Control Valve
Quad Mast
Replacement . . . . . . . . . . 7-140
Installation . . . . . . . . . . . . . . 7-135
Free Lift Cylinder
Removal . . . . . . . . . . . . . . . . 7-135
Installation . . . . . . . . . . . 7-136
Maintenance
Removal . . . . . . . . . . . . . 7-135
180 Day/500 HD . . . . . . . . . . . . . .4-6
Inspection . . . . . . . . . . . . . . . 7-131
360 Days/1500 HD . . . . . . . . . . . . .4-9
Main Lift Cylinder
90 Day . . . . . . . . . . . . . . . . . . . . . .4-5
Installation . . . . . . . . . . . 7-135
Maintenance Minder . . . . . . . . . . . . . . .4-3
Removal . . . . . . . . . . . . . 7-135
Disabling . . . . . . . . . . . . . . . . . . . . .4-4
Reassembly . . . . . . . . . . . . . . 7-131
Enabling . . . . . . . . . . . . . . . . . . . . .4-3
Reeving . . . . . . . . . . . . . . . . . 7-136
Maintenance Mode . . . . . . . . . . . . . . . 3-18
Removal
Maintenance Mode Menu . . . . . . . . . . 3-18
Complete . . . . . . . . . . . . . . . . 7-99
Maintenance, Scheduled . . . . . .4-2 to 4-15
Partial . . . . . . . . . . . . . . . . . . . 7-98
Mast

Roller Bearing (Puck) Adjustment 7-106 P

Skewing . . . . . . . . . . . . . . . . . . . .7-107
Tilt Adjustment . . . . . . . . . . . . . .7-141 Passwords . . . . . . . . . . . . . . . . . . . . . . 3-9
Types . . . . . . . . . . . . . . . . . . . . . . . 3-4 Changing a Password . . . . . . . . . . 3-10
Memory Location . . . . . . . . . . . . . . . . . 8-2 Config Mode . . . . . . . . . . . . . . . . . . 3-9
Menu Default . . . . . . . . . . . . . . . . . . . . . . 3-9
Configure Mode . . . . . . . . . . . . . . 3-11 Entering a Password . . . . . . . . . . . . 3-9
Maintenance Mode . . . . . . . . . . . 3-18 Maintenance Mode . . . . . . . . . . . . . 3-9
Messages . . . . . . . . . . . . . . . . 6-7 to 6-11 Pin Extraction
Model Designation . . . . . . . . . . . . . . . . 3-4 AMP Connectors . . . . . . . . . . . . . . 7-69
Modes of Operation . . . . . . . . . . . . . . 3-11 Pin Insertion
Configure . . . . . . . . . . . . . . . . . . 3-11 AMP Connectors . . . . . . . . . . . . . . 7-70
Maintenance . . . . . . . . . . . . . . . . 3-18 Pinout Matrix . . . . . . . . . . . . . . . . . . . 8-13
Run . . . . . . . . . . . . . . . . . . . . . . . 3-11 Potentiometer
See also Passwords . . . . . . . . . . . 3-11 Lift/Lower (VR2) . . . . . . . . . . . . . . 7-28
Motors Travel (VR1) . . . . . . . . . . . . . . . . . 7-30
AC . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Power Amplifier
Bearing Encoder . . . . . . . . . . 7-60 Connectors . . . . . . . . . . . . . 7-68, 7-72
Open Winding . . . . . . . . . . . . 5-17 Discharging Internal Capacitor . . . . 5-2
Shorted Winding . . . . . . . . . . 5-17 Replacement . . . . . . . . . . . . . . . . . 7-65
Temperature Sensor . . . . . . . . 7-59 Power Cables . . . . . . . . . . . . . . . . . . . 7-54
Armature . . . . . . . . . . . . . . . . . . . 5-16 Power Cables, Motor . . . . . . . . . . . . . . 7-56
DC . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Pressure
Field Winding Test . . . . . . . . . 5-16 Attachment Adjustment . . . . . . . . 3-17
Grounded Motor Test . . . . . . . 5-16 Relief Valve . . . . . . . . . . . . . . . . . . 7-83
Open Circuit Test . . . . . . . . . . 5-15 System, Adjustment . . . . . . . . . . . 7-83
Short Circuited Armature . . . . 5-16 System, Measuring . . . . . . . . . . . . 7-83
Lift . . . . . . . . . . . . . . . . . . . . . . . 7-64 Priority Bypass (SOL4) . . . . . . . . . . . . . 8-5
Power Cable Terminals . . . . . . . . 7-56 Prop Relief (SOL5) . . . . . . . . . . . . . . . . . 8-5
Steer . . . . . . . . . . . . . . . . . . . . . . 7-18 Proportional Lowering Valve
Storage Preparation . . . . . . . . . . . 3-20 Adjustment . . . . . . . . . . . . . . . . . . 7-84
Traction . . . . . . . . . . . . . . . . . . . . 7-62 Puck (Roller Bearing) Adjustment . . . 7-106
Troubleshooting
AC . . . . . . . . . . . . . . . . . . . . . 5-16
DC . . . . . . . . . . . . . . . . . . . . . 5-13 Q
Quad Mast
O
Check Valve . . . . . . . . . . . . . . . . 7-135
Inspection . . . . . . . . . . . . . . . 7-135
Oil Disassembly . . . . . . . . . . . . . . . . 7-130
Hydraulic Flow Control Valve Replacement . 7-140
Selecting . . . . . . . . . . . . . . . . 7-82 Free Lift Cylinder
Hydraulic, Checking Level . . . . . . 7-82 Installation . . . . . . . . . . . . . . 7-136
Quantities . . . . . . . . . . . . . . . . . . . 3-4 Removal . . . . . . . . . . . . . . . . 7-135
Open Circuit DC Motor Test . . . . . . . 5-15 Inspection . . . . . . . . . . . . . . . . . . 7-131
Open Winding AC Motor . . . . . . . . . . 5-17 Reassembly . . . . . . . . . . . . . . . . . 7-131
Operator Display . . . . . . . . . . . . . . . . . 3-8 Reeving . . . . . . . . . . . . . . . . . . . . 7-136
Steering Indicator Lights . . . . . . . . 3-8
Operator Display Card
Theory of Ops . . . . . . . . . . . . . . . . 8-4

