Maintenance Manual: Models 7500/7520 Reach-Fork Trucks

Maintenance Manual
Models 7500/7520 Reach-Fork ® Trucks
Models Serial Numbers

7500 65,001 and Up
7520
1252757A Issued: 16 February 2018

This publication, 1252757A, applies to the Models 7500/7520 Reach-Fork ® Lift Trucks,
S/N 65,001 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.
For revision information, see “Document Revision History” on page iii.
If you need assistance with your lift truck, or 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.
©2018 The Raymond Corporation.
The following terms are trademarks of The Raymond Corporation: Raymond, Auto Power Off,
Deep-Reach, Maintenance Minder, Reach-Fork, ThermaKit, iBattery, iPORT, iALERT, iCONTROL,
iWAREHOUSE, The ACR System, and Vantage Point. All other brand and product names are
trademarks or registered trademarks of their respective companies.
Models 7500/7520 Reach-Fork ® Trucks Table of Contents
Table of Contents
Document Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Service Information List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Manual Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Interactive Electronic Technical Manuals . . . . . . . . . . . . . . . . . . . . . . 1-3
Abbreviations and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Static Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Jacking Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Tie-Down for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Lift Truck Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Model Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Truck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
FlashWare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Evolution Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Maintenance Minder ™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Initial 90 Day/250 Deadman Hours (HD) Maintenance . . . . . . . . . . . 4-4
Every 180 Days or 500 HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Every 360 Days or 2000 HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Contactor Tip Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Chain Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Troubleshooting Power Amplifier Error Codes . . . . . . . . . . . . . . . . . 5-19
Hydraulic Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . 5-20
Symptom Tables: Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . 5-21
Symptom Tables: Travel Functions . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Symptom Tables: Electrical Symptoms . . . . . . . . . . . . . . . . . . . . . . 5-29
Messages, Codes, and Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Power Amp LED Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Messages and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Analog Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Input Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
Output Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-107
Publication: 1252757, Issued: 16 February 2018 i

Table of Contents Models 7500/7520 Reach-Fork ® Trucks
Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

List of Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Component Locator Photos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Special Tools, Decals, and Chassis . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Steering and Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Drive and Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85
Hydraulic Components, Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 7-107
Mast, Chain, Hose, Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-129
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Traction System Functional Operation . . . . . . . . . . . . . . . . . . . . . . . 8-2
Hydraulic System Functional Operation - Standard Lift/Lower . . . . . 8-6
Hydraulic System Functional Operation - Regen Lower . . . . . . . . . . 8-11
Electric Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Cold Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Pinout Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Lubrication Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Thread Adhesives, Sealants, and Lubricants . . . . . . . . . . . . . . . . . . . A-3
Component Specific Service/Torque Chart . . . . . . . . . . . . . . . . . . . . A-4
Torque Chart - Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Torque Chart - Straight Thread Face Seal O-Rings . . . . . . . . . . . . . . A-9
Torque Chart - Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Torque Chart - Metric (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11
Torque Chart - Standard (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12
Torque Chart - Metric (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13
Torque Chart - Thread Forming Screws . . . . . . . . . . . . . . . . . . . . . . A-14
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-15
Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-17
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
ii Publication: 1252757, Issued: 16 February 2018

Document Revision History
Revision Date Description of Changes
1252757A 16 February 2018 Initial Release
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
Publication: 1252757, Issued: 16 February 2018 iii

iv Publication: 1252757, Issued: 16 February 2018

Models 7500/7520 Reach-Fork ® Trucks Section 1. How to Use This Manual
Section 1. How to Use This Manual
Publication: 1252757, Issued: 16 February 2018 1-1

Section 1. How to Use This Manual Models 7500/7520 Reach-Fork ® Trucks
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.
• 3. Systems Overview includes general lift
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: 1252757, Issued: 16 February 2018

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
These abbreviations, acronyms, and symbols are used in this manual.
Term/Symbol Definition Term/Symbol Definition
A Ampere DC Direct Current

abbrev. abbreviation DdManH Deadman Pedal Hours
AC Alternating Current DGND Digital Ground
AGND Analog Ground diam. diameter
AM Auxiliary (Aux) Motor DMM Digital Multi-Meter
AME Aux Motor Encoder DOT US Department of
amp Ampere or amplifier Transportation
AMT Aux Motor Temp Sensor DVM Digital Volt-Meter
ANSI American National
E UL Electric Truck Type
Standards Institute
Certification Rating with
APA Auxiliary Power Amplifier
safeguards against inherent
API American Petroleum
fire and electrical shock
Institute
hazards
approx. approximately
assy assembly EE UL Electric Truck Type
aux auxiliary Certification Rating where
AWG American Wire Gauge electrical equipment is
completely enclosed
brkt bracket
EPO Emergency Power Off
BSM Battery Sensor Module
ESD Electrostatic Discharge
BSOC Battery State-of-Charge
ESDS Electrostatic Discharge
C Celsius or Centigrade Sensitive
CAN Controller Area Network
F Fahrenheit
CB Counterbalance valve
FF Forks-First
CCW Counterclockwise
Fork Ld Forks Leading (FF)
CD Coil Driver
Fork Trl Forks Trailing (TF)
CE Compensating Element
ft. foot or feet
(valve)
ft. lb. foot pound(s)
cfg configuration
FR Flow Regulator
cm centimeter
FRC Fuse/Relay Card
COP Computer Operating
FU Fuse
Program
CS Cold Storage
CV Check Valve
CW Clockwise

GA gauge m meter(s)
gal. gallon or gallons mA milliampere
gm gram(s) mm millimeter
GND ground MM Maintenance Minder ™
gpm gallons per minute mph miles per hour
MS steer motor
HOI Height Only Indicator mtg mounting
HSL High Speed Lift
HTI Height-Tilt Indicator N/A Not Applicable or Not
HTR Heater Available
N/C Normally Closed
in. inch or inches NLGI National Lubricating Grease
in. lb. inch pound(s) Institute
Nm Newton Meter
JP jack and pin connector
N/O Normally Open
K thousand
OACH Overall Collapsed Height
KeyH hours with key switch ON
OCSS Operator Compartment
kg kilogram(s)
Sensor System
kg/cm2 kilograms per centimeter
OSHA Occupational Safety and
squared
Health Association
km/h kilometers per hour
OTM over-the-mast
kPa kiloPascal(s)
oz. ounce(s)
l liter(s)
P pump or lift contactor
lb. pound or pounds
POD Priority On Demand valve
LPA Lift Power Amplifier
pot potentiometer
LPC Lift Power Contactor
psi pounds per square inch
LED Light Emitting Diode
PWM Pulse Width Modulation
Lift H Lift Hours
P/N Part Number
L/H load holding
L/L lift/lower qt. quart
LM Lift Motor
LME Lift Motor Encoder RAM Random Access Memory
LMT Lift Motor Temp sensor Regen regenerative lowering
LPA Lift Power Amplifier REL relief
LPC Lift Power Contactor RF Radio Frequency
lpm liters per minute ROM Read Only Memory
LR LPA precharge resistor rpm revolutions per minute
LS load shuttle R/R reach/retract
RSI Raymond Service
Information

S Switch @ at
SA Steer Amplifier ™ trademark
SAE Society of Automotive © copyright
Engineers + plus or positive
S/N Serial Number – minus or negative
SOL Solenoid ± plus or minus
spec specification ° degrees
SPL Splice °F degrees Fahrenheit
s/s Sideshift °C degrees Celsius
SSL Sideshift Left < less than
SSR Sideshift Right > greater than
Std Standard % percent
STR Steer Contactor = equals
SWM Supplier Wireless Module
temp temperature
TF Tractor-First
TM Traction Motor
TME Traction Motor Encoder
TMT Traction Motor Temp
sensor
TOTAL D Total Distance Traveled
TP Tie Point
TPA Traction Power Amplifier
TRAC D Traction Distance
TRAC H Traction Hours
TS Terminal Strip
T/S Troubleshoot
UL Underwriters Laboratories
UNC Unified Coarse thread
UNF Unified Fine thread
V Volts
VDC Volts Direct Current
ver. version
VM Vehicle Manager
VR variable resistor
WHLD Weight Height Limit Display

WMM Warehouse Management
Module
wrt with respect to

Models 7500/7520 Reach-Fork ® Trucks Section 2. Safety
Section 2. Safety

Section 2. Safety Models 7500/7520 Reach-Fork ® Trucks
Definitions
Definitions
This manual contains two kinds of safety
reminders:
Warning means a potentially hazardous

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

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

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

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

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

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

and inspection steps.

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

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

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

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

Battery Safety
Battery Safety Wear personal protective equipment to protect

eyes, face, and skin when checking, handling,
or filling batteries. This equipment includes
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
spark can ignite this gas, resulting in
serious damage or injury. Make sure a shower and eyewash station are
nearby in case of an accident.
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.
Read, understand, and follow procedures, A battery gives off explosive gases. Never
recommendations, and specifications in the smoke, use an open flame, or use anything that
battery and battery charger manufacturer’s gives off sparks near a battery.
manuals.
Keep the charging area well-ventilated to avoid

hydrogen gas concentration.

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 plate 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 • If you are removing or installing ESDS

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

Avoid touching the edge connectors.

Jacking Safety
Jacking Safety
Some maintenance procedures require the lift Use extreme care when the lift truck is
truck to be jacked up. To safely jack the truck: jacked up. Never block the lift truck
1. Lower the forks completely. Remove any between the telescopic and the floor.
load. Attach a chain to the top of the mast and
2. Place all controls in neutral. an overhead hoist to stabilize the mast if
jacking more than described in this
3. Block the wheels to prevent movement of procedure. Keep hands and feet clear
the vehicle. while jacking the lift truck. After the lift
4. Turn the key switch OFF and disconnect truck is jacked, place solid blocks or jack
the battery connector. stands beneath it to support it. Do not
5. If possible, stabilize the top of the mast rely on the jack alone to support the lift
with an overhead chain hoist. truck.
6. Before jacking the lift truck, examine the Figure 2-4. Correct Jacking Locations
A-frame down-travel adjustment bolt. See
Figure 2-3. If the bolt is missing, or the Jack only in
hole that it passes through is excessively these areas
worn, the A-frame will not be held in place
when the lift truck is jacked up; the
A-frame could pivot down and allow the
springs to fall out.
Figure 2-3. A-frame Down-Travel Adjustment Bolt No Jack Area
A-frame Springs
A-frame
To elevate the rear of the lift
Down-Travel truck:
Adjustment Bolt
1. Place the jack in the specified jacking
position. See Figure 2-4.
7. Place the jack under the designated
jacking points. See Figure 2-4. 2. Jack the rear of the lift truck so that the
drive tire is off the floor no more than 2 in.
(50 mm). If you must elevate the drive tire
more than 2 in., attach a suitable capacity
hoist to the lift truck at the overhead
guard.
3. Block the lift truck in place.

Jacking Safety
To elevate either side of the lift

truck:
1. Place the jack in the specified jacking
position. See Figure 2-4.
2. Jack the side of the truck so that the load
wheel is off the floor no more than 1/2 in.
(13 mm).
3. Block the lift truck in place.
NOTE: After working on a vehicle, test all
controls and functions to make sure
they operate correctly.

Tie-Down for Transport
Tie-Down for Transport

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

Welding Safety
Welding Safety • Test for shorts to frame (refer to

Troubleshooting). Correct any shorts
before you weld.
• Clean the area to be welded.
• Protect all lift truck components from
Flame cutting or welding on painted heat, weld spatter, and debris.
surfaces can produce potentially • Attach the ground cable as close to the
harmful fumes, smoke, and vapors. weld area as possible. Do not attach the
Before you do flame cutting or welding, ground cable to fasteners or other
remove the coating in the area where removable components.
the operation will occur.
• Disconnect all electrical connectors from
circuit cards before doing any type of
Coating removal can occur by
electric resistance welding.
mechanical and/or chemical methods.
Perform flame cutting and/or welding • Do not weld near electrical components.
only in well ventilated areas. • If you must weld near the battery
compartment, remove the battery from the
Before working on this lift truck, make sure lift truck.
that:
• Fire protection equipment is nearby.
• You know where the nearest eyewash
station is.
Disconnect the battery before you

attempt to inspect, service, or repair the
lift truck. Discharge all power amplifier’s
internal capacitor by jumpering the +
and – terminals with a 100 ohm 25W
resistor.

Models 7500/7520 Reach-Fork ® Trucks Section 3. Systems Overview
Section 3. Systems Overview

Section 3. Systems Overview Models 7500/7520 Reach-Fork ® Trucks
Introduction
Introduction
This manual provides information for
maintenance and repair of Models 7500/7520
Reach-Fork ® 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 nearest authorized
Raymond Sales and Service Center.

Lift Truck Specifications
Lift Truck Specifications

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

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

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

Serial number (see Note below)
Raymond model Approx. weight of truck

with heaviest battery
Nominal battery voltage installed, minus load
and operator
Approx. weight of
truck minus battery,
load, and operator
*Maximum battery
weight for this truck
*Minimum battery
weight for this truck
Power rating of battery
Load center dimensions Maximum load
capacities for this truck
*Battery weight must be between the minimum and maximum weight
NOTE: The lift truck serial number may also be

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

Model Designations
Model Designations Table 3-2. Configuration Codes

Config. Lift/Lower
Model Stance
Code System
Mast Series AC AC motor - Fore/Aft
BC standard lift/lower Dock
The model number includes the model and the 750
AD AC motor - HSL Fore/Aft
mast series designation. and Regen lower
BD Dock
Table 3-1. Mast Series Designation AC motor - HSL
AD
and Regen lower
Max Load
Model(s) Mast Forks Carriage AC motor - HSL, Fore/Aft
Lowered AE Regen lower and 32
in. wide mast
3500 lb. 752
7500 R35TT AC motor - HSL
(1587 kg) BD
Standard and Regen lower
4500 lb.
R45TT AC motor - HSL, Dock
7500 (2041 kg)
7520 BE Regen lower, and
3200 lb.
DR32TT Deep-Reach ® 32 in. wide mast
(1451 kg)
Serial Number
The complete truck serial number consists of a
three-digit model abbreviation, two-digit year of
manufacture, two letter configuration code, and
a six-digit serial number.
752-18-AD 123456
Model (7520) Serial number
Year of manufacture (2018) Configuration code
Configuration Codes
The first letter of the configuration code

identifies operator stance:
• A = Fore/Aft
• B = Dockstance
• C = Sit/Stand
The second letter of the configuration code

identifies the type of lift system:
• C = AC Lift
• D = High Speed Lift (HSL) w/Regenerative
(Regen) Lower
• E = HSL w/Regen Lower and 32 in. wide
mast

General Information
General Information
Battery Specifications
Weight Max
Width (in.) lb. (kg) Hours Amp
Min Max Hours
2000 2300
16.5 930
(908) (1044)
2300 2600
18.5 6 1085
(1044) (1180)
2600 2900
21.5 1240
(1180) (1315)
UL note 583 specifies that a battery should

have no more than 0.5 in. (13 mm) movement in
any horizontal direction.
Fluid Capacities
Hydraulic
Model Drive Unit
Reservoir
9.4 gal.
7500
0.92 gal. (35.6 liters)
(3.5 liters) 11.5 gal.
7520
(43.6 liters)
Refer to “Lubrication Specification Chart” on

page A-2.

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
Reach-Fork Lift Truck Installation Guide
P/N 1158774.

FlashWare
FlashWare the key switch OFF, connect cable

P/N 1120332/XXX to a USB port on the
device and the P3 connector on the
Overview manager. See Figure 3-2.
• Serial to Serial - this method requires a
FlashWare allows you to update software, view surge protector (P/N 154-010-801) to be
and configure options on the lift truck through connected in series with the cable to
the following features: protect the device. With the key switch
• Update Vehicle Manager software OFF, connect cable P/N 610-809/201 to a
serial port on the device and the J9
• Clear Primary Memory connector on the manager. See Figure 3-2.
• Clear Vehicle Manager • USB to Serial - this method requires the
• Reset factory default settings correct drivers to be installed on the
• Update Power Amplifier software device. With the key switch OFF, connect
cable P/N 610-809/W7P to a USB port on
For more detailed FlashWare information, click the PC and the J9 connector on the
on Help and select Help Topics from the menu Vehicle Manager. See Figure 3-2.
bar.
Figure 3-2. Truck FlashWare Connections
FlashWare can be installed on any
Serial connector (J9) USB connector (P3)
IBM-compatible PC. The PC 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.
If you are a Raymond Sales and Service Center

technician, obtain FlashWare from the
Raymond Portal software download site.
To install FlashWare on the PC, double-click the

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

There are two methods available to connect the
device to a manager:
• USB to USB - this method requires the
correct drivers to be installed on the
device. Typically, this type of connection is
much faster than a serial connection. With

FlashWare
Starting FlashWare
1. With the key switch ON, double-click the
FlashWare icon on the main desktop
screen or navigate via Start > Programs >
FlashWare. The truck opening screen
appears. See Figure 3-3.
Figure 3-3. Truck Opening Screen
NOTE: When entering or using FlashWare, it is

normal for a 50 series code to display.
2. From the menu bar, click
“Communications”, then select the
applicable connection type:
• COMx (9-pin Serial)
• COMx (USB)
NOTE: “x” numbers will 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.

Evolution Display
Evolution Display
Overview
The Evolution Display is the main Operator
interface. An LED light on the right of the
enclosure indicates when the unit is powered
ON. The Menu/Data screen is a touch screen
display that allows an operator to navigate
through the menus, enter information, and
answer questions. In certain applications, the
Navigation/Enter button, located on the dash
panel, may be more efficient. UP, DOWN,
RIGHT, and LEFT arrows allow navigation
through the display menus. The round button
in the center is the ENTER button used to make
selections or submit a response.
A Badge Reader allows operator’s to “Log In” to

iWAREHOUSE enabled trucks. Authorized
personnel must place (present) their badge near
the reader until an audible alarm (beep)
sounds, indicating a successful log in.
Figure 3-4. Display and Dash Panels
Menu/Data Touch Screen Power ON LED Video Input (optional) USB Ports
Harness
Connection
(JBD1)
Fore/Aft Dash Panel Dockstance Dash Panel
Badge Reader Navigation/Enter Button Badge Reader Navigation/Enter Button

Evolution Display
Dashboard
The Dashboard screen is displayed after
SelfTest and the Electronic Key (if enabled) is
entered.
Legend:
1. Menu Button
2. Time
3. Date
4. Load Weight
5. Communication Status icons
6. Battery State-of-Charge icon
7. Alert icon
8. Travel Speed icon
9. Hour meters
Not shown
Fork Height icon (optional)
Ambient Temperature (optional)
*Task Selection icon
*Mailbox
*Log In icon
*Log Out icon
* = iWAREHOUSE must be enabled
The information displayed on the Dashboard • Server - indicates communication is

screen is dependent on the options that are established with the iWAREHOUSE
enabled on the truck. The Dashboard screen RED server when illuminated
can contain/display the following: (iWAREHOUSE)
• Menu button (upper left of screen) - use to • Truck - indicates communication is
access Program Mode and sub-menu established with the truck’s Vehicle
items Manager when illuminated
• Time • Battery State-of-Charge icon
• Date • Alert icon - The Alert icon turns red,
• Load Weight icon (optional) flashes, and a banner containing an alert
message scrolls below the menu bar. Alert
• Communication status icons (upper right messages indicate fault codes and
of screen) informational messages.
• Bluetooth - indicates communication • Travel Speed icon
is established with the selected
Bluetooth device when illuminated • Hour Meters
• USB - indicates a flash drive (USB • Fork Height icon (optional)

stick) is plugged in to one of the two • Ambient Temperature (optional)
USB ports when illuminated • Task Selection icon (iWAREHOUSE)
• WiFi - indicates WiFi communication • Mailbox (iWAREHOUSE)
is established with the selected network
when illuminated (iWAREHOUSE) • Log In icon (iWAREHOUSE)
• Cellular - indicates Cellular • Log Out icon (iWAREHOUSE)

communication is established with the
selected network when illuminated
(iWAREHOUSE)

Evolution Display
Audio Tones
The lift truck signals various situations by

using different audio tone patterns.
• A single tone (chirp) occurs when the
enter button is used to enter a value in a
Program Mode.
• A double tone (high/low) indicates the
system has detected a fault condition. One
of the PC contactors may be de-energized
(open). Travel, lift/lower, and auxiliary
functions are disabled.
• A triple tone (high/medium/low) indicates
one of the following:
• Travel performance limitation: Travel
speed is limited to 1 mph (1.6 km/h).
Lift/lower, auxiliary functions, steering,
and horn all operate normally.
• Traction system shutdown: Travel is
disabled. Lift/lower, auxiliary
functions, steering, and horn all
operate normally.
• Lift system shutdown: Lift is disabled.
Lower, travel, steering, and auxiliary
functions all operate normally.
• A descending “arcade” tone indicates a
password or electronic key was entered
incorrectly.

Passwords
Passwords Entering a Password,

Superword, or Electronic Key
A password can be one to eight characters long
with any combination of letters, numbers, When prompted to log in, enter a valid
and/or spaces. A password of all spaces is not Password, Superword, or Electronic Key using
permitted. the alpha/numeric keys on the “Log In” screen.
Then select Enter in the upper right of the
screen.
Password
Password allows access to Program Mode,
however, not all items can be accessed. It is
intended for customer use in setting
performance parameters within those features
purchased with the lift truck. Factory default
Password is 1.
Superword
Superword allows access to all Program Mode
items. Superword is intended to limit service
access to qualified and trained service
To set or change a Password,
technicians. Superword, or Electronic Key
1. Select Menu on the Dashboard screen.
It is strongly recommended that, during
installation, you change the Superword from 2. Select Enter Program Mode.
the factory default to a code known only to the 3. Enter the current password and select
Sales and Service Center and/or owner so that Enter.
access to all Program Mode items is limited to
NOTE: Superword must be entered to set or
approved personnel. Record the new Superword
change a Superword or Electronic Key.
in a safe place. If this code is lost or forgotten, a
technician must reset the lift truck to factory 4. Select one of the following:
default settings. This requires the • Settings > Edit Password
reconfiguration of most variable settings.
Factory default Superword is 2. • Settings > Edit Superword
• Settings > Electronic Key
Electronic Key (optional) NOTE: Up to 20 different electronic keys can be
assigned.
Electronic Key is a software feature that allows
5. Enter the new password and select Save.
the customer to assign a unique password
(electronic key) to a specific operator. When the 6. Record the new password and keep it in a
key switch is turned ON, the operator is secure location.
prompted to enter his/her electronic key. Run
Mode cannot be entered unless a correct
electronic key is entered. Up to 20 different
electronic keys can be assigned. Factory default
Electronic Key is 3.

Modes of Operation
Modes of Operation
Overview
This lift truck has two modes of operation: Run
Mode and Program Mode. Run Mode is the
normal operating mode. Program Mode permits
configuration, calibration, and diagnostic
testing (service).
Run Mode
At power ON, a number of internal checks
(SelfTest) are performed. Upon a successful
completion of SelfTest, Run Mode is entered
and the Dashboard screen is displayed. For
information on the Dashboard, refer to
“Dashboard” on page 3-10.
NOTE: Run Mode is also entered when the lift
truck exits Program Mode.
To display the Run Mode menu:

1. Select Menu in the upper left corner of the
Dashboard.
2. Select the desired menu item within the

Run Mode menu.

Modes of Operation
Run Mode Menu

Run Mode Menu
Item Sub-Item Values Description
Log In screen
Enter Program Mode Cancel
Enter
Truck Serial Number yr-XXXXXX Lift truck serial number
Camera Activates video feed from optional Vantage Point ® Integrated camera when travel speed is less than 2.5 mph
(optional) (4 km/h).
Key Hours Total hours key switch has been turned ON
Travel Hours Total hours spent traveling
Hour Meters Deadman Hours View only Total hours on deadman
Lift Hours Total hours spent lifting
Travel Distance Total distance traveled
Display Software: x.x.x Display application software version
Display Serial Number: xxxxxxxxxx Display serial number
Vehicle Manager: xx.xx VM software version
Traction Power Amplifier
Software xx.x
Boot Block xx.x TPA software versions
Version Control Language xx.x
Parameter Block xx.x
Lift Power Amplifier
Software xx.x
Version Boot Block xx.x LPA software versions
Aux Power Amplifier (Regen Lower only)
Software xx.x
Boot Block xx.x APA software versions
OS Version x.x.x Display operating system software version
OS Build Date day/month/date/hr/min/sec/year Display operating system build date
Machine Name raymond-gdm

Modes of Operation
Program Mode 4. Select the desired menu item within the

“Program Mode” menu.
Use Program Mode for configuration,
calibration, and diagnostic testing of the lift
truck. A password is required to enter Program
Mode. See “Passwords” on page 3-12.
To enter Program Mode:

1. Select Menu in the upper left corner of the
Dashboard.
2. Select Enter Program Mode.
3. Enter the current Password or Superword

and select Enter.

Modes of Operation
Program Mode Menu

Program Mode Menu
Superword is required for items listed with an asterisk (*).

Exit Program Mode Exits Program Mode and returns display to Dashboard Screen.
Truck Serial Number yr-XXXXXX Lift truck serial number
Camera Activates video feed from optional Vantage Point ® Integrated camera when travel speed is less than 2.5 mph
(optional) (4 km/h).
Month/Day/Year
Date Select display style and set date.
Year/Month/Day
12 Hour Clock
Time Select display style and set time.
24 Hour Clock
English (default)
Units Select display units of measure.
Metric
English (default)
Language Spanish (if enabled via FlashWare) Select display language.
French (if enabled via FlashWare)
Set maximum travel speed allowed prior to
7.5 mph (default) communication between VM and Evolution
Display. Range: 0.0 to 7.5 mph (0.0 to 12 km/h)
*Init speed
Note: A 0 mph setting disables lift, auxiliary functions, and does not disengage the electric
brake. Raymond recommends that Init speed be set to 0.5 (0.8 km/h) to prevent operation
without being logged in.
Set maximum travel speed allowed when
communication between VM and Evolution
7.5 mph (default)
Display is interrupted.
Settings Range: 0.0 to 7.5 mph (0.0 to 12 km/h)
*Error speed
Note: During an Error speed condition where the Error speed is greater than the operator
speed, the operator speed setting limits the truck speed. Raymond recommends that Error
speed be set to 1.0 mph (1.6 km/h).
Edit Electronic Key Electronic Key 1-20
Enter/edit up to 20 different electronic keys.
(optional) 3_______
Edit Password 1_______ Edit current Password.
*Edit Superword 2_______ Edit current Superword.
Travel Meter Enabled
*Calculated Travel Enable
Meter Disable
Travel Meter Value Range: 0 - 160000 hrs
Set amount of time allowed before truck is
*Key Alarm Delay xxsec
automatically turned OFF.
Memory Reset
*Device Memory Reset the memory
Allows reset of Evolution Display memory.
Reset OK
Cancel
Reset Screen Calibration

Modes of Operation
Program Mode Menu


Key Hours Total hours key switch has been turned ON
Travel Hours Total hours spent traveling
Hour Meters Deadman Hours View only Total hours on deadman
Lift Hours Total hours spent lifting
Travel Distance Total distance traveled
Truck Tractor First Set maximum travel speed.
8.0 mph (default)
Max Speed Range: 0.0 to 8.0 mph (0.0 to 12.8 km/h)
Truck Forks First Max Set maximum travel speed.
8.0 mph (default)
Speed Range: 0.0 to 8.0 mph (0.0 to 12.8 km/h)
Hard (default)
Truck Max
Medium Select travel acceleration type.
Acceleration
Soft
Height Switch 1 Set maximum travel speed at Height Switch 1.
3.5 mph (default)
Speed Limit Range: 0.0 to 3.5 mph (0.0 to 5.6 km/h)
Height Switch 2 Set maximum travel speed at Height Switch 2.
Speed Limit 1.8 mph (default)
Range: 0.0 to 1.8 mph (0.0 to 2.9 km/h)
(optional)
Set height at which speed is reduced to Height
*Height Switch 2
OACH (default) Switch 2 configured speed limit value.
Height (optional)
Range: OACH to maximum elevated height
Travel Un-Nested Speed Set maximum travel speed with forks extended
3.5 mph (default)
(optional) Range: 0.0 to 3.5 mph (0.0 to 5.6 km/h)
Enabled (default) Fork Nested Switch (S14) tamper protection
*WatchS14
Disabled feature
Disable Limits or disables travel based on state of input
*Customer Interlock
Enable to the VM (must be enabled in FlashWare).
Travel (optional)
Customer Interlock Travel Speed Range: 0.0 to 7.5 mph (0.0 to 12 km/h)
Long (default)
Select type of coast after directional/speed
Coast Medium
control is released.
Short
Enable (default) Enable/disable Travel Alarm.
*Travel Alarm Tractor
Disable Set Travel Alarm activation speed.
First (optional)
Alert Speed Range: 0.0 to 8.0 mph (0.0 to 12.8 km/h)
Enable (default) Enable/disable Travel Alarm.
*Travel Alarm Forks
Disable Set Travel Alarm activation speed.
First (optional)
Alert Speed Range: 0.0 to 8.0 mph (0.0 to 12.8 km/h)

Modes of Operation
Program Mode Menu


Create New Create new Vertical Hold (VH) Position
Clear Delete existing VH Position
Vertical Hold Config Modify Name Modify existing VH Position name
(optional) Enter Height Enter height for new VH Position
Learn Height Lift forks to desired VH height and select
“Learn Height” for new VH Position
Standard Bypass (default) Press and hold UP arrow to bypass limit.
*Lift Bypass
Alternative Bypass Press and release UP arrow to bypass limit.
(optional)
No Bypass No bypass allowed.
Set height at which first lift cutout occurs.
*Lift Limit 1 (optional) OACH (default)
Set height at which second lift cutout occurs.
*Lift Limit 2 (optional) OACH (default)
Set maximum lower speed.
*Max Lower Speed 73% (default)
Range: 50 to 100%
Lift
Hard (default)
Lift Acceleration Medium Select type of lift acceleration.
Soft
Hard (default)
Lift Deceleration Medium Select type of lift deceleration.
Soft
Hard (default)
Lower Acceleration Medium Select type of lower acceleration.
Soft
Hard (default)
Lower Deceleration Medium Select type of lower deceleration.
Soft
Disable (default)
*Customer Interlock Limits or disables lift based on state of input to
Enable
Lift (optional) the VM (must be enabled in FlashWare).
Customer Interlock Lift Speed

Modes of Operation
Program Mode Menu


Select reach/retract speed.
1 Speed (default) Single speed reach/retract
2 Speed low/high Two speed reach/retract: faster speed
enabled by pushing opposite function button
Reach:
while forks are in motion.
2 Speed high/low Two speed reach/retract: slower speed
enabled by pushing opposite function button
while forks are in motion.
*Reach Time Out: 9 sec (default) Set amount of time before function times out.
Range: 0 to 60 sec.
*Tilt Time Out: 4 sec (default)
*SideShift Time Out: 4 sec (default) “Attachment” must be enabled in FlashWare
Carriage *Max High Reach 73% (default) Set max. high reach speed. Range: 0 to 100%
*Max High Retract 75% (default) Set max. high retract speed. Range: 0 to 100%
High Speed Reach
100% (default)
High Speed Reach Switch 1 Set reach speeds (based on value set in Max
Reach Speed
100% (default) High Reach). Range: 0 to 100%
Low Speed Reach
100% (default)
High Speed Retract
100% (default)
High Speed Retract Switch 1 Set retract speeds (based on value set in Max
Retract Speed:
100% (default) High Retract). Range: 0 to 100%
Low Speed Retract
100% (default)
Lift Cutout BSOC value at which lift cutout occurs (allows

20% (default) lift truck to travel to charging station).
Battery BSOC Reset % of charge a new battery must exceed for
75% (default) BSOC display to reset to new battery.
Truck Battery Weight Weight of battery installed in truck.

Modes of Operation
Program Mode Menu


Log holds up to 20 errors in order of
Error Log View Error Log
occurrence.
OK Clear error log entries.
Clear Error Log
Cancel Do not clear error log entries.
A “#” symbol in the error log indicates a power amplifier sub-code. Refer to “Troubleshooting Power Amplifier Error
Codes” on page 5-19 for more information.
All Tests
“Insert USB Now”
“Swipe Badge Now” Activates all Display related system tests.
“Press Each Button”
“Testing PLC Communication”
Memory Test
“Testing Memory Do Not Remove Activates Display Memory test.
Power”
USB Test
Tests USB ports on Display.
“Insert USB Now”
System Tests Badge Reader Test
Tests badge reader.
“Swipe Badge Now”
Button Test
Tests Navigation/Enter button.
“Press Each Button”
Battery Test
Tests backup battery in display.
“Testing Battery”
*Service
WiFi Test
Tests Display WiFi.
“Testing WiFi”
PLC Test Tests Power Line Communication for optional
“Testing PLC Communication” Battery Sensor Module.
Display Multiple Test
Diagnostics Analog
“Check the Boxes of the Tests You Wish
Analog
to Display (Up to 4 choices)”
Run
All Analog Tests Are Displayed See “Active Maintenance Mode” on
page 3-24. See “Electrical Test Summary List”
Display Multiple Test on page 6-31.
Diagnostics Input
“Check the Boxes of the Tests You Wish
Input
to Display (Up to 4 choices)”
Run
All Input Tests Are Displayed
“Warning Jack Up the Drive Wheel
Press Ok When Ready” See “Static Maintenance Mode” on page 3-23.
Output “Run Output Test by Checking the Box See “Electrical Test Summary List” on
OR Selecting the test enabling it and page 6-31.
using the tilt button to ramp”
OK Clears OCSS log entries.
Clear OCSS Count
Cancel Retains OCSS log entries.

Modes of Operation
Program Mode Menu


Restores factory values to all settings except:
Password and Superword
Electronic Key
Error Log, Lift Limit Height(s), Max High Reach
Reset Trucks memory (This Operation
and Retract Speeds, Height Switch 2
Results In Truck Reboot)
*Reset Defaults Disables: Maintenance Minder and Auto Off
OK
Restores factory values only if Program Mode
Cancel
was entered with Superword:
Battery Reset
Lift Cutout
Travel Alarms (TF and FF)
Enable Enable Auto Power Off feature.
Disable Disable Auto Power Off feature.
Auto Off Time Select amount of time before truck is
1 Min automatically powered OFF.
Auto Off 2 Min NOTE: Auto Power Off shuts down truck only
Configuration 3 Min when truck is in Run Mode.
4 Min
5 Min
10 Min
Enable Enable Maintenance Minder.
Disable (default) Disable Maintenance Minder.
Reset Resets internal timer to current deadman
Reset the Maintenance minder timer? pedal hours (restarts interval counter).
OK
Cancel
Maintenance Minder Message Only Enable/Disable “Message Only” reminder and
Enable
set interval from 50 to 500 deadman hours.
Disable
Interval (default = 250 hours)
Message and Lift Cutout
Enable Enable/Disable “Message” reminder with lift
Disable cutout and set interval from 50 to 500 deadman
Interval (default = 250 hours) hours.
“Return handle to neutral Press OK
Button”
Controls
OK
Cancel
“Lower carriage to the floor, then lift 4
*Learn inches, Press the horn Button when
Weight
Done”
Cancel
“Crack lower control, when Carriage
Lower starts to slightly move, press horn”
Cancel
*OCSS Count
Identifies number of times the OCSS beam has been interrupted.
(optional)

Modes of Operation
Program Mode Menu


Display Software: x.x.x Display application software version
Display Serial
xxxxxxxxxx Display serial number
Number:
Vehicle Manager: xx.xx VM software version
Traction Power
Amplifier
Software xx.x
Boot Block xx.x TPA software versions
Version Control xx.x
Language
Lift Power Amplifier
Software xx.x
Version
Boot Block xx.x
LPA software versions
Language
Aux Power Amplifier (Regen Lower only)
Software xx.x
Boot Block xx.x
APA software versions
Language
OS Version x.x.x Display operating system software version
OS Build Date day/month/date/hr/min/sec/year Display operating system build date
Machine Name raymond-gdm

Modes of Operation
Service Menu
Error Log
By entering Static Maintenance Mode,
The Error Log stores the last twenty error codes you are disabling the safety circuits.
recorded on the lift truck. Entries are stored in Therefore, you must take extra
order of occurrence, with the most recent error precautions while in Static Maintenance
first. Mode. Follow all instructions in this
manual for each test. If you are unsure
To access the Error Log: how to conduct a test while in
Maintenance Mode, STOP: Do Not
1. Enter Program Mode. Refer to “Program Proceed with the test. Contact an
Mode” on page 3-15. authorized Raymond Sales and Service
2. Select Service from the Program Mode Center.
menu.
3. Select Error Log from the Service menu. While performing Output Tests, elevate
the drive tire off the floor. See “Jacking
• If no errors are stored, the message No Safety” on page 2-9.
Errors in Log appears in the display.
• If errors have been logged, use the To Place the Lift Truck in Static Maintenance
scroll bar to scroll through the list. Mode:
To clear the Error Log, select Clear Error 1. Enter Program Mode with Superword.
Log from the Service Menu, then OK or Refer to “Program Mode” on page 3-15.
Cancel. 2. Select Service from the Program Mode
menu.
Static Maintenance Mode 3. Select the desired test category from the
Service menu: Analog, Input, or Output.
Static Maintenance Mode allows testing of
individual circuits while the lift truck is NOTE: When Output is selected, the following
standing still. You can use Static Maintenance message is displayed:
Mode for most tests.
WARNING: Jack Up The Drive Wheel,
Press Enter When Ready...
After you jack up and block the lift

truck, respond to the Ready prompt by
selecting Enter.
Test results are displayed to the right of the test

as soon as you select the test.
You must manually start Output tests. Select

the desired test number by scrolling and
highlighting the test.
O01 STR Tgl Off
Press the enter button. The Display shows the

test results to the right of the test number.
O01 STR Tgl On

Modes of Operation
Use the enter button to toggle the test.
O01 STR Tgl Off
To exit Output test, press the left button.
Active Maintenance Mode
Active Maintenance Mode allows circuits to be

tested during normal lift truck operation. You
can use Active Maintenance Mode for all analog
and digital input tests.
Up to four Analog tests and four Input tests can

be selected to run simultaneously in Active
Maintenance Mode. Tests can be displayed
whether you are on or off the deadman pedal.
Tests selected for Active Maintenance are stored

in memory even if the key switch is turned OFF.
To Enable a Test(s) For Active Maintenance

Mode:
1. Enter Program Mode with Superword.
Refer to “Program Mode” on page 3-15.
2. Select Service from the Program Mode
menu.
3. Select the desired test category from the
Service menu: Analog or Input.
4. Select the desired tests to run (up to 4
Analog and 4 Input).
5. Select Save.
6. To view tests, select Active Maintenance
from the Run Mode menu.
To Clear Active Maintenance Tests:

1. Enter Program Mode with Superword.
Refer to “Program Mode” on page 3-15.
2. Select Service from the Program Mode
menu.
3. Select the desired test category from the
Service menu: Analog or Input.
4. Select Clear.
5. Exit Service Mode and Program Mode.

Models 7500/7520 Reach-Fork ® Trucks Section 4. Scheduled Maintenance
Section 4. Scheduled Maintenance

Section 4. Scheduled Maintenance Models 7500/7520 Reach-Fork ® Trucks
Maintenance Guidelines
Maintenance Guidelines
Following a regularly scheduled maintenance
program:
• Promotes maximum truck performance
• Prolongs maximum truck life
• Reduces costly down time
• Prevents unnecessary repairs
Scheduled maintenance includes:

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

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

conditions, do these services more often as
specified in Table 4-1.
Table 4-1. Maintenance Frequency
Operating Service
Working Environment
Conditions Frequency
180 days or 500

Light to
An eight hour day of basic material handling hours, whichever
Moderate
comes first
• Extended heavy duty operation

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
• High temperature areas such as in steel mills, foundries, enclosed
(Type EE) applications 30 days or 100
Extreme hours, whichever
• Corrosive atmosphere such as:
comes first
• fish, meat, or poultry processing plants, tanneries, or any other
similar applications
• chlorine or salt-sea air environments
• Adverse high humidity, wet, damp, or moist conditions

Maintenance Minder ™
Maintenance Minder ™ Maintenance Minder can be set to alert the

operator when the lift truck is due for
scheduled maintenance in intervals of 50 to 500
Maintenance Minder is a feature that alerts the deadman hours. The default scheduled
operator when the lift truck is due for maintenance interval is 250 deadman hours.
scheduled maintenance.
Maintenance Minder, when enabled, monitors

deadman hours. When the time interval
between scheduled maintenance is exceeded,
the operator is informed as follows:
• One of two messages appears on the
display following the Daily Checklist
message:
• Scheduled Maintenance Due
• *Lift Cutout, Scheduled Maintenance
Due
• The audible alarm sounds the high-low
tone for approx. 5 seconds.
*Lift is not disabled until the key switch is

cycled OFF or the battery is disconnected. Lift is
disabled until Maintenance Minder is reset,
disabled, or the lift cutout option is turned OFF.
Configuring/Resetting
Maintenance Minder
NOTE: For instructions on selecting Modes of
Operation, see “Modes of Operation” on
page 3-13.
To Enable/Disable and Reset Maintenance

Minder, refer to Configuration > Maintenance
Minder in the “Program Mode Menu”.
NOTE: Maintenance Minder is disabled when
defaults are reset.
One of the two following reminders may be

selected:
• Message Only - “Scheduled Maintenance
Due” is displayed when the scheduled
maintenance time interval is exceeded.
• Message and Lift Cutout - “Scheduled
Maintenance Due” is displayed when the
scheduled maintenance time interval is
exceeded and lift is disabled the next time
the key switch is cycled OFF or the battery
is disconnected.

Initial 90 Day/250 Deadman Hours (HD) Maintenance
Initial 90 Day/250
Deadman Hours (HD)
Maintenance
4
Perform the following maintenance tasks 90 days after the lift truck is put into service or at 250 HD,
whichever comes first.
Component Task
Break free, reapply thread-locking compound (P/N 990-544), and re-torque mounting
Drive Unit
bolts to 170 ft. lb. (230 Nm).
Hydraulic
Reservoir and Change filter. Refer to “Hydraulic Filter” on page 7-87.
Manifold
Break mast to tractor mounting bolts free. Clean threads and reapply thread-locking
Mast compound (P/N 990-544). Re-torque mounting bolts. Refer to “Mating Mast to Tractor” on
page 7-164 or page 7-177.
Power
Re-torque power cable terminal nuts to 9.6 to 12.4 ft. lb. (13 to 16.8 Nm).
Amplifiers

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 tag for the lift truck. Report any lift trucks that
are running with batteries under the minimum or over the maximum allowable weight.
Battery
Inspect all battery connectors and leads for damage and cuts in protective coatings. Make
sure the battery gates are in place and not damaged. Make sure the battery has no more
than 0.5 in. (13 mm) free play in any direction.
In a open area, measure stopping distance. Traveling at 2 to 3 mph (3.2 to 4.8 km/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
Brake the load, floor, and tire conditions.
Examine for signs of oil on the pads or rotor. If oil is present, disassemble brake, clean
rotor, and replace pads.
Measure for correct air gap between armature and armature plate: 0.040 in. (1 mm) max.
See “Brake” on page 7-58.
Inspect contactor tips for burnt or pitted surfaces. Failure to replace the tips can cause
surfaces to weld together, causing unscheduled down time. With the key switch OFF and
Contactors
the battery disconnected, examine the plunger for smooth operation with no binding. If
binding occurs, the lift truck could malfunction or display intermittent fault codes.
Verify lift/lower function is smooth and controllable. Verify travel function is smooth and
Control responsive through full range of motion. Check for play in the center position of lift or
Handle(s) travel control; repair/replace control handle if necessary. Verify no codes on display.
Verify function of all switches. Make sure nylon insert is in the lift knob set screw hole.
Check free lift cylinder piston position. With forks completely lowered, make sure one
Cylinders
piston is not higher than the other.
The deadman pedal must operate smoothly with no binding. Check for correct activation
Deadman Pedal and deactivation of the deadman switch under the pedal. Refer to “Deadman Pedal” on
page 7-60.
Drain Holes Make sure the drain holes in the battery compartment are free of any debris.
Check oil level. Inspect for leaks. Make sure O-ring is present on the dipstick. Check
Drive Unit drive axle for play. Examine for drive unit radial ring wear. See “Radial Ring Inspection”
on page 7-44.
Inspect all power cables for nicks or cuts. Give special attention to those cables that are
not stationary, for example, cables to the Traction Motor. Replace any cable that is
damaged or shows signs of excessive heat. Failure to do so causes intermittent system
Electrical
shutdowns and/or electronic failures. Check the tension of the over-the-mast cables. Set
Cables
the tension on the spring at the carriage by sliding the cable grip to produce a length of
1.75 ±0.12 in. (44.5 ±3.0 mm) across the coils. Do not over tension. Tighten the cable tie
on the cable grip.
Fans Check for correct operation. Run “Test O23 - Toggle Fans” on page 6-121.

Component Task
Forks Perform fork inspection per page 4-12.
Frame and Perform a visual inspection of structural members for cracks, including but not limited to
Baselegs baselegs, main frame, and tractor.
Check bolt torque of major components (motors, pumps, brake, drive unit,
mast-to-tractor mounting bolts, overhead guard).
Hardware
Tighten any loose hardware. Replace any broken or missing hardware. Refer to torque
charts in “Appendix”.
Horn Make sure horn sounds correctly when activated.
Inspect all hydraulic hoses for leaks, nicks, cut, chafing, and bulges. Replace damaged
Hydraulic hoses as soon as possible. Inspect all fittings for leaks. Repair any leaks immediately.
Hoses Inspect over-the-mast hoses for correct tension. Make sure over-the-mast pulleys spin
freely and show no signs of wear.
Hydraulic
Check fluid level.
Reservoir
Check adjustment. Inspect for excessive stretch or wear (Tool P/N 939-10606). Lubricate.
Lift Chains
See “Chain Maintenance” on page 4-11.
Lubrication Lubricate all grease points. Refer to “Lubrication Points” on page 4-9.
Wipe old grease off mast uprights and apply new grease.
Inspect anti-rattle pads and anti-bow pads (7500 only). Anti-bow pad minimum thickness
is 0.187 in. (4.75 mm) and correct gap is 0.03 to 0.09 in. (0.8 to 2.3 mm). Examine mast
bearings and lift chain pulleys to ensure they spin freely during elevation. Inspect
Mast
carriage stops for tightness and wear. Inspect the outside of the main frame for wear,
especially if the lift truck is used in drive-in racks. Repair any grooves worn in the main
frame deeper than 1/8 in. (3 mm). Inspect rails for abnormal wear, metal flakes, or
shavings. Inspect pulleys. Make sure they spin freely.
AC - Check the cable lugs to make sure they are tight to the terminal studs. Both the
inside and outside nut should be torqued to the values listed in “Power Cable Terminal
Torques” on page 7-79. Replace any cable that shows signs of excessive heat. Check
sensor wires for sound connection and condition. Blow out the inside of the motor with
compressed air.
DC - Inspect brushes for excessive heat (discoloration of the pigtails). If excessive heat is
evident, inspect the armature circuit for loose connections. Check condition of
Motors commutator per photos on page 5-15. Inspect the brushes for even wear over the full
surface of the brush. If a brush is not contacting the complete surface, replace the
brushes. Inspect the brush rigging for damage or loose brush holders. Make sure that the
connections on the brush leads are tight. Check brush length and spring tension. Refer to
“DC Motor Service” on page 7-79. 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 to the values listed in “Power Cable Terminal Torques” on
page 7-79. Replace any cable that shows signs of excessive heat. Check sensor wires for
sound connection and condition.
Overhead
Inspect guard for physical damage. If structurally damaged, replace the guard.
Guard

Component Task
Power Make sure power amplifier heatsink fins are free of debris and that air flows freely
Amplifiers through them. Check torque of power cable hardware.
Check for electrical shorts to frame. See “Shorts to Frame” on page 5-2. Wipe
Shorts to Frame
compartments clean.
Make sure static straps are not worn or broken. Clean debris from straps. Check
resistance of resistor in standoff. Resistance must measure >200K and <250K. EE trucks
Static Straps require a phosphor bronze static strap; do not use steel braided cable on EE trucks.
Check resistance between the wire connected to the reservoir filter assembly and the
truck frame. Resistance must measure >200K and <250K.
Check that steering system function is smooth and responsive. Inspect pivot points and
bearings in the steering linkage. Inspect teeth on the steering gear and drive unit for
wear.
Check adjustment of the steerable caster. See “Steerable Caster” on page 7-24.
Steering
Lubricate the steer axle assembly.
Adjust steering snubber if necessary. Refer to “Steer Tiller Encoder” on page 7-22.
Check the gap on the steer limit switch (S11). Refer to “Steer Limit Switch (S11)” on
page 7-23.
Check all switches for correct operation and adjust as needed. Refer to “Component
Switches
Specific Service/Torque Chart” on page A-4.
Ventilation
Make sure ventilation slots in the tractor frame are open, with no obstructions or debris.
Slots
Warning Decals Replace any illegible or damaged decals.
Warning Lights Check for correct operation.
Examine for bond failure, chunking, and excessive or uneven wear.

Wheels/Tires Inspect load wheel bearings for binding or excessive play.
Inspect traction wheel axle and steerable caster wheel axle for excessive play.


4
Component Task
Drive Unit Change fluid.
Hydraulic
Change hydraulic fluid and filter. See “Hydraulic Filter” on page 7-87 and “Lift Pump
Reservoir and
Priming - Regen Lower” on page 7-89.
Manifold
Lift Pump
Separate pump and motor. Apply lubricant (P/N 1223184) to the splines.
Coupling
Steer Motor
Coupling Separate motor and gearbox. Apply lubricant (P/N 1223184) to the splines.
(Electric Steer)

Lubrication Points
Lubrication Points
Apply grease to the locations shown when
Scheduled Maintenance is performed.
4P5180009.tif
Deep-Reach
Wipe old grease off mast

uprights and apply new
grease.
Standard Reach

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

Chain Maintenance
Chain Maintenance
Lift Chain Inspection
Make sure chains are not damaged. Check the
chain for wear using a Chain Gauge
(P/N 939-10606).
Condition-Cause Chart
4
Condition Cause Maintenance Procedure
Use a chain gauge or lay the chain on a flat surface

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

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

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

Fork Inspection
Fork Inspection 2. Multiply these numbers by 0.005 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.
Figure 4-3. Fork Angle
Straightness of Blade and
Shank Shank
NOTE: This measurement can be done with the
forks on or removed from the carriage.
1. Measure the length of the blade and the
height of the shank. See Figure 4-2.
Figure 4-2. Measuring Fork Blade and Shank
Indicator
Lines
Blade
Shank
Blade

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

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

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

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

up to 4 in. (100 mm). It is not to be used
on full or lumber tapered forks. For
these forks, you must know the original
fork blade thickness and take a
measurement of the fork arm thickness.
If the difference in the measurement
exceeds 10% of the original thickness,
the fork must be removed from service.
3. Measure 2 in. (50 mm) out from the heel of
the fork. Fork Hooks
4. Place the caliper over the flanks of the fork 1. Remove the forks from the carriage.
arm blade at this 2 in. (50 mm) point. See
2. Determine the fork mounting class.
Figure 4-6.
a. Measure the height of the carriage or
Figure 4-6. Measuring Fork Blade Wear the distance between the hooks. See
Figure 4-7.
Figure 4-7. Determining Fork Mounting Class
Distance between hooks
Carriage Height
b. Compare this measurement to the table
below.
Fork Distance Carriage

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

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

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

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

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

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

Fork Inspection

Models 7500/7520 Reach-Fork ® Trucks Section 5. Troubleshooting
Section 5. Troubleshooting

Section 5. Troubleshooting Models 7500/7520 Reach-Fork ® Trucks
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:
• Save time and trouble by looking for • Accumulation of dirt
simple causes first. • Battery electrolyte leakage
• Use a Digital MultiMeter (DMM) such as a • Motor brush dust
Fluke meter for all measurements. Analog
• Motor brush leads touching the housing
meters can give inaccurate readings and
load down sensitive electronic circuits • Breakdown in insulation
enough to cause failure. Make sure meter • Bare wires
cables are connected to the correct meter
• Pinched wiring harness
jacks and that the correct function and
scale are selected. • Incorrect mounting of circuit cards
• Printed circuit boards are conformal
Shorts to frame can occur at numerous
coated. Make sure meter leads make a
locations on a lift truck, including:
good electrical connection with test points.
• Batteries
• When measuring voltage, connect the
positive meter lead to the connector or • Motors
probe point marked (+) in the test. • Cables, wiring, and harnesses
Connect the negative meter lead to the
• Heatsinks
connector or probe point marked (–).
• Bus bars
• Solenoids

• 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:
• Motors
Install another battery in the truck and
repeat this procedure from Step 1. • Heatsinks
• Power cables
If the test light does not illuminate,
• Power circuit components
continue to the next step.
• Control circuit components
3. Use a DMM set on the ampere function to
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, you get readings 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
tests.

NOTE: The functions being checked must be

energized. Example: to check for shorts
to frame in the travel circuit, travel must
be requested.
6. Use a DVM set to the current function to
measure current leakage to the truck
frame from truck B+, truck B– (not battery
B+ and B–), and all fuses and DC motor
terminals. Begin measuring at the highest
ampere scale and work toward the lowest.
If the current is less than 0.001A (1mA), go
to step 7. If the current is more than
0.001A (1mA), continue with the following
steps.
a. To identify the cause of the short to
frame, disconnect circuit components
until the leakage current reads less
than 0.001A (1mA). Do not reconnect
components one at a time, but leave
them disconnected until the leakage
current reads less than 0.001A (1mA).
Prevent disconnected terminals or
connectors from touching the lift truck
frame or other conductive surfaces.
b. The most likely areas to check are:
• Motors
• Heatsinks
• Power cables
• Power circuit components
• Control circuit components
c. Repair or replace the component(s)
causing the leakage current.
Repeat Step 6.
d. Reconnect all other components
previously disconnected, measuring
current between steps. If a reading is
greater than 0.001A (1mA) when
reconnecting a component, that
component or its wiring is bad. Repair
or replace as appropriate.
7. When, after all components are
reconnected, you get a reading less than
0.001A (1mA) there is no short to frame
condition with the truck or the battery. If
you previously removed the battery from
the truck, re-install the battery.

Battery State-of-Charge changes. Example - BSOC configured at

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

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 or

circuit card. The resistance should be <1 ohm.
Table 5-1. Fuse Chart

Fuse Amps Location Function
FU1 150 Contactor/Fuse Panel Power fuse for steering
FU2 500 Contactor/Fuse Panel Power fuse for travel
FU3 675 Contactor/Fuse Panel Power fuse for lift
FU4 100 Contactor/Fuse Panel Power fuse for Aux
FU5 15 Fuse/Relay Card Control fuse for Vehicle Manager (B+)
FU6 15 Fuse/Relay Card Control fuse for Vehicle Manager (B–)
FU7 5 Fuse/Relay Card Control fuse for aux power (B+)
FU8 5 Fuse/Relay Card Control fuse for aux power (B–)
FU9 10 Travel alarm Control fuse for travel alarm
FU11 10 In-line harness Control fuse for warning light and strobe
FU12 10 In-line harness Control fuse for working lights and fan
FU13 n/a Control Handle Thermal fuse for control handle external heater
FU14 10 ThermaKit Control Module Control fuse for ThermaKit handle and floor pad heaters
Under carriage top cover
FU15 2 Control fuse for optional Fork-Laser Module (B+)
near TS2
FU16 10 In-line harness near TP1 Control fuse for optional Fork-Laser Module (B–)
FU17 2 In-line harness near TP4 Control fuse for OCSS Heater option
FU19 2 In-line harness near TP4 Control fuse for Height Encoder heater
FU39 2 In-line harness near TP1 Power fuse for Evolution Display
Under carriage top cover
FU40 2 Control fuse for nested prox switch
near TS2
FU50 2 In-line harness near light on Control fuse for blue light
FU51 2 overhead guard Control fuse for blue light

Electrical Connections 1, 2, and 3 raised ridges at pin numbers 1, 2,

and 3. See Figure 5-1.
Terminology Figure 5-1. Molex Jack and Pin Connector
The term “connector JPx” means a mated Pin Identifier Lines

connector consisting of two connector halves. (black lines added for clarity)
One half contains male connectors, or pins (P);
the other half contains female connectors, or
jacks (J).
When you disconnect a mated JP connector,

you will have two connector halves. The
individual connector halves are designated “Jx”
and “Px.” If you cannot locate a connector
Jack Pins
designated “Jx” or “Px,” look for “JPx,” and vice
versa.
Use Table 5-2 (or the graphics beginning on
Molex connectors have ridges on the sides to page 5-10) to locate electrical connectors on the
help locate pin number 1. The short side has a lift truck.
single ridge at pin number 1. The long side has
Electrical Connector Locator Chart

Table 5-2. Connector Locator Chart
Connector Location Function/Destination
JPA Near Lift Motor Ambient Temp Sensor
JPA1 Near Aux Power Amp Aux Power Amp
JPA2 Aux Motor Encoder
Near Aux Motor
JPA3 Aux Motor Temperature Sensor
JPB+ Battery +
Above battery compartment
JPB– Battery –
JPB1 Near Traction Power Amp FAN-T
JPB2 Front center of tractor FAN-FW
Left side of operator
JPB3 FAN-DU
compartment
JPB4 Front center of tractor FAN-FW2
JPB6 Left side of Traction Motor FAN-TD
JPBD1 Display Display
JPBD2 Display USB Connector for Dash Panel
JPBR Near Traction Motor Brake
JPC2 USB Connector on VM
JPC3 FlashWare Connector on VM
JPC4 VM Secondary Handle Connector on VM
JPC6 Electric Steer Connector on VM
JPC9 FlashWare Connector on VM


JPC10 CAN-Bus Input/Output Connector on VM
JPC12 Primary Handle Connector on VM
JPC14 B+/– CAN Communications Connector on VM
JPC18 VM Coil Drivers Connector on VM
JPC20 Proportional Coil Drivers Connector on VM
JPC22 Digital Inputs Connector on VM
JPC24 Analog Inputs Connector on VM
JPD1 Connects main truck harness to display harness
Dash Panel
JPD2 Connects HTI System harness to display harness
JPD5 Cellular Modem Power for Cellular Modem
JPDPL1 Dash Panel USB Connector for Dash Panel
JPDS Right side of Traction Motor Deadman Switch
JPDV1 Evolution Display Video input from Vantage Point camera
Intermediate video cable connection to OTM cable -
JPDV2 Near Lift Power Amp
Tractor
Intermediate video cable connection to OTM cable -
JPDV3 Near Aux Manifold
Carriage
JPDV4 Vantage Point camera Vantage Point camera video output
JPE1 Steer Tiller Encoder 1
Near Main Hydraulic Manifold
JPE2 Steer Tiller Encoder 2
JPE3 Main frame near encoder Height Encoder
JPE4 Right side of Traction Motor Steer Motor Encoder
B– Aux Power, B+ Power Amp Connector on Fuse/Relay
JPF1
Card
JPF2 B+ Key Switch Relay Connector on Fuse/Relay Card
Fuse/Relay Card
JPF3 B– Connector on Fuse/Relay Card
Key Switch, EPO, Battery Sense Connector on Fuse/Relay
JPF4
Card
JPG1 Near Traction Power Amp ThermaKit Control
JPH1 Primary control handle Primary control handle connector
JPH2 Secondary Handle Potentiometer
Near secondary handle
JPH3 Secondary Handle Horn Button
JPHTA Near contactor panel Primary Handle External Heater
JPHTB Near Traction Power Amp Floor Pad Heater
JPHTC Near contactor panel Secondary Handle External Heater
JPL1 Near Lift Power Amp Lift Power Amp
JPL2 Lift Motor Encoder
Near Lift Motor
JPL3 Lift Motor Temperature Sensor


Transmit/Receive communication between Cellular
JPPP Cellular Modem
Modem and Display
JPS1 Near contactor panel Contactor Panel Interface
JPS2 Near main manifold Drive Unit Interface
JPS4 Near battery connector Mast Switch 1 Interface
JPS5 Near Lift Motor Lift Cutout Switch
JPS6 Near battery connector High Speed Travel Switch Interface
JPS10 Right side of Traction Motor Customer Input
JPS11 Near Lift Motor Main Lift Height Encoder
JPS16 Near battery connector Right Battery Gate Switch
JPS17 Near Lift Motor Left Battery Gate Switch
JPST Right side of Traction Motor Steer Limit
JPT1 Traction Power Amp Traction Power Amp
JPT2 Traction Motor Encoder
Near Traction Motor
JPT3 Traction Motor Temperature Sensor
JPTL Overhead guard Travel Light
JPW1 Working Light
JPW2 Working Light
Overhead guard
JPW3 Operator Fan
JPW5 Warning Light and Strobe
F/A - Near display bracket
JPX1 OCSS Connector
Dockstance - above VM
Sensor on main hydraulic
JPY1 Lift Pressure Sensor (CYL-P)
manifold
JP57A Impact Monitor Impact Monitor power and communication
JRDP1 Near main manifold Connector for Third Party Devices

Circuit Card Connectors
Vehicle Manager
Refer to Figure 5-2 for Vehicle Manager

connector locations.
Figure 5-2. 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
Refer to Figure 5-2 for Fuse/Relay Card

connector locations.
Figure 5-3. Fuse/Relay Card Component and Connector Location

Fuse/Relay Card physically different from the one pictured.

Inspect mounting screw in the upper left
Troubleshooting mounting hole of the Fuse/Relay Card (marked
FGND). If necessary, clean or replace this screw
Refer to Figure 5-3 on page 5-11 for Fuse/Relay
to ensure a solid connection to the frame.
Card component and connector location
information.
To test, measure the resistance from the FGND
screw to any piece of bare metal on the frame
Fuses with a DMM. Resistance should be <0.5 ohm.
Fuses for system power (FU5 and 6) and Aux

power (FU7 and 8) are present on the
Fuse/Relay Card. Refer to page 5-6 for
inspection and testing of fuses.
Relays
Relays are hard-mounted. If a relay fails, the

Fuse/Relay Card must be replaced.
Relay Circuit Possible Symptoms

Key-ON Key-ON options do not
K1
Aux Power power up with truck.
Contactors, solenoids,
Subsystem
K2 brake, horn, or fans do not
Power
operate.
Input Diodes
Amps do not power up or
Amp
K3
Power
have stopped NOTE: Remove connectors JP1 thru JP4 before
communicating. performing this test.
Keep-alive accessories for
Keep Alive
K4 Cold Storage do not To test the relay coil input diodes, locate CR5
Power
function. 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)
Inspection
side of the diode and the red probe on the
non-banded (left) side. Voltage should be
Visually inspect relay for discoloration, melting,
approximately 0.5V across each diode. An open
or other signs of overheating. If found, replace
circuit will be displayed if the diodes are tested
Fuse/Relay Card.
in the reverse direction. Replace the Fuse/Relay
Card as necessary.
Test
Perform Test O32 - Toggle Relays K1, K2, K3,

and K4 (Page 6-126). Replace Fuse/Relay Card
if necessary.
Capacitor and FGND
Problems with the filter capacitor (C3) are most

frequently observed on trucks equipped with an
RF scanner unit. Visually inspect the capacitors
for any sign of damage. The capacitors may be

Inrush Protection
A resettable fuse protects the VM battery sense

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.

DC Motors Figure 5-5. Mica Undercutting

Mica Segment
Types of DC Motors
NORMAL
There are two primary types of DC Motors (refer UNDERCUT
to Figure 5-4):
• A series-wound motor has only two
external connections because the
armature and field windings are connected High Mica
internally.
• A permanent magnet motor has two HIGH MICA
external connections. The field is produced
by an internal magnet.
The commutator must be smooth and clean to
NOTE: Field connections may be labeled A or S. provide maximum brush wear. When
Series wound motor field connections commutators are not correctly maintained,
may be labeled D. carbon dust can collect in the grooves between
the segments. This can lead to a short circuit in
Figure 5-4. DC Motor Circuits the armature.
Series-Wound Motor Permanent Magnet
Motor Remove the brushes from their box. Inspect the
S/D
contact surface and brush length. If brush
A2
MS+ surface has grooves or pit marks, it indicates a
burr on the commutator surface.
MS Good commutation is indicated by a dark

brown polished commutator and an evenly
MP polished brush wearing surface. See Table 5-3,
A1
MS– “Commutator Surfaces.”
A
If the commutator appears rough, pitted, or has
signs of burning or heavy arcing between the
Inspection commutator bars, remove the motor for
servicing.
Inspect commutator for surface condition and
high mica. Most armatures have the mica Servicing
undercut. If the armature on your motor does
not, do not attempt to cut it. Some conditions identified in Table 5-3 may be
resolved by cleaning the commutator with a
special polishing stone. Polishing the
commutator should only be attempted for these
specified conditions. Refer to “Polishing the
Commutator” on page 7-81.
Some conditions can be resolved by recutting

the commutator on a lathe. This requires
special equipment and training and should only
be performed at a qualified DC motor repair
facility.

Table 5-3. Commutator Surfaces
Condition Probable Cause Commutator Surface
Uniform coloring indicates satisfactory operation

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

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

surface. May also notice rattling or loud
operation. Frequently due to incorrect brush
Unsatisfactory
grade. Environmental conditions such as freezer
Condition-Streaky Film
operation or low humidity can be a contributing
with No Commutator Wear
factor. May be repaired with a polishing stone if
caught soon enough. Refer to “Polishing the
Commutator” on page 7-81.
Patchy colors of varying densities and shape.

Generally due to unclean operating conditions
and does not indicate damage to the commutator.
Unsatisfactory
Clean commutator with a polishing stone (refer to
Condition-Uneven Film
“Polishing the Commutator” on page 7-81) and
compressed air. Consider more frequent
scheduled maintenance intervals.
Dark areas can be isolated or regular. Indicates

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

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

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

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

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

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

in position for long periods. May also result from
operation in prolonged stall conditions. Storage
Unsatisfactory
marks are easily removed with a polishing stone
Condition-Brush Contact
(refer to “Polishing the Commutator” on
Mark
page 7-81). Stall marks should be cleaned and
inspected for damage or shorts. Motor should be
replaced if damage has occurred.
Condition is caused by high mica in every slot

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

overloaded machines or low brush pressure.
Check brush spring tension (refer to “Motor
Brush Spring Tension Inspection” on page 7-80).
Unsatisfactory
If not corrected, will result in damage to
Condition-Small Bright
commutator. May be repaired with a polishing
Spots
stone (refer to “Polishing the Commutator” on
page 7-81) if caught early and no scoring has
occurred. If damaged, motor should be replaced
or recut at a qualified repair facility.

Open Circuit Motor Test 3. If the ohmmeter indicates resistance of

less than 100,000 ohms, the motor is
An open circuit is an electrical circuit within the grounded. Clean, repair, or replace the
motor that is broken. This can be caused by: motor as necessary.
• bad brushes or brush springs
• a broken wire in field or armature winding Short-Circuited Armature
• loose or bad connections
A short-circuit in the armature causes heating
To test a motor for an open circuit: that could result in burning of:
1. Isolate the motor from the lift truck circuit • armature coil
by removing the power cables. Use two • brush wires
wrenches to avoid twisting the terminal • commutator segments
stud.
2. With the motor at room temperature, Short-Circuited Winding
connect leads of a digital ohmmeter to the
+ and – terminals of the motor. The meter A short-circuited winding is one where the
should read less than 1 ohm of resistance. insulation on the field or armature has broken
3. If the meter indicates high resistance, down at two or more points. The breakdown
check the condition of the brushes before creates a low resistance path that allows
replacing the motor. current to flow from one turn of the coil to
another adjacent coil turn, without actually
NOTE: If you find an open circuit in a flowing through the coil wire. The result is a
series-wound motor, the motor must be decrease in total resistance of the motor
disassembled by a motor rebuilding winding and an increase in the current flow.
facility to isolate the problem to the field The severity of the short circuit depends on its
or armature circuit. location.
Grounded Motor Test A shorted motor may be indicated by:

• slow or sluggish operation
In a grounded motor, an electrical circuit exists • running faster than normal
between the current-carrying conductors and
• overheating
the motor housing. This can be caused either by
direct contact or through conductive foreign • blowing a power fuse
material. • severe burning or discoloration on one or
more commutator segments every 90° of
The ground may be caused by: rotation
• insulation breakdown
These symptoms can be caused by problems
• brush leads touching the motor housing other than the motor itself, such as binding.
• build-up of carbon dust or other materials
Testing a motor for short circuited windings
To test for a grounded motor: requires special equipment at a motor
1. Isolate the motor from the lift truck circuit rebuilding facility.
by removing the power cables. Use two
wrenches to avoid twisting the terminal
studs.
2. Attach one lead of a megohm meter or
digital ohmmeter to a motor terminal and
the other lead to an unpainted surface of
the motor housing. Set the ohmmeter to
the highest scale.

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

armature) and a stator (in place of the DC field).
There is no electrical connection to the rotor;
current is induced in the rotor. The stator has
three windings staggered 120° apart, and three
external connections labeled U, V, and W. See
Figure 5-6.
Figure 5-6. 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.

Troubleshooting Power Amplifier Error Codes
Troubleshooting Power
Amplifier Error Codes
Sub-codes associated with amplifier error codes
AP, AQ, AT, D1, 5G, and 5J can be found in the
Service Mode History Log. Refer to the tables
below for their meaning and corrective action.
NOTE: Intermittent codes are most likely
caused by ESD or a short to frame.
NOTE: Hard codes indicate a component
failure.
Code AP (Traction), AQ (Aux), and AT (Lift) Sub-Codes

Sub-code Description Notes/Corrective Action
30 Cycle key switch to clear. If code does not

Amp internal software error. clear, replace amplifier and report
34 sub-code to Service Department.
36
45 Cycle key switch to clear. Check fuses, K3

Amp has unexpectedly dropped out of RUN mode. relay, and wiring to the amp. If code does
not clear, replace amplifier.
Code D1 (Aux), 5G (Traction), and 5J (Lift) Sub-Codes

Sub-code Description Notes/Corrective Action
37 Amp is active and has not received CAN messages

from the VM. Amp displays blink code 72.
Cycle key switch to clear. If code does not
45 Amp has failed to respond to VM.
clear, replace amplifier.
47 VM is active and has not received CAN messages
from the amp.
50 Cycle key switch to clear. Reload

Stored truck identity cannot be verified.
amplifier software via FlashWare.
51 Cycle key switch to clear. If code does not

Amp has failed to enter RUN mode.
clear, replace amplifier.

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

for troubleshooting, use blocks to secure
the carriage.
Use extreme care when blocking the

mast for any reason. Never remove a
block when it is supporting the mast.
Lower the carriage fully and retract the reach

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

chain hoist.
When you measure voltage at solenoids, make

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

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

contamination.
Anytime the reservoir on a truck with

Regenerative Lowering is drained and filled, the
lift pump must be primed. Refer to “Lift Pump
Priming - Regen Lower” on page 7-89.

Symptom Tables: Hydraulic Functions
Symptom Tables:
Hydraulic Functions
Refer to electrical/hydraulic schematics.
NOTE: If a component fails due to hydraulic
fluid contamination, replace the failed
component, flush, fill, and bleed the
hydraulic system. Refer to “Hydraulic
System Bleeding” on page 7-86.
Auxiliary Functions
No Auxiliary Functions Work (Reach/Retract, Tilt, Sideshift)
Possible Cause Action
Bad K2 relay circuit Troubleshoot K2 relay circuit.
Run Test O04 - Toggle AUX1 Directional Solenoid (Regen Lower)

Bad aux directional solenoid 5B or 5T
(Page 6-111) or Test O05 - Toggle AUX2 Directional Solenoid
(valve or wiring)
(Regen Lower) (Page 6-112).
Bad CV-4 Check for contamination. Replace CV-4.
Bad RV-4 Check for contamination. Replace RV-4.
Bad pump (P2) Replace pump.
All Auxiliary Functions are Slow

Incorrect hydraulic fluid for Replace hydraulic fluid with correct fluid. See “Lubrication
application Specification Chart” on page A-2.
Bad POD-1 valve Replace POD-1 valve.
Adjust aux pressure. See “Auxiliary Pressure Adjustment” on

Aux system relief pressure too low
page 7-95.
Bad LS1 shuttle Replace LS1.
Bad pump Operate lift and aux function. If aux works, replace pump.

