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Maintenance Manual
EASi Reach-Fork® Lift Truck
Model Series
0REACH.EPS
EASi Reach-Fork® Lift Truck EZ-D

DZ-D
PDMM-0109 7/31/02
This publication, PDMM-0109, applies to the EASi Reach-Fork® lift truck, Series EZ-D/DZ-D, 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.
Technical changes or additions to the text and illustrations are indicated by a vertical line to the left of the
change.
To order additional copies of this manual, contact your local authorized Raymond Dealer.
If you need assistance with your lift truck, contact your local authorized Raymond Dealer.
To locate a dealer, go to www.raymondcorp.com.
© 2002 The Raymond Corporation.

The following terms are trademarks of The Raymond Corporation: Auto Power Off, Deep-Reach, EASi,
intellidrive, intellispeed, Maintenance Minder, Raymond, Reach-Fork, and SMARTi. All other brand and product
names are trademarks or registered trademarks of their respective companies.
EASi Reach-Fork® Truck EZ-D/DZ-D Maintenance Manual
Table of Contents
Page Revision Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Map of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Design of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
START Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Static Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Jacking Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Tie-Down for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Welding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Lift Truck Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Operator Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Maintenance Guidelines . . . . . . . . . . . . . . . . . . . ..... .. . .. . . . . . . . . 4-2
Maintenance Minder™ Tool . . . . . . . . . . . . . . . . . ..... .. . .. . . . . . . . . 4-3
Operator’s Daily Checklist . . . . . . . . . . . . . . . . . . ..... .. . .. . . . . . . . . 4-6
Every 60 Days or 250 Deadman Hours (HD) . . . . ..... .. . .. . . . . . . . . 4-8
Every 180 Days or 1500 Deadman Hours (HD) . . ..... .. . .. . . . . . . . 4-14
Every 360 Days or 3000 Deadman Hours (HD) . . ..... .. . .. . . . . . . . 4-14
Scheduled Maintenance Points . . . . . . . . . . . . . . ..... .. . .. . . . . . . . 4-15
Motor Maintenance . . . . . . . . . . . . . . . . . . . . . . . ..... .. . .. . . . . . . . 4-19
Lubrication Points. . . . . . . . . . . . . . . . . . . . . . . . ..... .. . .. . . . . . . . 4-20
Chain Maintenance . . . . . . . . . . . . . . . . . . . . . . . ..... .. . .. . . . . . . . 4-26
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
How to Use This Chapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Electrical Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Shorts to Frame Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
DC Motor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
AC Motor Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Battery State-of-Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
PDMM-0109 7/31/02 iii

Hydraulic Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
Symptom Tables: Hydraulic Functions . . . . . . . . . . . . . . . . . . . . . . . . . .5-21
Symptom Tables:
Travel Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-30
Symptom Tables: Electrical Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . .5-32
Messages, Codes, and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Firmware Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Messages and Codes Summary List . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Power Amplifier LED Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17
Electrical Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-69
Circuit Card Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-70
Electrical Test Summary List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73
Analog Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75
Digital Input Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-93
Digital Output Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-111
Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Component Locator Photos. . . . . ..... . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Covers and Finish . . . . . . . . . . . ..... . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Steering and Controls. . . . . . . . . ..... . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Drive and Brake . . . . . . . . . . . . . ..... . . . . . . . . . . . . . . . . . . . . . . . . 7-41
Electrical Components . . . . . . . . ..... . . . . . . . . . . . . . . . . . . . . . . . . 7-81
Hydraulic Components . . . . . . . . ..... . . . . . . . . . . . . . . . . . . . . . . . 7-107
Mast, Chain, Hose and Cable . . . ..... . . . . . . . . . . . . . . . . . . . . . . . 7-153
Options . . . . . . . . . . . . . . . . . . . ..... . . . . . . . . . . . . . . . . . . . . . . . 7-185
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Traction System Functional Operation . ..... ..... . . . . . . . . . . . . . . . .8-1
Thermal Cut-Back . . . . . . . . . . . . . . . . ..... ..... . . . . . . . . . . . . . . .8-19
Steering System . . . . . . . . . . . . . . . . . . ..... ..... . . . . . . . . . . . . . . .8-20
Lift/Aux System Functional Operation . ..... ..... . . . . . . . . . . . . . . .8-24
Pinout Matrix . . . . . . . . . . . . . . . . . . . . ..... ..... . . . . . . . . . . . . . . .8-55
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Lubrication Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . ..... .. A-2
Thread Adhesives, Sealants, and Lubricants. . . . . . . . . . . . . . . ..... .. A-3
EZ-D/DZ-D Torque Quick Reference Chart. . . . . . . . . . . . . . . . ..... .. A-4
Torque Chart - Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . ..... .. A-6
Torque Chart - Straight Thread Face Seal O-Rings . . . . . . . . . . ..... .. A-6
Torque Chart - Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . ..... .. A-7
Torque Chart - Metric (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . ..... .. A-8
Torque Chart - Metric (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. A-8
iv PDMM-0109 7/31/02
Torque Chart - Standard (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-15
Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-23
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
PDMM-0109 7/31/02 v
vi PDMM-0109 7/31/02
Page Revision Record
This page is a record of the latest revised pages

in this manual. Whenever we revise a page, we
update this section and include it in the
revision. This lets you keep track of the latest
revised pages for this manual.
This is the first edition of this manual; there are
no page revisions. See “Map of the Manual” on
page 1-2 and “Design of the Manual” on page
1-3 for an explanation of the format and layout
of this manual.
PDMM-0109 7/31/02 vii

viii PDMM-0109 7/31/02

EASi Reach-Fork® Truck EZ-D/DZ-D Maintenance Manual How to Use This Manual
How to Use This Manual 1:
PDMM-0109 7/31/02 1-1

How to Use This Manual EASi Reach-Fork® Truck EZ-D/DZ-D Maintenance Manual
Map of the Manual
Map of the Manual

1MAP.WMF
Table of Trouble-
Contents shooting
Page Revision
Record Messages,
Codes, and
Tests
How to Use Component

This Manual Procedures
Map of the
Manual
Component
Locator Photos
Manual Design
Component
Procedures by Lift
Start Page Truck System
Theory of
Safety Operation
Systems Appendix
Overview
Scheduled Index
Maintenance
1-2 PDMM-0109 7/31/02

Design of the Manual

The EASi ™ Reach-Fork Truck Maintenance
Manual is designed with the following objectives
in mind:
• Provide technical coverage for expected
levels of user expertise.
• Anticipate your needs and reduce your
decisions regarding maintenance.
• Reduce page flipping through a “one-stop
shopping” approach.
The two-line running page header at the top of
each page tells you:
• Name of the manual
(EASi Reach-Fork® Truck Maintenance
Manual)
• Current chapter title
(for example, this page How to Use This
Manual)
• Current topic
(for example, this page Design of the
Manual)
We suggest you get in the habit of turning to the
START page first when you use this manual.
The START page asks a few simple questions to
guide you to the proper chapter.
• How to Use This Manual explains the
manual format and design and contains the
Table of Contents and START page.
• Safety explains warning and caution notes,
general safety rules and safety rules for
batteries, static, jacking, and welding.
• Systems Overview includes lift truck
specifications.
• Scheduled Maintenance outlines the
recommended schedule of preventive
services to keep your lift truck working
most efficiently.
• Troubleshooting is a set of general
troubleshooting guidelines, a
troubleshooting task flow, and a set of
troubleshooting tables for symptoms not
accompanied by a fault code.
PDMM-0109 7/31/02 1-3

• The START TROUBLESHOOTING chart

(on page 5-17) is a general task flow that
will guide you to the troubleshooting
procedure you need.
• Once you’re familiar with the symptoms
listed, you may instead simply find the
symptom in the troubleshooting
symptom tables. See “Symptom Tables:
Hydraulic Functions” on page 5-21.
• When you complete a troubleshooting
procedure, be sure to follow the steps in
End of Troubleshooting Chart END-1
(page 5-20).
• Messages, Codes, and Tests lists the
electrical fault codes, details for modes of
operation, and procedures for running
firmware electrical tests.
• Component Procedures gives step-by-step
procedures for testing, removal,
installation, and adjustment of individual
lift truck components. Components are
grouped by lift truck system:
• Covers and Finish
• Steering and Controls
• Drive and Brake
• Electrical Components
• Hydraulics
• Mast, Chain, Hose and Cable
• Options
To find a component procedure, you can
use one of three methods:
• Look up the component name in the list
of Component Procedures by lift truck
system (page 7-1).
• Find the component in the Component
Locator Photos (page 7-3).
• Look up the component name in the
Index.
• Theory of Operations explains flow within
hydraulic and electrical schematics for
various conditions of lift truck operation.
• Appendix contains reference information
such as torque values, lubrication
specifications, and system schematics.
• Index lists subjects alphabetically.
1-4 PDMM-0109 7/31/02

START Page
How to Use This Manual 1:
START Page
1STARTPG1.WMF
START: What do you want to do?
Go to Chapter 2
Review safety "Safety"
Yes
precautions?
No
Go to Chapter 3
Examine "Systems Overview"
Yes
specifications?
No
Go to Chapter 4
Do scheduled "Scheduled Maintenance"
Yes
maintenance?
No
Go to Chapter 5
Troubleshoot a "Troubleshooting"
Yes
problem?
No
Go to Chart
START-2
PDMM-0109 7/31/02 1-5

START Page
1STARTPG2.WMF
START-2
Trouble- Go to Chapter 6
shoot a "Messages, Codes,
fault code or run Yes and Tests"
a diagnostic
test?
No
Test,
Go to Chapter 7
inspect, adjust,
"Component Procedures"
remove/install a Yes
component?
Component Locator
No
Photos
Find Go to Chapter 8
Component Procedures by
information on "Theory of Operation"
Yes Lift Truck System
theory of
operation?
No
Go to Chapter A
Find
"Appendix"
general reference Yes
information?
No
Locate
Go to the Index
an object or
Yes
procedure by
name?
1-6 PDMM-0109 7/31/02

EASi Reach-Fork® Truck EZ-D/DZ-D Maintenance Manual Safety
Safety 2:
PDMM-0109 7/31/02 2-1

Safety EASi Reach-Fork® Truck EZ-D/DZ-D Maintenance Manual
Definitions
Definitions
Throughout this manual, you will see two kinds
of safety reminders:
! WARNING
Warning indicates a potentially
hazardous situation, which, if not
avoided, could result in death or
serious injury.
! CAUTION
Caution indicates a potentially
hazardous situation, which, if not
avoided, may result in minor or
moderate injury or in damage to the
lift truck or nearby objects. It may
also be used to alert against unsafe
practices.
2-2 PDMM-0109 7/31/02

General Safety
General Safety
Do not operate or work on this lift truck unless

you are trained, qualified, and authorized to do
so, and have read the Owner/Operator Manual.
28B15004D.EPS
Know the lift truck’s controls and what they do.
22823_001.eps
Do not operate this lift truck if it needs repair

or if it is in any way unsafe.
22823_002.eps
Operate this lift truck only from the operator’s

position.
22823_003.eps
PDMM-0109 7/31/02 2-3

General Safety
Before working on this lift truck, always turn

the key switch OFF and disconnect the lift
truck’s battery connector (unless this manual
tells you otherwise).
22823_004.eps
Do not wear watches, rings, or jewelry when

working on this lift truck.
2jewelry.eps
Follow the scheduled lubrication, maintenance

and inspection steps.
2schedmnt.eps
Follow exactly the safety and repair instructions

in this manual. Do not take “shortcuts.”
28b15008d.eps
2-4 PDMM-0109 7/31/02

General Safety
Do not use an open flame near the lift truck.
22823_005.eps
Do not use gasoline or other flammable liquids

for cleaning parts.
22823_006.eps
Clean up any hydraulic fluid, oil or grease that

has leaked or spilled on the floor.
2spills.eps
Always operate and park this lift truck indoors.
22823_007.eps
PDMM-0109 7/31/02 2-5

General Safety
Do not wash this lift truck with a hose.
22823_008.eps
Do not add to or modify this lift truck until you

contact your local Raymond Dealer to receive
written manufacturer approval.
22823_009.eps
Do not park this lift truck in a cold storage area

overnight.
2-6 PDMM-0109 7/31/02

Battery Safety
Battery Safety
! WARNING
As a battery is being charged, an
explosive gas mixture forms within
and around each cell. If the area is
not properly ventilated, this
explosive gas can remain in or
around the battery for several hours
after charging. Be 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.
! WARNING
Battery electrolyte is a solution of
sulfuric acid and water. Battery acid
causes burns. If any electrolyte
comes in contact with your clothing
or skin, flush the area immediately
with cold water. If the solution gets
on your face or in your eyes, flush
the area with cold water and get
medical help immediately.
Read, understand and follow procedures,

recommendations, and specifications in the
battery and battery charger manufacturer’s
manuals.
225l6s014.eps
PDMM-0109 7/31/02 2-7

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.
225L6S016.eps
Make sure a shower and eyewash station are

nearby in case of an accident.
204G6S059.eps
A battery gives off explosive gases. NEVER

smoke, use an open flame, or use anything that
gives off sparks near a battery.
223L6S012.eps
Keep the charging area well-ventilated to avoid

hydrogen gas concentration.
204g6s058.eps
2-8 PDMM-0109 7/31/02

Battery Safety
Turn the key switch OFF before disconnecting

the battery from the lift truck at the battery
connector. Do not break live circuits at the
battery terminals. A spark often occurs at the
point where a live circuit is broken.
22823_004.eps
Do not lay tools or metal objects on top of the

battery. A short circuit or explosion could
result.
204g6s057.eps
Keep batteries clean. Corrosion causes shorts

to the frame and possibly sparks.
2
Keep plugs, terminals, cables and receptacles in

good condition to avoid shorts and sparks.
227Y7S013.tif
PDMM-0109 7/31/02 2-9

Battery Safety
Vent
Hole
Keep filler plugs firmly in place at all times

except when the electrolyte level is checked,
when water is added to the cells or when the
specific gravity is checked.
Make sure the vent holes in the filler plugs are
open to allow the gas to escape from the cells.
209g6s047.tif
Do not allow cleaning solution, dirt or any

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

smaller or lighter weight battery could seriously
affect lift truck stability. See the lift truck’s
specification plate for more information.
22823_010.eps
NEVER plug a battery charger into the lift

truck’s battery connector. Plug the battery
charger only into the battery connector from the
battery.
22823_011.eps
2-10 PDMM-0109 7/31/02

Static Precautions
Static Precautions
The discharge of static electricity, called
electrostatic discharge, can damage electronic
circuit boards and devices used on the
Raymond EASi Reach-Fork® lift truck.
Static charges accumulate from normal Inertial
operation of the lift truck as well as movement Dampener Traction
or contact between non-conductive materials Cover Power
(plastic bags, synthetic clothing, synthetic soles Amplifier
on shoes, styrofoam coffee cups, etc.)
Accumulated static can discharge through
human skin to a circuit board or component by
touching the parts. Static discharge is also
ESD Ground Jack
possible through the air when a charged object
is close to another surface at a different 25077_034.TIF
electrical potential. Static discharge can occur Figure 2-1: ESD Ground Jack Location
without your seeing or feeling it.
Whenever working on or near static-sensitive
electronics, always use static discharge
precautions.
1. Place a static discharge wrist strap around
your wrist. Connect the ground lead to the
wrist strap connector. The wrist strap must
have a 1 megohm resistor to dissipate static
charges slowly.
2. Connect the ground plug to the ESD
ground jack on the lift truck. The ESD
ground jack is located by the inertial
dampener cover under the traction power
amplifier.
3. Handle circuit boards by edges only. Avoid
touching edge connectors.
4. If you will be removing or installing
static-sensitive components, place them on
a properly grounded static mat.
5. To transport static-sensitive components,
including failed components being
returned, place the components in an
antistatic bag or box (available from your
Raymond Dealer).
Test the wrist strap and related accessories
before each use to make sure they are working
properly.
PDMM-0109 7/31/02 2-11

Static Precautions
2mat2.tif
Figure 2-2: Anti-Static Kit with Wrist Strap and Mat
Figure 2-2 shows the components of the

Raymond antistatic field service kit, part
number 1-187-059. The kit includes a wrist
strap, ground cord and static-dissipative work
surface (mat). Follow the instructions packaged
with this kit.
Wrist straps are available in quantities of 25, as
P/N 1-187-058/001.
A wrist strap tester is available as
P/N 1-187-060/100.
Contact your local Raymond Dealer for
information.
2-12 PDMM-0109 7/31/02

Jacking Safety
Jacking Safety
You need to jack the lift truck off the floor to
perform some maintenance procedures. When
doing so, follow approved safety precautions:
1. Lower the forks completely. Remove any
load.
2. Place all controls in neutral.
3. Block the wheels to prevent movement of
the vehicle.
4. Turn the key switch OFF and disconnect
the battery connector.
A-frame Springs
5. If possible, stabilize the top of the mast with
an overhead chain hoist.
6. Before jacking the lift truck, examine the
A-frame down-travel adjustment bolt. See
Figure 2-3. If the bolt is missing, or the hole
through which it passes is excessively
worn, the A-frame will not be held in place
when the lift truck is jacked up; the
A-frame could pivot down and allow the A-frame
Down-Travel
springs to fall out. Adjustment Bolt
7. Place the jack under the designated jacking
points. See Figure 2-4. 213Y7S001.TIF
Figure 2-3: Verify A-frame Down-Travel Adjustment Bolt

(inertial dampener cover removed for clarity)
! WARNING
Use extreme care when 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
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.
PDMM-0109 7/31/02 2-13

Tie-Down for Transport
To elevate the rear of the lift truck:

Jack only in
1. Place the jack in the specified jacking these areas
position. 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
inches (50 mm). If you must elevate the
drive tire more than 2 inches, attach the lift
truck at the overhead guard to a suitable No Jack Area
capacity hoist.
3. Block the lift truck in place.
To elevate either side of the lift truck:

1. Place the jack in the specified jacking
position. See Figure 2-4.
2toyrch_t.eps
2. Jack the side of the truck so that the load
wheel is off the floor no more than 1/2 inch Figure 2-4: Correct Jacking Locations
(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

To transport your Raymond EASi Reach-Fork®
lift truck in an over-the-road vehicle or rail car,
follow these steps:
1. Lower the forks and locate the lift truck in
the center of the transport vehicle.
2. Using a suitable lifting device, remove the
battery. See “Battery Safety” on page 2-7.
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 will secure the lift truck to the
vehicle bed and prevent tip-over and
forward or backward movement.
2-14 PDMM-0109 7/31/02

Welding Safety
6. Secure the battery according to the battery

manufacturer’s instructions.
Welding Safety
! WARNING
Flame cutting or welding on painted
surfaces can produce potentially
harmful fumes, smoke and vapors.
Before doing flame cutting or
welding, remove the coating in the
area where the operation(s) will
occur.
Coating removal can occur by

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

that:
• Fire protection equipment is nearby.
• You know where the nearest eyewash
station is.
204G6S059.eps
PDMM-0109 7/31/02 2-15

Welding Safety
! CAUTION
Disconnect the battery before you
attempt to inspect, service, or repair
the lift truck.
• Test for shorts to frame as described in

“Shorts to Frame Test” on page 5-5. If you
find any shorts, correct them before you
weld.
• Clean the area to be welded.
• Protect all lift truck components from heat,
weld spatter and debris.
• Attach the ground cable as close to the weld
area as possible.
22823_004.eps
• Disconnect all electrical connectors from

circuit cards before doing any type of
electric resistance welding.
• Do not weld near electrical components.
• If you must weld near the battery
compartment, remove the battery from the
lift truck.
• When you are finished welding, re-install
connectors on circuit cards and do all
ground tests and electrical inspections
before operating the lift truck.
2-16 PDMM-0109 7/31/02

EASi Reach-Fork® Truck EZ-D/DZ-D Maintenance Manual Systems Overview
Systems Overview 3:
PDMM-0109 7/31/02 3-1

Systems Overview EASi Reach-Fork® Truck EZ-D/DZ-D Maintenance Manual
Introduction
Introduction
This manual provides information for

maintenance and repair of the Series
EZ-D/DZ-D EASi Reach-Fork® lift truck by
Raymond.
This manual contains the most current and
accurate procedures, drawings, and
photographs available at the time of
publication. Because Raymond® products are
continually improved, your lift truck may differ
slightly from that shown here; some changes in
parts, layout, or procedures may not be
reflected in this manual.
For the latest information on your Raymond lift
truck, contact your nearest authorized
Raymond Dealer.
3-2 PDMM-0109 7/31/02

Lift Truck Specifications
Lift Truck Specifications
This lift truck is rated for performance by load

center and load weight.
Review the specification plate located on the lift
truck’s left mast upright for detailed load
capacity and load center information.
Due to continuous product enhancement,
specifications are subject to change without
notice or obligation.
Raymond model Serial number* Nominal battery voltage
THE RAYMOND CORP. GREENE NY
MODEL SERIAL NUMBER VOLTS BATTERY WIDTH
Approximate weight in. (mm)
of lift truck with TRUCK WEIGHT BATTERY WEIGHT BATTERY MAX. RATED CAPACITY
Power rating of
heaviest battery
WITH MAXIMUM BATTERY MAXIMUM AMP HOURS battery
lb. (kg) lb. (kg)
installed, minus load WITHOUT BATTERY MINIMUM HOUR RATE
and operator
lb. (kg) lb. (kg)
HORIZONTAL MOTION OF BATTERY NOT TO EXCEED 0.5" (13mm) ATTACH RESTRAINT AS REQUIRED
Maximum battery
WITH ATTACHMENT OR
weight for this lift
WITH FORKS
ALTERNATE LOAD CENTER
truck
Approximate weight HORIZONTAL LOAD CENTER A in. mm A in. mm
of lift truck minus VERTICAL LOAD CENTER B in. mm B in. mm
battery, load, and LOAD CENTER SIDE TO SIDE C in. mm C in. mm

Minimum battery
operator MAX.
CAPACITY
l b.
DIM. D
in.
MAX.
CAPACITY
l b.
DIM. D
in.
MAX.
CAPACITY
l b.
DIM. D
in.
MAX.
CAPACITY
l b.
DIM. D
in.
weight for this lift
C
truck
Load center B
Battery weight must
dimensions be between the
A D
FL
OO
R
minimum and
Maximum load ATTACHMENT TYPE MODEL SERIAL NUMBER
maximum weight
capacity for this lift
truck
MANUFACTURED TO COMPLY WITH THE MANDATORY REQUIREMENTS OF ASME B56.1 PART III EFFECTIVE ON THE DATE OF
MANUFACTURE FOR TYPE ___ INDUSTRIAL TRUCKS WHEN EQUIPPED WITH TYPE EO BATTERY
INCLUDE MODEL AND SERIAL NUMBER ON ALL CORRESPONDENCE
Attachment
MADE IN CANADA 412-843 information
3412-843_B.EPS
Figure 3-1: Lift Truck Specification Plate
NOTE: * Lift truck serial number is also found:

• On the top of the left baseleg, near
the tractor
• On the top edge of the rear
bumper, to the left of center
PDMM-0109 7/31/02 3-3

Battery Specifications
Battery Specifications
Series Volts Nominal Width Weight (Pounds) Weight (Kilograms)

Hours Amperes
(inches) Min Max Min Max
16.5 2000 2300 908 1044 6 840
EZ-D 36
18.5 2300 2600 1044 1180 6 1085
16.5 1600 2200 726 999 6 1125
DZ-D 36
18.5 2300 2600 1044 1180 6 1085
Optional Battery Gates

UL note 583 specifies that a battery should
have no more than 0.5 inch (12 mm) movement
in any horizontal direction.
3-4 PDMM-0109 7/31/02

Operator Displays
Operator Displays
Main Operator Display

2 3
Icon legend (see drawings at right):
1. Battery Charge
2. Lift Limit (optional)
4
3. Service Required
4. Drive Motor or Power Panel 1
Over-Temperature
5. Lift Truck Speed 5
6. Message Display (SelfTest, Hour Meters,