R Test . . . . . . . . . . . . . . . . . . . . . . 6-102
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5
Raymond Service Information . . . . . . . . . iv Torque Specs . . . . . . . . . . . . . . . . 7-78
Reeving SOL3
2-Stage Mast . . . . . . . . . . . . . . . . 7-115 Test . . . . . . . . . . . . . . . . . . . . . . 6-100
3-Stage Mast below S/N 50501 . . 7-120 Theory . . . . . . . . . . . . . . . . . . . . . . 8-5
3-Stage Mast S/N 50501 Up . . . . 7-128 Torque Specs . . . . . . . . . . . . . . . . 7-78
Quad Mast . . . . . . . . . . . . . . . . . 7-136 SOL4
Roller Bearing Adjustment . . . . . . . . 7-106 Test . . . . . . . . . . . . . . . . . . . . . . 6-112
Run Mode . . . . . . . . . . . . . . . . . . . . . . 3-11 Theory . . . . . . . . . . . . . . . . . . . . . . 8-5
Torque Specs . . . . . . . . . . . . . . . . 7-78
SOL5
S Test . . . . . . . . . . . . . . . . . . . . . . 6-113
Theory . . . . . . . . . . . . . . . . . . . . . . 8-5
Safety Torque Specs . . . . . . . . . . . . . . . . 7-78
Battery . . . . . . . . . . . . . . . . . . . . . .2-5 SOL6
Decals . . . . . . . . . . . . . . . . . . . . . . 7-13 Test . . . . . . . . . . . . . . . . . . . . . . . 6-97
Definitions . . . . . . . . . . . . . . . . . . .2-2 Theory . . . . . . . . . . . . . . . . . . . . . . 8-5
General . . . . . . . . . . . . . . . . . . . . . .2-3 Torque Specs . . . . . . . . . . . . . . . . 7-78
Towing . . . . . . . . . . . . . . . . . . . . . 2-10 SOL7C/R
Welding . . . . . . . . . . . . . . . . . . . . . 2-11 Test . . . . . . . . . . . . . . . . . . . . . . 6-114
Scheduled Maintenance . . . . . .4-2 to 4-15 Theory . . . . . . . . . . . . . . . . . . . . . . 8-5
180 Day/500 HD . . . . . . . . . . . . . .4-6 Torque Specs . . . . . . . . . . . . . . . . 7-78
360 Day/1500 HD . . . . . . . . . . . . . .4-9 SOL9L/R
90 Day . . . . . . . . . . . . . . . . . . . . . .4-5 Test . . . . . . . . . . . . . . . . . . . . . . . 6-99
Chains . . . . . . . . . . . . . . . . . . . . . 4-11 Theory . . . . . . . . . . . . . . . . . . . . . . 8-5
Guidelines . . . . . . . . . . . . . . . . . . . .4-2 Torque Specs . . . . . . . . . . . . . . . . 7-78
Sealants, Specifications . . . . . . . . . . . .A-3 Soldering Procedures . . . . . . . . . . . . . 7-67
Serial Number Solenoid Tests
Location on Specification Tag . . . . .3-3 Aux. Direction . . . . . . . . . . . . . . . 6-97
Service Information, Raymond . . . . . . . . iv Aux. Relief . . . . . . . . . . . . . . . . . 6-113
Shorted Winding on AC Motor . . . . . . . 5-17 HSA 1 . . . . . . . . . . . . . . . . . . . . . 6-114
Shorts to Frame Test . . . . . . . . . . . . . .5-2 Lift Relief . . . . . . . . . . . . . . . . . . 6-100
Side Shifter Lift/Lower . . . . . . . . . . . . . . . . . 6-102
Inspection . . . . . . . . . . . . . . . . . . . 7-85 Load Hold . . . . . . . . . . . . . . . . . . 6-101
Installation . . . . . . . . . . . . . . . . . . 7-87 Priority Bypass . . . . . . . . . . . . . . 6-112
Removal . . . . . . . . . . . . . . . . . . . . 7-85 Sideshift . . . . . . . . . . . . . . . . . . . . 6-99
Sideshift Cylinder Tilt . . . . . . . . . . . . . . . . . . . . . . . . 6-98
Seal Replacement (Cascade) . . . . . 7-88 Special Tools . . . . . . . . . . . . . . . . . . . 7-12
Seal Replacement (Lift-Tek) . . . . . . 7-85 Specification Tag . . . . . . . . . . . . . . . . . 3-3
Sideshift Cylinders . . . . . . . . . . . . . . . .8-4 Specifications, Vehicle . . . . . . . . . . . . . 3-3
Sideshift Cylinders, Theory of Ops . . . .8-4 Standard/Metric Conversions . . . . . . A-15
Sideshift Solenoids (SOL9L/R) . . . . . . .8-5 Steer Caster
SOL1 Disassembly . . . . . . . . . . . . . . . . . 7-21
Test . . . . . . . . . . . . . . . . . . . . . . . 6-101 Installation . . . . . . . . . . . . . . . . . . 7-21
Theory . . . . . . . . . . . . . . . . . . . . . . .8-5 Reassembly . . . . . . . . . . . . . . . . . 7-22
Torque Specs . . . . . . . . . . . . . . . . 7-78 Removal . . . . . . . . . . . . . . . . . . . . 7-18
SOL10 Service . . . . . . . . . . . . . . . . . . . . . 7-22
Test . . . . . . . . . . . . . . . . . . . . . . . . 6-98 Steer Motor . . . . . . . . . . . . . . . . . . . . 7-18
Theory . . . . . . . . . . . . . . . . . . . . . . .8-5 Steer Position Sensor Theory . . . . . . . . 8-4
Torque Specs . . . . . . . . . . . . . . . . 7-78 Steer Valve Theory . . . . . . . . . . . . . . . . 8-5
SOL2 Steerable Wheel Assembly . . . . . . . . . 7-18

Steering A68 - Right Trac Motor Temp 6-52, 6-53

Indicator Lights . . . . . . . . . . . . . . . 3-8 A71 - Tilt Down (S7) . . . . . . . . . . . 6-54
System Theory . . . . . . . . . . . . . . . . 8-8 A72 - Tilt Up (S6) . . . . . . . . . . . . . 6-55
Storage A72 - Tilt Up/Down (SW4)
Hydraulic Cylinders . . . . . . . . . . . 3-20 (Optional Handle) . . . . . . . . . . 6-56
Hydraulic System . . . . . . . . . . . . 3-20 A73 - Sideshift Right (S9) . . . . . . . 6-57
Lift Chains . . . . . . . . . . . . . . . . . . 3-20 A74 - Sideshift Left . . . . . . . . . . . . 6-58
Motors . . . . . . . . . . . . . . . . . . . . . 3-20 A74 - Sideshift Switch (SW4)
Warranty Issues . . . . . . . . . . . . . . 3-20 (Optional Handle) . . . . . . . . . . 6-59
STR Contactor . . . . . . . . . . . . . . . . . . . 8-4 A75 - Attach Func 1 . . . . . . . . . . . 6-60
Switches A75 - Attach Func 1
Tests (Optional Handle) . . . . . . . . . . 6-61
S11 . . . . . . . . . . . . . . . . . . . . 6-75 A76 - Attach Fcn 2 (SW2)
S12 . . . . . . . . . . . . . . . . . . . . 6-76 (Optional Handle) . . . . . . . . . . 6-63
S18 . . . . . . . . . . . . . . . . . . . . 6-84 A76 - Attach Func 2 . . . . . . . . . . . 6-62
S21 . . . . . . . . . . . . . . . . . . . . 6-64 A76 - Attach Func 2
S22A . . . . . . . . . . . . . . . . . . . 6-88 (Optional Handle) . . . . . . . . . . 6-63
S22B . . . . . . . . . . . . . . . . . . . 6-89 A77 - EPO (S21) . . . . . . . . . . . . . . 6-64
S3 . . . . . . . . . . . . . . . . . . . . . 6-79 A80 - Aux Select Current (SOL6) . . 6-65
S6 . . . . . . . . . . . . . . . . . . . . . 6-55 A81 - Priority Bypass
S7 . . . . . . . . . . . . . . . . . . . . . 6-54 Current (SOL4) . . . . . . . . . . . . 6-66
S9 . . . . . . . . . . . . . . . . . . . . . 6-57 A82 - Aux. Relief Current (SOL5) . . 6-67
SW1 . . . . . . . . . . . . . . . . . . . . 6-79 A96 – BSM Curr . . . . . . . . . . . . . . 6-68
SW2 . . . . . . . . . . . . . . . . . . . . 6-63 A97 – BSM Volt . . . . . . . . . . . . . . . 6-69
SW3 . . . . . . . . . . . . . . . . . . . . 6-61 A98 – BSM Temp . . . . . . . . . . . . . 6-70
SW4 . . . . . . . . . . . . . . . . 6-56, 6-59 A99 – H20 Snse . . . . . . . . . . . . . . 6-71
System Architecture . . . . . . . . . . . . . . 8-2 I02 - High Speed Limit SW (S11) . . 6-75
I05 - Lift Limit (S12) . . . . . . . . . . . 6-76
T I13 - Lift Contactor (DC Lift) . . . . . 6-77
I14 - Steer Contactor . . . . . . . . . . 6-78
I15 - Horn (S3) . . . . . . . . . . . . . . . 6-79
Terminals, Motor Power Cable . . . . . . 7-56
I15 - Horn (SW1) . . . . . . . . . . . . . . 6-79
Tests
I19 - Left Traction RPM . . . . . . . . . 6-80
A04 - Travel Pot . . . . . . . . . . . . . . 6-32
I20 - Lift Motor RPM . . . . . . . . . . . 6-81
A05 - L/L Pot . . . . . . . . . . . . . . . . 6-33
I23 - CAN Communication Test . . . 6-82
A08 - Left Trac Motor Temp . . . . . 6-34
I65 - Tilt Position SW (S18) . . . . . . 6-84
A09 - Lift Motor Temp . . . . . . . . . 6-35
I82 - Right Traction RPM . . . . . . . 6-87
A10 - Left TPA Temp . . . . . . . . . . 6-36
I87 - Battery Gate 1 . . . . . . . . . . . 6-88
A100 – BSM Comm . . . . . . . . . . . 6-72
I88 - Battery Gate 2 . . . . . . . . . . . 6-89
A11 - Left Traction Current . . . . . 6-37
I89 - Steer Position Sensor . . . . . . 6-90
A13 - Press Sensor Voltage . . . . . 6-38
I91 - iPort Communication . . . . . . 6-91
A14 - Ext. Supply Sense (12VDC) 6-39
O00 - TPC Contactor . . . . . . . . . . . 6-94
A15 - Battery Voltage . . . . . . . . . . 6-40
O01 - Steer Contactor (STR) . . . . . 6-95
A19 - LPA Temp . . . . . . . . . . . . . . 6-41
O02 - Lift Contactor (LPC) . . . . . . . 6-96
A20 - Lift Motor Current . . . . . . . 6-42
O04 - Aux. Direction
A22 - Traction Throttle Request . . 6-43
Solenoid (SOL6) . . . . . . . . . . . . 6-97
A23 - Lift Request . . . . . . . . . . . . 6-44
O07 - Tilt Solenoid (SOL10) . . . . . . 6-98
A26 - Pot Supply (5VDC) . . . . . . . 6-45
O08 - Sideshift Solenoid
A34 - Lift/Lower Current (SOL2) 6-46, 6-47
(SOL9L, SOL9R) . . . . . . . . . . . 6-99
A36 - Ambient Temperature . . . . . 6-48
O09 - Lift Relief Solenoid (SOL3) . 6-100
A40 - Handle Heater Reference Voltage 6-49
O11 - Load Hold Solenoid (SOL1) 6-101
A65 - Right TPA Temp . . . . . . . . . 6-50
O12 - Lift/Lower Solenoid (SOL2) 6-102
A67 - Right Trac Motor Current . . 6-51