All Auxiliary Functions are Slow - Regen Lower

Bad or mis-adjusted RV-4 Adjust or replace RV-4.
Bad pump Measure pressure.
Bad aux motor Measure current draw.
No Tilt or Tilt One Direction Only; Other Aux Functions OK

Run Test I08 - Tilt Up Switch (Page 6-73) or Test I09 - Tilt Down
Bad tilt switch (S6 and/or S7)
Switch (Page 6-74).
Run Test O07 - Toggle Tilt Solenoid (Page 6-114). If contamination

Bad tilt solenoid valve or coil, or
is found, flush, refill, and bleed hydraulic system. Swap hoses with
wiring. Check for contamination.
sideshift to check valve and cylinder.
Broken tilt cylinder pin Replace tilt cylinder pin.
Measure pressure; normal operation should be below bypass

Mechanical binding in tilt cylinder or pressure. See “Auxiliary Pressure Adjustment” on page 7-95.
carriage Binding produces higher pressures. Repair/replace cylinder or
other binding components.
Tilt cylinder leaking internally Measure pressure.
Slow Tilt; Other Aux Functions OK


Mechanical binding in tilt cylinder or pressure. See “Auxiliary Pressure Adjustment” on page 7-95.
carriage Binding produces higher pressures. Repair/replace cylinder or
Examine for binding or contamination. Swap hoses with sideshift

Bad Tilt Solenoid
to check valve and cylinder.
No Sideshift or One Direction Only; Other Aux Functions OK

Run Test I10 - Sideshift Right Switch (Page 6-75) or Test

Bad sideshift switch (S8 and/or S9)
I11 - Sideshift Left Switch (Page 6-76).
Run Test O08 - Toggle the Sideshift Solenoid (Page 6-115). Swap
Bad sideshift solenoid or wiring
hoses with tilt to check valve and cylinder.

Mechanical binding in sideshift pressure. See “Auxiliary Pressure Adjustment” on page 7-95.
cylinder or carriage Binding produces higher pressures. Repair/replace cylinder or

Sideshift cylinder leaking internally Measure pressure.
Slow Sideshift; Other Aux Functions OK


Mechanical binding in sideshift pressure. See “Auxiliary Pressure Adjustment” on page 7-95.
cylinder or carriage Binding produces higher pressures. Repair/replace cylinder or
Bad sideshift solenoid valve Repair/replace sideshift solenoid valve.
Sideshift cylinder leaking internally Measure pressure.

Reach and Retract Do Not Work or are Slow; Other Functions OK

Run Test I06 - Reach Switch (Page 6-71). Check wiring. Check
Bad reach solenoid (valve or wiring)
valve for binding.
Inspect cylinder. Measure pressure; normal operation should be

below bypass pressure. See “Auxiliary Pressure Adjustment” on
Damaged or worn reach cylinders
page 7-95. Binding produces higher pressures. Repair/replace
cylinder or other binding components.
Inspect for damage. Measure pressure; normal operation should be

below bypass pressure. See “Auxiliary Pressure Adjustment” on
Damaged or worn scissors assembly
page 7-95. Binding produces higher pressures. Repair/replace
scissors assembly or other binding components.
Switches S4 and S5 both bad (or Run Test I06 - Reach Switch (Page 6-71) and Test I07 - Retract
wiring) Switch (Page 6-72).
Reach cylinder leaking internally Measure pressure.
RV-1 bad Replace RV-1.
Reach Does Not Work; Other Functions OK

Bad reach switch (S4) Run Test I06 - Reach Switch (Page 6-71).
Retract Does Not Work; Other Functions OK

Bad retract switch (S5) Run Test I07 - Retract Switch (Page 6-72).
Lift/Lower System
No Lift - Motor Runs
Bad POD-1 valve Replace POD-1 valve.
SOL3 main relief dump valve pressure

Replace SOL3.
too low
SOL2 lift/lower valve open Run Test O12 - Ramp Proportional Lower Solenoid (Page 6-117).

No Lift - Motor Runs - Regen Lower

Measure pressure at Main Manifold
Action
Port G1.
Replace CV-1 in pump manifold. If still no pressure, replace lift

If no pressure...
pump.
If pressure is at bypass... Inspect mast and cylinders for binding.
Make sure Emergency Lower Valve is closed. Adjust or replace

If pressure is less than 1500 psi but
RV-5 in main manifold. If still no lift, replace CV-5 in main
greater than 0 psi...
manifold. If still no lift, replace lift pump.
No Lift - Motor Does Not Run

Battery below BSOC cutout setting Check battery voltage and BSOC settings.
Maintenance Minder ™ interval

Display config settings for Maintenance Minder.
exceeded with LCutout specified
Bad Lift Cutout Switch Run Test I22 - Lift Cutout Switch (Page 6-82).
Third party device not functioning

Test per third party device documentation.
correctly.
Slow Lift with No Load

Action
Ports G1 and PP.
If pressure at G3 is in bypass and

Replace POD-1 valve. If readings remain the same, replace CV-1.
pressure is low at G1...
If pressure at G3 and G1 are in

Inspect mast and cylinders for binding or bad flow limiter.
bypass...
If pressure at G3 and G1 is less than

Replace SOL3. If still slow lift, replace lift pump.
1500 psi...
Slow Lift with No Load - Regen Lower

Action
Port G1.
If pressure is at bypass... Inspect mast and cylinders for binding or bad flow limiter.
Make sure Emergency Lower Valve is closed. Adjust or replace

RV-5 in main manifold. If still slow lift, replace CV-5 in main
If pressure is less than 1500 psi...
manifold. If still slow lift, replace CV-6 in main manifold. If still
slow lift, replace lift pump.

Unable to Pick Up a Load

Bad SOL3 Replace SOL3.
Bad lift pump Check pressures. Replace pump.
Unable to Pick Up a Load - Regen Lower

Bad Relief Valve RV-5 Adjust or replace RV-5.
Bad lift pump Replace lift pump.
NV-1 (Manual Lower Valve) Close NV-1 (located on lift/lower manifold).
Slow Lower
Clogged hydraulic filter Replace hydraulic filter.
Mechanical binding in bearings or

Adjust or replace bearings. Check shimming.
telescopics
Bad lift/lower proportional solenoid

Run Test O12 - Ramp Proportional Lower Solenoid (Page 6-117).
valve SOL2
Contamination in load holding

Inspect load holding solenoid SOL1 for contamination.
solenoid valve SOL1
Plugged or malfunctioning flow limiter Replace flow limiters.
Bad CV-2 (Regen Lower) Replace CV-2.
Intermittent Lower
Perform LEARN Lower. Run Test O12 - Ramp Proportional Lower

Bad SOL2 solenoid (valve or wiring)
Solenoid (Page 6-117). Check wiring. Replace SOL2.
Bad SOL1 load holding solenoid (valve Run Test O11 - Toggle Load Hold Solenoid (Page 6-116). Check
or wiring) wiring. Replace SOL1.
Plugged or malfunctioning flow limiter

Replace flow limiters.
valves
Load Drifting/Settling
Load too large for lift truck capacity Check load weight.

Open and close NV-1 (manual lower valve) to verify it is fully seated
Regen Lower: NV-1 not fully seated and that contamination is not preventing it from closing
completely.
Regen Lower: Leaking CV-6 Replace CV-6.
Leaking or contaminated load holding Replace SOL1.

solenoid SOL1

Symptom Tables: Travel Functions
Symptom Tables: Travel

Functions
Slow or Sluggish Acceleration
Configuration:
Set Accel to “medium” or “hard.” See “Program Mode Menu” on

Accel set to “soft”
page 3-16.
Mechanical:
Worn load wheel or idler wheel assy Replace load wheel/idler assembly as required.
Debris in load wheel axle or idler Remove debris.
Dragging brake Inspect brake for correct operation.
Binding drive unit Inspect for wear. Measure current draw.
Electrical:
Check temperature and temperature sensors for traction motor

Current is limited due to high
and power amplifier. Run Test A08 - Traction Motor Temperature
temperature
(Page 6-36) and Test A10 - TPA Temperature (Page 6-38).
Slow Travel
Mechanical:
Binding drive unit Check for excessive current draw in Traction Motor.
Dragging brake Inspect brake for correct operation.
Electrical:
Incorrect configuration of speed Reconfigure the lift truck. See “Program Mode Menu” on page 3-16.
If equipped with nested switch option,

Run Test I01 - Nested Switch (optional) (Page 6-69).
bad S14 switch
Bad height encoder (causing false

Run Test I26 - Height Indicator Encoder (Page 6-88).
speed limiting)
Bad Speed Limit 1 Switch S12 Run Test I02 - 1st Speed Limiting Switch (Page 6-70).
Bad High Speed Travel Switch S25 Run Test I63 - High Speed Travel Switch (optional) (Page 6-97).

Symptom Tables: Electrical Symptoms
Symptom Tables:
Electrical Symptoms
NOTE: Reference electrical schematics.
NOTE: For intermittent issues with optional
devices such as RF Units, check the
Fuse/Relay Card “Capacitor and FGND”
on page 5-12.
Motor Overheating
Application exceeds designed

workload -- short runs with Contact Sales and Service Center Service Manager to verify truck is
plugging/acceleration or heavy-duty correct for the application.
lifting cycles
Measure battery specific gravity at cutout, after battery has

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

brushes or springs Check brush spring tension.
Cable, terminal, or wiring problems.

Replace wiring or cables as needed. Make sure motor cables are
Look for loose or discolored terminals,
torqued correctly.
loose or damaged crimps.
High motor current due to binding Inspect gearbox or pump for binding. Check brake for correct
gearbox, pump, or dragging brake operation.
Cooling fans not functioning correctly. Run Test O23 - Toggle Fans (Page 6-121).
Note: See also “DC Motors” on page 5-14 and “AC Motors” on page 5-18.
Display is Dark
FU39 is blown Replace FU39.
Make sure JPBD1 connection is secure. Check wiring to display for

No power to the display
damage.
Display is bad Replace the Display.

Symptom Tables: Electrical Symptoms

Models 7500/7520 Reach-Fork ® Trucks Section 6. Messages, Codes, and Tests
Section 6. Messages, Codes, and Tests

Section 6. Messages, Codes, and Tests Models 7500/7520 Reach-Fork ® Trucks
Power Amp LED Diagnostics
Power Amp LED

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

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

flash followed by a number of quick orange LED
flashes. The 2-digit code flashed by the yellow
LED identifies the specific fault code; one or two
flashes by the red LED indicate whether the
first or second digit of the code will follow.
Specific codes:
• Code 12: Motor phase detected shorted.
• Code 37: Motor phase detected open.
• Code 72: Amp has not received CAN
messages from the VM.

Messages and Codes Summary List

Messages
Check Battery Gates . . . . . . . . . .. . .. .. . . . . . . . . . . . . . . . . . . . . . 6-7
Incorrect Lift Amp Installed . . . . .. . .. .. . . . . . . . . . . . . . . . . . . . . . 6-7
Battery Low . . . . . . . . . . . . . . . . .. . .. .. . . . . . . . . . . . . . . . . . . . . . 6-7
Incorrect Traction Amp Installed .. . .. .. . . . . . . . . . . . . . . . . . . . . . 6-7
Incorrect Aux Amp Installed . . . .. . .. .. . . . . . . . . . . . . . . . . . . . . . 6-7
Run Lower Learn . . . . . . . . . . . . .. . .. .. . . . . . . . . . . . . . . . . . . . . . 6-7
Codes
Code 1D - APA Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Code 1H - TPA Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Code 1V - LPA Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Code 2A - Traction Motor Approaching Overtemp . . . . . . . . . . . . . . . . 6-8
Code 2E - Traction Motor Temp Sensor Out-of-Range . . . . . . . . . . . . 6-8
Code 2G - Traction Motor Phase Open . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Code 2H - Traction Motor Encoder Failure . . . . . . . . . . . . . . . . . . . . . 6-9
Code 2T - TPA Current Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Code 2U - TPA Overcurrent or Short Circuit . . . . . . . . . . . . . . . . . . . 6-9
Code 2V - TPA High DC Bus Voltage . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Code 2X - TPA Power Supply Out-of-Range . . . . . . . . . . . . . . . . . . . 6-10
Code 31- Aux Motor Approaching Overtemp . . . . . . . . . . . . . . . . . . 6-10
Code 32 - Aux Motor Temp Sensor Out-of-Range . . . . . . . . . . . . . . . 6-10
Code 33 - Aux Motor Phase Open . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Code 34 - Aux Motor Encoder Failure . . . . . . . . . . . . . . . . . . . . . . . 6-10
Code 35 - APA Current Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Code 36 - APA Overcurrent or Short Circuit . . . . . . . . . . . . . . . . . . . 6-11
Code 37 - APA High DC Bus Voltage . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Code 38 - APA Power Supply Out-of-Range . . . . . . . . . . . . . . . . . . . 6-11
Code 39 - APA Pre-Charge Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Code 44 - MPC Detected Closed When Commanded Open . . . . . . . . 6-11
Code 45 - MPC Detected Open When Commanded Closed . . . . . . . . 6-11
Code 4B - Steer Contactor Detected Closed When Commanded Open 6-12
Code 4C - Steer Contactor Detected Open When Commanded Closed 6-12
Code 4D - TPA Pre-Charge Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Code 4E - LPA Pre-Charge Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Code 57- VM Not Responding to Display . . . . . . . . . . . . . . . . . . . . . 6-12
Code 58 - OCSS CAN Communication Error . . . . . . . . . . . . . . . . . . 6-13
Code 59 - CAN Transmission Buffer Error . . . . . . . . . . . . . . . . . . . . 6-13
Code 5A - CAN Bus Error/VM for BUS_I . . . . . . . . . . . . . . . . . . . . . 6-13
Code 5B - CAN Receive Bus Error/VM . . . . . . . . . . . . . . . . . . . . . . . 6-13
Code 5G - No Communications Received from TPA . . . . . . . . . . . . . 6-13
Code 5J - No Communications Received from LPA . . . . . . . . . . . . . . 6-14
Code 5M - TPA CAN Watchdog Timeout . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 5P - LPA CAN Watchdog Timeout . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 5Q - Display Not Responding . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 61 - Mast Switch #1 Not Crossed . . . . . . . . . . . . . . . . . . . . . . 6-14
Code 63 - HS Travel and 1st Speed Limiting Switches Do Not Agree . 6-15

Messages and Codes Summary List Models 7500/7520 Reach-Fork ® Trucks
Code 64 - No Pulses Seen from Height Indicator Encoder . . . . . . . . 6-15

Code 66 - Calculated Height Greater Than Configured Height . . . . . 6-15
Code 67 - Calculated Height Does Not Match 1st Speed Limiting
Switch (S12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Code 68 - Encoder Channels Reversed or Height Encoder Error . . . 6-16
Code 6D - Pressure Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . . 6-16
Code 6F - Lift Motor Overtemp . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 6G - Lift Motor Temp Sensor Out-of-Range . . . . . . . . . . . . . . . 6-16
Code 6T - LPA Current Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Code 6W - Failure Detected in Lift Motor Speed Sensor . . . . . . . . . . 6-17
Code 6X - LPA Fault: Overcurrent . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 6Y - LPA Fault: High DC Voltage . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 6Z - FlashWare Parameters Do Not Match Stored Values . . . . 6-17
Code 79 - Regen Lower Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Code 7G - Lift Motor Phase Open . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 7X - LPA Power Supply Out-of-Range . . . . . . . . . . . . . . . . . . . 6-18
Code 80 - Primary Throttle Pot Out-of-Range . . . . . . . . . . . . . . . . . . 6-18
Code 81 - Lift/Lower Pot Out-of-Range . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 82 - Handle Heater Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Code 83 - Primary Throttle Pot Out-of-Neutral . . . . . . . . . . . . . . . . . 6-19
Code 84 - Brake - Not Applied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 88 - +5VDC Power Supply Out-of-Range . . . . . . . . . . . . . . . . . 6-19
Code 8A - OCSS Photo Sensor Fault . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Code 8F - Lift/Lower Pot Out-of-Neutral . . . . . . . . . . . . . . . . . . . . . 6-19
Code 8G - Secondary Throttle Pot Out-of-Range . . . . . . . . . . . . . . . 6-20
Code 8H - Secondary Throttle Pot Out-of-Neutral . . . . . . . . . . . . . . 6-20
Code 8J - Ambient Air Temp Sensor Out-of-Range . . . . . . . . . . . . . 6-20
Code 8L - Brake Feedback Current Out-of-Range . . . . . . . . . . . . . . 6-20
Code 8M - Internal Handle Heater Failure . . . . . . . . . . . . . . . . . . . . 6-20
Code 8N - Optional Start Switch Closed at Start-Up . . . . . . . . . . . . 6-21
Code A0 - Incorrect VM Software Version . . . . . . . . . . . . . . . . . . . . 6-21
Code AH - Bad Display Checksum . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code AP - TPA Software Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code AQ - APA Software Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code AT - LPA Software Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code AV - Primary Memory Mismatch . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code D1 - No Communications Received from APA . . . . . . . . . . . . . 6-22
Code D2 - APA CAN Watchdog Timeout . . . . . . . . . . . . . . . . . . . . . . 6-22
Code F4 - VM COP Time-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code F5 - Bad Op Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code F8 - VM COP Not Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code FE - VM Not Calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code FG - 5 and/or 12V Power Supply Out-of-Range . . . . . . . . . . . 6-23
Code FH - Battery Voltage Out-of-Range . . . . . . . . . . . . . . . . . . . . . 6-23
Code FN - Relays Did Not Open at Power Off . . . . . . . . . . . . . . . . . . 6-24
Code FP - VM Internal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Code FR - VM Config Item Out-of-Range . . . . . . . . . . . . . . . . . . . . . 6-24
Code FT - VM Internal Software Error . . . . . . . . . . . . . . . . . . . . . . . 6-24
Code FV - Display Internal Software Error . . . . . . . . . . . . . . . . . . . . 6-24
Code G0 - Steer Tiller 1 Channel A/B Fault . . . . . . . . . . . . . . . . . . . 6-25
Code G3 - Steer Feedback Prox Sensor Fault . . . . . . . . . . . . . . . . . . 6-25
Code G4 - Open Detected in Steer Control Circuit . . . . . . . . . . . . . . 6-25

Models 7500/7520 Reach-Fork ® Trucks Messages and Codes Summary List
Code G5 - Short Detected in Steer Motor Encoder Circuit . . .. . .. . 6-25

Code G7 - Steer Tiller 2 Channel A/B Fault . . . . . . . . . . . . . .. . .. . 6-25
Code GD - Open Detected in Steer Motor Encoder Circuit . . .. . .. . 6-26
Code GE - Steer Encoder Failure . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-26
Code iM01 - Display Battery Bad . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-26
Code iM02 - ESD Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-26
Code iM03 - IPM Disconnected . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-26
Code iM04 - IPM Mounted Incorrectly . . . . . . . . . . . . . . . . . .. . .. . 6-27
Code M1 - iBattery Temp Sensor Failure . . . . . . . . . . . . . . . .. . .. . 6-27
Code M2 - iBattery Current Sensor Failure . . . . . . . . . . . . . .. . .. . 6-27
Code M3 - Battery Voltage Too High . . . . . . . . . . . . . . . . . . . .. . .. . 6-27
Code M4 - Battery Voltage Too Low . . . . . . . . . . . . . . . . . . . .. . .. . 6-27
Code M5 - Power Removed from BSM . . . . . . . . . . . . . . . . . .. . .. . 6-27
Code M6 - Battery Freeze Warning . . . . . . . . . . . . . . . . . . . . .. . .. . 6-28
Code M7 - Battery Over-Temp Warning . . . . . . . . . . . . . . . . .. . .. . 6-28
Code M8 - Battery Water Level Low . . . . . . . . . . . . . . . . . . . .. . .. . 6-28
Code M9 - Incorrect Battery Weight . . . . . . . . . . . . . . . . . . . .. . .. . 6-28
Code MA - BSM Not Initialized . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-28
Code MB - BSM Not Communicating . . . . . . . . . . . . . . . . . . .. . .. . 6-28
Code MC - VM and BSM Mismatch . . . . . . . . . . . . . . . . . . . .. . .. . 6-28
Code T3 - SOL2 Current Incorrect . . . . . . . . . . . . . . . . . . . . .. . .. . 6-29
Code VC - CAN Stuck In Reset State . . . . . . . . . . . . . . . . . . .. . .. . 6-29
Code X4 - Switch Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . 6-29

Messages and Codes Summary List Models 7500/7520 Reach-Fork ® Trucks

Messages and Codes
Messages and Codes

Messages
Message Displayed: Check Battery Gates
Code Title/Reason Test to Run Notes/Corrective Action
Check Battery Gates Test I83 - Left Battery Correctly install battery gates.
Travel has been requested with Gate Switch
the battery gates not properly (optional)
installed. (Page 6-103)
Test I84 - Right
Battery Gate Switch
(optional)
(Page 6-104)
Message Displayed: Lift Amp Incorrect

Incorrect Lift Amp Installed None Replace LPA with correct LPA.
The wrong LPA was installed.
Message Displayed: Lift Cut-Out Pending...Low Battery

Battery Low None Change battery. Self resetting.

Lift cutout point configured for
BSOC has been reached.
Message Displayed: Traction Amp Incorrect

Incorrect Traction Amp None Replace TPA with correct TPA.

Installed
The wrong TPA was installed.
Message Displayed: Aux Amp Incorrect

Incorrect Aux Amp Installed None Replace APA with correct APA.
The wrong APA was installed.
Message Displayed: Run Lower Learn

Run Lower Learn None Perform Learn Lower. Refer to “Program Mode
The stored value (minimum Menu” on page 3-16.
voltage required to activate lower)
is out-of-range.

Messages and Codes
Codes
Message Displayed: Code 1D Overheated. Allow Time to Cool
Code 1D - APA Overheated Test A12 - APA Cycle key switch to clear after APA has cooled.
The APA has reported its internal Temperature (Regen Note: The VM cannot cause this code.
temperature is 205°F (96°C). Lower) (Page 6-40)
Test O23 - Toggle
Fans (Page 6-121)
Message Displayed: Code 1H Overheated. Allow Time to Cool

Code 1H - TPA Overheated Test A10 - TPA Travel is disabled. Cycle key switch to clear
The TPA has reported its internal Temperature after TPA has cooled.
temperature is 205°F (96°C). (Page 6-38) Note: The VM cannot cause this code.
Test O23 - Toggle
Fans (Page 6-121)
Message Displayed: Code 1V Overheated, Allow Time to Cool

Code 1V - LPA Overheated Test A19 - LPA Lift is disabled. Cycle key switch to clear after
The LPA has reported its internal Temperature LPA has cooled.
temperature is 205°F (96°C). (Page 6-46) Note: The VM cannot cause this code.
Test O23 - Toggle
Fans (Page 6-121)
Message Displayed: Code 2A Overheated, Allow Time to Cool

Code 2A - Traction Motor Test A08 - Traction Traction performance is limited. Self resetting
Approaching Overtemp Motor Temperature after motor has cooled.
The TPA senses the Traction (Page 6-36) Note: The VM cannot cause this code.
Motor is approaching
overtemperature.
Message Displayed: Code 2E Inform Service

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

Messages and Codes
Message Displayed: Code 2G Inform Service

Code 2G - Traction Motor Phase Test O29 - Ramp Travel is disabled. Cycle key switch to clear.
Open Traction Motor Note: The VM cannot cause this code.
The TPA detects no current draw (Page 6-124)
in one of the three phases of the
motor.
Message Displayed: Code 2H Inform Service

Code 2H - Traction Motor Test I19 - Traction Traction performance is limited. Self resetting.
Encoder Failure Motor RPM Note: The VM cannot cause this code.
The Traction Motor Encoder (Page 6-80)
circuit is inoperative.
Message Displayed: Code 2T Inform Service

Code 2T - TPA Current Sensor None Traction performance is limited. Cycle key
Error switch to clear. If code does not clear, replace
The TPA has detected a current TPA.
calibration error. Note: The VM cannot cause this code.
Message Displayed: Code 2U Inform Service

Code 2U - TPA Overcurrent or Test A11 - Traction Traction is disabled. Cycle key switch to clear.
Short Circuit Motor Current Note: The VM cannot cause this code.
The TPA has sensed current in (Page 6-39)
excess of 540A.
Message Displayed: Code 2V Inform Service

Code 2V - TPA High DC Bus None Traction is disabled. Cycle key switch to clear.
Voltage If code occurs during plugging, replace all
The TPA has detected >50VDC at battery cables and connections that show
TPA+. signs of heat or corrosion. Install a battery
that is in good condition. If code persists,
replace the TPA.
Note: The VM cannot cause this code.

Messages and Codes
Message Displayed: Code 2X Inform Service

Code 2X - TPA Power Supply None Cycle key switch to clear. Disconnect +wire to
Out-of-Range Traction Motor temperature sensor and
The power supply output in the encoder. Cycle key switch. If code changes,
TPA is <4.5V, >5.5V, or too much troubleshoot wires and sensors. If code does
current is being drawn by an not change, replace TPA.
external component. Note: The VM cannot cause this code.
Message Displayed: Code 31 Overheated, Allow Time to Cool

Code 31- Aux Motor Test A16 - Aux Motor Aux is disabled except retract. Self resetting
Approaching Overtemp Temperature (Regen after motor has cooled.
The APA senses the Aux Motor is Lower) (Page 6-44) Note: The VM cannot cause this code.
approaching overtemperature.
Message Displayed: Code 32 Inform Service

Code 32 - Aux Motor Temp Test A16 - Aux Motor Aux is disabled except retract. Cycle key
Sensor Out-of-Range Temperature (Regen switch to clear.
The Aux Motor temperature Lower) (Page 6-44) Note: The VM cannot cause this code.
sensor is open or shorted.

Code 33 - Aux Motor Phase Test O27 - Ramp Aux Aux is disabled. Cycle key switch to clear.
Open Motor (Regen Lower) Note: The VM cannot cause this code.
The APA detects no current draw (Page 6-122)
motor.

Code 34 - Aux Motor Encoder Test I18 - Aux Motor Aux is disabled. Cycle key switch to clear.
Failure Encoder (Regen Note: The VM cannot cause this code.
The Aux Motor Encoder circuit is Lower) (Page 6-79)
inoperative.

Code 35 - APA Current Sensor None Aux performance is limited. Cycle key switch
Error to clear. If code does not clear, replace APA.
The APA has detected a current Note: The VM cannot cause this code.
calibration error.

Messages and Codes

Code 36 - APA Overcurrent or Test A18 - Aux Motor Aux is disabled. Cycle key switch to clear.
Short Circuit Current (Regen Note: The VM cannot cause this code.
The APA has sensed current in Lower) (Page 6-45)
excess of 150A.

Code 37 - APA High DC Bus None Aux is disabled. Cycle key switch to clear.
Voltage Install a battery that is in good condition. If
The APA has detected >50VDC at code persists, replace the APA.
APA+. Note: The VM cannot cause this code.

Code 38 - APA Power Supply None Aux is disabled. Cycle key switch to clear.
Out-of-Range Disconnect +wire to Aux Motor temperature
The power supply output in the sensor and encoder. Cycle key switch. If code
APA is <4.5V, >5.5V, or too much changes, troubleshoot wires and sensors. If
current is being drawn by an code does not change, replace APA.
external component. Note: The VM cannot cause this code.

Code 39 - APA Pre-Charge Failed None Aux is disabled. Cycle key switch to clear.
The APA failed to pre-charge Check for shorts in the cable connected to
correctly. APA+. If code does not clear, replace APA.

Code 44 - MPC Detected Closed Test O00 - Toggle Cycle key switch to clear.
When Commanded Open MPC Contactor Note: Low battery voltage can contribute to
The VM detected an incorrect (Page 6-108) burnt tips. If contactor tips are welded or
voltage at JPC24-21 during burnt, check the BSOC setting in Config Mode
SelfTest. menu.

Code 45 - MPC Detected Open Test O00 - Toggle Cycle key switch to clear.
When Commanded Closed MPC Contactor
The VM detected <12VDC at (Page 6-108)
JPC24-21 after the MPC coil was
energized.

Messages and Codes
Message Displayed: Code 4B Inform Service

Code 4B - Steer Contactor Test O01 - Toggle Cycle key switch to clear.
Detected Closed When STR Contactor
Commanded Open (Page 6-109)
The VM detected >10VDC at If open, run Test
JPC22-19 when the STR coil was I14 - Steering Fuse
de-energized. (Page 6-77).
Message Displayed: Code 4C Inform Service

Code 4C - Steer Contactor If contactor closes, Cycle key switch to clear.

Detected Open When run Test
Commanded Closed I14 - Steering Fuse
The VM detected <10VDC at (Page 6-77).
JPC22-19 when the STR coil was If contactor does not
energized. close, run Test
O01 - Toggle STR
Contactor
(Page 6-109).
Message Displayed: Code 4D Inform Service

Code 4D - TPA Pre-Charge None Cycle key switch to clear.

Failed Check for shorts in the cable connected to
The TPA failed to pre-charge TPA+. If code does not clear, replace TPA.
correctly. Note: The VM cannot cause this code.
Message Displayed: Code 4E Inform Service

Code 4E - LPA Pre-Charge Failed None Cycle key switch to clear.

The LPA failed to pre-charge Check for shorts in the cable connected to
correctly. LPA+. If code does not clear, replace LPA.

Code 57- VM Not Responding to Test I23 - CAN Bus Self resetting.
Display Test (Page 6-83)
The display has lost
communication with the VM over
the CAN bus. This code is
initiated by the display.

Messages and Codes

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

Communication Error Check for +12V at JPX1-1 and B– at JPX1-4
No communication received from on the OCSS CAN I/O Expander Module.
the OCSS controller. Verify continuity and connections of the
communication wires between the Expander
Module and the TPA.

Code 59 - CAN Transmission Test I23 - CAN Bus Cycle key switch to clear. Check for shorts to
Buffer Error Test (Page 6-83) frame, static, and electrical leakage from
The VM has detected a CAN battery.
transmission buffer error.
Message Displayed: Code 5A Inform Service

Code 5A - CAN Bus Error/VM for Test I23 - CAN Bus Cycle key switch to clear.
BUS_I Test (Page 6-83) Check for shorts to frame, static, and
The VM detected an error in the electrical leakage from battery.
CAN Bus. Note: This code cannot be caused by an error
on the secondary bus BUS_E.
Message Displayed: Code 5B Inform Service

Code 5B - CAN Receive Bus Test I23 - CAN Bus Cycle key switch to clear.
Error/VM Test (Page 6-83) Check for shorts to frame, static, and
CAN Receive Bus error in VM for electrical leakage from battery.
BUS_I. Note: This code cannot be caused by an error
on the secondary bus BUS_E.

Code 5G - No Communications Test I23 - CAN Bus Note: This code can be caused by bad K3
Received from TPA Test (Page 6-83) relay tips. Check LEDs on the power
The VM has received no amplifiers. If they are not illuminated, check
communication from the TPA. the K3 relay and SPL13.
For all sub-codes, cycle key switch to clear.
Check for electrical shorts and static strap
condition. Perform “Shorts to Frame Test” on
page 5-3. Check for LED heartbeat at the
amp. Refer to “Troubleshooting Power
Amplifier Error Codes” on page 5-19.

Messages and Codes
Message Displayed: Code 5J Inform Service

Code 5J - No Communications Test I23 - CAN Bus Note: This code can be caused by bad K3
Received from LPA Test (Page 6-83) relay tips. Check LEDs on the power
communication from the LPA. the K3 relay and SPL13.
Message Displayed: Code 5M Inform Service

Code 5M - TPA CAN Watchdog Test I23 - CAN Bus Cycle key switch to clear.
Timeout Test (Page 6-83) This code is generated by the TPA. This fault
CAN watchdog circuit timeout can be caused by a source external to the
detected by TPA. amplifier. Check for shorts to frame, static,
electrical leakage from battery, bad power amp
cables or wiring, and CAN Bus.
Message Displayed: Code 5P Inform Service

Code 5P - LPA CAN Watchdog Test I23 - CAN Bus Cycle key switch to clear.
Timeout Test (Page 6-83) This code is generated by the LPA. This fault
The CAN watchdog circuit has not can be caused by a source external to the
received communication from amplifier. Check for shorts to frame, static,
other amplifier circuits. electrical leakage from battery, bad power amp
Message Displayed: Code 5Q Inform Service

Code 5Q - Display Not Test I23 - CAN Bus Self resetting.

Responding Test (Page 6-83) Note: The display will most likely display Code
The VM is not receiving 57.
communication from the Display.

Code 61 - Mast Switch #1 Not Test I02 - 1st Speed Cross mast switch #1.
Crossed Limiting Switch
Too many height encoder pulses (Page 6-70)
were seen without detecting mast
switch #1 opening.

Messages and Codes

Code 63 - HS Travel and 1st Test I02 - 1st Speed Cross the 1st speed limiting switch several
Speed Limiting Switches Do Limiting Switch times.
Not Agree (Page 6-70) Note: Check the error log to see if a Code 64
The VM reads the 1st speed Test I63 - High Speed or 67 preceded the Code 63. If so,
limiting switch as closed when the Travel Switch troubleshoot per that code.
HS travel switch or Switch 2 (optional) (Page 6-97) Note: Switch 2 must be turned ON in
reads open. FlashWare for trucks with an elevated height
above 331 in.

Code 64 - No Pulses Seen from Test I02 - 1st Speed Lower the carriage, then lift past the first mast
Height Indicator Encoder Limiting Switch switch.
With the lift pump running or (Page 6-70) Troubleshoot HTI system. Code clears when
SOL2 energized, the first mast Test I86 - Lift Height pulses are detected. Cycle key switch.
limit switch is open, but the VM (Page 6-105) If code is intermittent, cause could be
detected no pulses from the proportional valve. Adjust valve - see
Height Indicator encoder. “Proportional Valve Adjustment” on page 7-93.
Note: The height that the code occurred is
displayed in the BSOC field of the error log.

Code 66 - Calculated Height Test I86 - Lift Height Lower the carriage below the configured
Greater Than Configured (Page 6-105) maximum height to clear.
Height Check actual mast height against configured
The carriage height calculated by height.
the VM, from information from Check actual fork height against indicated
the Height Indicator, is more than fork height when HTI counting begins.
6 in. (15 cm) greater than the
configured height of the lift truck.

Code 67 - Calculated Height Test I02 - 1st Speed Lift the carriage through the 1st speed limiting
Does Not Match 1st Speed Limiting Switch switch height or cycle the key switch to clear.
Limiting Switch (S12) (Page 6-70) Note: The height that the code occurred is
The VM detected S12 closed at an displayed in the BSOC field of the error log.
incorrect calculated height when
lowering.

Messages and Codes

Code 68 - Encoder Channels Test I02 - 1st Speed Cycle key switch to clear.
Reversed or Height Encoder Limiting Switch Check error log. If a #1 is displayed in the
Error (Page 6-70) BSOC field, check encoder belt for correct
With the lift pump running or Test I86 - Lift Height tension and routing. Make sure idler pulley is
SOL2 energized, the first mast (Page 6-105) not seized. If a #2 is displayed in the BSOC
limit switch is open, but the VM field, troubleshoot encoder wiring. Code clears
detected the encoder channels when correct pulses are detected.
reversed, counting backwards, or
has seen too many pulses per the
20ms sample period from the
Height Indicator encoder.
Message Displayed: Code 6D Inform Service

Code 6D - Pressure Sensor Test A13 - Pressure Cycle key switch to clear.
Out-of-Range Sensor Voltage
Voltage is <0.7V (indicating (Page 6-41)
<300 psi) or >5.0V (indicating
>3999 psi).
Message Displayed: Code 6F Overheated. Allow time to cool

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

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

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

Error Replace the LPA.
The LPA has detected an internal Note: The VM cannot cause this code.
fault.

Messages and Codes
Message Displayed: Code 6W Inform Service

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

Lift Motor Speed Sensor RPM (Page 6-81) Note: The VM cannot cause this code.
The lift feedback circuit, as seen
by the LPA, is not functioning.

Code 6X - LPA Fault: Test A20 - Lift Motor Cycle key switch to clear.
Overcurrent Current (Page 6-47) Note: The VM cannot cause this code.
The LPA has detected >675A or a
shorted output.
Message Displayed: Code 6Y Inform Service

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

Voltage Install good battery. Replace LPA.
The LPA has detected a DC input
voltage exceeding 50V at LPA (+).
Message Displayed: Code 6Z Inform Service

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

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

Code 79 - Regen Lower Fault Test A23 - Lift Cycle key switch to clear.
Throttle Request If code occurs after lift pump replacement,
(Page 6-49) make sure the correct pump was installed.
Test I20 - Lift Motor Remove one wire from SOL2. Elevate the
RPM (Page 6-81) carriage 12 in. (30.5 cm). Enter Test
Test O12 - Ramp O11 - Toggle Load Hold Solenoid (Page 6-116)
Proportional Lower and activate test. If the carriage lowers more
Solenoid (Page 6-117) than 2 in. (5 cm) in 5 seconds, replace SOL2.

Messages and Codes

Code 7G - Lift Motor Phase Test O28 - Ramp Lift Cycle key switch to clear.
Open Motor (Page 6-123) Note: The VM cannot cause this code.
The LPA detects no current draw
motor.

Code 7X - LPA Power Supply None Cycle key switch to clear. Disconnect +wire to
Out-of-Range Lift Motor temperature sensor and encoder. If
The power supply output in the code changes, troubleshoot wires and sensors.
LPA is <4.5V, >5.5V, or too much If code does not change, replace LPA.
current is being drawn by an
external component.

Code 80 - Primary Throttle Pot Test A04 - Throttle Cycle key switch to clear.
Out-of-Range Pot Voltage
The VM detects <0.15V or >2.1V (Page 6-34)
at JPC12-3. Test A26 - +5VDC
Power Supply
(Page 6-50)

Code 81 - Lift/Lower Pot Test A05 - Lift/Lower Cycle key switch to clear.
Out-of-Range Pot Voltage
The VM detected <0.15V or >2.1V (Page 6-35)
at JPC12-2. Test A26 - +5VDC
Power Supply
(Page 6-50)

Code 82 - Handle Heater Open Test A40 - Handle Cycle key switch to clear.
The circuit for the optional heater Heater Reference
in the primary control handle is (optional) (Page 6-58)
open.

Messages and Codes

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

Out-of-Neutral Pot Voltage Return control handle to neutral. Cycle key
Primary throttle pot (VR1) out of (Page 6-34) switch to clear.
learned neutral value. Test A26 - +5VDC
Power Supply
(Page 6-50)

Code 84 - Brake - Not Applied Test I19 - Traction Cycle key switch to clear.
The Traction Motor Encoder Motor RPM Check brake. See “Inspection” on page 7-58.
indicated movement during (Page 6-80)
SelfTest.

Code 88 - +5VDC Power Supply Test A26 - +5VDC Cycle key switch to clear.
Out-of-Range Power Supply
Control Handle +5VDC power (Page 6-50)
supply (located on the VM) is
out-of-range.
Message Displayed: Code 8A Inform Service

Code 8A - OCSS Photo Sensor Test I80 - OCSS Cycle key switch to clear.
Fault Upper Beam
The VM senses the beams are ON (optional) (Page 6-98)
with the deadman pedal UP. Test I81 - OCSS
Lower Beam
(optional)
(Page 6-100)
Message Displayed: Code 8F Inform Service

Code 8F - Lift/Lower Pot Test A05 - Lift/Lower Lift/lower disabled. Return control handle to
Out-of-Neutral Pot Voltage neutral.
Lift/Lower pot (VR2) out of (Page 6-35) Cycle key switch to clear.
learned neutral value.

Messages and Codes

Code 8G - Secondary Throttle Test A26 - +5VDC Return control handle to neutral.
Pot Out-of-Range Power Supply Cycle key switch to clear.
The VM detected <0.1V or >2.2V (Page 6-50)
at JPC4-4. Test A29 - 2nd
Traction Throttle Pot
Voltage (optional)
(Page 6-51)
Message Displayed: Code 8H Inform Service

Code 8H - Secondary Throttle Test A26 - +5VDC Return control handle to neutral.
Pot Out-of-Neutral Power Supply Cycle key switch to clear.
Secondary throttle pot (VR3) out (Page 6-50)
of learned neutral value. Test A29 - 2nd
Traction Throttle Pot
Voltage (optional)
(Page 6-51)
Message Displayed: Code 8J Inform Service

Code 8J - Ambient Air Temp Test A36 - Ambient Cycle key switch to clear.
Sensor Out-of-Range Air Temp Sensor Note: Control handle heaters are off when this
The voltage measured from the (optional) (Page 6-55) code is present.
ambient air temp sensor is
outside the reference range.
Message Displayed: Code 8L Inform Service

Code 8L - Brake Feedback Test A35 - Brake Cycle key switch to clear.
Current Out-of-Range Armature (Page 6-54) Note: The brake is either fully engaged or fully
The current measured in the disengaged when this code is present.
brake feedback circuit is zero, or
outside the reference range.
Message Displayed: Code 8M Inform Service

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

Heater Failure Heater Reference
The internal heater in the control (optional) (Page 6-58)
handle has malfunctioned.

Messages and Codes
Message Displayed: Code 8N Inform Service

Code 8N - Optional Start Switch Test I60 - Security Open, then close the optional start switch.
Closed at Start-Up Start Switch
The VM senses switch (S23) (optional) (Page 6-96)
closed.
Message Displayed: Code A0 Inform Service

Code A0 - Incorrect VM None Cycle key switch to clear. Re-flash the VM with
Software Version correct software. See “FlashWare” on page 3-7.
The Display and VM software
versions are incompatible.
Message Displayed: Code AH Inform Service

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

Checksum 1. If the problem is intermittent, check for
The Display and VM software shorts to frame. See “Shorts to Frame” on
checksums do not match. page 5-2.
2. Re-flash the software. See “FlashWare”
on page 3-7.
3. Replace the VM.
4. If the correct software version appears,
replace the Display.
Message Displayed: Code AP Inform Service

Code AP - TPA Software Fault None Cycle key switch to clear. If code does not
clear, upgrade TPA software via FlashWare.
For all sub-codes, refer to “Troubleshooting
Power Amplifier Error Codes” on page 5-19.
Message Displayed: Code AQ Inform Service

Code AQ - APA Software Fault None Note: This code can be caused by bad K3
relay tips. Check LEDs on the power
amplifiers. If they are not illuminated, check
the K3 relay and SPL13.

Messages and Codes
Message Displayed: Code AT Inform Service

Code AT - LPA Software Fault None Cycle key switch to clear. If code does not
clear, upgrade LPA software via FlashWare.
For all sub-codes, refer to “Troubleshooting
Power Amplifier Error Codes” on page 5-19.
Message Displayed: Code AV Inform Service

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

Mismatch Verify Display software is compatible with VM
The three primary memory software. Install a preprogrammed VM.
locations do not agree.
Message Displayed: Code D1 Inform Service

Code D1 - No Communications Test I23 - CAN Bus Note: This code can be caused by bad K3
Received from APA Test (Page 6-83) relay tips. Check LEDs on the power
communication from the APA. the K3 relay and SPL13.
Message Displayed: Code D2 Inform Service

Code D2 - APA CAN Watchdog Test I23 - CAN Bus Cycle key switch to clear.
Timeout Test (Page 6-83) This code is generated by the APA. This fault
CAN watchdog circuit timeout can be caused by a source external to the
detected by APA. amplifier. Check for shorts to frame, static,
electrical leakage from battery, bad power amp
Message Displayed: Code F4 Inform Service

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

The COP circuit has timed out 1. If the problem is intermittent, test the
before a reset was generated. circuit for “Inrush Protection” on
page 5-13. Also check for “Shorts to
Frame” on page 5-2.
on page 3-7.
3. Replace the VM.

Messages and Codes

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

Bad code was detected during 1. If the problem is intermittent, test the
SelfTest. Results in total circuit for “Inrush Protection” on
shutdown. page 5-13. Also check for “Shorts to
on page 3-7.
3. Replace the VM.

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

1. If the problem is intermittent, test the
circuit for “Inrush Protection” on
page 5-13. Also check for “Shorts to
on page 3-7.
3. Replace the VM.
Message Displayed: Code FE Inform Service

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

The VM detected an internal Cycle key switch.
calibration error. BSOC If the problem is intermittent, test the circuit
information could be inaccurate. for “Inrush Protection” on page 5-13. If code
continues, replace VM.
Message Displayed: Code FG Inform Service

Code FG - 5 and/or 12V Power Test A14 - +12VDC Cycle key switch.
Supply Out-of-Range Power Supply If the problem is intermittent, test the circuit
The +5 and/or +12V power supply (Page 6-42) for “Inrush Protection” on page 5-13.
voltage is out-of-range.
Message Displayed: Code FH Inform Service

Code FH - Battery Voltage Test A15 - Battery Cycle key switch. Check Fuse FU10.
Out-of-Range Voltage (Page 6-43) If the problem is intermittent, test the circuit
Battery voltage is <28V or >45V at for “Inrush Protection” on page 5-13.
SelfTest. Results in total
shutdown.

Messages and Codes
Message Displayed: Code FN Inform Service

Code FN - Relays Did Not Open Test O32 - Toggle Disconnect, then re-connect battery
at Power Off Relays K1, K2, K3, connector.
and K4 (Page 6-126) Check other relays and circuits associated
with the K4 relay tips.
If the problem is intermittent, test the circuit
for “Inrush Protection” on page 5-13.
Message Displayed: Code FP Inform Service

Code FP - VM Internal Fault None Cycle key switch. Replace VM.

Message Displayed: Code FR (displays for 5 seconds)

Code FR - VM Config Item None Out-of-range parameter is reset after 5

Out-of-Range seconds to the default value.
The value of a configurable If the problem is intermittent, test the circuit
parameter is out of the reference for “Inrush Protection” on page 5-13.
range.
Message Displayed: Code FT Inform Service

Code FT - VM Internal Software None Brake engages. Cycle key switch.

Error Document the sequence of events that
occurred just before the code displayed. Have
the Sales and Service Center service
technician supply them to Raymond Field
Service.
Message Displayed: Code FV Inform Service

Code FV - Display Internal None Cycle key switch.

Software Error Document the sequence of events that
occurred just before the code displayed. Have
the Sales and Service Center service
technician supply them to Raymond Field
Service.

Messages and Codes
Message Displayed: Code G0 Inform Service

Code G0 - Steer Tiller 1 Test I33 - Steer Tiller Cycle key switch.
Channel A/B Fault Encoder 1 Connect
Steer tiller 1 is missing pulses Detect (Page 6-90)
compared to steer tiller 2, or Test I35 - Steer Tiller
intermittent connection detected Encoder 1 - Channels
at JPC10-6 or JPC18-5. A & B (Page 6-92)

Code G3 - Steer Feedback Prox Test I24 - Steer Limit Cycle key switch. Verify the steer gear on the
Sensor Fault Switch (Page 6-86) drive unit is not slipping.
A steer motor encoder count
should have put the steer
feedback prox sensor past the
steer limit flag, but the flag was
not sensed. The steer prox sensor
is either low or high all the time.

Code G4 - Open Detected in Test I39 - Neutral Cycle key switch. Verify B+ and B–
Steer Control Circuit Pulses (Page 6-94) connections at STR contactor and TP4.
The VM did not detect either
neutral pulses at JPC6-1 or tiller
encoder inputs at JPC22-5,
JPC22-12, JPC22-13, and
JPC22-14.

Code G5 - Short Detected in Test I25 - Steer Motor Cycle key switch.
Steer Motor Encoder Circuit Encoder (Page 6-87)
A steer command or steer motor
encoder pulses were detected
without steer tiller encoder pulses
detected.

Code G7 - Steer Tiller 2 Test I34 - Steer Tiller Cycle key switch.
Channel A/B Fault Encoder 2 Connect
Steer tiller 2 is missing pulses Detect (Page 6-91)
compared to steer tiller 1, or Test I36 - Steer Tiller
intermittent connection detected Encoder 2 - Channels
at JPC10-7 or JPC18-6. A & B (Page 6-93)

Messages and Codes
Message Displayed: Code GD Inform Service

Code GD - Open Detected in Test I25 - Steer Motor Cycle key switch.
Steer Motor Encoder Circuit Encoder (Page 6-87) Verify correct steer flag is installed.
A steer command was issued Test I90 - Degrees
while traveling >1 mph (1.6 km/h) Turned Past Steer
but no steer position feedback Flag (Page 6-106)
encoder pulses were detected. Test A37 - Steer
Power Amp Current
(Page 6-56)
Message Displayed: Code GE Inform Service

Code GE - Steer Encoder Failure Test I33 - Steer Tiller Cycle key switch.
The VM detected connect-detect Encoder 1 Connect
failures or abnormal inputs on Detect (Page 6-90)
both channels of the steer tiller Test I34 - Steer Tiller
encoder. Encoder 2 Connect
Detect (Page 6-91)
Test I35 - Steer Tiller
Encoder 1 - Channels
A & B (Page 6-92)
A & B (Page 6-93)
Message Displayed: Code iM01 Inform Service

Code iM01 - Display Battery None Replace the Evolution Display.

Bad
The Evolution Display backup
battery is bad.

Code iM02 - ESD Reset None Check truck static strap. Verify correct
harness is installed.

Code iM03 - IPM Disconnected None Verify correct harness is installed and
The optional Impact Processing connector is correctly mated to IPM.
Module is disconnected.

Messages and Codes

Code iM04 - IPM Mounted None Verify the IPM is mounted correctly. Refer to
Incorrectly Publication No. 1266316.
The optional Impact Processing
Module is mounted incorrectly.
Message Displayed: Code M1 Inform Service

Code M1 - iBattery Temp None Verify iBattery settings on display.

Sensor Failure
The iBattery temperature sensor
has failed.

Code M2 - iBattery Current None Verify current sensor is installed correctly on

Sensor Failure battery cable. Verify iBattery settings on
The iBattery current sensor has display.
failed.

Code M3 - Battery Voltage Too None Check battery voltage. Verify iBattery settings
High on display.
The voltage measured at the
Battery Sensor Module (BSM) is
greater than 120% of the nominal
voltage.

Code M4 - Battery Voltage Too None Check battery voltage. Verify iBattery settings
Low on display.
The voltage measured at the BSM
is less than 80% of the nominal
voltage.

Code M5 - Power Removed from None Check iBattery power cabling. Verify iBattery
BSM settings on display. Reset in FlashWare.
The BSM has sensed B+ or B–
was removed.

Messages and Codes

Code M6 - Battery Freeze None Check battery temperature. Verify iBattery

Warning settings on display.
An internal battery temperature
of 32°F (0°C) was sensed.

Code M7 - Battery Over-Temp None Check battery temperature. Verify iBattery

Warning settings on display.
An internal battery temperature
of 122°F (50°C) was sensed.

Code M8 - Battery Water Level None Add water to battery.

Low
Message Displayed: Code M9 “Lift limited, installed battery is too light”

Code M9 - Incorrect Battery None Install correct weight battery.

Weight
Battery is below minimum rated
weight for truck.
Message Displayed: Code MA Inform Service

Code MA - BSM Not Initialized None Initialize BSM in FlashWare.
Message Displayed: Code MB Inform Service

Code MB - BSM Not None Verify iBattery is communicating on display.

Communicating
Message Displayed: Code MC Inform Service

Code MC - VM and BSM None Make sure the current sensor was not
Mismatch installed backward.
VM BSOC is low (raw value <20%)
and BSM BSOC is not (raw value
>40%).

Messages and Codes
Message Displayed: Code T3 Inform Service

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

Incorrect Current (Page 6-53)
Current being drawn by SOL2, as
seen by the VM, is not at the
expected level.
Message Displayed: Code VC Inform Service

Code VC - CAN Stuck In Reset Test I23 - CAN Bus Cycle key switch.
State Test (Page 6-83)
Message Displayed: Code X4 Inform Service

Code X4 - Switch Mismatch Test I02 - 1st Speed Cycle key switch. Cross First Speed Limit
System detects both S12 (First Limiting Switch Switch (S12) and/or Lift Cutout Switch (S27).
Speed Limit Switch) and S27 (Lift (Page 6-70)
Cutout Switch) ON at the same Test I22 - Lift Cutout
time. Switch (Page 6-82)

Messages and Codes

Models 7500/7520 Reach-Fork ® Trucks Section 6. Electrical Tests
Electrical Test Summary List

Section 6. Electrical Tests
Analog Tests
Test A04 - Throttle Pot Voltage . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-36
Test A05 - Lift/Lower Pot Voltage . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-37
Test A08 - Traction Motor Temperature . . . . . . . . . . . .. .. . .. . .. . 6-38
Test A09 - Lift Motor Temperature . . . . . . . . . . . . . . . .. .. . .. . .. . 6-39
Test A10 - TPA Temperature . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-40
Test A11 - Traction Motor Current . . . . . . . . . . . . . . . .. .. . .. . .. . 6-41
Test A12 - APA Temperature (Regen Lower) . . . . . . . . .. .. . .. . .. . 6-42
Test A13 - Pressure Sensor Voltage . . . . . . . . . . . . . . .. .. . .. . .. . 6-43
Test A14 - +12VDC Power Supply . . . . . . . . . . . . . . . .. .. . .. . .. . 6-44
Test A15 - Battery Voltage . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-45
Test A16 - Aux Motor Temperature (Regen Lower) . . . .. .. . .. . .. . 6-46
Test A18 - Aux Motor Current (Regen Lower) . . . . . . . .. .. . .. . .. . 6-47
Test A19 - LPA Temperature . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-48
Test A20 - Lift Motor Current . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-49
Test A22 - Traction Throttle Request . . . . . . . . . . . . . .. .. . .. . .. . 6-50
Test A23 - Lift Throttle Request . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-51
Test A26 - +5VDC Power Supply . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-52
Test A29 - 2nd Traction Throttle Pot Voltage (optional) .. .. . .. . .. . 6-53
Test A30 - 2nd Traction Throttle Request (optional) . . .. .. . .. . .. . 6-54
Test A34 - Lower Current . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-55
Test A35 - Brake Armature . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-56
Test A36 - Ambient Air Temp Sensor (optional) . . . . . .. .. . .. . .. . 6-57
Test A37 - Steer Power Amp Current . . . . . . . . . . . . . .. .. . .. . .. . 6-58
Test A39 - Analog Reference Voltage . . . . . . . . . . . . . .. .. . .. . .. . 6-59
Test A40 - Handle Heater Reference (optional) . . . . . . .. .. . .. . .. . 6-60
Test A41 - Emergency Power Off Switch . . . . . . . . . . . .. .. . .. . .. . 6-61
Test A42 - Travel Pot Learn Value . . . . . . . . . . . . . . . .. .. . .. . .. . 6-62
Test A43 - Lift Pot Learn Value . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-63
Test A96 - BSM Current . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-64
Test A97 - BSM Volt . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-65
Test A98 - BSM Temp . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-66
Test A99 - H2O Sense . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . .. . 6-67
Test A100 - BSM Communication . . . . . . . . . . . . . . . .. .. . .. . .. . 6-68
Input Tests
Test I00 - Deadman Switch . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . 6-68
Test I01 - Nested Switch (optional) . . . . . . . . . . . . . . . . . .. . .. . .. . 6-69
Test I02 - 1st Speed Limiting Switch . . . . . . . . . . . . . . . .. . .. . .. . 6-70
Test I06 - Reach Switch . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . 6-71
Test I07 - Retract Switch . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . 6-72
Test I08 - Tilt Up Switch . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . 6-73
Test I09 - Tilt Down Switch . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . 6-74
Test I10 - Sideshift Right Switch . . . . . . . . . . . . . . . . . . .. . .. . .. . 6-75
Test I11 - Sideshift Left Switch . . . . . . . . . . . . . . . . . . . .. . .. . .. . 6-76
Test I14 - Steering Fuse . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . 6-77
Test I15 - Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . 6-78
Test I18 - Aux Motor Encoder (Regen Lower) . . . . . . . . . .. . .. . .. . 6-79
Test I19 - Traction Motor RPM . . . . . . . . . . . . . . . . . . . . .. . .. . .. . 6-80
Test I20 - Lift Motor RPM . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. . 6-81

Electrical Test Summary List Models 7500/7520 Reach-Fork ® Trucks
Test I22 - Lift Cutout Switch . . . . . . . . . . . . . . . . . .. .. . .. . . . . . . 6-82

Test I23 - CAN Bus Test . . . . . . . . . . . . . . . . . . . . .. .. . .. . . . . . . 6-83
Test I24 - Steer Limit Switch . . . . . . . . . . . . . . . . . .. .. . .. . . . . . . 6-86
Test I25 - Steer Motor Encoder . . . . . . . . . . . . . . . .. .. . .. . . . . . . 6-87
Test I26 - Height Indicator Encoder . . . . . . . . . . . . .. .. . .. . . . . . . 6-88
Test I27 - Secondary Horn (optional) . . . . . . . . . . . .. .. . .. . . . . . . 6-89
Test I33 - Steer Tiller Encoder 1 Connect Detect . . .. .. . .. . . . . . . 6-90
Test I34 - Steer Tiller Encoder 2 Connect Detect . . .. .. . .. . . . . . . 6-91
Test I35 - Steer Tiller Encoder 1 - Channels A & B .. .. . .. . . . . . . 6-92
Test I36 - Steer Tiller Encoder 2 - Channels A & B .. .. . .. . . . . . . 6-93
Test I39 - Neutral Pulses . . . . . . . . . . . . . . . . . . . . .. .. . .. . . . . . . 6-94
Test I40 - Customer Interlock . . . . . . . . . . . . . . . . .. .. . .. . . . . . . 6-95
Test I60 - Security Start Switch (optional) . . . . . . . .. .. . .. . . . . . . 6-96
Test I63 - High Speed Travel Switch (optional) . . . . .. .. . .. . . . . . . 6-97
Test I80 - OCSS Upper Beam (optional) . . . . . . . . . .. .. . .. . . . . . . 6-98
Test I81 - OCSS Lower Beam (optional) . . . . . . . . . .. .. . .. . . . . . 6-100
Test I82 - OCSS Count (optional) . . . . . . . . . . . . . . .. .. . .. . . . . . 6-102
Test I83 - Left Battery Gate Switch (optional) . . . . . .. .. . .. . . . . . 6-103
Test I84 - Right Battery Gate Switch (optional) . . . .. .. . .. . . . . . 6-104
Test I86 - Lift Height . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . . . . . 6-105
Test I90 - Degrees Turned Past Steer Flag . . . . . . . .. .. . .. . . . . . 6-106
Output Tests
Test O00 - Toggle MPC Contactor . . . . . . . . . . . . . . . . . . . .... . . 6-108
Test O01 - Toggle STR Contactor . . . . . . . . . . . . . . . . . . . . .... . . 6-109
Test O02 - Toggle LPC Contactor . . . . . . . . . . . . . . . . . . . . .... . . 6-110
Test O04 - Toggle AUX1 Directional Solenoid (Regen Lower) ... . . 6-111
Test O05 - Toggle AUX2 Directional Solenoid (Regen Lower) ... . . 6-112
Test O06 - Toggle Reach Solenoid . . . . . . . . . . . . . . . . . . . .... . . 6-113
Test O07 - Toggle Tilt Solenoid . . . . . . . . . . . . . . . . . . . . . .... . . 6-114
Test O08 - Toggle the Sideshift Solenoid . . . . . . . . . . . . . . .... . . 6-115
Test O11 - Toggle Load Hold Solenoid . . . . . . . . . . . . . . . . .... . . 6-116
Test O12 - Ramp Proportional Lower Solenoid . . . . . . . . . . .... . . 6-117
Test O18 - Toggle Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 6-118
Test O19 - Audible Alarm . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 6-119
Test O20 - Travel Alarm (optional) . . . . . . . . . . . . . . . . . . . .... . . 6-120
Test O23 - Toggle Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . . 6-121
Test O27 - Ramp Aux Motor (Regen Lower) . . . . . . . . . . . . .... . . 6-122
Test O28 - Ramp Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . .... . . 6-123
Test O29 - Ramp Traction Motor . . . . . . . . . . . . . . . . . . . . .... . . 6-124
Test O30 - Toggle Brake Coil . . . . . . . . . . . . . . . . . . . . . . . .... . . 6-125
Test O32 - Toggle Relays K1, K2, K3, and K4 . . . . . . . . . . . .... . . 6-126
Test O33 - Handle Heater (optional) . . . . . . . . . . . . . . . . . . .... . . 6-127
Test O61 - Customer Output (optional) . . . . . . . . . . . . . . . .... . . 6-128

Analog Tests
Analog Tests
A Diagnosis and Repair table is provided for

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

provide a step-by-step approach to diagnosing a
problem and the necessary corrective action.
See the example below.
Table 6-1. Example Diagnosis and Repair Table

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

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

identifies the required
setting on the meter
for this step.

Test A04 - Throttle Pot Voltage Analog Tests
Test A04 - Throttle Pot NOTE: The values should change smoothly and
evenly as the handle is moved from full
Voltage tractor-first to full forks-first direction.
• In Active Maintenance Mode, if the voltage
This test displays the voltage the Vehicle fluctuates erratically as you move the
Manager reads from the primary control handle handle back and forth, replace the control
throttle potentiometer (VR1). handle cable.
NOTE: Run LEARN after you replace, repair, or • If there is a problem after reconnecting the
adjust VR1. control handle cable, inspect the pins in
the DB15 connector.
NOTE: For information on how to use Active
2. If voltages are not within reference ranges,
Maintenance Mode, refer to page 3-24.
the test has failed. Refer to Diagnosis and
Repair.
Run Test
1. The display shows the voltage the VM
reads from VR1.
Throttle Position Value Displayed
Full Tractor-First 0.45 to 0.8
Neutral 0.9 to 1.3
Full Forks-First 1.4 to 1.8
Diagnosis and Repair

Action/
Meter Scale
JPC12-1 JPH1-1
Disconnect
1 JPC12-12 JPH1-12 0 Ohms Perform step 2 Replace cable
JPC12/Ohms
JPC12-3 JPH1-3
Run Test
Replace control
Disconnect A26 - +5VDC
2 PC12-1 PC12-12 4.75 to 5.25V handle or pot
JPC12/DCV Power Supply
VR1
(Page 6-50)

Analog Tests Test A05 - Lift/Lower Pot Voltage
Test A05 - Lift/Lower Pot NOTE: The values should change smoothly and
Voltage lower to full lift.
• In Active Maintenance Mode, if the values
This test displays the voltage the Vehicle fluctuate erratically as you move the
Manager reads from the lift/lower handle back and forth, replace the control
potentiometer (VR2). handle cable.
NOTE: Run LEARN after you replace, repair, or • If there is a problem after reconnecting the
adjust the lift/lower potentiometer. control handle cable, inspect the pins in
the DB15 connector.
2. If voltages are not within reference ranges,
Repair.
Run Test
1. The display shows the voltage the VM
reads from VR2.
Full Lift 0.45 to 0.8
Neutral 0.9 to 1.3
Full Lower 1.4 to 1.8

Action/
Meter Scale
JPC12-1 JPH1-1
Disconnect
1 JPC12-12 JPH1-12 0 Ohms Perform step 2 Replace cable
JPC12/Ohms
JPC12-2 JPH1-2
Run Test
Replace control
2 PC12-1 PC12-12 4.75 to 5.25V handle or pot
VR2
(Page 6-50)

Test A08 - Traction Motor Temperature Analog Tests
Test A08 - Traction Motor the temperature for all devices falls
below 105°F (40.5°C).
Temperature
Run Test
This test displays Traction Motor temperature.
Limits
If the temperature displayed matches the truck
• Normal operation: ambient to 286°F operation to the limits listed, allow the truck to
(141°C) cool and investigate the operation of the brake
• Speed is linearly reduced starting at 286°F and drive unit. If the brake and drive unit are
(141°C) to 1 mph (1.6 km/h) at 311°F functioning correctly, look at the truck
(155°C) application for over use. If the temperature
• Temperature icon illuminates at 295°F displayed does not match the limits listed,
(146°C) proceed to Diagnosis and Repair.
• Fault Code 2A and travel limited to 1 mph

(1.6 km/h) at 311°F (155°C)
NOTE: Cooling fans are turned on when the
traction motor temperature exceeds
113°F (45°C).
Cooling fans are deactivated only when

Action/ Expected
Step (+) Lead (–) Lead Step Passed Step Failed
Meter Scale Results
Temp. Icon is illuminated OR Fault Code 2A is present and Traction Motor is hot to touch
Disconnect
1 >1200 ohms Perform step 2 Replace TPA
JPT1/Ohms
JPT1-8 JPT1-7 Less than See section on
Repeat step 1 after
2 measurement in motor Perform step 3
cooling for one hour.
step 1 overheating
Less than T/S Traction Replace Traction

Disconnect
3 JPT3-2 JPT3-1 measurement in Motor sensor Motor temp
JPT3/Ohms
step 1 wires sensor
Temp. Icon is illuminated OR Fault Code 2A is present and Traction Motor is NOT hot to touch
Disconnect
1 JPT1-8 JPT1-7 Replace TPA Perform step 2
JPT1/Ohms
<800 ohms T/S Traction Replace Traction
Disconnect
2 JPT3-2 JPT3-1 Motor sensor Motor temp
JPT3/Ohms
wires sensor

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

Temperature NOTE: For information on how to use Active
This test displays Lift Motor temperature. If the temperature displayed matches the truck
operation to the limits listed, allow the truck to
Limits cool. Check the mast for binding and
investigate the operation of the pump. If the
• Normal operation: ambient to 294°F mast and pump are functioning correctly, look
(145°C) at the truck application for over use. If the
• Temperature icon illuminates at 295°F temperature displayed does not match the
(146°C) limits listed, proceed to Diagnosis and Repair.
• Fault Code 6F and lift shutdown at 300°F
(149°C)
NOTE: Cooling fans are turned on when the lift
motor temperature exceeds 113°F
(45°C).

the temperature for all devices falls
below 105°F (40.5°C).

Action/ Expected
Meter Scale Results
Temp. Icon is illuminated OR Fault Code 6F is present and Lift Motor is hot to touch
Disconnect
1 >1200 ohms Perform step 2 Replace LPA
JPL1/Ohms
JPL1-8 JPL1-7 Less than See section on
Repeat step 1 after
step 1 overheating
Less than Replace Lift

Disconnect T/S Lift Motor
3 JPL3-2 JPL3-1 measurement in Motor temp
JPL3/Ohms sensor wires
step 1 sensor
Temp. Icon is illuminated OR Fault Code 6F is present and Lift Motor is NOT hot to touch
Disconnect
1 JPL1-8 JPL1-7 Replace LPA Perform step 2
JPL1/Ohms
<800 ohms Replace Lift
Disconnect T/S Lift Motor
2 JPL3-2 JPL3-1 Motor temp
JPL3/Ohms sensor wires
sensor

Test A10 - TPA Temperature Analog Tests
Test A10 - TPA

Temperature
This test measures the temperature of the TPA.
Limits
• Normal operation: ambient to 185°F (85°C)
• Travel performance is limited at 187°F
(86°C) and temperature icon illuminates
• Fault Code 1H is displayed at 205°F (96°C)
NOTE: Cooling fans activate when the TPA
temperature exceeds 113°F (45°C).

below 105°F (40.5°C).
Run Test
The TPA heatsink temperature is displayed.
As truck travels, the readings should increase

evenly over time. If not, the test has failed. Refer
to Diagnosis and Repair.

1. Check for dirt and debris in the TPA
cooling fins.
2. Drive truck hard for 15 to 20 minutes.
Check operation of the TPA cooling fans.
Run Test O23 - Toggle Fans (Page 6-121).
3. The TPA may be bad. Replace the TPA.

Analog Tests Test A11 - Traction Motor Current
Test A11 - Traction Motor • Phase currents should be approx. equal.

Significant differences indicate a problem.
Current 1. If any one phase differs significantly from
the other two, check power cable
This test displays the current in the Traction continuity. Replace cables as necessary.
Motor power circuits. See “Power Cable Terminals” on
page 7-79.
• If power cable continuity is OK,
Limits troubleshoot the Traction Motor. See
• 0 to 500A while driving or plugging “AC Motors” on page 5-18.
• Above 266°F (130°C) current is reduced • If all phases give high readings, the
linearly drive unit may be binding. Check drive
unit.
• Maximum current up to 540A when
deadman pedal is released, unaffected and 2. The TPA may be bad. Run “Test
unreduced by temperature O29 - Ramp Traction Motor” on
page 6-124.
Run Test
NOTE: This test shows better results in Active
Maintenance Mode.
NOTE: Set speed to 3.0 mph (4.8 km/h) in
Program Mode. See “Program Mode
Menu” on page 3-16.
System Condition Value Displayed (amps)
Static at Rest <20
(spikes at startup)
Travel 0 to 3.0 mph
80 at 3.0 mph
(4.8 km/h)
(4.8 km/h)
Plugging
(from 3.0 mph 275 Max
(4.8 km/h)
If values are not within reference limits, the test

has failed. Refer to Diagnosis and Repair.

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

clamp-on ammeter.
• The current should ramp evenly as the
truck accelerates and decelerates.

Test A12 - APA Temperature (Regen Lower) Analog Tests
Test A12 - APA

Temperature (Regen
Lower)
This test measures the temperature of the APA.
Limits
• Aux function performance is limited at
187°F (86°C) and temperature icon
illuminates
• Fault Code 1D is displayed at 205°F (96°C)
NOTE: Cooling fans activate when the APA

below 105°F (40.5°C).
Run Test
The APA heatsink temperature is displayed.
As aux functions are operated, the readings

should increase evenly over time. If not, the test

1. Check for dirt and debris in the APA
cooling fins.
2. Run aux functions hard for 15 to 20
minutes. Check operation of the APA
cooling fans. Run Test O23 - Toggle Fans
(Page 6-121).
3. The APA may be bad. Replace the APA.

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

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

near the elevated forks.
Run Test
Carriage Position Value Displayed (Volts)
Fully Lowered Approx. 1.0
Lifted in Free Lift Approx. 1.5
Lifted in Second Stage Approx. 2.0
The voltage shown on the display should

increase and decrease as the empty carriage is
raised or lowered. If it does not, the test has
failed. Refer to Diagnosis and Repair.

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

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

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

Power Supply
This test displays the VM +12V Power Supply
voltage.
Run Test
1. The display shows the voltage measured
from the +12V power supply.
2. The test is a success if the voltage
displayed is within these limits:
System Condition Value Displayed
Lift truck at rest 10.1 to 13.0V
If the reading fluctuates by more than

0.8V in 10 seconds, the test has failed.
Refer to Diagnosis and Repair.

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

Analog Tests Test A15 - Battery Voltage
Test A15 - Battery

Voltage
This test displays the voltage used to calculate
Battery State-of-Charge (BSOC).
Run Test
1. The battery voltage as shown on the
display should be 28 to 45VDC.
2. If the voltage displayed is not within this
range, the test has failed. Refer to
Diagnosis and Repair.

Action/ Expected
Meter Scale Results
Check battery voltage/

specific gravity
1 TP1 Perform step 2 Replace battery
T/S or replace battery
cables
DCV TP4 B+ T/S harness TP1 to
2 JPF4-1 Perform step 3
JPF4-1
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

Test A16 - Aux Motor Temperature (Regen Lower) Analog Tests
Test A16 - Aux Motor the temperature for all devices falls
below 105°F (40.5°C).
Temperature (Regen
Run Test
Lower)
This test displays Aux Motor temperature.
If the temperature displayed matches the truck
Limits operation to the limits listed, allow the truck to
cool. Check the carriage for binding and
• Normal operation: ambient to 294°F
investigate the operation of the pump. If the
(145°C)
carriage and pump are functioning correctly,
• Temperature icon illuminates at 295°F look at the truck application for over use. If the
(146°C) temperature displayed does not match the
• Fault Code 31and aux functions shutdown limits listed, proceed to Diagnosis and Repair.
at 300°F (149°C)
NOTE: Cooling fans are turned on when the
Aux Motor temperature exceeds 113°F
(45°C).