BSOC, Load Weight, Clock/Calendar,
6
Status and Error Messages)
7. Lift Bypass Button (location on Series EZ)
8. Key Switch (location on Series EZ)
8 7
313A7S029.EPS
Figure 3-2: Operator Display, Series EZ
Setting Default Displays

2 3
The Operator Display can show two defaults.
The “Off Deadman” default shows when you
turn the key switch ON and do not step on the
deadman pedal. The “On Deadman” default
4
shows when you turn the key switch ON and
step on the deadman pedal.
1
Available default displays are:

• Time 5
• Date
• Battery State-of-Charge (BSOC) 6
• Weight
313A7S030.EPS
• Model (Serial Number scrolls)
Figure 3-3: Operator Display, Series DZ
• Firmware Version
• SMARTi ® system (% space remaining on
card)
• Active Maintenance test
PDMM-0109 7/31/02 3-5

Main Operator Display
Selecting “Off Deadman” default

1. Step off the deadman pedal. Move the
directional/speed control full forward and
hold it there.
2. Use the tilt up/down buttons to select the
desired display. Release the tilt button and
then release the directional/speed control.
Selecting “On Deadman” default

1. Step off the deadman pedal. Move the
directional/speed control to full forward
and hold it there.
2. Step on the deadman pedal.
display you want. Release the tilt button,
step off the deadman pedal, and then
release the directional/speed control.
3-6 PDMM-0109 7/31/02

Modes of Operation
Modes of Operation
Overview of Modes
This lift truck has several modes of operation.
The main distinction is between Run Mode and
Program Mode. Run Mode is the normal
operating mode for the lift truck. Program Mode
permits configuration, calibration, and
maintenance testing.
Run Mode
When you power on the lift truck normally, the
on-board firmware does a number of internal
self-tests and enters the default mode of
operation, Run Mode. Run Mode is the normal
operating mode. In Run Mode, the Operator
Display shows the default display.
Run Mode is also entered when the lift truck
exits Program Mode.
Program Mode
Use Program Mode for configuration,
calibration, and maintenance testing of the lift
truck. You need a password in order to enter
Program Mode. See “Passwords” on page 3-8.
Program Mode is divided into three categories:
• Learn Mode
• Configure Mode
• Maintenance Mode
Learn Mode
Use Learn Mode to calibrate the lift truck for
correct operation. You can select the following
sub-categories for calibration:
• Controls
• Weight
To enter Learn Mode, you must enter the
Superword. For detailed description, see “Using
Learn Mode” on page 6-11.
PDMM-0109 7/31/02 3-7

Overview of Modes
Configure Mode
Use Configure Mode to adjust various lift truck
performance parameters to specific customer
requirements. To enter Configure Mode, you
must enter either the Password or Superword
for the lift truck.
Some items in Configure Mode appear only if
the Superword is entered. For detailed
description, see “Using Configure Mode” on
page 6-6.
Maintenance Mode
Use Maintenance Mode to test, cycle, and
troubleshoot individual electrical circuits. Static
and active testing are permitted on some tests.
To enter Maintenance Mode, you must enter the
Superword. For detailed description, see “Static
Maintenance Mode” on page 6-12 and see
“Active Maintenance Mode” on page 6-13.
Passwords
For detailed description of how to enter
passwords, see “Entering a Password or
Superword” on page 6-5.
Password
Password permits access to Configure Mode
only. It is intended for customer use in setting
performance parameters within those features
purchased with the truck.
Superword
Superword permits access to all Program
Modes. It is intended only for qualified and
trained service technicians.
We strongly recommend that, during
installation, you change the Superword from
the factory default to a code known only to the
dealer and/or owner so that access to
Maintenance Mode is limited to approved
personnel. Make sure to record the new
Superword in a safe place. If this code is lost or
forgotten, a technician will need to reset the lift
truck to factory default settings. This will make
necessary the reconfiguration of all variable
settings.
3-8 PDMM-0109 7/31/02

EASi Reach-Fork® Truck EZ-D/DZ-D Maintenance Manual Scheduled Maintenance
Scheduled Maintenance 4:
PDMM-0109 7/31/02 4-1

Scheduled Maintenance EASi Reach-Fork® Truck EZ-D/DZ-D Maintenance Manual
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 the chart below.
Service
Type of Service Working Environment
Frequency
60 days or
250 hours,
Normal An eight hour day of basic material handling
whichever
is less
Severe Extended operating hours or constant use 175 hours
All EE rated lift trucks

Dusty or sandy conditions: e.g. cement plant, lumber or flour
mills, coal dust or stone-crushing areas
High temperature areas: e.g., steel mills, foundries, enclosed
Extreme 100 hours
(EE) applications
Sudden temperature changes: e.g., freezer to room
temperature
Corrosive atmosphere: e.g., chlorine, salt-sea air
See “Lubrication Specification Chart” on

page A-2 in the Appendix for lubrication
specifications. Refer to the manufacturer’s
supplements for components not listed on the
following pages.
4-2 PDMM-0109 7/31/02

Maintenance Minder™ Tool
Maintenance Minder™
Tool
Maintenance Minder Tool is a feature that
permits prompting of a customer when the lift
truck is due for scheduled maintenance.
Maintenance Minder, when configured and
enabled, monitors the Hours on Deadman (HD)
meter. When the time interval for scheduled
maintenance has been exceeded, the operator is
informed in the following ways:
• One of two messages scrolls on the
Operator Display for at least 30 seconds
following the “DAILY CHECKLIST” message.
• “Scheduled Maintenance Due”
• “Lift Cutout, Scheduled Maintenance
Due”
• A wrench icon flashes
• The audible alarm sounds the high-low
tone for approximately 5 seconds.
Lift Cutout, when active, will not disable the lift
function until power to the control circuits is
cycled (key switch OFF or battery
disconnected). When control circuit power is
cycled, lift is disabled until Maintenance Minder
is reset or disabled, or the lift cutout option is
turned off.
Factory Configuration
For field installations, this feature must be
added to the configuration options via the
FlashWare program. The factory default is Off.
Enabling
Once installed in the configuration options via
Flashware, Maintenance Minder appears in the
Configure Mode menu. The initial factory
setting is “DISABLE.” To enable the feature, enter
Configure Mode.
NOTE: For instructions on selecting Modes of
Operation, see “Modes of Operation” on
page 6-3.
With Configuration Mode selected, use the tilt
control to display the “MNT MIND” item. Press
the horn button. When entered from a disabled
state, Maintenance Minder offers a submenu
PDMM-0109 7/31/02 4-3

with the options “QUIT MM” and “ENABLE.” Use

the tilt control to select “ENABLE.” Press the
horn button.
Setting Time Interval and Action Option

The first time you enter the time interval menu,
the Operator Display shows the Factory
Suggested setting, followed by the letters “FS.”
Afterwards, when you enter the time interval
menu, the Operator Display shows the last
used setting. Values from 50 to 500 hours, in
increments of 50, are available. Use the tilt
control to scroll to the desired time interval.
With the selected value displayed, press the
horn button.
Use the tilt control to select an action option.
Then press the horn button.
• “MSG ONLY” causes the Operator Display to
show “SCHEDULED MAINTENANCE DUE” when
the scheduled maintenance time interval
has been exceeded.
• “L CUTOUT” causes the Operator Display to
show “LIFT CUT OUT, SCHEDULED
MAINTENANCE DUE” when the scheduled
maintenance time interval has been
exceeded. Lift is disabled the next time the
power circuits are cycled.
Use the tilt control to select “QUIT MM” from the
submenu. If the status has changed, the
Operator Display will prompt you to save
changes. Press the horn button.
NOTE: From the Config Menu, exit by selecting
“QUIT CFG.” You will not be prompted
again to save changes, but any changes
saved when you “QUIT MM” will be
retained.
Changing Time Interval or Action Option

When Maintenance Minder is active, and you
want to change the time interval or action
option, enter Configure Mode.
the horn button. When entered from an enabled
state, Maintenance Minder offers a submenu
with the options “QUIT MM,” “RESET,” “DISABLE,”
and “SETUP.” Use the tilt control to select
“SETUP,” then press the horn button. The
4-4 PDMM-0109 7/31/02

current time interval is displayed (hours).

Continue as described under “Setting Time
Interval and Action Option” above.
Resetting Maintenance Minder

If you want to reset the reminder prompt when
Maintenance Minder is active and you have done
scheduled maintenance, enter Configure Mode.
the horn button. Use the tilt control to select
“RESET,” then press the horn button. Then
select “Quit MM” and press the horn button
again. Save changes, as prompted.
Disabling
When Maintenance Minder is active and you
want to disable it, enter Configure Mode.
the horn button. Use the tilt control to select
“DISABLE,” then press the horn button. Then
select “Quit MM” and press the horn button
again. Save changes, as prompted.
PDMM-0109 7/31/02 4-5

Operator’s Daily Checklist
Visual Inspection/Key Switch Turned OFF
Item No.
See “Scheduled
Maintenance Component What to Check Mark
Points”
beginning on
page 4-15.
TIRES
Tires No gouges, chunking, or flat spots

25 No bond failures
Sufficient tread (if applicable)
BATTERY
1 Battery Fully charged/correct water level/correct voltage, no

leakage, correct weight
correctly installed
3 Battery Gates Gates correctly installed and firmly in place
2 Emergency Emergency disconnect operates correctly
Disconnect
LIFT/LOWER/AUX SYSTEM
5 Cables/Hoses No damage to chains, hoses, or limit switches

Hydraulic Measure hydraulic fluid level in hydraulic reservoir
15 Reservoir
CONTROLS
Function Move smoothly without binding

8
Controls Return to neutral when released
GENERAL
Guards and covers installed and secure

23 Decals - Warning/Safety/Operational
Mast guard not damaged, cracked, or chipped (if
glass)
Examine floor under lift truck for any dripping that
possibly indicates a leak
Examine lift truck for loose or missing hardware
No ice or water accumulation in tractor end; no ice
or water on operator compartment floor
21 Examine static straps (under lift truck)
4-6 PDMM-0109 7/31/02


Operational Inspection/Key Switch Turned ON
Item No. Component What to Check Mark
HORN
14 Sounds when button is depressed
STEERING
24 Smooth, without binding or excess play
DIRECTIONAL/SPEED CONTROL
Moves smoothly without binding
Returns to neutral when released
8 Controls speed and direction correctly
Plugging operates correctly
Speed limits function correctly
LIFT/LOWER/AUX SYSTEM
Lift/lower controls move freely and return to neutral
8 when released
All controls perform their functions as specified
HOUR METERS
Should record hours of lift truck operation, hours
13
spent lifting, and total miles traveled
BRAKES
9 Pedal moves freely without binding
4 Lift truck stops in specified distance (8 to 10 ft. or
2.5 to 3.0 m)
Deadman brake operates correctly (travel circuits
disabled)
BATTERY DISCONNECT
2 Stops all functions when depressed
SAFETY
All warning and working lights operate
All limit switches operate correctly
Travel alarm (optional) and/or lift/lower alarm
operates
23 Safety decals present and legible
PDMM-0109 7/31/02 4-7

Every 60 Days or 250 Deadman Hours (HD)
Item No.
See “Scheduled
Maintenance Component What to do Refer to
Points”
beginning on
page 4-15.
Battery Compare the weight stamped on the battery in Page 3-3

the lift truck with the minimum and maximum
approved weights on the spec tag for the lift
truck. Report any lift trucks that are operating
with batteries under the minimum, or over the
maximum approved weight.
Make sure the emergency disconnect blocks are Page 7-82
on the lift truck. If blocks are missing, install
new blocks. Make sure that the emergency
1
disconnect operates correctly.
Test for voltage leaks to frame. Connect a 12-volt Page 5-5
test light between B+ side of connector and
battery case. If the light lights at all, even
momentarily, clean the battery. Repeat the
procedure, connecting the test light between B–
side of battery and battery case. If cleaning does
not remove voltage to frame, install a new
battery.
Battery Inspect all battery connectors and leads for Page 7-82
Connectors and damage and cuts in protective coatings. Shorts
2
Leads to the truck frame cause electronic component
failure or intermittent electrical failures.
4-8 PDMM-0109 7/31/02

Item No.
See “Scheduled
Points”
beginning on
page 4-15.
Brake and Brake Measure stopping distance. Lift truck should stop
Pads within 8 to 10 feet (2.5 to 3.0 m) from full speed,
depending on the load, floor, and tire conditions.
Examine for signs of oil on the pads or rotor. If oil Page 7-72
is present, disassemble brake and clean the
pads and rotor. Use a file, if necessary, to clean
the brake pad surface.
Measure minimum thickness of pad and steel Page 7-69
backing plate: 0.80 in. (20 mm)
4 Measure for correct gap: 0.005 to 0.008 in. (0.13 Page 7-69
to 0.20 mm) rotor-to-bottom-pad, at least 0.010
in. (0.25 mm) rotor-to-top-pad.
NOTE: Failure to keep brakes adjusted causes
premature pad and rotor wear and
excessive motor heat.
Examine master cylinder brake fluid level. Inspect
mounting hardware and adjusting nuts for
tightness.
Caster Assembly Measure adjustment (including steering Page 7-19

adjustment on steerable casters) Page 7-21
6
Inspect caster wheel axle and bearings for
excessive wear.
Contactors Inspect contact tips for burnt or pitted surfaces.

Failure to replace the tips can cause surfaces to
weld together, causing unscheduled down time.
NOTE: Burnt or pitted lift contactor tips can
result from a misadjusted or faulty lift
7
potentiometer.
With the key switch OFF and the battery
disconnected, examine the plunger for smooth
operation with no binding. If binding occurs, the
lift truck could display intermittent fault codes.
PDMM-0109 7/31/02 4-9

Item No.
See “Scheduled
Points”
beginning on
page 4-15.
Control Handle Make sure lift/lower function is smooth and

Functions controllable.
Make sure travel function is smooth and
responsive through full range of acceleration.
Test for play in the center position of lift or travel
control; replace control handle if necessary. Page 7-26
8
Run Test A04 - Throttle Pot Voltage and Test A05
- Lift/Lower Pot Voltage. Make sure voltage Page 6-76
changes smoothly throughout the entire range Page 6-77
of movement.
On lift trucks with ESD kits, make sure nylon
inserts are in the lift knob set screw holes.
Deadman Pedal Test for smooth operation with no binding. Page 7-76
Measure pedal height when released and adjust
or replace as needed. If you cannot adjust the
pedal to the correct height, install a new pedal.
Lack of full height in the pedal reduces the stroke
9
on the brake master cylinder and causes brakes
to drag, wear prematurely, and create excess heat
in the drive motor.
Page 6-94
Run Test I00 - Deadman Switch. Test correct
operation of the deadman switch by the pedal.
Drive Unit Examine fluid level. If low, check for leaks and
refill.
Inspect for leaks. Make sure O-ring is present on
10
the dipstick.
Examine for drive unit radial ring wear. Page 7-42
4-10 PDMM-0109 7/31/02

Item No.
See “Scheduled
Points”
beginning on
page 4-15.
Electrical Cables Inspect all power cables for nicks or cuts. Give Page 5-3
special attention to those cables that are not
stationary, for example, cables to the drive Page 7-86
motor. Replace any cable that is damaged or
shows signs of excessive heat. Failure to do so
will cause intermittent system shutdowns
and/or electronic failures.
Measure the tension of the over-the-mast pulley
cables. Set tension so the cables just stay on the
pulleys. Higher tension will cause premature
failure. Maximum spring tension is 5 to 7 in. lb.
(0.57 to 0.79 Nm).
Forks Examine for excessive wear, bends, cracks, Page 7-178

welding arcs, excessive heat, or unauthorized
11
modifications. Replace if found.
Measure fork thickness (tool P/N 922-369).
Hardware Make sure all hardware connecting wires and

cables are tight.
Retorque bolts of major components (motors, Page A-7
pumps, brake, drive unit, manifolds, Page A-8
mast-to-tractor mounting bolts, power cables). Page A-9
Tighten any loose hardware. Replace any broken
or missing hardware.
Horn Make sure horn sounds correctly when operated.

14
Examine mounting bracket insulators.
Hydraulic Hoses Inspect for leaks, nicks, cuts, chafing, and Page 5-16
bulges. Replace damaged or worn hoses
immediately.
Inspect fittings for leaks; repair immediately.
Hydraulic Examine fluid level and type. Page A-2

Reservoir Inspect the plate over the clean-out hole for
15
seepage. If found, apply new coat of sealant to
plate.
Learn Mode Enter “Program Mode” and run “Learn.” Page 6-11
PDMM-0109 7/31/02 4-11

Item No.
See “Scheduled
Points”
beginning on
page 4-15.
Lift and Examine for too much stretch or wear (tool Page 4-26
Equalization P/N 950-350/CG).
16
Chains Measure adjustment. Page 7-179
Lubricate. Page A-2
Lubrication Apply grease to all fittings on carriage and tractor. Page 4-20
Apply small amount of grease to steering gear on
drive unit.
Coat all chains and chain anchor nuts with film of Page A-2
spray lubricant.
Mast Inspect rails for abnormal wear, metal flakes or

shavings.
Inspect mast and 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 mast
17
deeper than 1/8 inch (3 mm).
Examine mast bearings
Retorque main frame mounting bolts (170 ft. lb.
or 230 Nm), reapplying thread-locking
compound (P/N 990-544). Page A-2
Wipe old grease off mast uprights and apply new
grease.
Motors Inspect brushes for excessive heat (discolored Page 7-91

pigtails).
Measure brush length and evenness of wear.
Measure brush spring tension.
18 Inspect brush rigging for damage or loose brush
holders
Retorque terminal stud nuts. Page 7-96
Use compressed air to clean the inside of the Page 4-19
motor.
Overhead Guard Retorque mounting bolts, reapplying

thread-locking compound (P/N 990-544).
19
Inspect guard for physical damage. If structurally
damaged, replace the guard.
4-12 PDMM-0109 7/31/02

Item No.
See “Scheduled
Points”
beginning on
page 4-15.
Power Amplifier Make sure power amplifier heat sink fins are free Page 7-103
and Fan of debris and that air flows freely through them.
26 Examine power amplifier fan for correct operation
and make sure area around fan is clear of
debris.
Shorts to Frame Using a non-flammable cleaner, clean any dirt

and oil buildup from inside the tractor
compartment.
Measure electrical leakage to frame. Page 5-5
Sideshift Make sure screws holding the lower mounting Page 7-149
Carriage hooks to the carriage bar are tight.
Inspect upper and lower bearing segments. If
20
segments measure less than 1/16 inch
(1.5 mm), replace them. Replace segments as a
set on the top or bottom as required.
Static Straps Make sure static straps are not worn or broken.
Clean debris from straps.
21 Measure resistance of resistor in standoff.
NOTE: EE lift trucks require phosphor-bronze,
not steel-braided straps.
Switches Examine all switches for correct operation and

adjustment
Ventilation Slots Make sure ventilation slots in the tractor frame

22
are clear of obstructions and debris.
23 Warning Decals Replace any unreadable or damaged decals. Page 7-12
Wheels/Tires Examine for bond failure, chunking, and

excessive or uneven wear.
Retorque mounting hardware.
Inspect load wheel bearings for binding or
25
excessive play.
Inspect drive axle and caster axle for excessive
play.
PDMM-0109 7/31/02 4-13


Perform all 60-day/250-hour checks, including daily checks, plus the following:
Item No.
See “Scheduled
Points”
beginning on
page 4-15.
Hydraulic Change fluid. Page 7-108

Reservoir Change filter.
Every 360 Days or 3000 Operating Hours
Perform all 60-day/250-hour and 180-day/1500-hour checks plus the following:
Item No.
See “Scheduled
Points”
beginning on
page 4-15.
Drive Unit Change fluid Page 7-62

Frame and Base Examine all structural parts of lift and tilt
Legs mechanism.
Visually examine base legs and frame members
for cracks.
4-14 PDMM-0109 7/31/02

Scheduled Maintenance Points

NOTE: Numbered arrows in photos on the
following pages refer to Item No. in
preceding scheduled maintenance
charts.
17
16
2
20
1,3
25
11
43292_034.TIF
Figure 4-1: Scheduled Maintenance Points, Mast View
PDMM-0109 7/31/02 4-15

19
16
23
24
15 8
22
7
26
18
14
10 (under frame)
4, 9
6, 25
25
45077_053.TIF
Figure 4-2: Scheduled Maintenance Points, Tractor View (EZ-D shown)
4-16 PDMM-0109 7/31/02

13
8,14
24
4,9
43292_010.TIF
Figure 4-3: Scheduled Maintenance Points, Operator Compartment (DZ-D shown)
PDMM-0109 7/31/02 4-17

21
25
6,25
4P5180009.TIF
Figure 4-4: Scheduled Maintenance Points, Underside
4-18 PDMM-0109 7/31/02

Motor Maintenance
Motor Maintenance
Motor Cleaning
Periodic cleaning is essential to prevent

overheating and electrical leakage (shorts). To
clean a motor correctly:
1. Wear safety glasses or goggles to protect
your eyes from dust and debris.
2. Work in a well ventilated area.
3. Using an OSHA approved air nozzle, use
clean, dry compressed air to blow carbon
dust and other foreign matter from:
• motor housing
401A7S002.TIF
• brush holders (DC motor)
Figure 4-5: Motor cleaning with compressed air
• commutator (DC motor)
• field and armature windings (if
accessible)
! CAUTION
Never use a chemical solvent to clean
a motor, as it can carry carbon dust
to inaccessible areas and cause
shorts within the motor.
Cleaning a motor with solvents

requires complete disassembly and
drying and must only be done by an
authorized motor repair shop.
PDMM-0109 7/31/02 4-19

Lubrication Points
Lubrication Points
NOTE: Locate items by numbers on the photos

that follow this list:
1. Steering linkage arm, pivot point
2. Steering linkage, steerable caster arm
3. Steering linkage, drive wheel arm
4. A-frame pivot bolts
5. Caster wheel bearing
6. Caster wheel axle
7. Steering shaft gear
8. Drive unit radial gear
9. Reach mechanism
10. Reach cylinder
11. Inner telescopic channels (left and right,
both sides)
12. Lift chains (spray)
13. Equalization chains
14. Sideshift carriage
4-20 PDMM-0109 7/31/02

Lubrication Point Locator Photos
1 (access in battery
2 compartment)
4 (access on
top side) 3
4P5180009.TIF
Figure 4-6: Lubrication Points, Steering Linkage and A-frame (underside view)
Deadman
4 Pedal
Battery
Compartment
4P5180010.TIF
4P5180011.TIF
Figure 4-7: Lubrication Points, Steering Linkage and A-frame (top views)
PDMM-0109 7/31/02 4-21

413Y7S001.TIF
4P5180019.TIF
Figure 4-8: Lubrication Points, Caster Wheel bearing and axle
44155_013.TIF
Figure 4-9: Lubrication Points, Steering Shaft and Drive Unit
4-22 PDMM-0109 7/31/02

9
4lube-rch.pcx
Figure 4-10: Reach Assembly (Deep-Reach® lift truck shown)
4P5180013.TIF
4P5180017.TIF
Figure 4-11: Reach Mechanism
PDMM-0109 7/31/02 4-23

10
4P5180016R.TIF
Figure 4-12: Lubrication Points, Reach Cylinder
4-24 PDMM-0109 7/31/02

11,13 11,13
12
15
14
44155_002.TIF
Figure 4-13: Lubrication Points, Mast and Carriage
14
413G6S092.TIF
413G6S104.TIF
Figure 4-14: Lubrication Points, Reach Mechanism; Sideshift Carriage
PDMM-0109 7/31/02 4-25