O18 - Horn . . . . . . . . . . . . . . . . . 6-103 Travel Potentiometer . . . . . . . . . . . . . 7-30

O20 - Travel Alarm . . . . . . . . . . . 6-105 Troubleshooting
O23 - Toggle Amplifier Fan . . . . . 6-106 Chains . . . . . . . . . . . . . . . . . . . . . 4-11
O28 - Ramp Lift Motor (AC Lift) . . 6-107 Communication Error Codes . . . . 5-18
O29 - Ramp Traction Motors . . . . 6-108 Drive Units . . . . . . . . . . . . . . . . . . 5-23
O30 - Electric Brakes . . . . . . . . . 6-109 Electrical . . . . . . . . . . . . . . . . . . . . 5-2
O32 - Toggle Relay Enable . . . . . . 6-110 Fuse/Relay Card . . . . . . . . . . . . . 5-11
O33 – Handle Heater . . . . . . . . . . 6-111 Fuses . . . . . . . . . . . . . . . . . . . . . . . 5-6
O36 - Priority Bypass Hydraulic Functions . . . . . . . . . . . 5-20
Solenoid (SOL4) . . . . . . . . . . . 6-112 Motors . . . . . . . . . . . . . . . 5-13 to 5-17
O37 - Aux. Relief Solenoid (SOL5) 6-113 AC . . . . . . . . . . . . . . . . . . . . . 5-16
O45 - HSA 1 Solenoid DC . . . . . . . . . . . . . . . . . . . . . 5-13
(SOL7C, SOL7R) . . . . . . . . . . 6-114 Pinout Matrix . . . . . . . . . . . . . . . . 8-13
O47 - Customer Output . . . . . . . 6-115 Shorts to Frame Test . . . . . . . . . . . 5-2
Shorts to Frame . . . . . . . . . . . . . . .5-2 Travel Functions . . . . . . . . . . . . . 5-24
Theory of Ops Truck Installation . . . . . . . . . . . . . . . . 3-5
BSOC . . . . . . . . . . . . . . . . . . . . . . .5-4
CAN Bus . . . . . . . . . . . . . . . . . . . . .8-3 V
Fuse/Relay Card . . . . . . . . . . . . . . .8-4
Lift Power Amp . . . . . . . . . . . . . . . .8-3
Valve
Lift/Lower . . . . . . . . . . . . . . . 8-9, 8-11
Check
Operator Display Card . . . . . . . . . . .8-4
Quad Mast . . . . . . . . . . . . . . 7-135
Pinout Matrix . . . . . . . . . . . . . . . . 8-13
CV1 Check Valve . . . . . . . . . . . . . 7-78
Steer Position Sensor . . . . . . . . . . .8-4
Pressure Relief . . . . . . . . . . . . . . . 7-83
Steer Valve . . . . . . . . . . . . . . . . . . .8-5
Proportional Lowering
Steering System . . . . . . . . . . . . . . .8-8
Adjustment . . . . . . . . . . . . . . . 7-84
Traction Power Amps . . . . . . . . . . .8-3
SOL1
Traction System . . . . . . . . . . . . . . .8-6
Test . . . . . . . . . . . . . . . . . . . 6-101
VM . . . . . . . . . . . . . . . . . . . . . . . . .8-3
Torque Spec . . . . . . . . . . . . . . 7-78
Thread Adhesives, Specifications . . . . . .A-3
SOL10
Thread-Forming Screws, Torque Chart A-12
Test . . . . . . . . . . . . . . . . . . . . 6-98
Tilt Solenoid (SOL10) . . . . . . . . . . . . . .8-5
Torque Spec . . . . . . . . . . . . . . 7-78
Tilt, Mast, Adjustment . . . . . . . . . . . 7-141
SOL2
Tire Pressing . . . . . . . . . . . . . . . . . . . . 7-45
Test . . . . . . . . . . . . . . . . . . . 6-102
Tools, Special . . . . . . . . . . . . . . . . . . . 7-12
Torque Spec . . . . . . . . . . . . . . 7-78
Torque Chart
SOL3
Component Specific . . . . . . . . . . . . .A-4
Test . . . . . . . . . . . . . . . . . . . 6-100
Face Seal O-Rings . . . . . . . . . . . . . .A-7
Torque Spec . . . . . . . . . . . . . . 7-78
Ferrous, Metric . . . . . . . . . . . . . . . .A-9
SOL4
Ferrous, Standard . . . . . . . . . . . . . .A-8
Test . . . . . . . . . . . . . . . . . . . 6-112
Hydraulic Fittings . . . . . . . . . . . . . .A-6
Torque Spec . . . . . . . . . . . . . . 7-78
Metric, Brass . . . . . . . . . . . . . . . . .A-11
SOL5
Standard, Brass . . . . . . . . . . . . . .A-10
Test . . . . . . . . . . . . . . . . . . . 6-113
Thread-Forming Screws . . . . . . . .A-12
Torque Spec . . . . . . . . . . . . . . 7-78
Towing Safety . . . . . . . . . . . . . . . . . . . 2-10
SOL6
TPC Contactor . . . . . . . . . . . . . . . . . . .8-4
Test . . . . . . . . . . . . . . . . . . . . 6-97
Traction Motor
Torque Spec . . . . . . . . . . . . . . 7-78
Power Cable Terminal Nuts . . . . . . 7-56
SOL7C/R
Traction Motor, see Motors, Traction . . 7-62
Test . . . . . . . . . . . . . . . . . . . 6-114
Traction Power Amplifiers . . . . . . . . . . 7-65
Torque Spec . . . . . . . . . . . . . . 7-78
Theory of Ops . . . . . . . . . . . . . . . . .8-3
Traction System Theory of Ops . . . . . . .8-6

SOL9L/R
Test . . . . . . . . . . . . . . . . . . . . 6-99
Torque Spec . . . . . . . . . . . . . . 7-78
Valve, Check, Quad Mast . . . . . . . . . .7-135
Valves
CB1, CB2 . . . . . . . . . . . . . . . . . . . 8-5
CV1 . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Vehicle Specifications . . . . . . . . . . . . . 3-3
VM, Theory of Ops . . . . . . . . . . . . . . . . 8-3
VR1 Test . . . . . . . . . . . . . . . . . . . . . . 6-32
VR2 Test . . . . . . . . . . . . . . . . . . . . . . 6-33
Warranty
Storage Issues . . . . . . . . . . . . . . . 3-20
Welding Safety . . . . . . . . . . . . . . . . . . 2-11
Wheel, Steerable . . . . . . . . . . . . . . . . 7-18
Wiring
Connectors . . . . . . . . . . . . . . . . . 7-67
Harness Terminology . . . . . . . . . . . 5-7
Soldering Procedures . . . . . . . . . . 7-67


1193671B
Printed by the Digital Print Center
The Raymond Corporation, Greene, NY
Schematics
Models Serial Numbers

4150 42,000 and Up This publication applies to the all subsequent releases of this product until
otherwise indicated in new editions or bulletins. Changes occur periodically to
4250 42,067 and Up the information in this publication.
If you need assistance with your lift truck, contact your local authorized
Raymond Sales and Service Center. To locate your local authorized Raymond
Sales and Service Center, go to www.raymondcorp.com.
Publication: 1193671B Issued: 13 Jun 2016
©2016 The Raymond Corporation