Action/ Expected
Meter Scale Results
Temp. Icon is illuminated OR Fault Code 31 is displayed and Aux Motor is hot to touch
Disconnect
1 >1200 ohms Perform step 2 Replace APA
JPA1/Ohms
JPA1-8 JPA1-7 Less than See section on
Repeat step 1 after
step 1 overheating
Less than Replace Aux

Disconnect T/S Aux Motor
3 JPA3-2 JPA3-1 measurement in Motor temp
JPA3/Ohms sensor wires
step 1 sensor
Temp. Icon is illuminated OR Fault Code 31 is displayed and Aux Motor is NOT hot to touch
Disconnect
1 JPA1-8 JPA1-7 Replace APA Perform step 2
JPA1/Ohms
<800 ohms Replace Aux
Disconnect T/S Aux Motor
2 JPA3-2 JPA3-1 Motor temp
JPA3/Ohms sensor wires
sensor

Analog Tests Test A18 - Aux Motor Current (Regen Lower)
Test A18 - Aux Motor • If readings are not within reference limits,
the test has failed.
Current (Regen Lower) If any one phase differs significantly from the
other two, check power cable continuity.
This test measures the Aux Motor current Replace cables as necessary. See “Power Cable
through the Aux Power Amplifier. Terminals” on page 7-79.
troubleshoot the Aux Motor. See “AC
Motors” on page 5-18.
The carriage will move during this test.
• If all phases give high readings, the
carriage may be binding. Check carriage.
The area around the forks should be

clear.
Limits
• 0 to 110A
• Maximum current 150A
Run Test
Maintenance Mode.
The display shows the current the APA reads

from one phase of the Aux Motor.
With default settings enabled, an empty

carriage will display a reading of 60 to 90A.
When requesting a function over relief,
approximately 100A. Readings are the same if a
clamp-on ammeter is used.


clamp-on ammeter.
motor speed increases and decreases.
• Phase currents should be approx. equal.

Test A19 - LPA Temperature Analog Tests
Test A19 - LPA

Temperature
This test displays the temperature of the Lift
Power Amplifier.
Limits
• Lift performance is limited at 187°F (86°C)
and temperature icon illuminates
• Fault Code 1V is displayed at 205°F (96°C)
NOTE: Cooling fans activate when the LPA

below 105°F (40.5°C).
Run Test
The display shows the heatsink temperature

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

increase evenly over time. If not, the test has

1. Check for dirt and debris in the LPA
cooling fins.
2. Run lift function hard for 15 to 20
minutes. Check operation of the LPA
cooling fans. Run Test O23 - Toggle Fans
(Page 6-121).
3. The LPA may be bad. Replace the LPA.

Analog Tests Test A20 - Lift Motor Current
Test A20 - Lift Motor • Phase currents should be approx. equal.

Current If any one phase differs significantly from the
other two, check power cable continuity.
This test measures the Lift Motor current Replace cables as necessary. See “Power Cable
through the Lift Power Amplifier. Terminals” on page 7-79.
troubleshoot the Lift Motor. See “AC
Motors” on page 5-18.
The carriage will move during this test.
• If all phases give high readings, the mast
may be binding. Check mast.
The area around the forks should be

clear. The ceiling clearance should allow
for the highest lift.
Limits
• 0 to 550A lifting
• Maximum current 675A
Run Test
Maintenance Mode.
The display shows the current the LPA reads

from one phase of the Lift Motor.
Lifting an empty carriage in free lift gives

readings of 280 to 320 amps.
NOTE: Readings are approx. the same if a
clamp-on ammeter is used.
If readings are not within reference limits, the

test has failed. Refer to Diagnosis and Repair.


clamp-on ammeter.
truck accelerates and decelerates.

Test A22 - Traction Throttle Request Analog Tests
Test A22 - Traction The display shows the percentage of throttle

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

control handle traction throttle request from
Neutral 0
VR1 being read by the VM.
Full Forks-First 0 to –100
Run Test
NOTE: Run LEARN after you replace, repair, or The values must change smoothly and evenly
adjust VR1. as the handle moves from full tractor-first to
full forks-first.
Maintenance Mode, refer to page 3-24. If values are not within reference limits, the test

Action/
Meter Scale
Disconnect JPC12-1 JPH1-1

1 JPC12 JPC12-12 JPH1-12 0 Ohms Perform step 2 Replace cable
/Ohms JPC12-3 JPH1-3
Run Test
2 JC12-1 JC12-12 4.75 to 5.25V Perform step 3
(Page 6-50)
Neutral: 0.9 to 1.3V

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

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

Request
This test displays the percentage of lift throttle
request from VR2 being read by the VM.
Run Test
NOTE: Run LEARN after you replace, repair, or
adjust the lift/lower potentiometer.
The display shows the percentage of lift request

the VM reads from VR2.
Full Lower 0 to –100
Neutral 0
Full Lift 0 to +100
The values must change smoothly and evenly

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


Action/
Meter Scale
Disconnect JPC12-1 JPH1-1

1 JPC12 JPC12-12 JPH1-12 0 Ohms Perform step 2 Replace cable
/Ohms JPC12-2 JPH1-2
Run Test
Disconnect
A26 - +5VDC
2 JPC12 JC12-1 JC12-12 4.75 to 5.25V Perform step 3
Power Supply
/DCV
(Page 6-50)
Neutral: 0.9 to 1.3V

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

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

Supply
This test measures the +5V Power Supply
voltage used for the control handle switches
and potentiometers.
Run Test
If the display does not read +5 ±0.25V, the test


Action/ Expected
Meter Scale Results
Disconnect JPC12
1 Perform step 2 Replace VM
and JPC4/DCV
PC12-1 PC12-12 4.75 to 5.25V Repair/replace Repair/replace

Connect JPC12,
secondary primary control
2 disconnect
control handle handle and
JPC4/DCV
and harness harness

Analog Tests Test A29 - 2nd Traction Throttle Pot Voltage (optional)
Test A29 - 2nd Traction

Throttle Pot Voltage
(optional)
This test displays the voltage the VM reads from
the optional secondary traction throttle
potentiometer (VR3).
adjust the throttle assembly.
Run Test
The test is a success if the voltage displayed is
within these limits:
VR3 Throttle Position Value Displayed
Full Tractor-First 1.4 to 1.8
Neutral 0.9 to 1.3
Full Forks-First 0.45 to 0.8
• The values should change smoothly and

tractor-first to full forks-first direction.
• If voltages are not within reference ranges,
Repair.

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

Test A30 - 2nd Traction Throttle Request (optional) Analog Tests
Test A30 - 2nd Traction

Throttle Request
(optional)
This test displays the percentage of secondary
control handle traction throttle request from
VR3 being read by the VM.
Run Test
adjust the throttle assembly.
The display shows the percentage of throttle

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

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

Repair.

Run “Test A29 - 2nd Traction Throttle Pot
Voltage (optional)” on page 6-51.

Analog Tests Test A34 - Lower Current
Test A34 - Lower Current

This test displays the current the proportional
lowering solenoid coil (SOL2) is drawing.
Run Test
The test is a success if the current displayed is:
State Value Displayed (amps)
Neutral Approx. 0
Full Lower Approx. 1.5
If the values displayed do not match the values

given in the table, the test has failed. Refer to

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

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

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

Test A35 - Brake Armature Analog Tests
Test A35 - Brake

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

within these limits:
Deadman Pedal Value Displayed
Up B+
Down Approx. 0V


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

1 JF2-2 JC20-14 Perform step 2
JPC20/Ohms 14.5 Ohms coil
T/S B+K2 from

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

Analog Tests Test A36 - Ambient Air Temp Sensor (optional)
Test A36 - Ambient Air

Temp Sensor (optional)
This test displays the ambient air temperature
of the area around the lift truck.
Run Test
The display should display the temperature of

the room where the truck is located.
If not, the test has failed. Refer to Diagnosis and

Repair.

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

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

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

Amp Current
This test displays the current the steer motor is
drawing.
Run Test
The test is a success if the current displayed is:
Steer Direction Value Displayed (amps)
At rest <3
Clockwise (CW) –20 to –50
Counterclockwise
20 to 50
(CCW)
Note: CW and CCW is drive unit direction.


1. If current is high, check for mechanical
binding in radial rings, steerable caster,
steer motor, and gear box. Check steer
motor resistance: MS+ to MS– should be
0.3 ohms.
2. If current is low, verify connections at STR
contactor and TP4. Check steer motor for
correct resistance: MS+ to MS– should be
0.3 ohms.
3. If everything checks OK, perform step 1
below.
Action/
Meter Scale
At rest: approx. 2.5V

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

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

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


Replace Vehicle Manager.

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

Heater Reference
(optional)
This test displays the voltage the Vehicle
Manager sees going through the internal
primary control handle heater (HTR6).
NOTE: Heater operation requires ambient
temperature sensor to be activated.
Heaters then turn on at 40°F (4.4°C).
Run Test
Heater OFF Heater ON
0V Approx. 6.0V

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

Action/ Expected
Meter Scale Results
Check cable
wiring. If OK,
Disconnect Approx. 9 to 12
1 JC12-7 JC12-12 Perform step 2 replace handle
JPC12/Ohms Ohms
or internal
heater
Relays Open:
TP4 on open circuit
2 Ohms JPF4-10 Perform step 3 T/S FRC
FRC Relays Closed:
<1 ohm
Disconnect PC12-7 PC12-12 Heater ON:

3 Perform step 1 Replace VM
JPC12/DCV on VM on VM approx. 3 to 8V

Analog Tests Test A41 - Emergency Power Off Switch
Test A41 - Emergency

Power Off Switch
This test shows the voltage the Vehicle Manager
is reading from the EPO switch.
Run Test
Displayed Value
State of Switch
(Volts)
Up (closed) B+
Down (open) 0


Action/ Expected
Meter Scale Results
Clean pin connection then

replace Fuse/Relay Card
Repair/replace wiring or
switch
DCV TP4 (B–) B+
Clean pin connection then
replace Fuse/Relay Card
Repair/replace wiring or
switch

Test A42 - Travel Pot Learn Value Analog Tests
Test A42 - Travel Pot

Learn Value
This test displays the voltage value that was
stored in the Vehicle Manager the last time
LEARN was performed on the primary travel
pot.

Analog Tests Test A43 - Lift Pot Learn Value
Test A43 - Lift Pot Learn

Value
This test displays the voltage value that was
stored in the Vehicle Manager the last time
LEARN was performed on the lift pot.

Test A96 - BSM Current Analog Tests
Test A96 - BSM Current

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 Sense
Test A99 - H2O Sense

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

Test A100 - BSM Communication Analog Tests
Test A100 - BSM

Communication
Communication level indicator between the
Evolution Display and Battery Sensor Module
(BSM). Range is 0 to 100%: 100% indicates
excellent communication, 0 indicates no
communication.

Input Tests
Input Tests

and Repair table.

Action/
Meter Scale

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

scale on the meter for
this step.

Test I00 - Deadman Switch Input Tests
Test I00 - Deadman

Switch
This test shows what the Vehicle Manager is
reading from the Deadman Switch (DS1).
Do not perform this test on a ramp.
Run Test
The display shows the state of the switch.
Operator Action Message Displayed
Off deadman Up
On deadman Down
If the display does not change when you step on

the pedal, the test has failed. Make sure the gap
between the proximity sensor (DS1) and the
indicator flag is within tolerance. Refer to
“Deadman Pedal” on page 7-60. Otherwise,
refer to Diagnosis and Repair.

Action/ Expected
Meter Scale Results
1 Disconnect JPC18, JPC22-8 4.5 to 5V Perform step 2

JPC20, and JPC22 JPC18-7 Replace VM
2 /DCV JPC20-2 10.5 to 13V Perform step 3
3 Disconnect JPDS JPDS-2 4.5 to 5V Perform step 4

JPDS-3 T/S wires to VM
4 /DCV JPDS-1 10.5 to 13V Replace DS1

Input Tests Test I01 - Nested Switch (optional)
Test I01 - Nested Switch

(optional)
reading from the Nested Switch (S14).

around an elevated mast.
Lift only in an area with a ceiling height

greater than the truck’s maximum
elevated height.
Run Test
The display shows the state of the switch:
Mast Position Message Displayed
Nested In
Unnested Out
If these results are not observed, the test has


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

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

Test I02 - 1st Speed Limiting Switch Input Tests
Test I02 - 1st Speed

Limiting Switch
reading from the 1st Speed Limiting Mast
Switch (S12).

Run Test
Run this test in Active Maintenance Mode. For
information on how to use Active Maintenance
Mode, refer to page 3-24.
The display should show the following:
Mast Position Message Displayed

Lowered Below
Raised Above
If these results are not observed, check the

adjustment of the switch per “Component
Specific Service/Torque Chart” on page A-4 and
retest. If the expected results are not observed,

Action/
Meter Scale
Disconnect T/S Fuse/Relay
1 PF3-8 Perform step 2
JPF3/Ohms Card
<1 Ohm T/S wires to
Disconnect
2 JS4-3 Perform step 3 switch and
JPS4/Ohms
retest
TP4
Disconnect
3 JS4-1 Perform step 5 Perform step 4
JPS4/DCV
10.5 to 13V T/S wires to
Disconnect
4 PC20-1 switch and Replace VM
JPC20/DCV
retest
5 JPS4-1 JPS4-2 Mast lowered:10.5 Perform step 6 Replace S12
DCV to 13V Repair/replace
6 JC20-1 JC22-1 Mast elevated: 6V Replace VM
wire

Input Tests Test I06 - Reach Switch
Test I06 - Reach Switch

reading from the Reach Switch (S4).
Run Test
1. The display shows the state of the switch:
State of Switch Message Displayed
Pressed In
Released Out
• In Active Maintenance Mode, if the

displayed message fluctuates erratically
as you move the handle back and forth,
replace the control handle cable.
• If there is a problem after reconnecting
the control handle cable, inspect the
pins in the DB15 connector.
2. If results do not match the preceding
table, the test has failed. Refer to

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

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

Test I07 - Retract Switch Input Tests
Test I07 - Retract Switch

reading from the Retract Switch (S5).
Run Test
Pressed In
Released Out


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

Input Tests Test I08 - Tilt Up Switch
Test I08 - Tilt Up Switch

reading from the Tilt Up Switch (S6).
Run Test
Pressed In
Released Out


Action/ Expected
Meter Scale Results
Disconnect
JPC12/DCV
>4V
Disconnect JPH1 Repair/replace
2 Perform step 3
/DCV cable to VM
JPH1-5 JPH1-12
3 DCV Replace VM

Test I09 - Tilt Down Switch Input Tests
Test I09 - Tilt Down

Switch
reading from the Tilt Down Switch (S7).
Run Test
Pressed In
Released Out


Action/ Expected
Meter Scale Results
Disconnect
JPC12/DCV
>4V
2 Perform step 3
/DCV cable to VM
JPH1-6 JPH1-12
3 DCV Replace VM

Input Tests Test I10 - Sideshift Right Switch
Test I10 - Sideshift Right

Switch
reading from the Sideshift Right Switch (S9).
Run Test
Pressed In
Released Out


Action/ Expected
Meter Scale Results
Disconnect
JPC12/DCV
>4V
2 Perform step 3
/DCV cable to VM
JPH1-9 JPH1-12
3 DCV Replace VM

Test I11 - Sideshift Left Switch Input Tests
Test I11 - Sideshift Left

Switch
reading from the Sideshift Left Switch (S8).
Run Test
Pressed In
Released Out


Action/ Expected
Meter Scale Results
Disconnect
JPC12/DCV
>4V
2 Perform step 3
/DCV cable to VM
JPH1-8 JPH1-12
3 DCV Replace VM

Input Tests Test I14 - Steering Fuse
Test I14 - Steering Fuse

This test reports the absence or presence of B+
voltage at the load side of the steer motor (STR)
contactor.
When this test is activated and the

deadman pedal is pressed, the steer
motor/pump activates.
Run Test
Deadman Pedal
Message Displayed
Position
Down Clsd (closed)
Up Open
NOTE: The steer contactor opens, but

capacitors in the steer amplifier take
approximately 30 seconds to bleed off.
If the STR contactor tips do not close, run Test

O01 - Toggle STR Contactor (Page 6-109).
If the display message does not change when

the test is activated, the test has failed. Refer to

Action/
Meter Scale
Remove FU1
1 Fuse Fuse 0 Ohms Perform step 2 Replace fuse FU1
/Ohms
STR Tips open: 0V Replace STR

2 STR-1 Perform step 3
STR Tips closed: B+ contactor tips
DCV TP4
STR Tips open: 0V T/S wiring from
STR Tips closed: B+ VM to contactor

Test I15 - Horn Switch Input Tests
Test I15 - Horn Switch

reading from the Horn Switch (S3).
Run Test
Pressed In
Released Out
If results do not match the preceding table, the


Action/ Expected
Meter Scale Results
Disconnect
JPC12/DCV
>4V
2 Perform step 3
/DCV cable to VM
JPH1-10 JPH1-12
3 DCV Replace VM

Input Tests Test I18 - Aux Motor Encoder (Regen Lower)
Test I18 - Aux Motor

Encoder (Regen Lower)
This test displays the Aux Motor Encoder (AME)
output as seen by the APA.
Do this test in an area free of

obstructions with ample room for the
Aux functions.
Run Test
“250 to approx. 2300 rpm” should be displayed.

NOTE: The display shows rpm as measured by
the APA.
If the expected results are not displayed,

perform Diagnosis and Repair.

Action/ Expected
Meter Scale Results
1 JPA1-26 JPA1-7 Perform step 2 Replace APA

5V T/S wiring from APA to
2 JPA2-1 Perform step 3
Aux Motor
JPA2-4
3 DCV JPA2-2 Perform step 4
At rest: 0V or Replace AME
4 JPA2-3 5V Perform step 5
Aux function
5 JPA1-31 requested: Perform step 6 T/S wiring from APA to
JPA1-7 approx. 2.5V
6 JPA1-32 Replace APA Aux Motor

Test I19 - Traction Motor RPM Input Tests
Test I19 - Traction Motor

RPM
This test displays the Traction Motor RPM as
seen by the TPA.

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

the TPA.


Action/ Expected
Meter Scale Results
1 JPT1-26 JPT1-7 Perform step 2 Replace TPA

5V T/S wiring from TPA to
2 JPT2-1 Perform step 3
Traction Motor
JPT2-4
3 DCV JPT2-2 Perform step 4
At rest: 0V or Replace TME
4 JPT2-3 5V Perform step 5
5 JPT1-31 Traveling: Perform step 6

approx. 2.5V T/S wiring from TPA to
JPT1-7
6 JPT1-32 Replace TPA Traction Motor

Input Tests Test I20 - Lift Motor RPM
Test I20 - Lift Motor RPM

This test displays the Lift Motor RPM as seen by
the LPA.

obstructions with ample room for lifting.
Run Test
Maintenance.
“0000 to ±2450 rpm” should be displayed.

the LPA.


Action/ Expected
Meter Scale Results
1 JPL1-26 JPL1-7 Perform step 2 Replace LPA

5V T/S wiring from LPA to
2 JPL2-1 Perform step 3
Lift Motor
JPL2-4
3 DCV JPL2-2 Perform step 4
Replace LME
4 JPL2-3 At rest: 0V or 5V Perform step 5
Lifting:
5 JPL1-31 approx. 2.5V Perform step 6 T/S wiring from LPA to
JPL1-7
6 JPL1-32 Replace LPA Lift Motor

Test I22 - Lift Cutout Switch Input Tests
Test I22 - Lift Cutout

Switch
This test displays what the VM is reading from
the Lift Cutout Switch (S27).
Run Test
Message
Mast Position
Displayed
Over Flag ON
Not Over Flag OFF

adjustment of the switch per the “Component

Action/ Expected
Meter Scale Results
1 JPC20-6 JPF3-12 Perform step 2 Replace VM

DCV 10.5 to 13V Repair/replace wiring
2 JPS5-1 JPS5-3-6 Perform step 3
to switch
3 JPC22-6 Perform step 4 Replace VM

Disconnect JPS5
JPF3-12 5V Repair/replace wiring
4 /DCV JPS5-2 Replace S27
to switch

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

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

• T if the TPA is communicating on the CAN
Bus
• L if the LPA is communicating on the CAN
Bus
• A if the APA is communicating on the CAN
Bus (Regen Lower only)
• V if the VM is communicating on the CAN
Bus
If T, L, A (Regen Lower only) and V are not

displayed, the test has failed. Perform

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

1 JPD1-3 from N/A N/A test. V is Perform step 2 Perform step 7
connector displayed
2 JT1-23 JL1-23 Perform step 3

0 Ohms Repair wiring
3 JT1-35 JL1-35 Perform step 4
Disconnect JPT1,
4 JPL1, JPD1, JPX1 JL1-35 JL1-23 Open circuit Perform step 5 Repair short
5 and JPA1 (Regen JL1-23 JA1-23 Perform step 6

Lower only)/Ohms 0 Ohms Repair wiring
6 JA1-35 Perform step 7
JL1-35
7 JA1-23 Open circuit Perform step 8 Repair short

Test I23 - CAN Bus Test Input Tests
Action/ Expected
Meter Scale Results
Able to enter
test. V is dis-
8 Disconnect JPT1 Replace TPA Perform step 9
played (L may
also display)
Perform step 10
Able to enter if equipped
9 Disconnect JPL1 test. V and T are Replace LPA w/Regen Lower,
N/A N/A
displayed otherwise
perform step 11
Able to enter
test. V is dis-
Disconnect JPA1
10 played (L and T Replace APA Perform step 11
(Regen Lower only)
may also
display)
11 JD1-6 JC14-11 Perform step 12

Disconnect JPD1 0 Ohms Repair wiring
12 JC14-4 Perform step 13
and JPC14/Ohms JD1-7
13 JD1-6 Perform step 1 Repair short
Disconnect JPD1/ Open circuit

14 PD1-6 PD1-7 Replace VM Replace Display
Ohms
T Missing
Verify LED's on
TPA are
Troubleshoot B+
illuminated. If
from K3 Relay
1 DCV JPT1-1 JPT1-7 B+ not, test TMT
and B– from
and TME
TP4.
circuits. If OK,
perform step 2.
2 Disconnect JPT1 JT1-23 JL1-23 Perform step 3

3 and JPL1/Ohms JT1-35 JL1-35 Replace TPA
L Missing
Verify LED's on
LPA are
Troubleshoot B+
illuminated. If
from K3 Relay
1 DCV JPL1-1 LPA B– B+ not, test LMT
and B– from
and LME
TP4.
circuits. If OK,
perform step 2.
2 Disconnect JPD1 JL1-23 JD1-2 Perform step 3

3 and JPL1/Ohms JL1-35 JD1-3 Replace LPA

Input Tests Test I23 - CAN Bus Test
Action/ Expected
Meter Scale Results
A Missing (Regen Lower)
Verify LED's on
APA are
Troubleshoot B+
illuminated. If
from K3 Relay
1 DCV JPA1-1 APA B– B+ not, test AMT
and B– from
and AME
TP4.
circuits. If OK,
perform step 2.
2 Disconnect JPA1 JA1-23 JL1-23 Perform step 3

3 and JPL1/Ohms JA1-35 JL1-35 Replace APA

Test I24 - Steer Limit Switch Input Tests
Test I24 - Steer Limit

Switch
This test reads the input to the Vehicle Manager
from the Steer Limit Switch (S11).
Run Test
Switch Position Message Displayed
Over Metal On
Not Over Metal Off
If the display does not change when the switch

transitions from “over metal” to “not over
metal”, the test has failed. Make sure S11 is
correctly adjusted. Refer to “Steer Limit Switch
(S11)” on page 7-23. Otherwise, refer to

Action/ Expected
Meter Scale Results
Disconnect
1 PC20-9 PC22-11 Perform step 2 Replace VM
JPC20/DCV 12V
2 JPST-1 JPST-3 Perform step 3 Repair/replace wiring
Disconnect
JPST/DCV 5V
4 JPST-2 JPST-3 Replace S11 Repair/replace wiring

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

Encoder
This test displays the encoder counts from the
Steer Motor Encoder.
Run Test
“0 to 255” should be displayed while steering. If

not, the test has failed. Perform Diagnosis and
Repair.

Action/
Meter Scale
Disconnect
JPE4/DCV
12V
T/S wiring to
2 JPE4-1 Perform step 3
VM
JPE4-4
3 JPE4-3 Perform step 4 Replace Steer
DCV Motor encoder
4 JPE4-2 Steering: approx. 1.8V Perform step 5
5 JPC22-10 Not steering: 0 or 4.5V Perform step 6 T/S wiring to

JPC10-9
6 JPC22-9 Replace VM encoder

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

Indicator Encoder
This test reads the input from the height
encoder to the display.
Run Test
Above free lift: counts increase “0 to 255” while

lifting and decrease “255 to 0” while lowering.
If not, the test has failed. Perform Diagnosis

and Repair.

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

5 Perform step 6
(Channel A) approx. 2.3V Repair/replace
JPD2-2
JPD2-4 wiring
6 Replace display
(Channel B)

Input Tests Test I27 - Secondary Horn (optional)
Test I27 - Secondary

Horn (optional)
reading from the Secondary Horn Switch (S10).
Run Test
Message
State of Switch
Displayed
Pressed In
Released Out


Action/ Expected
Meter Scale Results
Disconnect
JPC4/DCV
Repair/replace wiring to
2 JPH3-1 JPH3-2 Perform step 3
VM
>4V
3 DCV JPC4-3 JPC4-2 Perform step 4
switch
4 JPH3-3 JPH3-2 Replace switch
VM

Test I33 - Steer Tiller Encoder 1 Connect Detect Input Tests

Encoder 1 Connect Detect
This test verifies the Vehicle Manager sees the
12V circuit connected to the Steer Tiller
Encoder Channel 1.
Run Test
Connection Status Message Displayed
Connected Yes
Not Connected No


Action/ Expected
Meter Scale Results

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

Input Tests Test I34 - Steer Tiller Encoder 2 Connect Detect

Encoder 2 Connect Detect
This test verifies the Vehicle Manager sees the
12V circuit connected to the Steer Tiller
Encoder Channel 2.
Run Test
Connection Status Message Displayed
Connected Yes
Not Connected No


Action/ Expected
Meter Scale Results

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

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

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

Repair.

Action/ Expected
Meter Scale Results

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

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

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

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

Repair.

Action/ Expected
Meter Scale Results

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

DCV
4 JPE2-2 Perform step 5 Encoder
Turning tiller:
5 JPC22-13 approx. 2.5V Perform step 6
JPC18-6 Repair/replace wiring

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

This test displays the neutral pulses seen by
the Vehicle Manager from the Steer Power
Amplifier.
Run Test
Deadman Pedal Message Displayed
Toggles between On
Pressed
and Off
Released >15 sec = On or Off
If expected results are not displayed, run Test

I25 - Steer Motor Encoder (Page 6-87) and
verify encoder count is not fluctuating with no
steer command before Diagnosis and Repair is
performed.

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

Input Tests Test I40 - Customer Interlock
Test I40 - Customer

Interlock
This test shows what the VM is reading from
the Customer Interlock switch.
Run Test
Switch Position Message Displayed
Open OFF
Closed ON
If the expected results are not observed, refer to


Action/ Expected
Meter Scale Results
Disconnect
1 PC24-16 PC24-5 >4V Perform step 2 Verify option is enabled
JPC4/DCV
Open: >4V Repair/replace

2 DCV JPC24-16 JPC24-5 Replace VM
Closed: 0V switch/wiring

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

Switch (optional)
reading from the Security Start Switch (S23).
Run Test
Pressed In
Released Out


Action/
Meter Scale
Disconnect
1 >4.0V Perform step 2 Verify option is ON
JPC10/DCV
JPC10-2 JPC10-4
S23 open: >4.0V T/S switch and
2 DCV Replace VM
S23 closed: 0V wires

Input Tests Test I63 - High Speed Travel Switch (optional)
Test I63 - High Speed The display should show the following:
Travel Switch (optional) Mast Position Message Displayed
Lowered Below
Raised Above
reading from the High Speed Travel Switch
(S25).
Run Test
Run this test in Active Maintenance Mode.

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

Test I80 - OCSS Upper Beam (optional) Input Tests
Test I80 - OCSS Upper Run Test

Beam (optional) Make sure the beam is not blocked by objects,
debris, or dirt. The display shows the state of
the beam:
This test verifies the OCSS Upper Beam is
working correctly.
Maintenance Mode, refer to page 3-24. Down On
Up Off

test has failed. Perform Diagnosis and Repair.

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

Receiver (3 wires)
Down Yellow ON Receiver is receiving light beam (correctly aligned)
Emitter (2 wires) Down Green ON +12V present at EMTR_1
If the LEDs do not illuminate as described above, troubleshoot as follows:
Action/ Expected
Meter Scale Results
Fault: All LEDS not illuminated
Disconnect Check pins; Replace Expander

1 JX1-1 JX1-4 Perform step 2
JPX1/DCV; 10.7 to Module
Deadman 13V Replace harness between
2 pedal down PD1-1 PD1-4 Replace Display
Expander Module and OD
Fault: EMITTER - Green LED not illuminated
Disconnect
JPCS1/DCV;
1 JCS1-1 JCS1-2 Replace Emitter harness PCS1 Perform step 2
Deadman
pedal down 10.7 to
Disconnect 13V
Replace harness between Replace
JPX2/DCV;
2 PX2-4 PX2-9 Expander Module and Emitter Expander
Deadman
harness JX2 to JCS1 Module
pedal down
Fault: RECEIVER - Green LED not illuminated

Input Tests Test I80 - OCSS Upper Beam (optional)
Action/ Expected
Meter Scale Results
Disconnect
JPCS2/DCV;
1 JCS2-1 JCS2-4 Replace Receiver harness PCS2 Perform step 2
Deadman
pedal up 10.7 to
Disconnect 13V
JPX2/DCV;
2 PX2-1 PX2-6 Expander Module and Receiver Expander
Deadman
harness JX2 to JCS2 Module
pedal up
Fault: RECEIVER - Yellow LED not illuminated
Replace harness
between
Disconnect Expander
1 JPCS2 and JCS2-2 PX2-2 0 Ohms Perform step 2 Module and
JPX2/Ohms Receiver
harness JX2 to
JPCS2
Clean Emitter
Make sure Emitter is not obscured (dirty) and is
2 Perform step 3 eye and/or align
aligned correctly
correctly
Replace
Disconnect
3 PX2-2 PX2-6 Approx. 5V Replace Receiver harness PCS2 Expander
JPX2/DCV
Module

Test I81 - OCSS Lower Beam (optional) Input Tests
Test I81 - OCSS Lower Run Test

Beam (optional) Make sure the beam is not blocked by objects,
debris, or dirt. The display shows the state of
the beam:
This test verifies the OCSS Lower Beam is
working correctly.
Maintenance Mode, refer to page 3-24. Down On
Up Off

test has failed. Perform Diagnosis and Repair.

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

Receiver (3 wires)
Down Yellow ON Receiver is receiving light beam (correctly aligned)
Emitter (2 wires) Down Green ON +12V present at EMTR_2
If the LEDs do not illuminate as described above, troubleshoot as follows:
Action/ Step
Step (+) Lead (–) Lead Expected Results Step Failed
Meter Scale Passed
Fault: All LEDS not illuminated
Check pins; Replace Expander

1 Disconnect JX1-1 JX1-4 Perform step 2
Module
JPX1/DCV; 10.7 to
Deadman 13V Replace harness between
2 pedal down PD1-1 PD1-4 Expander Module and OD/TPA Replace Display
JX1 to JD1-1/JT1
Fault: EMITTER - Green LED not illuminated
Disconnect
JPCS3/DCV;
1 JCS3-1 JCS3-2 Replace Emitter harness PCS3 Perform step 2
Deadman
pedal down 10.7 to
Disconnect 13V
JPX2/DCV;
2 PX2-5 PX2-10 Expander Module and Emitter Expander
Deadman
harness PX2 to JCS1 Module
pedal down

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

Test I82 - OCSS Count (optional) Input Tests
Test I82 - OCSS Count

(optional)
This test displays the number of times the
beams have been broken on the OCSS system.
The number can be reset to 0 by activating the
Clear OCSS function at the end of the Service
menu.

Input Tests Test I83 - Left Battery Gate Switch (optional)
Test I83 - Left Battery

Gate Switch (optional)
The state of the Left Battery Gate Switch (S57),
as seen by the VM, is displayed.
Run Test
The input is good if these values are displayed:
Battery Gate Value Displayed
Removed Out
Installed In


Action/
Meter Scale
1 JPC24-1 10.5 to 13VDC Perform step 2

JPC24-8 Replace VM
2 JPC22-11 S57 Open: 5VDC Perform step 3
Repair wires to
3 JPS17-1 10.5 to 13VDC Perform step 4
DCV JPS17-3 VM
4 JPS17-2 Perform step 5 Replace S57

S57 Open: 5VDC
Closed: 0VDC Repair wires to
5 JPC22-11 JPC24-8 Replace VM
S57

Test I84 - Right Battery Gate Switch (optional) Input Tests
Test I84 - Right Battery

Gate Switch (optional)
The state of the Right Battery Gate Switch
(S58), as seen by the VM, is displayed.
Run Test
The input is good if these values are displayed:
Battery Gate Value Displayed
Removed Out
Installed In


Action/
Meter Scale
1 JPC20-10 10.5 to 13VDC Perform step 2

JPC24-3 Replace VM
2 JPC22-3 S58 Open: 5VDC Perform step 3
Repair wires to
3 JPS16-1 10.5 to 13VDC Perform step 4
DCV JPS16-3 VM
4 JPS16-2 Perform step 5 Replace S58

S58 Open: 5VDC
Closed: 0VDC Repair wires to
5 JPC22-3 JPC24-3 Replace VM
S58

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

This test displays fork height above free lift.
Run Test
NOTE: If encoder is disconnected, test will read
6553.
You should see: below free lift = 0; height

increase going up; height decrease going down.


Action/ Expected
Meter Scale Results
Disconnect
1 JPD2-1 JPD2-2 Perform step 2 Replace display
JPD-2/DCV 10.5 to 13V
2 JPE3-1 Perform step 3 T/S wiring
JPE3-4
Replace encoder
4 DCV JPE3-2 JPE3-4 Lifting: approx. Perform step 5
5 JPD2-3 2.4V Perform step 6

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

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

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

unit does not contact the hard stop on either
side during normal operation.
Run Test
Turn the steering wheel all the way in one
direction until the drive unit is against the
mechanical stop. Record the steering degrees
displayed. Turn the steering wheel all the way
in the opposite direction against the mechanical
stop. Compare this reading to the reading from
the opposite side.
Both sides should be approx. 10°.


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

Output Tests
Output Tests

and Repair table.

Action/
Meter Scale

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

scale on the meter for
this step.

Test O00 - Toggle MPC Contactor Output Tests
Test O00 - Toggle MPC

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

truck is jacked up. Never block the lift
truck between the telescopic and the
floor. Use a suitable hoist to stabilize the
mast. Keep hands and feet clear from
vehicle while jacking the lift truck. After
the lift truck is jacked, place solid blocks
or jack stands beneath it to support it.
DO NOT rely on the jack alone to
support the lift truck. See “Jacking
Safety” on page 2-9.
Jack the drive wheel off the floor for this test.
Run Test
NOTE: For information on how to use Static
Use the ENTER button to toggle the test ON and

OFF. The display shows ON or OFF.
If the contactor does not cycle in/out when the

test is toggled, the test has failed. Perform

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

Output Tests Test O01 - Toggle STR Contactor
Test O01 - Toggle STR

Contactor
This test turns the STR contactor ON and OFF.
DO NOT attempt to drive the truck while

performing this test.
Run Test



Action/ Expected
Meter Scale Results
Disconnect
1 PS1-11 Approx. 40 Ohms Perform step 2 T/S wires and coil
JPS1/Ohms PS1-10
2 Perform step 4 Perform step 3
TP4 B+ T/S wire to T/S K2 relay and
3 JPF2-1
JPS1-10 Fuse/Relay Card
DCV Test contactor
4 JPS1-11 Perform step 5
OFF: 0V for binding
B+
ON: approx. 24V T/S wire to
JPS1-11

Test O02 - Toggle LPC Contactor Output Tests
Test O02 - Toggle LPC

Contactor
This test turns the LPC contactor ON and OFF.
Ceiling height must be higher than the

maximum elevated height of the lift
truck under test.
Run Test



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

Output Tests Test O04 - Toggle AUX1 Directional Solenoid (Regen Lower)
Test O04 - Toggle AUX1 2. Remove wire JF2-5 from the connector at
the Fuse Relay Card.
Directional Solenoid 3. Connect a digital ammeter in series with
JPF2, positive lead (+) to PF2-5, and the
(Regen Lower) negative lead (–) to wire JF2-5.
4. Reconnect the battery connector and turn
This test turns SOL5T ON and OFF, verifying its the key switch ON.
correct operation electrically.
5. Run Test O07 and toggle the solenoid coil
ON. Use the ENTER button to toggle the
A successful test proves the SOL5T coil, wiring,
test ON and OFF. The display shows ON or
and related circuitry in the Vehicle Manager are
OFF. The ammeter must read approx.
functioning correctly.
720 mA.
It does not prove the SOL5T valve is functioning a. If the ammeter reading is correct, the
mechanically. solenoid coil is functioning electrically.
b. If the solenoid is not working correctly,
Run Test check for a mechanical problem in the
valve, such as binding or
NOTE: For information on how to use Static contamination. Perform Diagnosis and
Maintenance Mode, refer to page 3-23. Repair.
1. Turn the key switch OFF and disconnect
the battery connector.

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

1 JPC18-1 Approx. 33 Ohms Perform step 2
and JPF2/Ohms JPF2-5 wires
2 DCV TP4 B+ Replace VM T/S K2 circuit

Test O05 - Toggle AUX2 Directional Solenoid (Regen Lower) Output Tests
Test O05 - Toggle AUX2 2. Remove wire JF2-5 from the connector at
the Fuse Relay Card.
Directional Solenoid 3. Connect a digital ammeter in series with
JPF2, positive lead (+) to PF2-5, and the
(Regen Lower) negative lead (–) to wire JF2-5.
This test turns SOL5B ON and OFF, verifying the key switch ON.
its correct operation electrically.
5. Run Test O07 and toggle the solenoid coil
A successful test proves the SOL5B coil, wiring,
and related circuitry in the Vehicle Manager are
OFF. The ammeter must read approx.
functioning correctly.
720 mA.
It does not prove the SOL5B valve is functioning a. If the ammeter reading is correct, the
mechanically. solenoid coil is functioning electrically.
b. If the solenoid is not working correctly,
Run Test check for a mechanical problem in the
NOTE: For information on how to use Static contamination. Perform Diagnosis and
Maintenance Mode, refer to page 3-23. Repair.

Action/ Expected
Meter Scale Results


Output Tests Test O06 - Toggle Reach Solenoid
Test O06 - Toggle Reach 2. Disconnect wire REACH-1 from the reach
solenoid.
Solenoid 3. Connect a digital ammeter in series with
the reach solenoid coil, positive lead (+) to
This test turns the reach solenoid ON and OFF, the wire removed, and the negative lead (–)
verifying its correct operation electrically. to terminal REACH-1 on the solenoid.
A successful test proves the reach solenoid coil, the key switch ON.
wiring, and related circuitry in the Vehicle 5. Run Test O06 and toggle the solenoid coil
Manager are functioning correctly. ON. Use the ENTER button to toggle the
It does not prove the reach solenoid valve is OFF. The ammeter must read approx.
functioning mechanically. 560 mA.
a. If the ammeter reading is correct, the
Run Test solenoid coil is functioning electrically.
NOTE: For information on how to use Static b. If the solenoid is not working correctly,
Maintenance Mode, refer to page 3-23. check for a mechanical problem in the
contamination. Perform Diagnosis and
Repair.

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

1 JPC18-12 Perform step 2
and JPF2/Ohms JPF2-8 41 Ohms wires

Test O07 - Toggle Tilt Solenoid Output Tests
Test O07 - Toggle Tilt 2. Disconnect wire TILT-1 from the tilt
solenoid.
Solenoid 3. Connect a digital ammeter in series with
the tilt solenoid coil, positive lead (+) to the
This test turns the tilt solenoid ON and OFF, wire removed, and the negative lead (–) to
verifying its correct operation electrically. terminal TILT-1 on the solenoid.
A successful test proves the tilt solenoid coil, the key switch ON.
wiring, and related circuitry in the Vehicle 5. Run Test O07 and toggle the solenoid coil
It does not prove the tilt solenoid valve is OFF. The ammeter must read approx.
NOTE: This test is available only if the tilt
option is configured for the lift truck.
Repair.

Action/ Expected
Meter Scale Results


Output Tests Test O08 - Toggle the Sideshift Solenoid
Test O08 - Toggle the 2. Disconnect wire SIDESHIFT-1 from the

sideshift solenoid.
Sideshift Solenoid 3. Connect a digital ammeter in series with
the sideshift solenoid coil, positive lead (+)
This test turns the sideshift solenoid ON and to the wire removed and the negative lead
OFF, verifying its correct operation electrically. (–) to terminal SIDESHIFT-1 on the
solenoid.
A successful test proves the sideshift solenoid 4. Reconnect the battery connector and turn
coil, wiring, and related circuitry in the Vehicle the key switch ON.
Manager are functioning correctly. 5. Run Test O08 and toggle the solenoid coil
It does not prove the sideshift solenoid valve is test ON and OFF. The display shows ON or
functioning mechanically. OFF. The ammeter must read approx.
560 mA.
Run Test a. If the ammeter reading is correct, the
solenoid coil is functioning electrically.
Maintenance Mode, refer to page 3-23. b. If the solenoid is not working correctly,
check for a mechanical problem in the
NOTE: This test is available only if the sideshift
option is configured for the lift truck.
1. Turn the key switch OFF and disconnect Repair.

Action/ Expected
Meter Scale Results


Test O11 - Toggle Load Hold Solenoid Output Tests
Test O11 - Toggle Load 2. Disconnect wire SOL1-1 from the load
hold solenoid.
Hold Solenoid 3. Connect a digital ammeter in series with
the load hold solenoid coil, positive lead (+)
This test turns the Load Hold Solenoid (SOL1) to the wire removed, and the negative
ON and OFF, verifying its correct operation lead (–) to terminal SOL1-1 on the
electrically. solenoid.
A successful test proves the load hold solenoid the key switch ON.
coil, wiring, and related circuitry in the Vehicle 5. Run Test O11 and toggle the solenoid coil
It does not prove the load hold solenoid valve is OFF. The ammeter must read approx.
Repair.

Action/ Expected
Meter Scale Results

1 JPF2-5 JPC18-10 Approx. 30 Ohms Perform step 2
and JPF2/Ohms wires
2 DCV JPC18-10 TP4 B+ Replace VM T/S K2 circuit

Output Tests Test O12 - Ramp Proportional Lower Solenoid
Test O12 - Ramp

Proportional Lower
Solenoid
Refer to Test A34 - Lower Current (Page 6-53).

Test O18 - Toggle Horn Output Tests
Test O18 - Toggle Horn

This test turns the truck’s horn ON and OFF.
Run Test
1. Use the ENTER button to toggle the test
ON and OFF. The display shows ON or
OFF.
2. When the ENTER button is pressed, the
horn must sound. If it does not sound, the
test has failed. Perform Diagnosis and
Repair.

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

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

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

Output Tests Test O19 - Audible Alarm
Test O19 - Audible

Alarm
This test turns on the display alarm by
gradually increasing the PWM voltage.
Run Test
If the alarm does not sound when you press the
ENTER button, the test has failed. Replace
display.

Test O20 - Travel Alarm (optional) Output Tests
Test O20 - Travel Alarm

(optional)
This test toggles the Travel Alarm ON and OFF.
Run Test

If the alarm does not sound when you depress

the ENTER button, the test has failed. Perform

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

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

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

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

test ON and OFF. The display shows ON or OFF.
NOTE: Upon exiting this test, the power
amplifier fans remain in the state last
chosen (ON or OFF), until the technician
exits Program Mode. This permits
running Test O23 in conjunction with
other tests.
If the fans do not toggle ON/OFF when you

depress the TILT UP/DOWN buttons, the test
has failed. Perform Diagnosis and Repair.
NOTE: The fans are wired in parallel. If one fan
fails, it can cause the other fans to stop
working. Check fans before performing

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

Test O27 - Ramp Aux Motor (Regen Lower) Output Tests
Test O27 - Ramp Aux Use the TILT DOWN button to increase the RPM
request by 200 RPM increments, from a
Motor (Regen Lower) minimum of 250 RPM to a maximum of
2250 RPM.
This test ramps the Aux Motor by gradually TILT UP resets the request to 0.
increasing the command to the Aux Power
Amplifier via the CAN Bus. This test verifies the Use the HORN button to stop the motor, reset
Aux Power Amplifier can drive the Aux Motor. the RPM request to 0, de-energize the main
contactor, and exit the test.
Running this test for an extended period If the expected results are not displayed,
of time can cause damage to the Aux perform Diagnosis and Repair.
Motor, Aux Power Amplifier, or wiring.
Run Test
NOTE: This test will time out after 30 seconds.
The display first shows the current RPM

request.

Action/ Expected
Meter Scale Results
If current does not ramp

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

Output Tests Test O28 - Ramp Lift Motor
Test O28 - Ramp Lift The display first shows the current RPM
request.
Motor Use the TILT DOWN button to increase the RPM
This test ramps the Lift Motor by gradually minimum of 600 RPM to a maximum of
increasing the command to the Lift Power 3000 RPM.
Amplifier via the CAN Bus. This test verifies the
Lift Power Amplifier can drive the Lift Motor. TILT UP resets the request to 0.
Use the HORN button to stop the motor, reset

the RPM request to 0, de-energize the lift
The Lift Motor may rotate during this contactor, and exit the test. If instead, you
test. Make sure truck is in an area with press TILT UP, TILT DOWN, SIDESHIFT LEFT,
sufficient overhead clearance for lifting or SIDESHIFT RIGHT, the test is still active with
the mast. the request set to 0.

Running this test for an extended period
of time can cause damage to the Lift
Motor, Lift Power Amplifier, or wiring.
Run Test
NOTE: This test will time out after 30 seconds
and must be restarted if necessary.

Action/ Expected
Meter Scale Results

test cables to Lift Motor.
Current must be
If OK, replace Lift Motor.
Current probe even on all
If phases are low or
(amp clamp) on phases and
1 N/A N/A Replace LPA unequal, replace the
phases U, V, and ramp up as the
LPA. If phases are equal
W percentage
and high but motor runs
increases
slowly, check for
replace Lift Motor.

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

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

minimum of 25 RPM to a maximum of 725
The Traction Motor will rotate during this RPM.
test. Jack the drive wheels off the floor.
Use extreme caution whenever the lift Once the maximum RPM request is reached,
truck is jacked up. Never block the lift pressing TILT DOWN again resets the request to
truck between the telescopic and the 0. TILT UP also resets the request to 0.
mast. Keep hands and feet clear from Use the HORN button to stop the motor, reset
vehicle while jacking the lift truck. After the RPM request to 0, and exit the test. If
the lift truck is jacked, place solid blocks instead, you press TILT UP, TILT DOWN,
or jack stands beneath it to support it. SIDESHIFT LEFT, or SIDESHIFT RIGHT, the
DO NOT rely on the jack alone to test is still active with the request set to 0.
Safety” on page 2-9. If the expected results are not displayed,
Running this test for an extended period

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

Action/ Expected
Meter Scale Results

test cables to Traction
Current must be Motor. If OK, replace
Current probe even on all Traction Motor. If
(amp clamp) on phases and phases are low or
1 N/A N/A Replace TPA
phases U, V, and ramp up as the unequal, replace the
W percentage TPA. If phases are equal
increases and high but motor runs
slowly, check for
replace Traction Motor.

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

Coil
See “Test A35 - Brake Armature” on page 6-54.

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

K1, K2, K3, and K4
This test toggles the relays ON and OFF.
Run Test
NOTE: OFF is displayed when entering the test
even if the relays are closed.
Press the ENTER button to toggle the test.
The 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
** If the Cold Storage option is enabled, JPF2-4 may
be at B+ with the key OFF and the battery plugged
in.


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

Output Tests Test O33 - Handle Heater (optional)
Test O33 - Handle

Heater (optional)
This test proves the control handle heater is
working correctly.
Run Test
1. The display shows 25% if the voltage from
the VM to the handle heater is correct.
2. 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


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 JP12-7 JH1-7 Perform step 3 Replace cable from

Ohms 0 Ohms
3 JP12-12 JH1-13 Replace handle VM to handle

Test O61 - Customer Output (optional) Output Tests
Test O61 - Customer

Output (optional)
This test turns the Customer Output ON and
OFF.
Run Test
Press the ENTER button to toggle the test ON

and OFF. The display shows ON and OFF.
The voltage to the Custom Output is dependent

on the option connected at the output. It can be
approximately 5, 12, 24, or 36V (±10%). If the
voltage does not change from 0V to one of these
values when the ENTER button is toggled ON,
the test has failed. Perform Diagnosis and
Repair.

Action/
Meter Scale
1 JPS10-3 Test OFF = 0V Replace option Perform step 2

DCV TP4 Test ON = approx. Check wiring to
2 5, 12, 24, or 36V Perform step 3
customer option
JPT1-3
Disconnect
3 JPS10-3 0 Ohms Replace TPA T/S wiring
JPT1/Ohms

Models 7500/7520 Reach-Fork ® Trucks Section 7. Component Procedures
Section 7. Component Procedures

Section 7. Component Procedures Models 7500/7520 Reach-Fork ® Trucks
List of Component Procedures

Component Locator Photos . . . . . . . . . . 7-5 Electrical Components . . . . . . . . . . . . 7-65
Tractor, Standard Lift, Fore/ Battery Procedures . . . . . . . . . . . . . . . . 7-66
Aft Stance. . . . . . . . . . . . . . . . . . . . 7-6 Battery Connector/Cables . . . . . . . . 7-66
Tractor Deck, Standard Lift, Battery Exterior Cleaning . . . . . . . . . 7-67
Fore/Aft Stance . . . . . . . . . . . . . . . 7-7 Testing, Charging, and Maintenance. 7-67
Tractor Deck, Fore/Aft Stance, Battery State-of-Charge . . . . . . . . . . 7-68
Regen Lower . . . . . . . . . . . . . . . . . . 7-7 Wiring and Harness Connectors . . . . . . 7-69
Tractor, Standard Lift, Dockstance . . . 7-8 General Repair Procedures . . . . . . . . 7-69
Tractor Deck, Standard Lift, Molex Connectors. . . . . . . . . . . . . . . 7-70
Dockstance. . . . . . . . . . . . . . . . . . . 7-9 AMP Water-Resistant Connectors . . . 7-71
Standard Carriage, Operator View . . . 7-10 AMP Harness/Power Amp Connector 7-74
Underside Components . . . . . . . . . . . 7-11 Power Cables . . . . . . . . . . . . . . . . . . . . 7-77
Motors . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
Special Tools, Decals, and Chassis ... 7-13 Power Cable Terminals . . . . . . . . . . . 7-79
Special Tools . . . . . . . . . . . . . . . . .... 7-14 DC Motor Troubleshooting . . . . . . . . 7-79
Decals and Plates . . . . . . . . . . . . .... 7-15 AC Motor Troubleshooting . . . . . . . . 7-79
Baselegs . . . . . . . . . . . . . . . . . . . .... 7-20 DC Motor Service . . . . . . . . . . . . . . . 7-79
Polishing the Commutator . . . . . . . . 7-81
Steering and Controls . . . . . . . . . . . . . 7-21 AC Motor Service . . . . . . . . . . . . . . . 7-81
Steer Tiller Encoder . . . . . . . . . . . . . . . 7-22 Steer Amplifier . . . . . . . . . . . . . . . . . . . 7-83
Steer Limit Switch (S11) . . . . . . . . . . . 7-23 Cold Storage Conditioning . . . . . . . . . . 7-84
Vertical Gap Adjustment . . . . . . . . . . 7-23
Lateral Adjustment . . . . . . . . . . . . . . 7-23 Hydraulic Components . . . . . . . . . . . . 7-85
Steerable Caster . . . . . . . . . . . . . . . . . 7-24 Hydraulic System Bleeding . . . . . . . . . . 7-86
Initial Adjustment . . . . . . . . . . . . . . . 7-24 Hydraulic Filter . . . . . . . . . . . . . . . . . . 7-87
Caster Height Adjustment . . . . . . . . . 7-25 Lift Pump Replacement (Regen Lower) . . 7-88
Steering Linkage . . . . . . . . . . . . . . . . . 7-27 Lift Pump Priming - Regen Lower . . . . . 7-89
Control Handle . . . . . . . . . . . . . . . . . . 7-28 Aux Pump Priming - Regen Lower . . . . . 7-90
Primary Control Handle - Fore/ Lift Pressure Adjustment . . . . . . . . . . . 7-91
Aft Stance. . . . . . . . . . . . . . . . . . . 7-28 Manual Lowering of Fork Carriage . . . . 7-92
Dockstance Control Handle . . . . . . . . 7-33 Proportional Valve Adjustment . . . . . . . 7-93
Secondary Control Handle - Fore/ Auxiliary Pump/Motor Service -
Aft Stance. . . . . . . . . . . . . . . . . . . 7-37 Regen Lower . . . . . . . . . . . . . . . . . . . 7-94
Auxiliary Pressure Adjustment . . . . . . . 7-95
Drive and Brake . . . . . . . . . . . ...... 7-39 Main Manifold - Standard Lift . . . . . . . . 7-96
Drive Unit . . . . . . . . . . . . . . . ....... 7-40 Lift/Lower Manifold - HSL and
Required Tools . . . . . . . . . . ....... 7-41 Regen Lower . . . . . . . . . . . . . . . . . . . 7-97
Troubleshooting . . . . . . . . . ....... 7-43 Aux Manifold - Regen Lower . . . . . . . . . 7-98
Radial Ring Inspection . . . . ....... 7-44 Aux Manifold - Standard Reach
Drive Unit Removal . . . . . . . ....... 7-44 35.5 in. Wide Mast . . . . . . . . . . . . . . 7-99
Drive Unit Disassembly . . . . ....... 7-45 Standard Reach Manifold -
Drive Unit Assembly . . . . . . ....... 7-49 32 in. Wide Mast . . . . . . . . . . . . . . . 7-101
Brake . . . . . . . . . . . . . . . . . . ....... 7-58 Deep-Reach ® Manifold -
Deadman Pedal . . . . . . . . . . . ....... 7-60 35.5 in. Wide Mast . . . . . . . . . . . . . 7-103
Inertial Dampener . . . . . . . . . ....... 7-61 Deep-Reach ® Manifold -
Removal . . . . . . . . . . . . . . . ....... 7-61 32 in. Wide Mast . . . . . . . . . . . . . . . 7-104
Installation and Adjustment ....... 7-62 Tilt/Sideshift Manifold . . . . . . . . . . . . 7-105

Hydraulic Components, Cylinder . . . . 7-107 Carriage, Free Lift Cylinder, and

Lift Cylinder, Free Lift, Remove/Install 7-108 Hose/Cable Installation . . . . . . . 7-162
Model 7500 . . . . . . . . . . . . . . . . . . . 7-108 Mating Mast to Tractor . . . . . . . . . . 7-164
Model 7520 . . . . . . . . . . . . . . . . . . . 7-110 Mast, Model 7520
Lift Cylinder, Free Lift, Seal Repacking 7-112 (Complete Disassembly) . . . . . . . . . . 7-167
Lift Cylinder, Main, Remove/Install . . 7-114 Separation of Tractor and Mast. . . . 7-167
Left Side Main Lift Cylinder . . . . . . . 7-114 Hose/Cable, Free Lift Cylinder,
Right Side Main Lift Cylinder . . . . . . 7-115 and Carriage Removal . . . . . . . . 7-167
Lift Cylinder, Main, Seal Repacking . . 7-117 Main Lift Chain Removal. . . . . . . . . 7-169
Lift Cylinder Lowering Cushion . . . . . 7-118 Separation of Telescopics . . . . . . . . 7-170
Reach Cylinder . . . . . . . . . . . . . . . . . 7-120 Mast, Model 7520
Tilt Cylinder . . . . . . . . . . . . . . . . . . . . 7-123 (Complete Assembly) . . . . . . . . . . . . 7-172
Sideshift Cylinder . . . . . . . . . . . . . . . 7-125 Assembling and Shimming Outer
Flow Limiter, Main Lift . . . . . . . . . . . . 7-126 Telescopic to Main Frame . . . . . . 7-172
Flow Limiter, Free Lift . . . . . . . . . . . . 7-127 Assembling and Shimming Inner
Telescopic to Outer Telescopic . . 7-173
Mast, Chain, Hose, Cable . . . . . . . . . . 7-129 Main Lift Chain Installation . . . . . . 7-173
Carriage Bearings . . . . . . . . . . . . . . . 7-130 Shimming Carriage to Inner
Mast Shimming . . . . . . . . . . . . . . . . . 7-131 Telescopic . . . . . . . . . . . . . . . . . 7-174
Mast and Bearing Inspection . . . . . . 7-131 Carriage, Free Lift Cylinder, and
Shimming Procedure . . . . . . . . . . . . 7-132 Hose/Cable Installation . . . . . . . 7-174
Bow Pad Inspection . . . . . . . . . . . . . . 7-133 Mating Mast to Tractor . . . . . . . . . . 7-177
R35TT Masts . . . . . . . . . . . . . . . . . . 7-133 Back Tilt and Lateral Lean Inspection . 7-178
R45TT and DR32TT Masts. . . . . . . . 7-135
Carriage . . . . . . . . . . . . . . . . . . . . . . . 7-136
Chain Anchors . . . . . . . . . . . . . . . . . . 7-137
Main Lift Chain Anchors . . . . . . . . . 7-137
Free Lift Chain Anchors. . . . . . . . . . 7-138
Lift Chains . . . . . . . . . . . . . . . . . . . . . 7-140
Height Encoder Belt . . . . . . . . . . . . . . 7-142
Hose and Cable, Over-the-Mast . . . . . 7-145
Removal . . . . . . . . . . . . . . . . . . . . . 7-146
Installation . . . . . . . . . . . . . . . . . . . 7-147
Cable, Over-the-Mast . . . . . . . . . . . . . 7-151
Over-the-Mast Cable Replacement . . 7-151
Hose/Tubing, Free Lift Feed . . . . . . . . 7-154
Mast, Model 7500
(Complete Disassembly) . . . . . . . . . 7-155
Separation of Tractor and Mast . . . . 7-155
Hose/Cable, Free Lift Cylinder,
and Carriage Removal . . . . . . . . . 7-155
Main Lift Chain Removal . . . . . . . . . 7-156
Separation of Telescopics. . . . . . . . . 7-156
Mast, Model 7500
(Complete Assembly) . . . . . . . . . . . . 7-159
Assembling and Shimming Outer
Telescopic to Main Frame . . . . . . 7-159
Assembling and Shimming Inner
Telescopic to Outer Telescopic. . . 7-160
Main Lift Chain Installation . . . . . . . 7-160
Shimming Carriage to Inner
Telescopic . . . . . . . . . . . . . . . . . . 7-161


Component Locator Photos

Overhead Guard
Evolution Display
Main Lift Cylinder
Free Lift Cylinder
Tractor
Load Wheels
Baseleg
Battery Gate
Drive Wheel Steerable Caster Wheel

Tractor, Standard Lift, Fore/Aft Stance
Mast Guard
Dash Panel
Primary Control
Handle
Steer Tiller Secondary
Control Handle
(optional)
Hydraulic Filter
Hydraulic Fuse/Relay Card

Reservoir
Vehicle Manager
Horn
Aux Manifold
(Regen Lower only)
Contactor Panel
Brake
Electric Steer Specification Plate
Motor
Traction Motor Traction Power
Amp
Reservoir Drain
Hose Cooling Fan
Drive Unit
(not visible)
Inertial Dampener
ESD Ground Jack
Deadman Pedal
Steerable Caster
Wheel (not visible)
Traction Tire

Tractor Deck, Standard Lift, Fore/Aft Stance

Lift Power Amp Emergency Power Off
Dash Panel
Key Switch
Lift Pump
Main Manifold
Sounder
Fuse/Relay Card Primary Control Handle
Tractor Deck, Fore/Aft Stance, Regen Lower

Emergency Power Off Key Switch
Lift Power Amp Dash Panel
Lift/Lower Manifold Lift Pump
Steer Amplifier
Aux Motor
Sounder
Primary Control Handle

Fuse/Relay Card

Tractor, Standard Lift, Dockstance
Steer Tiller
Steer Amplifier
Hydraulic Filter Fuse/Relay Card
Hydraulic
Reservoir
Vehicle Manager
Horn
Contactor Panel
Brake
Specification Plate
Electric Steer
Traction Power
Motor
Amp
Cooling Fan
Traction Motor
Inertial Dampener
Drive Unit
ESD Ground Jack
(not visible)
Deadman Pedal
Steerable Caster
Wheel (not visible)
Aux Manifold
(Regen Lower only)

Tractor Deck, Standard Lift, Dockstance
Lift Power Amp Dash Panel Lift Pump Emergency Power Off
Main Manifold
Lift Motor
Control Handle

Standard Carriage, Operator View (Mast Guard removed for

clarity)
Free Lift
Cylinder
Hose Chain
Retainer/ Anchor
Guide
Bleed Screw
Aux
Manifold
Hose
Reach
Tensioning
Cylinder
Spring
Tilt Cylinder

Underside Components
Static Strap
Steering
Linkage
A-frame
Drive Wheel
Steerable Caster Wheel


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


Special Tools Special Tools, Decals, and Chassis
Special Tools
The following tools are available from your local
authorized Raymond Sales and Service Center.
Table 7-1. Special Tools
Tool Part Number Purpose
Anti-static Field Kit 1-187-059 ESD Protection
Anti-static Wrist Strap 1-187-058/001
Chain Gauge 939-10606 Lift chain inspection
Connector Unlatching 950-042 Separate AMP connectors
Crimp Tool 1069861 Crimp power cable lugs
End Cap 1090761/005 Model 7500 Free Lift Cylinder w/staging and Model 7520
Main Lift Cylinder end cap removal/installation
End Cap 1090761/007 Model 7500 Main Lift and Free Lift Cylinder w/o staging
end cap removal/installation
End Cap 1090761/004 Model 7520 Free Lift Cylinder end cap removal/
installation
Fork Wear Caliper 922-369 Fork inspection
Pin Extraction 950-009 AMP connector pin extraction
Pin Extraction 950-026 MOLEX connector pin extraction
Scissor Arm - Single Reach 761-870/T07 Install slotted nut on single reach scissor arm
Seal Driver 401-000-051 Free Lift Cylinder seal installation
Surge Protector 154-010-801 ESD/voltage surge protection for serial type FlashWare
connections
USB/CAN Interface 230489-001 FlashWare connection to truck

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

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

(both sides)
2 ACR or ACR Regen Tractor frame, with respect to battery

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

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

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

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

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

storage decal
14 Patent Decal Inside of Traction Motor compartment door,

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

centered with ventilation slots, above patent
decal
16 Traction Motor Warning Decal Inside of Traction Motor compartment door,

centered with ventilation slots, above
lubrication decal
17 Hydraulic Filter Locator On reservoir, forward of filler cap

Decals and Plates Special Tools, Decals, and Chassis
Decal and Specification Plate Locations
Identifier Description Location
18 Mast Specification Plate Right side of mast, 2 in. (50.8 mm) above top
of baseleg
19 ISO 9001 Decal Centered on mast main frame (both sides),

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

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

conformance
NOTE: Items in italics are safety decals.


Figure 7-1. Decal and Specification Plate Locations, Tractor
Fore/Aft Stance Dockstance
7 8
7 6
9
2
2
3
3
4
4
1
1
10 10
16
16
15 11
15 11
14
14
12
12
13
13

Decals and Plates Special Tools, Decals, and Chassis

Figure 7-2. Decal and Specification Plate Locations, Mast
23 (inside surface)
22
19
21
5
20
18


Figure 7-3. Warning/Safety Decals
10
17
23

Baselegs Special Tools, Decals, and Chassis
Baselegs
Baseleg weighs over 100 pounds
Removal (45 kg). Use a suitable lifting device to
assist in removing baseleg.
1. Lower the mast and retract the carriage
completely. 8. Slide the baseleg off the locating pins. See
Figure 7-5. If added force is needed to
separate the baseleg from the mast,
protect the casting from direct blows.
3. Remove the front cover(s).
Figure 7-5. Baseleg Removal, Model 7500 shown
4. Remove the battery gate on the side being
repaired.

vehicle while jacking the lift truck. After Locating
the lift truck is jacked, place solid blocks Pins
Installation
1. Apply anti-seize compound (P/N 990-452)
5. Jack and block the lift truck under the to the baseleg alignment pins and mating
side of the tractor. surfaces of main frame, baseleg, and
baseleg shim, if used. Insert locating pins
6. Remove the load wheel assembly mounting
into the mast.
bolts. Slide the load wheel assembly off the
baseleg. See Figure 7-4. 2. Using a suitable lifting device, install
baseleg. Refer to “Component Specific
Figure 7-4. Load Wheel Assembly and Baseleg Service/Torque Chart” on page A-4.
(closed toe version shown)
3. Slide load wheel assembly over baseleg.
4. Apply solvent (P/N 990-589), primer
(P/N 990-533), and retaining compound
(P/N 990-575) to the outside of the
mounting bolt sleeve and inside the
baseleg hole.
5. Install load wheel assembly. Refer to
“Component Specific Service/Torque
Chart” on page A-4.
6. Remove blocking and lower baseleg to the
floor.
7. Install front cover(s).
7. Remove the baseleg mounting bolts. 8. Install battery gate.

Steering and Controls
Steering and Controls


Steer Tiller Encoder Steering and Controls
Steer Tiller Encoder 3. Assemble the snubber and tighten the jam
nut on the eyebolt so that the force
required to turn the steering wheel is 5 to
Removal 7 in. lb. (0.5 to 0.8 Nm).
4. Apply thread-locking compound
(P/N 990-536) to the steering wheel cap
screws.
5. Position the steering wheel over the steer
tiller encoder. Install cap screws.
Use correct electrostatic discharge 6. Install the steering wheel cover.
precautions. See “Static Precautions” on
page 2-8. 7. Attach the steering wheel cover to the
steering wheel with two bolts.
2. Remove the top cover and steering cover. 8. Apply anti-seize compound (P/N 990-452)
(You must remove the knob, steering wheel to the shoulder bolt. Install the steering
cover, and steering wheel before removing knob.
the steering cover.) 9. Install the top cover.
3. Remove the snubber adjustment nut and
swing the halves of the snubber out of the
way. See Figure 7-6.
Figure 7-6. Steer Tiller Encoder and Snubber
Snubber
Adjustment Nut
4. Disconnect encoder harness connectors

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

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

Figure 7-7. Steer Limit Switch
Steer Limit Steer Motor

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

2. Open the Traction Motor compartment
door.
3. Loosen the nuts securing the switch to the
bracket.
4. Adjust the vertical gap between the switch
and the sensing rail to 0.12 to 0.25 in. (3.0
to 6.4 mm). Tighten the nuts.
Lateral Adjustment
1. Run Test I90 - Degrees Turned Past Steer
Flag (Page 6-106).
2. Adjust the mounting bracket so the
reading on both ends is as close to 10° as
possible.

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

bolts underneath.
b. Loosen the center steering link locking
Correct caster adjustment is critical for correct
bolts. See Figure 7-9.
performance. A misadjusted caster can cause
excessive braking distances, poor stability, or
Figure 7-9. Steering Adjustments
damage to inertial dampener components.
Drive
C Caster
Wheel Wheel
Initial Adjustment B
1. The drive and caster wheels should be
parallel.
2. Place a straightedge along the tractor B
frame. Measure the distance from the C
straightedge to the front edge of the drive
tire and to the back edge. Adjust steering
until the measurements are equal. The
drive wheel is now parallel to the tractor
A
frame. See Figure 7-8.
Figure 7-8. Setting Drive Wheel Parallel Steering Steering

Link Link
Straightedge Drive Tire Locking Adjusting
Bolts (4) Bolts (2)
E E
C c. Loosen jam nuts on center steering link

adjusting bolts and adjust the bolts to
get both wheels parallel to the tractor
frame.
d. Apply thread-locking compound
(P/N 1013829) to steering link
adjusting bolts and locking bolts.
C e. Tighten the jam nuts on the adjusting

bolts.
f. Tighten locking bolts and torque to
70 ft. lb. (95 Nm).
g. Re-install the battery rollers. Using a
A suitable battery removing device,
3. Place a straightedge along the opposite
re-install the lift truck battery.
side tractor frame. Measure the distance
Re-install battery gates.
from the straightedge to the front edge of
the caster wheel and to the back edge. If
Caster height adjustment varies, depending
the dimensions are not equal, adjust as
upon the type of mast. See “Caster Height
follows.
Adjustment” on page 7-25.
a. Turn the key switch OFF and
disconnect the battery connector.
Remove battery gates. Using a suitable
battery removing device, remove the
battery and battery rollers from the lift

Steering and Controls Steerable Caster
Caster Height Adjustment

NOTE: Make sure a correctly rated battery is
installed in the lift truck prior to making Use extreme caution whenever the lift
this adjustment. truck is jacked up. Never block the lift
1. Remove the inertial dampener cover plate. truck between the telescopic and the
See Figure 7-10. floor. Use a suitable hoist to stabilize the
Figure 7-10. Inertial Dampener Cover Plate vehicle while jacking the lift truck. After
Figure 7-12. A-frame Spring Adjustments
Initially
1 in. Initially
(25 mm) 6 in.
(152 mm)
Cover Plate
2. Check the A-frame down-travel

adjustment bolt in Figure 7-11. Make sure 3. Jack the lift truck until the caster is clear
it is installed correctly. If the bolt is of the floor.
missing, the A-frame could drop and allow 4. Turn the A-frame down-travel adjustment
the springs to escape when the truck is bolt to obtain an initial gap of 1 in.
jacked up. (25 mm) between the arm and frame.
Adjust the A-frame spring nuts to obtain
Figure 7-11. A-frame Down-Travel Adjustment Bolt
an initial spring length of 6 in. (152 mm).
A-frame Spring Nuts See Figure 7-11 and Figure 7-12.
5. Lower the lift truck back onto the floor.
Make sure the lift truck is sitting on a flat
floor surface.
6. Adjust the A-frame spring nuts to obtain
the spring length listed in the table that
follows. The dimension is measured from
the top of the spring to the top of the
A-frame
caster, not the frame.
Down-Travel
Adjustment Bolt Elevated Height Spring Length
Below 330 in. (8328 mm) 5.75 in. (146 mm)
Above 331 in. (8407 mm) 5.50 in. (140 mm)

Steerable Caster Steering and Controls

(P/N 1013829) and turn the A-frame
down-travel adjustment bolt to set the
correct gap between the bottom of the bolt
head and the top of the flat washer. See
Figure 7-12 and the table below.
Elevated Height Gap
All 0.12 in. (3.05 mm)
Note: Do not overtighten the bolt. The bolt head

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

up-travel stop bolt. See Figure 7-13.
Figure 7-13. A-frame Up-Travel Stop Adjustment
A-frame
Up-Travel
Stop Bolt
9. Turn the A-frame up-travel stop bolt to

adjust the gap between the bolt head and
the top of the A-frame as follows (See
Figure 7-13):
Elevated Height Gap
Below 330 in. (8328 mm) 0.38 in. (9.65 mm)
Above 331 in. (8407 mm) 0.25 in. (6.35 mm)

(P/N 1013829) to the A-frame up-travel
stop bolt. Tighten the jam nut.
11. Test the lift truck for correct braking
action.
12. Reinstall the inertial dampener cover
plate.