Chain Maintenance
Chain Maintenance
Defect-Cause Chart
Defect Cause Maintenance Procedure
Chain Elongation Wear Use a chain gauge or lay the chain on a

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

corrosion degreasing new
truck chains.
Cracked Plates Infrequent Oiling Replace the chain.
Rust
Corrosion
Chain Fatigue
Tight Joints Bent pins or plates Replace the chain.
Rusty joints or Replace the chain.

peened plate edges
Chain side wear Chain misalignment Replace the chain.
4-26 PDMM-0109 7/31/02

EASi Reach-Fork® Truck EZ-D/DZ-D Maintenance Manual Troubleshooting
Troubleshooting 5:
PDMM-0109 7/31/02 5-1

Troubleshooting EASi Reach-Fork® Truck EZ-D/DZ-D Maintenance Manual
How to Use This Chapter
How to Use This Chapter
This chapter contains a set of general

troubleshooting guidelines, a troubleshooting
task flow, and a set of troubleshooting tables for
symptoms not accompanied by a fault code.
Use the START TROUBLESHOOTING Chart
TS1 on Page 5-17 to guide you to the general
flow of troubleshooting.
Use the Symptom Tables beginning on
Page 5-21 to identify possible causes of
problems that are not accompanied by a fault
code on the Operator Display.
Every time you complete a troubleshooting
procedure, be sure to follow the steps in End of
Troubleshooting Chart END1 on page 5-20.
Another troubleshooting resource is the
Pinout Matrix on Page 8-55 in the Theory of
Operation chapter. The pinout matrix chart lists
functions and normal voltages of terminals and
harness connector pins.
If the troubleshooting symptom charts do not
isolate the problem, or if the symptoms are not
consistent or repeatable, go to the General
Troubleshooting Chart GEN1 on page 5-19.
This chart will help you approach the problem
in a systematic and logical manner.
5-2 PDMM-0109 7/31/02

Electrical Troubleshooting Guidelines
Many problems are caused by a faulty or dirty

battery. Make sure the battery is clean. See
“Battery Exterior Cleaning” on page 7-84.
Measure the electrolyte level and state of
charge. See “Testing, Charging, and
Maintenance” on page 7-85.
! WARNING
Be sure to jack and block the lift
truck whenever a troubleshooting
procedure requires turning key
switch S1 ON. This will prevent
accidents caused by unexpected
travel. See “Jacking Safety” on
page 2-13.
! CAUTION
Unless otherwise directed, disconnect
the battery connector when you
measure electrical circuits or
components with an ohmmeter.
Electrical current can damage the
ohmmeter.
Save time and trouble by looking for simple

causes first.
Visually examine all wiring and electrical
components for:
• Loose connections or connectors
• Loose or broken terminals
• Damaged terminals, blocks, or strips
• Exposed wire at terminations, excessive
strip gap
• Abrasions, scrapes, nicks in the wire,
damage from overheating or burns, or other
general insulation damage
• Broken wire strands and shorted conditions
(especially those that are close to metal
edges or surfaces)
PDMM-0109 7/31/02 5-3

During troubleshooting and repairs, you must

at times unplug a connector, move a harness,
cut a cable tie, or remove the wire from a
bracket. Note carefully the location of the wire
and all protective or mounting hardware before
moving the harness.
After repair, return or replace all protective
and/or mounting hardware to its original
condition. Protective materials are necessary to
provide reliable performance of the interconnect
system.
Examine and maintain any added materials
used to position or protect the wire. This
includes spiral wrap, brackets, cable ties,
fasteners, flexible conduit, etc.
Do not attach cable ties so tight that they pinch
or deform cable harnesses. Do not attach cable
ties to hydraulic hoses, which expand with
pressure, causing extra pinching of bundled
electrical cables.
Use a digital ohmmeter to test continuity in
wiring.
For general instructions on repairing wiring
problems, see “Wiring and Harness Connectors”
on page 7-86.
For information on electrical connector location
and function, see “Electrical Connections” on
page 6-69.
For diagrams showing electrical connector
location on circuit cards, see “Circuit Card
Connectors” on page 6-70.
Use a digital multi-meter such as a Fluke meter
for all measurements. Analog meters can give
inaccurate readings and load down sensitive
electronic circuits enough to cause failure.
Make sure to connect meter cables to the
correct meter jacks and to select the correct
function and scale.
When measuring voltage, connect the positive
meter lead to the connector or probe point
marked (+) in the test. Connect the negative
meter lead to the connector or probe point
marked (–).
Whenever measuring resistance, turn the key
switch OFF and disconnect the battery
connector. Battery current can damage an
ohmmeter.
5-4 PDMM-0109 7/31/02

Shorts to Frame Test
For troubleshooting electric motors, see

“Motors” on page 7-91.

“Shorts to frame” is an industry term for
unintentional current leakage paths between
normally isolated electrical circuits and their
metal enclosures.
Shorts to frame can be metallic connections,
such as a wire conductor contacting metal
through worn insulation. More often, shorts to
frame are resistive “leakage” paths caused by
contamination and/or moisture.
These leakage paths can result in unwanted
electrical noise on the metallic lift truck
structure, and can result in incorrect operation.
Shorts to frame can be caused by:
• Accumulation of dirt
• Battery electrolyte leakage
• Motor brush dust
• Motor brush leads touching the housing
• Breakdown in insulation
• Bare wires
• Pinched wiring harness
• incorrect mounting of circuit cards
Shorts to frame can occur at numerous
locations on a lift truck, including:
• Batteries
• Motors
• Cables, wiring, and harnesses
• Heat sinks
• Bus bars
• Solenoids
• Contactors
• Terminal strips
• Switches
• Power panel insulation
• Circuit card mounts
PDMM-0109 7/31/02 5-5

To test for shorts to frame:

2. To test the battery for shorts to case,
connect a 12-volt test light to the battery
case from battery B+, and then to the
battery case from battery B–. If the light
comes on at all, even momentarily, there is
a serious problem with the battery, either
external contamination or internal damage.
Do not continue until this condition is
corrected. Your meter can be damaged if
you proceed before correcting this
condition.
Install another battery in the lift truck and
repeat this procedure from step 1.
If the test light does not come on, continue
to the next step.
3. With the battery disconnected from the lift
truck, use a digital volt/ohm/ammeter on
the Ampere function to measure the
leakage current from the battery case to
battery B+ and from the battery case to
battery B–. Begin measuring at the highest
Ampere scale and work toward the lowest
scale. A reading of more than 0.001A (1 mA)
shows a serious short. Do not continue
until this condition is corrected. Your meter
can be damaged if you proceed before
correcting this condition.
Install another battery in the lift truck and
repeat this procedure from step 1.
If the current is less than 0.0002 A (0.2
mA), go to step 4. If the current is greater
than 0.0002 A (0.2 mA) and less than
0.001A (1 mA), remove the battery from the
lift truck, then continue with step 4. Make
sure the battery case does not touch the lift
truck frame during the remaining tests.
5-6 PDMM-0109 7/31/02

4. With the battery disconnected (or removed

and disconnected) from the lift truck, use a
digital ohmmeter to measure the resistance
from lift truck frame to truck B+, to truck
B– (not battery B+ and B–), and to all fuses
and motors. A reading of less than 1000
ohms shows a serious short. Do not
continue until this condition is corrected.
Your meter can be damaged if you proceed
before correcting this condition.
a. To identify the cause of the short to
frame, disconnect circuit components
until the low resistance condition
disappears. Do not reconnect
components one at a time, but leave
them disconnected until the low
resistance reading disappears. Prevent
disconnected terminals or connectors
from touching lift truck frame or other
conductive surfaces.
b. The most likely areas to examine are:
• Motors
• Heat sinks
• Power cables
• Power circuit components
• Control circuit components
c. Repair or replace the component
causing the low resistance condition,
Then repeat Step 4.
d. Reconnect all other components
previously disconnected, one at a time,
measuring resistance between steps. If a
reading is less than 1000 ohms when
reconnecting a component, that
component or its wiring is bad; repair or
replace as appropriate.
e. When, after all components are
reconnected, you get readings greater
than 1000 ohms, continue with the next
step.
5. Reconnect the battery connector to the lift
truck and turn the key switch ON. If the
battery was previously removed, make sure
the battery case does not touch the lift
truck frame.
PDMM-0109 7/31/02 5-7

6. Use a volt/ohm/ammeter on the current

function to measure leakage current to the
lift truck frame from B+, B–, and all fuses
and motor terminals. Begin measuring at
the highest Ampere scale and work toward
the lowest scale. If the current is less than
0.001A (1mA), go to step 7. If the current is
more than 0.001A (1 mA), continue to the
steps below.
a. To identify the cause of the short to
frame, disconnect circuit components
until the leakage current reads less than
0.001A (1 mA). 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 lift truck
frame or other conductive surfaces.
b. The most likely areas to examine are:
• Motors
• Heat sinks
• 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
more than 0.001A (1 mA) when
reconnecting a component, that
component or its wiring is bad.
Repair/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 lift truck or the battery.
If you previously removed the battery from
the lift truck, re-install the battery.
5-8 PDMM-0109 7/31/02

Fuses
Fuses
Test/Inspection
Examine the fuse for signs of overheating,
discoloration, cracking, or other physical
damage. Replace the fuse if you find damage.
To test a fuse, remove it or isolate it from the
electrical circuit. Do this by removing the fuse
from the lift truck or by removing all the
connections from one side of the fuse.
Use an ohmmeter set to Rx1 scale and measure
the resistance across the fuse. The resistance
should be less than 1 ohm.
Fuse Locator Chart
Fuse Amps Location Function

FU1 150 Contactor/Fuse Panel Power fuse for steering
FU2 350 Contactor/Fuse Panel Power fuse for travel
FU3 500 Contactor/Fuse Panel Power fuse for lift
FU4 10 Travel Alarm Control fuse for travel alarm
FU5 15 Relay Control Fuse Panel Control fuse for Vehicle Manager B+
FU6 15 Relay Control Fuse Panel Control fuse for aux power B–
FU7 15/5 Relay Control Fuse Panel Control fuse for aux power (key) B+
FU9 15/5 Relay Control Fuse Panel Control fuse for aux power (battery) B+
FU10 15 Relay Control Fuse Panel Control fuse for Vehicle Manager B–
FU13 10 In-line harness Control fuse for working lights and fan
FU14 10 In-line harness Control fuse for warning and strobe lights
FU15 1 Fan bracket Control fuse for lift motor cooling fan
FU16 1 Fan bracket Control fuse for traction motor cooling fan
FU17 4 Control handle Control handle heater
FU18 N/A Control Handle Thermal fuse for external control handle
heater
PDMM-0109 7/31/02 5-9

DC Motor Troubleshooting
DC Motor Series-Wound Motor

Troubleshooting S/D
Motor Types
Refer to Figure 5-1.
• The series-wound lift motor has only two
external connections because the armature MP
and field windings are connected internally.
• The compound-wound auxiliary motor has A
only two external connections because the
armature and field windings are connected Compound Motor
internally.
A
NOTE: Field connections might be labeled A or
S. Series wound motor field connections
might be labeled D. MX
Open Circuit Motor Test

An open circuit is one in which the electrical
circuit within the motor has been broken. This S/D
can be caused by:
5MOTOR_SERIES.EPS
MOTOR_COMPOUND.EPS
• Bad brushes or brush springs
Figure 5-1: Motor Circuits
• A broken wire in the field or armature
winding
• Loose or bad connections
Refer to Figure 5-1 for the following procedure:
1. Isolate the motor from the lift truck circuit
by removing the power cables. Use two
wrenches to avoid twisting the terminal
stud.
2. With the motor at room temperature,
connect the leads of a digital ohmmeter
between the individual circuits in the
motor.
3. Observe the following measurements:
Motor Probe Points Resistance

A to S Less than 1 ohm
Lift Motor Greater than
A to Frame
100,000 ohms
A1 to A2 Less than 1 ohm
Auxiliary Motor Greater than
A1 or A2 to Frame
100,000 ohms
5-10 PDMM-0109 7/31/02

4. If the meter indicates high resistance in the

armature, check the condition of the
brushes before replacing the motor.
5. If you find an open circuit in a
series-wound motor, the motor must be
disassembled by a motor rebuilding facility
to isolate the problem to the field or
armature circuit.
Grounded Motor Test

In a grounded motor, an electrical circuit exists
between the current-carrying conductors and
the motor housing. This can be caused either by
direct contact or through conductive foreign
material.
The ground may be caused by:
• Insulation breakdown
• Brush leads touching the motor housing
• Build-up of carbon dust or other
materials
Isolate the motor from the lift truck circuit by
removing the power cables. Use two wrenches
to avoid twisting the terminal studs.
Attach one lead of a megohm meter or a digital
ohmmeter to a motor terminal and the other
lead to an unpainted surface of the motor
housing. Set the ohmmeter to the highest scale.
If the ohmmeter reads resistance of less than
100,000 ohms, the motor is grounded. Clean,
repair, or replace the motor as necessary.
Short Circuited Armature or Field

Winding
A short circuited winding is one in which the
insulation on the field or armature has broken
down at two or more points. The breakdown
creates a low resistance path, allowing current
to flow from one turn of the coil to another
adjacent coil turn, without actually flowing
through the coil wire. The result is a decrease in
total resistance of the motor winding and an
increase in the current flow. The severity of the
short circuit depends on its location.
PDMM-0109 7/31/02 5-11

A shorted motor may be indicated by:

• Slow or sluggish operation
• Running faster than normal (suggests a
short in the field)
• Overheating
• Blowing a power fuse
• Burning of brush wires
• Severe burning or discoloration on
armature coil
• Severe burning or discoloration on one
or two commutator segments every 90°
of rotation.
These symptoms can be caused by problems
other than the motor itself, such as binding in a
related pump, hose, or solenoid valve
Testing a motor for short circuited windings
requires special equipment at a motor
rebuilding facility.
5-12 PDMM-0109 7/31/02

AC Motor Troubleshooting
AC Motor Troubleshooting
Motor Type
The drive motor is a brushless, 3-phase, U
internally delta-connected, variable speed AC
motor.
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 AC
three windings staggered 120° apart, and three 3φ
external connections labeled U,V, and W. See
Figure 5-2.
V W
Open Winding
If the AC motor fails with an open winding, the U
motor will move erratically, as if hunting, and AC
V
there will be a ticking sound. Rotation will be 3φ
much slower than normal. W
Using a clamping ammeter, measure current in
each of the motor power cables. The open phase
will read significantly lower than the other two
5MOTOR_AC3PHASEA.EPS
phases. MOTOR_AC3PHASEB.EPS
Figure 5-2: Drive Motor circuits

Shorted Winding
If the AC motor fails with a shorted winding, the
motor will move erratically, as if hunting, and
there will be a high-pitched sound.
Using a clamping ammeter, measure current in
each of the motor power cables. The shorted
phase will read significantly higher than the
other two phases.
PDMM-0109 7/31/02 5-13

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.
At power-up, BSOC tests the battery to
determine if it is the same battery that was
installed at power-down. If it is the same
battery, it continues to monitor the battery for
discharge and updates the Operator Display as
required.
If a different battery is detected, BSOC tests to
determine the state-of-charge of the new
battery. These tests are as follows:
• BSOC compares the charge of the
battery that was connected to the lift
truck with the new battery's charge. A
charge difference of at least 50%
between the two batteries resets BSOC
to show the state-of-charge of the new
battery, that is, the displayed
state-of-charge of the new battery minus
the displayed state-of-charge of the old
battery must equal or exceed 50. This
reset can be higher or lower than the old
battery. Example - A battery in the lift
truck is at 10% charge; the new battery
is at 95%. With more than a 50%
difference in the charge levels, BSOC
resets the Operator Display to show the
new battery's charge.
5-14 PDMM-0109 7/31/02

• BSOC looks at the configured reset

point. BSOC reset is programmable from
55% to 100% of total battery charge and
can be changed by entering the
Configure Mode using the Superword.
The new battery must be equal to or
greater than the configured percent of
charge before the BSOC will change.
Example - BSOC configured at 95%.
Plugging in a battery at anything below
95% charge will not change the Operator
Display. Older batteries may require a
lower configured value for BSOC since
older batteries may be unable to reach a
higher percent charge. Therefore, older
batteries may require BSOC configured
to 85% before the Operator Display will
reset to show the charge of the new
battery.
The following example describes installing a
new battery when the Operator Display does
not reset. Assume the following:
• BSOC configured at 95%, the battery
connected is at 45% charge, and the
new battery is at 92% charge.
Since the new battery charge has not changed
by at least 50% and the state-of-charge of the
new battery is not greater than the BSOC reset
configured value, the Operator Display
continues to show the old battery's charge of
45% (even though the new battery is at 92%).
What occurs is that the Operator Display
remains at 45% until the charge of the new
battery declines to 45%. Then the display
resumes its normal descent.
One final example. Assume the following:
• BSOC configured at 95%, the battery
connected is at 65% charge, and the
new battery is at 20% charge.
Again, the change in charge is not at least 50%
and the new battery is not above the configured
BSOC level. The Operator Display continues to
show 65%, but then descends rapidly as the lift
truck operates until the Operator Display
shows the original charge of 20%. Once the
display shows 20%, it resumes a normal
descent.
PDMM-0109 7/31/02 5-15

Hydraulic Troubleshooting Guidelines
Hydraulic Troubleshooting Guidelines
! WARNING
After elevating or reaching the
carriage for troubleshooting, be sure
to use blocks to secure the carriage.
Use extreme care when blocking the

mast for any reason. Never remove
a block when it is supporting the
mast.
Lower the carriage fully and 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.
5-16 PDMM-0109 7/31/02

Troubleshooting Procedure
Troubleshooting 5:
TS1: START TROUBLESHOOTING
TS1: START TROUBLESHOOTING
Is a
Message or
Yes
Fault Code
displayed?
Find
Message or Code
in Chapter 6
No
Is
symptom
listed in symptom Yes
tables in
Chap. 5?
Follow symptom
table directions
in Chapter 5
No
Go to
Chart GEN-1
5TS1A.WMF
PDMM-0109 7/31/02 5-17

GEN1: General Troubleshooting
GEN1: General Troubleshooting
Gather as much
information as you Eliminate unlikely
What is the problem?
can about the causes.
problem.
Where did it happen?
When did it happen?
What functions are affected?
Select and prioritize

What conditions trigger the problem? the most likely
causes.
Examine each
Talk directly with the likely cause, using
Process
operator or foreman. the tests in this
manual.
Test all other

Operate the lift truck truck functions
yourself. before returning the
lift truck to service.
Using schematics
if necessary,
identify all
components that
could cause the
problem.
5GEN_1.WMF
5-18 PDMM-0109 7/31/02

MISC: Miscellaneous Problems
END1: End of Troubleshooting Procedure
Operate the lift truck as it

Make sure ALL wires,
was being operated when
hoses, and cables that
the problem occurred.
you removed have been
Make sure the problem
reattached correctly.
does not recur.
Have the driver operate

Make sure all panels are the lift truck. Make sure
correctly reinstalled. the problem does not
recur.
Make sure any

component that was
Fill out any
drained has been refilled
required forms.
with the correct level of
fluid.
If you are a Raymond

Create the same dealer technician This is especially
conditions that occurred and contacted important if the
when the problem first Raymond Field Service solution you
happened. to discuss the problem, found is not in the
call them again to let troubleshooting
them know what fixed the chart.
problem.
End of Troubleshooting
5END1.WMF
PDMM-0109 7/31/02 5-19

END1: End of Troubleshooting Procedure
5-20 PDMM-0109 7/31/02

Symptom Tables: Hydraulic Functions

Troubleshooting 5:
Symptom Tables: Hydraulic Functions

NOTE: If you determine that a component
failed as a result of hydraulic fluid
contamination, replace the failed
component and flush, fill, and bleed
the hydraulic system. Reference
“Hydraulic Fluid Replacement” on
page 7-108.
NOTE: Reference electrical schematics
beginning on page A-15 and hydraulic
schematics beginning on page A-23.
Auxiliary Functions
Multiple Functions Affected
No Auxiliary Functions Work (Steer,

Reach/Retract, Tilt, Sideshift)
Possible Cause Action

Bad DIRA Solenoid (SOL4) or DIRB Run Test O04 and Test O05. Follow
solenoid (SOL5), or wiring recommendations in test.
Bad aux pump Measure pressures.
Bad aux motor Test aux motor.
Bad K2 relay Test circuit.
All Auxiliary Functions are Slow

Hydraulic fluid viscosity too high or too Replace hydraulic fluid with correct fluid.
low See “Lubrication Specification Chart” on
page A-2.
Bad EQ solenoid (SOL6) Run Test O09. Follow recommendations
in test.
Bad aux pump Measure pressures.
Bad aux motor Measure current draw.
Aux system relief pressure too low Adjust aux system pressure.
PDMM-0109 7/31/02 5-21

Auxiliary Functions
Tilt
No Tilt; other Aux Functions OK

Bad tilt switch (S6 and/or S7) Run Test I08 and/or I09. Follow
recommendations in test.
Bad tilt solenoid valve or coil, or wiring. Run Test O07. Follow recommendations
Check for contamination. in test. If contamination is found, flush,
refill, and bleed hydraulic system.
Mechanical binding in tilt cylinder or Repair/replace cylinder or other binding
carriage components. Measure pressures.
Broken tilt cylinder pin Replace tilt cylinder pin.
Slow Tilt; other Aux Functions OK

Mechanical binding in tilt cylinder or Repair/replace cylinder or other binding
carriage components.
Measure pressures.
Bad Tilt Solenoid Examine for binding or contamination.
5-22 PDMM-0109 7/31/02

Auxiliary Functions
Sideshift
No Sideshift or One Direction Only; Other

Aux Functions OK

Bad sideshift switch (S8 and/or S9) Run Test I10 and/or I11. Follow
Bad sideshift solenoid, or wiring Run Test O08. Follow recommendations
in test.
Mechanical binding in sideshift cylinder Repair/replace cylinder or other binding
or carriage components.
Measure pressures.
Sideshift - Slow Operation; Other Aux

Functions OK

Mechanical binding in sideshift cylinder Repair/replace cylinder or other binding
or carriage components.
Measure pressures.
Bad sideshift solenoid Examine for binding or contamination.
PDMM-0109 7/31/02 5-23

Auxiliary Functions
Reach
Reach - Does Not Work; Other Functions OK

Bad reach switch (S4) Run Test I06. Follow recommendations in
test.
Bad reach/retract solenoid, or wiring Run Test O06. Follow recommendations
in test.
Damaged or worn reach cylinder Measure pressure.
Worn scissors bearings or deformed Measure pressure.
scissors assembly
Reach - Slow Operation; Other Aux

Functions OK

Mechanical binding in reach cylinder or Measure pressure.
carriage
Bad reach/retract solenoid Examine for binding or contamination.
5-24 PDMM-0109 7/31/02

Auxiliary Functions
Retract
Retract - Does Not Work; Other Functions OK

Bad retract switch (S5) Run Test I07. Follow recommendations in
test.
Bad reach/retract solenoid Run Test O06. Follow recommendations
in test.
Damaged or worn reach cylinder Measure pressure.
Binding reach cylinder or carriage Measure pressure.
Retract - Slow Operation; Other Functions

OK

Mechanical binding in reach cylinder or Measure pressure
carriage
Bad reach/retract solenoid Examine for binding or contamination.
Binding reach cylinder or carriage Measure pressure.
PDMM-0109 7/31/02 5-25

Lift/Lower System
Lift/Lower System
Lift and Lower
Intermittent Lift and Lower

Bad lift/lower pot or wiring Run Test A05. Follow recommendations
in test.
Bad lift/lower solenoid SOL4 or wiring Run Test O12. Follow recommendations
in test.
Binding proportional valve or load Examine for binding or contamination.
holding solenoid)
Lift Function
No Lift