Models 4150/4250 Stand-Up Counterbalanced Lift Truck Schematics
Section 1.
Figure 1-1. Power Distribution Diagram - Model 4150
Publication: 1193671B, Issued: 13 Jun 2016 2

Figure 1-2. Power Distribution Diagram - Model 4250

Figure 1-3. Electrical Schematic - Model 4250 (AC Lift) - Sheet 1 of 5
A B C D E F G H
FOR NOTES SEE SHEET 4 MOTOR VELOCITY JPTL2 JPTL1 JPS2 JPC24
RED -1 -26
T VEL SENSOR+
TRACTION -1 BRN -1
+12VP VEHICLE
SPL4
BLACK -4 -7
T VEL SENSOR-
LEFT POWER
JPTL1
STEER
POSITION
-2 WHT -17
POS A MANAGER
2 TLE WHITE -3 -31 AMPLIFIER SENSOR
T VEL PHASE A CAN BUS -3 BLK -20
-21 POS B
BLUE -2 -32 CAN TERM H TERMINATION
2 RED JPTL3 -2 -8
T VEL PHASE B
T TEMP+
CAN TERM L
-34 -4 BLU JPC22-9
POS C
TLT WHT -1 -23

BUS+
-35
BUS-
MOTOR TEMPERATURE -11
ID0
-12
ID1
-
U
U
CONTACTOR V
PANEL TML V
4 B+K3
-1
TP1 W
W
+
FU1 FU3 FU2

100A 500A MOTOR VELOCITY JPTR2 JPTR1
750A
80 VDC 80 VDC 80 VDC RED -1 -26
CONTROL HANDLE
TP2 TP3 TP5 T VEL SENSOR+ TRACTION
SPL6
BLACK -4 -7
JP JPS1-1 T VEL SENSOR- SEE SHEET 4
RIGHT POWER
B+ 2 TRE WHITE -3 -31
3 -2
-3
1
2
STR
1
LPC
1
TPC BLUE -2 -32
T VEL PHASE A
T VEL PHASE B
AMPLIFIER
-4 2 2 RED JPTR3 -2 -8 JPTR1

T TEMP+
-23
TRT WHT -1 BUS+
-35
-13 BUS-
B+K3 4
TPC -11
JPS1 ID0
-12
-11 ID1
-
X Y U
-8
TPC U
SPL8
V
TMR V -1
4 B+K3
W
W
SPL1
SPL2
SPL3
+
X X MOTOR VELOCITY JPL2 JPL1

RED -1 -26
STR L VEL SENSOR+ LIFT POWER
LPC SPL5
BLACK -4 -7 AMPLIFIER
L VEL SENSOR-
4 Y Y
LME WHITE
BLUE
-3
-2
-31
-32
T VEL PHASE A
T VEL PHASE B
RED JPL3 -2 -8 JPL1 JPC14
JPS1 -5 -12 -6 -7 -9 -10 T TEMP+
-23 -11
LMT WHT -1 BUS+ BUS+
AUX(+) -35 -4
BUS- BUS-
-3
MOTOR TEMPERATURE -11 DGND
SM -13 ID0
B+K3 4 -12
-6 ID1 JPC9-2
JP LPC TXD
JL4-AC (AC LIFT)
FLASHWARE
B- AUX(-)
-1 -3
RXD
-2 -5
SPL12
PL4 U DGND
SPL7
-1 U
-2 JL4-DC (DC LIFT) V
AC LIFT LM -1
V
-1 4 B+K3
JPC3-1
ONLY
COMMUNICATIONS
W VBUS
-2 W -2
+ - D-
USB
-3
D+
TP4 -4
DGND
JPC18-9
LPC_CTRL
JPC22-20
LPC_SENSE
JPC20-15
JPC18-11 ISENSE2(K2) SOL2
STR_CONTACTOR
5 JPC22-19
JPC14-10
STR_SENSE LIFT/LOWER
-16
1 2
DGND
-2 -13
DGND ISENSE5(K2) SOL6
-1
B-F 1 2
-8 JPC18-1
B-F AUX SELECT
-9
B-F JPC20-17
ISENSE3(K2) SOL4
OPERATOR 1
JPD2 JPD1 2
DISPLAY -18
4 -1 -1 JPC6-6
+12V
PRIORITY BYPASS
UP -19
-6 -2 JPC24-14 ISENSE4(K2) SOL5
ADDR_LATCH
SPL9 1 2
-2 -3 JPC24-12 -20
DATA_LATCH PROP RELIEF
DN -5 -4 JPC22-10 JPF2-8 FUSE
DISP_MISO JPC18 ZONE C7
RELAY
-3 -5 JPC24-2 -10 SHEET 1
SOL1 CARD
JPF1-3
JPF2-1
JPF2-2
JPF1-6
JPF3-3
ALARM_PWM LOAD HOLD

ENTER -4 2 1
-10
-11
-12
JPB1 SOUNDER -6 JPC6-5

-5
-4
-5
-6
-7
-8
-9
-1 SHIFT_CLOCK
POWER AMP - +
-7 JPC6-2 JPC20-12
ACCESORY FAN OPTION DATA_OUT DUMP SOL3
(MODEL 4200 -2
JPF3-1 POWER -8 JPC6-4 2 1
ONLY) DGND
FU6 (15A) TS1
-2 -1 JPC18-12
HSA1 SOL7R
1 2 JPC18-17
JPF1-4 -2 B- PA_FAN 2 1
JPF1-1
-3 HRN
FU8 (15A/5A) JPB4-1 HRN+ -14
-2 SIDESHIFT SOL9R
-4 BATTERY HRN0 JPC18-16
JPF4-15
6 JPF4-3
1
FU7 (15A/5A)
2
K1
-5
KEY
HRN-
HORN
-15
2
SOL10
1
JPF2-9 -6 LEFT RIGHT H TILT

-4 1 2 BRAKE BRAKE 2 1
H-1(+)
-3
TRAVEL
K3 -5 JPB3-1 H-2(-) JPC18-18 SOL7C
ALARM TRAV/LIFT ALARM
JPF4-11 -2 2 1 MAST MOUNTED SOLENOIDS
OPTION
JPB4-2
-12
JPC20-14 SOL9L
-8
PCB BRAKES
2 1
MOUNTING FUSE/ JPH2 1
STUD
RELAY HSA2
-8 -1 SOL11 SOL12
JPF4-13 JPC14-6
CARD JPC22-21
RELAY_ENABLE MAST 1 2
CONNECTOR 2
EPO_SENSE
K4 K3 K2 K1 -2 1
JPC14-12
B+KEY
-5 JPDS
SOL13
2 1 -1 JPC10-1 -3
S21 +12VP
EPO -2 JPC22-8
S2 ON DEADMAN 2
FU5 (15A) S1 -4
-1 -10 1 2 -3 JPC22-11
DGND
1 2
KEYSWITCH DEADMAN
K2 K4 JPC14
OR ROTARY SWITCH SWITCH
-2 JPF2-4 -7
B+K4
-6 -13
7
Model 4250 - AC LIFT
B+K2
-7 -14
B+K2
T° JPF4-7 JPC24-24
BATTERY_SENSE_IN
JPF2-8 ZONE G5
TO SOLENOID 1
SHEET 1
MODEL 4250 - AC LIFT