Steering and Controls Steering Linkage
Steering Linkage
Use Figure 7-14 as a reference when
removing/replacing steering linkage
components. After replacing any components,
make sure the steering is adjusted correctly.
Figure 7-14. Steering Linkage
Section BB
and
Section CC
D
C
B
B
C D
A A
Detail of
Section AA
E E
Section EE
Section AA

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

1. Carefully peel the flex heater from the
travel pot. It is attached to the pot with
Primary Control Handle - double-sided tape. See Figure 7-16.
Fore/Aft Stance
Figure 7-16. Control Handle, Fore/Aft Stance
If a ThermaKit component fails, replace both Travel Pot Heater
handle shells; however, it may be more cost
effective to replace the entire handle.
Lift Pot
Disassembly
1. Remove the lift knob.
NOTE: The outer spring paddle may fall off
when the lift knob is removed.
Lift Pot
Connector Connector
ThermaKit Connector
Use correct electrostatic discharge
precautions. See “Static Precautions” on 2. Press the latch on the travel pot connector
page 2-8. and disconnect the travel pot from the flex
circuit. See Figure 7-16.
2. Remove the socket head cap screws from 3. Slide the travel pot out of the pivot shaft
the handle shell. assembly. See Figure 7-17.
3. Slide out the cable clamp.
NOTE: Do not lose the D-shaped clip inside the
4. Remove the screws securing the harness pivot shaft.
connector.
5. Carefully pull the flex circuit down the Figure 7-17. Pivot Shaft Assembly
cable clamp slot. See Figure 7-15. D-Clip
Figure 7-15. Flex Circuit in Cable Clamp Slot

Spring Snap Ring
Flex Circuit
Pin
Paddle
4. Remove the external snap ring.

NOTE: Observe orientation of the spring and
paddles on the pivot shaft.
5. Remove the spring and paddles from the
pivot shaft. See Figure 7-17.
6. Apply a thin coat of lubricant
6. Lift off the upper handle shell. If (P/N 990-635) to the inside surface of the
ThermaKit equipped, the upper shell can spring. Assemble spring between the
be removed but wiring will connect the two spring paddles. See Figure 7-18.
halves.

Steering and Controls Control Handle

Figure 7-18. Travel Pot Spring Assembly 3. Press the latch on the lift pot connector
and disconnect the lift pot from the flex
4. Carefully peel the flex heater from the lift
pot. It is attached to the pot with
double-sided tape.
5. Pull the lift pot/bracket assembly out of
the handle shell.
6. Slide the lift pot out of the lift pot bracket.
7. Slide the spring and paddles part way 7. Slide a new lift pot into the lift pot bracket.
down the pivot shaft to engage the lower The lift pot tang must slide into the slot on
spring tang. the lift pot bracket. See Figure 7-20.
8. Using the upper paddle, press the upper
Figure 7-20. Lift Pot and Bracket
spring tang over the pin on the pivot shaft.
With one paddle and one spring tang on
each side of the pin, slide all parts down to Tang Slot in
expose the snap ring groove. See Bracket
Figure 7-17.
9. Install the external snap ring. See
Figure 7-17.
10. Slide the travel pot shaft into the pivot
shaft assembly (make sure D-clip is in
pivot shaft). 8. Slide the inner spring paddle onto the lift
11. Re-tape the flex heater to the travel pot pot bracket.
body. Replace the double-sided tape if 9. Apply a thin coat of lubricant
necessary. See Figure 7-16. (P/N 990-635) to the inside surface of the
12. Re-seat the travel pot flex connector in the spring. Install the spring with one tang
handle shell. Re-connect the travel pot to resting on the inner spring paddle (not the
the flex circuit. See Figure 7-16. dowel pin).
10. Slide the outer spring paddle part way
Lift Pot Repair/Replacement onto the lift pot shaft to engage the outer
spring tang.
1. Slide the outer paddle and lift pot spring
off the lift pot shaft. See Figure 7-19. 11. Using the outer paddle, press the outer
spring tang over the dowel. Slide parts
NOTE: Observe orientation of the lift pot spring, together until the outer paddle is flush
paddles, and dowel pin. with the lift pot bracket. See Figure 7-19.
Figure 7-19. Lift Pot and Spring Assembly 12. Make sure the tilt/sideshift card is
correctly positioned. Slide the lift
Lift Pot Paddle (flush pot/bracket assembly into the lower
with bracket handle shell. See Figure 7-21.
stem)
Lift Pot Shaft
Connector Dowel Pin

Paddle Spring
2. Slide the inner spring paddle off the lift pot

shaft.


Figure 7-21. Lift Pot Bracket Position Figure 7-23. ThermaKit Heaters and Connector
ThermaKit Horn Reach/Retract
Slot in Shell Buttons
Connector Button
Tab on Pot
Bracket
ThermaKit
13. Re-tape the flex heater to the lift pot body. Heaters Tilt/Sideshift Card
Replace the double-sided tape if
necessary. Use a screwdriver blade to
press the heater against the pot body.
14. Re-connect the ThermaKit (if so equipped)
to the flex circuit. 2. Hold the tilt/sideshift button and card
between thumb and forefinger. Tip the
15. Align the tang on the travel pot with the
card back and remove it from the handle
2nd rib on the flex circuit side of the lower
shell (the gasket on the tilt/sideshift
handle shell. See Figure 7-22.
button may fall off as the tilt/sideshift
Figure 7-22. Travel Pot Alignment in Shell card is removed from the handle shell).
3. Carefully remove the lift pot connector
Tang from the slot in the handle shell.
4. Remove the reach/retract and horn
buttons from the handle shell.
5. Carefully remove the ThermaKit and travel
pot connectors from the slots in the handle
shell. See Figure 7-16.
6. Lift the flex circuit out of the handle shell.
Rib
7. Remove the tilt/sideshift button and
spring from the flex circuit by removing
one screw from the back of the
Flex Circuit Repair/Replacement
tilt/sideshift card.
1. Press the latch on the ThermaKit 8. To install the tilt/sideshift button and
connector and disconnect the ThermaKit spring on the tilt/sideshift card, place the
(if so equipped) from the flex circuit. See spring over the post on the back of the
Figure 7-23. tilt/sideshift button. Align the “A” on the
back of the button with the “A” on the
card. See Figure 7-24. Press the button
against the card so the post protrudes
through the back of the card. Thread the
screw into the post until it just bottoms,
then tighten an additional 1/8 turn. Do
not overtighten.


Figure 7-24. Tilt/Sideshift Card and Button • A - travel pot tang is entering the slot in
the shell
Orientation Letter ”A”
• B - plastic alignment post on upper
shell is entering the alignment hole on
the lower shell
• C - travel shaft pin on upper shell is
passing between the paddles of the
pivot shaft assembly
Tilt/Sideshift • D - reach/retract buttons are entering
Button Circuit Card the holes in the handle shell
• E - backing ribs that hold the horn
9. Slide the horn button over the positioning
button in place are not pinching the
pin.
flex circuit
10. Press the ThermaKit and travel pot
• F - harness connector end of the flex
connectors into the slots in the lower
circuit is entering the cable clamp slot
handle shell. See Figure 7-16.
without pinching.
11. Place the gasket over the tilt/sideshift
button. Gently position the tilt/sideshift Figure 7-26. Primary Control Handle Assembly - Fore/Aft
card in the handle shell. The bottom of the Stance
card sits forward of a ridge in the handle;
the card edge nearest the lift knob sits
behind a ridge in the handle. Confirm that D
the gasket is in place on the tilt/sideshift F A
button. See Figure 7-25. D A
Figure 7-25. Tilt/Sideshift Card Position B
Card Sits
Forward
of Ridge
C E
B
Card Sits 3. Squeeze the handle halves together.
Behind
Ridge 4. Place the tip of a screwdriver into the pivot
shaft set screw hole. Gently rotate the
shaft in both directions to confirm that the
pin in the upper handle shell is between
the paddles. Do not over-rotate the shaft,
as this can cause damage. You should feel
12. Correctly position the reach/retract spring tension immediately and there
buttons and route the harness connector should be no free play in the pivot shaft. If
end of the flex circuit through the locating you do not feel spring tension, lift off the
slots. upper handle shell, and repeat step 2.
5. Fasten the harness connector to the upper
Assembly handle shell. Tighten each screw until it
1. Confirm the flex circuit is routed correctly bottoms, plus an additional 1/16 turn. Do
through the locating slots. not overtighten.
2. Position the upper handle shell over the 6. Install the socket head cap screws.
lower shell and ease it into position. See Tighten each screw until it bottoms, plus
Figure 7-26. Make sure:

an additional 1/4 turn. Do not

overtighten.
7. Slide the cable clamp into the cable clamp
slot and secure.
8. Confirm the two spring paddles and spring
are in place. The outer paddle must be
flush with the end of the lift pot bracket.
See Figure 7-19.
9. Set the flat on the lift pot shaft 90° to the
top spring paddle. See Figure 7-27.
Figure 7-27. Lift Pot Shaft Alignment
Dowel Pin Paddles
10. Install the lift knob with the dowel pin in

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

Dockstance Control Handle 4. Lift the travel pot shaft out of the lower
handle shell.
If a ThermaKit component fails, replace both 5. Slide the travel pot out of the pivot shaft
handle shells; however, it may be more cost assembly. See Figure 7-28.
effective to replace the entire handle.
pivot shaft.
Disassembly
6. Remove the external snap ring./
1. Remove the lift knob.
Figure 7-29. Pivot Shaft Assembly
NOTE: The outer spring paddle may fall off
when the lift knob is removed. D-Clip
Spring Snap Ring

Pin
page 2-8.
Paddle
2. Remove the socket head cap screws from
the handle shell. NOTE: Observe orientation of the spring and
3. Lift off the upper handle shell. If paddles on the pivot shaft.
ThermaKit equipped, the upper shell can 7. Remove the spring and paddles from the
be removed but wiring will connect the two pivot shaft. See Figure 7-29.
halves.
(P/N 990-635) to the inside surface of the
Travel Pot Repair/Replacement spring. Assemble spring between the
1. Carefully peel the flex heater from the spring paddles. See Figure 7-30.
travel pot. It is attached to the pot with
Figure 7-30. Travel Pot Spring Assembly
double-sided tape.
2. Remove harness connector and travel pot
heater from lower shell. See Figure 7-28.
Figure 7-28. Pivot Shaft Components
Travel Pot Spring
Travel Pot Connector

Travel Pot
9. Slide the spring and paddles part way

down the pivot shaft to engage the lower
spring tang.
10. Using the upper paddle, press the upper
spring tang over the pin on the pivot shaft.
With one paddle and one spring tang on
Travel Pot Heater Pivot Shaft each side of the pin, slide all parts down to
Harness Connector expose the snap ring groove. See
3. Press the latch on the travel pot connector Figure 7-30.
and disconnect the travel pot from the flex 11. Install the external snap ring. See
circuit. See Figure 7-28. Figure 7-29.

12. Slide the travel pot shaft into the pivot Figure 7-32. Handle Shell - Dockstance
shaft assembly (make sure D-clip is in
Horn Button
pivot shaft). Lift Pot
13. Insert the pivot shaft assembly into the Reach/Retract Buttons Lift Pot Spring
lower handle shell. Make sure the tang on
the travel pot enters the center slot in the Lift Pot
shell. See Figure 7-31. Connector
Figure 7-31. Travel Pot Tang Alignment
Tang
Flex Circuit
ThermaKit Connector
Tilt/Sideshift Outer
Lift Pot Heater Button Paddle
2. Slide the inner spring paddle off the lift pot

shaft.
3. Press the latch on the lift pot connector
and disconnect the lift pot from the flex
4. Carefully peel the flex heater from the lift
pot. It is attached to the pot with
Slot
double-sided tape.
5. Pull the lift pot/bracket assembly out of
14. Re-tape the flex heater to the travel pot
the handle shell.
body. Replace the double-sided tape if
necessary. See Figure 7-28. 6. Slide the lift pot out of the lift pot bracket.
15. Re-seat the travel pot flex connector in the 7. Slide a new lift pot into the lift pot bracket.
handle shell. Re-connect the travel pot to The lift pot tang must slide into the slot on
the flex circuit. See Figure 7-28. the lift pot bracket. See Figure 7-33.
Figure 7-33. Lift Pot Tang and Bracket Slot

Lift Pot Repair/Replacement
Tang and Slot
1. Slide the outer paddle and lift pot spring
off the lift pot shaft. See Figure 7-19.
NOTE: Observe orientation of the lift pot spring,
paddles, and dowel pin.
8. Slide the inner spring paddle onto the lift

pot bracket.
(P/N 990-635) to the inside surface of the
spring. Install the spring with one tang
resting on the inner spring paddle (not the
dowel pin).
10. Slide the outer spring paddle part way
onto the lift pot shaft to engage the outer
spring tang.

11. Using the outer paddle, press the outer 5. Carefully remove the ThermaKit and travel
spring tang over the dowel. Slide parts pot connectors from the slots in the handle
together until the outer paddle is flush shell. See Figure 7-32.
with the lift pot bracket. See Figure 7-33. 6. Lift the flex circuit out of the handle shell.
12. Make sure the tilt/sideshift card is 7. Remove the tilt/sideshift button and
correctly positioned. Slide the lift spring from the flex circuit by removing
pot/bracket assembly into the handle one screw from the back of the
shell. See Figure 7-34. tilt/sideshift card.
Figure 7-34. Lift Pot/Bracket Assembly Insertion 8. To install the tilt/sideshift button and
spring on the tilt/sideshift card, place the
Bracket Sits on Card Notch Fits in Slot spring over the post on the back of the
tilt/sideshift button. Align the “A” on the
back of the button with the “A” on the
card. See Figure 7-35. Press the button
against the card so the post protrudes
through the back of the card. Thread the
screw into the post until it just bottoms,
then tighten an additional 1/8 turn. Do
not overtighten.
Figure 7-35. Tilt/Sideshift Card and Button

13. Re-tape the flex heater to the lift pot body.
Replace the double-sided tape if Orientation Letter ”A”
necessary. Use a screwdriver blade to
press the heater against the pot body.
14. Route lift pot wires under the
reach/retract buttons. Re-connect the lift
pot to the flex circuit at the connector.
15. Re-connect the ThermaKit (if so equipped)
to the flex circuit. Tilt/Sideshift
Button Circuit Card
Flex Circuit Repair/Replacement 9. Press the ThermaKit and travel pot
1. Press the latch on the ThermaKit connectors into the slots in the handle
connector and disconnect the ThermaKit shell. See Figure 7-32.
(if so equipped) from the flex circuit. See 10. Place the gasket over the tilt/sideshift
Figure 7-32. button. Gently position the tilt/sideshift
2. Hold the tilt/sideshift button and card card in the handle shell. The bottom of the
between thumb and forefinger. Tip the card sits forward of a ridge in the handle;
card back and remove it from the handle the card edge nearest the lift knob sits
shell (the gasket on the tilt/sideshift behind a ridge in the handle. Confirm that
button may fall off as the tilt/sideshift the gasket is in place on the tilt/sideshift
card is removed from the lower handle button. See Figure 7-36.
shell).
3. Lift the horn button off the positioning
pin.
4. Carefully remove the lift pot connector
from the slot in the handle shell.


Figure 7-36. Tilt/Sideshift Card Insertion as this can cause damage. You should feel
spring tension immediately and there
Horn Button Hole Card Sits
should be no free play in the pivot shaft. If
Forward of
Ridge
you do not feel spring tension, lift off the
upper handle shell, and repeat step 2.
5. Fasten the harness connector to the upper
handle shell. Tighten each screw until it
bottoms, plus an additional 1/16 turn. Do
not overtighten.
Card Sits 6. Install the socket head cap screws.
Behind Tighten each screw until it bottoms, plus
Ridge an additional 1/4 turn. Do not
overtighten.
11. Correctly position the reach/retract
buttons and re-connect the ThermaKit (if 7. Confirm the two spring paddles and spring
so equipped) to the flex circuit. are in place. The outer paddle must be
flush with the end of the lift pot bracket.
Assembly 8. Set the flat on the lift pot shaft parallel to
the top spring paddle. See Figure 7-38.
1. Confirm the flex circuit is routed correctly
through the locating slots. Figure 7-38. Lift Pot Shaft Alignment
2. Position the upper handle shell over the
lower shell and ease it into position. See
Figure 7-37. Make sure:
• A - travel pot tang is entering the slot in
the shell
• B - travel shaft rib on upper shell is
passing between the paddles of the
pivot shaft assembly
Figure 7-37. Sidestance Handle Assembly
9. Install the lift knob with the dowel pin in

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

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

Secondary Control Handle - Figure 7-40. Secondary Control Handle End Cap
Fore/Aft Stance End Plug M4x8 mm
Travel Pot Repair/Replacement

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

shell.
precautions. See “Static Precautions” on NOTE: Do not lose the D-shaped clip inside the
page 2-8. pivot shaft.
5. Remove the snap ring in the handle shell.
2. Attach the foam pad to the back of the new See Figure 7-39.
travel pot body.
6. Remove the pivot shaft assembly from
3. Turn the travel pot shaft so the flat on the handle shell.
shaft aligns with the tang on the pot body.
See Figure 7-39. 7. Observe the orientation of parts on the
pivot shaft and remove. See Figure 7-41.
Figure 7-39. Secondary Control Handle Travel Pot
Figure 7-41. Secondary Handle Pivot Shaft Components
D-Clip Slot
Tang
Snap Ring
4. Insert travel pot into the handle shell,

aligning the flat on the shaft with the 8. Apply a thin coat of lubricant
D-clip, and the tang on the pot body with (P/N 990-635) to the inside surface of the
the slot in the shell. See Figure 7-39. spring. Assemble parts in the correct order
on the shaft.
Disassembly/Assembly 9. Slide the spring and paddles part way

down the pivot shaft to engage the lower
1. Remove the end plug from the end of the spring tang.
handle. See Figure 7-40. 10. Using the upper paddle, press the upper
2. Remove the two button-head socket spring tang over the tab on the pivot shaft.
screws from the end of the handle. See With one paddle and one spring tang on
Figure 7-40. each side of the pin, slide all parts down to
3. Remove the handle grip from the handle expose the snap ring groove. See
shell. Figure 7-42.


Figure 7-42. Secondary Control Handle Pivot Shaft Figure 7-43. Secondary Handle, PH3 Connector
Alignment
Paddle/Tang
Spring
Tab on Shaft
Paddle/Tang Insulation
2. Remove the 2 in. (50.8 mm) length of

Tab on Shell Shell shrink tubing from the wires. See
Figure 7-43.
3. Remove the snap ring from the back of the
11. Install the external snap ring and two
horn button. See Figure 7-44.
nylon washers.
12. Confirm that the D-clip is inside the pivot Figure 7-44. Secondary Control Handle Horn Button
shaft.
13. Insert the pivot shaft assembly into the
handle shell. Make sure the tab on the
shell slides between the paddles on the
shaft assembly. See Figure 7-42.
14. Insert travel pot into the handle shell,
aligning the flat on the shaft with the
D-clip, and the tang on the pot body with
the slot in the shell. See Figure 7-39.
15. Slide the handle grip over the handle shaft Snap Ring
and shell assembly. Orient the notch in
the handle flange with the harness 4. Pull wiring out through the channel in the
channel in the grip. handle grip.
16. Install the two button-head socket screws 5. Thread new wires down the channel in the
at the end of the handle and end plug. handle grip.
6. Install the horn button in the grip and
Horn Button secure it with the snap ring.
1. With the handle disassembled, remove the 7. Install a 2 in. (50.8 mm) length of shrink
three wires from the PH3 connector, noting tubing over the wire ends.
their colors and locations for later 8. Re-connect connector PH3 to the horn
re-connection. See Figure 7-43. button wires: red to pin 1, black to pin 2,
white to pin 3. Make sure there is a
connector seal on the connector.
9. Shrink the tubing.
10. Reassemble handle.

Drive and Brake
Drive and Brake


Drive Unit Drive and Brake
Drive Unit
Figure 7-45. Drive Unit Exploded View
22 23 21 20 19 25 26
24
4
27
3
2
18
6
12 16
13
29
5 9
28 8 10 11 7 14 15 32

Drive and Brake Drive Unit
Table 7-3. Drive Unit Set-Up Legend Required Tools

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

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

Special Tools
The tool shown in Figure 7-46 is recommended

for removal/installation of the drive unit.
Figure 7-46. Drive Unit Removal/Installation Tool
Top View Edge View
35°
Typical
“Eye” welded
to plate
Four 0.342 to 0.350 in. (8.7 to 5/16-18 UNC-2B equally

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

Troubleshooting
Table 7-5. Troubleshooting Drive Unit Symptoms
Symptom Probable Cause Required Action
Oil leaks Damaged lip seal Replace lip seal, main cover and bearing shims,
and output shaft bearings
Worn or damaged output shaft Replace lip seal, main cover and bearing shims,
output shaft bearings, and output shaft
Housing/main cover joint Reseal
Worn or damaged housing Replace drive unit
Drive wheel Worn or damaged output shaft bearings Replace lip seal, main cover and bearing shims,
wobbles and output shaft bearings
Worn or damaged output shaft Replace lip seal, main cover and bearing shims,
output shaft bearings, and output shaft
Loose wheel mounting hardware Inspect housing and main cover for damage,
re-torque mounting hardware. Refer to
“Component Specific Service/Torque Chart” on
page A-4.
Noise Worn or damaged output shaft bearings Replace lip seal, main cover and bearing shims,
and output shaft bearings
Worn or damaged pinion bearings Replace pinion bearings and clamp nut
Worn or damaged gear set - Output shaft Replace lip seal, main cover and bearing shims,
is in good condition output shaft bearings, pinion bearings, gear set,
and clamp nut
Worn or damaged gear set - Output shaft Replace lip seal, main cover and bearing shims,
is worn or damaged output shaft bearings, pinion bearings, gear set,
clamp nut, and output shaft
Worn or damaged helical gear and pinion Replace helical gear and pinion
Steering Inadequate bearing lubrication Grease pivot bearing and spherical bearing
binds
Worn or damaged pivot bearing Replace radial ring set, steel balls, bearing filler
plug, and spherical bearing
Steering Worn or damaged spur gear Replace spur gear and spherical bearing
binds
Worn or damaged spherical bearing Replace spherical bearing and grease fittings
Worn or damaged pivot ring Replace pivot ring, radial ring set, steel balls,
bearing filler plug, and spherical bearing

Radial Ring Inspection Figure 7-47. Dial Indicator Placement
If worn radial rings are suspected as the cause

of play in the drive unit, perform the following
steps to determine if the rings should be
replaced.

1. Jack the rear of the truck up until the

drive tire is clear of the floor.
2. Place a magnetic base dial indicator on the
tractor bumper. Place the indicator pin on
top of the ring gear. See Figure 7-47.
NOTE: When positioning the indicator, try to
align it with a feature on the truck (such
as a grease fitting). This helps maintain
consistent results between trucks. Drive Unit Removal
3. Zero the indicator and lower the truck to 1. Turn the key switch OFF and disconnect
the floor. Observe the new indicator the battery connector.
reading. 2. Drain the oil from the drive unit.
4. If the reading exceeds 0.090 in. (2.3 mm), 3. Loosen the drive tire lug nuts.
replace the radial rings.
4. Remove the horn assembly.
NOTE: Any looseness that results in the pivot
5. Disconnect the power cables from the
ring casting contacting the drive unit
Traction Motor, labeling the cables if
housing as the unit turns during
necessary for later installation. Use two
steering requires that the radial rings be
wrenches to avoid twisting the motor
changed immediately.
studs.
6. Disconnect remainder of wires and brake
hose.
7. Remove mounting bolts for cable bracket.
8. Remove Traction Motor mounting bolts.
Lift brake assembly and motor off drive
unit.
9. Remove the steering shaft.

10. To facilitate the removal of the drive unit, Drive Unit Disassembly
construct the tool shown in Figure 7-46.
Attach the tool to the top of the drive unit Numbers within brackets [ ] correspond to
using the screws that held the Traction items shown in the exploded view, Figure 7-45
Motor. on page 7-40.
11. Remove the dust shield between the ring
gear and the tractor frame. Clean the outside of the drive unit thoroughly
and drain any remaining oil from the drive unit
by removing the drain plug [12].
Visually inspect the outside of the housing [1]

Use extreme caution whenever the lift truck for damage, wear, or cracks.
is jacked up. Never block the lift truck
between the telescopic and the floor. Use a
suitable hoist to stabilize the mast. Keep Pivot Ring Disassembly
hands and feet clear from vehicle while 1. On the pivot ring [18], remove the grease
jacking the lift truck. See “Jacking fitting [21] and the bearing filler plug [20].
Safety” on page 2-9. Inspect the bearing filler plug hole for
uneven wear.
12. Secure the lift truck with a suitable
capacity hoist attached to the overhead Figure 7-48. Remove Grease Fitting and Filler Plug
guard. Jack the rear of tractor so that the
bottom edge of the bumper is approx. Filler Plug
6.5 in. (16.5 cm) off the floor.
13. Remove the drive wheel.
14. Disconnect the steer linkage from the drive
unit; swing the linkage clear.
15. Place a temporary support under the drive
unit or attach a hoist to the tool installed
in Step 10. Pivot Ring
Drive unit weighs approximately 175 lb. 2. Turn the pivot ring [18] to remove the steel
(80 kg.) balls [25] through the bearing filler plug
hole.
16. Loosen, then remove the four mounting NOTE: If the pivot ring does not spin or turn, it
screws holding the drive unit to the tractor is an indication of damaged radial rings
frame. The steering stop also becomes and/or excessive wear to the channel in
unattached at this stage. housing. If this is the case, replace the
17. Lower the drive unit to the floor. Tip the entire drive unit. No further disassembly
drive unit over on its side and remove the is necessary.
hoist.
18. If you have trouble separating the tool
from the drive unit, thread mounting
screws in the threaded holes in the tool to
push the tool off the drive unit.


Figure 7-49. Remove Steel Ball Bearings Figure 7-51. Remove Radial Rings
Radial Rings
3. After removing all the steel balls, remove

the pivot ring [18] by working it off toward Main Cover and Output Shaft
drive end of the housing. Disassembly
Figure 7-50. Remove Pivot Ring 1. Visually inspect the housing around the
main cover [16] for wear outside the cover
bolts [13]. Refer to Figure 7-52.
NOTE: Excessive housing wear outside the
cover bolts can make them difficult to
Pivot Ring remove. If this occurs, replace the entire
drive unit. No further disassembly is
necessary.
2. Remove the main cover bolts [13].
3. Using a mallet, knock the flanged output
shaft [9] to break the seal on the main
cover [16].
4. Remove the radial rings [24] from the 4. Remove the main cover and output shaft
channel in the housing and inside the assembly. Refer to Figure 7-52.
pivot ring.
5. You need a press and 8 x 6 in. tube to
remove the bearing cup [14] on the end of
the output shaft.
Due to normal wear, the edges of the
radial rings could be very sharp.
5. Clean the grease from the radial ring

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

9. Remove the exterior retaining ring [11].
Figure 7-54. Press Out Output Shaft

Always watch for pinch points when
using a press or pressing tools.
Figure 7-52. Remove Cover and Output Shaft
Main Cover
10. To remove the bevel gear [7], support the

main cover assembly on 8 x 6 in. tube
under press. Press the output shaft [9]
down through the bevel gear. The bearing
cone [14] is removed at the same time.
Safety glasses are required after this Figure 7-55. Remove Bevel Gear
point in disassembly.
6. Place the main cover assembly, gear side

down, on the tube under press. Press the
output shaft [9] down slightly to create a
space between the bevel gear [7] and the
output bearing spacer [10].
Output Shaft
Figure 7-53. Press Down Output Shaft
Output Shaft
11. Remove the bearing cup [8] from the main

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

lip of the output bearing spacer, being
careful not to catch the exterior retaining
ring [11]. Refer to Figure 7-54.
8. Place the main cover assembly, gear side
up, on 12 x 6 in. tube so the bearing puller
clamp is resting on the tube. Press the
flanged output shaft [9] and the output
bearing spacer [10] out.


Figure 7-56. Remove Bearing Cup and Lip Seal Figure 7-58. Remove Clamp Nut
Lip Seal
Clamp Nut
13. Remove the output shaft bearing cone [8] 2. Using a brass punch and hammer, drive
in the base of the housing using two pry the spiral pinion [7] out of the housing.
bars. Insert the pry bars under the bottom
NOTE: You may need to remove the spiral
edge of the cone on opposite sides. Apply
pinion with a press or pressing device
even pressure on both tools to lift the cone
equivalent.
out.
Figure 7-59. Remove Spiral Pinion
Figure 7-57. Remove Output Shaft Bearing Cone
Helical Gear
Output Shaft
Bearing Cone
3. Remove the helical gear [3] and the

14. Remove the shims [28] from the housing
bearing cone [5] from the housing.
bore. Save shims for reference only, as
they are usually damaged when removing 4. Drive out the bearing cup [6]. Inspect the
the bearing cone. Install new shims during bearing cup and housing bores for wear.
reassembly. NOTE: The bearing cups and cones are usually
15. Remove the cover shims [32]. Save the damaged during removal. Replace them
shims for reference only. Install new shims as sets.
during reassembly.
Spiral Pinion Disassembly

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


Figure 7-60. Remove Bearing Cup
Always watch for pinch points when

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

pinion [7] until it is seated.
Figure 7-62. Press Bearing onto Spiral Pinion
Bearing Cup
Bearing Cone
Thoroughly wash the housing and visually
inspect entire housing again for excessive
damage, wear, or cracks. Spiral Pinion
Drive Unit Assembly
Safety glasses are required. Main Cover and Output Shaft

Assembly
Prepare the housing for assembly by running a
tap through all bolt and screw holes. Cleaning 1. Prior to installing the output shaft lip seal
the threads also makes sure that there is no [15], apply a thin layer of sealing adhesive
damage. around the seal surface of the main
housing, to prevent leaking. Install the lip
Spiral Pinion Assembly seal, spring side down, in the housing.
2. Press the lip seal [15] into the housing
1. Using a press or mallet, install the bearing until it is just below flush with the housing
cup into the housing bore. surface.
2. Install the second bearing cup [6] into the
housing bore on the opposite side. Figure 7-63. Press Lip Seal
Figure 7-61. Drive In Bearing Cup
Lip Seal
Bearing Cup 3. Press the output bearing cup [14] into the
main cover until it is seated. Place the
bearing cone into the bearing cup.

4. Push down on the bearing and turn to seat Figure 7-66. Install Main Cover and Bearing Cone
the bearing into the bearing cup.
Bearing Cone
Figure 7-64. Press Output Bearing Cup
Output
Bearing Cup
Output Shaft
10. Press the bearing cone onto the output

shaft.
5. Take a measurement from the edge of the Figure 7-67. Press on Bearing Cone
bearing cone [14] to the flange surface of
the main cover [16]. Make sure that the
dial indicator tips come into contact with
the flange surface.
Figure 7-65. Bearing Cone to Flange Measurement
11. Place the bevel gear [7] down over the

output shaft, teeth side up. Pressing the
bevel gear down seats the bearing cone
[14] into the bearing cup.
Figure 7-68. Press on Bevel Gear

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

13. Place the output bearing spacer [10], with Figure 7-71. Bearing Cup to Flange Measurement
the recessed area down, over the output
shaft. Place the bearing cone [8] on top of
the output shaft.
14. Press the bearing cone [8] down until it is
fully seated against the spacer and snap
ring.
Figure 7-69. Press Down Bearing Cone
Bearing Cone
18. Record final readings as Measurement E.

This is required during final assembly.
Helical Gear Assembly

Output
NOTE: The pinion shaft and bevel gear are a
Bearing
Spacer
matched set. Their alignment is critical.
Do not replace them separately.
15. Place the main cover assembly, flange side
up. Press the bearing cone [8] into place.
At the same time, pull the gear sideways to
eliminate any backlash in the spline area. Bearing can become extremely hot. Use
gloves to protect hands from burns.
Figure 7-70. Eliminate Backlash
1. Preheat the bearing cone with a bearing

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


Figure 7-72. Install Helical Gear and Pinion S2 = E + S1 - B - 0.006 preload
Clamp Nut S2 = Shim amount between cover plate face to
set preload of bearings for output shaft (S2).
S3 = J – F – G
S3 = Shim amount between drive unit housing

and lower bearing on spiral pinion.
Figure 7-73. Bearing Cone to Flange Measurement

Helical Gear
5. Remove clamp nut [4]. Apply

thread-locking compound (P/N 990-669)
to the threads of the spiral pinion.
Reassemble the clamp nut on the spiral
pinion and hand tighten.
6. While the bearing cone [6] is cooling,
calculate the formula for determining the
required shim [28] thickness.
Calculate Shim Formulas

Figure 7-74. Bearing Cup to Flange Measurement
• A = Dimension A stamped on housing
(2.102/2.108)
• B = Dimension B stamped on housing
(3.409/3.412)
• C = Number etched on back of gear
(nominal 1.812)
• D = Distance from bearing cone to flange
surface (see Figure 7-73)
• E = Distance from bearing cup to flange
surface (see Figure 7-74)
• F = Mounting distance etched on spiral
pinion
Installing and Testing Shims
• G = Distance from top of teeth on spiral
pinion to top of lower bearing cup on spiral 1. Remove any end play in the bearings
pinion between the helical gear [3] and the spiral
• J = Distance from centerline of output gear [7] using lock nut wrench. Wedge the
shaft to top of lower bearing cup on spiral helical gear, and tighten the clamp nut [4]
pinion until there is no end play between the
gears.
S1 = (B - A - E + D + C)
S1 = Shim amount behind bearing cup in main

housing to position gear for correct backlash
(S1).


Figure 7-75. Remove End Play Figure 7-76. Mark Spiral and Bevel Gears
Spiral Gear
2. Preload the helical gear [3] for 0.000 to 7. Place the predetermined shims [28] into
0.002. the housing bore for the bearing cup [8].
3. Remove any oil from the clamp nut [4]. Install the bearing cup into the housing
Apply thread-locking compound bore over the shims.
(P/N 990-544) to the threads in the clamp 8. Install the cover shims [32].
nut. Tighten the set screw in the clamp
nut to 140 in. lb. (15.8 Nm). Figure 7-77. Install Cover Shims
4. Spin the helical gear [3] to make sure the
bearings are not too tight. The helical gear
must spin freely for at least one full
rotation.
5. Only perform the following procedure if
the helical gear assembly is too tight.
a. Unscrew the clamp nut [4] the width of
one spanner slot (0.188 in./4.77 mm).
b. Tap the spiral bevel gear [7] to unseat Cover Shim
the bearing cone.
c. Place the predetermined shims [29] in 9. Place the main cover assembly over the
the housing bore for the bearing cup shims, making sure to line up the marked
[5]. teeth on both the spiral and bevel gears
d. Install the spiral pinion gear and helical [7].
gear. See “Helical Gear Assembly” on
page 7-51. Figure 7-78. Line Up Spiral and Bevel Gears
e. Repeat steps 1 thru 4 until the helical

gear spins at least one full rotation. Spiral gear
6. One tooth on the spiral gear [7] is etched
or marked with an X. With a marker, mark
that tooth surface for the purpose of lining
up the spiral and bevel gears [7] to check
backlash. One tooth on the matching bevel
gear is also marked. Mark that tooth
surface also.
Bevel Gear

10. Put in four housing cover bolts [13], evenly Pivot Ring Assembly
spaced and tighten. Refer to “Component
Specific Service/Torque Chart” on
page A-4.
Safety glasses are required.
Measuring Backlash
1. On the inside of the pivot ring [18], make
NOTE: Backlash tolerance is critical to the sure the roll pins [19] are installed and in
performance of the drive unit. Incorrectly good condition on either side of the
adjusted units will experience premature bearing filler plug hole. If they are missing
failure. or damaged, install new roll pins.
1. Wedge the helical gear [3], then slightly
turn the output shaft to determine Figure 7-80. Install Roll Pins
backlash. Backlash reading on the dial Pivot Ring
indicator should be between 0.004 and
0.006.
Figure 7-79. Backlash Measurement
Roll Pin
2. Install the grease fitting [27] on the outside

of the pivot ring.
3. Screw the grease fitting [21] in the bearing
filler plug.
4. Install radial rings [24]. Install the flat
2. Calculate any necessary adjustments to
radial ring on the inside flat surface of the
the shims. Remove the main cover
pivot ring. Place the ends of the chamfered
assembly and the bearing cup, and adjust
radial rings against the roll pins [19] to
the shims. Repeat Steps 6 thru 9
install them in the pivot ring.
“Installing and Testing Shims” until
backlash is between 0.004 and 0.006. Figure 7-81. Install Radial Rings
3. When backlash is within acceptable range,
Radial Rings
remove the main cover assembly and the
cover shims.
Main Cover Installation

1. Clean the cover mating surface on the
housing, then apply gasket compound
(P/N 1175668) sparingly.
2. Install the cover shims [32] and the main
cover assembly. Install the main cover Roll Pins
bolts [13], and torque. Refer to
“Component Specific Service/Torque 5. Install the outer radial rings [24] on the
Chart” on page A-4. housing. Refer to Figure 7-82.


Figure 7-82. Install Outer Radial Rings
Outer
Radial Ring Excessive thread-locking compound will
damage the ball bearings and pivot
ring. Use thread-locking compound
sparingly.

(P/N 1013829) sparingly to the filler plug
bolts [22]. Install the bolts and washers
[23] on either side of the bearing filler plug
[20] and tighten to 20 ft. lb. (27 Nm).
11. Grease and then test the pivot ring,
6. Lift the drive end of the housing and slide
checking to see that it spins freely.
the pivot ring over the housing. Be careful
not to jar the radial rings out of place.
Figure 7-84. Install Bearing Filler Plug
Slide the pivot ring into place just behind
the spur gear [26]. Filler Plug and
7. Make sure the pivot ring bearing filler plug Grease Fitting Filler Plug Bolt
hole is on top, in preparation for installing
the steel balls [25].
8. Put one ball at a time into the pivot ring
filler hole. Use a screwdriver to direct the
steel balls first to one side then the other.
Continue until all 70 balls are installed.
Figure 7-83. Install Ball Bearings Washer
Steel Ball
Drive Unit Installation
1. Install the new drive unit and connect the
steering linkage. Refer to “Component
page A-4.
2. Reinstall the steering shaft and hydraulic
motor.
3. Refill the drive unit with the correct type
fluid. Add fluid until level reaches the
9. Install the bearing filler plug [20] with the bottom of the helical gear.
grease fitting [21] pointing toward the spur
gear [26]. NOTE: When installing a new or RayBuilt ®
drive unit, the new traction motor pinion
gear shipped with the drive unit must
also be installed to ensure warranty
coverage. Failure to install the new
pinion gear can result in gear noise,
premature failure of the gear set, and/or
possible failure of the entire drive unit.
4. Install the traction motor and brake. Use a
fiber gasket between the traction motor

and drive unit. Refer to “Component

page A-4.
5. Connect cables, wires, and brake line.
Torque motor cables to 18 ft. lb. (24.4 Nm).
6. Install the drive unit dust shield.
7. Install the drive wheel. Torque the drive
tire lug bolts to 170 ft. lb. (230 Nm).
8. Install the horn assembly.
9. Check the drive unit fluid level.
10. Test the brake for correct operation.

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
tire. If the tire still does not press on,
replace the hub.
9. Release the press. Remove the wheel, tire
assembly, and the old tire from the press
table. Wipe off any grease. Inspect the
wheel and tire assembly.
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

Brake Drive and Brake
Brake and the coil body. Tighten the locking bolt

just enough to prevent rotation of the
motor shaft.
Inspection 7. Remove the retaining nut and washer from
the motor shaft. See Figure 7-85.
the battery connector. 8. Remove the three brake mounting bolts.
2. Open the motor compartment door. 9. Use a brake puller to remove the brake
assembly from the motor.
3. Check air gap between the armature and
armature plate near all three spacers. See
Figure 7-85. If air gap exceeds 0.040 in. Pad Replacement
(1 mm), replace the brake pads. See “Pad
1. Install the brake release bolts.
Replacement”.
NOTE: Do not overtighten the brake release
Figure 7-85. Checking Brake Air Gap bolts.
2. Turn the brake assembly over and remove
the three bolts securing the adapter plate.
Motor
See Figure 7-86.
Shaft
Figure 7-86. Adapter Plate Removal
Brake
Mounting
Bolt (qty. 3)
Armature
Armature
Plate
Adapter Spacer
Plate
Brake Removal
the battery connector. Adapter
Plate Bolts
2. Block the drive tire to prevent movement.
3. Open the motor compartment door.
4. Note the location of cable ties securing the 3. Remove the adapter plate. Inspect spacers
motor cable bundle to the cable bracket. and replace if damaged.
Cut cable ties to free the cables from the 4. Remove old pads from carrier and install
bracket. Remove the cable bracket. new pads. See Figure 7-87.
5. Disconnect the brake armature lead
connection.
6. Loosen one of the locking bolts and obtain
a spacer approx. 0.005 to 0.015 in.
(0.12 to 0.38 mm) thicker than the
measured total air gap (non-energized).
Insert spacer between the armature plate

Drive and Brake Brake

Figure 7-87. Pad Replacement Brake Installation
Small Flange Carrier 1. Correctly position the brake assembly on
(large flange motor. Make sure the keyways on the
opposite side)
motor shaft and carrier are correctly
aligned.
2. Gently tap the carrier flange onto motor
shaft until seated.
(P/N 990-536) and install the three brake
mounting bolts. Torque to 16 ft. lb.
(21.7 Nm).
Pad (qty. 6)
4. Remove brake release bolts and install in
their storage locations.
5. Loosen one of the retainer bolts and insert
5. Install adapter plate. Torque adapter plate
a 0.030 to 0.040 in. (0.76 to 1 mm) spacer
bolts to 6 ft. lb. (8.6 Nm).
between the armature plate and coil body.
NOTE: Leave the brake release bolts installed Tighten the retainer bolt just enough to
for reassembly to motor. prevent rotation of the motor shaft as the
retaining nut is torqued.
Coil Replacement 6. Install retaining nut and a new washer to
motor shaft. Torque retaining nut to 150
1. If installed, carefully remove the brake ft. lb. (203 Nm).
release bolts. Separate the coil from the
armature plate. 7. Loosen the retainer bolt and remove the
spacer.
NOTE: The brake release bolts are under
8. Attach the motor cable bracket. Apply
tension from the springs inside the coil
body.
to the bolts and torque to 6 ft. lb. (8.6 Nm).
2. With the coil inverted, make sure all eight 9. Attach the cable bundle to the cable
springs are inserted into the cavities. bracket with cable ties and connect the
NOTE: On coils with ten spring cavities, the two brake armature lead connector.
empty cavities must be 180° apart. 10. Unblock the drive tire. Reconnect the
3. Place the thin washer shaped spacer over battery connector and turn the key switch
the springs. ON.
4. Note the orientation and place the inverted 11. Make sure brake operates correctly and
armature plate on the coil directly over the traction motor rotates without interference
spacer. to motor cables.
5. Assemble the armature and coil: NOTE: When the truck is stationary, pressing
and releasing the deadman pedal should
a. Using a clamp, mate the armature plate
cause the brake to release and engage.
to the coil. Make sure the thin washer
When the truck is traveling, the brake
is correctly aligned.
should remain released (coil energized)
b. Install the brake release bolts through until the truck speed reaches 0.5 mph
the coil and armature plate and tighten. (0.8 km/h).
6. Install carrier, pads, and adapter plate.
Torque adapter plate bolts to 6 ft. lb.
(8.6 Nm).

Deadman Pedal Drive and Brake
Deadman Pedal
If the proximity sensor does not activate when
pedal is fully pressed, 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 7-88.
Figure 7-88. Deadman Pedal Adjustment

PEDAL PRESSED
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 Switch
(Page 6-68).
6. Reinstall deadman pedal in floor. Refer to
7. Reinstall pad over deadman pedal.
NOTE: If pad was previously glued, apply glue
(P/N 990-569/102) in locations
originally glued.

Drive and Brake Inertial Dampener
Inertial Dampener
Figure 7-89. Inertial Dampener Assembly
Mounting
Bracket
Slide Plate
Friction
Plate
Friction
Plate
Dampener
Spring
Spring
Retainer
Lock Nut
NOTE: The A-frame up-travel stop bolt Figure 7-90. Inertial Dampener (unrelated parts removed
adjustment is critical. Incorrect for clarity)
adjustment results in damage to the Dampener
Dampener Spring
Spring
inertial dampener. See “Steerable (1 (1
9/16
9/16
in.in.
oror
4040
mm)
Caster” on page 7-24. If extra A-frame
travel is required such that the stop bolt
adjustment cannot be maintained, Spring
Retainer Friction
remove the inertial dampener.
Plate
Removal
2. Remove the right side cover. Lock Nut
3. Remove the inertial dampener cover plate.

5. If necessary, turn the A-frame down-travel
4. Loosen and remove the inertial dampener
adjustment bolt clockwise until there is
lock nuts, spring retainer, two springs,
clearance between the dampener bolts and
and friction plate. See Figure 7-90.
the bottom of the slot in the slide plate.
See Figure 7-91 on page 7-62 and
Figure 7-95 on page 7-63.

Inertial Dampener Drive and Brake
6. Remove the cap screws holding the slide Figure 7-92. Inertial Dampener (A-frame springs, slide
plate mounting bracket to the frame. plate removed)
Remove the bracket. See Figure 7-91.
Friction Plate
Figure 7-91. Inertial Dampener (nuts, retainer, springs,
friction plate removed)
Cap Screws
A-frame
Spring Slide
Plate Bolt
Figure 7-93. Inertial Dampener (jacked up for shoulder

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

Bolt
floor. Use a suitable hoist to stabilize the Thread-Locking
mast. Keep hands and feet clear from Compound
or jack stands beneath it to support it. Installation and Adjustment
1. Attach the friction plate to the A-frame
yoke with the bolt and nylon lock nut.
2. Install the A-frame springs. Lower the lift
8. Jack the tractor up approx. 2 in. (50 mm) truck slightly on the jack to seat the
at the tractor frame and block. See springs in their retainer holes.
Figure 7-93. 3. Install the A-frame down-travel
9. Remove the A-frame springs. See adjustment bolt with the plastic washer
Figure 7-91 and Figure 7-92. between the metal washer and the frame.
Tighten until the distance between the top
10. Remove the bolt holding the friction plate
of the A-frame and the bottom of the
to the A-frame yoke. See Figure 7-92 and
A-frame spring upper weldment is 7 in.
Figure 7-93.
(17.7 cm).

Drive and Brake Inertial Dampener

Figure 7-94. Inertial Dampener parts 8. Install the inertial dampener cover plate.
Dampener Slide Plate 9. Reattach the right side cover.
Spring 10. Reconnect the battery connector and turn
Spring the key switch ON. Test truck for correct
Retainer operation.
Lock Nuts
Friction Plates
4. Attach the slide plate over the dampener

bolts. Apply thread-locking compound
(P/N 1013829) to the threads in the frame.
Attach the slide plate mounting bracket to
the frame with the two cap screws. The
pivot joint on the mounting bracket should
be free to flex. Torque the slide plate
mounting cap screws to 18 ft. lb.
(24.4 Nm).
Figure 7-95. Inertial Dampener adjustment

Pivot Joint Slide Plate
Clearance Here Friction Plate
5. Unblock and lower the lift truck to the

floor.
6. Attach the friction plate, two springs,
spring retainer, and two lock nuts.
Reference Figure 7-94 for orientation of
parts. Tighten the lock nuts until the
distance between the top of the spring
retainer and the friction plate is 1 9/16 in.
(40 mm) at both bolts. See Figure 7-90 on
page 7-61.
7. Adjust the idler. See “Steerable Caster” on
page 7-24.

Inertial Dampener Drive and Brake

Electrical Components
Electrical Components

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

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

Battery Safety, beginning on page 2-5.
Batteries for this lift truck weigh Some degreasers and parts cleaners will
between 2000 and 2900 lb. (908 to cause the connector shell to disintegrate.
1316 kg). Use extreme care during Avoid contacting battery connectors with
replacement. Use a suitable battery solvents.
moving device or hoist for lifting. Do not
extend a battery more than 1/3 of its Removal, Replacement, and
length outside the battery compartment Installation
without being attached to a
battery-moving device. The cables to either half of the connector have a
lip on their forward end. This lip snaps over a
Battery Connector/Cables spring-loaded retainer that is part of the
connector.
Location Figure 7-97. Battery Cable and Connector
The battery connector is located at the

front-right of the tractor, above the battery.
Figure 7-96. Battery Connector Location
Battery
Connector
When replacing battery cable ends,

remove only one end at a time from the
connector to avoid the cable ends
Inspection
touching and causing a short circuit. Do
1. Turn the key switch OFF and disconnect not allow the metal cable end to touch
the battery connector. the battery. Use insulated tools and
avoid contact with battery case or cable
2. Check the battery connector for damaged
ends.
cables.
3. Check to see if battery cables are pulling 1. To remove a cable from the connector,
out of the connector. push the retainer down while pulling the
4. Check the cables at the battery terminals. battery cable towards the rear and out of
Connections should be tight, with no the connector. See Figure 7-98 and
corrosion. Figure 7-97.

Electrical Components Battery Procedures

Figure 7-98. Battery Cable Removal from Connector Figure 7-99. Battery Cable and Filler Plug
Battery Cable
Filler Plug
Vent Hole
2. Do not attempt to repair battery cables by 5. Keep the top of the battery clean and dry.
crimping new terminals. Replace the Corrosion, dust, and moisture provide a
cable. conducting path to short-circuit cells or
create shorts to ground.
Battery Exterior Cleaning
1. Read, understand, and follow procedures,
recommendations and specifications in the Do not clean the top of the battery with
battery and battery charger the soda solution while it is installed in
manufacturer’s manuals. the lift truck. Water can seep into the
25l6s014.eps
electrical components and cause serious
damage.
6. Wash dirty batteries (or any that have had

electrolyte spilled on them) with a solution
of 1 lb. (0.45 kg) of baking soda added to
0.5 gal. (1.9 liters) of hot water.
7. Use a brush with flexible bristles to clean
the entire top of the battery with the soda
solution. Wait until all foaming stops,
2. Wear personal protective equipment. See indicating that the battery exterior is
“Battery Safety” on page 2-5. neutralized.
3. Turn the key switch OFF and disconnect 8. Rinse the battery with clean water.
the battery connector. Remove the battery 9. Dry the battery completely before
from the lift truck. reinstalling it.
4. Inspect the battery cables to make sure 10. Reinstall the battery in the lift truck, using
they are not frayed or loose. Inspect the a suitable battery moving device.
battery connector to make sure there is no Reconnect the battery connector.
foreign material inside the connector.
Make sure the filler plugs are tight and the
vent holes in the filler plugs are open. Testing, Charging, and
Maintenance
For information on testing, charging, and
maintaining your lift truck battery, consult the
battery manufacturer’s specifications and
instruction manual.

Battery Procedures Electrical Components
Never plug the battery charger into the

lift truck. This will severely damage the
lift truck’s electrical system. Plug the
charger only into the connector from the
battery.
6173_012.eps
Battery State-of-Charge
Battery State-of-Charge (BSOC) is a feature that
monitors and remembers the charge level of the
battery connected to the lift truck and prevents
excessive discharging of that battery. Operating
a lift truck using a discharged battery can
damage both the battery and the electrical
components of the lift truck. Refer to page 5-5
for a detailed description of how BSOC works
and the procedure for setting BSOC Cutout.

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

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

Use correct electrostatic discharge soldering small components in assemblies,
precautions. See “Static Precautions” on follow these guidelines:
page 2-8. • Make sure the soldering tip is clean. A
dirty tip does not transfer heat well and
When pulling a wire out through a bundle, cut encourages long dwell time and greater
off the pin or socket so it does not snag. When pressure. Apply light pressure on the
replacing wires, in some cases you can tape or terminal.
solder one end of a new wire to one end of the • Flux: rosin base
failed wire. Then you can pull the old wire out of
the bundle and pull the new wire into the • Solder: 60/40 rosin core or equivalent
bundle, all at the same time. Make sure to • Solder Iron: 15-25 watt “pencil-type”
disconnect the old wire from the new wire. maximum
• Tip Size: 3 mm (0.118 in.) diameter x
In other cases, it is easier to secure a new wire 30 mm (1.182 in.) long screwdriver tip.
to the outside of the existing wire bundle with Make sure the tip is clean.
straps of an appropriate size. You can leave the
failed wire in the bundle, or pull it by one end to • After soldering, clean the terminals with a
remove it from the bundle. brush dampened with an alcohol-based
cleaner (P/N 990-600/FOF). Do not allow
any cleaner to seep into the switches or
potentiometers, or contact contamination
may occur.

Wiring and Harness Connectors Electrical Components
Molex Connectors 1. Insert the extraction tool over the pin and
push all the way into the connector. This
For pin orientation of Molex connectors, see releases the locking ears on the pin.
Figure 5-1 on page 5-7. Molex connectors have 2. Pull the wire and pin from the connector.
pins with locking ears that engage ridges in the
plastic connector body. To remove a pin from a Pin Insertion
Molex connector, press these locking ears far
enough to clear the ridge in the connector. See
To insert a pin into a Molex connector, insert
Figure 7-100.
the pin into the back side of the connector and
push the wire all the way in until it clicks. The
Figure 7-100. Molex Connector, end view
locking ears have now engaged the connector.
See Figure 7-101.
Socket
Pin
Locking
Ears
Pin Extraction
To remove a pin from a Molex connector, use

pin extraction tool P/N 950-026.
Figure 7-101. Pin Extraction and Insertion
Top view of
connector Tool inserted over
pin
Extraction
Locking Tool
ears
Side view of
connector

AMP Water-Resistant
Connectors
AMP connectors provide water-resistant
connection by the use of seals between wires
and connectors and between the mating
connector halves. See Figure 7-102.
Figure 7-102. 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 7-103. 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 7-103.
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 7-104.


Figure 7-104. Removing Wire Figure 7-106. 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 7-105.
Figure 7-105. 2. Plug unused pin positions with sealing
plugs. See Figure 7-107.
Figure 7-105. 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 7-107. 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 7-106.
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 7-108.


Figure 7-108. 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 7-109.
Figure 7-109. Latching AMP Connector
Locking
Latches

AMP Harness/Power Amp

Connector
Connector Components
Figure 7-110. Power Amp Connector Components
Power Amp
Connector
JT1
and
JL1
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
shall fall into an area defined by a 2 mm
lock tabs. See Figure 7-111.
diameter cylinder whose center is the center
2. Pry open the wedge lock to the open line of the contact front end. See Figure 7-112.
position.
3. While rotating the wire back and forth over Assembly
a half turn (1/4 turn in each direction),
gently pull the wire until the contact is Make sure the wedge lock is open.
removed.
1. To insert a contact, push it straight into
the appropriate circuit cavity as far as it
Figure 7-111. AMP Connector (JT1 or JL1)
will go. See Figure 7-112 (a) and (b).
2. Pull back on the contact wire with a force
of 1 or 2 lb. to make sure the retention
fingers are holding the contact. See
Figure 7-112 (c).


Figure 7-112. Contact Insertion
3. After all contacts are inserted, close the

wedge lock to its locked position. Release
the locking latches by squeezing them
inward. See Figure 7-113.


Figure 7-113. Wedge Lock Latches
Be very careful when putting the wedge

lock in the locked position. Forcing the
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 7-114.
Figure 7-114. Wedge Lock Flush With Housing

amp002.tif
Testing
Do not pierce wire insulation with a sharp point

while troubleshooting.
The wedge lock has slotted openings in the

forward (mating) end. These slots accommodate
circuit test tabs that are approximately 3.3 by
0.6 mm, that 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.

Electrical Components Power Cables
Power Cables Table 7-6. Cable Jacket Strip Length - Short Barrels
AWG Lug P/N Strip Length

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

Table 7-7. Cable Jacket Strip Length - Long Barrels
Replace damaged cables or mounting hardware AWG Lug P/N Strip Length
as necessary.
1/0 1002217/001-003
Power cables are marked on the terminal lug 2/0 1002217/004-006 1-9/16 in. (40 mm)
with the location where they belong. If the
marking is missing or is not readable, remark 3/0 1002217/007-009
the cable with the correct information.
4/0 1002217/010-011 1-11/16 in. (43 mm)
NOTE: Terminal lugs may be replaced in the
field using the appropriate crimping 5. Insert cable into terminal.
tools. Crimping tool, lugs, and
6. Place cable and terminal into tool die and
heat-shrink are available through the
crimp. Refer to the following pictures for
Parts Distribution Center. Failure to use
what completed crimps should look like.
correct cables, terminal hardware, and
torque values can result in overheating Figure 7-115. Short Barrel Terminal
and damage to components.
Power Cable Repair

Traditional lug crimping techniques for power
cables on DC motors may not meet the higher
current requirements of AC motors. Use
Manual Crimp Tool (P/N 1069861) when
crimping power cables for all AC motors. This
tool may also be used to repair power cables for
DC motors.
1. Remove the bad cable(s).
2. Using the removed cable(s) for reference,
cut an appropriate amount of replacement
cable of the same gauge.
3. Set the adjustment screw on the manual
crimp tool head to match the cable gauge.
4. Strip the cable jacket to fit the terminal to
be crimped. Refer to Table 7-6 and
Table 7-7.

Power Cables Electrical Components

Figure 7-116. 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
Power Cable Terminals
Inspection
Table 7-8. Power Cable Terminal Torques
Location/Stud Figure 7-117. Motor Brush Location
Torque
Size/Type
Traction Motor Top Nut:

17 to 18.4 ft. lb.
Lift Motor (23 to 25 Nm)
Bottom Nut:
10.7 to 11 ft. lb.
(14.5 to 15 Nm)
Aux Motor (Regen Top Nut: 3 ft. lb. (4 Nm)

Lower only) Bottom Nut: 2.6 ft. lb.
(3.5 Nm)
Steer Motor 3.3 ft. lb. (4.5 Nm)
9.6 to 12.4 ft. lb.

Power Amplifiers
(13 to 16.8 Nm)
Contactor - M6 steel 4.2 ft. lb. (5.7 Nm)
Contactor - M8 steel 6.6 ft. lb. (9 Nm)
Contactor - M8 4.5 ft. lb. (6.1 Nm)

brass/copper Conduct a partial inspection of the motor
during scheduled maintenance. If the truck is
operated in a severe or caustic environment or
DC Motor Troubleshooting is used in an extended duty cycle application,
inspect the motor more frequently.
See “DC Motors” on page 5-14.
Set up and rigidly adhere to a strict inspection
schedule to obtain the maximum efficiency
AC Motor Troubleshooting from the electrical equipment.
See “AC Motors” on page 5-18. Each partial inspection of the motor must
include:
1. Inspect the brushes for wear and for
correct contact with the commutator.
Record the level of wear on the brushes.
This history provides an indication of
whether a brush must be changed or if it
can wait until the next inspection. Refer to
Table 7-9, “Minimum Brush Length and
Spring Tension,” on page 7-81 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. See Table 7-9 3. Move the brushes back down into their
on page 7-81. holders. Rotate the armature until the face
3. Clean brushes and holders. Wipe the of the brushes are contoured to match the
commutator with a dry, lint-free cloth. Do curve of the commutator.
not use lubricants of any kind on or 4. Remove the sandpaper.
around the commutator. 5. Blow any dust out of the motor with clean,
4. Check brush holders for a solid connection compressed air at a maximum of 30 psi
to the mounting support. Tighten the (207 kPa).
mounting screws as necessary.
5. Check the cap screws that hold the brush Motor Brush Spring Tension
cross-connectors to the brush holder
body. Inspection
6. Make sure the motor terminals are 1. Turn the key switch OFF and disconnect
secured tightly to the motor frame. Use the battery connector.
care not to strip the threads or crush the 2. Remove the operator compartment covers.
insulating parts. See “Power Cable
Terminals” on page 7-79. 3. Slide the brush up slightly in its holder.
7. Check all the cap screws around the frame 4. Insert a paper strip between the brush
for tightness. face and the commutator. See
Figure 7-118.
8. Keep the outside frame of the motor clean
and free from dirt. Maintain a free air Figure 7-118. Motor Brush Spring Tension Inspection
passage around the motor to permit heat
radiation. Spring
Scale
Replacement
NOTE: If one brush needs replacement, always
replace the entire set of brushes. New
brushes require a seat-in period of
approximately 100 hours. An increased
level of arcing is normal during this
period.
Leather
Use only genuine Raymond brushes. Using Loop
another type of brush could cause damage to
the commutator or cause excessive brush wear
and voids your warranty.
If the end of the brush is not already contoured

to fit the commutator, seat the brush to the Paper
commutator:
NOTE: If the motor commutator is not
accessible, form the brush contour
using a brush seating stone.
Rotation
1. Move the motor brush springs out of your
way. Pull paper in direction of rotation
2. Wrap a piece of 00 sandpaper around the 5. Place a small leather loop around the coil
commutator. Do not use emery cloth to spring for the brush. If the brush spring
seat brushes.

Electrical Components Motors
has a loop at the brush, hook the spring 4. With minimal pressure, run the stone
scale directly to the spring. back and forth across the commutator
6. Attach a 5 lb. (2.27 kilogram) spring scale until it is polished. Do not pass stone over
to the leather loop. the ends of the commutator segments.
7. While gently pulling the scale outward, 5. Thoroughly blow out the motor with
slowly pull the paper strip in the direction compressed air.
that the commutator normally rotates. 6. Inspect commutator. Reinstall the brush
8. When the paper strip begins to move or armature and cover.
freely, the spring scale will read the spring 7. Check operation.
brush tension.
9. Refer to Table 7-9 for correct spring AC Motor Service
tension.
Table 7-9. Minimum Brush Length and Spring Tension

Temperature Sensor Replacement
Motor Min. Brush Length Spring Tension Traction Motor
Steer 0.50 in. (13 mm) 15 oz. (425 grams) 1. Turn the key switch OFF and disconnect
10. Repeat steps 3 thru 9 for the remaining 2. Remove the brake assembly.
brushes. 3. Disconnect the temperature sensor
connector.
Polishing the Commutator 4. Disconnect motor power cables. Note
locations for reassembly later.
NOTE: Use a narrow masking tape (1/2 to
5. Remove the terminal board.
3/4 in. wide) and wrap the stone in a
spiral configuration, leaving only 6. Remove the four bolts that secure the top
enough stone exposed to make contact end bell to the bottom end bell.
with the commutator. As the length of 7. Remove the top end bell using a puller.
the stone becomes shorter with use, peel
8. Cut the bad temperature sensor cable.
back and remove portions of the tape.
9. Install a new temperature sensor with high
temperature silicone P/N 1110785/716.
Mount the sensor close to the location of
the original. Secure the cable with a cable
Make sure loose clothing is tied back. tie to one of the power leads for stress
Do not wear jewelry. Wear insulated relief.
gloves.
10. Re-install the top end bell.
1. If the motor has 4 or more brushes, 11. Re-install the four bolts that secure the
remove an accessible brush from the top end bell to the bottom end bell.
motor with the motor still installed in the 12. Re-install the brake assembly.
truck. If the motor only has 2 brushes or
13. Connect the new temperature sensor
the commutator is not accessible with the
cable.
stone, the armature must be installed in a
lathe or replaced. If so, go to step 4. 14. Install the terminal board and reconnect
power cables. Torque motor cable securing
2. Activate the motor.
nuts to 18 ft. lb. (24 Nm).
3. With the motor turning, carefully insert
the commutator stone into the brush box
the key switch ON.
area.

Motors Electrical Components
Lift and Aux Motor

2. Disconnect the temperature sensor
connector.
3. Remove the four bolts that secure the top
end bell to the bottom end bell.
4. Remove the top end bell.
5. Cut the bad temperature sensor cable.
6. Install a new temperature sensor with high
temperature silicone P/N 1110785/716.
Mount the sensor close to the location of
the original.
7. Re-install the top end bell.
8. Re-install the four bolts that secure the
top end bell to the bottom end bell.
9. Connect the new temperature sensor
cable.
the key switch ON.

Electrical Components Steer Amplifier
Steer Amplifier
Removal
2. Remove covers as required.

page 2-8.
3. Disconnect wire from TP4.

4. Remove the contactor/fuse panel cover.
5. Disconnect wire FU1-2 at the contactor
panel, removing cable ties as necessary.
6. Open the Traction Motor compartment.
7. Disconnect the steer motor primary power
wires at A1 and A2 on the motor. Cut cable
ties as needed.
8. Remove steer amplifier mounting bolts.
Installation
1. Install steer amplifier to frame.
2. Route steer motor wires to steer motor and
connect. Install cable ties where previously
removed.
3. Route and connect wire FU1-2 to the
contactor panel. Install cable ties where
previously removed. Make sure cable is
not pinched behind traction power
amplifier.
4. Connect the remaining wire to TP4.
5. Install the contactor cover, right front
cover, primary control handle cover, right
side cover, and front cover. Close the
Traction Motor compartment door.

Cold Storage Conditioning Electrical Components
Cold Storage Treat the following parts to prevent moisture

from entering:
Conditioning • TS3 - located on left side of tractor
bulkhead
NOTE: Conversion of Model 7500/7520 lift • TS2 - located on top of carriage
trucks for cold storage operation
• Deadman switch terminals
requires prior Raymond approval via
Form S207. • Proportional valve (SOL2) terminals
Model 7500/7520 lift trucks to be operated in a Corrosion Inhibitor Coating

cold storage environment require the following:
Coat or spray bare metal surfaces listed below
Components with Corrosion Inhibitor Coating (P/N 990-644):
• All-weather hydraulic fluid (P/N 1017238) • Reach cylinder cotter pins

• Main and free lift chain pulleys and shafts
NOTE: Do not add any additives to this
hydraulic fluid. • Main and free lift chain anchors and
threaded pins
• Ambient temperature sensor
• Drive unit dipstick
• Special cold storage control handle
assemblies with heaters
• Wire mesh mast guard
Condensation Drip Guard
• Suggested on fore/aft stance trucks: To add the control handle condensation drip
Condensation drip guard (P/N 1036240) guard (P/N 1036240) to the overhead guard of
• Optional heated floor pad Fore/Aft stance lift trucks, do the following:
1. Remove from the overhead guard the
Lubricants right-hand lower hex head cap screw,
located almost directly above the control
See the “Lubrication Specification Chart” on handle.
page A-2 for special hydraulic fluid and drive 2. Install an M16 flat washer onto the cap
unit lubricants for cold storage operation. screw.
3. Reinstall the cap screw with flat washer
Coat battery roller shafts with all-weather and drip guard. See Figure 7-119.
grease (P/N 1012992).
Figure 7-119. Condensation Drip Guard
Lubricate carriage fittings with all-weather
grease (P/N 1012992).
Sealing Treatment
Fill sockets and the front and back of both
halves of unsealed connectors with cold storage
sealing compound (P/N 990-445). Connect
wires and connectors. Coat the outside and
where connectors attach to the circuit board.
Coat terminals and terminal strips.
NOTE: Self-sealing AMP connectors (reference
page 7-71) do not need sealing
treatment.

Hydraulic Components
Hydraulic Components

Hydraulic System Bleeding Hydraulic Components
Hydraulic System Figure 7-121. Bleed Screw, Main Lift Cylinder Piston Cap
Bleeding
You must bleed the hydraulic system to remove Bleed Screw
any trapped air whenever you:
• change a hydraulic hose
• disconnect a hydraulic fitting
• remove a hydraulic cylinder
• remove the hydraulic pump
• remove the hydraulic reservoir Main Lift Cylinder
Piston Cap
• notice that the load is bouncing
6. Repeat steps 3 and 4 for each of the two
Procedure free lift cylinders.
1. Elevate the forks 2 to 3 in. (5 to 7.5 cm) off Figure 7-122. Bleed Screw, Free Lift Cylinder
the floor.
3. Loosen (do not remove) the bleed screw at
the top of the main lift cylinder. Hold a rag Bleed Screw
close to and beneath the bleed screw to
keep hydraulic fluid from spraying out.
Figure 7-120. Bleed Screw, Main Lift Cylinder

the key switch ON.
8. Lower the forks all the way down to the
floor.
9. Fully extend and retract the reach
mechanism several times.
Bleed Screw 10. If the truck is equipped with tilt, tilt the
carriage all the way forward and backward
several times.
11. If the truck is equipped with sideshift,
4. When hydraulic fluid starts flowing from shift the carriage all the way to the left and
the bleed screw hole, securely tighten the right several times.
bleed screw. 12. Thoroughly clean up any spilled hydraulic
5. Repeat steps 3 and 4 for the other main lift fluid.
cylinder. 13. Check the hydraulic reservoir level and
NOTE: Main lift cylinders also have a bleed refill as necessary. Do not overfill the
screw located in the piston cap at the reservoir.
top of the cylinder.

Hydraulic Components Hydraulic Filter
Hydraulic Filter
1. Remove the top cover.
2. If you have not drained the reservoir,
elevate the carriage to lower the hydraulic
fluid level and minimize hydraulic fluid
leakage.
4. Remove filter housing cap. See
Figure 7-123.
Figure 7-123. Filter Housing
5. Remove the filter element and filter

housing assembly as a unit from the tank.
To make sure that contaminants are not
re-introduced to the hydraulic system, DO
NOT dislodge the filter element from the
housing directly over the reservoir. Allow
residual oil to drip back into the tank and
move the entire assembly away from the
reservoir.
6. Invert the housing assembly and remove
the filter element. Clean the housing.
7. Install the new element. Re-install filter
housing assembly in reservoir.
8. Securely install filter housing cap.

Lift Pump Replacement (Regen Lower) Hydraulic Components
Lift Pump Replacement

(Regen Lower)
1. Elevate the carriage approx. 4 ft. (122 cm).
Clamp a 47 in. (119.4 cm) tall block to the
telescopic, leaving approx. 1 in. (2.54 cm)
between the block and the bottom of the
carriage. Do not lower the carriage onto
the block.
3. Remove the lift pump.
4. Install new lift pump. Refer to “Component
page A-4.
5. Remove the block from under the carriage.
the key switch ON. Lower the carriage to
the floor to fill the pump with oil prior to
lifting. Prime lift pump (refer to “Lift Pump
Priming - Regen Lower” on page 7-89).
7. Adjust the pressure relief valve. Refer to
“Lift Pressure Adjustment” on page 7-91.

Hydraulic Components Lift Pump Priming - Regen Lower
Lift Pump Priming -

Regen Lower
Perform the following procedure whenever the
reservoir is drained and filled, or the lift pump
is removed/replaced.
1. Make sure reservoir is filled to the correct
level.
2. Install a bleed hose with a shutoff valve on
the G1 test port on the main manifold.
Place the other end in the reservoir
breather cap hole.
3. Open the valve to allow flow back to the
reservoir.
4. Enter output test O28 and scroll to
1800 rpm.
5. Run output test O28 until carriage begins
to lift.
6. Close the valve and raise the carriage
approximately 2.5 ft. (0.75 m).
7. Open the manual lowering valve or bleed
hose shutoff valve until carriage is fully
lowered.
8. Close the valve and repeat the lifting and
manual lowering process until all air is
purged from the system.
9. Lower carriage to the floor and remove
bleed hose from G1 test port.
10. Bleed air from the lift cylinders. See
“Hydraulic System Bleeding” on page 7-86.
11. Check the hydraulic reservoir level. Do not
overfill the reservoir.

Aux Pump Priming - Regen Lower Hydraulic Components
Aux Pump Priming -

Regen Lower
Perform the following procedure whenever the
reservoir is drained and filled, or the aux pump
is removed/replaced.
1. Make sure reservoir is filled to the correct
level.
2. Install a bleed hose with a shutoff valve on
the G4 test port on the aux manifold. Place
the other end in the reservoir breather cap
hole.
3. Open the valve to allow flow back to the
reservoir.
4. Enter output test O27 and scroll to
1800 rpm.
5. Run output test O27 until fluid begins to
flow to the reservoir via the bleed hose
connected to G4.
6. Close the bleed hose valve.
7. Remove the bleed hose connected to the
G4 test port, exit output test O27. Make
sure aux functions operate correctly.
NOTE: If a large volume of air is present in the
system, it may not be possible to prime
the pump through the G4 test port alone
using steps 4 thru 6. If so, perform the
following:
a. Disconnect the P2 hose connection at
the aux manifold and secure it into a
clean bucket.
b. Enter output test O27.
c. Incrementally increase aux motor rpm
using output test O27 until fluid is
observed flowing into the bucket from
the hose disconnected from P2.
d. Reinstall the hose to the P2 connection
on the aux manifold.
e. Exit output test O27.
f. Check aux functions for correct
operation.
8. Check the hydraulic reservoir level. Do not
overfill the reservoir.