Battery problems Load-test the battery.
Bad lift (P) Contactor or wiring. Run test O02. Follow recommendations
in test.
Bad lift/lower potentiometer VR2 or Run Test A05. Follow recommendations
associated wiring in test.
Relief valve REL1 stuck open Examine valve for contamination in
hydraulic fluid.
If contamination is present, flush, fill
and bleed the hydraulic system and
clean the relief valve.
If no contamination is found, measure
pressures.
Bad lift pump Measure pressures.
Bad lift motor Test lift motor.
Optional lift-limit switch is bad Run Test I05. Follow recommendations in
test.
5-26 PDMM-0109 7/31/02

Lift/Lower System
Slow Lift

associated wiring in test.
Bad lift/lower proportional solenoid Run Test O12. Follow recommendations
in test. Examine for contamination.
Relief valve REL1 stuck open Examine valve for binding or
contamination.
If no contamination is found, replace
REL1.
Plugged or malfunctioning flow control Examine valve for binding or
valve in lift cylinder. contamination.
the flow control valves in the main lift
cylinders.
Binding in the mast Measure pressures.
Bad lift motor Test lift motor. Measure current vs.
pressures.
Unable to Pick Up a Load

Incorrect lift pressure adjustment Check and adjust lift pressure setting.
Contaminated or bad relief valve REL1 Examine valve for contamination.
If no contamination is found, measure
pressures.
Bad lift motor Test lift motor. Measure current vs.
pressures.
PDMM-0109 7/31/02 5-27

Lift/Lower System
Lower Function
Slow Lower

Bad lift/lower proportional solenoid Run Test O12. Follow recommendations
valve, 5-coil driver board, or wiring in test. Examine for binding.
Contamination in load holding solenoid Inspect load holding solenoid SOL1 for
valve SOL1 contamination or binding.
associated wiring. in test.
Mechanical binding in bearings or tele Adjust or replace bearings. Check
shimming.
Plugged or malfunctioning flow control Check for contamination in valve.
valve If contamination is present, flush, fill
and bleed the hydraulic system.
cylinders.
Intermittent Lower

associated wiring. in test.
Contamination in load holding solenoid Clean or replace load holding solenoid
valve SOL1 valve.
Plugged or malfunctioning flow control Check for contamination in valve.
valve If contamination is present, flush, fill
and bleed the hydraulic system.
cylinders.
5-28 PDMM-0109 7/31/02

Lift/Lower System
Load Drifting/Settling

Incorrect lift pressure adjustment Check and adjust lift pressure setting.
Contaminated or bad relief valve REL1 Check for contamination in valve.
If no contamination is found, check for
binding.
Leaking or contaminated load holding Check for contamination in solenoid.
solenoid SOL1 If contamination is present, flush, fill
clean the solenoid valve.
If no contamination is found, examine
the solenoid valve for binding.
Load too large for lift truck capacity Check load weight. Check lift pressure
setting.
PDMM-0109 7/31/02 5-29

Symptom Tables: Travel Functions
Symptom Tables:
Travel Functions
Slow or Sluggish Acceleration

NOTE: First determine if problem is See categories below.
configuration, mechanical, or
electrical:
Configuration:
Accel set to soft Set accel to medium or hard. See “Using
Configure Mode” on page 6-6.
Mechanical: Measure current draw.
Worn load wheel bearings Replace load wheel.
Debris in load wheel axle or caster Remove debris.
Dragging brake Adjust brake. See “Brake Adjustment” on
page 7-69.
Bad drive motor Examine for dirt, contamination, bent
shaft. Run Test A11.
Binding drive unit Measure current. Run Test A11.
Electrical:
Bad throttle pot (VR1) Run Test A04 – Throttle Potentiometer
Voltage (Page 6-76).
Bad drive motor or power amplifier Run Test O29. Follow recommendations
(may test OK with no load, but fail in test.
under load) Run Test A11. Follow recommendations
in test.
Current is limited due to drive motor or Run Test A08. Follow recommendations
bad temperature sensor in test.
5-30 PDMM-0109 7/31/02

Symptom Tables: Travel Functions
Slow Travel

NOTE: First determine if problem is See categories below.
mechanical or electrical:
Mechanical:
Binding drive unit Measure current draw. Run Test A11.
Bad drive motor Examine for dirt, contamination, bent
shaft. Run Test A11.
Worn load wheel bearings Replace load wheel.
Debris in wheel axle Remove debris.
page 7-69.
Electrical:
Bad throttle pot (VR1) Run Test A04 – Throttle Potentiometer
Voltage (Page 6-76).
Bad mast speed limit switch (S10 or S11) Run Test I01 or I03.
or associated wiring
Incorrect configuration Reconfigure the lift truck. See “Using
Configure Mode” on page 6-6.
Bad drive motor or power amplifier Run Test O29. Follow recommendations
(may test OK with no load, but fail in test.
under load) Run Test A11. Follow recommendations
in test.
Speed limited due to drive motor or bad Run Test A08. Follow recommendations
temperature sensor in test.
If equipped with nested switch option, Run Test I01.
bad S19 switch.
PDMM-0109 7/31/02 5-31

Symptom Tables: Electrical Symptoms
Symptom Tables:
Electrical Symptoms
NOTE: Reference electrical schematics
beginning on page A-15 and hydraulic
schematics beginning on page A-23.
Electrical Motors
Motor Overheating

Application exceeds designed workload -- Contact Dealer Service Manager to make
short runs with plugging/acceleration sure of application.
or heavy-duty lifting cycles
Bad battery Measure voltage, both open circuit and
under load. Replace if necessary with
fully-charged good battery. Load-test
the battery.
Incorrect BSOC Cutout value Measure battery specific gravity at
cutout, after battery has stabilized.
Compare to battery manufacturer
specifications for discharged battery.
Adjust BSOC Cutout as needed.
Clogged motor vents Examine and clear motor vent openings.
Cable, terminal, or wiring problems. Look Repair/replace wiring or cables as
for loose or discolored terminals, loose needed. Make sure motor cables are
or damaged crimps. torqued correctly.
Incorrect use of deadman pedal, resulting Instruct operator in correct stopping
in dragging brake procedures.
Worn or pitted TPC, PC, or P Contactor Examine the contactor tips. Replace tips
tips. as necessary.
Test TPC, PC, or P Contactor operation.
Run Test O00, O01, or O02. Follow
Motor current problem For drive motor, run Test A11 – Traction
Motor Current (Page 6-83).
Measure current.
Worn, damaged, or bad brushes or Examine motor brushes. See “DC Motor
springs (lift and aux motor only) Brushes” on page 7-91.
Measure brush spring tension. See “DC
Motor Brush Spring Tension” on
page 7-93.
Binding gearbox or pump Examine gearbox or pump for binding.
Clean, repair, or replace as necessary.
5-32 PDMM-0109 7/31/02


page 7-69.
Hot auxiliary motor caused by sticking Measure aux idle pressure.
DIRA/DIRB valve
Hydraulic fluid viscosity too high or too Replace hydraulic fluid with correct fluid.
low See “Lubrication Specification Chart” on
page A-2.
Pressure relief set too high Adjust pressure relief. See “Lift Pressure
Adjustment” on page 7-114.
See also “DC Motor Troubleshooting” on

page 5-10 and “AC Motor Troubleshooting” on
page 5-13.
PDMM-0109 7/31/02 5-33

Operator Display Problems
Scrambled or Intermittent Display

Electrostatic discharge from dirty, worn, Clean or replace static straps as needed.
or wrong type static straps
Loose JD1-JC5 harness, JD1-JC4 Reseat cards and harness connections.
harness, or card connectors
Intermittent wires or connectors in Test for continuity while flexing harness.
harness If no continuity is found, replace wiring
harness. See “Wiring and Harness
Connectors” on page 7-86.
Electrical noise in motors Retorque motor power cable connections.
See “Terminal Nuts” on page 7-96.
Electromagnetic interference from Route display cable away from power
improper cable routing cables.
Bad key switch Replace key switch. See “Operator
Display (OD)” on page 7-38.
Bad Operator Display card Replace Operator Display card. See
“Operator Display (OD)” on page 7-38.
5-34 PDMM-0109 7/31/02

Dead Lift Truck
Display is Dark; Lift Truck is not Operational

Battery problems Replace battery with fully-charged
battery. Adjust BSOC cutout.
Bad battery cables or connector Repair or replace as necessary.
Fuse FU5 may be blown. Remove fuse FU5 and test continuity. If
continuity is missing, replace fuse.
Problem in key switch circuit or with B+ Disconnect JPF3 at the fuse/relay card.
to Vehicle Manager or bad Vehicle Turn key switch ON. Measure
Manager continuity between JF3-2 and JF3-4. If
no continuity, either key switch S1 or
cable JF3 to key switch is bad. Measure
continuity across terminals of S1. If no
continuity, replace S1; if continuity,
replace cable JF3. Turn key switch OFF.
Reconnect JPF3.
Turn key switch ON. Check the following
voltages with respect to TP4 (–):
Check B+KA at JPC8-4 and JPC8-5.
Check B+KB at JPC10-19.
Check B+KC at JPC8-13.
If any voltage is missing, troubleshoot
associated relays and wiring.
Problem with +12 volt power supply Run Test A14.
Bad Operator Display Replace Operator Display. See “Operator
Display (OD)” on page 7-38.
PDMM-0109 7/31/02 5-35

5-36 PDMM-0109 7/31/02

EASi Reach-Fork® Truck EZ-D/DZ-D Maintenance Manual Messages, Codes, and Tests
Messages, Codes, and Tests 6:
PDMM-0109 7/31/02 6-1

Messages, Codes, and Tests EASi Reach-Fork® Truck EZ-D/DZ-D Maintenance Manual
Firmware Changes
Firmware Changes
Vehicle Manager
This manual is written to a Vehicle Manager
firmware baseline of Version 01.1. The following
table summarizes version changes in EASi
Reach-Fork® Series EZ-D/DZ-D lift truck
Vehicle Manager firmware affecting messages,
fault codes, electrical tests, and modes of
operation. The table does not discuss details of
engineering changes contained in these
versions.
Version Date Series Changes

01.1 07-15-02 EZ-D/DZ-D Initial version
Power Amplifier
This manual is written to a Power Amplifier
firmware baseline of Version x.xx. The following
table summarizes version changes in EASi
Reach-Fork® Series EZ-D/DZ-D lift truck power
amplifier firmware. The table does not discuss
details of engineering changes contained in
these versions.
Version Date Series Changes

6108 7-15-02 EZ-D/DZ-D Initial version
6-2 PDMM-0109 7/31/02

Modes of Operation
Modes of Operation
Overview of Modes Learn Mode
This lift truck has several modes of operation. Use Learn Mode to calibrate the lift truck for
The main distinction is between Run Mode and correct operation. You can select the following
Program Mode. Run Mode is the normal categories for calibration:
operating mode for the lift truck. Program Mode • Controls (travel, lift/lower)
permits configuration, calibration, and
• Weight
diagnostic testing (maintenance).
To enter Learn Mode, you must enter the
Run Mode Superword.
For detailed description, see “Using Learn
When you power on the lift truck normally, the
Mode” on page 6-11.
on-board firmware does a number of internal
self-tests and enters the default mode of
operation, Run Mode. Run Mode is the normal Maintenance Mode
operating mode. In Run Mode, the Operator Use Maintenance Mode to test, cycle, and
Display shows the default display. For troubleshoot individual electrical circuits
information on setting the default display, see related to the intellidrive ® systems.
“Main Operator Display” on page 3-5. Maintenance Mode is divided into two
Run Mode is also entered when the lift truck categories: static and active.
exits Program Mode. To enter Maintenance Mode, you must enter the
Superword.
Program Mode For detailed description, see “Using
Use Program Mode configuration, calibration, Maintenance Mode” on page 6-12.
and diagnostic testing of the lift truck. You need
a password in order to enter Program Mode. See Passwords
“Passwords” below.
Program Mode is divided into three categories: Electronic Operator Key
• Configure Mode Electronic Operator Key is a configurable

software feature which permits the customer to
• Learn Mode set an operator electronic key or operator
• Maintenance Mode password. With Operator Key enabled, when
the operator turns the key switch ON, the
Configure Mode software prompts operator to enter the
electronic key. The lift truck will not enter Run
Configure Mode is used to adjust various lift Mode unless the correct electronic key is
truck performance parameters to specific entered.
customer requirements. To enter Configure
Mode, you must enter either the Password or
Password
Superword for the lift truck.
Password permits access to Configure Mode
Some items in Configure Mode will appear only
only. It is intended for customer use in setting
if the Superword is entered.
performance parameters within those features
For detailed description, see “Using Configure purchased with the lift truck.
Mode” on page 6-6.
PDMM-0109 7/31/02 6-3

Run Mode Tones
Superword
Superword permits access to all Program
Modes. Superword is intended to limit service
access to qualified and trained service
technicians.
We strongly recommend that, during
installation, you change the Superword from
the factory default to a code known only to the
dealer and/or owner so that access to
Maintenance Mode is limited to approved
personnel. Make sure to record the new
Superword in a safe place. If this code is lost or
forgotten, a technician will need to reset the lift
truck to factory default settings. This will make
necessary the reconfiguration of all variable
settings.
Run Mode Tones

The lift truck signals various situations by
using different tone patterns.
1. A single tone (chirp) occurs when:
• The horn button is used to enter a value
in a Program Mode.
2. A double tone (high/low) means 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.
3. A triple tone (high/medium/low) means one
of the following:
• Travel performance limitation: The lift
truck is limited to a maximum travel
speed of 1 MPH (1.6 km/h). Lift, lower,
auxiliary functions, steering, and horn
all operate normally.
• Traction system shutdown: The lift
truck is disabled for travel. Lift, lower,
auxiliary functions, steering, and horn
all operate normally.
• Lift system shutdown: The lift truck is
not permitted to lift. Lower, travel,
steering, and aux all operate normally.
4. A descending “arcade” tone means:
• An incorrect password or electronic key
was entered.
6-4 PDMM-0109 7/31/02

Entering Program Mode
Entering Program Mode 5. When you have completed entering all the
characters in the Password or Superword,
1. If the lift truck has electronic key, turn the press the horn button once.
key switch ON. At the electronic key
prompt, enter the Password or Superword, 6. If you enter an invalid Password or
as specified below. Superword, a descending “arcade” tone
sounds and the following message scrolls
2. If the lift truck does not have electronic on the Operator Display before returning to
key, enter Program Mode in this way: With the password prompt screen:
the key switch OFF, press and hold the
horn and sideshift right buttons at the INVALID CODE TRY AGAIN
same time. 7. If you make a mistake while entering a
Turn the key switch ON. character, repeat steps 2 through 5.
You will see an eight character password Once you have entered the correct Password or
prompt field, displaying underscores: Superword, you will see one of the following
displays:
________
• If you entered the Password, the Operator
Enter the Password or Superword for the
Display shows:
lift truck. See “Entering a Password or
Superword” below. QUIT CFG
• If you entered the Superword, the Operator
Entering a Password or Display shows:
Superword QUIT PGM
A Password or Superword may be from one to
eight characters in length, having any To change Password or Superword
combination of letters, numbers, and/or spaces 1. Enter the Configure Mode using the current
(indicated by an underscore). A password of all Password or Superword. See “Using
spaces is not permitted. Configure Mode” on page 6-6. If Password
1. When the password prompt displays, an is entered, Password is available for
eight character field of underscores change, but Superword is not.
appears. Initially, the left-most character 2. Use the tilt up/down buttons to scroll to
position is flashing, showing it is the the Password or Superword item.
currently selected position.
3. With Password or Superword selected,
2. Use the sideshift left/right buttons to press the horn button. (If Password was
select a different character position. The entered in step 1 above, Password is
selected position will flash. available for change, but Superword is not.
3. Once you select the character position, use 4. Enter the new password as specified under
the tilt up/down buttons to select the “Entering a Password or Superword” above.
number, letter, or space you want. The
character set wraps between “z” and “-” 5. With the new password displayed, press the
(space). In other words, to go quickly from horn button.
the letter “z” to the number “0,” press the 6. Save the new password as specified under
tilt down button twice. “To Save New Values” on page 6-6.
-0123456789
ABCDEFGHIJKLMNOPQRSTUVWYZ
4. Repeat steps 2 and 3 for the remaining

characters in the Password or Superword.
PDMM-0109 7/31/02 6-5

Using Configure Mode
Using Configure Mode NOTE: Changes are not saved until you exit
Configure Mode and reply YES to the
Use Configure Mode to adjust various lift truck prompt.
performance parameters to specific customer
requirements. To enter Configure Mode, you To Configure Additional Items
must enter either the Password or Superword
for the lift truck. • After configuring the first item, press the
horn button. Navigate to the next item as
Some items in Configure Mode appears only if specified under “To configure an item.”
the Superword is entered.
“Configure Mode Settings” on page 6-8 lists all If You Make a Mistake
possible lift truck configurations and options. If
your lift truck does not have one or more of the • If you make a mistake in configuring an
listed options, those options do not appear in item, simply navigate back to that item and
the Operator Display. configure it again.
To Place the Lift Truck in Configure Mode To Save New Values
1. Enter Program Mode as specified on Changes to configuration values are not saved
page 6-5. until you exit Configuration Mode. If you have
made changes to configured values:
2. Enter Password or Superword.
1. Use the tilt up/down buttons to scroll to
3. If you entered the Password, the Operator the QUIT CFG item. Press the horn button.
display shows:
2. The Operator Display shows:
QUIT CFG
SAVE? N
4. If you entered the Superword, the Operator
Display shows: 3. Use the tilt up/down buttons to select Y
(YES). Press the horn button. Your new
QUIT PGM values are saved.
Press the tilt up button until Config is 4. If you entered via Superword, the Operator
displayed. Press the horn button. The Display shows:
Operator Display shows:
CONFIG
QUIT CFG
Use the tilt up/down buttons to select QUIT
PGM and press the horn button. The
To Configure an Item Operator Display shows:
1. Use the tilt up/down buttons to move to DONE
the item you want.
5. The lift truck enters the Run Mode,
2. To configure the selected item, press the
beginning with SelfTest diagnostics.
horn button. Follow the directions on the
Operator Display. Use tilt up/down
buttons to select among specified values or If You Change Your Mind About Making
to enter a numerical value. Use sideshift Changes
left/right buttons to select a position within Changes to configuration values are not saved
a field (e.g., the minutes within the time until you exit Configuration Mode. If you made
display). configuration changes, but do not wish to keep
When you have entered the values you the changes:
want via the tilt up/down buttons, press 1. Use the tilt up/down buttons to scroll to
the horn button. The values are accepted the QUIT CFG item. Press the horn button.
and the Operator Display shows the name
of the item you last selected.
6-6 PDMM-0109 7/31/02

Using Configure Mode

SAVE? N
3. With N (NO) selected, press the horn
button. All changes are discarded.
4. If you entered via Superword, the Operator
Display shows:
CONFIG
Use the tilt up/down buttons to select QUIT
PGM and press the horn button. The
DONE
5. The lift truck enters Run Mode, beginning
with SelfTest diagnostics.
To Reinstate Factory Default Settings

1. Enter Configure Mode and use the tilt up
button to select DEFAULT. Press the horn
button. The Operator Display shows:
RESET? N
Use the tilt up/down buttons to select Y
(YES). Press the horn button.
2. Use the tilt down button to select the QUIT
CFG item. Press the horn button.
SAVE? N
4. Use the tilt up/down buttons to select Y
(YES). Press the horn button. Factory
default settings are restored for all items
except:
• Password
• SuperWord
• Electronic Key
• Mnt Mind
• SMARTi ®
5. If you entered via Superword, the Operator
Display shows:
DONE
6. The lift truck enters Run Mode, beginning
with SelfTest diagnostics.
PDMM-0109 7/31/02 6-7

Configure Mode Settings

Configure Mode Menu
NOTE: * Indicates Factory Default
Shaded items are available only from the Superword menu structure.
Item Values Description
* Reset? N Restore all settings to Factory Default

Default
Reset? Y
* 7.5 Maximum Travel Speed

Speed 0.0 to 7.5 m.p.h.
(0.0 to 12.1 km/h)
Hard Travel Acceleration

Accel * Medium
Soft
* Hard Lift Acceleration

Lift Medium
Soft
Short Coast Distance after releasing directional/speed control

Coast Medium
* Long
20 Battery State-of-Charge Lift Cut-Out Value

Cutout
0 - 50%
Units * English Display Units

Metric
* 2-Speed Reach Speed

Reach
Hi
* 3.5 Travel Speed Limit at Height 1

Switch 1 (option) 0 to 3.5 m.p.h.
(0 to 5.6 km/h)
* 1.8 Travel Speed Limit at Height 2

Switch 2 (option) 0 to 1.8 m.p.h.
(0 to 2.9 km/h)
UnNested * 3.5 Travel Speed Limit with Reach Extended

(option) 0 to 3.5 m.p.h.
(0 to 5.6 km/h)
6-8 PDMM-0109 7/31/02

Configure Mode Menu

None Travel Alarm enabled for forks leading, forks trailing,

* Both Dir both directions, or not enabled.
AlarmT (option)
Fork Trl
Fork Ld
________ Electronic Key prompt. Note: If you make the electronic

key and password the same, the lift truck will recognize
only the password. If you make the electronic key and
Elec Key (option) the superword the same, the truck will recognize only
the electronic key. If you make the password and
superword the same, the lift truck will recognize only
the password.
Password _______ Change Password. See note under Electronic Key.
Superwrd _______ Change Superword. See note under Electronic Key.
VM xx.y Display lift truck firmware and SMARTi ® firmware

Version PAT xx.y versions. Cannot be changed.
SM x.y
The percentage of charge which a new battery must

exceed in order for the BSOC display to be reset to the
BSOC * 75 new battery. For an explanation of how BSOC is
calculated, see “Battery State-of-Charge” on page 5-14.
55-100%
Quit MM Maintenance Minder™ tool

Save? *Y Save changes before exiting Maint Minder
Setup Set interval and type of action
Interval Reminder interval from 50-500 hours
on deadman pedal, by 50
* 200 FS Factory default
Action Action to be taken at specified interval
LCutout Disable lift
Mnt Mind
* MsgOnly Display message but do not disable lift
Disable Disables the feature (when enabled)
Reset Resets internal timer to current deadman pedal hours
(restarts the countdown)
Enable Enables the feature, using last stored setup
See “Maintenance Minder™ Tool” on page 4-3.
PDMM-0109 7/31/02 6-9

Configure Mode Menu

* Disabled Auto Power Off ™ device

XX Disabled, 1, 2, 3, 4, 5, 10 minutes
Auto Off
NOTE: Auto Power Off will shut down a lift truck only
when the lift truck is in Run Mode.
SN _ _ _ _ _ Displays the lift truck serial number. Cannot be