Figure 1-4. Electrical Schematic - Model 4150 - Sheet 2 of 5
A B C D E F G H
MOTOR VELOCITY JPTL2 JPTL1 JPS2 JPC24
RED -1 -26
T VEL SENSOR+
TRACTION -1 BRN -1
+12VP VEHICLE
SPL4
BLACK -4 -7
T VEL SENSOR-
LEFT POWER
JPTL1
STEER
POSITION
-2 WHT -17
POS A MANAGER
TLE WHITE -3 -31 AMPLIFIER SENSOR
T VEL PHASE A CAN BUS -3 BLK -20
-21 POS B
2 BLUE
RED JPTL3
-2
-2
-32
-8
T VEL PHASE B
CAN TERM H
CAN TERM L
-34
TERMINATION -4 BLU JPC22-9
POS C
T TEMP+
TLT WHT -1 -23
BUS+
SEE NOTE 2
-35
BUS- JPC12-1 JPH1-11
MOTOR TEMPERATURE -11 +5VP +5VP FLEX CIRCUIT
ID0
-12
BASED HANDLE
+5VP
ID1
- -3 -13
TRAVEL VR1
U +
U DGND +5VP
CONTACTOR V 4 +5VP
0 SW1
PANEL TML V
B+K2
-1
-2 -12 -
TP1 W LIFT VR2
W DGND
+
DGND
-10 -10
HORN +
FU1 FU3 FU2 +5VP
-4 -14 0 SW3
100A 500A 750A MOTOR VELOCITY JPTR2 JPTR1 FUNCTION 4A
80 VDC 80 VDC 80 VDC -11 -1
RED -1 -26
T VEL SENSOR+ FUNCTION 4B -
TP2 TP3 TP5 SPL6 TRACTION
BLACK -4 -7 DGND
JP JPS1-1 T VEL SENSOR- -5 -15
RIGHT POWER S6
3 B+
-2
-3
1 1 1
TRE WHITE
BLUE
-3
-2
-31
-32
T VEL PHASE A AMPLIFIER
TILT_UP
TILT_DOWN
-6 -6
S7
+5VP
+
0 SW2
STR LPC TPC T VEL PHASE B
2 -8 -8
-4 2 2 RED JPTR3 -2 -8 JPTR1 SSHIFT_LEFT S8
T TEMP+ -
-23 -9 -9
TRT WHT -1 BUS+ SSHIFT_RIGHT S9 DGND
-35 -12 -2
SEE NOTE 2 -13 BUS-
B+K3 4 DGND DGND
TPC -11
JPS1 ID0 HTR6
-12 -7 -7
-11 ID1 H_HTR
CONTROL HANDLE
-
X Y U
-8
TPC U
SPL8
V
TMR V -1
4 B+K3
W
W
SPL1
SPL2
SPL3
+
JPC12-1
+5VP +5VP SWITCH INPUT
CONTROL HANDLE
X +5VP
X
-3
STR TRAVEL VR1
LPC
4 Y Y
DGND
+5VP
S3
JPC14 -2
JPS1 -5 -12 -6 -7 -9 -10 LIFT VR2
MP-S -11 DGND
BUS+
-4 DGND
AUX(+) BUS-
-10
-3 HORN
DGND -4 S4
SM DC FUNCTION 4A
LIFT -11
JP JPC9-2 FUNCTION 4B DGND
MOTOR TXD
FLASHWARE
B- AUX(-)
-3 -5
MP RXD TILT_UP S6
-5
DGND -6
SPL7
TILT_DOWN S7 S5
-8
SSHIFT_LEFT S8
DGND
JPC3-1 -9
SSHIFT_RIGHT S9
COMMUNICATIONS
MP-A VBUS
-12
- -2
D- DGND DGND
USB
-3
D+
TP4 -4
DGND
JPC18-9
LPC_CTRL
JPC22-20
LPC_SENSE
JPC20-15
JPC18-11 ISENSE2(K2) SOL2
5 JPC22-19
STR_CONTACTOR
STR_SENSE LIFT/LOWER
-16
1 2
JPC14-10
DGND
-2 -13
DGND ISENSE5(K2) SOL6
-1
B-F 1 2
-8 JPC18-1
B-F AUX SELECT
-9
B-F JPC20-17
ISENSE3(K2) SOL4
OPERATOR 1
JPD2 JPD1 2
DISPLAY -18
4 -1 -1 JPC6-6
+12V
PRIORITY BYPASS
UP -19
-6 -2 JPC24-14 ISENSE4(K2) SOL5
ADDR_LATCH
SPL9 1 2
-2 -3 JPC24-12 -20
DATA_LATCH PROP RELIEF
DN -5 -4 JPC22-10 JPF2-8 FUSE
DISP_MISO JPC18 ZONE C7
RELAY
-3 -5 JPC24-2 -10 SHEET 2
SOL1 CARD
JPF1-3
JPF2-1
JPF2-2
JPF3-3
LOAD HOLD
JPF1-6
ALARM_PWM
ENTER -4 2 1
-10
-11
-12
SOUNDER -6 JPC6-5
-5
-6
-8
-9
-5
-4
-7
SHIFT_CLOCK
-7 JPC6-2 JPC20-12
ACCESORY DATA_OUT DUMP SOL3
JPF3-1 POWER -8 JPC6-4 2 1
FU6 (15A) TS1 DGND
-2 -1 JPC18-12
HSA1 SOL7R
1 2
JPF1-4 -2 B- 2 1
JPF1-1
-3 HRN
FU8 (15A/5A) JPB4-1 HRN+ -14
-2 SIDESHIFT SOL9R
6 1 2 JPF4-15 -4 BATTERY
-5
HRN0
HRN-
JPC18-16
HORN 2 1
FU7 (15A/5A) K1 -15

JPF4-3 -6 KEY SOL10
JPF2-9 LEFT RIGHT H TILT
-4 1 2 BRAKE BRAKE 2 1
H-1(+)
-3
TRAVEL
K3 -5 JPB3-1 H-2(-) JPC18-18 SOL7C
ALARM TRAV/LIFT ALARM
JPF4-11 -2 2 1 MAST MOUNTED SOLENOIDS
OPTION
JPB4-2
-12
JPC20-14 SOL9L
-8
PCB BRAKES
2 1
MOUNTING FUSE/ JPH2 1
STUD
RELAY HSA2
-8 -1 SOL11 SOL12
JPF4-13 JPC14-6
CARD JPC22-21
RELAY_ENABLE MAST 1 2
CONNECTOR 2
EPO_SENSE
K4 K3 K2 K1 -2 1
JPC14-12
B+KEY
-5 JPDS
SOL13
2 1 -1 JPC10-1 -3
S21 +12VP
EPO -2 JPC22-8
S2 ON DEADMAN 2
FU5 (15A) S1 -4
-1 -10 1 2 -3 JPC22-11
DGND
1 2
KEYSWITCH DEADMAN
JPC14
4 K2 K4 OR ROTARY SWITCH SWITCH
-2 JPF2-4 -7
B+K4
7 -6 -13
B+K2
Model 4150 - DC LIFT

-7 -14
B+K2
T° JPF4-7 JPC24-24
BATTERY_SENSE_IN
JPF2-8 ZONE G5
TO SOLENOID 1
SHEET 2
MODEL 4150 - DC LIFT

Figure 1-5. Electrical Schematic - Options - Sheet 3 of 5
A B C D E F G H
TS1 JPW5 WL TS1 SL

-5 -3 FU20 VEHICLE
2 -2 FU12
WHT
BLK
-2
-1
RED + - BLK WARNING LIGHT
OPTION -1 2A 125V
2
S35
1
SL(-)
RD + - BK
MANAGER
+12VP
JPC20
-3
JPS14
-3
S22A CONNECTOR TO CONNECTOR TO
JPC22
2A -3 -1 LEFT THIRD PARTY DEVICE RAYMOND TM
GATE_L
CLIPBOARD SPOTLIGHT OPTION BATTERY RXD TXD PC9-2
JRDP1-1
JPC24
GATE TXD RXD
-3 -2 -2 -3
DGND OPTION SHLD -5
JPC20 JPS13 -3 DGND

-4 -3 BATT-
+12VP -5
S22B
JPC22 BATT+
RIGHT -6
-4 -1
GATE_R
BATTERY FU35
2 AMP JPC9
JPC24 GATE
-4 -2 125VDC -3
DGND OPTION
iPORT
TP1
RS-232
TP1
TP4
-2 TRUCK
JPC20 JPS5
-8 -4
MODEL 4250 ONLY VM
+12VP BATT+ BATT-
S11 S11 B+
WORKING LIGHTS JPC22 -5
JPWL3 HI-SPEED MAST TILT SPEED
OPTION -22 -1
-1 HIGH_SPD REDUCTION iPORT SUPPLIER WIRELESS MODULE
LIMIT OR
1 2 JPC24 TT AND QM ONLY
SEE INSTALLATION MANUAL FOR DETAILS