Hydraulic Components Lift Pressure Adjustment
Lift Pressure Adjustment 12. Continue trying to elevate and turn the
relief valve adjusting screw to obtain a
pressure reading 200 psi (1379 kPa)
See Table 7-10 for maximum lift pressures. greater than that required to lift the
maximum rated load (the value recorded
Table 7-10. Maximum Lift Pressures in Step 8). Turn the adjusting screw
Model/Mast Maximum Lift Pressure clockwise to increase pressure,
counterclockwise to decrease pressure.
7500/R35TT
7500/R45TT 3300 psi (22,753 kPa) For maximum permissible lift pressure,
see Table 7-10.
7520/R45TT
13. Tighten the lock nut on the lift pressure
7500/DR32TT relief valve (RV-5).
3600 psi (24,821 kPa) 14. Check the pressure again. If the value has
7520/DR32TT
changed, repeat this procedure until the
correct pressure reading is obtained.
NOTE: Lift pressure is set by software in trucks 15. Turn the key switch OFF and disconnect
without regenerative lower. the battery connector.
1. Lower the carriage completely. Disable any 16. Remove the pressure gauge from the lift
lift cutout or lift deceleration options. pressure test port and replace the cap.
2. Turn the key switch OFF and disconnect 17. Reinstall the top cover. Reconnect the
the battery connector. battery connector and turn the key switch
ON.
18. Enable any lift cutout or lift deceleration
4. Remove the cap from the G1 lift pressure
options that were disabled in Step 1. Verify
test port on the lift/lower manifold. See
truck operation.
page 7-97.
5. Connect a pressure gauge capable of
reading at least 5000 psi (34,470 kPa).
the key switch ON.
7. Place the maximum rated load on the
forks.
8. Elevate the carriage past free lift (until the
telescopics begin to lift). Record the
pressure required to lift the load.
9. Lower the carriage and remove the load.
10. Loosen the lock nut on the main lift
pressure relief valve (RV-5) on the
lift/lower manifold. See page 7-97.
Make sure truck is in an area with

sufficient overhead clearance for lifting
the mast.
11. Elevate the carriage until the upper limit is

reached.

Manual Lowering of Fork Carriage Hydraulic Components
Manual Lowering of Regen Lower

Fork Carriage 1. Manually open the needle valve NV-1. See
“Lift/Lower Manifold - HSL and Regen
Lower” on page 7-97.
If the fork carriage is hung up and unable to be
2. After making necessary repairs to the lift
lowered normally, use the following procedure
truck, close NV-1.
to lower the carriage.
NOTE: Make sure the forks and carriage are
free from racks and other obstructions
before lowering.
Standard Lift
1. Manually open the load holding valve
SOL1. See “Main Manifold - Standard Lift”
on page 7-96. On the top of SOL1 is a
small knurled knob. Press the knob and
turn counterclockwise until the knob pops
up.
2. If there is power on the lift truck, try to
lower by using the lift/lower knob.
a. If this is successful, go to step 4.
b. If this is unsuccessful, continue to the
next step.
3. Manually adjust the proportional lift/lower
valve SOL2 to cause the carriage to lower.
a. Loosen the lock nut on top of SOL2.
b. Using a hex-key wrench, adjust the
brass adjustment screw clockwise until
the carriage begins to move.
c. Turning the screw clockwise increases
lowering speed. Turning the screw
counterclockwise slows the lowering
speed.
4. After making necessary repairs to the lift
truck, return SOL1 and SOL2 to their
original positions.
a. Press the knob on top of SOL1 and turn
the knob clockwise until it locks in the
down position.
b. Adjust the proportional lift/lower valve
as described under “Proportional Valve
Adjustment” on page 7-93.

Hydraulic Components Proportional Valve Adjustment
Proportional Valve
Adjustment
The Proportional Valve must be adjusted after
the “Manual Lowering of Fork Carriage”
procedure is performed.
NOTE: If the carriage hesitates when lowering
or cannot be feathered on trucks with
Standard Lift, perform LEARN Lower.
1. Raise the fork carriage to eye level.
4. Refer to “Main Manifold - Standard Lift” on
page 7-96. Loosen the jam nut and lock
nut holding the adjusting screw on the
proportional valve (SOL2).
the key switch ON.
6. Run Test O11 - Toggle Load Hold Solenoid
(Page 6-116).
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.
8. Run LEARN Lower.
9. Check for correct lowering operation,
empty and loaded, using Test A23 - Lift
Throttle Request (Page 6-49). Carriage
movement should start at approximately 9
to 10% request.
10. Reinstall the top cover.

Auxiliary Pump/Motor Service - Regen Lower Hydraulic Components
Auxiliary Pump/Motor
Service - Regen Lower Be careful not to damage the O-ring
during removal and installation.
Inspect the coupling after disassembly. There

should be no sign of damage or excessive wear.
When it is necessary to separate the aux
pump and motor on a truck with Regen
If pump replacement is necessary, refer to “Aux
Lower, the hydraulic reservoir must be
Pump Priming - Regen Lower” on page 7-90.
drained below the aux pump inlet
before separating the pump and motor
to prevent continuous fluid leakage.
Take necessary precautions to protect

components from minor hydraulic fluid
spillage.
The pump-to-motor connection has a coupling

and is lubricated with system hydraulic fluid by
the pump. The pump-to-motor connection
cavity is sealed by an O-ring on the pump side
of the connection.
Figure 7-124. Aux Pump/Motor

Hydraulic Components Auxiliary Pressure Adjustment
Auxiliary Pressure
Adjustment
Standard Lift
3. Loosen the lock nut on the aux pressure
relief valve (RV-4) on the Main manifold
(non-regen) or Aux manifold (regen lower).
4. Remove the cap from the G2 test port on
the AC Main manifold or from G4 on the
Aux manifold (regen). Connect a pressure
gauge capable of measuring 5000 psi
(34,470 kPa).
the key switch ON.
6. Tilt the carriage all the way back against
the stops.
7. While continuing to try tilting the carriage
backward, use a hex key to turn the
auxiliary pressure adjusting screw to
obtain a pressure of 2000 psi
(13,790 kPa).
9. Tighten the lock nut on the aux pressure
relief valve. Remove the pressure gauge
from the auxiliary pressure test port and
replace the cap.
10. Reinstall the top cover.

Main Manifold - Standard Lift Hydraulic Components
Main Manifold -
Standard Lift
This manifold, located on the tractor deck, controls lift/lower and aux functions on trucks with
standard lift/lower.
A1
G2 port
CV-1
G1 port
Tank
SOL1
(manual lower
valve)
Torque
Item
ft. lb. (Nm)
A1 and A2 21 (28)
CV-1 Check Valve 50 (68)
SOL2 RV-4 SOL3 CYL-1 55 (75)
CYL-P Pressure
12 (16)
Transducer
CYL-1 HTI (optional) G1 and G2 ports 21 (28)
HTI Pressure Switch 12 (16)
CYL-P A2 LS-1 Load Shuttle 20 (27)

LS-1 P1 55 (75)
POD-1 Priority on
35 (47)
Demand
REL-2 Aux Relief 25 (34)
P1 Return (Suction) to
55 (75)
Pump
RV-4 25 (34)
S-RET 21 (28)
SOL1 Load Holding
50 (68)
w/locking tab
coil nut: 5 (6.8)
(manual lower)
SOL2 Lift/Lower
95 (129)
Proportional
coil nut: 0.5 (0.7)
(Run LEARN Lower)
POD-1
SOL3 Proportional 25 (34)
Main Relief/Dump coil nut: 5 (6.8)
SOL5 20 (27)
SOL5B/5T Aux
coil nut: 5 (6.8)
TANK 55 (75)

Hydraulic Components Lift/Lower Manifold - HSL and Regen Lower
Lift/Lower Manifold -
HSL and Regen Lower
This manifold, located on the tractor deck, controls lift/lower functions on trucks equipped with
high-speed lift and regenerative lower.
SOL1
CV-6
CYL-P
CYL-1
NV-1 (manual lower valve)
CV-5
P1
G1 port
Torque
Item
ft. lb. (Nm)
CYL-1 55 (75)
CYL-P Pressure
12 (16)
Transducer
SOL2 CV-5 Check Valve 30 (41)
CV-6 Check Valve
50 (68)
w/locking tab
G1 port 21 (28)
NV-1 (manual lower) 30 (41)
P1 55 (75)
RV-5 30 (41)
RV-5 SOL1 Load Holding 50 (68)
w/locking tab coil nut: 5 (6.8)
SOL2 Lift/Lower 95 (129)
w/locking tab coil nut: 0.5 (0.7)

Aux Manifold - Regen Lower Hydraulic Components
Aux Manifold - Regen

Lower
This manifold, located under the front left saddle bag, controls aux functions on trucks equipped
with regenerative lower.
HTI (optional) A1 A2
SOL5B/SOL5T
CV-4
G4 port
RV-4
Torque
Item
ft. lb. (Nm)
A1 and A2 25 (34)
P2
CV-4 20 (27)
G4 port 25 (34)
HTI Pressure Switch 15 (20)
P2 25 (34)
RV-4 20 (27)
20 (27)
SOL5B/5T
coil nut: 5 (6.8)
T 25 (34)

Hydraulic Components Aux Manifold - Standard Reach 35.5 in. Wide Mast
Aux Manifold - Standard

Reach 35.5 in. Wide
Mast
This manifold, located on the fixed portion of the carriage, controls reach, tilt, and sideshift
functions on trucks with a 35.5 in. wide mast.
Reach
Solenoid
Sideshift
Solenoid
Tilt
Solenoid
Torque
Item
ft. lb. (Nm)
A1 and A2 15 (20)
CV 25 (34)
20 (27)
Reach Solenoid
coil nut: 5 (6.8)
RC and RR 15 (20)
SSR 20 (27)
Tilt Solenoid
coil nut: 5 (6.8)
TC and TR 15 (20)
A1 20 (27)
Sideshift Solenoid
coil nut: 5 (6.8)
SSR and SSL 15 (20)
A2
SSL TR

Aux Manifold - Standard Reach 35.5 in. Wide Mast Hydraulic Components
Removal 6. Install mast guard.

1. Reach (extend) the fork carriage fully.
the key switch ON. Remove the carriage
Block the scissor assembly so it cannot
blocking.
retract.
8. Lower the carriage completely.
the battery connector. 9. Turn the key switch OFF and disconnect
3. Remove manifold cover. Disconnect
solenoid coil wires. Label as needed for 10. Connect the solenoid coil wires and install
correct re-connection. manifold cover. Refer to “Component
page A-4.
the key switch ON.
5. Elevate the carriage approx. 2.5 ft.
the key switch ON.
(0.75 m).
12. Bleed the hydraulic system as necessary.
6. Block the carriage so it cannot lower.
See “Hydraulic System Bleeding” on
7. Tilt forks completely down. page 7-86.
8. Turn the key switch OFF and disconnect 13. Test auxiliary functions for correct
the battery connector. operation. Check the manifold connections
9. Remove mast guard. for leaks.
10. Disconnect the reach cylinder at the inner
scissor to permit removal of the manifold.
11. Remove auxiliary manifold mounting
screws.
12. Disconnect and cap the auxiliary hoses
from the manifold. Label as needed for
re-connection.
13. Place manifold in a vice and remove the
solenoid coils and valves from the
manifold. Note the position of all the
fittings and remove them.
Installation
1. Install all fittings in the new manifold in
the same orientation as they were in the
manifold removed.
2. Install and torque all valves and solenoid
coils.
3. Position the manifold and connect all
auxiliary hoses.
4. Install auxiliary manifold on carriage.
Refer to “Component Specific
Service/Torque Chart” on page A-4.
5. Connect reach cylinder to inner scissor.
Apply thread-locking compound
(P/N 1013829) to threads of cylinder pin
screws.

Hydraulic Components Standard Reach Manifold - 32 in. Wide Mast
Standard Reach
Manifold - 32 in. Wide
Mast
This manifold, located on the fixed portion of the carriage, controls the reach function on standard
reach trucks with a 32 in. wide mast.
RV1
Reach Solenoid
RV2
RC
RR
A2 IN
A1 OUT
A2 OUT A1 IN
Torque
Item
ft. lb. (Nm)
A1 IN and A2 IN 15 (20)
A1 OUT and A2 OUT 15 (20)
20 (27)
Reach Solenoid
coil nut: 5 (6.8)
RC and RR 15 (20)
RV1 and RV2 20 (27)

Standard Reach Manifold - 32 in. Wide Mast Hydraulic Components
Removal 7. Reconnect the battery connector and turn

the key switch ON. Remove the carriage
1. Reach (extend) the fork carriage fully. blocking.
Block the scissor assembly so that the
8. Lower the carriage completely.
scissors cannot retract.
10. Connect the solenoid coil wires and install
3. Remove manifold cover. Disconnect
manifold cover. Refer to “Component
solenoid coil wires. Label as needed for
correct re-connection.
page A-4.
the key switch ON.
the key switch ON.
5. Elevate the carriage approx. 2.5 ft.
12. Bleed the hydraulic system as necessary.
(0.75 m).
See “Hydraulic System Bleeding” on
6. Block the carriage so it cannot lower. page 7-86.
7. Tilt forks completely down. 13. Test reach function for correct operation.
8. Turn the key switch OFF and disconnect Check the manifold connections for leaks.
9. Remove mast guard.
10. Disconnect the reach cylinder at the inner
scissor to permit removal of the manifold.
11. Remove manifold mounting screws.
12. Disconnect and cap the auxiliary hoses
from the manifold. Label as needed for
re-connection.
13. Place manifold in a vice and remove the
solenoid coil and valves from the manifold.
Note the position of all the fittings and
remove them.
Installation
the same orientation as they were in the
manifold removed.
coil.
3. Position the manifold and connect all
auxiliary hoses.
4. Install manifold on carriage. Refer to
5. Connect reach cylinder to inner scissor.
(P/N 1013829) to threads of cylinder pin
screws.
6. Install mast guard.

Hydraulic Components Deep-Reach ® Manifold - 35.5 in. Wide Mast
Deep-Reach ® Manifold -
35.5 in. Wide Mast
This manifold, located on the fixed portion of the carriage, controls the reach function on
Deep-Reach trucks with a 35.5 in. wide mast.
Reach Solenoid CB-1 CB-2 REL-3
RR
Torque
Item
ft. lb. (Nm)
CB-1 and CB-2 35 (47)
CV-3 6 (8.1)
CV-3 RC and RR 20 (27.1)
25 (34)
RC Reach Solenoid
coil nut: 5 (6.8)
REL-3 50 (67.8)
Removal 3. Position the manifold and connect all the

hydraulic hoses.
1. Reach the carriage out and lower to the
4. Reconnect the solenoid wires.
floor. Block the reach mechanism so that
the scissors cannot retract. 5. Mount the manifold to the scissors.
2. Turn the key switch OFF and disconnect 6. Reconnect the battery connector and turn
the battery connector. the key switch ON.
3. Remove the two manifold mounting bolts 7. Remove the blocking.
to gain access to all hydraulic fittings. 8. Bleed the hydraulic system. See
4. Label as required all the solenoid wires “Hydraulic System Bleeding” on page 7-86.
and remove. 9. Test the auxiliary functions for correct
5. Disconnect and cap all hydraulic hoses. operation and check connections for leaks.
Note the location of each hose.
6. Remove the manifold from the truck.
Installation
the same orientation that they were in the
manifold removed.
coils.

Deep-Reach ® Manifold - 32 in. Wide Mast Hydraulic Components
Deep-Reach ® Manifold -
32 in. Wide Mast
This manifold, located on the fixed portion of the carriage, controls the reach function on
Deep-Reach trucks with a 32 in. mast.
Reach Solenoid CB-1 CB-2 REL-3

RR
A2
A1
RC
Torque
Item
ft. lb. (Nm)
A1 and A2 25 (34)
CB-1 and CB-2 35 (47)
A2 A1 CV-3 6 (8.1)
RC and RR 20 (27.1)
25 (34)
Reach Solenoid
coil nut: 5 (6.8)
CV-3 REL-3 50 (67.8)
Removal 10. Disconnect and cap the lower manifold

hoses once the manifold is clear of the
1. Reach the carriage out and lower to the inner scissor weldment.
floor. Block the reach mechanism so that
the scissors cannot retract.
Installation
the battery connector. 1. Install all fittings in the new manifold in
3. Label the solenoid wires and disconnect. the same orientation that they were in the
manifold removed.
4. Remove the two manifold mounting bolts
to gain access to all hydraulic fittings.
coils.
the key switch ON. 3. Position the manifold and connect all the
hydraulic hoses. Reconnect the solenoid
6. Elevate the carriage approximately 4 ft. wires.
(1.2 m) and block the carriage so it can not
lower. 4. Install the manifold on the carriage.
7. Tilt forks completely down.
the key switch ON. Remove the blocking.
8. Disconnect and cap the upper hydraulic
hoses closest to the reach cylinder. 6. Bleed the hydraulic system. See
9. Remove the manifold mounting bolts and
slide the manifold out through the inner 7. Test the auxiliary functions for correct
scissor weldment. operation and check connections for leaks.

Hydraulic Components Tilt/Sideshift Manifold
Tilt/Sideshift Manifold
This manifold, located on the carriage, controls tilt and sideshift functions on all Deep-Reach trucks
and trucks with a 32 in. mast.
Tilt
Solenoid
Sideshift
Solenoid
Torque
Item
ft. lb. (Nm)
A1 and A2 15 (20)
Refer to Parts Manual for “Tilt Only” Manifold
20 (27)
Tilt Solenoid
coil nut: 5 (6.8)
TC and TR 15 (20)
20 (27)
Sideshift Solenoid
coil nut: 5 (6.8)
SSR and SSL 15 (20)
Removal 2. Install and torque all valves and solenoid

coils.
1. Reach the fork carriage out and fully lower
3. Mount the manifold to the carriage.
to the floor.
4. Connect the hydraulic hoses.
2. Tilt the forks fully down.
5. Connect the wiring to the solenoids.
the battery connector. 6. Reconnect the battery connector and turn
the key switch ON.
4. Disconnect the wiring for the solenoids.
7. Bleed the hydraulic system. See
5. Disconnect and cap the hydraulic hoses.
Note the location of the hoses.
8. Test the auxiliary functions for correct
6. Remove the manifold from the truck.
operation and check connections for leaks.
7. Remove the solenoid valves from the
manifold.
8. Note the position of all fittings and remove
them from the manifold.
Installation
the same orientation that they were in the
manifold removed.

Tilt/Sideshift Manifold Hydraulic Components

Hydraulic Components, Cylinder
Hydraulic Components, Cylinder


Lift Cylinder, Free Lift, Remove/Install Hydraulic Components, Cylinder
Lift Cylinder, Free Lift, 12. Disconnect the hydraulic line at the
bottom of the cylinder. Plug and cap the
Remove/Install fittings to prevent contamination from
entering the system.
NOTE: Place a pan below the main frame to
Model 7500 catch any hydraulic fluid when the line
is disconnected.
Left Side Free Lift Cylinder
13. Remove the upper free lift cylinder retainer
clamps.
Removal
14. Position the carriage at an appropriate
1. Remove mast guard.
height to allow removal of the cylinder.
2. Elevate telescopics to access the
over-the-mast (OTM) hoses/cable clamp at
cylinder.
the bottom of the free lift cylinder.
3. Remove the clamp and the free lift cylinder Installation
set screw at the bottom of the cylinder
mounting bracket. Remove any cable ties NOTE: The left side free lift cylinder contains a
securing the hoses/cable to the cylinder. flow limiter located at the bottom of the
cylinder. See “Flow Limiter, Free Lift” on
4. Fully lower the telescopics carefully so as page 7-127.
not to damage the hoses and cable.
1. Install the flow control, fitting, and feed
5. Using a suitable lifting device, lift the
hose at the bottom of the cylinder.
carriage to relieve the tension on the lift
chains and hoses. 2. Position the cylinder into the truck.
6. Turn the key switch OFF and disconnect 3. Install the upper free lift cylinder retainer
the battery connector. clamp.
7. Remove the master link from the free lift 4. Connect the hydraulic line at the bottom of
chain at the free lift cylinder anchor bolt. the cylinder.
8. Drape the chain over the carriage 5. Lift the carriage assembly to provide slack
assembly. in the lift chains and hoses for assembly.
9. Remove the chain pulley to access the 6. Apply thread-locking compound
pulley bracket assembly mounting bolt. (P/N 1013829) to the threads of the
Remove the pulley bracket assembly from mounting bolt and install the pulley
the piston and set to the side with the bracket assembly.
hoses and cable in place. 7. Install the chain pulley and the free lift
10. Mark the OTM hoses and cable at the chain.
upper free lift cylinder retainer for the 8. Install the OTM upper free lift cylinder
correct stretch when reassembled. Remove retainer, noting the marks made on the
the retainer. hoses/cable when removed.
11. Using the lifting device, lift and block the 9. Lower the carriage and remove the lifting
carriage assembly to a height that permits device.
access to the tubing at the bottom of the
cylinder.
the key switch ON.
NOTE: As the carriage is being lifted, feed the 11. Carefully lift the telescopics to access the
right side free lift chain towards the bottom of the free lift cylinder.
operator compartment to avoid jamming
of the chain. 12. Install the OTM hoses/cable clamp at the
bottom of the free lift cylinder. Make sure
there is correct clearance between the

Hydraulic Components, Cylinder Lift Cylinder, Free Lift, Remove/Install
bracket, hoses/cable, and the front plate NOTE: Place a pan below the main frame to
of the tractor. catch any hydraulic fluid when the line
13. Bleed the hydraulic system. See is disconnected.
“Hydraulic System Bleeding” on page 7-86. 12. Remove the set screw at the bottom of the
14. Check the truck for leaks and correct cylinder.
operation. 13. Position the carriage at an appropriate
15. Install the mast guard. height to permit removal of the cylinder.
Right Side Free Lift Cylinder cylinder.
Removal Installation
1. Remove the upper free lift cylinder retainer 1. Position the cylinder into the truck.
clamp. 2. Install the upper free lift cylinder retainer
NOTE: You can gain easier access by raising the clamp.
telescopics. 3. Position and block carriage to permit
access to bottom of the cylinder.
2. Fully lower the forks to the floor.
4. Install the set screw at the bottom of the
cylinder.
5. Connect the hydraulic line at the bottom of
4. Remove the mast guard.
the cylinder.
6. Lift the carriage assembly to provide slack
carriage to relieve the tension on the lift
to install the free lift chain.
chain.
7. Install the ring adapter. Apply
6. Remove the master link from the free lift
thread-locking compound (P/N 1013829)
chain at the free lift anchor bolt.
to the mounting bolt threads and install
7. Remove and drape the chain over the the pulley bracket assembly to the piston.
carriage assembly.
8. Install the chain pulley and the free lift
NOTE: Twist the pulley assembly to permit the chain.
removal of the chain. 9. Install the OTM electrical cable and
8. Remove the chain pulley to access the reconnect TS3-1.
pulley bracket assembly mounting bolt. 10. Lower the carriage and remove the lifting
9. Remove the pulley bracket assembly and device.
ring adapter. 11. Reconnect the battery connector and turn
10. Using the lifting device, lift and block the the key switch ON.
carriage assembly to a height that permits 12. Bleed the hydraulic system. See
access to the bottom of the cylinder. “Hydraulic System Bleeding” on page 7-86.
NOTE: As the carriage is being lifted, feed the 13. Check the truck for leaks and correct
left side free lift chain toward the operation.
operator compartment to avoid jamming 14. Install the mast guard.
the chain.
11. Disconnect the hydraulic line at the
bottom of the cylinder. Plug and cap the
fitting to avoid contamination from
entering the system.

Lift Cylinder, Free Lift, Remove/Install Hydraulic Components, Cylinder
Model 7520 7. Elevate the mast and remove the blocking.

Left Side Free Lift Cylinder the key switch ON.
Removal “Hydraulic System Bleeding” on page 7-86.
1. Elevate the carriage so the fittings at the 10. Check the truck for leaks and correct
bottom of the cylinder are accessible. operation.
2. Block the carriage and fully collapse the 11. Install the mast guard.
free lift cylinders.
3. Turn the key switch OFF and disconnect Right Side Free Lift Cylinder
4. Remove mast guard. Removal
5. Cut the cable ties on the hose clamps. 1. Remove the TS2 terminal cover on top of
the fixed carriage.
NOTE: Place a chalk witness mark on the hoses
2. Disconnect the OTM cable at TS2 and
to aid in reassembly.
disconnect the cable from the carriage
6. Loosen/remove the hose retainer clamps assembly.
at the top of the cylinder and release the 3. Remove the mast guard.
hoses.
4. Elevate the carriage so the fittings at the
7. Disconnect the free lift chain at the chain bottom of the cylinder are accessible.
anchor and feed the chain over the pulley.
5. Block the carriage and fully collapse the
8. Remove the chain pulley to access the
free lift cylinders.
pulley bracket mounting bolt.
9. Remove the pulley bracket from the the battery connector.
cylinder.
7. Cut the cable ties on the cable clamps.
10. Disconnect and cap the hydraulic line at
the bottom of the cylinder. NOTE: Place a chalk witness mark on the cable
11. Remove the nut from the cylinder upper to aid in reassembly.
retaining anchor at the inner telescopic 8. Feed the cable through the pulley/spring
crosstie. tension bracket and set aside.
12. Using a suitable lifting device, carefully 9. Disconnect the free lift chain at the chain
remove the cylinder. anchor and feed the chain over the pulley.
Installation
1. Using a suitable lifting device, install the
11. Remove the pulley bracket from the
cylinder onto the two locating pins on the
cylinder.
inner telescopic lower crosstie.
12. Disconnect and cap the hydraulic line at
2. Install the upper retainer nut at the
the bottom of the cylinder.
crosstie.
13. Remove the nut from the cylinder upper
3. Connect the hydraulic line and fittings at
retaining anchor at the inner telescopic
crosstie.
4. Reattach the pulley bracket and chain
14. Using a suitable lifting device, carefully
pulley.
remove the cylinder.
5. Using a new master link, install the free
lift chain to the upper chain anchor.
6. Secure the hoses to the clamps.

Hydraulic Components, Cylinder Lift Cylinder, Free Lift, Remove/Install
Installation
1. Using a suitable lifting device install the
cylinder onto the two locating pins on the
inner telescopic lower crosstie.
2. Install the upper retainer nut at the
crosstie.
3. Connect the hydraulic line and fittings at
NOTE: The flow limiter fitting is installed in the
bottom right side free lift cylinder.
4. Reattach the pulley bracket and chain
pulley.
5. Using a new master link, install the free
lift chain to the upper chain anchor.
6. Secure the cable to the clamps and feed
through the spring tension bracket and
over the pulley.
7. Hook the tensioner to the bracket.
8. Elevate the mast and remove the blocking.
9. Route and reattach the cable to the fixed
carriage.
10. Connect the cable wires to TS2 and
reinstall the TS2 cover plate.
the key switch ON.
13. Check the truck for leaks and correct
operation.
14. Install the mast guard.

Lift Cylinder, Free Lift, Seal Repacking Hydraulic Components, Cylinder
Lift Cylinder, Free Lift, 13. Inspect the inside of the housing for
damage and clean as required.
Seal Repacking
Reassembly
Disassembly 1. If the piston was removed, install the
piston and the three staging zone
There is a staging zone mechanism in the free mechanism stop screws that were removed
lift cylinders in addition to a cushion at the in step 8 of the disassembly procedure.
bottom of the cylinder. 2. Lubricate the wiper seal, packing seal,
1. Remove the mast guard. O-rings, and backup ring with new
hydraulic fluid and install into their
2. Lower the carriage onto a suitable block
respective grooves on the gland. Make sure
and fully lower cylinder to relieve the
they are correctly positioned.
tension on the hoses, cable, and free lift
chains. 3. Install the pressure ring with the seal
towards the open end of the housing. See
Figure 7-125.
4. Remove the free lift chain master link at Figure 7-125. Pressure Ring Orientation
the free lift cylinder anchor bolt and lay
the chain over the carriage.
NOTE: Twist the right side pulley to remove the
chain from the pulley.
6. Remove the pulley bracket assembly. Set
the left side to one side, keeping the hoses
and cable in place.
7. For 3 in. lowered height option, remove the
adapter ring.
8. If you are removing the piston, remove the
three staging zone mechanism stop screws 4. Apply thread-locking compound
and the bleeder screw. It may be necessary (P/N 990-571) to the threads of the gland.
to loosen the upper OTM retainer to allow 5. Lubricate the piston rod with new
the removal of the three stop screws. hydraulic fluid. Carefully slide the gland
NOTE: Mark the hoses and cable to make sure over it.
of correct stretch when reassembled. 6. Torque the end cap to 200 ft. lb. (271 Nm).
9. Using the correct cylinder end cap tool, 7. Apply a film of lubricant (P/N 990-652) to
remove the end cap (gland). Refer to the top of the gland and housing to
Table 7-1, “Special Tools,” on page 7-14. prevent moisture entry.
10. On a clean work surface, remove the wiper 8. Install the snap ring inside the housing.
seal, packing seal, O-rings, and backup Make sure that the snap ring is fully
ring from the gland. Note the position and seated in the groove.
orientation of each when removing. 9. Wipe away any excess hydraulic fluid.
11. Inspect the surfaces of the gland for any 10. Tighten the upper OTM retainer, if
scratches or damage. Remove minor previously loosened.
imperfections using fine emery cloth.
11. For 3 in. lowered height option, install the
12. Clean the gland. adapter ring.

Hydraulic Components, Cylinder Lift Cylinder, Free Lift, Seal Repacking

(P/N 1013829) to the threads of the
mounting bolt and install the pulley
bracket assembly.
13. Install the chain pulley and the free lift
chain.
the key switch ON.
15. Remove the block from beneath the
carriage.
operation.

Lift Cylinder, Main, Remove/Install Hydraulic Components, Cylinder
Lift Cylinder, Main, 13. Remove the connector.

Remove/Install cylinder from the truck.
Installation
Left Side Main Lift Cylinder
1. Install the fitting and feed hose at the
Removal bottom of the cylinder.
2. Attach mast guard bracket onto the
1. Remove mast guard, top cover, and left
cylinder.
front cover.
3. Position the cylinder into the truck.
2. Remove the retainer bolt at the bottom of
the cylinder. 4. Apply thread-locking primer
(P/N 990-666) to both the right and left
3. Place a block approx. 18 in. (457 mm) long
mast mounting bolt threads and the hole
between the inner telescopic crosstie and
threads. Permit to dry for several minutes.
the outer telescopic crosstie. Place a block
approx. 12 in. (305 mm) in length between
(P/N 990-544) to the threads of the mast
the outer telescopic crosstie and the main
mounting bolts. Install the mast connector
frame crosstie.
and torque the bolts to 160/170 ft. lb.
NOTE: This provides the necessary hose/cable (217/230 Nm).
slack and clearance to remove cylinder. 5. Install the mast connector snap ring.
4. Fully lower the carriage. 6. Remove the jack.
5. Turn the key switch OFF and disconnect 7. Connect feed hose at the bulkhead fitting.
the battery connector. Remove battery.
8. Attach the OTM hose/cable retainer
6. Remove the bolt, washer, and spacer at the bracket to the cylinder.
top of the piston.
9. Install the cylinder mounting L-bracket(s)
7. Remove the cylinder mounting with sleeves and bolts. Do not tighten at
L-bracket(s). this time.
NOTE: Models with an OACH of 131 in. 10. Install battery. Reconnect the battery
(333 cm) and above have two brackets. connector and turn the key switch ON.
8. Remove the OTM hose/cable retainer 11. Carefully rotate the lift knob to raise the
bracket from the cylinder. piston to the telescopic crosstie.
9. Place a pan below the tractor and 12. Model 7500: Install bolt, washer, and
disconnect the cylinder feed hose at the spacer at the crosstie to top of the piston.
tractor bulkhead fitting. Model 7520: Install the bolt, washer, and
outer sleeves at the crosstie to the top of
NOTE: The feed hose can remain connected to the piston.
the bottom of the cylinder to assist in
removal. 13. Model 7500: Apply thread-locking
compound (P/N 1013829) to the threads
10. From inside the battery compartment, and tighten, leaving a 0.12 in. (3 mm) gap
loosen the right side mast connector between the head of the bolt and washer.
mounting bolts. Model 7520: Apply thread-locking
11. Remove the left side mast bolts and the compound (P/N 1013829) to the threads
mast connector snap ring. and torque bolt to 55 ft. lb. (75 Nm).
12. Place a jack beneath the tractor to slightly 14. Tighten the cylinder mounting L-bracket
spread the tractor and the mast to allow bolts to 55 ft. lb. (75 Nm).
the removal of the connector.

Hydraulic Components, Cylinder Lift Cylinder, Main, Remove/Install
15. Remove the blocks from the telescopics 11. Place a jack beneath the tractor to slightly
and the main frame. spread the tractor and mast to allow the
16. Install the retainer bolt at the bottom of removal of the connector.
the cylinder. 12. Remove the connector.
17. Bleed the hydraulic system. See 13. Using a suitable lifting device, remove the
“Hydraulic System Bleeding” on page 7-86. cylinder from the truck.
18. Check for leaks and correct operation.
19. Install the mast guard, top cover, and left Installation
front cover. NOTE: The right side main lift cylinder houses
a flow limiter located in the manifold
Right Side Main Lift Cylinder block at the bottom of the cylinder. See
“Flow Limiter, Main Lift” on page 7-126.
Removal 1. Install the flow control, fitting, and feed
hose at the bottom of the cylinder.
1. Remove mast guard, top cover, and right
front cover. 2. Attach mast guard bracket to cylinder.
2. Elevate telescopics and remove the 3. Position the cylinder into the truck.
retainer bolt at bottom of cylinder. 4. Apply thread-locking primer
3. Place a block at least 12 in. (305 mm) in (P/N 990-666) to mast mounting bolt
length between the main frame and the threads and the hole threads. Permit to
outer telescopic crosstie and fully lower dry for several minutes. Apply
the carriage. thread-locking compound (P/N 990-544)
to the threads of the mast mounting bolts.
NOTE: This length provides the clearance Install the mast connector and torque the
required to remove the cylinder. bolts to 160/170 ft. lb. (217/230 Nm).
4. Fully lower the carriage. 5. Install the mast connector snap ring.
5. Turn the key switch OFF and disconnect 6. Remove the jack from the truck.
the battery connector. 7. Connect the feed hose at the tractor
6. Remove the bolt, washer, and spacer at the bulkhead fitting.
top of the piston and outer telescopic 8. Install the cylinder mounting L-bracket(s)
crosstie. with sleeves and bolts. Do not tighten at
7. Remove the cylinder mounting this time.
L-bracket(s). 9. Install the retainer bolt at the bottom of
NOTE: Models with an OACH of 131 in. the cylinder.
(333 cm) and above have two upper 10. Reconnect the battery connector and turn
brackets. the key switch ON.
8. Place a pan below tractor. Disconnect the 11. Carefully rotate the lift knob to raise the
cylinder feed hose at the tractor bulkhead. piston to the telescopic crosstie.
Plug and cap the fittings to prevent 12. Model 7500: Install bolt, washer, and
contamination from entering the system. spacer at the crosstie to top of the piston.
NOTE: Leave feed hose connected to cylinder to Model 7520: Install the bolt, washer, and
assist in removal of the cylinder. outer sleeves at the crosstie to the top of
the piston.
9. From inside the battery compartment,
loosen the left side mast bolts. 13. Model 7500: Apply thread-locking
10. Remove the right side mast bolts and the and tighten, leaving a 0.12 in. (3 mm) gap
mast connector snap ring. between the head of the bolt and washer.

Lift Cylinder, Main, Remove/Install Hydraulic Components, Cylinder
Model 7520: Apply thread-locking

and torque bolt to 55 ft. lb. (75 Nm).
14. Tighten the cylinder mounting L-bracket
bolts to 55 ft. lb. (75 Nm).
15. Remove the block from between the
telescopic and the main frame.
operation.
18. Install the mast guard, top cover, and right
front cover.

Hydraulic Components, Cylinder Lift Cylinder, Main, Seal Repacking
Lift Cylinder, Main, Seal 4. Torque the gland to 200 ft. lb. (271 Nm).
Repacking the key switch ON.
6. Carefully rotate the lift knob to raise the
piston to the telescopic crosstie.
Disassembly
7. Install the bolt, washer, and spacer at the
1. Slightly elevate the mast and place a block crosstie to the top of the piston.
between the outer telescopic crosstie and
the main frame. NOTE: Apply thread-locking compound
(P/N 1013829) to the threads of the bolt
2. Fully lower the carriage.
and tighten, leaving a 0.12 in. (3 mm)
3. Turn the key switch OFF and disconnect gap between the head of the bolt and the
the battery connector. washer.
4. Remove the bolt, washer, and spacer at the 8. Remove the block from between the outer
top of the piston and the outer telescopic telescopic crosstie and the main frame.
crosstie.
5. Retract the piston into the housing enough “Hydraulic System Bleeding” on page 7-86.
to allow the removal of the end cap (gland).
6. Using the correct cylinder end cap tool, operation.
remove the end cap (gland). Refer to
Table 7-1, “Special Tools,” on page 7-14.
7. On a clean working surface, remove the
packing seal, wiper seal, and square seal
from the end cap. Note position and
orientation of each when removing.
NOTE: Model 7520 has an additional buffer
seal.
8. Inspect the surfaces of the gland for any
scratches or damage. Remove minor
imperfections using fine emery cloth.
9. Inspect the inside of the housing for
damage and clean as required.
10. Clean the threads on the gland and the
cylinder.
Reassembly
1. Lubricate with new hydraulic fluid, the
packing seal, wiper seal, and square seal,
and install into their respective grooves on
the gland. Make sure they are correctly
seated within the grooves and are not
twisted.
(P/N 990-571) to the threads of the gland.
3. Lubricate the piston rod with new
hydraulic fluid and carefully install the
gland.

Lift Cylinder Lowering Cushion Hydraulic Components, Cylinder
Lift Cylinder Lowering 4. Compress the spring and hold it in place

with a drill bit or drift pin inserted in one
Cushion of the hydraulic fluid ports in the cushion
housing.
5. Install the snap ring.
Main Lift Cylinders 6. Carefully release cushion pressure.
7. Reassemble the cylinder. See “Lift
Removal
Cylinder, Main, Seal Repacking” on
1. Remove the main lift cylinder. Refer to page 7-117.
page 7-114. 8. Install the cylinder. Refer to page 7-114.
2. Remove the piston rod from the cylinder.
See “Lift Cylinder, Main, Seal Repacking” Free Lift Cylinders
on page 7-117.
3. Place the piston rod on a clean padded Removal
working surface.
4. Compress the spring and hold it in place There is a staging zone mechanism in the free
with a drill bit or drift pin inserted in one lift cylinders in addition to a cushion at the
of the hydraulic fluid ports in the cushion bottom of the cylinder.
housing.
1. Using an eye bolt and hoist, remove the
piston rod from the cylinder.
2. Perform steps 1 thru 9 of “Lift Cylinder,
When the snap ring is removed, the Free Lift, Seal Repacking” on page 7-112.
cushion spring ejects the cushion from 3. Place the piston rod on a clean padded
the piston. Keep body away from the working surface.
piston end when performing this
procedure. 4. Compress the spring and hold it in place
5. Remove the snap ring from inside of the of the hydraulic fluid ports in the cushion
cylinder. housing.
6. Release the cushion slowly.

7. Remove the ring retainer and seal from the
cushion. When the snap ring is removed, the
cushion spring ejects the cushion from
8. Replace the cushion, spring, seal, and/or
the piston. Keep body away from the
retainer components as necessary. If
piston end when performing this
replacing the cushion, install the cap
procedure.
screw in the end of the cushion.
5. Remove the snap ring from inside of the
Reassembly cylinder.
1. Lubricate the inside of the piston surface 6. Release the cushion slowly.
with clean hydraulic fluid. 7. Remove the retaining ring and the two
2. Lubricate the seal with clean hydraulic O-rings on the inside and outside of the
fluid and install on the cushion. Install the ring.
retainer ring on the cushion. 8. Remove the spring and decel piston.
3. Insert and seat the cushion spring in the 9. Remove the decel bearing and piston ring
center of the piston. Insert and seat the from the decel piston.
cushion on the end of the cushion spring.

Hydraulic Components, Cylinder Lift Cylinder Lowering Cushion
10. Remove the spring and plug from the

cushion housing (piston plug).
11. Remove the O-ring from the plug.
Reassembly
1. Lubricate new O-rings, piston ring, and
decel bearing with clean hydraulic fluid.
2. Install the new piston ring and decel
bearing in the decel piston.
3. Lubricate the inside of the piston surface
with clean hydraulic fluid.
4. Install the new O-ring in the groove in the
plug and install the plug in the cushion
housing.
5. Seat the plug in the housing by inserting
the spring and the decel piston in the
cushion housing.
6. Install the other spring.
7. Install new O-rings on the inside and
outside of the retaining ring.
8. Install the retaining ring on the shaft of
the decel piston.
9. Compress the spring and hold it in place
of the hydraulic fluid ports in the cushion
housing.
10. Install the snap ring in the cushion
housing.
11. Release the cushion slowly.
12. Reassemble the cylinder. Perform steps 2
thru 14 of “Lift Cylinder, Free Lift, Seal
Repacking” on page 7-112.

Reach Cylinder Hydraulic Components, Cylinder
Reach Cylinder 10. Slide the piston assembly off the end of the
rod.
11. Slide the cushion sleeve off the rod. Note
Removal the direction of the taper.
1. Remove the mast guard. 12. Remove the head assembly.
2. Raise the carriage until the reach cylinder 13. Remove the head static seal O-rings,
is accessible from the operator’s backup washers, rod inside diameter
compartment. dynamic seal, and the rod wiper. Use care
to avoid scratching the groove.
3. Fully retract the carriage.
14. Remove the O-ring and backup washers
4. Block the carriage.
from the piston assembly.
Reassembly
6. Place a pan below the reach cylinder.
1. Remove any burrs or sharp edges caused
7. Remove and cap the reach hoses at the
from disassembly before installing the new
reach cylinder.
seals.
8. Remove the screw and cotter pin holding
2. Clean all parts with solvent. Lubricate
the piston yoke in place.
parts with petroleum jelly or clean
9. Remove the clevis pin and spacers. hydraulic fluid as indicated.
10. Remove the screw and cotter pin at the 3. Lubricate and install the new rod,
housing end. dynamic seal, and rod wiper in their
11. While supporting the cylinder, remove the respective inside grooves of the head
clevis pin and spacers holding the cylinder assembly.
in place. 4. Lubricate and install the new head static
seal O-rings and head static seal backup
Disassembly washers on the outside grooves of the head
assembly.
1. With the cylinder removed, drain all 5. Lubricate the head assembly inside seals
hydraulic fluid from the cylinder assembly. and carefully slide the head assembly onto
2. Clamp the cylinder base end in a bench the rod assembly.
vise. Cover the ports with a clean rag.
3. Remove the external lock ring.
4. Push the head assembly into the tube
assembly approx. 3/4 in. (19 mm).
5. Remove the spacer.
6. Remove the internal lock ring.
7. Important: Look for and remove any sharp
edges from the back corner of the internal
lock ring groove, if present.
8. Grip the rod firmly and pull the rod
assembly out of the tube assembly. (Oil
can spray out of the cylinder ports).
9. Clamp the rod at the wrench flats or clevis
in a soft-jawed vise. Loosen the retaining
nut on the piston assembly.

Hydraulic Components, Cylinder Reach Cylinder

Figure 7-126. Reach Cylinder (Deep-Reach shown) Installation
1. Place the spacers on the cylinder (hold
them in place with grease) and position the
cylinder housing into the yoke on the
carriage. Insert the clevis pin and secure
with the cotter pin and screw.
2. Place the spacers on the carriage bracket
(hold them in place with grease). Position
the piston yoke and insert the clevis pin.
Secure with the cotter pin and screw.
3. Reconnect the hydraulic hoses.
4. Unblock the carriage.
the key switch ON.
7. Adjust the reach cylinder. See “Adjustment
Procedure” on page 7-122.
operation.
Adjustment
6. Install the piston O-ring and backup
washers in the outside groove of the piston With the forks fully extended, the top of the
assembly. scissor roller must not protrude more than
7. Slide the cushion sleeve onto the rod. 0.90 in. (22.8 mm) from the top of the roller
channel wear bar on the fork carriage. This
NOTE: The taper on the cushion faces the head takes precedence over the extended dimension.
assembly. See Figure 7-127.
8. Carefully slide the piston assembly onto
the rod assembly. Install a new prevailing Figure 7-127. Scissor Roller Dimension
torque nut and tighten.
9. Lubricate the piston and head assembly
and carefully slide it into the tube
assembly.
11. Install a new internal lock ring in the
groove in the tube assembly bore.
12. Grip the rod firmly and pull outward until
the head assembly is tight against the lock
ring.
Roller Channel Wear Bar
13. Install the spacer and external lock ring in
the head assembly.

Reach Cylinder Hydraulic Components, Cylinder
When the reach is fully extended, the gap between the plastic block and the metal
dimension from the front of the main frame to block (Deep-Reach) or fixed carriage (Standard
the face of the forks when level should be: Reach). This is a backup stop only. Shim the
plastic block to produce a gap of:
Carriage Dimension
Carriage Gap
R35TT 28.25 in. (717.6 mm)
Std Reach 0.125 to 0.250 in. (3.2 to 6.4 mm)
R45TT 28.38 in. (720.00 mm)
Deep-Reach 0.125 to 0.375 in. (3.2 to 9.5 mm)
DR32TT 53.40 in. (1356.4 mm)
Reach Scissor Roller Shimming
Figure 7-128. Reach Fully Extended Dimension Make sure at least half of the thickness of the
scissor roller is running on the roll plate wear
bar. Shim as needed between the shoulder of
the scissor arm stud and the bearing inner
race. See Figure 7-129.
Figure 7-129. Reach Scissor Roller Bearing Shimming
NOTE: The face of the fork to the front of the

load wheel (or wheel box) should be a
minimum of 0.50 in. (13 mm). If not,
perform the adjustment procedure that
follows. Shim Here
Adjustment Procedure
1. Loosen the jam nut that holds the piston
Adjustment
to the yoke.
2. Remove the pin that secures the yoke to The top of the scissor roller must not protrude
the carriage. more than 0.90 in. (22.8 mm) from the top of
the roller channel on the fork carriage. This
3. Turn the yoke to obtain the correct takes precedence over the extended dimension.
dimension.
Figure 7-130. Scissor Roller Dimension
4. Install the pin to secure the yoke to the
carriage.
(P/N 1013829) to the threads on the
piston and torque the jam nut to 175 ft. lb.
(237 Nm).
Retract Adjustment
Model 7500 lift trucks are designed with reach

and retract stops inside the reach cylinder at
both ends of the stroke. When the scissors
mechanism is fully retracted, there should be a

Hydraulic Components, Cylinder Tilt Cylinder
Tilt Cylinder Figure 7-131. Tilt Cylinder, Disassembly

Head Static Seal
Backup Washer
Removal Internal Lock
Head Static Ring
1. Extend and block the scissor assembly so Seal O-ring
Spacer
it cannot retract.
2. Position and block the carriage at a External Lock
comfortable working height. Ring
3. Spread the forks on the carriage to gain

complete access to the tilt cylinder. Rod Wiper
4. Tilt the forks completely up. Rod Wear

Ring
5. Turn the key switch OFF and disconnect Rod Dynamic
the battery connector. Tube Seal
Assembly
6. Remove the snap rings from the tilt pin.
Piston
7. Place a block between the fork carriage Assembly
and the carriage frame. Head Assembly
8. Remove the tilt pin.
9. Place a pan below the tilt cylinder and
disconnect and cap the hydraulic hoses.
Note the orientation of the fittings and
position of the hoses.
10. Support the tilt cylinder and remove the
mounting bolts from the mounting blocks. Pin Hole
Base
End
Disassembly Rod
With the cylinder removed, drain all hydraulic

fluid from the cylinder assembly. Clamp the
cylinder at the base end in a bench vise. Cover Piston
the ports with a clean rag. Refer to Figure 7-131 Wear
for the following steps. Ring
1. Remove the external lock ring.
2. Remove the spacer. Piston
Seal
4. Remove the internal lock ring.
Rod Piston
5. Important: Remove the sharp edge from the O-Ring
back corner of the internal lock ring
groove. 8. Loosen the piston assembly with a
spanner wrench. Unthread the piston
6. Grip the rod through the hole in the pin assembly from the rod.
and pull the rod assembly out of the tube
assembly. 9. Slide the head assembly off the rod from
the piston end.
7. Clamp the rod in a bench vise at the pin
hole end. 10. Clean the male threads of the rod. Remove
the rod piston O-ring.

Tilt Cylinder Hydraulic Components, Cylinder
11. Remove the head static seal O-ring, 13. Install the spacer and external lock ring on
backup washer, wear ring, rod dynamic the head assembly.
seal, and rod wiper. Use care to avoid 14. Stroke the cylinder rod back and forth by
scratching grooves. hand. It should move smoothly, without
12. Remove the wear ring and piston dynamic binding or heavy drag.
seal from the piston assembly. Use care to 15. Reinstall the cylinder assembly on the
avoid scratching grooves. carriage.
13. Clean all parts in solvent.
Installation
Reassembly
1. Make sure the hydraulic fittings are in the
1. Remove any burrs or sharp edges caused same orientation on the cylinder as when
from disassembly before installing new removed.
seals. 2. Install the yokes on the cylinder and
2. Lubricate parts as indicated below with position the cylinder in place. Bolt the
petroleum jelly or clean hydraulic fluid. yokes to the carriage.
3. Lubricate and install a new rod wear ring, 3. Connect the hydraulic hoses noting their
rod dynamic seal, and rod wiper in their correct orientation and position.
respective inside grooves of the head 4. Coat the tilt cylinder pin with all weather
assembly. grease (P/N 1012992). Install the tilt
4. Lubricate and install a new head static cylinder pin and snap rings.
seal, O-ring, and head static seal backup 5. Reconnect the battery connector and turn
washer on the outside grooves of the head the key switch ON.
assembly.
6. Remove the blocks.
5. Lubricate the head assembly inside seals
with hydraulic fluid and carefully slide the 7. Check for clearance between the free lift
head assembly onto the rod assembly. feed hose assembly, tilt hoses, and fittings
when the carriage is fully lowered and
6. Install the piston wear ring and piston seal retracted.
in their respective outside grooves of the
piston assembly. 8. Check the tilt function for correct
operation and leaks.
7. Install the rod piston O-ring in the groove
of the rod. 9. Bleed the hydraulic system. See
8. Apply red thread-locking compound
(P/N 990-571) to the male threads of the
piston. Carefully thread the piston
assembly onto the rod assembly. Torque to
200 ft. lbs. (271 Nm).
9. Lubricate the piston and head assembly
with hydraulic fluid and carefully slide it
into the tube assembly.
11. Install a new internal lock ring in the
groove in the tube assembly bore.
12. Grip the rod through the pin hole and pull
outward until the head assembly is tight
against the lock ring.

Hydraulic Components, Cylinder Sideshift Cylinder
Sideshift Cylinder 4. Remove the wear ring, wiper, and rod seal
from the gland. Use care to avoid
scratching surfaces.
Removal 5. Make sure cylinder and gland grooves are
clean.
1. Extend and block the scissor assembly so
it cannot retract.
2. Position and block the carriage at a
Reassembly
comfortable working height. 1. Remove any burrs or sharp edges caused
3. Spread the forks on the carriage to gain from disassembly before installing new
complete access to the sideshift cylinder. seals.
4. Tilt the forks completely up. 2. Lubricate parts as indicated below with
petroleum jelly or clean hydraulic fluid.
the battery connector. 3. Lubricate and install a new wear ring, rod
seal, and wiper in their respective inside
6. Place a pan below the sideshift cylinder
grooves of the head assembly.
and disconnect and cap the hydraulic
hoses. 4. Re-install the rod and stroke the cylinder
rod back and forth by hand. It should
7. Support the sideshift cylinder and remove
move smoothly, without binding or heavy
the mounting pins.
drag.
Disassembly Installation
NOTE: Only the outer wear ring, outer wiper,
1. Reinstall the cylinder assembly on the
and outer rod seal on each side can be
carriage.
replaced.
2. Connect the hydraulic hoses noting their
1. With the cylinder removed, drain all correct orientation and position.
hydraulic fluid from the cylinder assembly.
2. Clamp the cylinder at the base end in a the key switch ON.
bench vise and cover the ports with a
clean rag. 4. Remove the blocks.
3. Pull the rod out of each side to access the 5. Check the sideshift function for correct
outer wear ring, outer wiper, and outer rod operation and leaks.
seal. See Figure 7-132. 6. Bleed the hydraulic system. See
Figure 7-132. Sideshift Cylinder, Disassembly
Outer Wear
Ring
Outer Rod Seal
Outer Wiper

Flow Limiter, Main Lift Hydraulic Components, Cylinder
Flow Limiter, Main Lift Removal

1. Fully lower the carriage to the floor.
The main lift cylinder flow limiters restrict 2. Turn the key switch OFF and disconnect
lowering flow to 15 gpm (57 lpm). These flow the battery connector.
limiters can be replaced without removing the
cylinder. 3. Remove the front cover(s).
4. Place a pan below the baseleg at the left
Main lift cylinder flow limiter(s) are located at side main lift cylinder.
the bottom of the main lift cylinder(s). 5. Disconnect and cap the hose at the bottom
of the cylinder.
Figure 7-133. Flow Limiter Location - Model 7500
Main Lift Flow Limiter 6. Remove the fitting from the manifold
block.
7. Remove the flow limiter noting the
direction of the arrow.
Installation
1. Install the flow limiter. Make sure the
arrow points in the up direction.
2. Install the fitting in the manifold block.
3. Reconnect the hose to the cylinder.
Left Side Main
Lift Cylinder 4. Reconnect the battery connector and turn
the key switch ON.
Note: Trucks with an OACH above 146 in. have “Hydraulic System Bleeding” on page 7-86.
a flow limiter in both main lift cylinders.
operation.
Figure 7-134. Flow Limiter Location - Model 7520
7. Install the front cover(s).
Left Side Main

Lift Cylinder
Main Lift Flow Limiter
Note: Model 7520 trucks have a flow limiter in

both main lift cylinders.

Hydraulic Components, Cylinder Flow Limiter, Free Lift
Flow Limiter, Free Lift Figure 7-135. Free Lift Flow Limiter (Model 7500 shown)
Flow
The free lift flow limiter is located in the SAE Limiter
fitting at the bottom of the left side free lift
cylinder on a Model 7500 and at the bottom of
the right side free lift cylinder on a Model 7520.
Removal
2. Raise the telescopics until the bottom of
the left free lift cylinder is accessible from
the operator’s compartment.
3. Place a block of sufficient length (approx.
24 in./610 mm) between the outer
telescopic crosstie and the main frame to
hold the position in step 2.
4. Fully lower the carriage. Installation
5. Extend the reach mechanism to allow 1. Install the flow limiter fitting in the
easier removal of the free lift lines and manifold block.
fittings.
2. Install the set screw at the bottom of the
6. Turn the key switch OFF and disconnect cylinder.
3. Reconnect the hydraulic line at the bottom
7. Place a pan below the baseleg at the left of the cylinder.
free lift cylinder.
8. Remove and cap the hydraulic line at the the key switch ON.
bottom of the free lift cylinder. See
Figure 7-135. 5. Remove the block between the outer
telescopic and main frame.
9. Remove the set screw at the bottom of the
free lift cylinder to permit the cylinder to 6. Bleed the hydraulic system. See
rotate for the removal of the fitting. “Hydraulic System Bleeding” on page 7-86.
10. Remove the fitting from the manifold 7. Check the truck for leaks and correct
block. operation.
11. Remove the flow limiter noting the 8. Install the mast guard.
direction of the arrow.

Flow Limiter, Free Lift Hydraulic Components, Cylinder

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


Carriage Bearings Mast, Chain, Hose, Cable
Carriage Bearings the bearing is fully seated, bend the flat

washer to contact the bearing so the
bearing does not walk on the shaft.
The upper carriage roller bearing is accessible
5. Repeat steps 1 thru 4 for the five
when the carriage is elevated. The carriage
remaining bearings.
must be removed to access the middle and
lower bearings. The bearings are shimmed at 6. Clean and re-grease the telescopic
the factory to a 0.00 ±0.010 overall interference channels.
between the bearings and the inner telescopic 7. Re-install the carriage. See “Carriage” on
after the inner telescopic is shimmed and page 7-136.
inserted in the outer telescopic. Inspect
8. Test the reach/retract function of the
bearings for damage or wear and replace as
carriage.
required.
Removal Adjustment
1. Remove the carriage. See “Carriage” on Test carriage operation. If there is any kick or if
page 7-136. the forks are not level, adjust the eccentric pins
2. Remove the socket head cap screw and as necessary. Start with lower carriage roller
washer on the end of the bearing. bearing pins.
3. The bearing should slide off the shaft with

hand pressure. A suitable bearing puller
can be used if required.
Installation
Shim the top and middle bearings to obtain an
overall width equal to the minimum inner
telescopic dimension (±0.010 in./0.25 mm)
taken from the inside to inside of the I-beam
webs at the front flange of the inner telescopic.
Shim the bottom bearings to obtain an overall

width equal to the minimum inner telescopic
dimension (±0.010 in./0.25 mm) taken from the
inside to inside of the I-beam webs at the rear of
the inner telescopic.
If possible, maintain an equal amount of shim

thickness on each side of the carriage when
shimming the bearings.
1. Install or remove the required amount of
shims.
2. Install the bearing on the shaft.
(P/N 1013829) to the socket head cap
screw and fasten the screw and washer in
place.
4. If the inner race of the bearing does not
protrude past the end of the shaft when

Mast, Chain, Hose, Cable Mast Shimming
Mast Shimming Compare the wear pattern on the rail (where the
roller rides) to the examples shown in
Figure 7-136.
Shimming a mast makes a smooth running unit
• If the wear pattern is optimal, shimming is
that is not too tight or too loose. If you find any
adequate
marks within the telescopics or main frame
where the rollers have been running, remove • If the wear pattern is excessive, shimming
them using a sanding disc and 80 grit paper. Do is too tight
not attempt to remove all marks, only the • If the wear pattern varies between optimal
ridges. Shim the bearings to the tightest spot on and excessive, the telescopic weldment is
the assembly (as the rollers run up and down suspect
the rail). Buff small areas that are slightly
higher than the rest of the web to avoid NOTE: Uneven wear can also indicate which
shimming the major portion of the rail too loose. bearing set is too tight.
The shims used under each roller bearing come
Figure 7-136. Mast Bearing Wear Patterns
in the following sizes: thin, medium, and thick.
Although you can use different combinations of Approx. 1 in. (25.4 mm)
wide wear pattern
shims to obtain the correct adjustment, you
should try to maintain equal shim thickness on
each side of the mast.
Mast and Bearing Inspection OPTIMAL

WEAR
PATTERN
Observe mast operation in free and main lift Shimming is
with no load. adequate
• When stopping a lift or lower, there should

be a slight bounce
• If the bounce dampens out quickly, the
mast may be shimmed too tight
Side of rail bearing rides on
Observe mast operation at full elevated height,

just short of hitting hard stops, with no load.
• The telescopic should all act as one.
EXCESSIVE
• The interface between the telescopics
WEAR
should be snug with no excessive relative PATTERN
motion between the telescopics when the Shimming is
truck is moved back and forth slightly. If too tight
motion is excessive, the mast may be
shimmed too loose.
• If a 0.010 in. feeler gauge can be inserted Example of good wear
between the roller and beam web at the Wear pattern greater than pattern on mast with
tightest spot, they are shimmed too loose. 1 in. (25.4 mm) wide several hundred hours
Some telescopics can be narrower at the
top or bottom, therefore shimming
clearance should be measured at the
tightest location.

Mast Shimming Mast, Chain, Hose, Cable
Shimming Procedure prevent the bearing from walking on the

stud shaft.
1. Elevate the mast to gain access to the
bearings. Figure 7-137. Inner Race
2. Place a block between the outer telescopic
crosstie and the main frame.
NOTE: When removing the upper bearings, use
caution not to let the bearing fall down
into the mast assembly. If the bearings
are worn or damaged, replace them.
5. Remove the bolt and roller stud sleeve
securing the roller bearing to the
respective mast or telescopic.
6. Remove the bearing.
14. Install the bearing assembly into its
NOTE: It may be necessary to drive a wedge respective mast or telescopic. Make sure
between the respective telescopics to that the flat spot of the bearing stud aligns
provide clearance for removal and with the welded stop on the mast or
installation. telescopic.
7. Remove the socket head cap screw and 15. Install the roller stud sleeve.
washer retaining the bearing on the stud. 16. Apply thread-locking compound
NOTE: Shim the main frame top bearing and (P/N 1013829) to the threads of the
the outer telescopic lower bearing set to mounting bolt and torque to 260 ft. lb.
a 0.000 ±0.010 in. overall interference. (352.5 Nm).
8. Shim the outer telescopic upper bearing 17. Reconnect the battery connector and turn
set to 0.000 ±0.010 in. overall the key switch ON.
interference with the inner telescopic after 18. Remove the block from between the outer
the top main frame bearings have been telescopic and the main frame.
correctly shimmed. 19. Test the operation of the elevating
9. Shim the inner telescopic lower bearing set assembly.
to 0.000 ±0.010 in. overall interference
with the outer telescopic after the outer
telescopic lower bearings have been set.
10. Install or remove the required amount of
shims.
11. Install the bearing on the shaft.
(P/N 990-536) to the socket head cap
screw and fasten the screw and washer in
place.
protrude past the end of the bearing stud
when the bearing is fully seated, bend the
flat washer to contact the bearing to

Mast, Chain, Hose, Cable Bow Pad Inspection
Bow Pad Inspection

R35TT Masts
1. Elevate the mast to expose the bow pads
mounted on the outside of the inner
telescopic and the outside of the outer
telescopic. Pads are on both leading and
trailing edges of the rail. See Figure 7-138.
Figure 7-138. Bow Pad Location - R35TT Mast
2 Bow Pads on each leading and trailing edge

of inner and outer telescopic - 16 pads total
2. Examine each bow pad and measure its

thickness. If the thickness is <0.187 in.
(4.75 mm), replace the pad.

Bow Pad Inspection Mast, Chain, Hose, Cable
3. Lower the mast. Check the clearance gap

of the bow pads between the inner
telescopic and the outer telescopic as
shown in Figure 7-139. Add or remove
shims to obtain the correct gap.
Figure 7-139. Inner Telescopic Bow Pad Gaps
4. Elevate the mast so that the pads are at

the top of the main frame. Measure the
gaps between the outer telescopic and
main frame. Shim as required to obtain a
gap of 0.03 to 0.09 in. (0.8 to 2.3 mm).

Mast, Chain, Hose, Cable Bow Pad Inspection
R45TT and DR32TT Masts 2. Examine each bow pad and measure its
thickness. If the thickness is <0.187 in.
1. Elevate the mast to expose the bow pads (4.75 mm), replace the pad.
mounted on the outside of the inner
3. Lower the mast. Check the clearance gap
telescopic. Pads are on the leading (forks
of the bow pads between the inner
side) edge of the rail. See Figure 7-140.
telescopic and the outer telescopic. See
Figure 7-140. Bow Pad Location - R45TT/DR32TT Mast Figure 7-141.
Figure 7-141. Measuring Inner Telescopic Bow Pad Gap
4. Shim as required to obtain a gap of 0.03 to

0.09 in. (0.8 to 2.3 mm).
3 Bow Pads on each

leading edge of
inner telescopic
- 6 pads total

Carriage Mast, Chain, Hose, Cable
Carriage NOTE: Twist the left side free lift pulley to allow
the carriage stop mounting block to
clear.
The carriage is removed through the top of the
mast.
Installation
1. Lower the carriage assembly into
telescopic.
A standard carriage without forks 2. Continue lowering carriage to an
weighs approx. 880 lb. (363 kg). A appropriate height and reconnect free lift
Deep-Reach ® carriage without forks chains to the anchors.
weighs approx. 1100 lb. (500 kg).
3. Connect the OTM hoses to the auxiliary
manifold.
Removal 4. Remove the lifting device.
1. Remove mast guard and top cover. 5. Connect the cable to TS2 at carriage and
2. Remove forks. TS3 in tractor.
3. Remove the mounting bolts from the 6. Attach the manifold cover to the carriage.
hose/cable guide and retainer at the back Apply thread-locking compound
of the carriage. (P/N 1013829) to the mounting bolts and
torque to 30 ft. lb. (42 Nm).
4. Retract scissor assembly.
7. Mount the auxiliary manifold to the
5. Disconnect the Over-The-Mast (OTM)
carriage. Apply thread-locking compound
cable at TS3 in the tractor.
(P/N 1013829) to the mounting bolts and
6. Remove the auxiliary manifold cover and torque to 21 ft. lb. (29 Nm).
disconnect the OTM cable at TS2. Remove
8. Extend the reach. Block the carriage at an
the auxiliary manifold mounting screws.
appropriate height to relieve the tension
7. Elevate the carriage to gain access from on the OTM hoses and cable to install the
the operator’s compartment to the carriage hose/cable guide retainer at the back of
stops and the OTM hose fittings at the the carriage.
auxiliary manifold.
8. Turn the key switch OFF and disconnect (P/N 1013829) to the mounting bolts and
the battery. install the hose/cable guide retainer at the
9. Remove the OTM hoses from the carriage back of the carriage.
manifold. Cap hoses and plug the fittings. 10. Install the carriage stops. Refer to
10. Remove the carriage stops. “Component Specific Service/Torque
carriage assembly to relieve the tension 11. Install the forks.
from the free lift chains. 12. Check the tension of the hoses, cable, and
12. Remove the master link from the free lift free lift chains and adjust as required.
chains at the free lift cylinder anchor 13. Bleed the hydraulic system. See
bolts. Twist the right side pulley to allow “Hydraulic System Bleeding” on page 7-86.
the removal of the chain.
14. Check for leaks and test the truck for
13. Drape the chains over the carriage correct operation.
assembly.
15. Install the top cover and mast guard.
14. Carefully lift the carriage assembly out of
the mast assembly.

Mast, Chain, Hose, Cable Chain Anchors
Chain Anchors Upper Chain Anchor Removal

1. Remove the chain anchor bolt and the
anchor pin retainer. See Figure 7-143.
Main Lift Chain Anchors
Figure 7-143. Upper Main Lift Chain Anchor Removal
Preparation for Removal
1. Place a block between the outer telescopic
crosstie and the main frame crosstie and a
slightly longer block between the inner
telescopic crosstie and the outer telescopic
crosstie. This provides the required slack
in the chains. See Figure 7-142.
Figure 7-142. Blocking Telescopics
2. Grasp the chain and remove the anchor

pin.
NOTE: You can remove the pin by using a slide
hammer or by using a large socket
(1 1/16 in.), an M8 x 50 mm bolt, and
Blocking washers to act as a pulling device. See
Figure 7-144.
2. Lower the carriage and block at a height
that allows access to the lower chain Figure 7-144. Anchor Pin Removal
anchors at the bottom of the inner
telescopic. If only the upper anchors are
being removed, fully lower the carriage.
3. To hold the chain in position, attach a pair

of locking pliers to the chain nearest the
chain sheave.
4. Remove the chain anchor from the lift
chain.

Chain Anchors Mast, Chain, Hose, Cable
Upper Chain Anchor Installation Figure 7-145. Lower Main Lift Chain Anchor, Model 7500
1. Install the mast stop to the chain anchor.

2. Attach the chain anchor to the lift chain,
making sure that the two holes in the
Master Link
anchor are facing towards the outside.
3. Remove the locking pliers, position the Cotter
chain anchor and install the anchor pin. Pin
You can install the chain anchor bolt Chain
Anchor
temporarily to assist in the installation of
the pin.
4. Install the chain anchor pin retainer. Chain Anchor
Apply thread-locking compound Block
anchor bolt and torque to 130 ft. lb. Adjusting
(174 Nm). Nut
Cotter Pin
the key switch ON.
6. Remove the blocks from between the
telescopic crossties.
7. Adjust the lift chains until there is a Lower Chain Anchor Installation
0.25 in. (6.4 mm) gap at the narrowest
point between the inner and outer 1. Reinstall the master link to the lift chain
telescopics when the carriage is fully and chain anchor.
lowered. Make sure there is equal tension 2. Install the chain anchor into the chain
on the lift chains after the adjustment. anchor block and thread the adjusting nut
on to the distance recorded earlier. Install
8. Test the truck for correct operation.
the cotter pin at the end of the chain
anchor.
Lower Chain Anchor Removal
1. Disconnect the lift chain master link from the key switch ON.
the chain anchor at the bottom of the 4. Remove the blocks from between the
inner telescopic. telescopic crossties.
2. Note the distance of the adjusting nut. 5. Adjust the lift chains until there is a
This distance is used as a preliminary 0.25 in. (6.4 mm) gap at the narrowest
adjustment when re-installing. point between the inner and outer
3. Remove the cotter pin and chain anchor telescopics when the carriage is fully
adjusting nut. lowered. Make sure there is equal tension
4. Remove the chain anchor from the on the lift chains after the adjustment.
telescopic. 6. Test the truck for correct operation.
Free Lift Chain Anchors

Upper Chain Anchor Removal
1. Elevate and block the carriage at a
convenient working height.

Mast, Chain, Hose, Cable Chain Anchors
2. Lower the carriage to relieve tension on the 7. Remove blocking from carriage.
chains. 8. Test the truck for correct operation.
the battery connector. Lower Chain Anchor Removal
NOTE: Right side lower free lift chain anchors
5. Left side only: Remove the hose/cable are welded to the carriage. Use the
retaining block. following procedure to remove the left
6. Disconnect the lift chain master link from side chain anchor.
the chain anchor.
1. Elevate and block the carriage at a
7. Note the distance of the adjusting nut. convenient working height.
This distance is used as a preliminary
2. Lower the carriage to relieve tension on the
adjustment when re-installing.
chains.
8. Remove the nut from the chain anchor
bolt. Remove anchor from anchor block.
Figure 7-146. Upper Free Lift Chain Anchor, Model 7500 4. Remove the mast guard.
5. Disconnect the lift chain master link from
the chain anchor.
6. Unscrew the anchor from the anchor
block.
Figure 7-147. Lower Free Lift Chain Anchor
Master Link
Master Link
Chain Anchor
Chain Anchor Chain Anchor

Block
Chain Anchor
Adjusting Nut Block
Upper Chain Anchor Installation

1. Insert the chain anchor in the chain
anchor block. Lower Chain Anchor Installation
2. Install a new master link to the lift chain 1. Screw the chain anchor into the chain
anchor and secure with a new cotter pin. anchor block.
3. Thread the adjusting nut on the chain 2. Attach a new master link to the chain
anchor bolt to the distance recorded anchor and secure with a new cotter pin.
earlier. 3. Reinstall the mast guard.
4. Left side only: Reattach the hose/cable 4. Reconnect the battery connector and turn
retaining block. the key switch ON.
5. Reinstall the mast guard. 5. Remove blocking from carriage.
6. Reconnect the battery connector and turn 6. Test truck for correct operation.
the key switch ON.