Serial #
changed.
Quit Clk Set Time and Date

Time
Clock AM
PM
Date
Enable SMARTi ® System activation/deactivation

SMARTi ®
*Disable
6-10 PDMM-0109 7/31/02

Using Learn Mode
Using Learn Mode 5. The Operator Display momentarily shows:
To place the lift truck in Learn Mode: DONE
1. Enter Program Mode. The Operator Display then shows:
2. Enter Superword. The Operator Display CONTROLS

shows:
QUIT PGM Learn Weight
3. Use the tilt up/down buttons to select Learn Weight stores a series of pressure
LEARN, then press the horn button. The readings used to calculate the weight during
Operator Display shows: actual use when the mast is lifting, lowering, or
at rest:
QUIT LRN
1. From the Learn Menu, select WEIGHT and
4. Use the tilt up/down buttons to select the press the horn button. The Operator
desired category. You can select the Display scrolls:
following categories:
LOWER CARRIAGE TO FLOOR THEN LIFT 4
CONTROLS INCHES. PRESS HORN BUTTON WHEN
WEIGHT DONE.
5. With the item you want selected, press the Follow the directions given in the prompt.
horn button. 2. When you press the HORN button, the
Operator Display momentarily shows:
Learn Controls READING
Use Learn Controls to determine the neutral 3. The Operator Display scrolls:
position of:
RAISE CARRIAGE OUT OF FREE LIFT. PRESS
• VR1 travel control HORN BUTTON WHEN DONE.
• VR2 lift/lower control
Follow the directions given in the prompt.
4. When you press the HORN button, the
1. Enter Learn Mode, select CONTROLS, and Operator Display momentarily shows:
press the horn button. READING
2. When you select Learn Controls, the
then:
Operator Display scrolls:
DONE
RETURN TRAVEL CONTROL TO NEUTRAL;
PRESS HORN BUTTON 5. The Operator Display scrolls:
Release the directional/speed control and LOWER CARRIAGE TO FLOOR. PRESS HORN
press the horn button. BUTTON WHEN DONE.
3. The Operator Display momentarily shows: Follow the directions given in the prompt.
DONE When the system has recorded the
readings, the Operator Display momentarily
4. The Operator Display scrolls: shows:
RETURN LIFT CONTROL TO NEUTRAL; PRESS DONE
HORN BUTTON
The Operator Display then shows:
Release the lift control and press the horn
button. WEIGHT
PDMM-0109 7/31/02 6-11

Using Maintenance Mode
Using Maintenance Mode 4. You can select the following from

Maintenance Mode:
Maintenance Mode is divided into two
categories: static and active. QUIT MNT
OUTPUT
Static Maintenance Mode INPUT
Static Maintenance Mode permits testing of ANALOG
individual circuits while the lift truck is
standing still. You can use Static Maintenance CLR ACTM [only if tests are selected for
Mode for most analog and digital input and active maintenance mode]
digital output tests. ERRORLOG
Use the tilt up/down buttons to select the
test category desired, then press the horn
! WARNING button.
By entering Static Maintenance 5. If you select Output tests, the Operator
Mode, you are disabling the safety Display scrolls this warning:
circuits related to the intellidrive ® JACK UP THE DRIVE WHEEL.
system. Therefore, you must take
READY?
extra precautions while in Static
Maintenance Mode. Follow all After you jack up and block the lift truck,
instructions in this manual for each respond to the Ready prompt by pressing
the horn button.
test. If you are unsure how to
conduct a test while in Maintenance 6. Within a test category, tests numbers are
Mode, STOP: DO NOT PROCEED with displayed, in numerical sequence. Use the
tilt up/down buttons to move to the test
the test. Contact an authorized you want.
Raymond Dealer.
The QUIT option, to exit this test category, is
the first selection in the list. If you are
While in Static Maintenance Mode: currently positioned nearer the bottom of
Elevate the drive tire off the floor. the list, it may be faster to scroll to the
bottom of the list and press the down
See “Jacking Safety” on page 2-13.
button. The list “wraps” between the last
and first entries in the list.
To Place the Lift Truck in Static Maintenance 7. Analog and Input test results are displayed
Mode as soon as you select the test, to the right of
1. Enter Program Mode. the test number. For example, Test A04
might report 2.4 volts as:
2. Enter Superword.
A04 2.4
3. Use the tilt up/down buttons to select
MAINT, then press the horn button. 8. You must explicitly start output tests.
Select the test number you want.
O11
Press the horn button. The Operator
Display shows the test results to the right
of the test number.
O11 OFF
6-12 PDMM-0109 7/31/02

Active Maintenance Mode
Use the tilt up/down buttons to toggle the You can select up to six tests at a time to run in
switch setting. Active Maintenance Mode. Tests can be
displayed whether you are on or off the
O11 ON
deadman pedal. You can select different tests
To exit the test, press the horn button. The for the ON and OFF deadman conditions.
test number displays, without any results.
Tests selected for active maintenance are stored
O11 in memory even if the key switch is turned OFF.
9. The Error Log stores the last twenty fault
codes recorded on the lift truck. Entries are To Enable a Test For Active Maintenance
stored in order of occurrence, with the most Mode
recent error first. 1. Enter Static Maintenance Mode.
a. To access the Error Log, use the tilt 2. Select the test you want and press the horn
up/down buttons to select ERRORLOG, button. An asterisk (*) appears between the
then press the horn button. test number and the results field to show
b. If no errors are stored, the message that this test is selected for Active
NOERRORS appears in the display. After a Maintenance Mode.
few seconds, the following message If a test is not eligible for active
scrolls: “THERE ARE NO ERRORS LOGGED. maintenance or if you have already selected
PRESS HORN BUTTON TO QUIT.” Press the six tests, the horn sounds.
horn button to continue.
c. If errors have been logged, the following more tests from the same category. To
menu options are active: select more tests from a different category,
QUIT select QUIT from the current category and
select the other category from the MAINT
CLEAR menu. Use the tilt up/down buttons to
1) CODE select more tests from that category.
4. Quit Maintenance Mode and quit Program
N) CODE
Mode. Let the lift truck enter Run Mode.
Use the tilt up/down buttons to select
5. To select the test that will be displayed
an option and to examine the error list.
when you are OFF the deadman pedal:
d. Pausing at an entry will result in a
a. While the deadman pedal is still up,
message scrolling the time, date, and
move the directional/speed control
BSOC value related to the fault code.
full forward and hold it there.
e. To clear and reset the error log, select
b. Use the tilt up/down buttons to scroll
the CLEAR option and press the horn
to the test you want. Release the tilt
button. The log is cleared.
button and then release the
NOTE: There is no verification prompt to clear the directional/speed control.
log. Be sure you want to erase all entries 6. To select the test that will be displayed
before pressing the horn button. when you are ON the deadman pedal:
Active Maintenance Mode move the directional/speed control to
Active Maintenance Mode permits testing full forward and hold it there.
circuits related to the intellidrive ® system while b. Step on the deadman pedal.
the lift truck is enabled for normal operation.
You can use Active Maintenance Mode for all c. Use the tilt up/down buttons to scroll
analog and digital input tests. to the test you want. Release the tilt
button, step off the deadman pedal, and
PDMM-0109 7/31/02 6-13

Active Maintenance Mode
then release the directional/speed

control.
7. To scroll through the selected tests:
move the directional/speed control to
the full forward position.
b. Use the tilt up/down buttons.
To Clear a Test From the Active Maintenance

List
1. Re-enter Maintenance Mode.
either INPUT or ANALOG and scroll to the
test you want to disable.
3. Press the horn button.
4. The asterisk will disappear. The test has
now been disabled.
To Clear All Active Maintenance Tests At

Once
1. Go to the Program Mode via Superword.
MAINT, then press the horn button. The
QUIT MNT
CLRACTM item. This item only appears if you
have selected one or more tests for active
maintenance.
4. Press the horn button. Active maintenance
tests are disabled. The Operator Display
shows:
QUIT MNT
6-14 PDMM-0109 7/31/02

Messages and Codes Summary List


Code 1H – Traction Power Amplifier Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Code 1T – Battery Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Code 2A – Traction Motor Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Code 2C – Traction Power Amplifier Temperature Sensor Out-of-Range . . . . . . . . . . . . 6-24
Code 2E – Traction Motor Temperature Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . 6-25
Code 2H – Failure Detected in Traction Motor Feedback Encoder . . . . . . . . . . . . . . . . . 6-26
Code 2M – Traction Power Amplifier Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Code 2P – Traction Power Amplifier Reverted to Default Parameters . . . . . . . . . . . . . . 6-28
Code 2R – Traction Power Amplifier Pulse Sensor Warning . . . . . . . . . . . . . . . . . . . . . 6-29
Code 2T – Traction Power Amplifier Current Calibration Error . . . . . . . . . . . . . . . . . . . 6-30
Code 2U – Traction Power Amplifier Overcurrent or Short Circuit . . . . . . . . . . . . . . . . 6-31
Code 2V – Traction Power Amplifier High DC Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Code 42 – Lift Contactor Detected Closed When Commanded Open . . . . . . . . . . . . . . . 6-33
Code 43 – Lift Contactor Detected Open When Commanded Closed . . . . . . . . . . . . . . . 6-34
Code 44 – PC Contactor Detected Closed When Commanded Open . . . . . . . . . . . . . . . 6-35
Code 45 – PC Contactor Detected Open When Commanded Closed . . . . . . . . . . . . . . . 6-36
Code 4D – No Charging Traction DC Input Voltage During Start-Up . . . . . . . . . . . . . . 6-37
Code 4F – TPC Contactor Detected Closed When Commanded Open . . . . . . . . . . . . . . 6-38
Code 4G – TPC Contactor Detected Open, Low DC Bus After Power-Up . . . . . . . . . . . . 6-39
Code 59 – CAN Transmission Buffer Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Code 5A – CAN Bus Error/Vehicle Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Code 5B – CAN Receive Bus Error/Vehicle Manager . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Code 5D – No SMARTi® System Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Code 5G – No Communications Received from Traction Power Amplifier . . . . . . . . . . . 6-44
Code 5L – Excessive CAN Errors - Traction Power Amplifier . . . . . . . . . . . . . . . . . . . . 6-45
Code 5M – Traction Power Amplifier CAN Watchdog Timeout . . . . . . . . . . . . . . . . . . . . 6-46
Code 63 – First and Second Speed Limiting Switches Do Not Agree . . . . . . . . . . . . . . . 6-47
Code 6D – Pressure Sensor Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
Code 6F – Lift Motor Overheated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Code 6G – Lift Motor Temperature Sensor Out-of-range . . . . . . . . . . . . . . . . . . . . . . . . 6-50
Code 80 – Throttle Potentiometer Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
Code 81 – Lift Potentiometer Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
Code 83 – Travel Control Handle Pot Out of Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
Code 84 – Brake inoperable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
Code 87 – Traction Power Amplifier Fan Inoperable . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
Code 8F – Lift Control Handle Pot Out of Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
Code A0 – Incorrect Software For Proper Lift Truck Operation . . . . . . . . . . . . . . . . . . . 6-57
Code AG – Communications To/From Operator Display Failed . . . . . . . . . . . . . . . . . . . 6-58
Code AH – Bad Operator Display Checksum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59
Code AJ – Bad VM ROM Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
Code AK – Bad VM RAM Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
Code AL – Bad Battery Backed-Up VM RAM Memory . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
Code EC – Operating System Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63
Code F4 – Vehicle Manager COP Time-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Code F5 – Bad Op Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
Code F8 – Vehicle Manager COP Not Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66
Code FG – 12 Volt Power Supply Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
Code FH – Battery Voltage Out-of-Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68
Code VC – CAN integrated circuit does not reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69
PDMM-0109 7/31/02 6-15

6-16 PDMM-0109 7/31/02

Power Amplifier LED Diagnostics

Power Amplifier LED

Diagnostics
Status
Indicator
LED
65077_049.TIF
Figure 6-1: Power Amplifier Status Indicator LED
Error conditions involving the power amplifier

usually display as fault codes on the Operator
Display.
The power amplifier also contains a light
emitting diode (LED) status indicator, which
supplies very limited diagnostic information.
When the LED is illuminated (steady or
flashing), the amplifier is receiving power.
A steady LED means the amplifier is operating
normally.
A blinking LED means a malfunction.
PDMM-0109 7/31/02 6-17

Power Amplifier LED Diagnostics Electrical Codes
Electrical Codes
NOTE: In this section, the table shows, for

each message or code, the expected
operating status of the lift truck,
based on software, after the message
or code has been displayed.
Other factors, such as mechanical
failures, could prevent the lift truck
from operating as specified in the
table.
6-18 PDMM-0109 7/31/02

Electrical Codes Code 1H
Code 1H
Code Title Code 1H – Traction Power Amplifier Overheated
The temperature reading from the power amplifier

Reason
shows overheating.
System Response
Alarm Sounds Yes
Operator Display Code 1H. Overheated. Allow time to cool.
Travel PC Contactor De-energized
PC Contactor Energized
Lift (P) Contactor Energized
Performance Limits
Travel System Disabled
Auxiliary System No limits
Lift/Lower System No limits
Permit time for the power amplifier to cool. Turn the key
How to Clear
switch OFF, then ON.
Test A10 – Traction Power Amplifier Heatsink

Tests to Run Temperature (Page 6-82)
Test O23 – Toggle Power Amplifier Fan (Page 6-127)
NOTE: Reference “Thermal Cut-Back” on

page 8-19.
PDMM-0109 7/31/02 6-19

Code 1T Electrical Codes
Code 1T
Code Title Code 1T – Battery Low
Reason Lift cutout point configured for BSOC has been reached.
System Response
Alarm Sounds Yes
Operator Display Code 1T. Battery low.
Travel PC Contactor Energized
Lift (P) Contactor
Performance Limits
Travel System No limits
Lift/Lower System No lift; lower enabled
How to Clear Change battery. Self resetting.
Tests to Run none
6-20 PDMM-0109 7/31/02

Electrical Codes Code 2A
Code 2A
Code Title Code 2A – Traction Motor Overheated
The traction power amplifier has found that the traction

Reason
motor has overheated.
System Response
Alarm Sounds Yes
Operator Display Code 2A. Overheated, Allow Time to Cool.
Performance Limits
Travel System 1 mph speed limit
How to Clear Permit time for the motor to cool. Self resetting.
Tests to Run Test A08 – Traction Motor Temperature (Page 6-78)
NOTE: Reference “Thermal Cut-Back” on

page 8-19.
NOTE: The Vehicle Manager cannot cause this
code.
Test:
1. Make sure power cables are torqued
correctly at both traction power amplifier
and drive motor. See "Terminal Nuts" on
page 7-96.
2. If BSOC cutout is set too low, a weak
battery can result in overheating.
3. Examine motor for mechanical binding.
4. Examine brake for dragging.
5. If problem still exists, evaluate the duty
cycle and application.
PDMM-0109 7/31/02 6-21

Code 2C Electrical Codes
Code 2C
Code 2C – Traction Power Amplifier Temperature

Code Title
Sensor Out-of-Range
The traction power amplifier temperature sensor has

Reason
returned a value outside the valid reference range.
System Response
Alarm Sounds Yes
Operator Display Code 2C. Inform Service.
Performance Limits
Travel System Reduced acceleration
How to Clear Self-resetting
Tests to Run none

code.
Corrective Action:
• Replace the traction power amplifier. See
“Traction Power Amplifier” on page 7-103.
NOTE: Make sure to reconnect the power cables
in the correct sequence with flared nuts,
torquing to 15 ft. lb. (20.3 Nm).
6-22 PDMM-0109 7/31/02

Electrical Codes Code 2E
Code 2E
Code 2E – Traction Motor Temperature Sensor

Code Title
Out-of-Range
The traction motor temperature sensor has returned a

Reason
value outside the valid reference range.
System Response
Alarm Sounds Yes
Operator Display Code 2E. Inform Service.
Performance Limits
How to Clear Permit time to cool. Self-resetting
Tests to Run Test A08 – Traction Motor Temperature (Page 6-78)

code.
PDMM-0109 7/31/02 6-23

Code 2H Electrical Codes
Code 2H
Code 2H – Failure Detected in Traction Motor

Code Title
Feedback Encoder
Reason The speed feedback circuit is not operating correctly.
System Response
Alarm Sounds Yes
Operator Display Code 2H. Inform Service.
Performance Limits
How to Clear Turn the key switch OFF, then ON.
Test I19 – Drive Motor Speed Sensor (Page 6-109)

Tests to Run
See below

code.
6-24 PDMM-0109 7/31/02

Electrical Codes Code 2M
Code 2M
Code Title Code 2M – Traction Power Amplifier Failed
Reason The traction power amplifier has found an internal fault.
System Response
Alarm Sounds Yes
Operator Display Code 2M. Inform Service.
Performance Limits
Travel System Traction system shutdown
Tests to Run

code.
Corrective Action:
PDMM-0109 7/31/02 6-25

Code 2P Electrical Codes
Code 2P
Code 2P – Traction Power Amplifier Reverted to

Code Title
Default Parameters
The traction power amplifier has found an internal

Reason
software malfunction.
System Response
Alarm Sounds Yes
Operator Display Code 2P. Inform Service.
Performance Limits
Should clear automatically after 30 seconds; if not, cycle

How to Clear
key switch OFF/ON.
Tests to Run
NOTE: This code can appear when first turning

key switch ON after installing a new
Vehicle Manager or traction power
amplifier.
Corrective Action:
• Replace traction power amplifier. See
6-26 PDMM-0109 7/31/02

Electrical Codes Code 2R
Code 2R
Code 2R – Traction Power Amplifier Pulse Sensor

Code Title
Warning
At least one channel of the drive motor speed sensor is

Reason
malfunctioning.
System Response
Alarm Sounds Yes
Operator Display Code 2R. Inform Service.
Performance Limits
Tests to Run Test I19 – Drive Motor Speed Sensor (Page 6-109)

code.
PDMM-0109 7/31/02 6-27

Code 2T Electrical Codes
Code 2T
Code 2T – Traction Power Amplifier Current

Code Title
Calibration Error
The traction power amplifier has found an internal fault

Reason
with the current sensor.
System Response
Alarm Sounds Yes
Operator Display Code 2T. Inform Service.
Performance Limits
Travel System 2.5 mph speed limit
Tests to Run none

code.
Corrective Action:
6-28 PDMM-0109 7/31/02

Electrical Codes Code 2U
Code 2U
Code 2U – Traction Power Amplifier Overcurrent or

Code Title
Short Circuit
The traction power amplifier has found current more

Reason
than 480A for longer than 3 seconds.
System Response
Alarm Sounds Yes
Operator Display Code 2U. Inform Service.
Performance Limits
Test O29 – Ramp the Traction Power Amplifier

Tests to Run
(Page 6-128)
NOTE: Overcurrent occurs at about 480A.
PDMM-0109 7/31/02 6-29

Code 2V Electrical Codes
Code 2V
Code 2V – Traction Power Amplifier High DC

Code Title
Voltage
The traction power amplifier has found input voltage

Reason
more than 50 volts.
System Response
Alarm Sounds Yes
Operator Display Code 2V. Inform Service.
Performance Limits
Tests to Run none

code.
Corrective Action:
1. Verify that B+ is present at the + terminal of
the power amplifier.
2. Replace the traction power amplifier. See
6-30 PDMM-0109 7/31/02

Electrical Codes Code 42
Code 42
Code 42 – Lift Contactor Detected Closed When

Code Title
Commanded Open
The Vehicle Manager sensed the lift contactor closed

Reason
after the lift contactor was commanded open.
System Response
Alarm Sounds Yes
Operator Display Code 42. Inform Service.
Lift (P) Contactor De-energized
Performance Limits
Lift/Lower System Lift disabled; lower enabled
Tests to Run Test O02
NOTE: If contactor tips are welded or burnt,

measure battery specific gravity and
each cell’s voltage.
Adjust BSOC cutout as required.
PDMM-0109 7/31/02 6-31

Code 43 Electrical Codes
Code 43
Code 43 – Lift Contactor Detected Open When

Code Title
Commanded Closed
The Vehicle Manager found the lift contactor open after

Reason
the lift contactor was commanded closed.
System Response
Alarm Sounds Yes
Performance Limits
If contactor tips do not close: Test O02

Tests to Run
If contactor tips close: Test I13
NOTE: If contactor tips are welded or burnt,

measure battery specific gravity and
each cell’s voltage.
Adjust BSOC cutout as required.
6-32 PDMM-0109 7/31/02

Code 44
Code 44 – PC Contactor Detected Closed When

Code Title
Commanded Open
The Vehicle Manager found the PC contactor closed after

Reason
the PC contactor was commanded open.
System Response
Alarm Sounds Yes
PC Contactor De-energized
Performance Limits
Auxiliary System Disabled
If contactor tips do not close: Test I14.

Tests to Run
If contactor tips close: Test O01
PDMM-0109 7/31/02 6-33

Code 45
Code 45 – PC Contactor Detected Open When

Code Title
Commanded Closed
The Vehicle Manager found the PC contactor open after

Reason
the PC contactor was commanded closed.
System Response
Alarm Sounds Yes
Performance Limits
Travel System 1.0 mph (1.6 km/h) speed limit
If contactor tips do not close: Test O01

Tests to Run
If contactor tips close: Test I14
6-34 PDMM-0109 7/31/02

Electrical Codes Code 4D
Code 4D
Code 4D – No Charging Traction DC Input Voltage

Code Title
During Start-Up
The traction power amplifier did not find the correct

Reason
voltage during start-up.
System Response
Alarm Sounds Yes
Operator Display Code 4D. Inform Service.
Performance Limits
Tests to Run Test O00 – Toggle the TPC Contactor (Page 6-112)

code.
PDMM-0109 7/31/02 6-35

Code 4F Electrical Codes
Code 4F
Code 4F – TPC Contactor Detected Closed When

Code Title
Commanded Open
The traction power amplifier found a voltage after the

Reason
traction contactor was commanded open.
System Response
Alarm Sounds Yes
Operator Display Code 4F. Inform Service.
Performance Limits

code.
6-36 PDMM-0109 7/31/02

Electrical Codes Code 4G
Code 4G
Code 4G – TPC Contactor Detected Open, Low DC

Code Title
Bus After Power-Up
The traction power amplifier did not find the correct

Reason voltage after the traction contactor was commanded
closed.
System Response
Alarm Sounds Yes
Operator Display Code 4G. Inform Service.
Performance Limits

code.
PDMM-0109 7/31/02 6-37

Code 59
Code Title Code 59 – CAN Transmission Buffer Error
Reason There is an error on the CAN bus
System Response
Alarm Sounds Yes
Performance Limits
Travel System Shutdown
Tests to Run Test I23 – CAN Bus Test (Page 6-110)
6-38 PDMM-0109 7/31/02

Electrical Codes Code 5A
Code 5A
Code Title Code 5A – CAN Bus Error/Vehicle Manager
Reason There is an error in the CAN bus.
System Response
Alarm Sounds Yes
Operator Display Code 5A. Inform Service.
Performance Limits
PDMM-0109 7/31/02 6-39

Code 5B Electrical Codes
Code 5B
Code Title Code 5B – CAN Receive Bus Error/Vehicle Manager
There is a CAN Receive Bus error in the Vehicle

Reason
Manager.
System Response
Alarm Sounds Yes
Operator Display Code 5B. Inform Service.
Performance Limits
Auxiliary System No power assisted steering
6-40 PDMM-0109 7/31/02

Electrical Codes Code 5D
Code 5D
Code Title Code 5D – No SMARTi® System Response
The Vehicle Manager is not receiving inputs from the

Reason
SMARTi module.
System Response
Alarm Sounds Yes
Performance Limits
Travel System 1.0 mph (1.6 km/h) Speed Limit
PDMM-0109 7/31/02 6-41

Code 5G Electrical Codes
Code 5G
Code 5G – No Communications Received from

Code Title
Traction Power Amplifier
No communication has been received from the traction

Reason
power amplifier.
System Response
Alarm Sounds Yes
Performance Limits
6-42 PDMM-0109 7/31/02

Electrical Codes Code 5L
Code 5L
Code 5L – Excessive CAN Errors - Traction Power

Code Title
Amplifier
The traction power amplifier has found an excessive

Reason
number of CAN errors.
System Response
Alarm Sounds Yes
Operator Display Code 5L. Inform Service.
Performance Limits
PDMM-0109 7/31/02 6-43

Code 5M Electrical Codes
Code 5M
Code 5M – Traction Power Amplifier CAN Watchdog

Code Title
Timeout
The CAN watchdog circuit has not received

Reason
communication from other amplifier circuits.
System Response
Alarm Sounds Yes
Operator Display Code 5M. Inform Service.
Performance Limits
6-44 PDMM-0109 7/31/02

Code 63
Code 63 – First and Second Speed Limiting

Code Title
Switches Do Not Agree
The Vehicle Manager reads the second speed limiting

Reason switch as closed when the first speed limiting switch
reads open.
System Response
Alarm Sounds Yes
Performance Limits
Speed limited to configured speed for the second speed