3 TS1
S10
SPL11
JPWL5
-1
JPWL1
-1 WORK
DGND
-8 -2
SWITCH
OPTION
FOR SERIAL NUMBERS
50500 AND HIGHER
JPWL4 JPWL2 LIGHTS
-3 -1 -2 -1 -1
iWAREHOUSE-RED SYSTEM
ACCESSORY POWER LEFT RIGHT REV BOTTLER'S
JPC20 JPT1
(BATTERY) 2 1 1 1 1 MODEL 4250 ONLY TILT OPTION
S15 JPWL4 JPWL2 -5 -1
-1 +12VP
-2 -2 2 2 2 S18
ACCESSORY POWER JPC22
-5 -2 MAST
B- JPWL5 JPWL1 TILT_DIN
TILT
-2 -2
JPC24
SWITCH
JPWL3 -5 -3
DGND OPTION
-2
-22 -4
TILT_AIN
TP1 (B+)
JPC20 JPS6
MODEL 4250 ONLY
-6 -4
+12VP
S12
JPC22 S12
-6 -1 LIFT
LIFT_LIM MAST TILT SPEED
LIMIT OR JPHT1
JPC24 REDUCTION
SWITCH -1 HTR6
-6 -3 (QUAD MAST ONLY)
DGND OPTION
FOR SERIAL NUMBERS LESS
B-
THAN 50500. -2
CONTROL HANDLE
TP4
4 THERMOSTAT
VM JPC24 JPY1
-13 -1
+12VP PRESSURE TP4 (B-)
-18 -2 (WEIGHT)
PRESSURE_AIN PRESS
-10 -3 SENSOR
DGND OPTION SWITCH BASED HANDLE
INTERNAL HEATER
OPTIONAL HEATED PLATES FOR OCSS OPTION
TP1 (B+)
FU17
T-OCSS
HTR7+ RIGHT SIDE
5 UPPER LOWER
OPERATOR'S COMPARTMENT
HTR7-
SENSOR SYSTEM
(OCSS) OPTION
VEHICLE
JPC20 JPW1
MANAGER -1 -1 BRN
+12VP UPPER
FAN HTR8+ LEFT SIDE
JPC10 SPL10 LEFT
TS1 -2 SF -1
JPFA-1 UPPER LOWER -3 -2 BLU EMITTER
ACCESSORY POWER -5 + - ENABLE
KEY HTR8- JPC20
TS1 -2
JPFA-2 FB +12VP
ACCESSORY POWER -2 JPW4
B- JPC22 -1 BRN
TP4 (B-) -13 -3 BLK LOWER
BEAM_L
OPERATOR'S COOLING FAN OPTION LEFT
JPC18
DETECTOR
-5 -4 BLU
DGND
JPC20 JPW3
-9 -1 BRN
+12VP LOWER
JPC20 RIGHT
-10 -2 BLU
+12VP EMITTER
JPW2
JPC22 -1 BRN
-14 -2 BLK UPPER
6 BEAM_R
JPC18
RIGHT
DETECTOR
-6 -4 BLU
DGND
MODEL 4250 ONLY
S18 MAST TILT CENTERING OPTION
**MUTUALLY EXCLUSIVE WITH BOTTLERS TILT OPTION
VEHICLE
MANAGER
JPC24 JPA
-23 -1
AMBIENT
VEHICLE +5VP
T JPC24 JPT1
-7 -2 MANAGER -22 -4
DGND VR6
TILT_AIN
JPC24 JPT1 JPT5 JPT5
-5 -3 -2 -4 DGND
DGND DGND
JPC20 JPT1
AMBIENT TEMPERATURE SENSOR OPTION -5 -1 -1 +12V +5V -3
+12VP
JPT1
7 TILT_DIN
JPC22
-5 -2

Figure 1-6. Electrical Schematic - Options - Sheet 4 of 5
A B C D E F G H
VEHICLE
MANAGER
2 SEE SHEET 1
JPC12-1 JPH1-1
+5VP +5VP ANALOG INPUT
CONTROL HANDLE
+5VP
OPTION
-3 -3
TRAVEL VR1
DGND
+5VP +5VP +
0
-2 -2 SW1
LIFT VR2
-
DGND DGND
-10 -10
HORN +5VP
-4 -4
FUNCTION 4A
SW3
3 DGND
+5VP
-11 -11
FUNCTION 4B
+5VP
SW2
-5 -5
SSHIFT DGND
JOYSTICK
SW4
-8 -8
TILT
-12 -12
DGND DGND
-13
HTR6
-7 -7
H_HTR
4
JPC12-1
+5VP +5VP SWITCH INPUT
CONTROL HANDLE
+5VP
-3
TRAVEL VR1
DGND
+5VP
S3
-2
LIFT VR2
DGND
CONTROL HANDLE
DGND
-10
HORN
-4 S4
FUNCTION 4A
-11
FUNCTION 4B DGND
-5
TILT_UP S6
-6
TILT_DOWN S7 S5
-8
5 SSHIFT_LEFT
-9
S8
DGND
SSHIFT_RIGHT S9
-12
DGND DGND
JPC12-1 JPH1-11
+5VP +5VP FLEX CIRCUIT
BASED HANDLE
+5VP
-3 -13
TRAVEL VR1
+
DGND +5VP
0 SW1
+5VP
-2 -12 -
LIFT VR2
DGND
6 DGND
-10 -10
HORN +
+5VP
-4 -14 0 SW3
FUNCTION 4A
-11 -1
FUNCTION 4B -
DGND
-5 -15
TILT_UP S6
+
-6 -6 +5VP
TILT_DOWN S7 0 SW2
-8 -8
SSHIFT_LEFT S8
-
-9 -9
SSHIFT_RIGHT S9 DGND
-12 -2
DGND DGND
HTR6
-7 -7
H_HTR

Figure 1-7. Electrical Schematic - Legend - Sheet 5 of 5
LEGEND LEGEND
NOTES: IDENT. ZONE/SHEET DESCRIPTION IDENT. ZONE/SHEET DESCRIPTION

1. MAST IN FULLY LOWERED POSITION.
AUX(+) A4/1&2 STEER MOTOR POSITIVE TERMINAL
KEY SWITCH OFF, EPO NOT DEPRESSED, NOT ON DEADMAN. S3 G3/2&4 CONTROL HANDLE HORN SWITCH
AUX(-) A4/1&2 STEER MOTOR NEGATIVE TERMINAL
MOTOR ENCODER COLOR CODES SHOWN ARE FOR 4K TRACTION MOTORS (STD & EE).
S4 G3/2&4 CONTROL HANDLE FUNCTION 4A SWITCH
2.
FOR 5K TRACTION MOTORS (STD & EE), PIN 2 IS WHITE AND PIN 3 IS BLUE. EMERGENCY POWER OFF (S21) S5 G3/2&4 CONTROL HANDLE FUNCTION 4B SWITCH
EPO C7/1&2
S6 G4/2&4 CONTROL HANDLE TILT UP SWITCH FLEX CIRCUIT CONTROL HANDLE
3. THIS PART SHALL COMPLY WITH RESTRICTED SUBSTANCES QAP D20014464. S7 G4/2&4 CONTROL HANDLE TILT DOWN SWITCH
FU1 B3/1&2 POWER FUSE FOR STEER
S8 G4/2&4 CONTROL HANDLE SHIFT LEFT SWITCH
4 B+ POWER FOR AMPLIFIERS MAY COME FROM K2 (JPF1-6) OR K3 (JPF1-3). FU2 B3/1&2 POWER FUSE FOR TRAVEL
S9 G4/2&4 CONTROL HANDLE SHIFT RIGHT SWITCH
FU3 B3/1&2 POWER FUSE FOR LIFT
FU5 B7/1&2 CONTROL FUSE FOR VEHICLE MANAGER B+ S11 D3/3 HIGH SPEED LIMIT SWITCH
FU6 B6/1&2 CONTROL FUSE FOR VEHICLE MANAGER B- S12 D4/3 LIFT LIMIT SWITCH
FU7 B6/1&2 CONTROL FUSE FOR AUX. POWER B+ S15 B2/3 WORKING LIGHT SWITCH
FU8 B6/1&2 CONTROL FUSE FOR AUX. POWER B- S18 D3/3 MAST TILT SWITCH OPTION
FU12 A2/3 CONTROL FUSE FOR WARNING LIGHT & STROBE S22A, S22B D2, D3/3 BATTERY GATE SWITCHES
FU17 D5/3 CONTROL FUSE FOR HEATER FOR OCSS PHOTO EYE OPTION SF B5/3 SWITCH FOR OPERATOR'S FAN
FU20 C2/2 FUSE FOR CLIPBOARD SPOTLIGHT OPTION S35 C2/3 SWITCH FOR CLIPBOARD SPOTLIGHT OPTION
JPF1-3
JPF2-1
JPF2-2
A4/1&2
JPF1-6
FU35 F3/3 iPORT SUPPLIER WIRELESS MODULE SM STEER MOTOR
SL C2/3 SPOTLIGHT FOR CLIPBOARD
-5
HRN E6/1&2 HORN
H E6/1&2 TRAVEL ALARM SOL1 G6/1&2 LOAD/HOLD SOLENOID
SOL2 G5/1&2 LIFT/LOWER PROPORTIONAL SOLENOID
HTR6 G3, G5/1 HEATER FOR CONTROL HANDLE (INTERNAL)
SOL3 G5/1&2 DUMP SOLENOID
HTR7 D5/3 HEATER FOR RIGHT SIDE OCSS PHOTO EYE G5/1&2
SOL4 PRIORITY BYPASS SOLENOID
HTR8 D5/3 HEATER FOR LEFT SIDE OCSS PHOTO EYE G5/1&2
SOL5 PROPORTIONAL RELIEF SOLENOID
SOL6 G6/1&2 AUX SELECT SOLENOID
JPA B6/3 CONNECTOR FOR TEMPERATURE SENSOR SOL7C G6/1&2 SOLENOID FOR HIGH-SPEED ATTACHMENTS
JPB+ A3/1&2 BATTERY + SOL7R G6/1&2 SOLENOID FOR HIGH-SPEED ATTACHMENTS
JPB- A4/1&2 BATTERY - SOL9L G6/1&2 SIDESHIFT LEFT SOLENOID
JPB1 E6/1&2 POWER AMP FAN OPTION CONNECTOR SOL9R G6/1&2 SIDESHIFT RIGHT SOLENOID
JPB3 D6/1&2 BRAKE CONNECTOR-LEFT SOL10 G6/1&2 TILT SOLENOID
JPB4 D6/1&2 BRAKE CONNECTOR-RIGHT SOL11 H6/1&2 HIGH SPEED ATTACHMENT 2 SOLENOID
JPC3 F5/1&2 USB CONNECTOR ON VM SPL1 E4/1&2 SPLICE