Lift Chains Mast, Chain, Hose, Cable
Lift Chains chain anchor bolt temporarily to assist in

the installation of the pin.
4. Install the anchor pin retainer. Apply
Chains, Main Lift thread-locking compound (P/N 1013829)
to the threads of the anchor bolt and
Removal torque to 130 ft. lb. (174 Nm).
5. Attach the chain and the lower chain
1. Place a block between the outer telescopic anchor, using a new master link and cotter
crosstie and the main frame crosstie and a pin.
slightly longer block between the inner
telescopic crosstie and the outer telescopic 6. Remove the blocks between the telescopics
crosstie. This provides the required slack and the main frame and fully lower the
in the chains for their removal. See forks to the floor.
Figure 7-142 on page 7-137. 7. Measure the gap at the narrowest point
2. Lower the carriage and block at a height between the top crossties of the inner and
that allows access to the chain anchor at outer telescopics when the carriage is in
the bottom of the inner telescopic. free lift. Adjust the lift chains until the gap
is 0.38 in. (9.7 mm) on a Model 7500 or
0.62 in. (15.7 mm) on a Model 7520. Make
sure there is equal tension on the lift
4. Disconnect the lift chain master link from chains after the adjustment.
the lower chain anchor at bottom of inner
NOTE: The gap adjustment should be done with
telescopic.
no load on the chains.
5. Remove the chain anchor bolt and the
anchor pin retainer. See Figure 7-144 on 8. Lubricate the chains and test the truck
page 7-137. operation.
6. Grasp the chain and remove the anchor
pin. Chains, Free Lift
NOTE: You can remove the pin by using a slide
hammer or by using a large socket Removal
(1 1/16 in.), an M8 x 50 mm bolt and 1. For easy access to the lift chain master
washers to act as a pulling device. links at the carriage anchor blocks, elevate
7. Remove the chain anchor and chain from the carriage to a convenient working
the telescopic. height. Using a suitable hoist or stand,
secure the carriage at this height.
8. Remove the master link between chain
and chain anchor. Figure 7-148. Carriage Chain Anchor
Installation
NOTE: Replace both chains when either is bad.
1. Attach the upper chain anchor to the new
chain using a new master link and cotter
pin.
2. Make sure the two holes in the upper
chain anchor are facing towards the
outside. Feed the chain from the outside to
the inside over the chain sheave.
3. Position the upper chain anchor and
install the anchor pin. You can install the

Mast, Chain, Hose, Cable Lift Chains
2. Activate “lower” to relieve the tension on 6. Slowly raise the carriage, using the lift
the free lift chains. button to place the weight of the carriage
3. Turn the key switch OFF and disconnect on the free lift chains.
the battery connector. 7. Remove the hoist.
4. Remove the mast guard. 8. Fully lower the carriage.
5. Remove the master links at the adjustable 9. With the reach mechanism retracted, forks
chain anchors. level with the floor, and the key switch
6. Remove the master links at the carriage OFF, adjust the anchor nuts equally until
chain anchors. The right side requires the the forks are approx. 3 in. (76 mm) off the
removal of a retainer tab and pin rather floor (or just touching the floor with the
than a cotter pin. floor lower height option). Make sure there
is equal pressure on the chains when the
Figure 7-149. Retainer Tab (right side) carriage is fully lowered.
7. Remove the chains.
Installation
1. Position the chain over the pulley and
fasten the chain to the carriage anchor
with a new master link.
2. Secure the left side with a cotter pin and
the right side with the pin and retainer
tab, applying thread-locking compound
retainer screw.
3. Fasten the chain to the adjustable chain
anchor with a new master link and secure
with a new cotter pin.
NOTE: Bend the ends of the cotter pins over 90°
after installation.
4. Reinstall the mast guard.
the key switch ON.

Height Encoder Belt Mast, Chain, Hose, Cable
Height Encoder Belt 6. With the belt snug around the hook eye,
trim the belt 1 in. (25.4 mm) longer. Attach
two cable ties loosely to form a loop of belt
Model 7500 around the hook eye. With the belt snug,
pull the belt approximately 0.5 in.
(0.12 mm) tighter to apply tension to the
Removal spring and tighten the cable ties.
1. Elevate the mast to access the belt end at 7. Trim any excess belt at the loop.
the lower outer telescopic crosstie. 8. Reconnect the battery connector and turn
2. Remove the belt and the tension spring. the key switch ON.
3. Completely lower the mast. 9. Check the operation of the encoder.
the battery connector. Model 7520
5. Note the routing and orientation of the belt
and remove the shoulder bolt at the upper Removal
belt attachment point.
1. Lift and block the mast high enough to
access the belt and its mounting eye.
Installation
NOTE: The tensioning spring is at the bottom of
1. Install the shoulder bolt into the outer the belt, hooked to a bracket.
telescopic upper crosstie.
2. Loop the new belt tightly around the
shoulder bolt and secure with cable ties.
3. Access the height encoder assembly.
NOTE: Trim any excess at the belt loop to make
sure that the doubled section does not a. If there is an access plate secured by
interfere with the encoder gears. diagonally opposed screws, remove
them. Do not remove the bottom
3. Route the belt through the encoder. See button-head screws. See Figure 7-151.
Figure 7-150.
Figure 7-151. Height Encoder with Access Plate
Figure 7-150. Height Encoder Belt Routing
Remove these screws
Belt
Access
Plate
Idler
Do Not remove these screws
b. If there is no access plate, remove the

bottom two button-head screws. Do not
Toothed Gear
remove the diagonally opposed screws,
as they hold the encoder assembly
4. Carefully elevate the mast to access the together. See Figure 7-152.
lower belt attachment point.
5. Attach the tension spring to the bracket.

Mast, Chain, Hose, Cable Height Encoder Belt

Figure 7-152. Height Encoder without Access Plate around the toothed gear and idler. See
Do Not remove these screws Figure 7-154.
Figure 7-154. Height Encoder Belt Routing
Belt
Idler
Remove these screws
4. Remove the old belt. Make sure you

retrieve the tension spring through the
access hole at the bottom of the outer
telescopic.
Toothed Gear
Installation
Encoder Assembly
1. Using cable ties, make a 1 in. (25 mm) loop Mounting Screws
in the bottom of the new encoder belt and
attach it to the tension spring.
5. Attach the top end of the belt to a stiff wire
2. Attach a small weight on the tension and feed the belt up through the encoder
spring. Drop the weighted spring down the assembly hole.
mast channel. Clamp the belt at the top so
it does not fall completely down into the 6. Loop the belt around the eye at the top of
channel. the mast and clamp it temporarily in
place.
3. Access the spring through the hole at the
bottom of the mast channel. Attach the 7. Secure the height encoder assembly.
spring to the bracket. See Figure 7-153. a. If there is an access plate, install the
access plate with the nylon locking
Figure 7-153. Height Encoder Belt Tension Spring nuts. See Figure 7-151.
b. If there is no access plate, fit the
encoder assembly back into the mast
channel. Keep slight tension on the belt
and make sure the belt wraps correctly
around the gear and idler. Secure the
encoder assembly with mounting
screws. See Figure 7-152.
8. Make sure the belt feeds past the mast
bearing without becoming entangled in the
bearing. See Figure 7-155.
4. Thread the belt through the encoder

assembly. Make sure it is routed correctly

Height Encoder Belt Mast, Chain, Hose, Cable

Figure 7-155. Height Encoder Belt and Mast Bearing
Belt
Mast Bearing
9. With the belt snug around the hook eye,

trim the belt 1 in. (25 mm) longer. Attach
two cable ties loosely to form a loop of the
belt around the hook eye. With the belt
snug, pull the belt approx. 0.5 in. (12 mm)
tighter to apply tension to the spring, and
tighten the cable ties. Trim any excess belt
at the loop. See Figure 7-156.
Figure 7-156. Height Encoder Belt, Top
Hook Eye
Add Cable
Ties Here
Belt

the key switch ON.
11. Elevate the mast, remove the blocking. Lift
and lower the carriage to test correct
operation.

Mast, Chain, Hose, Cable Hose and Cable, Over-the-Mast
Hose and Cable, Figure 7-158. Over-the-Mast Hose/Cable - Right Side

(Model 7500 shown)
Over-the-Mast
Figure 7-157. Over-the-Mast Hose/Cable - Left Side (Model
7500 shown)
Main Lift
Cylinder Upper Free Lift
Hose/Cable Cylinder
Retainer Hose/Cable
Retainer
Carriage
Hose/Cable
Retainer
Lower Free Lift

Cylinder NOTE: For replacement of the OTM electrical
Hose/Cable cable only, see “Cable, Over-the-Mast”
Retainer on page 7-151.

Hose and Cable, Over-the-Mast Mast, Chain, Hose, Cable
Removal 7. Disconnect and plug/cap the OTM hoses

and fittings at the auxiliary manifold.
1. Remove top cover, left front cover, and
mast guard.
the key switch ON.
2. Lower carriage to floor and block scissor
9. Elevate and block carriage at an
assembly. See Figure 7-159.
appropriate height to access the
Figure 7-159. Blocking Scissor Assembly hose/cable retainer and guide at the back
of the carriage from the tractor side.
11. Remove hose/cable retaining block from
back of carriage. See Figure 7-161.
Figure 7-161. Hose/Cable Retainer on Carriage

4. Disconnect the OTM cable at connector
TS3 in tractor.
5. Remove auxiliary manifold cover from
carriage. Disconnect the OTM cable at
terminal strip TS2. See Figure 7-160.
12. Feed hoses and cable through guide at
Figure 7-160. Auxiliary Manifold Access back of carriage.
13. Feed hoses and cable through pulley
bracket at top of free lift cylinder.
14. Remove upper hose/cable retainer from
free lift cylinder. See Figure 7-158 on
page 7-145.
the key switch ON.
16. Carefully elevate the telescopics high
enough to access the lower retainer on free
lift cylinder and the retainer on the
telescopic from the tractor side. Place a
hardwood block of sufficient length
between the outer and inner telescopics.
6. Remove auxiliary manifold mounting This removes tension from the OTM hoses
screws to permit access to the OTM hose and the lift hose and makes the removal
fittings at the manifold. and installation of the retainers easier.
NOTE: There may be shims between the Carefully lower the mast until you have
manifold and carriage. the desired tension. See Figure 7-162.


Figure 7-162. Blocking Telescopics Figure 7-163. Positioning Hose Retainer
17. Turn the key switch OFF and disconnect NOTE: OTM hose lengths on Model 7500 lift
the battery connector. trucks are equal. Reference
18. Remove the lower free lift cylinder Figure 7-186 on page 7-162 for correct
hose/cable retainer and the hose/cable hose/cable routing.
retainer from the bottom of the inner 1. While observing correct routing, connect
telescopic. hoses to auxiliary manifold at carriage and
19. Feed hoses and cable through pulley at the cable to terminal strip TS2.
top of inner telescopic. 2. Mount auxiliary manifold to carriage.
20. Remove hose/cable retainer at left main Apply thread-locking compound
lift cylinder. (P/N 1013829) to mounting bolt threads
21. Reconnect the battery connector and turn and torque to 21 ft. lb. (29 Nm).
the key switch ON. 3. Reconnect the battery connector and turn
22. Carefully elevate telescopics and remove the key switch ON.
blocking. 4. Carefully elevate and block carriage high
23. Fully lower mast and carriage. enough to access the hose/cable retainer
and guide at the back of the carriage.
the battery connector. 5. Turn the key switch OFF and disconnect
25. Disconnect and plug/cap hoses and
fittings at A1 and A2 on the main 6. Feed hoses and cable through guide and
manifold. retainer.
26. Feed hoses and cable through opening in 7. Remove slack from hoses and cable
tractor bulkhead. between retainer and manifold. Adjust and
tension the cable to allow the cable to loop
away at the bottom edge of the hose/cable
Installation bracket on the carriage. This loop should
be 0.75 in. ±0.25 in. below the bracket.
NOTE: To help install the retainers, use two
Make sure the cable is long enough to
modified (M6-1 x 70) bolts to locate and
remove the auxiliary manifold cover and
support the retainer during assembly.
access TS2. Tighten the retainer. See
See Figure 7-163.
Figure 7-164.


Figure 7-164. Carriage Hose/Cable Retainer Figure 7-165. Free Lift Pulley Routing of Hoses and Cable
Aux Hose A2
Aux Hose A1
Electrical
Cable
Electrical Cable
Aux Hose A1
Aux Hose A2
13. Install hoses, cable, and retainer at top of

free lift cylinder. See Figure 7-166.
8. Attach manifold cover to carriage. Apply Figure 7-166. Upper Hose/Cable Retainer, Main Lift and
thread-locking compound (P/N 990-536) Free Lift Cylinders
to the mounting bolt threads and torque to
30 ft. lb. (42 Nm). Main Lift
9. Reconnect the battery connector and turn Retainer
the key switch ON.
10. Fully lower carriage to the floor.
12. Feed hoses and cable through free lift
pulley, from fork side to tractor side. Make
sure hoses and cable do not cross each
other. The electrical cable is in the
left-hand position.
Free Lift
Retainer
14. Remove slack from hoses and cable

between upper free lift cylinder and
carriage retainers. Temporarily tighten
retainer.
15. Find the correct L3 value from Table 7-11
or Table 7-12 on page 7-150. Measure and
mark hoses above the upper free lift
cylinder retainer, using the L3 value. L3
equals the length the hoses are to be
stretched over the free lift cylinder. See
Figure 7-167.


Figure 7-167. Marking L3 Dimension side. Make sure hoses and cable do not
cross each other.
stretch
24. Install OTM hoses, lift hose, and cable in
retainer at left main lift cylinder.
25. Remove slack from hoses and cable.
Adjust cable grip and spring so that spring
L3 dimension
is stretched to an overall length of
1.75 ±0.12 in. (44.5 ±3 mm) across the
coils. Leave sufficient bend of slack hose
so that an additional 0.5 in. (13 mm) of
cable length can be taken up if required.
Temporarily tighten retainer.
26. Measure and mark the lift hose above the
retainer with the appropriate L2 value
16. Reconnect the battery connector and turn from Table 7-11 or Table 7-12 on
the key switch ON. page 7-150. Measure and mark the OTM
17. Place block under carriage and lower hoses above the retainer with the
carriage to relieve tension on hoses. appropriate L1 value from Table 7-11 or
Table 7-12 on page 7-150.
18. Pull down on the hoses until marks are
flush with top of retainers. Tighten the 27. Repeat step 17 of the installation
four retainer bolts. Do not tighten the procedure.
lower clamp bolts on the retainer assembly 28. Pull down on the hoses until marks are
yet. flush with the top of the retainers. Tighten
19. Install hoses, cable, retainer, and clamp at retainers.
bottom of free lift cylinder and inner 29. Reconnect the battery connector and turn
telescopic. Carefully elevate the telescopics the key switch ON. Remove blocking from
high enough to access the lower retainer telescopics. Turn the key switch OFF and
on free lift cylinder and the retainer on the disconnect the battery connector.
telescopic from the tractor side. Place a
30. Tighten two lower clamp bolts on upper
hardwood block of sufficient length
free lift cylinder hose/cable retainer.
between the outer and inner telescopics.
Carefully lower the mast until you have 31. Secure hoses and cable to the free lift
the desired tension. Observe correct cylinder with cable ties every 16 to 24 in.
routing to make sure hoses and cable have (40 to 60 cm).
sufficient clearance. See Figure 7-162 on 32. Route hoses and cable through the tractor
page 7-147. opening, along the tractor bulkhead, and
20. Turn the key switch OFF and disconnect attach with the hose/cable clamps. See
the battery connector. Figure 7-168.
21. Remove slack from hoses and cable
between inner telescopic retainer and
upper retainer on free lift cylinder.
Temporarily tighten retainer and clamp.
the key switch ON. Remove blocking from
telescopics. Turn the key switch OFF and
23. Feed hoses and cable through pulleys at
top of telescopic, from fork side to tractor


Figure 7-168. Hose/Cable Retainer Clamps on Tractor Table 7-11. Model 7500 OTM Hose Stretch Values
Stretch Value Stretch Value
L1 L2 L3
(1/4 in. (1/2 in. (hoses/
OACH hose hose OACH cable over
Range over tele) over tele) Range free lift cyl)
(in.) in. (mm) in. (mm) (in.) in. (mm)
87-93 1.50 (38) 1.50 (38)
94-107 1.75 (45) 1.75 (45) 87-116 1.00 (25)
108-117 2.25 (57) 2.25 (57)
118-130 2.50 (64) 2.50 (64)
131-140 2.75 (70) 3.00 (76) 117-146 1.25 (32)
141-146 3.00 (76) 3.25 (83)
147-155 3.25 (83) 3.50 (89)
147-161 1.38 (35)
156-161 3.50 (89) 3.75 (95)
Table 7-12. Model 7520 OTM Hose Stretch Values

Stretch Value Stretch Value
L1 & L2 L3
OACH (hoses over OACH (hoses/cable over
Range tele) Range free lift cyl)
(in.) in. (mm) (in.) in. (mm)
33. Observing correct routing, connect OTM 142-146 2.75 (70)
142-156 1.50 (38)
hoses to A1 and A2 at the main manifold. 147-154 3.00 (76)
Connect the OTM cable to connector JPS3. 155-163 3.25 (83)
157-170 1.63 (42)
34. Reconnect the battery connector and turn 164-170 3.50 (89)
the key switch ON. Test the lift truck for
171-178 3.75 (95)
correct operation and check for leaks. 171-184 1.75 (45)
179-184 4.00 (102)
35. Cycle all auxiliary functions several times
185-190 4.25 (108) 185-190 1.88 (48)
to purge air from the hydraulic system.
36. Check hydraulic fluid level and add fluid
as required.
37. Install mast guard and covers.

Mast, Chain, Hose, Cable Cable, Over-the-Mast
Cable, Over-the-Mast 9. Remove the cable from the retainer/guide

at the back of the carriage and the free lift
cylinder pulley. See Figure 7-158 on
Over-the-Mast Cable page 7-145.
Replacement 10. Position the cable grip onto the
replacement cable so that the spring
This procedure describes the installation of the anchor end of the cable grip is oriented
new cable as the old one is being removed. towards the TS2 end of the cable and the
loop is approx. 20 in. (51 cm) from the end
1. Mark the OTM hoses at all the hose/cable
of the cable. See Figure 7-170.
retainers to make sure of the correct
stretch when reassembled. (If required, Figure 7-170. Cable Grip on TS2 end of OTM cable
use Table 7-11, “Model 7500 OTM Hose
Stretch Values,” on page 7-150.)
2. Remove the top cover, left front cover, and
mast guard.
11. If installing bulk cable, strip 3 in. (76 mm)
of insulation from cable, strip wires, and
4. Disconnect the OTM cable at TS3 on the attach spade lugs.
tractor.
12. Attach a cable tie around the braided end
5. Remove the auxiliary manifold cover from of the cable grip to prevent the grip from
the carriage and disconnect the OTM cable slipping. Do not tighten at this time.
at TS2.
13. Install the new cable in the carriage
6. Reconnect the battery connector and turn retainer/guide and route to TS2.
the key switch ON.
NOTE: Position the hoses using the marks
7. Elevate and block the carriage at an made in step 1 and make sure that there
appropriate height to access the is enough slack in the cable for the
hose/retainer and guide at the back of the installation and removal of the auxiliary
carriage from the operator compartment. manifold cover.
This also relieves tension on the hoses for
easier assembly. See Figure 7-169. 14. Reconnect the battery connector and turn
the key switch ON. Remove blocking and
Figure 7-169. Blocking the Carriage lower the carriage. Turn the key switch
OFF and disconnect the battery connector.
15. Connect cable spade lugs to TS2.
16. Attach aux manifold cover to carriage.
the key switch ON. Elevate and block
carriage as in step 7.
18. Tighten the carriage hose and cable
retainer.
the key switch ON. Remove blocking and
lower the carriage. Turn the key switch
8. Turn the key switch OFF and disconnect 20. Feed the cable through the free lift pulley
the battery connector. and position it in the upper free lift

Cable, Over-the-Mast Mast, Chain, Hose, Cable
cylinder retainer. Do not tighten at this loop of the cable grip and the latch of
time. the cable tie it does not interfere with
the free lift cylinder mounting pin.
NOTE: Remove all twist from the cable when
installing. 25. Reconnect the battery connector and turn
the key switch ON. Carefully elevate the
telescopics high enough to access the
the key switch ON. Elevate and block
lower retainer on the free lift cylinder and
carriage. Turn the key switch OFF and
the retainer on the telescopic from the
operator’s compartment.
22. Adjust and tension the cable to allow the
26. Place a hardwood block of sufficient length
cable to loop away at the bottom edge of
(approx. 30 in.) between the outer and
the hose/cable bracket on the carriage.
inner telescopics. This removes the
This loop should be 0.75 in. ±0.25 in.
tension from the OTM hoses and the lift
below the bracket. See Figure 7-171.
hose to make the removal and installation
Figure 7-171. Service Loop (Standard Carriage shown) of the retainers easier. Carefully lower the
mast until you have the desired tension.
See Figure 7-172.
Figure 7-172. Blocking Telescopics
Carriage Hose/
Cable Guide
Service Loop 27. Turn the key switch OFF and disconnect
28. Remove and install the cable at the lower
Tension Spring free lift cylinder and bottom inner
telescopic hose/cable retainers. Observe
correct routing to make sure hoses and
23. Position the hoses and cable using the cable have sufficient clearance. Tighten
marks made in step 1 and tighten the the retainers.
upper 4 bolts, but not the bottom 2 bolts 29. Remove and feed the cable through the
of the upper free lift cylinder retainer. pulley at the top of the inner telescopic.
24. Set the tension on the spring at the Observe correct routing and make sure the
carriage by sliding the cable grip to cable is not twisted.
produce a length of 1.75 ±0.12 in. 30. Remove the old cable and insert the new
(44.5 ±3.0 mm) across the coils. Do not cable through the passage hole.
over tension. Tighten the cable tie on the
cable grip. See Figure 7-171. 31. Reassemble the retainer, aligning witness
marks on the hoses, and tighten the bolts.
NOTE: Orient the loop of the cable grip fore-aft
so that as the cable passes through the

Mast, Chain, Hose, Cable Cable, Over-the-Mast
Insert the new cable through the passage NOTE: Colors will not match at TS2.
hole.
41. Attach cable to frame with a cable tie and
32. If installing bulk cable, install cable grip self-adhesive cable tie anchor. See
with the loop pointing down towards the Figure 7-174.
tractor.
33. Reconnect the battery connector and turn Figure 7-174. Cabling at Terminal Strip
the key switch ON. Remove the blocking
between the inner and outer telescopic.
34. Tighten the bottom two bolts of the free lift
cylinder hose/cable retainer.
35. Secure hoses and cable to the free lift
cylinder with cable ties every 16 to 24 in.
(40.6 to 60.9 cm) as you lower the carriage
all the way. Turn the key switch OFF and
36. If installing exact replacement cable, pull
the cable through the main lift cylinder
retainer until all slack is removed. Mark
the cable at the top of the retainer. Tighten
42. Install the mast guard and covers.
the retainer bolts.
37. Set the tension on the spring at the
the key switch ON. Elevate the carriage
carriage by sliding the cable grip to
and place a hardwood block between the
produce a length of 1.75 ±0.12 in.
inner and outer telescopic. Carefully lower
(44.5 ±3.0 mm) across the coils. Do not
the carriage to relieve the hose and cable
over tension. Tighten the cable tie on the
tension. Turn the key switch OFF and
cable grip.
Figure 7-173. Main Lift Cylinder Retainer Cable Spring 44. Position the cable so that the mark on the
Tension cable is 0.5 in. (13 mm) above the retainer.
45. Position the OTM hoses and the lift hose
as marked in step 1 of the Over-the-Mast
Cable Replacement procedure. Tighten the
retainer.
the key switch ON. Remove the block
between the inner and outer telescopic.
47. Lower the carriage. Turn the key switch
48. Remove and route the cable along the
tractor bulkhead and attach with the
hose/cable clamps.
38. Cut the OTM cable 20 in. (508 mm) past
the bottom of the main lift cylinder
retainer.
39. Strip 3 in. (76 mm) of insulation from the
cable, strip the wires, and attach spade
lugs.
40. Connect the wires at TS3.

Hose/Tubing, Free Lift Feed Mast, Chain, Hose, Cable
Hose/Tubing, Free Lift Figure 7-175. Free Lift Feed Hose/Tube (Model 7500
shown)
Feed
Removal
2. Raise the telescopics until the bottom of
the free lift feed tubing is accessible from
the operator’s compartment.
3. Place a block of sufficient length between
the outer telescopic crosstie and the main
frame to hold the position in step 2.
5. Extend the reach mechanism to allow
easier removal of the free lift feed tubing.
7. Place a pan below the free lift tubing.
8. Remove the necessary components. See
Figure 7-175.
Installation
1. Replace the necessary components. Make
sure the assembly is tight and correctly
positioned on the crosstie.
the key switch ON.
3. Remove the block between the outer
telescopic crosstie and the main frame.
operation.

Mast, Chain, Hose, Cable Mast, Model 7500 (Complete Disassembly)
Mast, Model 7500 12. Disconnect the main lift hose fitting at the
left side of the tractor.
(Complete Disassembly)
Separation of Tractor and Mast Make sure the weight of the mast is fully
supported by the hoist and the tractor is
blocked where it meets the mast before
loosening the mast mounting bolts.
• Do this procedure with a minimum 13. Place blocks snugly under the tractor near
of two technicians in a shop the mast.
equipped with a suitable hoist. 14. Attach a lifting strap around the top
• Do not permit observers to stand crossties of all three mast sections. Draw
nearby. tight with hoist. Make sure the weight of
• Wear gloves, safety glasses, the mast is supported by the hoist.
steel-toed safety boots, and a safety 15. Use an impact wrench to remove the mast
helmet (hard hat). mounting bolts inside the battery
1. Lower and retract the fork carriage compartment, four on the top, eight on the
completely. bottom.
2. Turn the key switch OFF and disconnect 16. Using a lift truck, carefully separate the
the battery connector. Remove battery tractor about 6 in. (15 cm).
gates. Using a suitable battery removal 17. Remove the hose/cable retaining bracket
device, remove the battery. on the front of the tractor bulkhead.
3. Remove the top cover and the left and right 18. Remove the hose/cable retainer on the
front covers. main lift cylinder.
4. Remove the mast guard. 19. Reinstall mast mounting bolts and
5. Secure a hoist strap around the overhead washers and tighten lightly (to prevent
guard. Take the weight off the guard. misplacing them).
Remove mounting bolts. Remove the
overhead guard. Hose/Cable, Free Lift Cylinder,
6. Disconnect and cap right side main lift and Carriage Removal
hose at the tractor bulkhead fitting.
1. Remove the auxiliary manifold cover from
7. Disconnect the ambient temperature
the carriage. See Figure 7-176 on
sensor connector JPA on the tractor deck.
page 7-156.
8. Disconnect the mast switch connector
2. Disconnect the wires of the OTM cable
JPS4 (near the lift pump). Feed harness
from TS2, labeling as needed for
through tractor opening at left side.
re-connection.
9. Disconnect OTM cable at TS3 on the
3. Remove auxiliary manifold mounting
tractor deck.
screws to permit access to the OTM hose
10. Disconnect the hose/cable retaining fittings at the manifold.
clamp from the left front corner of the
tractor near the opening in the bulkhead. NOTE: There may be shims between the
manifold and carriage.
11. Disconnect and plug hydraulic hoses A1
and A2 at the main manifold, labeling as
needed for correct reassembly. Feed hoses
through opening in tractor bulkhead.

Mast, Model 7500 (Complete Disassembly) Mast, Chain, Hose, Cable

Figure 7-176. Auxiliary Manifold Access 17. Disconnect and cap the hose to the left
main lift cylinder.
18. Rig lifting straps around the carriage.
Using a hoist, carefully lift the carriage out
of the inner telescopic and lower the
carriage to the floor.
Main Lift Chain Removal

1. Rig a lifting strap of one hoist around the
lower crosstie of the main frame (the one
where the overhead guard attaches).
2. Rig a lifting strap of another hoist around
the top crossties of both inner and outer
4. Disconnect and plug/cap the OTM hoses telescopics. Using the hoist, raise the
and fittings at the auxiliary manifold. telescopics about 10 in. (25 cm).
Label as needed for correct re-connection. 3. Remove chain anchor bolt and access
5. Remove cable ties on upper hose retaining cover from sides of main frame.
block. Loosen upper and lower hose/cable 4. Remove the chain anchor pin by using a
retaining blocks. slide hammer or by using a large socket
6. Jack carriage up about 3 in. (7.6 cm). (1 1/16 in.), an M8 x 50 mm bolt, and
Remove master links on free lift chains. washers to act as a pulling device. See
Feed free lift chains through pulleys and Figure 7-177 and Figure 7-144 on
drape over front of carriage. page 7-137.
7. Remove hose/cable retaining block on
Figure 7-177. Main Lift Chain Upper Chain Anchor
back of carriage.
Bolt
8. Remove hoses and cable from guide at
back of carriage.
Cover
9. Remove upper and lower hose/cable
retainers from free lift cylinder.
10. Feed hoses and cable through right side Pin
free lift cylinder pulley.
11. Remove tee tubing from free lift cylinders.
Chain
12. Remove set screws from bottom of right Anchor
free lift cylinders. Lift each free lift cylinder
off the mounting hook at the top and the
mounting block at the bottom. Install set
screws so they are not misplaced.
5. Pull the chain anchor/mast stop out of the
13. Remove carriage stops from back of main frame.
carriage.
6. Feed main lift chains from inside to
14. Remove the lower hose/cable pulley from outside over the chain sheave.
the top of the outer telescopic.
15. Remove the upper hose/cable pulley from
the top of the outer telescopic.
Separation of Telescopics
16. Disconnect the tee tubing to the right side 1. Using the hoists, carefully lower the mast
main lift cylinder. to a horizontal position on jack stands.

2. Loosen the L-bracket bolts holding the Figure 7-180. Outer Telescopic Lower Bearing and
main lift cylinders to the telescopic. Anti-Rattle Pads
3. Remove the top mounting bolt, washer,
and sleeve holding the main lift cylinder to
the outer telescopic. See Figure 7-178.
Figure 7-178. Main Lift Cylinder Mounting Hardware

Mounting Bolt
Washer
Shims
Sleeve
Pad
6. Remove anti-rattle pads and shims from

Outer
bottom of inner telescopic. See
Telescopic
Figure 7-181.
Figure 7-181. Inner Telescopic Lower Bearing and

Anti-Rattle Pads
4. Remove main lift chain sheaves from top of
outer telescopic. Sheaves attach with a pin
and a set screw on the inside. See Shim
Figure 7-179.
Figure 7-179. Main Lift Chain Sheave Pad
Chain
Spacer
Sheave
Spacer
Pin
Set Screw Shims
Pad
5. Remove anti-rattle pads and shims from 7. Using a suitable hoist, pull the inner
bottom of outer telescopic. See telescopic halfway out of the outer
Figure 7-180. telescopic.

8. Remove the upper roller bearings and

shims from the top of the outer telescopic.
See Figure 7-182.
Figure 7-182. Outer Telescopic Upper Bearing
Sleeve
Stud
Shims
Bearing
9. Remove the lower roller bearings and

shims from the bottom of the inner
telescopic. See Figure 7-181.
10. Using a suitable hoist, remove the inner
telescopic from the outer telescopic.
11. Using a suitable hoist, pull the outer
telescopic halfway out of the main frame.
shims from the main frame. See
Figure 7-183.
Figure 7-183. Main Frame Upper Bearing

Bolt
Stud
Shims
Bearing

shims from the outer telescopic. See
Figure 7-180.
14. Using a suitable hoist, remove the outer
telescopic from the main frame.

Mast, Chain, Hose, Cable Mast, Model 7500 (Complete Assembly)
Mast, Model 7500 Figure 7-184. Inner Race
(Complete Assembly)
Assembling and Shimming
Outer Telescopic to Main Frame
Lower Bearings of Outer Telescopic
1. Begin the assembly with the main frame
positioned horizontally on jack stands.
2. Attach the lower roller bearing to one side
of the outer telescopic. Make sure the flat
spot on the bearing outer stud is correctly
positioned against the mast. This is 9. Using the hoist, slide the outer telescopic
important because the correct bearing the entire length of the main frame,
alignment is canted with respect to the checking for binding. The tightest spots
channel. See Figure 7-180. are generally at the crossties. Add or
3. Using a suitable hoist, insert the outer remove shims as necessary to maintain a
telescopic into the main frame as far as snug but free-running fit.
the crosstie.
4. Attach the lower roller bearing to the other Upper Bearings of Main Frame
side of the outer telescopic.
1. With the outer telescopic inserted halfway
5. Using a pry bar, move the outer telescopic into the main frame, attach the upper
and bearing to one side. roller bearing to one side of the main
6. Use spare shims as a gauge to determine frame. Make sure the flat spot on the
the amount of shims required to cause the bearing outer stud is correctly positioned
roller bearing to contact the main frame. against the mast. See Figure 7-183.
7. Remove both lower bearings. Install one 2. Attach, but do not tighten, the upper roller
half of the total shim thickness required to bearing to the other side of the main
each roller bearing. Reinstall the bearings. frame.
Apply thread-locking compound 3. Use spare shims as a gauge to determine
(P/N 990-536) to the bearing mounting the amount of shims required to cause the
bolt and torque to 260 ft. lb. (352 Nm). roller bearing to contact the outer
8. If the inner race of the bearing does not telescopic.
protrude past the end of the bearing stud 4. Remove both upper bearings. Install one
when the bearing is fully seated, bend the half of the total shim thickness required to
flat washer to contact the bearing to each roller bearing. Reinstall the bearings.
prevent the bearing from walking on the Apply thread-locking compound
stud shaft. See Figure 7-184. (P/N 990-536) to the bearing mounting
bolt and torque to 260 ft. lb. (352 Nm).
prevent the bearing from walking on the
stud shaft. See Figure 7-184.

Mast, Model 7500 (Complete Assembly) Mast, Chain, Hose, Cable
6. Using the hoist, slide the outer telescopic as necessary to maintain a snug but
the entire length of the main frame, free-running fit.
checking for binding. Add or remove shims
as necessary to maintain a snug but Upper Bearings of Outer Telescopic
free-running fit.
1. With the inner telescopic inserted halfway
7. R35TT mast only: Check the clearance
into the main frame, attach the upper
gap of the bow pads between outer
roller bearing to one side of the outer
telescopic and main frame. Shim as
telescopic. Make sure the flat spot on the
required to obtain a gap of 0.03 to 0.09 in.
bearing outer stud is correctly positioned
(0.8 to 2.3 mm).
against the mast. See Figure 7-182.
2. Attach, but do not tighten, the upper roller
Assembling and Shimming bearing to the other side of the outer
Inner Telescopic to Outer telescopic.
Telescopic 3. Use spare shims as a gauge to determine
the amount of shims required to cause the
Lower Bearings of Inner Telescopic roller bearing to contact the inner
telescopic.
of the inner telescopic. Make sure the flat 4. Remove both upper bearings. Install one
spot on the bearing outer stud is correctly half of the total shim thickness required to
positioned against the mast. See each roller bearing. Reinstall the bearings.
Figure 7-181. Apply thread-locking compound
(P/N 990-536) to the bearing mounting
2. Using a suitable hoist, insert the inner bolt and torque to 260 ft. lb. (352 Nm).
telescopic into the outer telescopic as far
as the crosstie. 5. If the inner race of the bearing does not
3. Attach the lower roller bearing to the other when the bearing is fully seated, bend the
side of the inner telescopic. flat washer to contact the bearing to
4. Using a pry bar, move the inner telescopic prevent the bearing from walking on the
and bearing to one side. stud shaft. See Figure 7-184.
5. Use spare shims as a gauge to determine 6. Using the hoist, slide the inner telescopic
the amount of shims required to cause the the entire length of the outer telescopic,
roller bearing to contact the outer checking for binding. Add or remove shims
telescopic. as necessary to maintain a snug but
6. Remove both lower bearings. Install one free-running fit.
half of the total shim thickness required to 7. Check the clearance gap of the bow pads
each roller bearing. Reinstall the bearings. between inner telescopic and outer
Apply thread-locking compound telescopic. Shim as required to obtain a
(P/N 990-536) to the bearing mounting gap of 0.03 to 0.09 in. (0.8 to 2.3 mm).
7. If the inner race of the bearing does not Main Lift Chain Installation
when the bearing is fully seated, bend the 1. Install anti-rattle pads and shims at
flat washer to contact the bearing to bottom of inner and outer telescopics.
prevent the bearing from walking on the Shim so pads are snug against mast. See
stud shaft. See Figure 7-184. Figure 7-180 and Figure 7-181.
8. Using the hoist, slide the inner telescopic 2. Install the main lift chain sheaves to the
the entire length of the outer telescopic, top of the outer telescopic. Sheaves install
checking for binding. Add or remove shims with a large pin and a set screw on the
inside. See Figure 7-179.

3. Install but do not tighten a new sleeve and Shimming Carriage to Inner
collar, washer, and mounting bolt through
the telescopic crosstie and into the
Telescopic
cylinder housing of each main lift cylinder. 1. Drape the free lift chains forward over the
See Figure 7-178. carriage backrest. Rig lifting straps around
4. Rig lifting straps around the upper the carriage.
crossties of all three mast sections. 2. Install the lower set of roller bearings,
5. Using a suitable hoist, raise the mast to a without shims, in the carriage.
vertical position. 3. Using a hoist, carefully lift the carriage
6. Rig a lifting strap of one hoist around the and insert it into the inner telescopic until
lower crosstie of the main frame (the one the bearings just enter the telescopic.
where the overhead guard attaches). 4. Using a pry bar, move the carriage
7. Rig a lifting strap of another hoist around bearings to one side.
the top crossties of both inner and outer 5. Use spare shim(s) as a gauge to determine
telescopics. Using the hoist, lower the the amount of shims required to remove
telescopics to about 10 in. (25 cm) from side play.
the floor.
6. Remove the carriage from the inner
8. Make sure the two holes in the upper telescopic far enough to expose the
chain anchor block are towards the bearings being shimmed.
outside. Feed the main lift chain from the
7. Remove the bearings being shimmed from
outside to the inside over the chain
the carriage. Install one half of the total
sheave.
shim thickness required to each roller
9. Feed the upper chain anchor block down bearing.
between the main frame and outer
8. Using the hoist, reinsert the carriage into
telescopic until holes are aligned between
the inner telescopic. Check for tight areas
block and main frame. Insert the chain
while moving the carriage to the bottom of
anchor bolt (without the access cover) and
the inner telescopic.
lightly tighten the bolt to draw the chain
anchor block to the main frame. 9. Remove the carriage from the inner
telescopic far enough to expose the
10. Thread a bolt into the hole in the chain
bearings being shimmed.
anchor retaining pin. Insert the pin and
drive it in. Remove the bolt from the pin. 10. Remove the bearings being shimmed from
the carriage.
11. Remove the chain anchor bolt. Apply
thread-locking compound (P/N 990-544) NOTE: The carriage may have to be removed
to bolt threads. Install access cover and several times to obtain the correct fit.
torque bolt to 130 ft. lb. (174 Nm).
11. Install the center set of roller bearings,
12. Lower the telescopics into the main frame without shims, in the carriage.
approx. 3 in. (7.6 cm) from the floor.
12. Repeat steps 4 thru 10 for the center set of
13. Install master links to attach the main lift bearings.
chains to the lower chain anchor blocks.
13. Install the upper set of roller bearings,
Lower the telescopics completely. Tighten
without shims, in the carriage.
the chain anchor nuts until the inner
telescopic just lifts off its stops. 14. Repeat steps 4 thru 10 for the upper set of
bearings.

Carriage, Free Lift Cylinder, and 6. Reference Figure 7-186 for the following
steps, that route the hoses/cable.
Hose/Cable Installation
1. Drape the free lift chains forward over the Figure 7-186. OTM Hose and Cable Installation
carriage backrest. Rig lifting straps around
the carriage. Using a hoist, carefully lift
the carriage, insert it into the inner
telescopic, and lower the carriage to about
3 in. (7.6 cm) above the floor.
2. Route cable and hoses around upper
pulleys. Attach upper hose/cable pulley to
the top of the outer telescopic. Apply
to the threads of the studs and torque as
shown in Figure 7-185.
3. Route auxiliary hoses around lower
pulleys. Attach lower hose pulley to the
top of the outer telescopic. Apply
to the threads of the studs. See
Figure 7-185.
Figure 7-185. OTM Hose/Cable Pulleys
4. Install carriage stops. Refer to “Component

page A-4.
5. Remove set screws from free lift mounting
blocks. Lift each free lift cylinder into place
over the mounting hook at the top and the 7. Connect hose and crossover tube to free
mounting block at the bottom. Apply lift cylinders. See Figure 7-187.
to set screw threads and install set screws
in mounting blocks.


Figure 7-187. Free Lift Cylinder Crossover Tube Figure 7-189. Lower Hose/Cable Retainer, Free Lift
Cylinder
8. Feed hydraulic hoses and electrical cable

through the free lift pulley, from tractor
side to forks side. The electrical cable
must be on the left-hand side. See
Figure 7-188.
Figure 7-188. OTM Hoses and Cable at Free Lift Pulley
10. Assemble, but do not tighten, the

hose/cable retainer at the top of the free
lift cylinder. See Figure 7-190.
Figure 7-190. Upper Hose/Cable Retainer, Free Lift

Cylinder
Electrical Cable
Aux Hose A1
Aux Hose A2
9. Attach, but do not tighten, the hose/cable

retainer bracket at the bottom of the free
11. Feed hoses and cable around the guide on

the carriage. Attach the cable tension
spring and position the cable grip to
provide a 0.75 in. (19 mm) gap between
the OTM electrical cable and the bottom of
the hose guide. See Figure 7-191.


Figure 7-191. Hose/Cable Guide on Carriage cover. Attach the manifold cover to the
carriage. Refer to “Component Specific
20. Assemble, but do not tighten, the
hose/cable retainer on the left side main
21. Secure the mast with hoist lifting strap
wrapped loosely around the top crossties
of all three mast sections. Wrap the lifting
strap of a second hoist around the upper
crosstie of the inner telescopic. Using the
hoist, lift the inner telescopic about 6 in.
(15 cm).
22. Tighten the hose/cable retainer on the left
side main lift cylinder.
23. Lower the inner telescopic.
Gap
Mating Mast to Tractor

1. Position the tractor about 10 in. (25 cm)
from the mast. Place blocks under the
tractor near the mast to match the bolt
hole height in tractor and mast.
2. Attach the hose/cable retaining bracket on
the front (mast side) of the tractor
bulkhead. See Figure 7-192.
12. Feed the free lift chains over free lift
pulleys, from forks side to tractor side.
Install master links to attach the free lift
chains to the chain anchor blocks.
13. Take slack out of hoses and cable. Make
sure hoses do not cross each other.
14. Install hose/cable retainer on carriage.
See Figure 7-191.
15. Lower the carriage all the way to the floor.
16. Tighten the upper and lower hose/cable
retainers on the free cylinders. Attach two
cable ties on the upper retainer.
17. With the auxiliary manifold removed from
the carriage, connect auxiliary hydraulic
hoses to the manifold, making sure to
observe correct labeling.
18. Attach the manifold to the carriage. Apply
21 ft. lb. (29 Nm).
19. Connect the OTM cable wires to the
terminal block on the auxiliary manifold


Figure 7-192. Hose/Cable Retainer Clamps on Tractor 6. Torque bolts 1 thru 8 to 170 ft. lb.
(230 Nm) in the sequence shown in
Figure 7-194.
Figure 7-194. Tightening Lower Mast Mounting Bolts -

Second Torque Sequence
#1 #3 #5 #7
#2 #4 #6 #8
View from inside battery compartment
7. Tighten four upper mast mounting bolts

and torque to 170 ft. lb. (230 Nm).
8. Connect the main lift hose fitting at the left
side of the tractor.
9. Route the auxiliary hoses and electrical
cable through the tractor opening. Secure
hoses and cable with retainer clamps. See
Figure 7-192.
10. Install the battery connector bracket.
11. Connect auxiliary hoses A1 and A2 at the
main manifold, observing labels.
3. With the mast secured by a hoist, use a lift
12. Connect OTM cable connector JPS3 on the
truck to mate the tractor to the mast.
tractor deck. See Figure 7-156.
13. Feed the mast switch harness into the
(P/N 990-544) around the first 2 to 3
tractor, across the top of the deck to the
threads of the mast mounting bolts.
right side near the lift pump. Connect
5. Tighten lower mast mounting bolts 1 thru connector JPS4.
4 and torque to 130 ft. lb. (176 Nm) in the
14. Connect the ambient temperature sensor
sequence shown in Figure 7-193. Check
cable connector JPA on the tractor deck.
for a gap between the mast plate and the
tractor mounting plate at bolt #5. 15. Connect HTI encoder to JP13 and JPS11.
a. If gap is less than 0.010 in. (0.25 mm), 16. Connect the right side main lift hose to the
tighten bolts 5 thru 8 to 130 ft. lb. fitting on the tractor bulkhead.
(176 Nm). 17. Install the overhead guard. Refer to
b. If gap is more than 0.010 in. (0.25 mm), “Component Specific Service/Torque
install shim(s) as needed to reduce gap Chart” on page A-4.
to 0.010 in. (0.25 mm) or less. Torque 18. Install the mast guard.
bolts 5 thru 8 to 130 ft. lb. (176 Nm).
19. Using a suitable battery moving device,
Figure 7-193. Tightening Lower Mast Mounting Bolts - First install the battery. Install battery gates.
Torque Sequence 20. Install covers.
#1 #3 #7 #5 21. Make sure all hoist straps and blocks are
removed.
#2 #4 #8 #6 22. Reconnect the battery connector and turn
Install shim(s) between mast and tractor mounting plates at bolts 5 and 6
the key switch ON.

24. Test all lift truck functions.

(P/N 990-536) and tighten main lift
cylinder L-bracket mounting bolts to
55 ft. lb. (74.5 Nm).
26. Using a work basket and lift truck, grease
the channels of all sections of the mast.

Mast, Model 7520 blocked where it meets the mast before

loosening the mast mounting bolts.
(Complete Disassembly) 12. Place blocks snugly under the tractor near
the mast.
Separation of Tractor and Mast 13. Attach a lifting strap around the top
crossties of all three mast sections. Draw
tight with hoist. Make sure the weight of
the mast is supported by the hoist.
14. Remove the battery connector bracket to
• Do this procedure with a minimum permit access to the top right mast
of two technicians in a shop mounting bolts.
equipped with a suitable hoist.
15. Use an impact wrench to remove the mast
• Do not permit observers to stand mounting bolts inside the battery
nearby. compartment, four on the top, eight on the
• Wear gloves, safety glasses, bottom.
steel-toed safety boots, and a safety
16. Using a lift truck, carefully separate the
helmet (hard hat).
tractor about 6 in. (15 cm).
1. Lower and retract the fork carriage
17. Reinstall mast mounting bolts and
completely.
washers and tighten lightly (to prevent
2. Turn the key switch OFF and disconnect misplacing them).
the battery connector. Remove battery
gates. Using a suitable battery removal
device, remove the battery. Hose/Cable, Free Lift Cylinder,
3. Remove the top cover and the left and right and Carriage Removal
front covers. 1. Remove the auxiliary manifold cover from
4. Remove the mast guard. the carriage. See Figure 7-195 on
page 7-168.
5. Secure a hoist strap around the overhead
guard. Take the weight off the guard. 2. Disconnect the wires of the OTM cable
Remove mounting bolts. Remove the from terminal strip TS2, labeling as
guard. needed for re-connection.
6. Disconnect and cap right side main lift 3. Remove auxiliary manifold mounting
hose at the tractor bulkhead fitting. screws to permit access to the OTM hose
fittings at the manifold.
7. Disconnect the ambient temperature
sensor connector JPA on the tractor deck. NOTE: There may be shims between the
8. Disconnect the mast switch connector manifold and carriage.
JPS4 (near the lift pump). Feed harness
through tractor opening at right side.
9. Disconnect OTM cable connector JPS3 on
the tractor deck.
10. Disconnect and plug hydraulic hoses A1
and A2 at the main manifold, labeling as
needed for correct reassembly. Feed hoses
through opening in tractor bulkhead.
11. Disconnect the main lift hose fitting at the
left side of the tractor.
NOTE: Make sure the weight of the mast is fully
supported by the hoist and the tractor is


Figure 7-195. Auxiliary Manifold Access Figure 7-197. U-clamp, OTM Electrical Cable
U-clamp
4. Disconnect and plug/cap the OTM hoses

and fittings at the auxiliary manifold.
Label as needed for correct re-connection.
5. Place a chalk witness mark on the hoses to
aid in reassembly. 8. Cut cable ties on hose clamps on left side
6. Remove hose retaining clamp near top of free lift cylinder.
the left side free lift cylinder. See 9. Loosen the hose retaining clamp on the
Figure 7-196. carriage near the bottom of the left side
free lift cylinder. Slide clamp inward to free
Figure 7-196. Hose Retaining Clamp, Left Free Lift Cylinder the hoses. See Figure 7-198.
Figure 7-198. Hose Retaining Clamp, Left Free Lift Cylinder,

Bottom (35.5 in. mast shown)
7. Loosen the U-clamp on the right side free

lift cylinder and feed the OTM cable
through. See Figure 7-197. 10. Feed hoses and cable through free lift
cylinder pulleys.
11. Jack carriage up about 3 in. (7.6 cm) to
provide slack in chains. Remove master
links on free lift chains. Feed free lift

chains through pulleys and drape over Figure 7-199. Free Lift Cylinder Mounting Stud and Pin
front of carriage. (35.5 in. mast shown)
12. Remove carriage stops at the top of the Free Lift Cylinder
inner telescopic. Mounting Stud
13. Rig lifting straps around the carriage.
Using a hoist, carefully lift the carriage out
of the inner telescopic and lower the
carriage to the floor.
14. Disconnect and plug the hydraulic supply
hose at the bottom of the free lift cylinders.
15. Disconnect the free lift crossover hose and
cap both cylinders.
16. Remove the nylon locking nut from the
mounting stud on the free lift cylinder. Lift
each free lift cylinder off the mounting
stud at the top and off the pin at the
bottom. See Figure 7-199.
Free Lift Cylinder
Mounting Pin
Main Lift Chain Removal

1. Rig a lifting strap of one hoist around the
lower crosstie of the main frame (the one
where the overhead guard attaches).
2. Rig a lifting strap of another hoist around
the top crossties of both inner and outer
telescopics. Using the hoist, raise the
telescopics about 10 in. (25 cm).
3. Remove the kickback block, pads, and
shims at the bottom of the inner


Figure 7-200. Inner Telescopic Kickback Block, Pad, Shims Separation of Telescopics
(35.5 in. mast shown)
1. Using the hoists, carefully lower the mast
to a horizontal position on jack stands.
Kickback 2. Loosen the L-bracket bolts holding the
Block main lift cylinders to the telescopic.
3. Remove the top mounting bolt, washer,
Mounting and sleeve holding the main lift cylinder to
Screws the outer telescopic. See Figure 7-202.
Figure 7-202. Main Lift Cylinder Mounting Hardware

Mounting Bolt
Kickback Shim
Pad Washer
Sleeve
4. Remove the chain anchor retaining nut
from the chain anchor block at the bottom
of the inner telescopic.
5. Remove the bolt and access cover to the
upper chain anchor at the sides of main
frame. See Figure 7-201.
6. Remove the chain anchor pin by using a Outer
Telescopic
slide hammer or by using a large socket
(1 1/16 in.), an M8 x 50 mm bolt, and 4. Remove main lift chain sheaves from top of
washers to act as a pulling device. outer telescopic. Sheaves attach with a pin
See Figure 7-201 and Figure 7-144 on and a retaining screw on the front. See
page 7-137. Figure 7-203.
Figure 7-201. Main Lift Chain Upper Chain Anchor
Figure 7-203. Main Lift Chain Sheave
Bolt
Sheave
Cover
Spacer Chain
Pin Bearing
Chain Snap Ring

Anchor
Pin
Retaining Screw
7. Pull the chain anchor/mast stop out of the
main frame.
5. Remove anti-rattle pads and shims from
8. Feed main lift chains from inside to
bottom of outer telescopic. See
outside over the chain sheave.
Figure 7-204.


Figure 7-204. Outer Telescopic Lower Bearing and Figure 7-206. Main Frame Upper Bearing
Anti-Rattle Pads
Bolt
Stud
Bearing
Retaining
Shim Screw and
Washer
Bearing
Pad Shim Cover

shims from the outer telescopic. See
6. Using a suitable hoist, pull the inner
Figure 7-204.
telescopic halfway out of the outer
telescopic. 13. Using a suitable hoist, remove the outer
telescopic from the main frame.
shims from the top of the outer telescopic.
See Figure 7-205.
Figure 7-205. Outer Telescopic Upper Bearing
Stud
Shim
Bearing
Bearing Retaining
Screw and Washer

shims from the bottom of the inner
9. Using a suitable hoist, remove the inner
telescopic from the outer telescopic.
10. Using a suitable hoist, pull the outer
telescopic halfway out of the main frame.
shims from the main frame. See
Figure 7-206.

Mast, Model 7520 Figure 7-207. Inner Race
(Complete Assembly)
Assembling and Shimming
Outer Telescopic to Main Frame
Lower Bearings of Outer Telescopic
1. Begin the assembly with the main frame
positioned horizontally on jack stands.
of the outer telescopic. Make sure the flat
positioned against the mast. This is 9. Using the hoist, slide the outer telescopic
important because the correct bearing the entire length of the main frame,
alignment is canted with respect to the checking for binding. The tightest spots
channel. See Figure 7-204. are generally at the crossties. Add or
3. Using a suitable hoist, insert the outer remove shims as necessary to maintain a
telescopic into the main frame as far as snug but free-running fit.
the crosstie.
4. Attach the lower roller bearing to the other Upper Bearings of Main Frame
side of the outer telescopic.
1. With the outer telescopic inserted halfway
5. Using a pry bar, move the outer telescopic into the main frame, attach the upper
and bearing to one side. roller bearing to one side of the main
6. Use spare shims as a gauge to determine frame. Make sure the flat spot on the
the amount of shims required to cause the bearing outer stud is correctly positioned
roller bearing to contact the main frame. against the mast. See Figure 7-206.
7. Remove both lower bearings. Install one 2. Attach but do not tighten the upper roller
half of the total shim thickness required to bearing to the other side of the main
each roller bearing. Reinstall the bearings. frame.
Apply thread-locking compound 3. Use spare shims as a gauge to determine
(P/N 990-536) to the bearing mounting the amount of shims required to cause the
bolt and torque to 260 ft. lb. (352 Nm). roller bearing to contact the outer
8. If the inner race of the bearing does not telescopic.
protrude past the end of the bearing stud 4. Remove both upper bearings. Install one
when the bearing is fully seated, bend the half of the total shim thickness required to
flat washer to contact the bearing to each roller bearing. Reinstall the bearings.
prevent the bearing from walking on the Apply thread-locking compound
stud shaft. See Figure 7-207. (P/N 990-536) to the bearing mounting
prevent the bearing from walking on the
stud shaft. See Figure 7-207.

6. Using the hoist, slide the outer telescopic Upper Bearings of Outer Telescopic
the entire length of the main frame,
checking for binding. Add or remove shims 1. With the inner telescopic inserted halfway
as necessary to maintain a snug but into the main frame, attach the upper
free-running fit. roller bearing to one side of the outer
telescopic. Make sure the flat spot on the
bearing outer stud is correctly positioned
Assembling and Shimming against the mast. See Figure 7-200.
Inner Telescopic to Outer 2. Attach but do not tighten the upper roller
Telescopic bearing to the other side of the outer
telescopic.
Lower Bearings of Inner Telescopic 3. Use spare shims as a gauge to determine
the amount of shims required to cause the
roller bearing to contact the inner
of the inner telescopic. Make sure the flat
telescopic.
positioned against the mast. See 4. Remove both upper bearings. Install one
Figure 7-200. half of the total shim thickness required to
each roller bearing. Reinstall the bearings.
2. Using a suitable hoist, insert the inner
telescopic into the outer telescopic as far
(P/N 990-536) to the bearing mounting
as the crosstie.
3. Attach the lower roller bearing to the other
side of the inner telescopic.
4. Using a pry bar, move the inner telescopic when the bearing is fully seated, bend the
and bearing to one side. flat washer to contact the bearing to
5. Use spare shims as a gauge to determine prevent the bearing from walking on the
the amount of shims required to cause the stud shaft. See Figure 7-206.
roller bearing to contact the outer 6. Using the hoist, slide the inner telescopic
telescopic. the entire length of the outer telescopic,
6. Remove both lower bearings. Install one checking for binding. Add or remove shims
half of the total shim thickness required to as necessary to maintain a snug but
each roller bearing. Reinstall the bearings. free-running fit.
Apply thread-locking compound 7. Check the clearance gap of the bow pads
(P/N 990-536) to the bearing mounting between inner telescopic and outer
bolt and torque to 260 ft. lb. (352 Nm). telescopic. Shim as required to obtain a
7. If the inner race of the bearing does not gap of 0.03 to 0.09 in. (0.8 to 2.3 mm).
when the bearing is fully seated, bend the Main Lift Chain Installation
prevent the bearing from walking on the 1. Install anti-rattle pads and shims at
stud shaft. See Figure 7-207. bottom of inner and outer telescopics.
8. Using the hoist, slide the inner telescopic Shim so pads are snug against mast. See
the entire length of the outer telescopic, Figure 7-204 and Figure 7-200.
checking for binding. Add or remove shims 2. Install the main lift chain sheaves to the
as necessary to maintain a snug but top of the outer telescopic. Sheaves install
free-running fit. with a large pin and a retaining screw on
the front. See Figure 7-203.
3. Install, but do not tighten, a new sleeve
and collar, washer, and mounting bolt
through the telescopic crosstie and into

the cylinder housing of each main lift 2. Install the lower set of roller bearings,
cylinder. See Figure 7-202. without shims, in the carriage.
4. Rig lifting straps around the upper 3. Using a hoist, carefully lift the carriage
crossties of all three mast sections. and insert it into the inner telescopic until
5. Using a suitable hoist, raise the mast to a the bearings just enter the telescopic.
vertical position. 4. Using a pry bar, move the carriage
6. Rig a lifting strap of one hoist around the bearings to one side.
lower crosstie of the main frame (the one 5. Use spare shim(s) as a gauge to determine
where the overhead guard attaches). the amount of shims required to remove
7. Rig a lifting strap of another hoist around side play.
the top crossties of both inner and outer 6. Remove the carriage from the inner
telescopics. Using the hoist, lower the telescopic far enough to expose the
telescopics to about 10 in. (25 cm) from bearings being shimmed.
the floor. 7. Remove the bearings being shimmed from
8. Make sure the two holes in the upper the carriage. Install one half of the total
chain anchor block are towards the shim thickness required to each roller
outside. Feed the main lift chain from the bearing.
outside to the inside over the chain 8. Using the hoist, reinsert the carriage into
sheave. the inner telescopic. Check for tight areas
9. Feed the upper chain anchor block down while moving the carriage to the bottom of
between the main frame and outer the inner telescopic.
telescopic until holes are aligned between 9. Remove the carriage from the inner
block and main frame. Insert the chain telescopic far enough to expose the
anchor bolt (without the access cover) and bearings being shimmed.
lightly tighten the bolt to draw the chain
anchor block to the main frame. 10. Remove the bearings being shimmed from
the carriage.
10. Thread a bolt into the hole in the chain
anchor retaining pin. Insert the pin and NOTE: You might need to remove the carriage
drive it in. Remove the bolt from the pin. several times to obtain the correct fit.
11. Remove the chain anchor bolt. Apply 11. Install the center set of roller bearings,
thread-locking compound (P/N 990-544) without shims, in the carriage.
to bolt threads. Install access cover and 12. Repeat steps 4 thru 10 for the center set of
torque bolt to 130 ft. lb. (174 Nm). bearings.
12. Lower the telescopics into the main frame 13. Install the upper set of roller bearings,
approx. 3 in. (7.6 cm) from the floor. without shims, in the carriage.
13. Insert chain anchor bolts into chain 14. Repeat steps 4 thru 10 for the upper set of
anchor blocks. Lower the telescopics bearings.
completely. Tighten the chain anchor nuts
until the inner telescopic is 3/8 in.
(9.5 mm) off the outer telescopic. Carriage, Free Lift Cylinder, and
Hose/Cable Installation
Shimming Carriage to Inner 1. Drape the free lift chains forward over the
Telescopic carriage backrest. Rig lifting straps around
the carriage. Using a hoist, carefully lift
1. Drape the free lift chains forward over the the carriage and insert it into the inner
carriage backrest. Rig lifting straps around telescopic and lower the carriage to about
the carriage. 3 in. (7.6 cm) above the floor.

2. Route lift hose and cable around upper Figure 7-209. Over-the-Mast Hose and Cable Installation
pulleys. See Figure 7-208.
3. Route auxiliary hoses around lower
pulleys. See Figure 7-208.
Figure 7-208. Over-the-Mast Hose/Cable Pulleys
Cable
Main Lift
Aux
4. Install carriage stops at top of inner

telescopic. Apply thread-locking
compound (P/N 990-536) to mounting
bolts and torque to 35 ft. lb. (47.5 Nm).
5. Lift each free lift cylinder into place over
the mounting stud at the top and the pin
at the bottom. See Figure 7-199 on
page 7-169.
6. Refer to Figure 7-209 for the following
steps to route the hoses/cable.

7. Connect supply hose and crossover tubing Figure 7-212. OTM Hoses and Cable at Free Lift Pulley
to free lift cylinders. See Figure 7-210.
Figure 7-210. Free Lift Cylinder Hose Connection

Aux Hoses Electrical Cable
Crossover Tubing
10. Attach and tighten the hose retaining

clamp on the carriage near the bottom of
8. Attach and tighten the hose retainer the left side free lift cylinder. See
bracket at the bottom of the free lift Figure 7-198 on page 7-168.
cylinder. See Figure 7-211.
11. Replace cable ties on hose clamps on left
Figure 7-211. Lower Hose/Cable Retainer, Free Lift side free lift cylinder.
Cylinder (35.5 in. wide mast shown) 12. Feed the OTM electrical cable through the
U-clamp on the right side free lift cylinder.
See Figure 7-209 on page 7-175.
13. Attach and tighten the hose retaining
clamp near top of the left side free lift
cylinder. See Figure 7-196 on page 7-168.
14. Feed the free lift chains over free lift
pulleys, from forks side to tractor side.
Install master links to attach the free lift
chains to the chain anchor blocks.
15. Take slack out of hoses and cable.
16. Lower the carriage all the way to the floor.
17. Tighten the upper and lower hose clamps
on the free lift cylinders.
18. With the auxiliary manifold removed from
the carriage, connect auxiliary hydraulic
hoses to the manifold, making sure to
9. Feed hydraulic hoses and electrical cable observe correct labeling.
through the free lift pulleys, from tractor 19. Attach the manifold to the carriage. Apply
side to forks side. See Figure 7-212. thread-locking compound (P/N 990-536)
21 ft. lb. (29 Nm).

20. Connect the OTM cable wires to TS2. 7. Connect the main lift hose fitting at the left
Attach the manifold cover to the carriage. side of the tractor.
Refer to “Component Specific 8. Install the battery connector bracket.
9. Connect auxiliary hoses A1 and A2 at the
main manifold, observing labels.
Mating Mast to Tractor 10. Connect OTM cable connector JPS3 on the
1. Position the tractor about 10 in. (25 cm) tractor deck. See Figure 7-156.
from the mast. Place blocks under the 11. Feed the mast switch harness into the
tractor near the mast to match the bolt tractor, across the top of the deck to the
hole height in tractor and mast. right side near the lift pump. Connect
2. With the mast secured by a hoist, use a lift connector JPS4.
truck to mate the tractor to the mast. 12. Connect the ambient temperature sensor
3. Apply thread-locking compound cable connector JPA on the tractor deck.
(P/N 990-544) around the first 2 to 3 13. Connect HTI encoder to JP13 and JPS11.
threads of the mast mounting bolts.
14. Connect the right side main lift hose to the
4. Tighten lower mast mounting bolts 1 thru fitting on the tractor bulkhead.
4 and torque to 130 ft. lb. (176 Nm) in the
15. Install the overhead guard. Refer to
sequence shown in Figure 7-213. Check
for a gap between the mast plate and the
tractor mounting plate at bolt #5.
a. If gap is less than 0.010 in. (0.25 mm),
tighten bolts 5 thru 8 to 130 ft. lb. 17. Using a suitable battery moving device,
(176 Nm). install the battery. Install battery gates.
b. If gap is more than 0.010 in. (0.25 mm), 18. Install covers.
install shim(s) as needed to reduce gap 19. Make sure all hoist straps and blocks are
to 0.010 in. (0.25 mm) or less. Torque removed.
bolts 5 thru 8 to 130 ft. lb. (176 Nm).
Figure 7-213. Tightening Lower Mast Mounting Bolts - First the key switch ON.
Torque Sequence 21. Bleed the hydraulic system. See
#1 #3 #7 #5 “Hydraulic System Bleeding” on page 7-86.
22. Test all lift truck functions.
#2 #4 #8 #6 23. Apply thread-locking compound and
Install shim(s) between mast and tractor mounting plates at bolts 5 and 6
tighten main lift cylinder L-bracket
mounting bolts to 55 ft. lb. (74.5 Nm).
5. Torque bolts 1 thru 8 to 170 ft. lb. 24. Using a work basket and lift truck, grease
(230 Nm) in the sequence shown in the channels of all sections of the mast.
Figure 7-214.
Figure 7-214. Tightening Lower Mast Mounting Bolts -

Second Torque Sequence
#1 #3 #5 #7
#2 #4 #6 #8
6. Tighten four upper mast mounting bolts

and torque to 170 ft. lb. (230 Nm).

Back Tilt and Lateral Lean Inspection Mast, Chain, Hose, Cable
Back Tilt and Lateral NOTE: Maximum lean for a particular truck
can be determined by the following
Lean Inspection formula:
Maximum Lean (in.) = 0.005 x EH (in.)
When the baselegs are changed or if the 7. Compare the measured lateral lean to the
eccentric sleeve at the wheel plate/baseleg calculated dimension to determine if it is
connection has been disturbed, the back tilt within the acceptable limit.
and lateral lean of the reach truck must be 8. If the measured back tilt or lateral lean
inspected and adjusted. does not fall within acceptable limits, the
NOTE: Select a floor location that is flat and *adjustment (eccentric) sleeve(s) can be
level as possible. replaced or rotated to achieve the required
results.
NOTE: A new drive tire, caster tire, and load
wheels should be installed and the If no adjustment is required, a *concentric
caster adjusted prior to inspection. See sleeve is used.
“Caster Height Adjustment” on
page 7-24. *Available through the Parts Distribution
1. Secure a plumb-bob line to one of the Center.
forks.
The following formulas can be used as a
NOTE: The plumb-bob line cannot move fore or guide to determine the appropriate colored
aft during the procedure. sleeve:
2. Raise the forks 12 in. (30.5 cm) off the • Green (0.063 in. back tilt change)
floor and mark the position (on the floor) (EH x 0.186) divided by truck wheelbase
at the suspended plumb bob point. • Yellow (0.094 in. back tilt change)
3. Raise the forks to full elevation (without (EH x 0.279) divided by truck wheelbase
making contact with the mechanical stops)
NOTE: Lowering the load wheel center
and mark the new position on the floor at
increases back tilt. Raising the load
the suspended plumb-bob point.
wheel center decreases back tilt.
4. Measure the distance between the two
points in the truck’s fore and aft direction. 9. Following installation of the appropriate
This is the truck’s back tilt. sleeve, the back tilt, lean, and caster
settings should be rechecked per steps 4
5. Measure the distance between the two thru 7.
points in the side to side direction. This is
the truck’s lateral lean. 10. Once the eccentric sleeve color and
orientation is determined, it must be
6. Compare the measured back tilt to the secured in position with thread-locking
following table to determine if it is within compound (P/N 990-575). Before applying
acceptable limits. the compound, clean the sleeve and
baseleg hole with solvent (P/N 990-500/
Elevated Back Tilt (in.) RD1) and primer (P/N 990-533) (if a
Height (EH) Max. Nom. Min. concentric sleeve is used, thread- locking
373 - 444 4.0 2.65 1.3 compound is not required). Parts assembled
using thread-locking compound should be
331 - 372 2.5 1.75 1.0 allowed to set for a minimum of 15
301 - 330 2.5 1.7 1.0 minutes before final assembly.
271 - 300 2.5 1.5 1.0 11. If eccentrics cannot resolve the lean
241 - 270 2.0 1.4 0.5 condition, shim the upper mast to tractor
mount to correct a lean. A maximum of
240 & below 2.0 1.2 0.5 two 0.12 in. thick spacers should be used.

Mast, Chain, Hose, Cable Back Tilt and Lateral Lean Inspection
Tack weld shims to main frame when all

adjustments are finalized. A digital level on
the side of the main frame will give an
indication of the lean correction. A reading
of 0.1 to 0.2 degrees off vertical should
allow the lean to be corrected. The goal is
to level the main frame.
12. If the main frame is level and the
telescopics lean more than 0.2 degrees,
re-shim the outer telescopic to bring it
back into range. This is done by removing
shims from the opposite side of the lean of
the telescopic and placing them on the
side of the truck that the truck is leaning
toward.

Back Tilt and Lateral Lean Inspection Mast, Chain, Hose, Cable

Models 7500/7520 Reach-Fork ® Trucks Section 8. Theory of Operation
Section 8. Theory of Operation

Section 8. Theory of Operation Models 7500/7520 Reach-Fork ® Trucks
Traction System Functional Operation
Traction System internal to the VM. The VM also uses this

input to calculate BSOC and compares it
Functional Operation to the last battery voltage in its memory.
The VM then determines if the display
requires updating.
Battery Connected • The tips of K1, K2, K3, and K4 close,
supplying B+ to the following:
When the battery is connected, the truck has
• B+K3 at JPT1-1, JPL1-1, and JPA-1
B+ and B– supplied to the following points:
(Regen Lower) are used by the
• B+ to JPF4-3 and 4-4 through FU7 and to amplifiers to power their internal
the normally open tips of K1 relay and circuitry that includes power supplies.
JPF4-15. The power supplies provide 12V to the
• B+ to JPF4-1 and 4-2 through FU5 to the velocity sensors (encoders) and
normally open tips of K2, K3, K4, the K4 temperature sensors for the Traction,
coil, and the key switch S1. JPF4-1 and Lift, and Aux (Regen Lower) Motors.
JPF4-2 also supply the VM with • B+K3 at JPT1-12 and JPL1-11 to
BATTERY_SENSE_IN at JPC24-24. It is establish whether the amp is a traction
protected by a thermistor for overcurrent amp or a lift amp.
conditions caused by shorts in the wiring.
• all hydraulic solenoids, Nested Switch,
• B+ to the normally open tips of the Steer Horn, Brake, and FAN-T, -FW, -FW2,
and Main contactors. LM, and -DU are supplied by B+K2.
• B– is supplied to all points labeled B–, B–F, • connections for optional devices at
any sensor connection with a (–) negative JPF2-9 by B+K1.
label and DGND.
• B+ is supplied to the VM by B+K4. It is
used to power the heaters on trucks
Key Turned ON with the Cold Storage option.
• With all microprocessors powered up,
When the key switch is turned ON, B+ is SelfTest continues:
supplied to the following points:
• the VM checks to make sure its power
• through the EPO switch to the coils of K1, supplies are within range.
K2, and K3.
• the VM checks the BUS to make sure
• to JPC14-12 at the VM as B+ Key. This, communications are functioning with
internal to the VM, activates the power all other devices (DISPLAY, LPA, TPA
supply circuits that supply all 12V and 5V and APA (Regen Lower)).
outputs from the VM and activates the
microprocessor in the VM. Steady power • the amplifiers check the pre-charge
supply output is maintained as long as circuit voltages to make sure they are
battery voltage remains above 17V. 12V is in range. If not, a message is sent over
supplied to the display. The display the BUS to the VM and a code is
contains a microprocessor that requires displayed.
firmware updates any time the VM is • the VM checks the status of the MPC
updated. and STR contactors to make sure they
• the processor in the VM looks at are open. On trucks with Regen Lower,
BATTERY_SENSE_IN (JPC24-24) and it also checks the AUX contactor.
verifies it is within the required • the VM activates the circuitry to close
parameters for the amps, 28 to 45V. If it is, the contactors. The contactors are
there is an output from the processor to checked to make sure power is supplied
RELAY_ENABLE at JPC14-6 taking the through the contactor tips using the
relay coils for K1, K2, K3, and K4 to B– sense lines.