Travel System
limiting switch
Test I02 – First Speed Limiting Switch (S10) (Page 6-96)

Tests to Run Test I03 – Second Speed Limiting Switch (S11) (option)
(Page 6-97)
PDMM-0109 7/31/02 6-45

Code 6D Electrical Codes
Code 6D
Code Title Code 6D – Pressure Sensor Out-of-Range
Reason Pressure sensor out-of-range (0V or greater than 5V)
System Response
Alarm Sounds Yes
Performance Limits
Travel System Limited to maximum load conditions
Lift/Lower System Single stage pump operation only
Tests to Run Test A13 – Pressure Sensor Voltage (Page 6-84)
6-46 PDMM-0109 7/31/02

Electrical Codes Code 6F
Code 6F
Code Title Code 6F – Lift Motor Overheated
The Vehicle Manager has found that the lift motor

Reason
temperature has exceeded 133°C (271°F).
System Response
Alarm Sounds Yes
Operator Display Code 6F. Overheated. Allow time to cool.
Performance Limits
How to Clear Permit time to cool. Self resetting.
Tests to Run Test A09 – Lift Motor Temperature (Page 6-80)
PDMM-0109 7/31/02 6-47

Code 6G Electrical Codes
Code 6G
Code 6G – Lift Motor Temperature Sensor

Code Title
Out-of-range
The temperature sensor voltage from the lift motor is not

Reason
within acceptable limits.
System Response
Alarm Sounds Yes
Performance Limits
Tests to Run Test A09 – Lift Motor Temperature (Page 6-80)
6-48 PDMM-0109 7/31/02

Code 80
Code Title Code 80 – Throttle Potentiometer Out-of-Range
Reason Throttle potentiometer voltage is out-of-range.
System Response
Alarm Sounds Yes
Performance Limits
Tests to Run Test A04 – Throttle Potentiometer Voltage (Page 6-76)
PDMM-0109 7/31/02 6-49

Code 81
Code Title Code 81 – Lift Potentiometer Out-of-Range
Reason Lift potentiometer voltage is out-of-range.
System Response
Alarm Sounds Yes
Performance Limits
Lift/Lower System Lift and lower disabled
Tests to Run Test A05 – Lift/Lower Potentiometer Voltage (Page 6-77)
6-50 PDMM-0109 7/31/02

Code 83
Code Title Code 83 – Travel Control Handle Pot Out of Neutral
During SelfTest, the travel control potentiometer is out

Reason
of neutral by more than 0.2 volts of the learned value.
System Response
Alarm Sounds Yes
Performance Limits
Release travel control handle. Turn the key switch OFF,

How to Clear
then ON.
Tests to Run Test A04 – Throttle Potentiometer Voltage (Page 6-76)
NOTE: The acceptable learn values for neutral

are 1.8 to 3.2 volts. The “deadband” for
being in neutral is the learned value
±0.2 volts.
PDMM-0109 7/31/02 6-51

Code 84
Code Title Code 84 – Brake inoperable
The restraining ability of the brake is tested every time

the lift truck is powered up. With the brake set, the
Reason
traction motor is briefly energized. If the motor rotates,
this code is displayed.
System Response
Alarm Sounds Yes
Performance Limits
Tests to Run
Corrective Action:
• Adjust brake. See “Brake Adjustment” on
page 7-69.
6-52 PDMM-0109 7/31/02

Code 87
Code Title Code 87 – Traction Power Amplifier Fan Inoperable
Traction power amplifier fan voltage is less than 10V or

Reason greater than 30V and power amplifier temperature has
exceeded 90°C (194°F).
System Response
Alarm Sounds Yes
Performance Limits
Tests to Run Test O23 – Toggle Power Amplifier Fan (Page 6-127)
PDMM-0109 7/31/02 6-53

Code 8F Electrical Codes
Code 8F
Code Title Code 8F – Lift Control Handle Pot Out of Neutral
During Selftest, the lift control potentiometer is out of

Reason
neutral by more than 0.2 volts of the learned value.
System Response
Alarm Sounds Yes
Operator Display Code 8F. Inform Service.
Performance Limits
Lift/Lower System Lift and lower disabled
Release lift control handle. Turn the key switch OFF,

How to Clear
then ON.
Tests to Run Test A05 – Lift/Lower Potentiometer Voltage (Page 6-77)
NOTE: The acceptable learn values for neutral

are 1.8 to 3.2 volts. The “deadband” for
being in neutral is the learned value
±0.2 volts.
6-54 PDMM-0109 7/31/02

Electrical Codes Code A0
Code A0
Code A0 – Incorrect Software For Proper Lift Truck

Code Title
Operation
An incorrect software level has been found for this lift

Reason truck, or the vehicle identification in memory has been
corrupted.
System Response
Alarm Sounds Yes
Operator Display Code A0. Inform Service.
Performance Limits
Lift/Lower System Disabled
Tests to Run None
Corrective Action:
• Update lift truck with correct software for
this model truck. Use the FlashWare
program to load new firmware.
PDMM-0109 7/31/02 6-55

Code AG Electrical Codes
Code AG
Code AG – Communications To/From Operator

Code Title
Display Failed
Serial communication to/from the Operator Display has

Reason
failed or is incorrect.
System Response
Alarm Sounds Yes
Operator Display Code AG. Inform Service. [or display could be blank]
Performance Limits
Travel System 1.0 mph speed limit
Tests to Run none
Corrective Action:
1. If the problem is intermittent, test for
shorts to frame. See “Shorts to Frame Test”
on page 5-5.
2. If you can enter Program Mode, replace the
Operator Display.
3. Check continuity of cable JC5-JD1 from
the VM to the Operator Display.
Repair/replace as necessary. If the cable is
good, replace the Operator Display.
4. Replace the Vehicle Manager.
6-56 PDMM-0109 7/31/02

Electrical Codes Code AH
Code AH
Code Title Code AH – Bad Operator Display Checksum
The software checksum in the Operator Display does not

Reason
match the one in the Vehicle Manager.
System Response
Alarm Sounds Yes
Operator Display Code AH. Inform Service.
Performance Limits
Travel System 1.0 mph
Tests to Run none
Corrective Action:
on page 5-5.
2. Display the firmware version by using the
TILT UP/DOWN buttons to select
“Firmware Version” on the operator display.
a. If the current firmware version is
incorrect, replace the Vehicle Manager.
b. If the current firmware version is
correct, replace the Operator Display
with a preprogrammed one.
PDMM-0109 7/31/02 6-57

Code AJ Electrical Codes
Code AJ
Code Title Code AJ – Bad VM ROM Memory
The Vehicle Manager ROM memory test during SelfTest

Reason
has failed.
System Response
Alarm Sounds Yes
Operator Display Code AJ. Inform Service.
Performance Limits
Tests to Run none
Corrective Action:
on page 5-5.
incorrect, obtain new firmware. Use the
FlashWare program to load new
firmware.
correct, replace the Vehicle Manager.
6-58 PDMM-0109 7/31/02

Electrical Codes Code AK
Code AK
Code Title Code AK – Bad VM RAM Memory
Reason The VM RAM memory test during SelfTest has failed.
System Response
Alarm Sounds Yes
Operator Display Code AK. Inform Service.
Performance Limits
Tests to Run none
Corrective Action:
on page 5-5.
firmware.
PDMM-0109 7/31/02 6-59

Code AL Electrical Codes
Code AL
Code Title Code AL – Bad Battery Backed-Up VM RAM Memory
The non-volatile RAM memory test during SelfTest has

Reason
failed.
System Response
Alarm Sounds Yes
Operator Display Code AL. Inform Service.
Performance Limits
Tests to Run none
Corrective Action:
on page 5-5.
firmware.
6-60 PDMM-0109 7/31/02

Electrical Codes Code EC
Code EC
Code Title Code EC – Operating System Error
Reason A fault was found in the operating system.
System Response
Alarm Sounds Yes
Operator Display Code EC. Inform Service.
Performance Limits
Tests to Run none
Corrective Action:
on page 5-5.
2. Obtain new firmware, regardless of version
displayed on Operator Display. Use the
FlashWare program to load new firmware.
PDMM-0109 7/31/02 6-61

Code F4 Electrical Codes
Code F4
Code Title Code F4 – Vehicle Manager COP Time-out
The COP circuit has timed out before a reset was

Reason
generated.
System Response
Alarm Sounds Yes
Operator Display Code F4. Inform Service.
Performance Limits
Tests to Run None
Corrective Action:
on page 5-5.
6-62 PDMM-0109 7/31/02

Electrical Codes Code F5
Code F5
Code Title Code F5 – Bad Op Code
Reason A bad operation code was found during SelfTest.
System Response
Alarm Sounds Yes
Performance Limits
Tests to Run None
Corrective Action:
on page 5-5.
PDMM-0109 7/31/02 6-63

Code F8 Electrical Codes
Code F8
Code Title Code F8 – Vehicle Manager COP Not Enabled
Reason Vehicle Manager COP not enabled.
System Response
Alarm Sounds Yes
Performance Limits
Tests to Run None
Corrective Action:
on page 5-5.
6-64 PDMM-0109 7/31/02

Electrical Codes Code FG
Code FG
Code Title Code FG – 12 Volt Power Supply Out-of-Range
Reason The +12 volt power supply voltage is out of range.
System Response
Alarm Sounds Yes
Operator Display Code FG. Inform Service.
Performance Limits
Tests to Run Test A14 – Power Supply +12V DC (Page 6-85)
PDMM-0109 7/31/02 6-65

Code FH Electrical Codes
Code FH
Code Title Code FH – Battery Voltage Out-of-Range
Reason Battery voltage is less than 32V or more than 39V.
System Response
Alarm Sounds Yes
Operator Display Code FH. Inform Service.
Performance Limits
Tests to Run Test A15 – Battery Voltage (Page 6-87)
6-66 PDMM-0109 7/31/02

Electrical Codes Code VC
Code VC
Code Title Code VC – CAN integrated circuit does not reset
Reason The CAN integrated circuit does not leave the reset state.
System Response
Alarm Sounds Yes
Operator Display Code VC. Inform Service.
Performance Limits
PDMM-0109 7/31/02 6-67

Code VC Electrical Codes
6-68 PDMM-0109 7/31/02

EASi Reach-Fork® Truck EZ-D/DZ-D Maintenance Manual Electrical Tests
Electrical Connections
Electrical Tests 6:
Electrical Connections
Terminology
The term “connector JPx” means a mated
connector having two connector halves. One
Pin Identifier Lines
half has male connectors, or pins (P); the other (black lines added for clarity)
half has female connectors, or jacks (J).
When you disconnect a mated JP connector,
you will have two connector halves. The
individual connector halves are specified by
“Jx” and “Px.” If you cannot find a connector
designated “Jx” or “Px,” look for “JPx,” and vice
versa.
For example, connector JP1 is the mated main Jack Pins
Operator Display connector. J1 represents the
68C04013S.TIF
jack connections (in the harness). P1 represents
Figure 6-2: Molex Jack and Pin Connector
the pin connections (on the Operator Display).
Molex connectors have ridges on the sides to
help locate pin number 1. The short side has a
single ridge at pin number 1. The long side has
1, 2, and 3 raised ridges at pin numbers 1, 2,
and 3. See Figure 6-2.
Electrical Connector Locator Chart

See legend on electrical schematic beginning on
page A-21.
PDMM-0109 7/31/02 6-69

Electrical Tests EASi Reach-Fork® Truck EZ-D/DZ-D Maintenance Manual
Circuit Card Connectors
Circuit Card Connectors

Vehicle Manager
Forward Row
Back Row
JPC6
64155_029.TIF
Figure 6-3: Vehicle Manager connectors
6-70 PDMM-0109 7/31/02

Relay/Control Fuse Panel
TS2
1 2 3
PF1 FU8
7
5A
14
FU6
15A
1 8
FU10
15A
PF5
3 6 K3 K1 K2
1 4
T2
PF3
T4
1
3
PF4 FU7
1 5A
T3
6 14
FU5
PF2 15A
1 7
FU9
5A
T1 3 2 1
TS1
6R154_012_559.EPS
Figure 6-4: Relay/Control Fuse Panel connectors
PDMM-0109 7/31/02 6-71

6-72 PDMM-0109 7/31/02

Electrical Test Summary List

Electrical Tests 6:

Analog Tests
Test A04 – Throttle Potentiometer Voltage . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. 6-76
Test A05 – Lift/Lower Potentiometer Voltage . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. 6-77
Test A08 – Traction Motor Temperature . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. 6-78
Test A09 – Lift Motor Temperature . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. 6-80
Test A10 – Traction Power Amplifier Heatsink Temperature. . . .. . .. .. . .. .. . .. . .. 6-82
Test A11 – Traction Motor Current . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. 6-83
Test A13 – Pressure Sensor Voltage . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. 6-84
Test A14 – Power Supply +12V DC . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. 6-85
Test A15 – Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. 6-87
Test A22 – Traction Throttle Request . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. 6-88
Test A23 – Lift Throttle Request . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. 6-89
Test A24 – Traction Power Amplifier Internal Temperature . . . .. . .. .. . .. .. . .. . .. 6-90
Test A26 – Power Supply +5V DC . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. 6-91
Test A27 – Power Amplifier Fan Voltage . . . . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. 6-92
Input Tests
Test I00 – Deadman Switch (S2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-94
Test I01 – Nested Switch (S19) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-95
Test I02 – First Speed Limiting Switch (S10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96
Test I03 – Second Speed Limiting Switch (S11) (option) . . . . . . . . . . . . . . . . . . . . . . . . 6-97
Test I04 – Lift Bypass Switch (S12) (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-98
Test I05 – Lift Limit Switch (S13) (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-99
Test I06 – Reach Switch (S4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-100
Test I07 – Retract Switch (S5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-101
Test I08 – Tilt Up Switch (S6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-102
Test I09 – Tilt Down Switch (S7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-103
Test I10 – Sideshift Right Switch (S9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-104
Test I11 – Sideshift Left Switch (S8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-105
Test I13 – Lift Fuse (FU3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-106
Test I14 – Auxiliary Fuse (FU1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-107
Test I15 – Horn Switch (S3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-108
Test I19 – Drive Motor Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-109
Test I23 – CAN Bus Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-110
Output Tests
Test O00 – Toggle the TPC Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-112
Test O01 – Toggle the PC Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-113
Test O02 – Toggle the P Contactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-114
Test O04 – Toggle the DIRA (SOL5) Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-115
Test O05 – Toggle the DIRB (SOL4) Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-116
Test O06 – Toggle the Reach Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-117
Test O07 – Toggle the Tilt Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-118
Test O08 – Toggle the Sideshift Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-119
Test O09 – Toggle the EQ (SOL6) Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-120
Test O10 – Toggle 2nd Pump (SOL8) Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-121
PDMM-0109 7/31/02 6-73

Test O11 – Toggle the Load Hold (SOL1) Solenoid . . . . . . . . . . .. . .. . .. .. . . . . . . . . 6-122

Test O12 – Ramp the Proportional Lift/Lower (SOL3) Solenoid .. . .. . .. .. . . . . . . . . 6-123
Test O18 – Toggle the Horn . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. .. . . . . . . . . 6-124
Test O19 – Audible Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . .. .. . . . . . . . . 6-125
Test O20 – Travel Alarm Test (Option). . . . . . . . . . . . . . . . . . . .. . .. . .. .. . . . . . . . . 6-126
Test O23 – Toggle Power Amplifier Fan . . . . . . . . . . . . . . . . . . .. . .. . .. .. . . . . . . . . 6-127
Test O29 – Ramp the Traction Power Amplifier . . . . . . . . . . . . .. . .. . .. .. . . . . . . . . 6-128
6-74 PDMM-0109 7/31/02

Analog Tests
Electrical Tests 6:
Analog Tests
PDMM-0109 7/31/02 6-75

Test A04 – Throttle Potentiometer Voltage Analog Tests
Test A04 – Throttle Diagnosis and Repair

Potentiometer Voltage
This test displays the voltage that the Vehicle
! CAUTION
Manager reads from the throttle potentiometer Use correct precautions against
(VR1). electrostatic discharge. See “Static
NOTE: Run Learn mode after you replace, Precautions” on page 2-11.
repair, or adjust the throttle assembly.
For information on how to use 1. Run Test A26 – Power Supply +5V DC
maintenance mode, see “Using (Page 6-91).
Maintenance Mode” on page 6-12. 2. If the 5V power supply is OK, the throttle
potentiometer (VR1) or related wiring could
Run Test be bad. Repair or replace the control
handle. See “Control Handle” on page 7-26.
1. The Operator Display shows the voltage Run Learn Mode and rerun Analog Test
that the Vehicle Manager reads from the A04.
throttle potentiometer (VR1).
3. The Vehicle Manager could be
2. The test is a success if the voltage displayed malfunctioning. Replace the Vehicle
is within these limits: Manager. Run Configure Mode, then Learn
Mode. Re-run the test.
Throttle Position Voltage Displayed NOTE: For instructions on selecting Modes of

Full Tractor First Greater than 0.45 V page 6-3.
Neutral 2.00 to 3.00 V
Full Forks First Less than 4.65 V
• The values must change smoothly and

evenly as the handle moves from full
tractor-first to full forks-first direction.
• If voltages are within reference limits
and the fault code continues, re-learn
controls.
• If voltages are not within reference
limits, then the test is a failure.
6-76 PDMM-0109 7/31/02

Analog Tests Test A05 – Lift/Lower Potentiometer Voltage
Test A05 – Lift/Lower Diagnosis and Repair

Potentiometer Voltage
This test displays the voltage that the Vehicle
! CAUTION
Manager reads from the lift/lower Use correct precautions against
potentiometer (VR2). electrostatic discharge. See “Static
NOTE: Run Learn mode after you replace, Precautions” on page 2-11.
repair, or adjust the lift/lower
potentiometer. 1. Verify +5V power supply. Run Test
For information on how to use A26 – Power Supply +5V DC (Page 6-91).
maintenance mode, see “Using 2. If the 5V power supply is OK, the lift/lower
Maintenance Mode” on page 6-12. potentiometer (VR2) or associated wiring
may be bad. See “Control Handle” on
Run Test page 7-26. Run Learn Mode and rerun
Analog Test A04.
1. The Operator Display shows the voltage
that the Vehicle Manager reads from the 3. The Vehicle Manager may be
lift/lower potentiometer (VR2). malfunctioning. Replace the Vehicle
Manager. Run Configure Mode, then Learn
2. The test is a success if the voltage displayed Mode. Re-run the test.
is within these limits:
Throttle Position Voltage Displayed page 6-3.
Full Lift Greater than 0.45 V

Neutral 2.0 to 3.0 V
Full Lower Less than 4.6 V
• The values must change smoothly and

evenly as the handle moves from full
lower to full lift.
• If voltages are within reference limits
and the fault code is still displayed,
re-learn controls.
• If voltages are not within reference
limits, then the test is a failure.
• Voltage will be zero if the potentiometer
is disconnected.
PDMM-0109 7/31/02 6-77

Test A08 – Traction Motor Temperature Analog Tests
Test A08 – Traction Motor Diagnosis and Repair

Temperature
This test measures the temperature of the
! CAUTION
traction motor. Use correct precautions against
electrostatic discharge. See “Static
Limits Precautions” on page 2-11.
• Normal operation: ambient to 125°C
(258°F) If the Operator Display reads –99°F, there is
an open or shorted circuit.
• Down-rated at 126°C (259°F) to 148°C
(299°F) 1. Turn the key switch OFF and disconnect
• Temperature icon lights at 135°C (275°F) the battery connector. Disconnect JPT3.
Using an ohmmeter, measure the
• Fault Code 2A at 149°C (300°F) resistance of the temperature sensor
between JT3-1 and JT3-2. Correct
Run Test resistance is between 500 and 1520 ohms.
NOTE: For information on how to use a. If the resistance is correct, go to step 2.

maintenance mode, see “Using b. If the resistance is incorrect, replace the
Maintenance Mode” on page 6-12. temperature sensor. See “Temperature
The Operator Display shows the Sensor, Traction” on page 7-102.
temperature of the traction motor. 2. Use a digital voltmeter to measure voltage
between B+ and JPT3-1 (–). Correct reading
1. Put the lift truck in Active Maintenance
is battery voltage. If voltage is correct, go to
Mode. Drive the lift truck. Traction motor
step 3. If voltage is incorrect, continue to
temperature increases.
step 2.
2. Park the lift truck. Remove covers and open
the drive motor compartment door. Traction 3. Measure voltage between B+ and JPT1-4.
motor temperature will decrease. Correct voltage is battery voltage.
3. After 24 hours the traction motor a. If voltage is correct, troubleshoot wiring

temperature should be within ±25°F (14°C) from JPT1-4 through JPS10-7 to
JPT3-1.
of room temperature.
4. If you do not see these results, the test is a b. If voltage is incorrect, replace the
failure. traction power amplifier. See “Traction
Power Amplifier” on page 7-103.
4. Measure voltage between JPT3-2 (+) and
B–. Correct voltage is approximately 3.8
volts. If voltage is correct, go to step 5, If
voltage is incorrect, continue to step 4.
5. Measure voltage from JPT1-7 (+) to B–.
Correct voltage is approximately 3.8 volts.
6-78 PDMM-0109 7/31/02

Analog Tests Test A08 – Traction Motor Temperature
a. If voltage is correct, troubleshoot wiring

from JPT1-7 through JPS10-5 to
JPS3-2.
b. If voltage is incorrect, replace the
traction power amplifier. See “Traction
Power Amplifier” on page 7-103.
If the temperature reading does not change

as the lift truck operates:
1. Disconnect connector JPT3. Use a digital
voltmeter to measure voltage from JPT3-1
(+) to JPT3-2 (–). Correct voltage is
approximately 3.8 volts. Correct reading on
Operator Display is –99°F (-72°C).
a. If readings are correct, replace the
temperature sensor.
b. If readings are not correct, continue to
step 2.
2. Disconnect wire JPT1-7. Turn the key
switch OFF and ON.
a. If the Operator Display shows –99°F,
troubleshoot the harness for short
circuits.
b. If the Operator Display does not show
–99°F (–72°C), replace the traction
power amplifier. See “Traction Power
Amplifier” on page 7-103.
page 6-3.
PDMM-0109 7/31/02 6-79

Test A09 – Lift Motor Temperature Analog Tests
Test A09 – Lift Motor Diagnosis and Repair

Temperature
This test measures the temperature of the lift
! CAUTION
motor. Use correct precautions against
• Normal operation: ambient to 100°C
(212°F) Turn the key switch OFF, then ON.
• Down-rated at 101°C (213°F) to 132°C
(270°F) If the Operator Display reads 32°F, there is
an open or shorted circuit.
• Temperature icon lights at 101°C (213°F)
• Fault Code 6F at 133°C (271°F)
the battery connector. Disconnect JPZ.
Using an ohmmeter, measure the
Run Test resistance of the temperature sensor
between JPZ-1 and JPZ-2. Correct
NOTE: For information on how to use
resistance is between 800 and 3000 ohms.
maintenance mode, see “Using
Measure resistance between JPZ-1 and
Maintenance Mode” on page 6-12.
motor frame, and between JPZ-2 and motor
The Operator Display shows the frame. Correct resistance is 1 megohm or
temperature of the lift motor. greater.
1. Put the lift truck in Active Maintenance a. If the resistance is correct, go to step 2.
Mode. Operate the lift/lower system. b. If the resistance is incorrect, replace the
Traction motor temperature increases. temperature sensor.
2. Park the lift truck. Remove covers and open 2. Use a digital voltmeter to measure voltage
the drive motor compartment door. Lift between B+ and JPZ-2 (–). Correct reading
motor temperature will decrease. is battery voltage. If voltage is correct, go to
3. After 24 hours the lift motor temperature step 3. If voltage is incorrect, continue to
should be within ±25°F (14°C) of room step 2.
temperature. 3. Measure voltage between B+ from the VM
4. If you do not see these results, the test is a and JPC10-23 (–). Correct voltage is battery
failure. voltage.
from JPC10-23 to JPZ-2.
b. If voltage is incorrect, replace the Vehicle
Manager.
4. Measure voltage between JPZ-1 (+) and B–.
Correct voltage is approximately 5 volts. If
voltage is correct, go to step 5, If voltage is
incorrect, continue to step 4.
5. Measure voltage from JPC10-1 (+) to B–
from the VM. Correct voltage is
approximately 5 volts.
6-80 PDMM-0109 7/31/02