JPC4 D5/3 OPTIONAL LEVER #1 CONNECTOR SPL2 F4/1&2 SPLICE
JPC6 F5/1&2 CONNECTOR ON VM SPL3 F4/1&2 SPLICE
JPC9 F4/1&2 CONNECTOR ON VM FOR FLASHWARE SPL4 D2/1&2 SPLICE
JPC10 F4/1&2 CAN; DIGITAL INPUTS & OUTPUTS CONNECTOR ON VM SPL5 D4/1&2 SPLICE
JPC12 G3, G4/1&2 HANDLE CONNECTOR ON VM SPL6 D3/1&2 SPLICE
JPC12A D6/3 CONNECTOR FOR LEVER OPTION HARNESS SPL7 E5/1&2 SPLICE
JPC12B E6/3 CONNECTOR FOR LEVER OPTION HARNESS SPL8 E3/1&2 SPLICE
JPC14 F4/1&2 B+, B-, CAN COMMUNICATIONS CONNECTOR ON VM SPL9 C5/1&2 SPLICE
JPC18 F5/1&2 COIL DRIVERS CONNECTOR ON VM SPL10 F4/3 SPLICE
JPC20 G6/1&2 PROPORTIONAL COIL DRIVERS ON VM SPL11 B3/3 SPLICE
SPL12 E5/1 SPLICE
JPC22 F2/1&2 DIGITAL INPUTS CONNECTOR ON VM
JPC24 F2/1&2 ANALOG INPUTS CONNECTOR ON VM
JPD1 F5/1&2 DISPLAY CONNECTOR

JPD2 E5/1&2 DISPLAY CONNECTOR FOR OVERLAY
JPDS E7/1&2 CONNECTOR FOR DEADMAN B4/1&2
STR STEER POWER CONTACTOR
JPFA B5/3 CONNECTOR FOR OPERATOR FAN SW1 H2/1 CONTROL HANDLE HORN SWITCH
OPTIONAL
JPF1 B6/1&2 B- AUX POWER, B+ POWER AMPS CONNECTOR ON FUSE/RELAY CARD SW2 H3/1 CONTROL HANDLE ANALOG PUSHBUTTON FOR FUNCTION 4B
ANALOG
JPF2 C5/1&2 B+ KEY SWITCH RELAYS CONNECTOR ON FUSE/RELAY CARD SW3 H3/1 CONTROL HANDLE ANALOG PUSHBUTTON FOR FUNCTION 4A
HANDLE
JPF3 B5/1&2 B- CONNECTOR ON FUSE/RELAY CARD SW4 G3/1 CONTROL HANDLE TILT/SIDESHIFT JOYSTICK
JPF4 B6/1&2 KEY SWITCH, EPO, BATTERY SENSE CONNECTOR ON FUSE/RELAY CARD
JPH1 G2, G4/1 CONTROL HANDLE CONNECTOR

JPH2 G6/1&2 CONNECTOR FOR MAST H-1(+) E6/1&2 TRAVEL ALARM POSITIVE TERMINAL
JPHT1 F2/3 MODEL 4100 HANDLE HEATER H-2(-) E6/1&2 TRAVEL ALARM NEGATIVE TERMINAL
TLE C2/1&2 TRACTION LEFT MOTOR ENCODER

TLT C2/1&2 TRACTION LEFT TEMPERATURE SENSOR
JPL1 D4/1 LIFT POWER AMP CONNECTOR
C4/1 TML D3/1&2 TRACTION MOTOR LEFT
JPL2 LIFT ENCODER CONNECTOR
TMR D4/1&2 TRACTION MOTOR RIGHT
JPL3 C4/1 LIFT MOTOR TEMPERATURE SENSOR CONNECTOR
JPL4-AC,-DC C4/1 LIFT POWER CONTACTOR CONFIGURATION CONNECTOR
TP1 B3/1&2 TIE POINT ON B+
JPRDP1 F2/3 iPORT SUPPLIER WIRELESS MODULE TP2 B3/1&2 TIE POINT ON AUXILIARY MOTOR FUSE
TP3 B3/1&2 TIE POINT ON LIFT MOTOR FUSE
JPS1 B4/1&2 CONTACTOR PANEL INTERFACE CONNECTOR TP4 A5/1&2 TIE POINT ON B-
JPS2 F2/1&2 STEERING POSITION SENSOR CONNECTOR TP5 B3/1&2 TIE POINT ON TRACTION MOTOR FUSE
JPS5 D3/3 HIGH SPEED LIMIT OPTION CONNECTOR
JPS6 D3/3 LIFT LIMIT SWITCH OPTION CONNECTOR TRE C3/1&2 TRACTION RIGHT MOTOR ENCODER
JPS13 D3/3 RIGHT BATTERY GATE SWITCH CONNECTOR TRT C3/1&2 TRACTION RIGHT TEMPERATURE SENSOR
JPS14 D2/3 LEFT BATTERY GATE SWITCH CONNECTOR
JPT1 D3/3 MAST TILT SENSING OPTION CONNECTOR D6/1&2 TERMINAL STRIP FOR ACCESSORY POWER
TS1
JPTL1, JPTR1 D2, D3/1&2 TRACTION AMP CONNECTORS C3/1
TPC TRACTION POWER CONTACTOR
JPTL2, JPTR2 D2, D3/1&2 TRACTION MOTOR ENCODER CONNECTORS
JPTL3, JPTR3 C2, C3/1&2 TRACTION MOTOR TEMPERATURE SENSOR CONNECTORS
VR1 G2, G4/1,G4/2 CONTROL HANDLE VARIABLE INPUT DEVICE FOR TRAVEL
JPWL1 B3/3 CONNECTOR FOR WORKING LIGHT VR2 G2, G4/1,G4/2 CONTROL HANDLE VARIABLE INPUT DEVICE FOR LIFT/LOWER
JPWL2 B3/3 CONNECTOR FOR WORKING LIGHT VR3 E5/3 LEVER #1 VARIABLE INPUT DEVICE
JPWL3 C3/3 CONNECTOR FOR WORKING LIGHT VR4 E6/3 LEVER #2 VARIABLE INPUT DEVICE
JPWL4 B3/3 CONNECTOR FOR WORKING LIGHT VR5 E6/3 LEVER #3 VARIABLE INPUT DEVICE
JPWL5 B2/3 CONNECTOR FOR WARNING LIGHT B2/3
WL WARNING LIGHT
JPW1 F4/3 CONNECTOR FOR OCSS-UPPER LEFT EMITTER SOUNDER E5/1&2 DISPLAY AUDIBLE ALARM
JPW2 F5/3 CONNECTOR FOR OCSS-UPPER RIGHT DETECTOR
JPW3 F4/3 CONNECTOR FOR OCSS-LOWER RIGHT EMITTER T B7/3 AMBIENT TEMPERATURE SENSOR
JPW4 F4/3 CONNECTOR FOR OCSS-LOWER LEFT DETECTOR D5/3 THERMOSTAT FOR HEATERS FOR OCSS PHOTO EYES
T-OCSS
JPW5 B2/3 CONNECTOR FOR WARNING LIGHT
FAN B5/3 OPERATOR'S COOLING FAN
JPY1 B4/3 CONNECTOR WEIGHT PRESSURE SENSOR OPTION
K1 C6/1&2 KEYSWITCH RELAY-OPTIONS