• the VM verifies the EPO switch is closed • after SelfTest is complete, the MPC
using EPO_SENSE. contactor remains energized for approx.
• the software and configured parameters 30 seconds. If no function requests are
are checked in the LPA, TPA, APA made by the operator, it opens. The STR
(Regen Lower), Display, and VM to contactor opens on all trucks as soon
make sure they are within limits and as the circuits are tested. The VM also
correct. monitors the temperature inputs from
the TPA, LPA, and APA (Regen Lower).
• the amplifiers check to make sure there Anytime one of the readings goes above
are no shorts in the power circuits. the limits defined in the Analog Tests,
• the VM checks to make sure the the VM turns on fans T, FW, FW2, DU,
Deadman Switch is open. and closes the Aux contactor.
• the VM checks to make sure the Steer
Tiller Encoder is connected. Deadman Pedal Pressed
• the VM checks to make sure the lift
potentiometer (VR2) and throttle When the deadman pedal is pressed, the
potentiometer (VR1) are within 0.2V of Deadman Switch (DS1) is closed, supplying the
the “LEARNed” neutral position and are VM with B– through JPC22-8, DEADMAN DS1.
not outside the allowable minimum and This activates circuitry that informs the VM the
maximum voltages. They are switch is closed.
continuously monitored and messages
are displayed if activated prior to With the Deadman Switch closed, the VM tells
closing the deadman switch. the LPA, TPA, and APA (Regen Lower) it is
closed and commands the MPC and STR
• the TPA is commanded to activate the
contactors to be closed. The VM now reacts to
Traction Motor to make sure current is
any request from control pots or switches for
seen and there are no motor velocity
lift/lower, travel, and aux functions. When the
sensor (encoder) inputs. This is to make
Deadman Switch is opened again, the MPC
sure the power circuits are functional
remains energized for 30 seconds with no
and the brake is applying resistance to
functions commanded and then opens. On
the Traction Motor.
trucks with Regen Lower, the Aux contactor
• the VM checks the state of the control remains closed for 25 seconds, then opens. The
handle switches to make sure they are STR contactor remains energized for 3 seconds
in the open position. They are and then opens. The Deadman Switch then
continuously monitored and messages must close again for the contactors to energize.
are displayed if activated prior to
closing the deadman switch. With the Deadman Switch closed, the TPA
• the VM checks the information from the continuously monitors the input from the
TPA, LPA, and APA (Regen Lower) to Traction Motor Encoder (TME). If no travel
make sure the motor temperature request is seen from the control handle and
sensor readings are within range and inputs are seen from the sensor, the TPA
determines if speed limiting is required. powers the Traction Motor as required to keep
the truck in the same position. This prevents
• the VM checks pressure transducer
unwanted movement on uneven surfaces, dock
readings to make sure they are within
plates or ramps, or if placing a pallet in the rack
range.
system.
• the VM checks to make sure the
Ambient Temperature Sensor is within
the acceptable range. Electric Steering
• the VM checks its memory for all NOTE: This information is based on a truck
previously logged faults that have not that is not programmed for Reverse
been cleared. Steering. If programmed for Reverse

Steering, the VM reverses the CW and applied to it, MS-A1 or MS-A2. The VM then
CCW commands to the Steer Amplifier. monitors the inputs from the Steer Motor
It also looks for feedback from the Steer Encoder to determine the direction and speed
Motor Encoder in the opposite direction. the motor is turning and compares it to the
request. The VM also monitors the Steer Motor
On trucks with electric steering, when the VM current from the Steer Amplifier on JPC6-3,
closes the STR contactor, the VM begins to STEER_CURRENT. Current limit for the Steer
monitor the inputs from the Steer Amplifier, Motor is approx. 100 amps and is controlled by
Steer Tiller Encoder, and the Steer Motor the Steer Amplifier. The VM uses this input
Encoder. The VM is looking for a current draw when checking the steering system for shorts or
on the 12V lines that power the two Steer Tiller opens in the power circuit. The VM also
Encoders. With no steer requests from the Steer monitors the input from the END OF STEER
Tiller Encoder, the VM looks for an input from ROTATION SWITCH (S11), mounted next to the
the Steer Amplifier on JPC6-1, drive unit. This is a proximity switch that is
NEUTRAL_PULSE. This feedback from the Steer turned ON and OFF by a metal ring mounted to
Amplifier informs the VM that the Amplifier is the drive unit. As the drive unit nears the end of
connected and powered up. The its rotation, the metal ring is no longer under
NEUTRAL_PULSE is created by the VM sending the proximity switch and the switch opens prior
a very low steering command over the CCW and to hitting the drive unit’s mechanical stop.
CW wires to the Steer Amplifier. These When the input to the VM goes high at
commands are alternated back and forth JPC22-22 STEER_LIMIT, the VM no longer
between CCW and CW. This creates a toggling sends out a steer command in that direction. It
high/low input on the NEUTRAL_PULSE line only sends out commands when there is a
that changes about 10 times a second. When a request in the opposite direction from the
steer command is present, this input does not operator. This prevents the steering system
toggle as fast and the VM ignores it. When the from being held in current limit.
operator turns the steering wheel, a set of
square wave voltages (chopped DC voltage) is
sent to the VM on Channels A _1, B_1, A _2, and
Travel Request
B_2. The VM looks at the square waves as sets.
A _1 and B_1 are one set and A _2 and B_2 are Primary Control Handle
another set. Based on which channel of the set
is seen first, A or B, the VM determines the With the Deadman Switch (DS1) closed, the VM
direction the operator has requested the drive constantly sends an RPM request that causes
unit to turn. The VM determines the requested the TPA to maintain the speed requested by the
speed by the amount of time between the operator. With the Primary Control Handle in
square waves. Less OFF time between them neutral, the request is always at 0 RPM. When
means a faster rotation was requested. Two sets the VM sees a change in the “LEARNed” neutral
are used so the VM can compare them and voltage from the Primary Control Handle travel
verify the encoder is functioning correctly. Once pot (VR1) at JPC12-3, it first checks for any
this information is processed, the VM sends out inputs that activate a speed limit condition. If
a chopped DC voltage to the Steer Amplifier none are seen, it calculates the direction and
over CCW_PWM or CW_PWM. CCW_PWM is a percent of full speed requested based on the
request for the drive unit to be turned in the “LEARNed” values. A message is sent to the TPA
counterclockwise direction and CW_PWM is a over the BUS as a command to travel in the
command to turn in the clockwise direction. appropriate direction at the RPM to obtain the
Based on the OFF time between the square requested speed. The TPA then determines the
waves, the Steer Amplifier determines the speed correct sequence to energize the motor leads (U,
of rotation requested and sends the appropriate V, and W) to move the truck in the correct
voltage to the Steer Motor. Direction of Steer direction. The TPA also determines the required
Motor/Drive Unit rotation is controlled by the amount of voltage to send through the motor
side of the Steer Motor that has positive voltage leads based on the acceleration parameters

programmed and the requested RPM. The TPA

then monitors the feedback from the TME to
adjust the voltage to the Traction Motor to
maintain the requested RPM and direction. Any
conditions that prevent the TPA from
maintaining these requests are sent over the
BUS to the VM. The VM tells the Display, via
the BUS, to display a message informing the
operator. The VM also invokes any system shut
down or limitations based on the information
from the TPA.
Secondary Control Handle
Travel requests from the Secondary Control

Handle are processed in the same way as the
Primary Control Handle. The only difference is
that forks-first travel speed is limited by the VM
to 1 mph (1.6 km/h).

Hydraulic System Functional Operation - Standard Lift/Lower
Hydraulic System pressure feedback to the pilot line of the POD

valve to allow it to position itself for correct
Functional Operation - auxiliary and lift function operation.
Standard Lift/Lower Hydraulic Filter
The hydraulic system has one filter in the

System Components reservoir. All hydraulic fluid is filtered on the
return to the reservoir. There is an internal
Lift Motor (LM) bypass (CV7) set at 43 psi (296 kPa).
The Lift Motor is a brushless, three-phase Main Lift System

internally delta connected variable-speed AC
motor. The main lift system consists of four single
acting hydraulic cylinders. Hydraulic fluid flows
Lift Motor Encoder (LME) from the main manifold through a tee-fitting in
the tractor, through fittings in the left and right
The Lift Motor Encoder is a two-channel front of the tractor bulkhead. The right side
encoder. It provides the lift power amplifier with hose feeds the right side main lift cylinder. The
motor speed for motor speed regulation during left side divides again at a tee-fitting, supplying
lift and aux functions. both the left side main lift cylinder and the free
lift cylinders. At the bottom of the free lift
Lift Motor Temperature Sensor (LMT) cylinders, another tee-fitting divides the flow
between left and right free lift cylinders. A flow
The Lift Motor Temperature Sensor is mounted limiter is installed at one of the free lift and one
internally in the Lift Motor. Its provides the Lift or both of the main lift cylinders.
Power Amplifier (LPA) with the temperature of
the lift motor. When the operator requests lift, the entire lift
system is pressurized. Since the carriage
Main Lift/Aux Pump (P1) weighs less than the carriage plus telescopic,
the free lift cylinders extend first, elevating the
Pump P1 is a positive displacement gear pump carriage. When they reach the limit of their
that rotates clockwise from the shaft end. P1 is travel, the main lift cylinders extend, elevating
used for all lift and aux functions. the telescopics.
Priority On Demand (POD) Valve Load Holding Valve (SOL1)
This is a pilot operated spring return valve that The load holding valve is a normally closed
divides flow between the lift and auxiliary solenoid valve used to hold the carriage and
functions as required. It also provides a path to telescopics in an elevated position. It
the reservoir for excess hydraulic fluid from P1. incorporates an override to allow lowering the
carriage and telescopics manually.
Load Shuttle (LS-1)
Proportional Lower Valve (SOL2)
The load shuttles are 2-input, pressure
activated, 2-position valves. In each shuttle, the The proportional lower valve is a pressure
higher of the input pressures passes through compensated flow control solenoid valve used to
the valve at the pressure out port. The output lower the carriage and telescopics. As the
port provides flow used to operate pressure- voltage to the valve increases, the flow through
activated devices such as piloted relief or the valve increases, regardless of the pressure.
metering valves. The load shuttles provide

Proportional Relief (SOL3/Dump) Sideshift Cylinder
SOL3 is a proportional solenoid valve used as a The sideshift cylinder is a double-acting

system relief. In addition, SOL3 is used to divert hydraulic cylinder used to shift the load left and
hydraulic fluid from Pump P1 back to the right with respect to the mast.
reservoir after a lift is stopped and the pump is
still spinning. It also acts as a valve to port Tilt Cylinder
excess hydraulic fluid back to the reservoir from
the auxiliary functions. The tilt cylinder is a double-acting hydraulic
cylinder used to tilt the forks up and down.
Flow Limiter Valve
SOL5B/SOL5T
Flow limiter valves are used to limit the
maximum lower speed of the forks. A pilot port SOL5 is a directional solenoid valve providing
forces restricted flow through the restricted directional control to the reach, tilt, and
portion of the valve during lower once flow sideshift functions. De-energized, flow is
reaches 15 gpm (56.8 lpm); it is then limited to blocked to the aux functions and directed to the
4 to 5 gpm (15 to 19 lpm). A spring and pilot reservoir. When SOL5B is energized, flow is
port keep the restricted portion of the valve directed to port A1 for tilt up, sideshift right, or
closed, allowing free flow during lift. reach. When SOL5T is energized, flow is
directed to port A2 for tilt down, sideshift left, or
Auxiliary System retract.
The auxiliary system consists of up to three Reach/Retract Solenoid (REACH SOL)

double acting hydraulic cylinders. Hydraulic
fluid flows from the lift pump into the main REACH SOL is a normally closed solenoid valve
manifold on the tractor. Then through the used to block (de-energized) or allow (energized)
manifold and out port A1 or A2, depending on fluid flow to and from the reach cylinders.
the direction the aux function was requested to
move. Fluid then flows through the Sideshift Solenoid (SIDESHIFT SOL)
over-the-mast hose and into the aux manifold
on the carriage at port A1 or A2. Fluid then SIDESHIFT SOL is a normally closed solenoid
flows through a tee in the manifold which valve used to block (de-energized) or allow
allows flow to all three aux solenoid valves, (energized) fluid flow to and from the sideshift
Reach, Tilt and Sideshift. Fluid then flows cylinder.
through the solenoid valve that was energized
and leaves the aux manifold on the carriage at Tilt Solenoid (TILT SOL)
port SSR, SSL, RC, RR, TC or TR through the
hoses on the carriage into one of the double TILT SOL is a normally closed solenoid valve
acting cylinders, moving the cylinder in the used to block (de-energized) or allow (energized)
requested direction. fluid flow to and from the tilt cylinder.
Reach/Retract Cylinder Aux Relief Valve (RV4)
The reach/retract cylinder is a double-acting RV4 is a relief valve used to protect auxiliary
hydraulic cylinder used for extending and system components against excessive pressure.
retracting the forks. It is factory-adjusted to 2000 psi (13790 kPa). A
manual adjustment knob can be turned
clockwise to increase the relief pressure, or
counterclockwise to decrease the relief
pressure.

Theory of Lift/Aux Functions When the lift knob is returned to neutral, the
Lift Motor is ramped down. SOL3 opens to
relieve any pressure spikes in the system.
Lift
Lift speed varies directly with Lift Motor rpm. Lower

The voltage supplied to the Lift Motor is
proportional to the amount of lift request from Lowering is accomplished via the proportional
VR2 (faster lift = higher motor voltage). valve SOL2 (L/L). Lowering Speed is not a
Maximum lift speed for a given weight load is function of weight on the forks. An increasing
governed by software. voltage increases the flow through the valve
regardless of the pressure in the system. When
Weight is calculated from inputs to the VM from VR2 is moved to request Lower, a voltage is sent
the pressure transducer. Weight of the empty to the VM at JPC12-2. The VM sees a voltage
carriage and telescopic is calculated during different from the “LEARNed” neutral voltage.
LEARN Mode. The VM energizes SOL1 at JPC18-10. SOL2
opens proportionally to the requested rate of
Prior to requesting a lift, all valves are in the lower via a voltage from the VM at JPC20-16.
de-energized state. With SOL1 energized, fluid flows out of the lift
cylinders, through the flow limiters, through
When VR2 is moved to request lift, a voltage is SOL1, and then through energized SOL2. After
sent to the VM at JPC12-2. The VM sees a fluid exits these valves, it returns to the tank
voltage different from the “LEARNed” neutral via the hydraulic fluid filter.
voltage, and sends an RPM request to the lift
power amplifier via BUS+/BUS– (JPC14-11 and Auxiliary Functions
JPC14-4 through the display to JPL1-23 and
JPL1-35). Tilt
The VM supplies B– to the Main Pump Fork tilt allows the operator to raise or lower the
Contactor (MPC) coil at JPC18-8, that closes the tips of the forks. Standard fork tilt is 5° up and
normally open contactor tips. 2° down.
The MPC coil is energized when the Deadman When the deadman pedal is pressed, the VM
Switch (DS1) is activated. sends a command via BUS+/BUS– to the LPA.
The VM supplies B– to the MPC coil at JPC18-8,
When the MPC is energized, the contactor tips closing the normally open contactor tips.
close, allowing B+ to be supplied to the LPA,
that supplies voltage to the Lift Motor to make it The Tilt Up Switch (S6) is pressed, completing a
rotate. circuit between JPC12-5 and JPC12-12 at the
VM.
The VM supplies B– to the SOL3 coil at
JPC20-12 to regulate maximum lift pressure The VM energizes the following solenoids:
based on mast configuration.
• SOL3 (Dump) at JPC20-12
The POD valve (POD-1) receives pressure at • SOL5B at JPC20-20
port 4, placing pressure on the pilot line of the • TILT SOL at JPC18-15
valve. This pressure moves the spool in the
valve to allow flow out port 2 to CV1, the Pump P1 rotates at a speed predetermined in
de-energized Load Holding Solenoid (SOL1), software. Flow is ported to the POD valve at port
through the flow limiters in the base of the lift 3 and out at port 4. Fluid then flows through
cylinders, and into the lift cylinders, producing SOL5B or SOL5T, depending on the direction of
lift. the function requested. SOL5 is a proportional
solenoid, but the VM sends a fixed voltage to it,

regulating the speed of the requested function. The VM energizes the following solenoids:
If more oil than is needed flows to SOL5, back • SOL3 (Dump) at JPC20-12
pressure is present at port 4 of the POD valve.
This shifts the spool of the POD valve and sends • SOL5B at JPC20-20 or SOL5T at
the excess oil to SOL3 via port 2. SOL3 is open JPC20-18, depending on direction
to allow the excess oil to flow back to the filter • REACH SOL at JPC18-12
and reservoir. After leaving SOL5, the oil flows
to the LS-1. The LS-1 ports oil back to the POD Pump P1 rotates at a speed predetermined in
valve at port 1 to help regulate the flow to the software. Flow is ported to the POD valve at port
auxiliary function. From LS-1, the fluid flows to 3 and out at port 4. Fluid then flows through
the Tilt Solenoid (TILT SOL) on the carriage. The SOL5B or SOL5T, depending on the direction of
TILT SOL allows fluid flow to the requested the function requested. SOL5 is a proportional
function. solenoid, but the VM sends a fixed voltage to it,
regulating the speed of the requested function.
NOTE: LS-1 also supplies a pilot pressure to
If more oil flows to SOL5 than is needed, back
REL2 to open the auxiliary relief if
pressure is present at port 4 of the POD valve.
pressure gets too high.
This shifts the spool of the POD valve and sends
the excess oil to SOL3 via port 2. SOL3 is open
Fluid flows through the energized TILT SOL and
to allow the excess oil to flow back to the filter
then to the tilt cylinder.
and reservoir. After leaving SOL5, the oil flows
to the LS-1. The LS-1 ports oil back to the POD
Reach/Retract
valve (at port 1) to help regulate the flow to the
auxiliary function. From LS-1, the fluid flows to
Reach extends the forks away from the mast.
the reach solenoid on the carriage. The
The reach/retract function can be configured to
Reach/Retract Solenoid allows fluid flow to the
have single speed reach/retract or two speed
requested function.
reach/retract. Single speed moves at the speed
of high-speed set in Config. NOTE: LS-1 also supplies a pilot pressure to
REL2 to open the auxiliary relief if
To use two speed reach, press S5 after pressing pressure gets too high.
S4. Doing this switches from low speed to
high-speed reach. For high speed retract, press Fluid flows through the energized Reach/
S5, then S4. Retract Solenoid and then to the reach cylinder.
High-speed or single-speed reach/retract: Sideshift

When the deadman pedal is pressed, the VM
sends a command via BUS+/BUS– to the LPA. Sideshift allows the operator to move the fork
The VM supplies B– to the MPC at JPC18-8, carriage to the left or right relative to the mast.
which closes the normally open contactor tips. The amount of sideshift is 2 or 4 in. (5 or 10 cm)
depending on the baseleg opening.
When the Reach Switch (S4) or the Retract
Switch (S5) is pressed, a circuit is completed to When the deadman pedal is pressed, the VM
the VM. sends a command via BUS+/BUS– to the LPA.
The VM supplies B– to the MPC at JPC18-8,
On lift trucks with two speeds selected, the VM closing the normally open contactor tips.
activates high speed when the other switch is
also pressed. When the Sideshift Right or Left Switch (S9 or
S8) is pressed, a circuit is completed to the VM.
NOTE: To change reach speed (high speed
versus low speed), the VM adjusts the
The VM energizes the following solenoids:
voltage to SOL5 to regulate the valve for
more or less flow. • SOL3 (Dump) at JPC20-12

• SOL5B at JPC20-20 or SOL5T at In order to operate reach or retract, S4 or S5 is

JPC20-18, depending on direction used to send an input to the VM at JPC12-4 or
• SIDESHIFT SOL at JPC18-14 JPC12-11.
Pump P1 rotates at a speed predetermined in When the request to lift and reach is made, the
software. Flow is ported to the POD valve at port VM energizes the following solenoids:
3 and out at port 4. Fluid then flows through • SOL3 (Dump) at JPC20-12
SOL5B or SOL5T, depending on the direction of • SOL5B at JPC20-20 or SOL5T at
the function requested. SOL5 is a proportional JPC20-18, depending on direction
solenoid, but the VM sends a fixed voltage to it,
regulating the speed of the requested function. • REACH SOL at JPC18-12
If more oil flows to SOL5 than is needed, back
pressure is present at port 4 of the POD valve. As Pump P1 begins to rotate, fluid flows into the
This shifts the spool of the POD valve and sends POD valve at port 3. The POD valve is used to
the excess oil to SOL3 via port 2. SOL3 is open bias flow between lift and aux. Port 3 is
to allow the excess oil to flow back to the filter connected to port 4. With pressure at port 4,
and reservoir. After leaving SOL5, the oil flows the pilot line moves the spool to allow flow to
to the LS-1. The LS-1 ports oil back to the POD both lift and aux.
valve (at port 1) to help regulate the flow to the
auxiliary function. From LS-1, the fluid flows to With the valve in this position, fluid flows to
the Sideshift Solenoid on the carriage. The Check Valve 1 (CV1). Fluid flows through CV1
Sideshift Solenoid allows fluid flow to the and passes through the free flow portion of the
requested function. flow limiters (located in the base of the lift
cylinders) and into the lift cylinders.
NOTE: LS-1 also supplies a pilot pressure to
REL2 to open the auxiliary relief if SOL3 (Dump) is used as a proportional relief to
pressure gets too high. limit system pressure to a safe level. With this
valve: 0V = 3500 psi (24132 kPa). The pressure
Lift while using Aux Functions relief is set by the VM and firmware at approx.
2V, which equals 3200 psi (22063 kPa).
The MPC is energized when the Deadman
Switch (DS1) is activated. The POD valve also meters fluid to the
requested aux function. As the metered flow
The VM internally supplies B– to the MPC at enters SOL5B or SOL5T (depending on the
JPC18-8, which closes the normally open direction of function requested), the voltage
contactor tips. applied to the valve by the VM causes it to open.
When the MPC coil is energized, the contactor SOL5 is a proportional solenoid. The VM sends
tips close, allowing B+ to be supplied to the a fixed voltage to it to open it a specific amount,
LPA, which supplies voltage to the Lift Motor. depending on the function requested.
When VR2 is moved to request lift, a voltage is The load shuttle sends pressure to the pilot line
sent to the VM at JPC12-2. The VM sees a of the POD valve to allow the valve to correctly
voltage different from the “LEARNed” neutral divide the fluid between lift and auxiliary.
voltage, and sends a request to the LPA via
BUS+/BUS– (JPC14-11 and JPC14-4 to When using auxiliary functions only (no lift),
JPL1-23 and JPL1-35). the speed of the motor is approx. 400 rpm. If
slow lift is used along with an auxiliary
The voltage supplied to the Lift Motor is function, the motor/pump speed may increase
proportional to the amount of lift requested due to the need for more fluid to the functions.
from VR2 (faster lift = higher motor voltage).
NOTE: The Lift Motor/pump is variable speed.

Hydraulic System Functional Operation - Regen Lower
Hydraulic System Aux Motor Temperature Sensor (AMT)
Functional Operation - The Aux Motor Temperature Sensor is mounted

internally in the Aux Motor. Its provides the Aux
Regen Lower Power Amplifier (APA) with the temperature of
the aux motor.
System Components Aux Pump (P2)
Lift Motor (LM) The aux pump rotates clockwise and supplies
oil flow and pressure for the aux functions.
The Lift Motor is a brushless, three-phase
internally delta connected variable-speed AC Hydraulic Filter
motor.
The hydraulic system has one filter in the
Lift Motor Encoder (LME) reservoir. All hydraulic fluid is filtered on the
return to the reservoir. There is an internal
The Lift Motor Encoder is a two-channel bypass (CV7) set at 43 psi (296 kPa).
encoder. It provides the lift power amplifier with
motor speed for motor speed regulation during Check Valve 7 (CV7)
lift and lower.
CV7 (located in the oil filter) opens when there
Lift Motor Temperature Sensor (LMT) is approx. 44 psi (303 kPa) on the oil filter to
allow return oil to bypass the filter so hydraulic
The Lift Motor Temperature Sensor is mounted function speeds are not reduced and the filter is
internally in the Lift Motor. Its purpose is to tell not ruptured.
the lift power amplifier the temperature of the
lift motor.
Main Lift System
Main Lift/Lower Pump (P1) The main lift system consists of four single
acting hydraulic cylinders. Hydraulic fluid flows
Pump P1 rotates clockwise and counter- from the main manifold through a tee-fitting in
clockwise and is used to control the speed for the tractor, through fittings in the left and right
all lift and lower functions. front of the tractor bulkhead. The right side
hose feeds the right side main lift cylinder. The
Aux Motor (AM) left side divides again at a tee-fitting, supplying
both the left side main lift cylinder and the free
The Aux Motor is a brushless, three-phase lift cylinders. At the bottom of the free lift
internally delta connected variable-speed AC cylinders, another tee-fitting divides the flow
motor. between left and right free lift cylinders. A flow
limiter is installed at one of the free lift and one
Aux Motor Encoder (AME) or both of the main lift cylinders.
The Aux Motor Encoder is a two-channel When the operator requests lift, the entire lift
encoder. It provides the Aux Power Amplifier system is pressurized. Since the carriage
(APA) with motor speed for motor speed weighs less than the carriage plus telescopic,
regulation during aux functions. the free lift cylinders extend first, elevating the
carriage. When they reach the limit of their
travel, the main lift cylinders extend, elevating
the telescopics.

Load Holding Valve (SOL1) manifold on the tractor. Then through the
manifold and out port A1 tractor or A2 tractor,
The load holding valve is a normally closed depending on the direction the aux function
solenoid valve used to hold the carriage and was requested to move. Fluid then flows
telescopics in an elevated position. through the over-the-mast hose and into the
aux manifold on the carriage at port A1 carriage
Proportional Lower Valve (SOL2) or A2 carriage. Fluid then flows through a tee in
the manifold which allows flow to all three aux
The proportional lower valve is a pressure solenoid valves, Reach, Tilt and Sideshift. Fluid
compensated flow control solenoid valve used to then flows through the solenoid valve that was
lower the carriage and telescopics. energized and leaves the aux manifold on the
carriage at port SSR, SSL, RC, RR, TC or TR
Flow Limiter Valve through the hoses on the carriage into one of
the double acting cylinders, moving the cylinder
Flow limiter valves are used to limit the in the requested direction.
maximum lower speed of the carriage. A pilot
port forces restricted flow through the restricted Reach/Retract Cylinder
portion of the valve during lower once flow
reaches 15 gpm (56.8 lpm); it is then limited to The reach/retract cylinder is a double-acting
4 to 5 gpm (15.1 to 18.9 lpm). A spring and pilot hydraulic cylinder used for extending and
port keep the restricted portion of the valve retracting the forks.
closed, allowing free flow during lift.
Sideshift Cylinder
Check Valve 1 (CV1)
The sideshift cylinder is a double-acting
CV1 acts as a suction line to the pump and hydraulic cylinder used to shift the load left and
routes lowering return oil through the hydraulic right with respect to the mast.
filter.
Tilt Cylinder
Check Valve 2 (CV2)
The tilt cylinder is a double-acting hydraulic
CV2 prevents aux system return oil from cylinder used to tilt the forks up and down.
entering the lift system. It also maintains a
system pressure of 15 psi (103 kPa) when a SOL5B/SOL5T
lower request is removed for pump
pre-pressurization. SOL5 is a directional solenoid valve providing
directional control to the reach, tilt, and
Check Valve 5 (CV5) sideshift functions. De-energized, flow is
directed to the reservoir. When SOL5B is
CV5 allows pre-pressurization of the system to energized, flow is directed to port A1 for tilt up,
transition from a lower to a lift command. sideshift right, or reach. When SOL5T is
energized, flow is directed to port A2 for tilt
Check Valve 6 (CV6) down, sideshift left, or retract.
CV6 allows oil to bypass SOL1 and SOL2 during Reach/Retract Solenoid (REACH SOL)
lift to reduce flow resistance.
REACH SOL is a normally closed solenoid valve
Auxiliary System used to block (de-energized) or allow (energized)
fluid flow to and from the reach cylinder.
The auxiliary system consists of up to three
double acting hydraulic cylinders. Hydraulic
fluid flows from the aux pump into the aux

Sideshift Solenoid (SIDESHIFT SOL) When VR2 is moved to request lift, a voltage is
sent to the VM at JPC12-2. The VM sees a
SIDESHIFT SOL is a normally closed solenoid voltage different from the “LEARNed” neutral
valve used to block (de-energized) or allow voltage, and sends an RPM request to the lift
(energized) fluid flow to and from the sideshift power amplifier via BUS+/BUS– (JPC14-11 and
cylinder. JPC14-4 through the display to JPL1-23 and
JPL1-35).
Tilt Solenoid (TILT SOL)
The VM supplies B– to the Main Pump
TILT SOL is a normally closed solenoid valve Contactor (MPC) coil at JPC18-8, that closes the
used to block (de-energized) or allow (energized) normally open contactor tips.
fluid flow to and from the tilt cylinder.
The MPC coil is energized when the Deadman
Aux Relief Valve (RV4) Switch (DS1) is activated.
RV4 is a relief valve used to protect auxiliary When the MPC is energized, the contactor tips
system components against excessive pressure. close, allowing B+ to be supplied to the LPA,
It is factory-adjusted to 2000 psi (13790 kPa). that supplies voltage to the Lift Motor to make it
rotate.
Check Valve 3 (CV3)
With the pump turning, oil is drawn from the
CV3 allows oil to return to the reservoir on reservoir, opening CV-1. The pressure caused
Deep-Reach trucks if the forks hit an by the pump moves the spool in the valve to
obstruction when reach is extended. allow flow through CV-6, SOL2, and SOL1,
through the flow limiters in the base of the lift
Check Valve 4 (CV4) cylinders, and into the lift cylinders, producing
lift.
CV4 prevents return flow from the aux or lift
system from entering the pressure port of the When the lift knob is returned to neutral, the
P2 pump. Lift Motor is ramped down. When the pump
stops turning, CV-1 and CV-6 return to their
normally closed state.
Theory of Lift/Aux Functions
Lower
Lift
When VR2 is moved to request lower, a voltage
Lift speed varies directly with Lift Motor rpm.
is sent to the VM at JPC12-2. The VM sees a
The voltage supplied to the Lift Motor is
voltage different from the “LEARNed” neutral
proportional to the amount of lift request from
voltage, and determines how to respond. If the
VR2 (faster lift = higher motor voltage).
request is for less than ½ speed lower, the VM
Maximum lift speed for a given weight load is
energizes SOL1 and varies the voltage to SOL2
governed by software.
to control the lowering speed. Once the
requested speed is greater than ½ of full
Weight is calculated from inputs to the VM from
lowering speed, SOL2 is opened fully and
the pressure transducer. Weight of the empty
lowering speed is controlled by the Lift Motor
carriage and telescopic is calculated during
rpm. The voltage supplied to the Lift Motor is
LEARN Mode.
proportional to the amount of lower request
from VR2. The VM sends a request to the lift
Prior to requesting a lift, all valves are in the
power amplifier via BUS+/BUS– (JPC14-11 and
de-energized state.
JPC14-4 through the display to JPL1-23 and
JPL1-35). The VM supplies B– to the Main

Pump Contactor Coil (MPC) at JPC18-8, closing ON/OFF solenoid. After leaving SOL5, the oil
the normally open contactor tips. flows to the Tilt Solenoid (TILT SOL) on the
carriage. The TILT SOL allows fluid flow to the
The MPC is energized when the Deadman cylinder. The APA monitors AM speed from the
Switch (DS1) is activated. inputs supplied by the Aux Motor Encoder
(AME) at JPA1-31 and JPA1-32 and adjusts the
When the MPC is energized, the contactor tips voltage to the AM as required to match the
close, allowing B+ to be supplied to the LPA, requested rpm.
supplying voltage to the Lift Motor to make it
rotate at the requested speed. Reach/Retract
Oil flows from the lift cylinders through the now Reach extends the forks away from the mast.
energized SOL1 and SOL2, through the lift The reach/retract function can be configured to
pump (spinning the lift motor backwards), have single speed reach/retract or two speed
through CV2, and back to the reservoir. As the reach/retract. Single speed moves at the speed
motor spins backwards, voltage/current flow is of high-speed.
created. When this happens, the LPA diverts
this regenerated voltage/current flow back to Two speed reach/retract has two selections in
the battery where it is absorbed by (charges) the the Config Menu, lo/hi and hi/lo. Two speed
battery. When the lower request is removed, reach is activated by pressing S5 after pressing
SOL1 and SOL2 are de-energized. When system S4. Doing this switches from low speed to high
pressure reaches approximately 15 psi speed reach if the truck is configured for lo/hi.
(103 kPa), CV2 returns to its normally closed If the truck is configured for hi/lo, pressing S5
state, keeping 15 psi (103 kPa) at the lift pump after pressing S4 switches from high speed to
to make sure that the lift pump remains full of low speed. To change retract speed, press S5,
oil. The 15 psi (103 kPa) is enough to keep CV5 then S4.
open. It remains open until a lift request is
made and it is forced closed by the lift pump High-speed or single-speed reach/retract:
spinning.
When the Reach Switch (S4) or Retract Switch
Auxiliary Functions (S5) is pressed, DGND is sent to the VM at
JPC12-4 or JPC12-11. The VM sees the voltage
Tilt go low and sends an rpm request to the Aux
Power Amp via BUS+/BUS– (JPC14-11 and
When the Tilt Up Switch (S6) or Tilt Down JPC14-4, through the display to JPA1-23 and
Switch (S7) is pressed, DGND is sent to the VM JPA1-35. The VM also energizes the following
at JPC12-5 or JPC12-6. The VM sees the components:
voltage go low and, based on software, sends an • SOL5B at JPC18-9 or SOL5T at JPC18-1,
rpm request to the Aux Power Amp via depending on direction
BUS+/BUS– (JPC14-11 and JPC14-4, through • REACH SOL at JPC18-12
the display to JPA1-23 and JPA1-35. The VM
also energizes the following components: The APA supplies voltage to the AM based on
• SOL5B at JPC18-9 or SOL5T at JPC18-1, the settings in the Config menu. Pump P2
depending on direction rotates at the speed commanded by the APA.
• TILT SOL at JPC18-15 Fluid then flows through SOL5B or SOL5T,
depending on the direction of the function
The APA supplies voltage to the AM to meet the requested. SOL5 is an ON/OFF solenoid. After
required rpm. Pump P2 rotates at the speed leaving SOL5, the oil flows to the Reach
commanded by the APA. Fluid then flows Solenoid (REACH SOL) on the carriage. The
through SOL5B or SOL5T, depending on the REACH SOL allows fluid flow to the cylinder.
direction of the function requested. SOL5 is an The APA monitors AM speed from the inputs
supplied by the Aux Motor Encoder (AME) at

JPA1-31 and JPA1-32 and adjusts the voltage

to the AM as required to match the requested
rpm.
Sideshift
When the Sideshift Left Switch (S8) or Sideshift

Right Switch (S9) is pressed, DGND is sent to
the VM at JPC12-8 or JPC12-9. The VM sees
the voltage go low and, based on software,
sends an rpm request to the Aux Power Amp via
BUS+/BUS– (JPC14-11 and JPC14-4, through
the display to JPA1-23 and JPA1-35. The VM
also energizes the following components:
• SOL5B at JPC18-9 or SOL5T at JPC18-1,
depending on direction
• SIDESHIFT SOL at JPC18-14
The APA supplies voltage to the AM to meet the

required rpm. Pump P2 rotates at the speed
commanded by the APA. Fluid then flows
through SOL5B or SOL5T, depending on the
direction of the function requested. SOL5 is an
ON/OFF solenoid. After leaving SOL5, the oil
flows to the Sideshift Solenoid (SIDESHIFT SOL)
on the carriage. The SIDESHIFT SOL allows
fluid flow to the cylinder. The APA monitors AM
speed from the inputs supplied by the Aux
Motor Encoder (AME) at JPA1-31 and JPA1-32
and adjusts the voltage to the AM as required to
match the requested rpm.

Electric Brake Operation
Electric Brake Operation

Overview
This truck uses an electric brake. With the
brake coil de-energized, the brake is in a
“normally applied” state due to spring pressure.
With the brake coil energized, the brake is held
in a released state due to magnetic force.
Brake Release
When the deadman pedal is pressed, the brake
coil is energized. The current flow creates a
magnetic field that draws the armature plate
against the coil body, compressing the brake
coil springs. The carrier and pads, attached to
the Traction Motor shaft, are free to rotate.
Brake Application
If the lift truck is traveling when the deadman
pedal is released, the VM causes the lift truck to
plug to a stop. When the VM senses the lift
truck has stopped, it de-energizes the brake
coil. The magnetic field holding the brake
released now collapses. The springs in the
brake coil push the armature plate down on the
top of the carrier and pads. The brake pads
pressed between the armature plate and the
adapter plate prevent the Traction Motor shaft
from rotating.
Brake Release Screws

Two brake release screws are stored near the
brake coil body. These screws are used when
unpowered travel (towing) is necessary or when
disassembling the brake itself. The brake
release bolts are threaded into the armature
plate. The screws pull the armature plate up,
overcoming the spring pressure.

Cold Storage
Cold Storage
On trucks with the Cold Storage option, the VM
looks at the Ambient Temperature Sensor
mounted on the overhead guard. If the
temperature indicates the truck is parked
inside the freezer, the VM does not turn off the
RELAY_ENABLE circuit when the key switch is
opened. When the key switch is turned OFF,
K1, K2, and K3 all open because they are
powered from the key switch. The K4 coil and
tips receive power directly from the battery
through FU5. When the tips are closed, K4
supplies B+ to internal circuitry of the VM. This
is only used on trucks equipped with the Cold
Storage option. The VM uses the input from the
K4 tips to keep its circuitry powered up. This is
done so the VM can keep the circuitry activated
for the control handle heater. The display is
shut down and no other functions are operable
until the key is turned ON and the truck is
powered up.
On Regen Lower trucks equipped with the Cold

Storage option, cooling fans are powered on
below 51°F (10.5°C).

Pinout Matrix
Pinout Matrix • Normal Level: the approximate voltage

that you should see on that wire for the
state indicated. Unless otherwise
The pinout matrix table lists functions and indicated, voltages are Direct Current (DC)
normal voltages of terminals and harness and are measured with respect to (wrt) B–
connector pins. The matrix columns have the at TP4.
following meanings:
• Signal Source: the device or connection
• Item #: sequential number to aid in that supplies the signal directly to the
reference. wire.
• Connection: the actual wire numbers or • Signal User: the device or connection to
component abbreviations on the electrical which the wire directly delivers the signal.
schematic.
• Function Description: brief definition of
the signal carried on the wire.
• Theory of Operation:
• A detailed description of the signal
carried on the wire. If the signal is
variable, it indicates the state of a
related component that causes the
signal to vary.
• Identifies possible causes for lack of
correct signal.
Table 8-1. Pinout Matrix
Function Signal Signal

Item Connection Theory of Operations Normal Level
Description Source User
B+ to the APA used to pre-charge the

APA B+ amplifier and produce the AC phases U, V,
1 APA B+ B+ MPC APA
(Regen only) and W to the Aux Motor. Voltage increases
from 0V to B+ as the amplifier charges.
B– from TP4 on the Power Panel. Used for

APA B– APA power circuits. Without B–, U, V, and Battery Voltage
2 APA B– TP4 APA
(Regen only) W cannot be produced and the Aux Motor wrt B+
will not operate.
B+ present when K3 is energized. This is

used to power the control circuits of the
JPA1-1 APA. It is also used by the APA to produce K3 energized:
3 B+K3 K3 APA
(Regen only) +5V for the A Vel Sensor+ and the internal B+
circuits of the APA. If voltage is not present,
check K3 coil and tip circuit.
JPA1-7 Battery Voltage DGND on

4 I/O GND Return path for the AME and AMT. AME, AMT
(Regen only) wrt B+ VM
Analog voltage that varies with the aux

JPA1-8 motor temperature. Used by the APA to 75°F (24°C):
5 A TEMP+ AMT APA
(Regen only) adjust motor performance when a motor approx. 1V
overtemp condition exists.

Pinout Matrix

Carries the positive component of the

digital communications between all devices
JPA1-23
6 BUS_1+ on the CAN-Bus. Troubleshoot using Test 2.94V CAN-Bus CAN-Bus
(Regen only)
I23. No useful information can be gained
by measuring the voltage on this wire.
JPA1-26 A VEL
7 +5V supply to the Aux Motor Encoder. 5.0V APA AME
(Regen only) SENSOR+
This square wave is generated whenever

there is movement of the AME. The
frequency varies directly with the speed of Motor
JPA1-31 A VEL the Aux Motor. Identical formation to A Vel Stationary: >4V
8 AME APA
(Regen only) PHASE A Phase B, except for the phasing between or <1V;
the two. The APA uses the quadrature phase Turning: 2V
relationship between Phases A and B to
determine aux motor speed.

there is movement of the AME. The
JPA1-32 A VEL the Aux Motor. Identical formation to A Vel Stationary: >4V
9 AME APA
(Regen only) PHASE B Phase A, except for the phasing between or <1V;
the two. The APA uses the quadrature phase Turning: 2V
determine aux motor speed.
Carries negative component of the digital

communications between all devices on the
JPA1-35
10 BUS_1– CAN-Bus. Troubleshoot using Test I23. No 2.2V CAN-Bus CAN-Bus
(Regen only)
useful information can be gained by
measuring the voltage on this wire.
B– supply from the Display to the Height Battery Voltage Height

11 JPBD1-1 DGND Display
Encoder (via JPD2-2). wrt B+ Encoder
“Transmit” component of the digital

No usable Cellular
12 JPBD1-2 TX communication between the Display and Display
voltage Modem
Cellular Modem.
Battery Voltage
13 JPBD1-4 DGND B– supply from TP4 to the Display. TP4 Display
wrt B+
B+ supply from TP1 (via FU39) to the

14 JPBD1-7 B+_FU39 B+ TP1 Display
Display.
“Receive” component of the digital

No usable Cellular
15 JPBD1-8 RX communication between the Display and Display
voltage Modem
Cellular Modem.
B– supply from the Display to the Cellular Battery Voltage Cellular

16 JPBD1-10 DGND Display
Modem. wrt B+ Modem

Pinout Matrix

Channel A is one part of the fork height

position feedback from the Height Encoder Not turning:
(via JPD2-3). It is a square wave (0V and >4.5V or
4.5V) identical to Channel B, but a different <0.5V; Height
17 JPBD1-13 CHANNEL A Display
phase. The Display uses the phase Turning either Encoder
relationship of the two channels to direction:
determine the direction and speed of the approx. 2.5V
carriage.
Battery Voltage
18 JPBD1-14 PLC_GND B– supply from TP4 to the Display. TP4 Display
wrt B+
Positive component of the digital

19 JPBD1-17 BUS_1+ CAN-Bus. Troubleshoot using Test I23. No Approx. 2.5V CAN-Bus CAN-Bus
Output from the Tilt Pressure Switch (S18) to Tilted: B+ wrt

20 JPBD1-18 TILT PRESS the Display (via JPD2-9) to indicate when TP1 S18 Display
the forks are level. Not Tilted: 0V
Channel B is one part of the fork height

position feedback from the Height Encoder Not turning:
(via JPD2-4). It is a square wave (0V and >4.5V or
4.5V) identical to Channel A, but a different <0.5V; Height
21 JPBD1-19 CHANNEL B Display
phase. The Display uses the phase Turning either Encoder
relationship of the two channels to direction:
determine the direction and speed of the approx. 2.5V
carriage.
B– supply from the Display to the Tilt Battery Voltage

22 JPBD1-20 DGND Display S18
Pressure Switch (S18) via JPD2-10. wrt B+
B+ supply from TP1 (via FU39) to the

23 JPBD1-21 PLC B+ TP1 Display
Display.
Negative component of the digital

24 JPBD1-23 BUS_1– CAN-Bus. Troubleshoot using Test I23. No Approx. 2.5V CAN-Bus CAN-Bus
+12V supply from the VM to the Display

25 JPBD1-24 +12VD 10.5 to 13V VM Display
(via JPD1-5).
B– supply from the Display to the CAN I/O Battery Voltage

26 JPBD1-25 DGND Display OCSS
Expander Module (OCSS) via JPD1-4. wrt B+
+5V supply from the Display to the Height Height

27 JPBD1-26 +5VD 5V Display
Encoder via JPD2-1. Encoder
Dash Panel
28 JPBD2-1 VBUS +5V supply to Dash Panel Assembly 5V Display
Assembly

Pinout Matrix

Carries the negative component of the USB

communications. No useful information can
29 JPBD2-2 D– N/A
be gained by measuring the voltage on this Navigatio
wire. n Buttons,
Display
Carries the positive component of the USB Badge
communications. No useful information can Reader
30 JPBD2-3 D+ N/A
be gained by measuring the voltage on this
wire.
Battery Voltage Dash Panel

31 JPBD2-4 DGND DGND to Dash Panel Assembly Display
wrt B+ Assembly
32 JPC3-1 thru 4 USB Communications Port
+5V supply to the solid state potentiometer

Secondary
and switch in the optional Secondary
33 JPC4-1 +5VP 5±0.25V VM Control
Control Handle. Measure wrt DGND
Handle
JPC12-12.
Reference for the switches and

Secondary
potentiometer in the optional Secondary Battery Voltage
34 JPC4-2 DGND VM Control
Control Handle. If this voltage is not correct, wrt B+
Handle
intermittent handle codes may appear.
S10 open: Secondary

Input to the VM from horn button (S10) in
35 JPC4-3 S_HORN >4.5V; Control VM
the optional Secondary Control Handle.
Closed: <0.5V Handle
Input to the VM from the wiper of the Neutral: 1.1V; Secondary

36 JPC4-4 S_THROTTLE Secondary Control Handle potentiometer. Full TF: 1.6V; Control VM
Measure wrt DGND JPC4-2. Full FF: 0.5V Handle
Deadman Up:
4.6V;
NEUTRAL_ This input tells the VM that the steer CCW steer: 0V; Steer
37 JPC6-1 VM
PULSE amplifier is connected and functioning. CW steer: 4.5V; Amplifier
No steering:
voltage varies
Steering CW:
This is a control voltage used to rotate the 11.6V;
drive unit in the CW direction. The average At rest: 11.5V; Steer
38 JPC6-2 CW_PWM VM
DC value varies, depending on the amount Steering CCW: Amplifier
and speed of steering requested. 9V slow
5V fast
Analog voltage which varies with the steer Steering CW:

motor current and is sent from the steer 3.0V;
STEER_ Steer
39 JPC6-3 amplifier to the VM. This voltage is used by At rest: 2.5V; VM
CURRENT Amplifier
the VM to establish current reading for Steering CCW:
opens or shorts in the steer system. 2.1V
Reference for the control circuits in the steer

Battery Voltage Steer
40 JPC6-4 DGND amplifier. If missing, the steer amplifier does VM
wrt B+ Amplifier
not power up.

Pinout Matrix

Steering CCW:
This is a control voltage used to rotate the 11.6V;
drive unit in the CCW direction. The At rest: 11.5V; Steer
41 JPC6-5 CCW_PWM VM
average DC value varies depending on the Steering CW: Amplifier
amount and speed of steering requested. 9V slow
5V fast
Operating voltage from the VM for the

Steer
42 JPC6-6 +12V control circuits in the steer amplifier. If this is 10.7 to 13V VM
Amplifier
missing, the steering is inoperable.
43 JPC9 FlashWare Connection
Input to the VM when the Aux Start Switch Switch open:

44 JPC10-2 AUX START (S23) is closed, allowing the truck to start 5V; S23 VM
when the option is enabled. Closed: <0.5V
Voltage from the VM to the Thermakit

Control Card to control heaters in the ON: <0.5V;
45 JPC10-3 THERM_EN VM Heaters
Primary and Secondary Control Handles OFF: >10.5V
and heated floor pad.
Battery Voltage
46 JPC10-4 DGND B– supply to S23 from the VM. VM S23
wrt B+
Encoder
+12V supply to Steer Encoder 1. Used as a
connected: 9V; Steer Tiller
47 JPC10-6 +12V_EN1 connect detect to verify the Steer Tiller VM
Disconnected: Encoder
Encoder is connected to the VM.
10.7 to 13V
Encoder
+12V supply to Steer Encoder 2. Used as a
connected: 9V; Steer Tiller
48 JPC10-7 +12V_EN2 connect detect to verify the Steer Tiller VM
Disconnected: Encoder
Encoder is connected to the VM.
10.7 to 13V
Steer
Battery Voltage
49 JPC10-9 DGND B– for the Steer Motor Encoder. VM Motor
wrt B+
Encoder
+5V supply to the solid state potentiometers

Primary
and switches in the Primary Control Handle.
50 JPC12-1 +5VP 4.9V VM Control
If this is <4.75V, the handle will not function
Handle
correctly. Measure wrt DGND at JPC12-12.
Neutral: 1.0V;
Input to the VM from the wiper of the
Full Lower:
51 JPC12-2 LIFT primary lift pot (VR2). Measure wrt DGND VR2 VM
1.84V;
at JPC12-12.
Full Lift: 0.30V
Input to the VM from the wiper of the Neutral: 1.2V;

52 JPC12-3 P_THROTTLE primary throttle pot (VR1). Measure wrt Full FF: 1.9V; VR1 VM
DGND at JPC12-12. Full TF: 0.45V
Input to the VM from the reach switch (S4). S4 open:

Note: When other aux function switches >4.0V;
53 JPC12-4 REACH S4 VM
are activated, reading can change by as S4 closed:
much as 0.5V. <0.5V

Pinout Matrix

S6 open:
>4.0V;
54 JPC12-5 TILT_UP Input to the VM from the tilt up button (S6). S6 VM
S6 closed:
<0.5V
S7 open:
Input to the VM from the tilt down button >4.0V;
55 JPC12-6 TILT_DOWN S7 VM
(S7). S7 closed:
<0.5V
OFF: <0.5V; Primary

56 JPC12-7 H_HTR DC supply to handle heater (HTR6). ON: 7.5 to VM Control
8.5V Handle
S8 open:
Input to the VM from the sideshift left button >4.0V;
57 JPC12-8 SSHIFT_LEFT S8 VM
(S8). S8 closed:
<0.5V
S9 open:
Input to the VM from the sideshift right >4.0V;
58 JPC12-9 SSHIFT_RIGHT S9 VM
button (S9). S9 closed:
<0.5V
Input to the VM from the primary control S3 open:

handle horn switch (S3). Note: When >4.0V;
59 JPC12-10 P_HORN S3 VM
other aux function switches are activated, S3 closed:
reading can change by as much as 0.5V. <0.5V
Input to the VM from the retract switch (S5). S5 open:

Note: When other aux function switches >4.0V;
60 JPC12-11 RETRACT S5 VM
are activated, reading can change by as S5 closed:
much as 0.5V. <0.5V
Reference for all switches and

potentiometers in the primary control Primary
61 JPC12-12 DGND handle. If this voltage is not <0.5V wrt TP4 VM Control
on the power panel, then intermittent Handle
handle codes may appear.
This connects B–F on the VM to TP4 (B–)

62 JPC14-1 B–F FRC VM
through FU6 on the Fuse/Relay Card (FRC). Battery Voltage
This connects DGND and AGND on the VM wrt B+

to TP4 (B–) through FU6 on the Fuse/Relay
63 JPC14-2 DGND Card. This is the reference for all circuits on FRC VM
the truck that are referenced to either
DGND or AGND.
Reference for the control circuits in the

64 JPC14-3 DGND VM Display
display.

communications from the VM. Troubleshoot
65 JPC14-4 BUS_1– using Test I23. No useful information can 2.24V VM CAN-Bus
be gained by measuring the voltage on this
wire.

Pinout Matrix

Operating voltage from the VM to the

66 JPC14-5 +12VD +10.5 to 13V VM Display
display.
Control path for K1, K2, K3, and K4 on the

Fuse/Relay Card. After S1 is closed, all Relays OFF: B+; K1, K2,
RELAY_
67 JPC14-6 relays are energized simultaneously during Relays ON: VM K3, and
ENABLE
SelfTest if the voltage at Battery_Sense_In is <3.0V K4
at an acceptable level.
B+ provided to the VM when K4 is closed.

This voltage is used to power the heaters in
Cold
cold storage trucks. If the Ambient Temp K4 closed: B+;
68 JPC14-7 B+K4 K4 Storage
Sensor detects <40°F, the VM keeps this K4 open: 0.2V
heaters
circuit ON to power the heaters, even with
the Key Switch turned OFF.
Connects DGND and AGND on the VM to

TP4 (B–) through FU6 on the Fuse/Relay
69 JPC14-8 B–F Card. This is the reference for all circuits on FRC VM
DGND or AGND.

Battery Voltage
70 JPC14-9 B–F Card. This is the reference for all circuits on FRC VM
wrt B+
DGND or AGND.

71 JPC14-10 DGND Card. This is the reference for all circuits on FRC VM
DGND or AGND.
Carries positive component of the digital

72 JPC14-11 BUS_1+ CAN-Bus. Troubleshoot using Test I23. No 2.8V CAN-Bus CAN-Bus
B+ that is switched by Key Switch (S1) and

used to power functions on the VM that are
initiated after S1 is closed, and are not S1 closed: B+;
73 JPC14-12 B+KEY S1 VM
affected by the EPO. This includes the VM S1 open: 0.3V
power supplies and the operation of the
microprocessor.

This voltage is used to power the hydraulic K2 closed: B+; Hydraulic
74 JPC14-13 B+K2 K2
solenoids on the tractor. They are K2 open: 0.3V Solenoids
de-energized when the EPO is open.

This voltage is used to power the hydraulic K2 closed: B+; Hydraulic
75 JPC14-14 B+K2 K2
solenoids on the tractor. They are K2 open: 0.3V Solenoids
de-energized when the EPO is open.

Pinout Matrix

De-energized:
Control path for directional solenoid
JPC18-1 B+
76 AUX1 (SOL5T) for the aux functions on trucks with VM SOL5T
(Regen only) Energized: 20
Regen Lower.
to 25V
Reference for Channel 1 of the Steer Tiller Steer Tiller

77 JPC18-5 DGND VM
Encoder. Encoder
Battery Voltage
Reference for Channel 2 of the Steer Tiller Steer Tiller
78 JPC18-6 DGND wrt B+ VM
Encoder. Encoder
79 JPC18-7 DGND Reference for the Deadman Switch (DS1). VM DS1
Contactor
Open: B+;
Control path for the Main Power Contactor
MAIN_ Closed: 0V for
80 JPC18-8 (MPC) that is supplied B– by the VM to VM MPC
CONTACTOR 2 to 3 seconds,
close the contactor.
then approx.
12V
De-energized:
JPC18-9 B+;
81 AUX2 (SOL5B) for the aux functions on trucks with VM SOL5B
(Regen only) Energized: 20
Regen Lower.
to 25V
De-energized
Control path for the Load Holding solenoid
(K2 closed): B+;
82 JPC18-10 L/H (SOL1) that is switched to B– by the VM to VM L/H SOL1
Energized:
energize the L/H solenoid coil (lowering).
13.3V
Contactor
Control path for the Steer Contactor (STR)
STR_ Open: B+;
83 JPC18-11 that is supplied B– by the VM to close the VM STR
CONTACTOR Closed: approx.
contactor.
12V
De-energized
(K2 closed): B+; Reach
84 JPC18-12 REACH_SOL Control path for Reach solenoid coil. VM
Energized: Solenoid
13.2V
De-energized
SIDESHIFT_ (K2 closed): B+; Sideshift
85 JPC18-14 Control path for Sideshift solenoid coil. VM
SOL Energized: Solenoid
13.1V
De-energized
(K2 closed): B+; Tilt
86 JPC18-15 TILT_SOL Control path for Tilt solenoid coil. VM
Energized: Solenoid
13.1V
De-energized
Control path for the horn that is switched to (K2 closed): B+;
87 JPC18-16 HORN VM Horn
B– by the VM to energize the horn. Energized:
0.02 V
De-energized
Control path for the amplifier and motor
(K2 closed): B+;
88 JPC18-17 FAN compartment fans that are controlled VM Fans
Energized:
together by the VM.
0.09V

Pinout Matrix

B– supply from the VM to turn ON the Alarm ON: 0V; Travel Light
89 JPC18-18 ALARM VM
optional travel light and alarm. Alarm OFF: B+ and Alarm
+12V supply for 1st Speed Limiting Switch

90 JPC20-1 +12VP VM S12
(S12).
+12V supply to the Deadman Switch 1

91 JPC20-2 +12VP VM DS1
(DS1).
+12V supply for the optional High Speed

92 JPC20-3 +12VP VM S25
Travel Switch (S25).
Pressure
93 JPC20-4 +12VP +12V supply for the Pressure Transducer. VM
Transducer
+12V supply for the optional Lift Cutout

94 JPC20-6 +12VP VM S27
Switch (S27). 10.7 to 13V
Steer
95 JPC20-7 +12VP +12V supply for the Steer Motor Encoder. VM Motor
Encoder
Thermakit
+12V supply for the optional Cold Storage
96 JPC20-8 +12VP VM Control
Comfort Package.
Card
97 JPC20-9 +12VP +12V supply to the Steer Limit Switch (S11). VM S11
+12V supply to the Right Battery Gate

98 JPC20-10 +12VP VM S58
Switch (S58).
Control path for SOL3, a combination De-energized:

proportional relief and dump valve. This is B+;
used both as a variable system relief and to When lift
dump oil back to the reservoir when lift is request stops:
99 JPC20-12 DUMP VM SOL3
no longer requested and the Lift Motor/ 12V for 1 to 2
pump is slowing down. This permits seconds;
immediate lower without waiting for the Aux functions
pump to stop turning. energized: 24V
100 JPC20-13 B+DUMP B+ from K2 to SOL3. B+ VM SOL3
Brake ON: B+;

Control path for the electrically released
101 JPC20-14 BRAKE Brake OFF: 0V VM Brake
brake on the Traction Motor.
at first, then 9V
102 JPC20-15 B+L/L B+ supplied to SOL2 when K2 is energized. B+ VM SOL2
De-energized:
B+;
Control path for the Lift/Lower Solenoid No lower:
103 JPC20-16 L/L SOL2. Voltage present during lower 37.6V varies VM SOL2
depends on the lower request from VR2. proportionally to
Full lower:
18.8V
104 JPC20-17 B+AUX1 B+ supply for SOL5T solenoid. B+ VM SOL5T

Pinout Matrix

De-energized:
B+
105 JPC20-18 AUX1 (SOL5T) for the aux functions on trucks with VM SOL5T
Energized: 20
a DC Aux motor.
to 25V
106 JPC20-19 B+AUX2 B+ supply for SOL5B solenoid. B+ VM SOL5B
De-energized:
B+;
107 JPC20-20 AUX2 (SOL5B) for the aux functions on trucks with VM SOL5B
Energized: 20
a DC Aux motor.
to 25V
Used by the VM to determine when the Telescopics

SPEED_LIMIT_ telescopic is unnested. Speed is reduced at nested: <0.5V;
108 JPC22-1 S12 VM
1 this point to the value set in Configure Telescopics
Mode. unnested: >4V
Used by the VM to determine when the

BATTERY GATE
109 JPC22-3 Right Battery Gate is in place (S58 is S58 VM
RT SW
closed). Open: 5V;
Input to the VM to determine when the Closed: 0V
HS TRAVEL
110 JPC22-4 carriage is above the high speed travel S25 VM
SW
switch (S25).
Channel_A_1 is one part of the steering

request from the Steer Tiller Encoder on
electric steer trucks when the steering tiller is >4.5V or <0.5V
moved. It is a square wave (0V and 4.5V) when tiller
CHANNEL_A_ identical to Channel_B_1 but different stationary. DC Steer Tiller
111 JPC22-5 VM
1 phase. The VM uses the phase relationship value when Encoder
of the two channels to determine the turning handle
direction and speed of the steering request. approx. 2.5V
When the tiller is stationary, the voltage can
be either high or low.
Input to the VM to determine when the

LIFT CUTOUT
112 JPC22-6 carriage is above the Lift Cutout switch S27 VM
SW Open: 5V;
(S27).
Closed: 0V
BATTERY GATE Input to the VM to determine when the Left
113 JPC22-7 S57 VM
LT SW Battery Gate is in place (S57 is closed).
Input to the VM from the Deadman Switch

(DS1). This is used by the VM to determine
Released: >4V;
114 JPC22-8 DEADMAN DS whether to ignore or comply with other DS1 VM
Pressed: <0.5V
operational requests from either of the
control handles.

Pinout Matrix

ChannelA_4 is one part of the steering

position feedback from the Steer Motor
Encoder when the drive unit is rotated. It is
a square wave (0V and 4.5V) identical to
Not turning: 0V
ChannelB_4 but different phase. The VM Steer
or 4.5V;
115 JPC22-9 CHANNELA_4 uses the phase relationship of the two Motor VM
Turning either
channels to determine that the direction and Encoder
direction: 2.5V
speed of the steering response is the same
as that requested. When the drive unit is
stationary, the voltage can be either high or
low.
ChannelB_4 is one part of the steering

position feedback from the Steer Motor
Encoder when the drive unit is rotated. It is
a square wave (0V and 4.5V) identical to
Not turning: 0V
ChannelA_4 but different phase. The VM Steer
or 4.5V;
116 JPC22-10 CHANNELB_4 uses the phase relationship of the two Motor VM
Turning either
channels to determine that the direction and Encoder
direction: 2.5V
speed of the steering response is the same
as that requested. When the drive unit is
stationary, the voltage can be either high or
low.
Battery Voltage
117 JPC22-11 DGND Reference for Steer Limit Switch (S11). VM S11
wrt B+
Channel_B_1 is one part of the steering

electric steer trucks when the steering tiller is Not turning:
moved. It is a square wave (0V and 4.5V) >4.5V or
CHANNEL_B_ identical to Channel_A_1 but different <0.5V; Steer Tiller
118 JPC22-12 VM
1 phase. The VM uses the phase relationship Turning either Encoder
of the two channels to determine the direction:
Channel_A_2 is one part of the steering

CHANNEL_A_ identical to Channel_B_2 but different <0.5V; Steer Tiller
119 JPC22-13 VM

Pinout Matrix

Channel_B_2 is one part of the steering

CHANNEL_B_ identical to Channel_A_2 but different <0.5V; Steer Tiller
120 JPC22-14 VM
K2 Closed
Control path for the optional Nested Switch
(carriage
NESTED (S14) on the carriage. The VM reduces
121 JPC22-18 nested): B+; S14 VM
SWITCH travel speed to the configured value when
Open
the switch is open.
(unnested): 0V
B+ when there is not an open between B+ Closed: B+;

and STR2. This voltage is used by the VM to Open: Voltage
122 JPC22-19 FU1_SENSE FU1-2 VM
determine the state of FU1 and the STR drops slowly to
contactor. 0V
Voltage used by the VM to determine the Aux Closed: B+

123 JPC22-20 FU4_SENSE FU4-2 VM
state of the Aux and FU4. Open: 0V
EPO Closed:
Sense wire used by the VM to determine
124 JPC22-21 EPO_SENSE B+; EPO VM
when the EPO is open.
Open: 0V
The Steer Limit Switch (S11) stops drive unit Open (metal): 4
rotation when closed. This switch is closed to 7V;
125 JPC22-22 STEER_LIMIT S11 VM
just before the hard stops are reached for Closed (air):
both CW and CCW rotation. 0.7V
+12V supply to Left Battery Gate Switch

126 JPC24-1 +12VP 10.5 to 13VDC VM S57
(S57).
B– supply to Right Battery Gate Switch

127 JPC24-3 DGND VM S58
(S58) from the VM.
Custom
128 JPC24-5 DGND B– supply to Custom Input/Output device. VM
I/O device
Battery Voltage
Pressure
129 JPC24-6 DGND Reference for pressure transducer. wrt B+ VM
Transducer
B– supply to Left Battery Gate Switch (S57)

130 JPC24-8 DGND VM S57
from the VM.
131 JPC24-11 DGND Reference for the Ambient Temp Sensor. T VM
+12V supply to Custom Input/Output Custom

132 JPC24-13 +12VP 10.5 to 13VDC VM
device. I/O device

Pinout Matrix

Custom
CUSTOM
133 JPC24-16 Input from Custom I/O device #1to VM. I/O VM
INPUT 1
Open: >4V; device #1
Closed: <1V Custom
CUSTOM
134 JPC24-17 Input from Custom I/O device #2 to VM. I/O VM
INPUT 2
device #2
No load: 1.0V;
1000 lb.
Analog DC voltage that varies directly as (454 kg) out of Pressure
135 JPC24-18 PRESSURE VM
the pressure varies. free lift: 1.8V; Transducer
2500 lb.
(1134 kg): 2.5V
Contactor
Open: slowly
MAIN_CONT_ Sense wire used by the VM to determine the
136 JPC24-21 drops from B+ to MPC2 VM
SENSE state of the Main Contactor.
0V;
Closed: B+
Input to the VM from the Ambient Temp

AMBIENT- 73°F (22.8°C):
137 JPC24-23 Sensor. This informs the VM when to turn T VM
TEMP 3V
ON the optional heaters.
Used by the VM to determine the correct

battery is connected. It accepts any voltage
BATTERY_ between 28V and 45V. If the correct
138 JPC24-24 B+ FRC VM
SENSE_IN battery is sensed, Relay_Enable is
energized during start-up. After start-up, this
voltage is used to determine BSOC.
+12V supply from the VM to the CAN I/O

139 JPD1-1 +12VD 10.5 to 13V VM OCSS
Expander Module (OCSS) via SPL16.
+12V supply from the VM to the Height Height

140 JPD2-1 +12VP 10.7 to 13V VM
Encoder via SPL16. Encoder
+12V supply from the VM to the Cellular Cellular

141 JPD5-1 +12VD 10.5 to 13V VM
Modem (via SPL20). Modem
Cellular
142 JPD5-2 DGND B– from the VM to the Cellular Modem. VM
Modem
143 JPF1-1 Battery Voltage

B– B– to FU8 on the Fuse/Relay Card (FRC). TP4 FRC
144 JPF1-2 wrt B+
Aux Power,
145 JPF1-4 B–F B–F from FU8 to power the optional WMM. FU8 to B–
WMM
Optional
146 JPF1-6 B+K2 B+ to SPL-7 to power optional devices. B+ K2
Devices

Pinout Matrix

Contactor
147 JPF2-1 B+K2 B+K2 to the contactor coils. K2
Coils
Horn,
148 JPF2-2 B+K2 B+K2 to power the horn and brake.
Brake
149 JPF2-3 B+K2 B+K2 to power the compartment fans. Fans

K2 energized:
150 JPF2-5 B+K2 B+K2 to power L/H SOL1. B+ SOL1
K2
SOL1,
JPF2-5 B+K2 to power L/H SOL1, AUX2 SOL5B,
151 B+K2 SOL5B,
(Regen only) and AUX1 SOL5T.
SOL5T
B+K2 to the reach, sideshift, tilt solenoids, Carriage

152 JPF2-8 B+K2
and Nested Switch (S14). Functions
K1 energized:
153 JPF2-9 B+K1 B+ to TS1. K1 TS1
B+
154 JPF3-1
B– B– to FU6 on the FRC. TP4 FRC
155 JPF3-2 Battery Voltage
wrt B+
B–F for 1st Speed Limiting Switch (S12) on
156 JPF3-8 B–F FU6 S12
mast.
157 JPF4-1
B+ to FU5 and the thermistor on the FRC.
158 JPF4-2
B+ B+ TP1 FRC
159 JPF4-3
B+ to FU7 on the FRC.
160 JPF4-4
B+ supply from EPO to K1, K2, and K3. All

functions associated with those functions
S1 and EPO
161 JPF4-5 B+EPO are inoperable when the EPO is open. This EPO K1, K2, K3
closed: B+
also supplies voltage to EPO_Sense on the
VM.
FU5 good: B+;

162 JPF4-10 B+ B+ from FU5 to Key Switch (S1). FU5 S1
FU5 open: 0V
163 JPF4-12 B+KEY B+ from Key Switch (S1) to the EPO. S1 closed: B+ S1 EPO
Optional
164 JPF4-15 B+ B+ for battery connected aux power. B+ FU7
Aux Power

used to power the control circuits of the LPA.
It is also used by the LPA to produce +5V for K3 energized:
165 JPL1-1 B+K3 K3 LPA
the L Vel Sensor+ and the internal circuits of B+
the LPA. If voltage is not present, check K3
coil and tip circuit.
Battery Voltage DGND on

166 JPL1-7 I/O GND Return path for the LME and LMT. LME, LMT
wrt B+ VM

Pinout Matrix

Analog voltage that varies with the lift

motor temperature. Used by the LPA to 75°F (24°C):
167 JPL1-8 L TEMP+ LMT LPA
adjust motor performance when a motor approx. 1V
B+ to the LPA when K3 is closed, informing

168 JPL1-11 ID1 B+ K3 LPA
the amp it is the lift amp.

169 JPL1-23 BUS_1+ CAN-Bus. Troubleshoot using Test I23. No 2.94V CAN-Bus CAN-Bus
L VEL
170 JPL1-26 +5V supply to the Lift Motor Encoder. 5.0V LPA LME
SENSOR+

there is movement of the LME. The
the Lift Motor. Identical formation to L Vel Stationary: >4V
171 JPL1-31 L VEL PHASE A LME LPA
Phase B, except for the phasing between or <1V;
the two. The LPA uses the quadrature phase Turning: 2V
determine lift motor speed.

there is movement of the LME. The
the Lift Motor. Identical formation to L Vel Stationary: >4V
172 JPL1-32 L VEL PHASE B LME LPA
Phase A, except for the phasing between or <1V;
the two. The LPA uses the quadrature phase Turning: 2V
determine lift motor speed.

173 JPL1-35 BUS_1– CAN-Bus. Troubleshoot using Test I23. No 2.2V CAN-Bus CAN-Bus

used to power the control circuits of the
TPA. It is also used by the TPA to produce K3 energized:
174 JPT1-1 B+K3 K3 TPA
+5V for the T Vel Sensor+ and the internal B+
circuits of the TPA. If voltage is not present,
check K3 coil and tip circuit.
TA CUSTOM Custom
175 JPT1-3 Output from TPA to Custom device. B+ TPA
OUT device
Battery Voltage DGND on

176 JPT1-7 I/O GND Return path for the TME and TMT. TME, TMT
wrt B+ VM
Analog voltage that varies with the traction

motor temperature. Used by the TPA to 75°F (24°C):
177 JPT1-8 T TEMP+ TMT TPA
adjust motor performance when a motor approx. 1V

Pinout Matrix

B+ to the TPA when K3 is closed, informing

178 JPT1-12 ID0 B+ K3 TPA
the amp it is the traction amp.
Carries positive component of the digital

179 JPT1-23 BUS_1+ CAN-Bus. Troubleshoot using Test I23. No 2.93V CAN-Bus CAN-Bus
T VEL
180 JPT1-26 +5V supply to the TME. 5.0V TPA TME
SENSOR+
Generated when there is movement of the

TME. It is a square wave that is either high
Motor
(>8V) or low (<1V). The frequency varies
Stationary: >4
181 JPT1-31 T VEL PHASE A directly with motor speed. Identical to T VEL TME VM
or <1V;
Phase B except for phase. The VM uses the
Turning: 2V
relationship between phases to determine
travel direction and speed.
Generated when there is movement of the

TME. It is a square wave that is either high
Motor
or low. The frequency varies directly with
Stationary: >4
182 JPT1-32 T VEL PHASE B motor speed. Identical to T VEL Phase A TME VM
or <1V;
except for phase. The VM uses the
Turning: 2V
relationship between phases to determine
travel direction and speed.
Carries the negative component of the

digital communication between all devices
183 JPT1-35 BUS_1– 2.2V CAN-Bus CAN-Bus
on the CAN-Bus. Troubleshoot using Test
I23.
B+ supply to the Impact Monitor from TP1 Impact

184 JP57A-1 B+ B+ TP1
(via SPL19). Monitor

185 JP57A-2 BUS_1+ CAN-Bus. Troubleshoot using Test I23. No Approx. 2.5V CAN-Bus CAN-Bus
Negative component of the digital

186 JP57A-3 BUS_1– CAN-Bus. Troubleshoot using Test I23. No Approx. 2.5V CAN-Bus CAN-Bus
Battery Voltage Impact

187 JP57A-4 GND B– supply from TP4 to the Impact Monitor. TP4
wrt B+ Monitor
B+ to the LPA used to pre-charge the

amplifier and produce the AC phases U, V,
188 LPA B+ LPA B+ B+ MPC LPA
and W to the Lift Motor. Voltage increases
from 0V to B+ as the amplifier charges.