Analog Tests Test A09 – Lift Motor Temperature

from JPZ-1 through SPL-1 to JPC10-1.
b. If voltage is incorrect, replace the Vehicle
Manager.
If the temperature reading does not change

as the lift truck operates:
1. Disconnect connector JPZ. Use a digital
voltmeter to measure voltage from JPZ-1 (+)
to JPZ-2 (–). Correct voltage is
approximately 5 volts.
a. If voltage is correct, replace the
temperature sensor.
b. If voltage is not correct, continue to step
2.
2. Disconnect connector JPC11. Turn the key
switch OFF, then ON.
a. If Operator Display shows 32°F (0°C),
troubleshoot the harness for short
circuits.
b. If the Operator Display does not show
32°F (0°C), replace the Vehicle Manager.
page 6-3.
PDMM-0109 7/31/02 6-81

Test A10 – Traction Power Amplifier Heatsink Temperature Analog Tests
Test A10 – Traction Power

Amplifier Heatsink Temperature
traction power amplifier heatsink.
Limits
• Normal operation: ambient to 79°C (175F)
• Slowed at 80°C (176°F) to 115°C (239°F)
• Fault Code 1H at 115°C (239°F)
Run Test
The Operator Display will show the heatsink
temperature which the traction power amplifier
reads.
As drive is operated, the readings should
increase evenly over time. If not, the test is a
failure.
Diagnosis and Repair

1. Check for dirt and debris in the traction
power amplifier cooling fins.
2. Check operation of the power amplifier
cooling fans. Run Test O23 – Toggle Power
Amplifier Fan (Page 6-127).
3. The traction power amplifier may be
malfunctioning. Replace the traction power
amplifier. See “Traction Power Amplifier” on
page 7-103.
NOTE: It is essential to reconnect the power
cables in the proper sequence with
flanged nuts, torquing to 15 ft. lb.
(20.3 Nm).
page 6-3.
6-82 PDMM-0109 7/31/02

Analog Tests Test A11 – Traction Motor Current
Test A11 – Traction Motor Diagnosis and Repair

Current
This test measures the current in the traction
! CAUTION
motor. Use correct precautions against
• 0-400A while driving, reverse polarity
during plugging NOTE: Examine all motor and power amplifier
connections for tightness and corrosion.
• maximum current up to 480A for 1-2
seconds Attach a clamping ammeter around one of the
motor power cables and record readings while
Run Test traveling. Repeat this step for the other two
motor phase power cables.
If any one phase differs significantly from the
other two, measure power cable continuity.
Replace cables as necessary.
This test could show better results in
1. If power cable continuity is OK, replace the
Active Maintenance.
drive motor.
1. The Operator Display shows the current
2. If all phases give high readings, the drive
that the Vehicle Manager reads from the
unit could be binding. Examine drive unit.
current sensor.
System Condition Current Displayed Operation, see “Modes of Operation” on
page 6-3.
Static at Rest less than 20 amps
greater than 280
Stalled
amps
• The current must ramp evenly as the

truck accelerates and decelerates.
• If readings are not within reference
limits, then the test is a failure. Perform
diagnosis.
PDMM-0109 7/31/02 6-83

Test A13 – Pressure Sensor Voltage Analog Tests
Test A13 – Pressure Sensor +12 volts. If voltage is incorrect, replace

the Vehicle Manager.
Voltage
b. Connect a digital voltmeter between
This test measures the voltage from the JPY4-1 (+) and JPY4-3 (–). Correct
pressure sensor used for load weight sensing. voltage is +12 volts. If voltage is
incorrect, repair or replace the wiring
between PY4 and JC11.
! CAUTION 2. Connect a digital voltmeter between
Use extreme caution when working JPY4-2(+) and JPY4-3(–). With no weight on
near the elevated forks. the forks and the forks lowered, the correct
voltage is approximately 1.0 volts. As
weight is added to the forks, the correct
Limits voltage increases. If voltage is incorrect,
replace the pressure sensor.
• The operator display shows the voltage
present with various load weights. 3. Connect a digital voltmeter between
JPC11-3(+) and JPC11-2(–). With no weight
on the forks and the forks lowered, the
Load Weight Voltage correct voltage is approximately 1.0 volts.
0 (no load) 1V As weight is added to the forks, the correct
4500 lb. 4.7 V voltage increases.
a. If voltage is not present, repair/replace
the wiring.
• If the weight sensor is disconnected, the
operator display shows 0 V. b. If voltage is correct, but the weight is not
displayed on the Operator Display,
Run Test replace the Vehicle Manager.
NOTE: For information on how to use Operation, see “Modes of Operation” on
maintenance mode, see “Using page 6-3.
1. The voltage shown on the operator display
must increase and decrease in a linear
fashion as the load weight is either
increased or decreased. If it does not, the
test is a failure.
! CAUTION
Use correct precautions against
Precautions” on page 2-11.
1. Test for +12 volts to the sensor:

a. Connect a voltmeter between JPC11-4
(+) and JPC11-2 (–). Correct voltage is
6-84 PDMM-0109 7/31/02

Analog Tests Test A14 – Power Supply +12V DC
Test A14 – Power Supply +12V a. If the Operator Display is dark, or the
voltage is not within the reference range,
DC go to step 4.
This test measures the +12V Power Supply b. If the Operator Display is no longer
voltage. dark, and the voltage is within the
reference range, go to step 6.
Run Test 4. Turn the key switch OFF and disconnect
the battery connector. Disconnect
NOTE: For information on how to use connector JPC5. Connect a digital voltmeter
maintenance mode, see “Using between PC5-1 (+) and PC5-8 (–) At the
Maintenance Mode” on page 6-12. Vehicle Manager. Reconnect the battery
1. The Operator Display shows the voltage connector and turn the key switch ON.
measured from the +12 volt power supply. Re-run the test.
2. The test is a success if the voltage displayed a. If the voltage is NOT within the reference
is within these limits: range, the Vehicle Manager could be
malfunctioning. Replace the Vehicle
Manager. Run Configure Mode, then
System Condition Voltage Displayed Learn Mode.
Lift truck at rest 10.5 to 13.0 V
b. If the voltage is within the reference
range, continue to step 5.
• If the reading fluctuates by more than 5. Turn the key switch OFF and disconnect
0.8 volts in 10 seconds, then the test is the battery connector. Disconnect
a failure. Perform diagnosis. connector JPD1 from the Operator Display.
• If the Operator Display is dark, then the Measure the wiring harness JC5-JD1
test is a failure. Perform diagnosis. (including slice SPLD-1) for continuity.
a. Repair or replace wiring as necessary.
Diagnosis and Repair b. If the harness is OK, replace the
Operator Display.
! CAUTION 6. One of the disconnected circuits is drawing
Use correct precautions against the 12 volts down. Isolate the failing circuit
as follows:
Precautions” on page 2-11. a. Connect a digital voltmeter between
PC5-1 (+) and PC5-8 (–).
b. Turn the key switch OFF and disconnect
1. Turn the key switch OFF and disconnect the battery connector. Reconnect one of
the battery connector. the connectors previously disconnected.
2. Disconnect all connectors from the Vehicle Reconnect the battery connector and
Manager except JPC5 to the Operator turn the key switch ON.
Display and JPC8 for B+KEY. If the voltmeter measures within the
3. Connect a digital voltmeter between PC5-1 reference range, this circuit is not the
(+) and PC5-8 (–). Reconnect the battery problem. Go to step 6c.
connector and turn the key switch ON. If the voltage is outside the reference
range, this circuit has a problem.
Troubleshoot the circuit and repair or
PDMM-0109 7/31/02 6-85

Test A14 – Power Supply +12V DC Analog Tests
replace components and wiring as

needed.
c. Repeat step 6b until you identify the
failing circuit.
page 6-3.
6-86 PDMM-0109 7/31/02

Analog Tests Test A15 – Battery Voltage
Test A15 – Battery Voltage 5. The Vehicle Manager may be

This test measures the voltage used to calculate Manager. Run Configure Mode, then Learn
the battery state of charge. Mode. Re-run the test.
Run Test Operation, see “Modes of Operation” on
page 6-3.
1. Acceptable battery voltage as shown on the
operator display is 32 to 39 volts DC.
2. If the voltage displayed is not in this range,
the test is a failure.
! CAUTION
1. If the voltage is out of range, check the

battery with a voltmeter. The battery may
need servicing.
2. Check the battery specific gravity. Consult
the battery manufacturer’s guide for
procedures and reference values.
3. Measure resistance from TP1 to JPF2-1.
Correct resistance is approximately 5.11K
ohms (due to the resistor on the
relay/contactor fuse panel.
a. If the resistance is incorrect,
repair/replace the relay contactor fuse
panel or its associated wiring.
b. If the resistance is OK, proceed to the
next step.
4. Measure resistance from JPF2-1 to JPC8-7.
a. If continuity is not present,
repair/replace the wiring harness.
b. If continuity is present, proceed to the
next step.
PDMM-0109 7/31/02 6-87

Test A22 – Traction Throttle Request Analog Tests
Test A22 – Traction Throttle

Request
This test displays the percentage of traction
throttle request from VR1 being read by the VM.
Run Test
NOTE: Run Learn mode after you replace,
repair, or adjust the throttle assembly.
For information on how to use
The Operator Display shows the percentage of
throttle request that the Vehicle Manager reads
from the throttle potentiometer (VR1).
Acceptable values are:
Percentage
Throttle Position
Displayed
Full Tractor First 0 to +100
Neutral 0
Full Forks First 0 to –100
The values must change smoothly and evenly

as the handle moves from full tractor first to full
forks first.
If percentages are not within reference limits,
! CAUTION
The throttle potentiometer (VR1) or its related

wiring could be bad. Run test A04.
page 6-3.
6-88 PDMM-0109 7/31/02

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 mode after you replace,
repair, or adjust the lift/lower
potentiometer.
The Operator Display shows the percentage of
lift request that the Vehicle Manager reads from
the lift potentiometer (VR2).
Acceptable values are:
Percentage
Throttle Position
Displayed
Full Lower 0 to –100
Neutral 0
Full Lift 0 to +100
The values must change smoothly and evenly

as the handle moves from full lower to full lift.
If percentages are not within reference limits,
! CAUTION
Run Test A05. Follow directions in test.

page 6-3.
PDMM-0109 7/31/02 6-89

Test A24 – Traction Power Amplifier Internal Temperature Analog Tests
Test A24 – Traction Power

Amplifier Internal Temperature
traction power amplifier printed circuit board.
Limits
• Normal operation: ambient to 99°C (211°F)
• Slowed at 100°C (212°F) to 124°C (256°F)
• Fault Code 1H at 125°C (257°F)
Run Test
The Operator Display displays the internal
temperature of the traction power amplifier.
With the lift truck at rest and at ambient
temperature, watch the operator display. It
must show the approximate temperature of the
area where the lift truck is located.
If the temperature on the operator display
seems different from the ambient temperature,
then the test is a failure.

1. Check for dirt and debris in the traction
power amplifier cooling fins.
2. Check operation of the power amplifier
cooling fans. Run Test O23 – Toggle Power
Amplifier Fan (Page 6-127).
3. The traction power amplifier may be
malfunctioning. Replace the traction power
amplifier.
NOTE: It is essential to reconnect the power
cables in the proper sequence with
flanged nuts, torquing to 15 ft. lb.
(20.3 Nm).
page 6-3.
6-90 PDMM-0109 7/31/02

Analog Tests Test A26 – Power Supply +5V DC
Test A26 – Power Supply +5V

DC
This test measures the +5V Power Supply
Voltage.
Run Test
If the operator display does not read +5 ± 0.5
volts. the test is a failure.
! CAUTION

2. Disconnect JC6 from the Vehicle Manager.
3. Connect a digital voltmeter between JC6-15
(+) and JC6-13 (AGND) (–).
4. Reconnect the battery connector and turn
the key switch ON. Correct voltage is 5
volts.
a. If 5 volts is present, replace the control
handle. See “Control Handle” on
page 7-26.
b. If 5 volts is not present, replace the
Vehicle Manager.
page 6-3.
PDMM-0109 7/31/02 6-91

Test A27 – Power Amplifier Fan Voltage Analog Tests
Test A27 – Power Amplifier Fan

Voltage
Test A27 test provides no useful diagnostic
information.
To test the power amplifier fan, run Test
O23 – Toggle Power Amplifier Fan (Page 6-127).
6-92 PDMM-0109 7/31/02

Digital Input Tests

Electrical Tests 6:
Digital Input Tests
PDMM-0109 7/31/02 6-93

Test I00 – Deadman Switch (S2) Digital Input Tests
Test I00 – Deadman Switch (S2) Diagnosis and Repair
The deadman switch is closed when the

operator steps on the deadman pedal. The ! CAUTION
deadman input is routed to the Vehicle Manager Use correct precautions against
at JPC7-16 on the Vehicle Manager. No travel electrostatic discharge. See “Static
can occur unless the deadman switch is closed.
1. Test the switch for correct operation, using
! WARNING a digital ohmmeter.
Do not do this test on a ramp. 2. Test the wires to the switch for continuity.
Repair or replace as required.
3. Place a jumper on the Vehicle Manager
Run Test between pins JPC7-16 and JPC7-5. The
NOTE: For information on how to use Operator Display should show a change of
maintenance mode, see “Using state. If not, replace the Vehicle Manager.
This test shows best results in Active
Maintenance mode.
The Operator Display shows the state of the
switch.
Operator Operator
Action Display Message
Off deadman UP
On deadman DOWN
If the display does not change when you step on

the pedal, the test is a failure.
6-94 PDMM-0109 7/31/02

Digital Input Tests Test I01 – Nested Switch (S19)
Test I01 – Nested Switch (S19) 3. Place a jumper on the Vehicle Manager
between pins JPC9-3 and JPC10-10. The
NOTE: This test applies only to lift trucks with Operator Display should show a change of
the nested switch option. state. If not, replace the Vehicle Manager.
This test shows what the Vehicle Manager is

reading from the nested switch (S19).
! CAUTION
Use extreme caution when working
around an elevated mast.
! WARNING
Lift only in an area with a ceiling
height greater than the truck’s
maximum elevated height.
Run Test
switch.
Operator Display
Mast Position
Message
Nested ON
Unnested OFF
! CAUTION

a digital ohmmeter.
2. Test the wires to the switch for continuity.
PDMM-0109 7/31/02 6-95

Test I02 – First Speed Limiting Switch (S10) Digital Input Tests
Test I02 – First Speed Limiting Diagnosis and Repair

Switch (S10)
! CAUTION
reading from the first speed limiting mast Use correct precautions against
switch (S10). electrostatic discharge. See “Static
! WARNING 1. Test the switch for correct operation, using

Do not attempt high speeds during a digital ohmmeter.
this test. Speed limiting while 2. Test the wires to the switch for continuity.
elevated could be defeated during Repair or replace as required.
this test. 3. Place a jumper on the Vehicle Manager
Operator Display should show a change of
! CAUTION state. If not, replace the Vehicle Manager.
Run Test
NOTE: You must run this test in Active
Maintenance Mode.
switch.
Operator Display
Mast Position
Message
Lowered ON
Raised OFF
6-96 PDMM-0109 7/31/02

Digital Input Tests Test I03 – Second Speed Limiting Switch (S11)
Test I03 – Second Speed Diagnosis and Repair

Limiting Switch (S11) (option)
NOTE: This test applies only to lift trucks with
! CAUTION
the second speed limiting switch option. Use correct precautions against
reading from the second speed limiting Precautions” on page 2-11.
switch (S11) (if installed).
a digital ohmmeter.
! CAUTION
! WARNING state. If not, replace the Vehicle Manager.

Run Test
Maintenance Mode.
switch.
Operator Display
Mast Position
Message
Lowered ON
Raised OFF
PDMM-0109 7/31/02 6-97

Test I04 – Lift Bypass Switch (S12) (option) Digital Input Tests
Test I04 – Lift Bypass Switch Diagnosis and Repair

(S12) (option)
! CAUTION
the lift inhibit bypass switch option. Use correct precautions against
reading from the lift inhibit bypass switch S12 Precautions” on page 2-11.
(if installed).
a digital ohmmeter.
! CAUTION

Run Test
Maintenance Mode.
switch.
Operator Display
Switch Position
Message
Closed ON
Open OFF
6-98 PDMM-0109 7/31/02

Digital Input Tests Test I05 – Lift-Limit Switch (S13) (option)
Test I05 – Lift-Limit Switch (S13) Diagnosis and Repair

(option)
! CAUTION
the lift-limit switch option. Use correct precautions against
reading from the lift-limit mast switch S13 (if Precautions” on page 2-11.
installed).
a digital ohmmeter.
! CAUTION

Run Test
Maintenance Mode.
switch.
Operator Display
Mast Position
Message
Lowered ON
Raised OFF
PDMM-0109 7/31/02 6-99

Test I06 – Reach Switch (S4) Digital Input Tests
Test I06 – Reach Switch (S4)

Use this test to monitor the state of reach
switch (S4). This test shows what the Vehicle
Manager is reading from the switch.
Run Test
This test shows better results in Active
Maintenance.
switch:
Reach Audible Operator

Button Alarm Display
Depressed Sounding In
Released Off Out
If results do not match the preceding table, the

test is a failure. Perform diagnosis.
! CAUTION
1. Use a digital ohmmeter to test the switch

and cable for correct operation. Measure for
continuity between pins JPC6-1 and
JPC6-14 with the switch activated. If
continuity is not present, replace the
control handle.
2. Run Test I06. Disconnect JPC6 from the
Vehicle Manager. Place a jumper between
pins JPC6-1 and JPC6-14 on the Vehicle
Manager. The Operator Display should
show a change of state. If not, replace the
Vehicle Manager.
page 6-3.
6-100 PDMM-0109 7/31/02

Digital Input Tests Test I07 – Retract Switch (S5)
Test I07 – Retract Switch (S5)

Use this test to monitor the state of retract
Run Test
NOTE: This test shows better results in Active
Maintenance.
switch:
Retract Audible Operator

Depressed Sounding In
Released Off Out

! CAUTION

control handle.
Vehicle Manager.
page 6-3.
PDMM-0109 7/31/02 6-101

Test I08 – Tilt Up Switch (S6) Digital Input Tests
Test I08 – Tilt Up Switch (S6) NOTE: For instructions on selecting Modes of
Use this test to monitor the state of tilt up page 6-3.
Run Test
Maintenance.
NOTE: If you can enter Maintenance Mode and
use this switch to select tests, then the
switch is working correctly.
switch:
Audible Operator
Tilt Button
Alarm Display
Depressed Sounding Down
Released Off Up

! CAUTION

control handle.
Vehicle Manager.
6-102 PDMM-0109 7/31/02

Digital Input Tests Test I09 – Tilt Down Switch (S7)
Test I09 – Tilt Down Switch (S7) NOTE: For instructions on selecting Modes of
Use this test to monitor the state of tilt down page 6-3.
Run Test
Maintenance.
NOTE: If you can enter Maintenance Mode and
use this switch to select tests, then the
switch is working correctly.
switch:
Audible Operator
Tilt Button
Alarm Display
Released Off Up

! CAUTION

control handle.
Vehicle Manager.
PDMM-0109 7/31/02 6-103

Test I10 – Sideshift Right Switch (S9) Digital Input Tests
Test I10 – Sideshift Right Switch NOTE: For instructions on selecting Modes of
(S9) page 6-3.
Use this test to monitor the state of sideshift
right switch (S9). This test shows what the
Vehicle Manager is reading from the switch.
Run Test
Maintenance.
switch:
Sideshift Audible Operator

Released Off Up

! CAUTION

control handle.
Vehicle Manager.
6-104 PDMM-0109 7/31/02

Digital Input Tests Test I11 – Sideshift Left Switch (S8)
Test I11 – Sideshift Left Switch NOTE: For instructions on selecting Modes of
(S8) page 6-3.
Use this test to monitor the state of sideshift left
Run Test
Maintenance.
switch:
Sideshift Audible Operator

Released Off Up

! CAUTION

control handle.
Vehicle Manager.
PDMM-0109 7/31/02 6-105

Test I13 – Lift Fuse (FU3) Digital Input Tests
Test I13 – Lift Fuse (FU3)

This test reports the absence or presence of B+
voltage at the load side of the lift (P) contactor.
Run Test
You must run this test in Active
Maintenance Mode.
Use the following table as a guideline.
VR2
Operator
Lift/Lower B+ Voltage
Display
Control Pot Status
Message
Position
Requesting
B+ present C (Closed)
Lift
No Lift
B+ absent O (Open)
Request
If the display message does not change when

the test is activated, the test is a failure.
! CAUTION
1. Using a digital ohmmeter, test the fuse.

(+) and TP4 (–). Correct voltage is battery
voltage.
a. If voltage is correct with the contactor
closed, replace and Vehicle Manager.
b. If voltage is incorrect, troubleshoot the
wiring.
page 6-3.
6-106 PDMM-0109 7/31/02

Digital Input Tests Test I14 – Auxiliary Fuse (FU1)
Test I14 – Auxiliary Fuse (FU1)

This test reports the absence or presence of B+
voltage at the load side of the PC contactor.
Run Test
This test can be run in Active
Maintenance Mode.
Use the following table as a guideline.
Deadman Operator
B+ Voltage
Pedal Display
Status
Position Message
Down B+ present C (Closed)
Up B+ absent O (Open)
If the display message does not change when

the test is activated, the test is a failure.
! CAUTION
1. Using a digital ohmmeter, test the fuse.