K2 C7/1&2 KEYSWITCH RELAY-SOLENIODS, ATTACHMENTS, HORN
K3 C6/1&2 KEYSWITCH RELAY, POWER AMPS
K4 C7/1&2 KEYSWITCH RELAY
LM D5/1 AC LIFT MOTOR

LME C4/1 LIFT MOTOR ENCODER
LMT C4/1 LIFT MOTOR TEMPERATURE SENSOR
LPC B3/1&2 LIFT POWER CONTACTOR
MP B4/2 DC LIFT MOTOR
PRESS B4/3 LIFT PRESSURE SENSOR
S1 D7/1&2 KEY SWITCH

S2 E7/1&2 DEADMAN SWITCH
S3 H4/1&2 CONTROL HANDLE HORN SWITCH
S4 H4/1&2 CONTROL HANDLE FUNCTION 4A SWITCH
S5 H4/1&2 CONTROL HANDLE FUNCTION 4B SWITCH
S6 G4/1&2 CONTROL HANDLE TILT UP SWITCH SWITCHED BASED CONTROL HANDLE
S7 G4/1&2 CONTROL HANDLE TILT DOWN SWITCH
S8 G4/1&2 CONTROL HANDLE SHIFT LEFT SWITCH
S9 G4/1&2 CONTROL HANDLE SHIFT RIGHT SWITCH
S10 B2/3 REVERSE WORKING LIGHT SWITCH

Figure 1-8. Hydraulic Schematic - Model 4250 - AC Lift (Sheet 1 of 3)
SIDE SHIFT
SSR SSL
Shown with Integral Sideshift,
1 SOL-9L
1 attachment ready, and optional Lift
2
AR Pressure Transducer
2 2 1
SOL-9R
SOL-7R
G2 AC
2 1
AUX-P
AC MOTOR
TACH
SOL-4
SOL-7C CB-1
M
4 3 2 1
SOL-6
TR
3 4 2 1
3 3
P1
P1 TILT
1 1 SOL-10 3
2
2 SOL-5
1 TC
2 1
100
PSI
2 SPRING CB-2
CV1 G1
STEER VALVE 1 2 1 2
CYL1
REL-1
SOL-1
M
S-RET
P MAIN LIFT
P2 1
T FREE LIFT
E
SOL-2
SOL-3
1
L R
2
FILTER 2
PRESSURE LINES
RETURN AND PILOT LINES
HYD STEER MOTOR COMPONENT BOUNDARIES
CYL-P
Model 4250 - AC LIFT

Figure 1-9. Hydraulic Schematic - Model 4150 - DC Lift (Sheet 2 of 3
SIDE SHIFT
SSR SSL
1 SOL-9L
1
2
AR
Shown with Integral Sideshift
2 2 1
SOL-9R
SOL-7R
G2 AC
2 1
AUX-P
AC MOTOR
TACH
SOL-4
SOL-7C CB-1
M
4 3 2 1
SOL-6
TR
3 4 2 1
3 3
P1
P1 SOL-10 TILT
1 1 3
2
2 SOL-5
1 TC
2 1
100
PSI
2 SPRING CB-2
CV1 G1
STEER VALVE 1 2 1 2
CYL1
REL-1
SOL-1
M
S-RET
P MAIN LIFT FREE LIFT
P2 1
T
E
SOL-2
SOL-3
1
L R
2
FILTER 2
PRESSURE LINES
RETURN AND PILOT LINES
HYD STEER MOTOR COMPONENT BOUNDARIES
CYL-P
Model 4150 - DC LIFT

Figure 1-10. Hydraulic Schematic - Auxiliary Function Options (Sheet 3 of 3)
AC
PUSH/PULL
AR
SIDE SHIFT CYLINDERS
A1 A2 SOL-11
AUX2
SOL-11 2 1 B1
SSL PB PR
SSR 4 3
B2
GB HI FLOW
1 SOL-13
2 AUX. 2
AUX1
GRIPPER 2 1 C1
AC AC 5 6
CYLINDERS
2 1 4 3
1 C2
2 4
3 HI FLOW
GR SOL-12
AUX. 1
SIDESHIFT
EXT D1
2 1
AR AR
4 3 D2
RET
CARRIAGE MOUNTED SOLENOID SIDE
USED FOR SELECTING BETWEEN TWO CARRIAGE MOUNTED SOLENOID SHIFT
4200-INTEGRAL SIDESHIFT SHOWN WITH
4250 INTEGRAL SIDESHIFT SHOWN WITH HIGH SPEED AUXILIARY FUNCTIONS FOR SIDE SHIFT & 2 AUX FUNCTIONS
PUSH/PULL ATTACHMENT
PUSH/PULL ATTACHMENT
SHEET RETAINER
CYLINDER PUSH/PULL SIDE SHIFT SSL
SIDE SHIFT CYLINDERS
SOL-11 SSR
4200-
SSR SSL
SSL PB PR
SSR
GB
1
2
AC
OPEN
AC
2
1
GR
AR CLAMP
EXT
GRIPPER
AR CYLINDERS
RET
4250 BOX
4250 CLAMP
CLAMPWITH
BOXCLAMP
4200-BOX WITHINTEGRAL
WITH SIDESHIFT
INTEGRAL
INTEGRAL SIDESHIFT
SIDESHIFT
SIDE SHIFTING PUSH/PULL ATTACHMENT
Auxiliary Function Options

Maintenance Manual Models 4150/4250: Stand-Up Counterbalanced Lift Trucks With The ACR System

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Maintenance Manual Models 4150/4250: Stand-Up Counterbalanced Lift Trucks With The ACR System

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Maintenance Manual

Models Serial Numbers

1193671B Issued: 13 Jun 2016

©2016 The Raymond Corporation.

Publication: 1193671, Issued: 13 Jun 2016 i

Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

ii Publication: 1193671, Issued: 13 Jun 2016

Document Revision History

A 15 May 2014 Initial Release

Publication: 1193671, Issued:13 Jun 2016 iii

Service Information List

RSI Number Subject Issue Date

CTB-14-008A Lift Chain Adjustment November 4, 2014

MUL-15-003 Fuse/Relay Card Troubleshooting April 7, 2015

CTB-15-004 Drive Unit Updates July 27, 2015

MUL-15-007 Electrical Troubleshooting September 10, 2015

MUL-15-008 New Pump Spline Lubricant October 1, 2015

CTB-15-008 New Brake Assembly Available October 29, 2015

CTB-15-007 New Software Release October 30, 2015

iv Publication: 1193671, Issued:13 Jun 2016

Section 1. How to Use This Manual

Publication: 1193671, Issued: 13 Jun 2016 1-1

Manual Design • 7. Component Procedures contains

1-2 Publication: 1193671, Issued: 13 Jun 2016

Interactive Electronic Technical Manuals

Blue text in the Maintenance Manual is linked

Publication: 1193671, Issued: 13 Jun 2016 1-3

Abbreviations and Symbols

CAN Controller Area Network kg kilogram(s)

1-4 Publication: 1193671, Issued: 13 Jun 2016

Abbreviations and Symbols

Term/Symbol Definition Term/Symbol Definition

Publication: 1193671, Issued: 13 Jun 2016 1-5

Abbreviations and Symbols

1-6 Publication: 1193671, Issued: 13 Jun 2016

Publication: 1193671, Issued: 13 Jun 2016 2-1

Indicates a potentially hazardous

Indicates a potentially hazardous

2-2 Publication: 1193671, Issued: 13 Jun 2016

General Safety Before working on this lift truck, always turn

Do not wear watches, rings, or jewelry when

Know the truck’s controls and what they do.

Follow the scheduled lubrication, maintenance,

Follow exactly the safety and repair instructions

Publication: 1193671, Issued: 13 Jun 2016 2-3

Clean up any hydraulic fluid, oil, or grease that

Always operate and park this lift truck indoors.

2-4 Publication: 1193671, Issued: 13 Jun 2016

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

As a battery is being charged, an

Battery electrolyte is a solution of

Keep the charging area well-ventilated to avoid

Wear personal protective equipment to protect

Publication: 1193671, Issued: 13 Jun 2016 2-5

Do not lay tools or metal objects on top of the

Make sure the vent holes in the filler plugs are

Keep batteries clean. Corrosion causes shorts

Do not allow cleaning solution, dirt, or any

2-6 Publication: 1193671, Issued: 13 Jun 2016