Pinout Matrix


LPA power circuits. Without B–, U, V, and Battery Voltage
189 LPA B– LPA B– TP4 LPA
W cannot be produced and the Lift Motor wrt B+
will not operate.
190 MS-A1 Steering CW:

Output from the Steer Amplifier (SA) to the slow - approx.
Steer Motor (MS). Can be positive or 4V; fast -
negative, depending on steer direction approx. 28V; Steer
B+ or B– MS
191 MS-A2 requested. Steering CCW: Amplifier
Connect + meter lead to A1. slow - approx. –
Connect – meter lead to A2. 4V; fast -
approx. –28V
B+ from the Steer Contactor through FU1 to

Steer
192 STR-2 B+ the Steer Amp (SA) to power the steer B+ FU1
Amplifier
motor.
B– from TP4 to the Steer Amp to power the Battery Voltage Steer
193 TP4 B– TP4
steer motor. wrt B+ Amplifier
B+ to the TPA used to pre-charge the

amplifier and produce the AC phases U, V,
194 TPA B+ B+ and W when the MPC is closed to power B+ MPC TPA
the Traction Motor. Voltage increases from
0V to B+ as the amplifier charges.

TPA power circuits. Without B–, U, V, and Battery Voltage
195 TPA B– B– TP4 TPA
W cannot be produced and the Traction wrt B+
Motor will not operate.
One of three phases from the APA to the VAC between

Aux Motor. This AC voltage is produced by two phases:
the APA and is dependent on B+ at the + Stationary:
U on APA AUX MOTOR
196 terminal and B– on the APA. This AC 0VAC; APA AM
(Regen only) PHASE U
voltage is measured between any two Full Lift: 24VAC;
phases and varies from 0VAC at rest to Stall: approx.
approx. 24VAC at full RPM. 4VAC
One of three phases from the LPA to the Lift VAC between
Motor. This AC voltage is produced by the two phases:
LPA and is dependent on B+ at the + Stationary:
LIFT MOTOR
197 U on LPA terminal and B– on the LPA. This AC voltage 0VAC; LPA LM
PHASE U
is measured between any two phases and Full Lift: 24VAC;
varies from 0VAC at rest to approx. 24VAC Stall: approx.
at full RPM. 4VAC
VAC between
One of three phases from the TPA to the
two phases:
Traction Motor. This AC voltage is produced
Stationary:
TRACTION by the TPA and is dependent on B+ at the +
0VAC;
198 U on TPA MOTOR terminal and B– on the TPA. This AC voltage TPA TM
Full Travel:
PHASE U is measured between any two phases and
24VAC;
varies from 0VAC at rest to approx. 24VAC
Stall: approx.
at full RPM.
4VAC

Pinout Matrix


the APA and is dependent on B+ at the + Stationary:
V on APA AUX MOTOR
(Regen only) PHASE V
LPA and is dependent on B+ at the + Stationary:
LIFT MOTOR
200 V on LPA terminal and B– on the LPA. This AC voltage 0VAC; LPA LM
PHASE V
at full RPM. 4VAC
VAC between
two phases:
Stationary:
0VAC;
201 V on TPA MOTOR terminal and B– on the TPA. This AC voltage TPA TM
Full Travel:
PHASE V is measured between any two phases and
24VAC;
Stall: approx.
at full RPM.
4VAC

the APA and is dependent on B+ at the B+ Stationary:
W on APA AUX MOTOR
(Regen only) PHASE W
LPA and is dependent on B+ at the B+ Stationary:
LIFT MOTOR
203 W on LPA terminal and B– on the LPA. This AC voltage 0VAC; LPA LM
PHASE W
at full RPM. 4VAC
VAC between
two phases:
Stationary:
0VAC;
204 W on TPA MOTOR terminal and B– on the TPA. This AC voltage TPA TM
Full Travel:
PHASE W is measured between any two phases and
24VAC;
Stall: approx.
at full RPM.
4VAC

Pinout Matrix

Models 7500/7520 Reach-Fork ® Trucks Section A. Appendix
Section A. Appendix
Publication: 1252757, Issued: 16 February 2018 A-1

Section A. Appendix Models 7500/7520 Reach-Fork ® Trucks
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°F to +120°F 990-616/02 (2 gal./7.6 liters)
(+10°C to +49°C) 990-616/03 (5 gal./18.9 liters)
Hydraulic Reservoir
(CS trucks - in and out of
1266010
cooler/freezer) Hydraulic Fluid ISO VG32
Note: Do not add any additives.
0° to +80°F
(–18° to +27°C)
Hydraulic Reservoir
(Freezer trucks) 990-618/TX1 (1 gal./3.8 liters)
Hydraulic Fluid MIL-H-5606E
–20° to +32°F 990-618/01 (1 gal./3.8 liters)
(–29° to 0°C)
Note: For ambient temperature ranges of 0° to +32°F (-18° to 0°C) and +50° to +80°F (+10° to +27°C),
specific environmental, application, and operating conditions should be considered when selecting a
hydraulic fluid.
Mast Uprights, Bearings,

and so forth
(all-weather) Grease NLGI 2 1012992
–20°F to +120°F
(–29°C to +49°C)
High Performance/
1151877/001 (Rexoil)
Lift Chains High Load Chain Aerosol
1151877/002 (Rocol)
Spray
A-2 Publication: 1252757, Issued: 16 February 2018

Thread Adhesives, Sealants, and Lubricants
Thread Adhesives, Sealants, and Lubricants

Supplier/
Description/Application Part Number
Number/Color
Adhesive (floor pad installation) 990-569/102
Anti-Seize Lubricant, Heavy Duty High Temperature 990-452
Cleaner - alcohol based 990-600/FOF
Contact cleaner 996-600/CC2
Corrosion inhibitor coating 990-644
Grease with teflon 990-652
Lubricant (control handle spring) 990-635
Lubricant (Spline Shaft) 1223184
Permatex 80062 or
Sealant 1175668
80063
Silicone - high temp 1110785/716
Silicone sealant (cold storage) 990-659
Solvent 990-500/RD1
Thread-locking accelerator/primer 990-666 7649 (19269)
Thread-locking compound primerless 990-669 2760
Thread-locking compound1/4 to 3/4 in. dia. contamination

1013829 243/Blue
tolerant
Thread-locking compound up to 1 in. dia. 990-544 271/Red
Thread-locking compound up to 1.5 in. dia. 990-571 277/Red
Thread-locking compound high strength 990-575 680/Green
Thread-locking primer 990-533 T7471
*Loctite is a registered trademark of the Loctite Corporation. Brand endorsement is not implied here, but
listed only as a commonly identified product.

Component Specific Service/Torque Chart

Torque to:
(use Dry values for pre-applied
Thread-Locking thread-locking compound)
Component Sub-Component(s)
Compound
Lubricated Dry
ft. lb. (Nm) ft. lb. (Nm)
mtg bolts 21 (29) 27 (36.5)

Auxiliary Manifold 1013829
cover mtg bolts 24 (32) 31 (42)
motor mtg bolt locknuts 27 (36.5)

Auxiliary Motor (Regen Lower) n/a
power cables n/a 4.2 (5.7)
pressure fitting torque 45 (61) n/a

Auxiliary Pump (Regen Lower)
mtg bolts 1013829 15 (21) 27 (36.5)
Baseleg 7500 - mtg bolts 165 (223)

Apply anti-seize compound 990-669 n/a
(P/N 990-452) to alignment pins. 7520 - mtg bolts 295 (434)
Battery Gate Switches Adjust the gap between the switch and target to 0.16 in. (4 mm) max.
Carriage Stops n/a 1013829 35 (47.5) 50 (68)
Deadman Pedal Assembly

Pedal travel:
assembly to frame n/a 15 (21) 27 (36.5)
Fore/Aft Stance - 3.50 in. (90 mm)
Dockstance: 3.58 in. (99 mm)
housing cover bolts 1013829 24 (32) 31 (42)
mtg bolts 990-544 170 (230) n/a

Drive Unit
steer linkage (shoulder)
1013829 150 (204) 150 (204)
bolt
Drive Wheel mtg bolts n/a 170 (230) n/a
EPO Switch n/a 1013829 6 (8.6) 8 (11)
Adjustment: Fully lower carriage and adjust gap between switch and rail
High Speed Travel Switch (S25)
from 0.10 to 0.22 in. (2.54 to 5.58 mm).
Horn brkt to frame 1013829 15 (21) 27 (36.5)
Hose, Over-the-Mast pulley stud 1013829 130 (174)
1013829 (apply to n/a

Inertial Dampener mtg cap screws 22 (30)
frame)
Adjustment:
1. Fully raise carriage and adjust gap between switch and rail from
Lift Cutout Switch (S27) 0.10 to 0.25 in. (2.54 to 6.35 mm).
2. Align the vertical center line of the switch just below the bottom edge
of the rail so the sensor LED is OFF.

Torque to:
Compound
Lubricated Dry
lift pump mtg bolts 55 (75) 90 (122)

1013829
motor mtg bolts to deck 42 (57) 56 (76)
Lift Motor
Apply anti-seize compound Top Nut:
(P/N 990-638) to pump spline and 17 to 18.4
mating surfaces. (23 to 25)
power cables
Bottom Nut:
10.7 to 11
(14.5 to 15)
P1 fitting 85 (115)
Lift Pump input fitting 120 (163)

Apply anti-seize compound n/a n/a
(P/N 990-638) to spline, mating
surfaces.
lift pump mtg bolts 1013829 55 (75) 90 (122)
wheel plate mtg bolts 50 (68)
Load Wheel Assembly (locknuts) top plate bolt n/a n/a 21 (29)
nose bolt (closed toe) 55 (74)
Manifold, Auxiliary
mtg bolts
(Reach/Tilt/Sideshift)
21 (29) 27 (36.5)
Manifold, Main mtg bolts 1013829
Manifold, Std Reach mtg bolts

(32 in. wide mast) cover mtg bolts 24 (32) 31 (42)
mast to tractor mtg Refer to “Mating Mast to Tractor” on

Mast
bolts page 7-164 or page 7-177.
Overhead Guard mtg bolts 1013829 130 (174) 170 (230)

Torque to:
Compound
Lubricated Dry
amplifier bolts to brkt 6 (8.6) 11 (15)
brkt mtg bolts to deck 15 (21) 27 (36.5)

Power Amplifier, Lift
8 to 8.6
power cables n/a
(11 to 11.6)
amplifier bolts to brkt 6 (8.6) 11 (15)

n/a
brkt mtg nuts to deck 15 (21) 27 (36.5)
Power Amplifier, Traction
8 to 8.6
power cables
(11 to 11.6)
n/a
Proportional Valve
n/a 95 (129)
Run LEARN Lower
Pulleys, Over-the-Mast pulley stud 1013829 130 (174) n/a
slotted nut (use tool

Scissor Arm - Single Reach n/a n/a 30 (42)
P/N 761-870/T07)
Steer Limit Switch S11 switch brkt to drive unit 1013829 9 (12) 11 (15)
Adjustment:
1. Lower carriage and adjust gap between switch and rail from 0.10 to
Speed Limiting Switch, First (S12) 0.25 in. (2.54 to 6.35 mm).
2. Align the vertical center line of the switch just above the bottom edge
of the rail so the sensor LED is ON.
pinion gear set screw 6 (8.6) 8 (11)

Steer Motor, Electric pinion gear mtg bolt 21 (29) 31 (42)
Note: Apply anti-seize compound 1013829
(P/N 990-638) to pinion gear. motor mtg bolts 30 (42) 56 (76)
Orient pinion gear with shoulder
toward mounting bolt. flange mtg bolts 95 (129) 110 (149)
power cables n/a n/a 3.3 (4.5)
Steer Tiller cap screws 1013829 15 (21) 27 (36.5)

Torque to:
Compound
Lubricated Dry
cable brkt 6 (8.6) 11 (15)
pinion gear nut 1013829 85 (115) n/a
mtg bolts 13 (17) 28 (38)

Traction Motor
Note: When replacing Traction Top Nut:
Motor, thoroughly clean motor 17 to 18.4
shaft, keyway, and threads with (23 to 25)
P/N 990-666. power cables n/a n/a
Bottom Nut:
10.7 to 11
(14.5 to 15)
steer limit sensing rail 9 (12) 11 (15)

1013829
Travel Light mtg bolts 23 (31) 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.
in. lb. Nm Nm in. lb. Nm in. lb. Nm in. lb. Nm in. lb. Nm in. lb. Nm in. lb. Nm
lb.
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 1.2
5 19 2.2
6 34 3.9
8 79 9
10 150 17
Note: Use “oiled” values for bolts with

thread-locking compound.

Torque Chart - Thread Forming Screws
Torque Chart - Thread Forming Screws

Standard Thread-Forming Screws Metric Thread-Forming Screws
Nearest Plate Torque Nearest Plate Torque
Size
Thickness (in.) in. lb. Nm Size Thickness
in. lb. Nm
0.0469 4 0.5 in. (mm)
2-56 0.0625 4 0.5 0.039 (1.0) 9 1.0
0.0938 5 0.6 M3 x 0.5 0.079 (2.0) 9 1.0
0.0625 6 0.7 0.118 (3.0) 14 1.6
3-48 0.0938 7 0.8 0.079 (2.0) 16 1.8
0.1250 7 0.8 M4 x 0.7 0.118 (3.0) 29 3.3
0.0312 6 0.7 0.157 (4.0) 38 4.3
4-40 0.0625 9 1.0 0.098 (2.5) 25 2.8
0.0938 11 1.2 M5 x 0.8 0.138 (3.5) 53 6.0
0.0625 12 1.4 0.197 (5.0) 62 7.0
5-40 0.0938 18 2.0 0.118 (3.0) 44 5.0
0.1250 20 2.3 M6 x 1.0 0.177 (4.5) 89 10.0
0.0625 14 1.6 0.236 (6.0) 89 10.0
6-32 0.0938 20 2.3 0.157 (4.0) 177 20.0
0.1250 22 2.5 M8 x 1.25 0.236 (6.0) 248 28.0
0.0938 30 3.4 0.315 (8.0) 266 30.0
8-32 0.1250 45 5.1 0.197 (5.0) 266 30.0
0.1875 45 5.1 M10 x 1.5 0.315 (8.0) 398 45.0
0.0938 35 4.0 0.394 (10.0) 487 55.0
10-24 0.1250 45 5.1 0.236 (6.0) 531 60.0
0.1875 55 6.2 M12 x 1.75 0.354 (9.0) 575 65.0
0.0938 35 4.0 0.472 (12.0) 885 100.0
10-32 0.1250 50 5.6
0.1875 70 7.9
0.1250 65 7.3
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

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
41/64 .641 .64 16.272
21/32 .665 .66 16.669
43/64 .672 .67 17.065
11/16 .688 .69 17.462
45/64 .703 .70 17.859
23/32 .719 .72 18.256
47/64 .734 .73 18.653
3/4 .750 .75 19.050
49/64 .766 .77 19.447
25/32 .781 .78 19.844
51/64 .797 .80 20.241
13/16 .812 .81 20.637
53/64 .828 .83 21.034
27/32 .844 .84 21.431
55/64 .859 .86 21.828
7/8 .875 .88 22.225
57/64 .891 .89 22.622
29/32 .906 .91 23.019
59/64 .922 .92 23.416
15/16 .938 .94 23.812
61/64 .953 .95 24.209
31/32 .969 .97 24.606
63/64 .984 .98 25.003
1.000 1.00 25.400

Standard/Metric Conversions
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 7500/7520 Reach-Fork ® Trucks Section I. Index
Section I. Index
A Model 7520 . . . . . . . . . . . 7-174
Inner Tele to Outer Tele
Abbreviations, List of . . . . . . . . . . . . . . 1-4 Model 7500 . . . . . . . . . . . 7-160
AC Motors . . . . . . . . . . . . . . . . . . . . . 5-18 Model 7520 . . . . . . . . . . . 7-173
Acronyms, List of . . . . . . . . . . . . . . . . 1-4 Outer Tele to Main Frame
Active Maintenance Mode . . . . . . . . . 3-24 Model 7500 . . . . . . . . . . . 7-159
Adjustment Model 7520 . . . . . . . . . . . 7-172
Auxiliary Pressure . . . . . . . . . . . . 7-95 Reach Carriage . . . . . . . . . . . . . . 7-130
Proportional Valve . . . . . . . . . . . . 7-93 Bleeding Hydraulic System . . . . . . . . . 7-86
Reach Cylinder . . . . . . . . 7-121, 7-122 Bow Pads
AMP Connectors . . . . . . . . . . . . . . . . 7-71 R35TT . . . . . . . . . . . . . . . . . . . . . 7-133
Analog Tests . . . . . . . . . . . . . 6-33 to 6-66 R45TT/DR32TT . . . . . . . . . . . . . 7-135
Summary List . . . . . . . . . . . . . . . 6-31 Brake
See Tests, Analog for Individual Tests Application, Theory . . . . . . . . . . . . 8-16
Anchors, Chain . . . . . . . . . . . . . . . . .7-137 Floating Disk . . . . . . . . . . . . . . . . 7-58
Auxiliary Coil Replacement . . . . . . . . . . 7-59
Functions, Troubleshooting . . . . . 5-21 Installation . . . . . . . . . . . . . . . 7-59
Manifold . . . . . . . . . . . . . . . . . . . . A-5 Pad Replacement . . . . . . . . . . . 7-58
Mounting . . . . . . . . . . . . . . A-4, A-5 Removal . . . . . . . . . . . . . . . . . 7-58
Regen Lower . . . . . . . . . . . . . 7-98 Overview . . . . . . . . . . . . . . . . . . . . 8-16
Manifold - Standard Reach Release Screws, Use of . . . . . . . . . 8-16
35.5 in. Wide Mast . . . . . . . . . 7-99 Release, Theory . . . . . . . . . . . . . . . 8-16
Motor . . . . . . . . . . . . . . . . . . . . . . A-4 Theory of Operation . . . . . . . . . . . 8-16
Pressure Adjustment . . . . . . . . . . 7-95 BSOC (Battery State-of-Charge) . 5-5, 7-68
Pump . . . . . . . . . . . . . . . . . . . . . . A-4 Lift Cutout Adjustment . . . . . . . . . . 5-5
Valve SOL5B/5T . . . . . . . . . 7-96, 7-98
Auxiliary Motor Service - Regen Lower 7-94 C
Auxiliary Pump Service - Regen Lower 7-94
Cable Installation, Mast
B Model 7500 . . . . . . . . . . . . . . . . . 7-162
Model 7520 . . . . . . . . . . . . . . . . . 7-174
Backlash, Drive Unit . . . . . . . . . . . . . 7-54 Cable Removal, Mast
Baseleg . . . . . . . . . . . . . . . . . . . . 7-20, A-4 Model 7500 . . . . . . . . . . . . . . . . . 7-155
Battery Model 7520 . . . . . . . . . . . . . . . . . 7-167
Charging . . . . . . . . . . . . . . . . . . . 7-67 Cable, Over-the-Mast . . . . . . . . . . . . 7-145
Cleaning Exterior . . . . . . . . . . . . . 7-67 Cable Only Replacement . . . . . . . 7-151
Connector/Cables . . . . . . . . . . . . 7-66 Cable, Terminology . . . . . . . . . . . . . . . . 5-7
Maintenance . . . . . . . . . . . . . . . . 7-67 Cables, Power . . . . . . . . . . . . . . . . . . . 7-77
Safety . . . . . . . . . . . . . . . . . . . . . . 2-5 Card
State-of-Charge (BSOC) . . . . . 5-5, 7-68 Fuse/Relay . . . . . . . . . . . . . . . . . . 5-11
Testing . . . . . . . . . . . . . . . . . . . . 7-67 Tilt/Sideshift Switch
Battery Gate Switches . . . . . . . . . . . . . A-4 Fore/Aft Stance . . . . . . . . . . . . 7-35
Battery Specifications . . . . . . . . . . . . . 3-5 Vehicle Manager . . . . . . . . . . . . . . 5-10
Bearings
Mast, Shimming . . . . . . . . . . . . .7-131
Carriage to Inner Tele
Model 7500 . . . . . . . . . . .7-161
Publication: 1252757, Issued: 16 February 2018 I-1

Section I. Index Models 7500/7520 Reach-Fork ® Trucks
Carriage . . . . . . . . . . . . . . . . . . . . . . 7-136 Flex Circuit Assembly . . . . 7-28

Bearings . . . . . . . . . . . . . . . . . . . 7-130 Pot Heaters 7-28, 7-29, 7-30, 7-33,
Installation into Mast 7-34, 7-35
Model 7500 . . . . . . . . . . . . . . 7-162 ThermaKit Heater 7-30, 7-31, 7-35
Model 7520 . . . . . . . . . . . . . . 7-174 Fore-Aft Stance
Manual Lowering . . . . . . . . . . . . . . 7-92 Primary
Removal from Mast Pot Heaters . . . . . . . .7-29, 7-34
Model 7500 . . . . . . . . . . . . . . 7-155 Shell Disassembly . . .7-28, 7-33
Model 7520 . . . . . . . . . . . . . . 7-167 ThermaKit Heater . . .7-30, 7-35
Stops . . . . . . . . . . . . . . . . . . . . . . .A-4 Secondary . . . . . . . . . . 7-37 to 7-38
Caster Assembly . . . . . . . . . . . . . . . . . 7-24 ThermaKit Heater . . . . . . . 7-37
Height Adjustment . . . . . . . . . . . . 7-25 Tilt/Sideshift Switch . . . . . . . . . . . 7-36
Caster, Steerable . . . . . . . . . . . . . . . . 7-24 Dockstance . . . . . . . . . . . . . . . 7-35
Height Adjustment . . . . . . . . . . . . 7-25 Fore/Aft Stance . . . . . . . . . . . 7-31
Caution, Definition . . . . . . . . . . . . . . . .2-2 Conversion
CB1 & CB2 Counterbalance Decimal to Fraction . . . . . . . . . . . A-15
Valve . . . . . . . . . . . . . . . . 7-103, 7-104 Fraction to Decimal . . . . . . . . . . . A-15
Chains Conversions, Standard/Metric . . . . . . A-17
Anchors . . . . . . . . . . . . . . . . . . . 7-137 Corrosion Inhibitor, Cold Storage . . . . 7-84
Condition-Cause Chart . . . . . . . . . 4-11 Counterbalance Valve CB1 &
Free Lift . . . . . . . . . . . . . . . . . . . 7-140 CB2 . . . . . . . . . . . . . . . . .7-103, 7-104
Main Lift, 7500 . . . . . . . . . . . . . . 7-140 Cushion, Lift Cylinder Lowering
Maintenance . . . . . . . . . . . . . . . . . 4-11 Main Lift . . . . . . . . . . . . . . . . . . . 7-118
Changing Password or SuperWrd . . . . 3-12 Cutout Switch, Lift (S27) . . . . . . . . . . . A-4
Check Valve CV-1 Check Valve . . . . . . . . . . . . . . . 7-96
CV-1 . . . . . . . . . . . . . . . . . . . . . . . 7-96 CV-3 Check Valve . . . . . . . . .7-103, 7-104
CV-3 . . . . . . . . . . . . . . . . 7-103, 7-104 Cylinder
Circuit Card Connectors . . . . . . . . . . . 5-10 Free Lift
Fuse/Relay Card . . . . . . . . . . . . . . 5-11 . . . . . . . . . . . . . . . . . . . . . . . 7-118
Vehicle Manager . . . . . . . . . . . . . . 5-10 Model 7500 . . . . . . . . .7-155, 7-162
Cleaning Model 7520 . . . . . . . . .7-167, 7-174
Battery . . . . . . . . . . . . . . . . . . . . . 7-67 Seal Repacking . . . . . . . . . . . 7-112
Lift Truck . . . . . . . . . . . . . . . . . . . .2-4 Left Side Free Lift
Codes Remove/Install
Power Amp Sub-codes . . . . . . . . . . 5-19 7500 . . . . . . . . . 7-108 to 7-109
Power Amplifier . . . . . . . . . . . . . . . .6-2 7520 . . . . . . . . . 7-110 to 7-111
Summary List . . . . . . . . . . . . . . . . .6-3 Main Lift . . . . . . . . . . . . 7-114 to 7-116
Cold Storage Conditioning . . . . . . . . . . 7-84 Lowering Cushion . . . . . . . . . 7-118
Cold Storage, Theory of Operation . . . . 8-17 Seal Repacking . . . . . . . . . . . 7-117
Configuration Codes . . . . . . . . . . . . . . .3-4 Reach . . . . . . . . . . . . . . . . . . . . . 7-120
Connectors Adjustment . . . . . . . . .7-121, 7-122
AMP . . . . . . . . . . . . . . . . . . 7-71, 7-74 Tilt . . . . . . . . . . . . . . . . . .7-123, 7-125
Circuit Card . . . . . . . . . . . . . . . . . 5-10 CYL-P Pressure Transducer . . . .7-96, 7-97
Fuse/Relay Card . . . . . . . . . . . . . . 5-11
Molex . . . . . . . . . . . . . . . . . . . . . . 7-70 D
Vehicle Manager . . . . . . . . . . . . . . 5-10
Contactor Tip Inspection . . . . . . . . . . . 4-10
DC Motor
Control Handle
Test . . . . . . . . . . . . . . . . . . . . . . . 5-17
Dockstance . . . . . . . . . . . . 7-33 to 7-36
Troubleshooting . . . . . . . . . . . . . . 5-14
Pot Heaters . . . . . . . . . . 7-33, 7-36
Deadman
Fore/Aft Stance
Pedal Assembly . . . . . . . . . . . . . . . A-4
Primary . . . . . . . . . . . . 7-28 to 7-32
Deadman Pedal Adjustment . . . . . . . . 7-60
I-2 Publication: 1252757, Issued: 16 February 2018

Decals and Plates . . . . . . . . . 7-15 to 7-19 Electrostatic Discharge

Decimal to Fraction Conversion . . . . . A-15 See Static Precautions
Deep-Reach Encoder
Tilt/Sideshift Manifold . . . . . . . . .7-105 Height (HTI/HI) . . . . . . . . . . . . . . 7-142
Deep-Reach Manifold Steering . . . . . . . . . . . . . . . . . . . . 7-22
32 in. Wide Mast . . . . . . . . . . . . .7-104 Entering a Password or SuperWord . . 3-12
35.5 in. Wide Mast . . . . . . . . . . . .7-103 EPO Switch . . . . . . . . . . . . . . . . . . . . . A-4
Digital Input Tests . . . . . . . . .6-67 to 6-106 Error Log . . . . . . . . . . . . . . . . . . . . . . 3-23
Summary List . . . . . . . . . . . . . . . 6-31 Error Messages
See Tests, Input for Individual Tests Power Amplifier . . . . . . . . . . . . . . . . 6-2
Digital Output Tests . . . . . .6-107 to 6-128 Summary List . . . . . . . . . . . . . . . . . 6-3
Summary List . . . . . . . . . . . . . . . 6-32 ESD Ground Jack . . . . . . . . . . . . . . . . 2-8
See Tests, Output for Individual Tests Evolution Display . . . . . . . . . . . . 3-9, 3-10
Display . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Display, Evolution . . . . . . . . . . . . . . . 3-10 F
Document Revision History . . . . . . . . . . .iii
Drive Tire Pressing . . . . . . . . . . . . . . 7-57
Fault Codes
Drive Unit . . . . . . . . . . . . . . . 7-40 to 7-56
Power Amplifier . . . . . . . . . . . . . . . . 6-2
Assembly . . . . . . . . . . . . . 7-49 to 7-55
Summary List . . . . . . . . . . . . . . . . . 6-3
Helical Gear . . . . . . . . . . . . . . 7-51
Filter, Hydraulic . . . . . . . . . . . . . . . . . 7-87
Output Shaft . . . . . . . . . . . . . 7-49
FlashWare
Pivot Ring . . . . . . . . . . . . . . . 7-54
Connecting to Truck . . . . . . . . . . . . 3-7
Spiral Pinion . . . . . . . . . . . . . 7-49
Starting . . . . . . . . . . . . . . . . . . . . . 3-8
Backlash Measurement . . . . . . . . 7-54
FlashWare Installation . . . . . . . . . . . . . 3-7
Disassembly . . . . . . . . . . 7-45 to 7-49
FlashWare Program . . . . . . . . . . . . . . . 3-7
Output Shaft . . . . . . . . . . . . . 7-46
Flex Circuit Assembly
Pivot Ring . . . . . . . . . . . . . . . 7-45
Fore/Aft Stance . . . . . . . . . . . . . . 7-28
Spiral Pinion . . . . . . . . . . . . . 7-48
Flow Limiter
Exploded Parts Diagram . . . . . . . 7-40
Free Lift . . . . . . . . . . . . . . . . . . . 7-127
Helical Gear Assembly . . . . . . . . . 7-51
Main Lift . . . . . . . . . . . . . . . . . . . 7-126
Installation . . . . . . . . . . . . . . . . . 7-55
Fluid Capacities . . . . . . . . . . . . . . . . . . 3-5
Output Shaft
Fork
Assembly . . . . . . . . . . . . . . . . 7-49
Angle . . . . . . . . . . . . . . . . . . . . . . 4-12
Disassembly . . . . . . . . . . . . . 7-46
Hooks . . . . . . . . . . . . . . . . . . . . . . 4-14
Pivot Ring
Inspection . . . . . . . . . . . . . . . . . . . 4-12
Assembly . . . . . . . . . . . . . . . . 7-54
Markings . . . . . . . . . . . . . . . . . . . 4-15
Disassembly . . . . . . . . . . . . . 7-45
Positioning Locks . . . . . . . . . . . . . 4-13
Removal . . . . . . . . . . . . . . . . . . . 7-44
Tip Height . . . . . . . . . . . . . . . . . . . 4-13
Shim Formulas . . . . . . . . . . . . . . 7-52
Wear . . . . . . . . . . . . . . . . . . . . . . . 4-13
Shim Installation . . . . . . . . . . . . . 7-52
Fraction to Decimal Conversion . . . . . A-15
Spiral Pinion
Free Lift Cylinder
Assembly . . . . . . . . . . . . . . . . 7-49
Model 7500 . . . . . . . . . . . 7-155, 7-162
Disassembly . . . . . . . . . . . . . 7-48
Model 7520 . . . . . . . . . . . 7-167, 7-174
Remove/Install
Drive Wheel and Tire . . . . . . . . . . . . . . A-4
7500 . . . . . . . . . . . . 7-108 to 7-109
7520 . . . . . . . . . . . . 7-110 to 7-111
E Seal Repacking . . . . . . . . . . . . . . 7-112
Fuse/Relay Card Connectors . . . . . . . 5-11
Electrical Tests Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Summary List . . . . . . . . . . . . . . . 6-31
Electronic Key . . . . . . . . . . . . . . . . . . 3-12

G Hydraulic
Filter . . . . . . . . . . . . . . . . . . . . . . 7-87
Ground Jack, ESD . . . . . . . . . . . . . . . .2-8 Fluid Capacity . . . . . . . . . . . . . . . . 3-5
Manifold
See Manifold
H System
Bleeding . . . . . . . . . . . . . . . . . 7-86
Harness Troubleshooting
Inspection . . . . . . . . . . . . . . . . . . . 7-69 Guidelines . . . . . . . . . . . . . 5-20
Repair . . . . . . . . . . . . . . . . . . . . . . 7-69 Symptoms . . . . . . . 5-21 to 5-27
Soldering Procedures . . . . . . . . . . . 7-69
Terminology . . . . . . . . . . . . . . . . . .5-7
I
Heater
Control Handle
Dockstance IETM . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Potentiometers . . . . . . . . . . 7-33 Inertial Dampener . . . . . . . . . . . . . . . 7-61
Fore/Aft Stance Input Tests . . . . . . . . . . . . . 6-67 to 6-106
Potentiometers 7-28, 7-29, 7-30, Summary List . . . . . . . . . . . . . . . . 6-31
7-33, 7-34, 7-35 See Tests, Input for Individual Tests
ThermaKit . . . .7-30, 7-31, 7-35 Installation of Truck . . . . . . . . . . . . . . . 3-6
Fore-Aft Stance Interactive Electronic Technical
Potentiometers . . . . . 7-29, 7-34 Manuals . . . . . . . . . . . . . . . . . . . . . 1-3
ThermaKit . . . .7-30, 7-35, 7-37
Height Encoder Belt J
7500 . . . . . . . . . . . . . . . . . . . . . . 7-142
7520 . . . . . . . . . . . . . . . . . . . . . . 7-142 Jacking Safety . . . . . . . . . . . . . . . . . . . 2-9
Helical Gear Assembly, Drive Unit . . . . 7-51
High Speed Travel Switch (S25) . . . . . . .A-4
K
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Horn Switch
Test 018 . . . . . . . . . . . . . . . . . . . 6-118 Key, Electronic . . . . . . . . . . . . . . . . . . 3-12
Test I15 . . . . . . . . . . . . . . . . . . . . . 6-78
Hose L
Free Lift . . . . . . . . . . . . . . . . . . . 7-154
Installation, Mast Lift
Model 7500 . . . . . . . . . . . . . . 7-162 Chain Inspection . . . . . . . . . . . . . 4-11
Model 7520 . . . . . . . . . . . . . . 7-174 Cutout Switch (S27) . . . . . . . . . . . . A-4
Over-the-Mast . . . . . . . . . . . 7-145, A-4 Cylinder
Removal, Mast Free Lift
Model 7500 . . . . . . . . . . . . . . 7-155 Model 7500 . . . . . .7-155, 7-162
Model 7520 . . . . . . . . . . . . . . 7-167 Model 7520 . . . . . .7-167, 7-174
HTI Remove/Install
Belt Replacement . . . . . . . . . . . . 7-142 7500 . . . . . . 7-108 to 7-109
Codes and Tests
Test I26 . . . . . . . . . . . . . . . . . . 6-88
Test I86 . . . . . . . . . . . . . . . . . 6-105
Pressure Switch
Torque . . . . . . . . . . . . . . 7-96, 7-98
Hung-Up Carriage, Lowering . . . . . . . . 7-92

7520 . . . . . . .7-110 to 7-111 Component Torque . . . . . . 7-98

Main Lift . . . . . . . . .7-114 to 7-116 Standard Reach
Function 35.5 in. Wide Mast . . . . . . 7-99
Troubleshooting . . . . . . . . . . . 5-24 Component Torque . . . . . . 7-99
Motor Auxiliary - AC Lift
Temperature Sensor . . . . . . . . 7-82 Mounting Bolt Torque . . . . . . . . A-5
Torque Specs . . . . . . . . . . . . . . A-5 Deep-Reach
Power Amplifier . . . . . . . . . . . . . . . A-6 32 in. Wide Mast . . . . . . . . . . 7-104
Pressure Adjustment . . . . . . . . . . 7-91 Component Torque . . . . . 7-104
Pump . . . . . . . . . . . . . . . . . . . . . . A-5 35.5 in. Wide Mast . . . . . . . . 7-103
Priming - Regen Lower . . 7-89, 7-90 Component Torque . . . . . . . . 7-103
Lift Pump Lift/Lower
Replacement - Regen Lower . . . . . 7-88 Regen Lower . . . . . . . . . . . . . . 7-97
Lift/Lower Component Torque . . . . . . 7-97
Function Main . . . . . . . . . . . . . . . . . . . . . . . . A-5
Theory . . . . . . . . . . . . . . . . . . . 8-8 Standard Lift
Regen Lower . . . . . . . . . . . 8-13 Component Torque . . . . . . 7-96
Manifold Standard Lift/Lower . . . . . . . . 7-96
Regen Lower . . . . . . . . . . . . . 7-97 Standard Reach
System 32 in. Wide Mast . . . . . . . . . . 7-101
Troubleshooting . . . . . . . . . . . 5-24 Component Torque . . . . . 7-101
Valve SOL2 . . . . . . . . . . . . . 7-96, 7-97 Tilt/Sideshift
Limit Switch, Speed, First (S12) . . . . . . A-6 32 in. Wide Mast . . . . . . . . . . 7-105
Limit Switch, Steer S11 . . . . . . . . 7-23, A-6 Component Torque . . . . . . . . 7-105
Linkage, Steering . . . . . . . . . . . . . . . 7-27 Deep-Reach . . . . . . . . . . . . . . 7-105
Load Manual Lowering of Carriage . . . . . . . 7-92
Holding Valve SOL1 . . . . . . . . . . . 7-96 Mast
Shuttle LS-1 . . . . . . . . . . . . . . . . 7-96 Model 7500
Load Holding Valve SOL1 . . . . . . . . . 7-97 Assembly . . . . . . . . 7-159 to 7-166
Load Wheel Assembly . . . . . . . . . . . . . A-5 Disassembly . . . . . . 7-155 to 7-158
Loctite® Main Lift Chain Installation . . 7-160
See Thread Adhesives Main Lift Chain Removal . . . . 7-156
Lower Mating Tractor to Mast . . . . . 7-164
Function Separation of Telescopics . . . 7-156
Troubleshooting . . . . . . . . . . . 5-26 Separation of Tractor and
Lowering Carriage Manually . . . . . . . 7-92 Mast . . . . . . . . . . . . . . . . 7-155
LS-1 Load Shuttle . . . . . . . . . . . . . . . 7-96 Model 7520
Lubrication Points . . . . . . . . . . . . . . . . 4-9 Assembly . . . . . . . . 7-172 to 7-177
Lubrication Specification Chart . . . . . . A-2 Disassembly . . . . . . 7-167 to 7-171
Main Lift Chain Installation . . 7-173
M Main Lift Chain Removal . . . . 7-169
Mating Tractor to Mast . . . . . 7-177
Separation of Telescopics . . . 7-170
Main Lift Cylinder . . . . . . . .7-114 to 7-116
Separation of Tractor and
Seal Repacking . . . . . . . . . . . . . .7-117
Mast . . . . . . . . . . . . . . . . 7-167
Main Manifold . . . . . . . . . . . . . . . . . . . A-5
Shimming . . . . . . . . . . . . . . . . . . 7-131
Standard Lift/Lower . . . . . . . . . . 7-96
Types . . . . . . . . . . . . . . . . . . . . . . . 3-4
Maintenance Minder ™ Tool . . . . . . . . . 4-3
Manifold
Auxiliary . . . . . . . . . . . . . . . . . . . . A-5
Mounting Bolt Torque . . . . . . . A-4
Regen Lower . . . . . . . . . . . . . 7-98

Mast Bearing Shimming Operator Compartment Sensor System

Carriage to Inner Tele Test I80 – Upper Beam . . . . . . . . . 6-98
Model 7500 . . . . . . . . . . . . . . 7-161 Test I81 – Lower Beam . . . . . . . . 6-100
Model 7520 . . . . . . . . . . . . . . 7-174 Output Tests . . . . . . . . . . . 6-107 to 6-128
Inner Tele to Outer Tele Summary List . . . . . . . . . . . . . . . . 6-32
Model 7500 . . . . . . . . . . . . . . 7-160 See Tests, Output for Individual Tests
Model 7520 . . . . . . . . . . . . . . 7-173 Outrigger
Outer Tele to Main Frame See Baseleg
Model 7500 . . . . . . . . . . . . . . 7-159 Overhead Guard Installation . . . . . . . . A-5
Model 7520 . . . . . . . . . . . . . . 7-172 Over-the-Mast Hose . . . . . . . . . . . . . . . A-4
Messages and Codes Over-the-Mast Hose/Cable . . . . . . . . 7-145
Power Amplifier . . . . . . . . . . . . . . . .6-2 Cable Only Replacement . . . . . . . 7-151
Modes of Operation . . . . . . . . . 3-13 to 3-24
Overview . . . . . . . . . . . . . . . . . . . . 3-13 P
Program . . . . . . . . . . . . . . . . . . . . 3-15
Service
Passwords
Active Maintenance . . . . . . 3-24
Changing Password or SuperWrd . 3-12
Error Log . . . . . . . . . . . . . . 3-23
Electronic Key . . . . . . . . . . . . . . . 3-12
Static . . . . . . . . . . . . . . . . . 3-23
Entering Password or SuperWord . 3-12
Run . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Password . . . . . . . . . . . . . . . . . . . 3-12
Tones . . . . . . . . . . . . . . . . . . . 3-11
SuperWrd . . . . . . . . . . . . . . . . . . . 3-12
Molex Connectors . . . . . . . . . . . . . . . . 7-70
Pin Extraction
Motors
AMP Connectors . . . . . . . . . . . . . . 7-71
AC . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Molex Connectors . . . . . . . . . . . . . 7-70
Lift Temp Sensor . . . . . . . . . . . 7-82
Pin Insertion
Open Winding . . . . . . . . . . . . . 5-18
AMP Connectors . . . . . . . . . . . . . . 7-72
Shorted Winding . . . . . . . . . . . 5-18
Molex Connectors . . . . . . . . . . . . . 7-70
Traction Temp Sensor . . . . . . . 7-81
Pinout Matrix . . . . . . . . . . . . . 8-18 to 8-35
Auxiliary . . . . . . . . . . . . . . . . . . . . .A-4
Pivot Ring, Drive Unit
DC . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Assembly . . . . . . . . . . . . . . . . . . . 7-54
armature . . . . . . . . . . . . . . . . . 5-17
Disassembly . . . . . . . . . . . . . . . . . 7-45
Field Winding Test . . . . . . . . . . 5-17
POD-1 Valve . . . . . . . . . . . . . . . . . . . . 7-96
Grounded Motor Test . . . . . . . . 5-17
Power Amplifier
Open Circuit Test . . . . . . . . . . 5-17
Connector . . . . . . . . . . . . . . . . . . 7-74
Short Circuited Armature . . . . 5-17
Discharging Internal Capacitor . . . . 5-2
winding . . . . . . . . . . . . . . . . . . 5-17
LED Diagnostics . . . . . . . . . . . . . . . 6-2
Lift - Torque Specs . . . . . . . . . . . . .A-5
Lift . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Power Cable Terminals . . . . . . . . . 7-79
Sub-Codes . . . . . . . . . . . . . . . . . . 5-19
Steering - Torque Specs . . . . . . . . . .A-6
Traction . . . . . . . . . . . . . . . . . . . . . A-6
Traction - Torque Specs . . . . . . . . . .A-7
Power Cables . . . . . . . . . . . . . . . . . . . 7-77
Motor . . . . . . . . . . . . . . . . . . . . . . 7-79
AC . . . . . . . . . . . . . . . . . . . . . . 5-18
Pressure Adjustment
DC . . . . . . . . . . . . . . . . . . . . . . 5-14
Auxiliary . . . . . . . . . . . . . . . . . . . . 7-95
Pressure Switch, HTI
O Torque . . . . . . . . . . . . . . . . .7-96, 7-98
Pressure Transducer CYL-P . . . . . . . . 7-96
OCSS Torque . . . . . . . . . . . . . . . . . . . . . 7-97
Test I80 – Upper Beam . . . . . . . . . 6-98 Primary Control Handle . . . . . 7-28 to 7-32
Test I81 – Lower Beam . . . . . . . . 6-100 Priority-on-Demand Valve POD-1 . . . . 7-96
Oil Quantities . . . . . . . . . . . . . . . . . . . .3-5 Program Mode . . . . . . . . . . . . . . . . . . 3-15
Open Circuit DC Motor Test . . . . . . . . 5-17 Menu . . . . . . . . . . . . . . . . . .3-14, 3-16
Open Winding AC Motor . . . . . . . . . . . 5-18 Menu Settings . . . . . . . . . 3-16 to 3-22

Proportional Valve Adjustment . . . . . 7-93 Scheduled Maintenance

Pulleys, Over-the-Mast . . . . . . . . . . . . A-6 180 Days . . . . . . . . . . . . . . . . . . . . 4-5
Pump 2000 Deadman Hours . . . . . . . . . . . 4-8
Auxiliary . . . . . . . . . . . . . . . . . . . . A-4 360 Days . . . . . . . . . . . . . . . . . . . . 4-8
Lift . . . . . . . . . . . . . . . . . . . . . . . . A-5 500 Deadman Hours . . . . . . . . . . . . 4-5
Chains . . . . . . . . . . . . . . . . . . . . . 4-11
R Charts . . . . . . . . . . . . . . . . . 4-2 to 4-8
Guidelines . . . . . . . . . . . . . . . . . . . 4-2
Lubrication Points . . . . . . . . . . . . . 4-9
Reach Carriage
Maintenance Minder ™ Tool . . . . . . . 4-3
See Carriage
Seal Repacking
Reach Cylinder . . . . . . . . . . . . . . . . .7-120
Free Lift Cylinder . . . . . . . . . . . . 7-112
Adjustment . . . . . . . . . . . 7-121, 7-122
Main Lift Cylinder . . . . . . . . . . . . 7-117
Reach Function
Sealants, Specifications . . . . . . . . . . . . A-3
Theory of Operation
Secondary Control Handle . . . 7-37 to 7-38
Lift . . . . . . . . . . . . . . . . . . . . . . 8-9
SelfTest . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Regen Lower . . . . . . . . . . . . . 8-14
Sensor
Reach Valve
Lift Motor Temperature . . . . . . . . . 7-82
Deep-Reach . . . . . . . . . . . 7-103, 7-104
OCSS
Std Reach . . . . . . . . . . . . . 7-99, 7-101
Lower Beam Test I81 . . . . . . . 6-100
REL-2 Relief Valve . . . . . . . . . . . . . . . 7-96
Upper Beam Test I80 . . . . . . . . 6-98
REL-3 Relief Valve (DR) . . . . . 7-103, 7-104
Serial Number
Relief Valve REL-2 . . . . . . . . . . . . . . . 7-96
Description of . . . . . . . . . . . . . . . . . 3-4
Relief Valve REL-3 (DR) . . . . . 7-103, 7-104
Location on Specification Plate . . . . 3-3
Retract Function
Service Information Documents . . . . . . . iii
Service Intervals
Run Mode . . . . . . . . . . . . . . . . . . . . . 3-13
See Scheduled Maintenance Charts
Menu Settings . . . . . . . . . . . . . . . 3-14
Service Menu
Tones . . . . . . . . . . . . . . . . . . . . . 3-11
Active Maintenance Mode . . . . . . . 3-24
Run Mode Menu . . . . . . . . . . . . . . . . 3-14
Service Mode
Static Service Mode . . . . . . . . . . . . 3-23
S Service/Torque Chart, Component
Specific . . . . . . . . . . . . . . . . . . . . . . A-4
Safety Shimming
Battery . . . . . . . . . . . . . . . . . . . . . 2-5 Drive Unit . . . . . . . . . . . . . . . . . . . 7-52
Decals . . . . . . . . . . . . . . . 7-15 to 7-19 Mast Bearings . . . . . . . . . . . . . . . 7-131
Definitions . . . . . . . . . . . . . . . . . . . 2-2 Carriage to Inner Tele
ESD . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Model 7500 . . . . . . . . . . . 7-161
General . . . . . . . . . . . . . . . . . . . . . 2-3 Model 7520 . . . . . . . . . . . 7-174
Jacking . . . . . . . . . . . . . . . . . . . . . 2-9 Inner Tele to Outer Tele
Static Precautions . . . . . . . . . . . . . 2-8 Model 7500 . . . . . . . . . . . 7-160
Tie-Down for Transport . . . . . . . . 2-11 Model 7520 . . . . . . . . . . . 7-173
Welding . . . . . . . . . . . . . . . . . . . . 2-12 Outer Tele to Main Frame
Model 7500 . . . . . . . . . . . 7-159
Model 7520 . . . . . . . . . . . 7-172
Shorted Winding on AC Motor . . . . . . 5-18
Shorts to Frame Test . . . . . . . . . . . . . . 5-2
Sideshift Function
Theory
Regen Lower . . . . . . . . . . . . . . 8-15
Theory of Operation . . . . . . . . . . . . 8-9

Sideshift Valve Symptom Tables

Deep-Reach . . . . . . . . . . . . . . . . . 7-105 Dark display . . . . . . . . . . . ...... 5-29
Std Reach . . . . . . . . . . . . . . . . . . . 7-99 Electrical Symptoms . . . . . ...... 5-29
SOL1 Load Holding Valve . . . . . 7-96, 7-97 Hydraulic Functions . . . . . 5-21 to 5-27
SOL2 Lift/Lower Valve . . . . . . . 7-96, 7-97 Travel Functions . . . . . . . . ...... 5-28
SOL3 Proportional Main Relief/
Dump Valve . . . . . . . . . . . . . . . . . 7-96 T
SOL5B/5T Auxiliary Valve . . . . 7-96, 7-98
Soldering Procedures . . . . . . . . . . . . . 7-69
Temperature Sensor, Lift Motor . . . . . 7-82
Special Tools . . . . . . . . . . . . . . . . . . . . 7-14
Temperature Sensor, Traction Motor . 7-81
Specification Plate . . . . . . . . . . . . . . . . .3-3
Terminals, Motor Power Cable . . . . . . 7-79
Speed Limiting Switch, First (S12) . . . . .A-6
Tests
Spiral Pinion, Drive Unit
Analog . . . . . . . . . . . . . . . 6-33 to 6-66
Assembly . . . . . . . . . . . . . . . . . . . 7-49
Test A04 – Primary Throttle
Disassembly . . . . . . . . . . . . . . . . . 7-48
Potentiometer (VR1) Voltage 6-34
Standard/Metric Conversions . . . . . . .A-17
Test A05 – Lift/Lower Potentiometer
Static
Voltage . . . . . . . . . . . . . . . 6-35
Precautions . . . . . . . . . . . . . . . . . . .2-8
Test A08 – Traction Motor
Service Mode . . . . . . . . . . . . . . . . . 3-23
Temperature . . . . . . . . . . . 6-36
Steer
Test A09 – Lift Motor
Limit Switch S11 . . . . . . . . . . 7-23, A-6
Temperature . . . . . . . . . . . 6-37
Motor . . . . . . . . . . . . . . . . . . . . . . .A-6
Test A10 – TPA
Steerable Caster . . . . . . . . . . . . . . . . . 7-24
Temperature . . . . . . .6-38, 6-40
Height Adjustment . . . . . . . . . . . . 7-25
Test A100 – BSM Comm . . . . . 6-66
Steering
Test A11 – Traction Motor
Encoder . . . . . . . . . . . . . . . . . . . . 7-22
Current . . . . . . . . . . . . . . . 6-39
Limit Switch S11 . . . . . . . . . . 7-23, A-6
Test A14 – Power Supply
Linkage . . . . . . . . . . . . . . . . . . . . . 7-27
+12VDC . . . . . . . . . . . . . . 6-42
Steerable Caster . . . . . . . . . . . . . . 7-24
Test A15 – Battery Voltage . . . 6-43
Height Adjustment . . . . . . . . . . 7-25
Test A16 – Aux Motor Temperature
Steering, Electric
(Regen Lower) . . . . . . . . . . 6-44
Theory of Operation . . . . . . . . . . . . .8-3
Test A18 – Aux Motor Current . 6-45
Stops, Carriage . . . . . . . . . . . . . . . . . . .A-4
Test A20 – Lift Motor Current . 6-47
SuperWrd . . . . . . . . . . . . . . . . . . . . . . 3-12
Test A22 – Primary Traction Throttle
Changing . . . . . . . . . . . . . . . . . . . 3-12
(VR1) Request . . . . . . . . . . 6-48
Entering . . . . . . . . . . . . . . . . . . . . 3-12
Test A23 – Lift Throttle (VR2)
Switch
Request . . . . . . . . . . . . . . . 6-49
High Speed Travel (S25) . . . . . . . . .A-4
Test A26 – Travel and Lift/
HTI Pressure S18
Lower +5VDC Power Supply 6-50
Torque . . . . . . . . . . . . . . 7-96, 7-98
Test A29 – Secondary Throttle
Lift Cutout (S27) . . . . . . . . . . . . . . .A-4
Potentiometer (VR3) Voltage 6-51
Speed Limiting, First (S12) . . . . . . .A-6
Test A30 – Secondary Traction
Steer Limit S11 . . . . . . . . . . . 7-23, A-6
Throttle (VR3) Request . . . 6-52
Tilt/Sideshift . . . . . . . . . . . . 7-35, 7-36
Test A34 – Solenoid 2 (Lift/Lower)
Fore/Aft Stance . . . . . . . 7-31, 7-35
Current . . . . . . . . . . . . . . . 6-53
Switch Adjustment . . . . . . . . . . . . . . . .A-4
Test A35 – Brake Current . . . . 6-54
Switch Gap . . . . . . . . . . . . . . . . . . . . . .A-4
Test A36 – Ambient Temperature
Switches
Sensor . . . . . . . . . . . . . . . 6-55
Battery Gate . . . . . . . . . . . . . . . . . .A-4
Test A37 – Steer Power Amplifier
EPO . . . . . . . . . . . . . . . . . . . . . . . .A-4
Current . . . . . . . . . . . . . . . 6-56
Symbols, List of . . . . . . . . . . . . . . . . . .1-4
Test A41 – Emergency Power
Off (EPO) Switch . . . . . . . . 6-59

Test A42 – Primary Travel Pot Learn Test I81 – OCSS Lower Beam
Value . . . . . . . . . . . . . . . . 6-60 Test . . . . . . . . . . . . . . . . . 6-100
Test A43 – Lift Pot Learn Value 6-61 Test I82 – OCSS Cnt . . . . . . . 6-102
Test A96 – BSM Curr . . . . . . . 6-62 Test I83 – BatGateL . . . . . . . . 6-103
Test A97 – BSM Volt . . . . . . . 6-63 Test I84 – BatGateR . . . . . . . 6-104
Test A98 – BSM Temp . . . . . . 6-64 Test I86 – Lift Height . . . . . . . 6-105
Test A99 – H20 Snse . . . . . . . 6-65 Test I90 – Degrees Turned Past
Input Steer Flag . . . . . . . . . . . . 6-106
Test I00 – Deadman Output
Switch (S2) . . . . . . . . . . . . 6-68 Test O00 – Toggle the MPC
Test I02 – First Speed Limiting Contactor . . . . . . . . . . . . 6-108
Switch (S12) . . . . . . . . . . . 6-70 Test O01 – Toggle the STR
Test I06 – Reach Switch (S4) . 6-71 Contactor . . . . . . . . . . . . 6-109
Test I07 – Retract Switch (S5) . 6-72 Test O02 – Toggle the LPC
Test I08 – Tilt Up Switch (S6) . 6-73 Contactor . . . . . . . . . . . . 6-110
Test I09 – Tilt Down Switch (S7) 6-74 Test O06 – Toggle Reach
Test I10 – Sideshift Right Solenoid . . . . . . . . . . . . . 6-113
Switch (S9) . . . . . . . . . . . . 6-75 Test O07 – Toggle Tilt
Test I11 – Sideshift Left Solenoid . . 6-111, 6-112, 6-114
Switch (S8) . . . . . . . . . . . . 6-76 Test O08 – Toggle the Sideshift
Test I14 – Steering Fuse (FU1) 6-77 Solenoid . . . . . . . . . . . . . 6-115
Test I15 – Horn Switch (S3) . . 6-78 Test O11 – Toggle the Load
Test I18 – Aux Motor Encoder Hold (SOL1) Solenoid . . . . 6-116
(Regen Lower) . . . . . . . . . . 6-79 Test O12 – Ramp the Proportional
Test I19 – Traction Motor Lower (SOL2) Solenoid . . . 6-117
Encoder . . . . . . . . . . . . . . 6-80 Test O18 – Toggle Horn . . . . . 6-118
Test I20 – Lift Motor Speed Test O19 – Audible Alarm . . . 6-119
Sensor . . . . . . . . . . . . . . . 6-81 Test O23 – Toggle Fans . . . . . 6-121
Test I22 – Lift Cutout Test O27 – Ramp Aux Motor
Switch (S27) . . . . . . . . . . . 6-82 (Regen Lower) . . . . . . . . . 6-122
Test I23 – CAN Bus Test . . . . . 6-83 Test O28 – Ramp Lift Motor . . 6-123
Test I24 – Steer Limit Test O29 – Ramp Traction
Switch (S11) . . . . . . . . . . . 6-86 Motor . . . . . . . . . . . . . . . 6-124
Test I25 – Steer Motor Encoder 6-87 Test O30 – Toggle the Brake
Test I26 – Height Indicator Coil . . . . . . . . . . . . . . . . . 6-125
Encoder . . . . . . . . . . . . . . 6-88 Test O32 – Toggle Relays K1,
Test I33 – Steer Tiller Encoder 1 K2, K3, and K4 . . . . . . . . 6-126
Connect Detect . . . . . . . . . 6-90 Test O33 – Handle Heater . . . 6-127
Test I34 – Steer Tiller Encoder 2 Test O61 – Customer Output . 6-128
Connect Detect . . . . . . . . . 6-91 Shorts to Frame . . . . . . . . . . . . . . . 5-2
Test I35 – Steer Tiller Encoder 1 Summary List . . . . . . . . . . . . . . . . 6-31
(Channel A & B) . . . . . . . . 6-92
Test I36 – Steer Tiller Encoder 2
(Channel A & B) . . . . . . . . 6-93
Test I39 – Neutral Pulses . . . . 6-94
Test I40 – Customer Interlock 6-95
Test I60 – Security Start Switch
(optional) . . . . . . . . . . . . . 6-96
Test I63 – High Speed Travel Switch
(S25) . . . . . . . . . . . . . . . . 6-97
Test I80 – OCSS Upper Beam
Test . . . . . . . . . . . . . . . . . 6-98

Theory of Operation Tire

BSOC . . . . . . . . . . . . . . . . . . . . . . .5-5 Drive, Pressing . . . . . . . . . . . . . . . 7-57
Cold Storage . . . . . . . . . . . . . . . . . 8-17 Tire, Drive . . . . . . . . . . . . . . . . . . . . . . A-4
Electric Brake . . . . . . . . . . . . . . . . 8-16 Tones, Run Mode . . . . . . . . . . . . . . . . 3-11
Lift Tools, Special . . . . . . . . . . . . . . . . . . . 7-14
Reach/Retract . . . . . . . . . . . . . .8-9 Torque Chart
Lift/Lower . . . . . . . . . . . . . . . . . . . .8-8 Brass, Standard . . . . . . . . . . . . . . A-12
Pinout Matrix . . . . . . . . . . 8-18 to 8-35 Face Seal O-Rings . . . . . . . . . . . . . A-9
Regen Lower Ferrous, Metric . . . . . . . . . . . . . . . A-11
Lift/Lower . . . . . . . . . . . . . . . . 8-13 Hydraulic Fittings . . . . . . . . . . . . . . A-8
Reach/Retract . . . . . . . . . . . . . 8-14 Metric (Brass) . . . . . . . . . . . . . . . . A-13
Sideshift . . . . . . . . . . . . . . . . . 8-15 Thread-Forming Screws . . . . . . . . A-14
Tilt . . . . . . . . . . . . . . . . . . . . . 8-14 Torque Specs
Regen Lower and AC Aux Auxiliary Manifold
System Components . . . . . . . . 8-11 Standard Reach . . . . . . . . . . . 7-99
SelfTest . . . . . . . . . . . . . . . . . . . . . .8-2 Auxiliary Manifold w/Regen Lower 7-98
Sideshift . . . . . . . . . . . . . . . . . . . . .8-9 Deep-Reach Manifold . . . . . . . . . 7-103
Standard Lift/Lower 32 in. Wide Mast . . . . . . . . . . 7-104
System Components . . . . . . . . .8-6 Lift/Lower Manifold w/
Tilt . . . . . . . . . . . . . . . . . . . . . .8-8 Regen Lower . . . . . . . . . . . . . . 7-97
Steering System . . . . . . . . . . . . . . .8-3 Main Manifold
Traction System . . . . . . . . .8-2 to 8-17 Non-Regen . . . . . . . . . . . . . . . 7-96
Battery Connected . . . . . . . . . . .8-2 Standard Reach Manifold
Deadman Pedal Depressed . . . . .8-3 32 in. Wide Mast . . . . . . . . . . 7-101
Key Switch Turned On . . . . . . . .8-2 Tilt/Sideshift Manifold . . . . . . . . 7-105
Requesting Travel . . . . . . . . . . .8-4 Traction Motor
ThermaKit Power Cable Terminal Nuts . . . . . . 7-79
Dockstance . . . . . . . . . . . . . 7-33, 7-36 Traction Motor Torque Specs . . . . . . . . A-7
Fore-Aft Stance Traction Power Amplifier . . . . . . . . . . . A-6
Primary . . . . . . . . . . . . . 7-30, 7-35 LED Diagnostics . . . . . . . . . . . . . . . 6-2
Fore/Aft Stance Traction System Functional Operation
Primary . . . . 7-28, 7-30, 7-31, 7-35 See Theory of Operation,
Thread Adhesives, Specifications . . . . . .A-3 Traction System
Thread-Forming Screws, Torque Chart A-14 Transducer, Pressure CYL-P . . . . . . . . 7-96
Tie-Down for Transport . . . . . . . . . . . . 2-11 Torque . . . . . . . . . . . . . . . . . . . . . 7-97
Tilt Transmission
Cylinder . . . . . . . . . . . . . 7-123, 7-125 See Drive Unit
Function Transport, Tie-Down for . . . . . . . . . . . 2-11
Theory Travel Functions, Troubleshooting . . . 5-28
Regen Lower . . . . . . . . . . . 8-14 Travel Light . . . . . . . . . . . . . . . . . . . . . A-7
Standard Lift/Lower . . . . . . .8-8 Travel Switch, High Speed (S25) . . . . . . A-4
Troubleshooting . . . . . . . . . . . . 5-22
Valve
Deep-Reach . . . . . . . . . . . . . . 7-105
Std Reach . . . . . . . . . . . . . . . . 7-99
Tilt/Sideshift
Manifold (32 in. Wide Mast) . . . . . 7-105
Manifold (Deep-Reach) . . . . . . . . . 7-105
Switch
Dockstance . . . . . . . . . . . . . . . 7-36
Fore/Aft Stance . . . . . . . . . . . . 7-31

Troubleshooting SOL5B/5T Auxiliary . . . . . . 7-96, 7-98

Auxiliary Tilt
Functions . . . . . . . . . . . . . . . 5-21 Deep-Reach . . . . . . . . . . . . . . 7-105
Chains . . . . . . . . . . . . . . . . . . . . . 4-11 Std Reach . . . . . . . . . . . . . . . . 7-99
DC motors Vehicle Manager
short-circuited armature . . . . 5-17 Circuit Card Connectors . . . . . . . . 5-10
short-circuited winding . . . . . 5-17
Dead Lift Truck . . . . . . . . . . . . . . 5-29 W
Drive Unit . . . . . . . . . . . . . . . . . . 7-43
Electrical . . . . . . . . . . . . . . . . . . . . 5-2
Warning, Definition . . . . . . . . . . . . . . . 2-2
Fuses . . . . . . . . . . . . . . . . . . . . . . 5-6
Welding Safety . . . . . . . . . . . . . . . . . . 2-12
Hydraulic
Wheel
Guidelines . . . . . . . . . . . . . . . 5-20
Load . . . . . . . . . . . . . . . . . . . . . . . . A-5
Symptoms . . . . . . . . . 5-21 to 5-27
Wiring
Lift Function . . . . . . . . . . . . . . . . 5-24
General . . . . . . . . . . . . . . . . . . . . . 7-69
Lift/Lower Functions . . . . . . . . . . 5-24
Harness Terminology . . . . . . . . . . . 5-7
Lower Function . . . . . . . . . . . . . . 5-26
Inspection . . . . . . . . . . . . . . . . . . . 7-69
Motors . . . . . . . . . . . 5-14 to 5-18, 5-29
Repair . . . . . . . . . . . . . . . . . . . . . . 7-69
AC . . . . . . . . . . . . . . . . . . . . . 5-18
Soldering Procedures . . . . . . . . . . 7-69
DC . . . . . . . . . . . . . . . . . . . . . 5-14
Wrist strap, ESD . . . . . . . . . . . . . . . . . 2-8
Pinout Matrix . . . . . . . . . 8-18 to 8-35
Retract Function . . . . . . . . . . . . . 5-24
Shorts to Frame Test . . . . . . . . . . . 5-2
Sideshift Function . . . . . . . . . . . . 5-22
Symptom Tables . . . . . . . 5-21 to 5-29
Tilt Function . . . . . . . . . . . . . . . . 5-22
Travel Functions . . . . . . . . . . . . . 5-28
Truck Installation . . . . . . . . . . . . . . . . 3-6
Valve
CB1 & CB2
Counterbalance . . . . . 7-103, 7-104
CV-1 Check Valve . . . . . . . . . . . . 7-96
CV-3 Check Valve . . . . . . 7-103, 7-104
LS-1 Load Shuttle . . . . . . . . . . . . 7-96
POD-1 . . . . . . . . . . . . . . . . . . . . . 7-96
Proportional, Adjustment . . . . . . . 7-93
Reach
Deep-Reach . . . . . . . . 7-103, 7-104
Std Reach . . . . . . . . . . 7-99, 7-101
REL-2 Relief . . . . . . . . . . . . . . . . 7-96
REL-3 Relief (DR) . . . . . . . 7-103, 7-104
Sideshift
Deep-Reach . . . . . . . . . . . . . .7-105
Std Reach . . . . . . . . . . . . . . . 7-99
SOL1 Load Holding . . . . . . . 7-96, 7-97
SOL2 Lift/Lower . . . . . . . . . 7-96, 7-97
SOL3 Proportional Main Relief/
Dump . . . . . . . . . . . . . . . . . . 7-96


1252757A
Printed by the Digital Print Center,

The Raymond Corporation, Greene, NY
Schematics
Models Serial Numbers

7500/7520 65,001 and Up This publication applies 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, 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: 1252757A Issued: 16 February 2018
©2018 The Raymond Corporation.

Models 7500/7520/7700/7720 Reach-Fork ® Truck Schematics
Figure 1-1. Power Distribution Diagram - Standard Lift
Standard Lift
Publication: 1252757A, Issued: 16 February 2018 2

Figure 1-2. Power Distribution Diagram - Regen Lower
Regen Lower

Figure 1-3. Electrical Schematic - Standard Lift (Sheet 1 of 7)
A B C D E F G H
7
Standard Lift

Figure 1-4. Electrical Schematic - Regen Lower (Sheet 2 of 7)
A B C D E F G H
7 Regen Lower

Figure 1-5. Electrical Schematic - Blank Page (Sheet 3 of 7)
A B C D E F G H

Figure 1-6. Electrical Schematic - Evolution Display (Sheet 4 of 7)
A B C D E F G H
7 Evolution Display

Figure 1-7. Electrical Schematic - Options (Sheet 5 of 7)
A B C D E F G H
7 Options

Figure 1-8. Electrical Schematic - Options (con’t) (Sheet 6 of 7)
A B C D E F G H
7 Options - continued

Figure 1-9. Electrical Schematic - Legend (Sheet 7 of 7)
8
6
JPHE1 5 H3 CONNECTOR FOR HEIGHT ENCODER HEATER

Figure 1-10. Hydraulic Schematic - Standard Lift (Sheet 1 of 2)
HTI (option)
SIDE SHIFT
G2 SIDE
SHIFT
ESS RV-4 1
3 4 SSR
2000 psi
M SOL-5B 1 2 SSL
POD-1
1 2 A1 A1
# 12 P1 4 3 2
1
LS-1 # 4 HOSE (7X00)
RV2 REACH
3
P1 2
RC
2 1 4 3 4
3 A2 A2
1 2
RV1 RR
G1
SOL-5T
G3 REACH TILT
1 2 CV-1 CYL-1
3 4 TC
2 1 2
TR
1 SOL-1
TILT
SOL-3
1
2 1
# 12
MAIN LIFT FREE LIFT
SOL-2
TANK 2
CFS (option)
# 8 HOSE (7X00)
CYL-P
COMPONENT RELIEF SETTING
KEY RV-1 700 psi
PRESSURE LINES RV-2 1000 psi
RETURN LINES RV-3 1150 psi
PILOT LINES RV-4 2000 psi

Standard Lift
COMPONENT BOUNDARIES SOL-3 3100 psi MAX

Figure 1-11. Hydraulic Schematic - Standard Lift (Sheet 2 of 2)
SINGLE REACH WITH TILT
SIDE
SHIFT SSR
3 4
1 2 SSL
A1 RV2 REACH
3 4 RC
A2
1 2
RR
RV1
REACH TILT
3 4 TC
1 2
TR
TILT
DEEP REACH WITH TILT AND SIDE SHIFT

DEEP REACH WITH TILT
CB-1 1,600 PSI
CV-3
2 PSI RV-3 CB-1 1,600 PSI
1,150 PSI RC CV-3
T B 2 3 1
2 PSI RV-3
REACH T B 2 3 1 1,150 PSI RC
A1 3 4 1 REACH
A1 3 4 1
1 2 1
1 2 1
A2
2 3 2 A2
RR 2 3 2
RR
REACH REACH
CB-2 825 PSI CB-2 825 PSI
TILT
SIDE SHIFT
SIDE TILT
SHIFT SSR
3 4 A1
TC
3 4
1 2 SSL 1 2 TR
A2
A1
A2
3 4 TC TILT
1 2
TR
Standard Lift - Options
TILT OPTIONS FOR AUX FUNCTIONS
Figure 1-12. Hydraulic Schematic - Regen Lower (Sheet 1 of 3)
Regen Lower
Figure 1-13. Hydraulic Schematic - Regen Lower - con’t (Sheet 2 of 3)
Regen Lower - continued

Figure 1-14. Hydraulic Schematic - Regen Lower - Narrow Mast (Sheet 3 of 3)
Regen Lower - Narrow Mast


Maintenance Manual: Models 7500/7520 Reach-Fork Trucks

Uploaded by

Copyright:

Available Formats

Maintenance Manual: Models 7500/7520 Reach-Fork Trucks

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Maintenance Manual: Models 7500/7520 Reach-Fork Trucks

Uploaded by

Copyright:

Available Formats

Maintenance Manual

Models 7500/7520 Reach-Fork ® Trucks

Models Serial Numbers

1252757A Issued: 16 February 2018

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

To locate your local authorized Raymond Sales and Service Center, go to

©2018 The Raymond Corporation.

Document Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Publication: 1252757, Issued: 16 February 2018 i

Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

ii Publication: 1252757, Issued: 16 February 2018

Document Revision History

Revision Date Description of Changes

1252757A 16 February 2018 Initial Release

Service Information List

RSI Number Subject Issue Date

Publication: 1252757, Issued: 16 February 2018 iii

iv Publication: 1252757, Issued: 16 February 2018

Section 1. How to Use This Manual

Publication: 1252757, Issued: 16 February 2018 1-1

Manual Design • 7. Component Procedures contains

1-2 Publication: 1252757, Issued: 16 February 2018

Interactive Electronic Technical Manuals

Blue text in the Maintenance Manual is linked

Publication: 1252757, Issued: 16 February 2018 1-3

Abbreviations and Symbols

Term/Symbol Definition Term/Symbol Definition

A Ampere DC Direct Current

1-4 Publication: 1252757, Issued: 16 February 2018

Abbreviations and Symbols

Term/Symbol Definition Term/Symbol Definition

Publication: 1252757, Issued: 16 February 2018 1-5

Abbreviations and Symbols

Term/Symbol Definition Term/Symbol Definition

WHLD Weight Height Limit Display

1-6 Publication: 1252757, Issued: 16 February 2018

Publication: 1252757, Issued: 16 February 2018 2-1

Warning means a potentially hazardous

Caution means a potentially hazardous

2-2 Publication: 1252757, Issued: 16 February 2018

Do not operate or work on this lift truck unless

Before working on this lift truck, always turn

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

Do not wear watches, rings, or jewelry when

Follow the scheduled lubrication, maintenance,

Publication: 1252757, Issued: 16 February 2018 2-3

Do not wash this lift truck with a hose.

Do not add to or modify this lift truck until you

Clean up any hydraulic fluid, oil, or grease that

2-4 Publication: 1252757, Issued: 16 February 2018

Battery Safety Wear personal protective equipment to protect

As a battery is being charged, an

Keep the charging area well-ventilated to avoid

Publication: 1252757, Issued: 16 February 2018 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: 1252757, Issued: 16 February 2018