(+) and TP4 (–). Correct voltage is battery
voltage.
a. If voltage is correct with the contactor
closed, replace and Vehicle Manager.
3. If voltage is incorrect, troubleshoot the
wiring.
page 6-3.
PDMM-0109 7/31/02 6-107

Test I15 – Horn Switch (S3) Digital Input Tests
Test I15 – Horn Switch (S3)

Use this test to monitor the state of the horn
Run Test
This test shows better results in Active
Maintenance.
switch:
Audible Operator
Horn Button
Alarm Display
Depressed Sounding On
Released Off Off

! CAUTION

control handle.
Vehicle Manager.
page 6-3.
6-108 PDMM-0109 7/31/02

Digital Input Tests Test I19 – Drive Motor Speed Sensor
Test I19 – Drive Motor Speed 3. Connect a digital voltmeter between

JPT2-1 (+) and JPT2-3 (–). Correct voltage
Sensor with the lift truck traveling is approximately
7.5 volts. If voltage is not correct, replace
This test reads the output from the speed the speed sensor.
sensor on the drive motor.
4. Connect a digital voltmeter between
! CAUTION with the lift truck traveling is approximately
Do this test in an area free of 7.5 volts. If voltage is not correct, replace
the speed sensor.
obstructions with ample room for
maneuvering. 5. Connect a digital voltmeter between
with the lift truck traveling is approximately
Run Test 7.5 volts. If voltage is not correct, repair or
replace the wiring.
with the lift truck traveling is approximately
This test must be run in Active 7.5 volts.
Maintenance.
a. If voltage is correct, replace the power
Use the following table as a guideline. amplifier.
b. If voltage is not correct, repair or replace
Sensor Signal Operator Display the wiring.
Status Message
Tractor First 0 to -4000 Operation, see “Modes of Operation” on
Forks First 0 to +4000 page 6-3.
The Operator Display shows rpm as measured

by the speed sensor. Set desired travel speed in
Configure Mode for best accuracy.
! CAUTION

JPT1-3 (+) and JPT1-4 (–). Correct voltage is
12 volts. If voltage is not correct, replace
the traction power amplifier.
JPT2-1 (+) and JPT2-4 (–). Correct voltage is
12 volts. If voltage is not correct, repair or
replace the wiring.
PDMM-0109 7/31/02 6-109

Test I23 – CAN Bus Test Digital Input Tests
Test I23 – CAN Bus Test resistor in the harness between JPT1-10
and JPT1-13.
This test shows whether the Vehicle Manager is d. Connect the power amplifier. Use a
communicating with the Traction Power digital ohmmeter to measure resistance
Amplifier and SMARTi® (optional). between BUS+ and BUS– at any
connector. If resistance is not 120 ohms,
Run Test the power amplifier is shorting the bus.
NOTE: For information on how to use e. Connect the Vehicle Manager. Use a
maintenance mode, see “Using digital ohmmeter to measure resistance
Maintenance Mode” on page 6-12. at any connector. If the resistance is not
60 ohms, make sure there is a splice
The Operator Display shows: between JPC4-9 and JPC4-12.
• T if the Traction Power Amplifier is f. If the truck has SMARTi, connect it. Use
communicating with the Vehicle Manager a digital ohmmeter to measure
• S if the optional SMARTi module is resistance at any connector. If
communicating with the Vehicle Manager. resistance is not 60 ohms, SMARTi is
shorting the bus.
If (T) is missing, the test is a failure. If (S) is
missing, and if the lift truck has SMARTi and if g. Repair/replace components/wiring as
SMARTi is enabled in the Configuration menu, necessary.
the test is a failure. 4. Replace the power amplifier.
Diagnosis and Repair Operation, see “Modes of Operation” on
page 6-3.
! CAUTION
1. Disconnect the SMARTi module at

connector JR1. If the (T) returns, disable
the SMARTi in Configuration Mode and
rerun test. If the (T) returns, replace the
SMARTi module and rerun the test.
2. Make sure power is applied to the related
device by verifying that the power LED is
illuminated.
3. Test continuity of BUS+/BUS–;
a. Disconnect all CAN Bus connections.
b. Test for continuity between all BUS+
connections. Test for continuity between
all BUS– connections.
c. Use a digital ohmmeter to measure
resistance between BUS+ and BUS– at
any connector. If resistance is not 120
ohms, make sure there is a 120 ohm
6-110 PDMM-0109 7/31/02

Digital Output Tests

Electrical Tests 6:
Digital Output Tests
PDMM-0109 7/31/02 6-111

Test O00 – Toggle the TPC Contactor Digital Output Tests
Test O00 – Toggle the TPC 3. Make sure the precharge circuit is
operating correctly. Connect a DVM
Contactor between AC traction amp (+) and AC
traction amp (B–). Reconnect the battery
This test turns the TPC contactor ON and OFF. connector and turn the key switch ON. The
voltage must ramp to battery voltage
(approximately).
! CAUTION
Jack the drive wheels off the floor a. If the voltage ramps, go to step 7.
for this test. b. If the voltage does not ramp, go to
step 4.
! WARNING the battery connector.
5. Disconnect wires from T3 and T1 on the
The traction system might not act as relay control fuse panel.
expected during this test. If the
6. Measure resistance from T3 to T1 on the
traction power amplifier is shorted,
relay control fuse panel. Correct resistance
the truck could start to travel when is between 6 and 12 ohms.
the contactor is toggled ON/OFF.
a. If resistance is correct, go to step c.
b. If resistance is not correct, allow time for
Run Test the circuit to cool. Measure resistance
again. If resistance is still not correct,
replace the relay control fuse panel.
Maintenance Mode” on page 6-12. c. The circuit was in an over-current
condition. Measure the value of resistor
Use the TILT UP/DOWN buttons to toggle the TR. Correct resistance is 15 ohms.
test ON and OFF. The operator display shows
ON or OFF. d. Check the circuit for shorts to B– or to
the truck frame.
If the contactor does not cycle in/out when the
test is toggled, then the test is a failure. 7. Measure the value of resistor TR. Correct
resistance is 15 ohms.
Diagnosis and Repair 8. Reconnect the battery connector and turn
the key switch ON.
9. Manually close the TPC contactor tips and
! CAUTION measure voltage between TPC-X (+) and
Use correct precautions against TP4 (–). Correct voltage is battery voltage. If
electrostatic discharge. See “Static voltage is incorrect, troubleshoot the
Precautions” on page 2-11. wiring.
10. Measure resistance of PC contactor coil.
Correct resistance is approximately 39
1. Turn the key switch OFF and disconnect ohms.
11. Measure continuity between JT1-2 and
2. Examine the contactor for binding. Repair TPC-Y.
or replace as necessary.
6-112 PDMM-0109 7/31/02

Digital Output Tests Test O01 – Toggle the PC Contactor
Test O01 – Toggle the PC 5. Reconnect the battery connector and turn
the key switch ON.
Contactor
6. Run Test O01. Correct voltage with the
This test is used to turn the PC contactor ON contactor ON is 24 volts. Correct voltage
and OFF. with the contactor OFF is 0 volts.
a. If the voltages are correct, troubleshoot
the coil and related wiring again.
! CAUTION
b. If the voltages are not correct, replace
The auxiliary system might not act as the Vehicle Manager.
expected during this test. The
auxiliary motor runs when the NOTE: For instructions on selecting Modes of
contactor is toggled ON. page 6-3.
Run Test
Use the TILT UP/DOWN buttons to toggle the
ON or OFF.
If the contactor does not cycle in/out when the
test is toggled, then the test is a failure.
! CAUTION

2. Disconnect connector JPC8 at the Vehicle
Manager.
3. Use a digital ohmmeter to measure
resistance between JPC8-14 and JPC8-18.
Correct resistance is approximately 40
ohms. If resistance is incorrect,
troubleshoot the solenoid coil and related
wiring.
JPC8-14 (+) and JPC8-18 (–) at the Vehicle
Manager.
PDMM-0109 7/31/02 6-113

Test O02 – Toggle the P Contactor Digital Output Tests
Test O02 – Toggle the P ! CAUTION

Contactor Use correct precautions against
This test turns the P contactor ON and OFF. electrostatic discharge. See “Static
Maintenance Mode” on page 6-12. 3. Disconnect JPC9. Use a digital ohmmeter to
measure resistance between JC9-2 and
JC9-4 at the harness. Correct resistance is
! CAUTION approximately 19.6 ohms. If resistance is
Turning the P contactor on (in this not correct, troubleshoot the coil and
test) should not cause the carriage to related wiring.
lift, since the proportional valve is 4. Reconnect the battery connector and turn
expected to be open. If, however, the key switch ON.
there is a fault in the valve, the forks 5. Connect positive meter lead to JPC9-2 (+).
could lift. Connect negative meter lead to JPC9-4 (–)
on the Vehicle Manager. Run Test O02.
Expected readings are:
Run Test
The test is a success if the P contactor tracks Test Status Voltage
the On/Off shown on the display. OFF 0 volts
approximately 24
P Contactor Operator Display ON
volts
Closed On
Open Off a. If voltages are correct, retest the coil and
related wiring.
If results do not match the preceding table, the b. If voltages are not correct, replace the
test is a failure. Perform diagnosis. Vehicle Manager.
Diagnosis and Repair Operation, see “Modes of Operation” on
1. Turn the key switch OFF and disconnect page 6-3.
2. The plunger in the P contactor could be
binding or operating incorrectly. Visually
examine for correct operation:
a. Examine the contactor tips for signs of
welding.
b. Make sure the return spring is operating
correctly.
6-114 PDMM-0109 7/31/02

Digital Output Tests Test O04 – Toggle the DIRA (SOL5) Solenoid
Test O04 – Toggle the DIRA Diagnosis and Repair

(SOL5) Solenoid
This test turns the DIRA solenoid ON and OFF,
! CAUTION
verifying its correct operation electrically. Use correct precautions against
A successful test proves that the DIRA solenoid
coil, wiring, and related circuitry in the vehicle Precautions” on page 2-11.
manager are operating correctly.
It does not prove that the DIRA solenoid valve is 1. Disconnect JPC9 from the Vehicle Manager.
operating correctly mechanically. Measure the resistance between JC9-7 and
JC9-4. Correct resistance is approximately
NOTE: If the horn does not work and the truck 29 ±5 ohms. If the resistance is outside this
does not lower, test the B+KA circuit for range, troubleshoot the solenoid coil and
battery positive before running this test. related wiring.
2. Connect the (+) lead of a DVM to JP9-4 and
Run Test the (–) lead to JP9-7 on the Vehicle
NOTE: For information on how to use Manager.
maintenance mode, see “Using a. Toggle the test ON. Correct voltage is
Maintenance Mode” on page 6-12. 24 V.
1. Turn the key switch OFF and disconnect b. Toggle the test OFF. Correct voltage is
the battery connector. 0 V.
2. Disconnect wire SOL5-1 from the DIRA If the voltages are not correct, replace the
solenoid. Vehicle Manager. If the voltages are correct,
3. Connect a digital ammeter in series with retest the coil and related wiring.
the DIRA solenoid coil, positive lead (+) to
the wire removed and the negative lead (–)
to terminal SOL5-1 on the solenoid.
page 6-3.
the key switch ON.
5. Run Test O04 and toggle the solenoid coil
ON. Use the TILT UP/DOWN buttons to
toggle the test ON and OFF. The operator
display shows ON or OFF.
6. Correct ammeter reading is 650 to 900
milliamps.
a. If the ammeter reading is correct, the
solenoid coil is operating correctly
electrically.
b. If the solenoid is not operating correctly,
examine the valve for a mechanical
problem, such as binding or
contamination.
PDMM-0109 7/31/02 6-115

Test O05 – Toggle the DIRB (SOL4) Solenoid Digital Output Tests
Test O05 – Toggle the DIRB Diagnosis and Repair

(SOL4) Solenoid
This test turns the DIRB solenoid ON and OFF,
! CAUTION
A successful test proves that the DIRB solenoid
It does NOT prove that the DIRB solenoid valve 1. Disconnect JPC9 from the Vehicle Manager.
is operating correctly mechanically. Measure the resistance between JC9-10
and JC9-4. Correct resistance is
NOTE: If the horn does not work and the truck approximately 29 ±5 ohms. If the resistance
does not lower, test the B+KA circuit for is outside this range, troubleshoot the
battery positive before running this test. solenoid coil and related wiring.
2. Connect the (+) lead of a DVM to PC9-4 and
Run Test the (–) lead to JPC9-10 on the Vehicle
2. Disconnect wire SOL4-1 from the DIRB If the voltages are not correct, replace the
the DIRB solenoid coil, positive lead (+) to
to terminal SOL4-1 on the solenoid.
page 6-3.
the key switch ON.
display shows ON or OFF. Correct ammeter
reading is read 650 to 900 milliamps.
electrically.
contamination.
6-116 PDMM-0109 7/31/02

Digital Output Tests Test O06 – Toggle the Reach Solenoid
Test O06 – Toggle the Reach Diagnosis and Repair

Solenoid
This test turns the reach solenoid ON and OFF,
! CAUTION
A successful test proves that the reach solenoid
It does NOT prove that the reach solenoid valve 1. Disconnect JPC9 from the Vehicle Manager.
is operating correctly mechanically. Measure the resistance between JC9-9 and
Run Test the (–) lead to PC9-8 on the Vehicle
2. Disconnect wire REACH-1 from the reach If the voltages are not correct, replace the
the reach solenoid coil, positive lead (+) to
to terminal REACH-1 on the solenoid.
page 6-3.
the key switch ON.
display shows ON or OFF. The correct
ammeter reading is 350 to 650 milliamps.
electrically.
contamination.
PDMM-0109 7/31/02 6-117

Test O07 – Toggle the Tilt Solenoid Digital Output Tests
Test O07 – Toggle the Tilt Diagnosis and Repair

Solenoid
This test turns the tilt solenoid ON and OFF,
! CAUTION
A successful test proves that the tilt solenoid
It does NOT prove that the tilt solenoid valve is 1. Disconnect JPC9 from the Vehicle Manager.
operating correctly mechanically. Measure the resistance between JC9-3 and
NOTE: This test is available only if the tilt b. Toggle the test OFF. Correct voltage is
option is configured for the lift truck. 0 V.
1. Turn the key switch OFF and disconnect If the voltages are not correct, replace the
the battery connector. Vehicle Manager. If the voltages are correct,
2. Disconnect wire TILT-1 from the tilt retest the coil and related wiring.
solenoid. NOTE: For instructions on selecting Modes of
3. Connect a digital ammeter in series with Operation, see “Modes of Operation” on
the tilt solenoid coil, positive lead (+) to the page 6-3.
wire removed and the negative lead (–) to
terminal TILT-1 on the solenoid.
the key switch ON.
electrically.
contamination.
6-118 PDMM-0109 7/31/02

Digital Output Tests Test O08 – Toggle the Sideshift Solenoid
Test O08 – Toggle the Sideshift Diagnosis and Repair

Solenoid
This test turns the sideshift solenoid ON and
! CAUTION
OFF, verifying its correct operation electrically. Use correct precautions against
A successful test proves that the sideshift
solenoid coil, wiring, and related circuitry in the Precautions” on page 2-11.
vehicle manager are operating correctly.
It does NOT prove that the sideshift solenoid 1. Disconnect JPC9 from the Vehicle Manager.
valve is operating correctly mechanically. Measure the resistance between JC9-3 and
JC9-12. Correct resistance is
NOTE: If the horn does not work and the truck approximately 39 ±5 ohms. If the resistance
does not lower, test the B+KA circuit for is outside this range, troubleshoot the
battery positive before running this test. solenoid coil and related wiring.
NOTE: This test is available only if the sideshift b. Toggle the test OFF. Correct voltage is
option is configured for the lift truck. 0 V.
1. Turn the key switch OFF and disconnect If the voltages are not correct, replace the
the battery connector. Vehicle Manager. If the voltages are correct,
2. Disconnect wire SIDESHIFT-1 from the retest the coil and related wiring.
sideshift solenoid. NOTE: For instructions on selecting Modes of
3. Connect a digital ammeter in series with Operation, see “Modes of Operation” on
the sideshift solenoid coil, positive lead (+) page 6-3.
to the wire removed and the negative lead
(–) to terminal SIDESHIFT-1 on the
solenoid.
the key switch ON.
electrically.
contamination.
PDMM-0109 7/31/02 6-119

Test O09 – Toggle the EQ (SOL6) Solenoid Digital Output Tests
Test O09 – Toggle the EQ (SOL6) Diagnosis and Repair

Solenoid
This test turns the equalizing (EQ) solenoid ON
! CAUTION
and OFF, verifying its correct operation Use correct precautions against
electrically. electrostatic discharge. See “Static
A successful test proves that the equalizing Precautions” on page 2-11.
(EQ) solenoid coil, wiring, and related circuitry
in the vehicle manager are operating correctly. 1. Disconnect JPC9 from the Vehicle Manager.
It does NOT prove that the equalizing (EQ) Measure the resistance between JC9-9 and
solenoid valve is operating correctly JC9-4. Correct resistance is approximately
mechanically. 39 ±5 ohms. If the resistance is outside this
range, troubleshoot the solenoid coil and
NOTE: If the horn does not work and the truck related wiring.
does not lower, test the B+KA circuit for
battery positive before running this test. 2. Connect the (+) lead of a DVM to PC9-4 and
the (–) lead to PC9-9 on the Vehicle
Manager.
Run Test
a. Toggle the test ON. Correct voltage is
NOTE: For information on how to use 24 V.
Maintenance Mode” on page 6-12. b. Toggle the test OFF. Correct voltage is
0 V.
the battery connector. If the voltages are not correct, replace the
Vehicle Manager. If the voltages are correct,
2. Disconnect wire SOL6-1 from the equalizing retest the coil and related wiring.
(EQ) solenoid.
3. Connect a digital ammeter in series with
the equalizing (EQ) solenoid coil, positive
page 6-3.
lead (+) to the wire removed and the
negative lead (–) to terminal SOL6-1 on the
solenoid.
the key switch ON.
electrically.
contamination.
6-120 PDMM-0109 7/31/02

Digital Output Tests Test O10 – Toggle 2nd Pump (SOL8) Solenoid
Test O10 – Toggle 2nd Pump Diagnosis and Repair

(SOL8) Solenoid
This test turns the 2nd pump solenoid OFF and
! CAUTION
ON, verifying its correct operation. Use correct precautions against
A successful test proves that the wiring and
related circuitry in the Vehicle Manager and Precautions” on page 2-11.
2nd pump solenoid coil driver are all operating
correctly. It also proves that the 2nd pump 1. Disconnect JPC9 and JPC10 from the
solenoid coil and its harness are operating Vehicle Manager. Measure the resistance
correctly electrically. between JC9-11 and JC10-22. Correct
It does not prove that the 2nd pump solenoid resistance is approximately 39 ±5 ohms. If
itself is operating correctly mechanically. the resistance is outside this range,
troubleshoot the solenoid coil and related
wiring.
Run Test
2. Connect the (+) lead of a DVM to PC9-11
NOTE: For information on how to use and the (–) lead to PC10-22 on the Vehicle
maintenance mode, see “Using Manager.
a. Toggle the test ON. Correct voltage is
1. Turn the key switch OFF and disconnect 24 V.
b. Toggle the test OFF. Correct voltage is
2. Disconnect wire from 2ND-1. 0 V.
3. Connect an ammeter in series with 2nd
If the voltages are not correct, replace the
pump solenoid as follows:
Vehicle Manager. If the voltages are correct,
a. Positive (+) to terminal of 2ND-1 retest the coil and related wiring.
b. Negative (-) to wire removed from 2ND-1 NOTE: For instructions on selecting Modes of
4. Reconnect the battery connector and turn Operation, see “Modes of Operation” on
the key switch ON. page 6-3.

electrically.
contamination.
PDMM-0109 7/31/02 6-121

Test O11 – Toggle the Load Hold (SOL1) Solenoid Digital Output Tests
Test O11 – Toggle the Load Hold Diagnosis and Repair

(SOL1) Solenoid
This test turns the load hold solenoid ON and
! CAUTION
OFF, verifying its correct operation electrically. Use correct precautions against
A successful test proves that the load hold
solenoid coil, wiring, and related circuitry in the Precautions” on page 2-11.
vehicle manager are operating correctly.
It does NOT prove that the load hold solenoid 1. Disconnect JPC9 from the Vehicle Manager.
valve is operating correctly mechanically. Measure the resistance between JC9-6 and
2. Disconnect wire SOL1-1 from the load hold If the voltages are not correct, replace the
the load hold solenoid coil, positive lead (+)
to the wire removed and the negative
lead (–) to terminal SOL1-1 on the solenoid.
page 6-3.
the key switch ON.
electrically.
contamination.
6-122 PDMM-0109 7/31/02

Digital Output Tests Test O12 – Ramp the Proportional Lift/Lower
Test O12 – Ramp the Diagnosis and Repair

Proportional Lift/Lower (SOL3)
Solenoid ! CAUTION
This test turns ON the proportional lift/lower
solenoid by increasing the PWM signal.
! CAUTION 1. Turn the key switch OFF and disconnect

The lowering function normally uses the battery connector.
the proportional lift/lower solenoid 2. Disconnect the wires to the coil of
in conjunction with the load hold proportional lower solenoid SOL3.
solenoid.
3. Use a digital ohmmeter to measure the
resistance of the coil. Correct resistance is
Run Test 12 to 24 ohms. Replace the coil if the
reading is out of this range.
NOTE: For information on how to use 4. Reconnect the SOL3 coil wires.
Maintenance Mode” on page 6-12. 5. Test the solenoid circuit:
1. 0 to 90% appears on the operator display. a. Connect a digital voltmeter between

Use the TILT UP/DOWN buttons to SOL3-2 (+) and SOL3-1 (–) on the
increase or decrease the percentage. solenoid.
2. Use the following table as a reference guide b. Reconnect the battery connector and
for testing. All values are approximate. turn the key switch ON.
c. Run Test 012. While ramping the
Approximate display, the voltmeter must indicate the
Operator
Voltage On values listed in the previous table. If it
Display Message
Meter does not, continue to the next step.
0% 0
d. While ramping the display, use the
15% 4.5 digital voltmeter to measure voltage
30% 9.0 between JPC9-5 (+) and JPC9-11 (–).
45% 15.0 If the voltage increases with the
percentage, repair or replace the cable
60% 20.0
JC9-SOL3.
75% 26.0
If the voltage is not correct, the Vehicle
90% 32.0 Manager could be malfunctioning.
Replace the Vehicle Manager. Run
Configure Mode, then Learn Mode.
Re-run the test.
PDMM-0109 7/31/02 6-123

Test O18 – Toggle the Horn Digital Output Tests
Test O18 – Toggle the Horn 4. If wiring continuity is OK, verify voltage
between JPC8-15 (+) and JPC8-16 (–) at the
This test turns the truck’s horn ON and OFF. Vehicle Manager. If voltage is not present,
the Vehicle Manager could be
Run Test
Manager. Run Configure Mode, then Learn
NOTE: For information on how to use Mode. Re-run the test.
maintenance mode, see “Using NOTE: For instructions on selecting Modes of
Maintenance Mode” on page 6-12. Operation, see “Modes of Operation” on
1. Use the TILT UP/DOWN buttons to toggle page 6-3.
the test ON and OFF. The operator display
shows ON or OFF.
2. When you press the ENTER key the horn
must sound. If it does not sound, then this
test is a failure.
! CAUTION

2. Disconnect the wires from the horn
terminals. Use a digital voltmeter to
measure the voltage to the horn.
a. If voltage is not present, go to step 3
below.
b. If voltage is present, replace the horn.
3. Use a digital ohmmeter to test for
continuity between each of the pin sets in
the table below:
From To
JC8-16 H-1
H-2 JC8-15
Repair/replace wiring as necessary. See

“Wiring and Harness Connectors” on
page 7-86.
6-124 PDMM-0109 7/31/02

Digital Output Tests Test O19 – Audible Alarm
Test O19 – Audible Alarm

This test turns on the operator display alarm by
gradually increasing the PWM signal.
Run Test
If the sonalert does not sound when you press
the horn button, then this test is a failure.
! CAUTION
1. If you are able to access the maintenance

mode, then the keypad and related wiring is
operating correctly.
2. If the sonalert does not work, the operator
display cable JC5-JD1 could be bad. Turn
the key switch OFF and disconnect the
battery connector. Use an ohmmeter to test
for continuity between JPC5-5 and JPD1-5.
Repair or replace as necessary.
3. Connect the (+) lead of a DVM to JPD1-9
and the (–) lead to JPD1-5. Hold the PC
contactor tips closed and turn key switch
ON. The correct meter reading increases
from 0V to approximately 2V for a short
period of time.
a. If voltage is present, replace the
operator display.
b. If the voltage is not present, the Vehicle
Manager could be malfunctioning.
Configure Mode, then Learn Mode.
Re-run the test.
page 6-3.
PDMM-0109 7/31/02 6-125

Test O20 – Travel Alarm Test (Option) Digital Output Tests
Test O20 – Travel Alarm Test

(Option)
This test toggles the travel alarm ON and OFF.
Run Test
ON or OFF.
! CAUTION

2. Remove fuse FU4. Use a digital ohmmeter
to test FU4 for continuity.
a. If there is continuity, go to step 3.
b. If there is no continuity, replace the
fuse.
3. Connect a meter to H2 (+) and H2 (–). Run
the test. If the meter indicates near battery
voltage, replace the travel alarm.
4. If the meter does not indicate near battery
voltage, connect the (+) lead of the meter to
JPC10-20 and the (–) lead to JPC10-16.
Run the test again. If the meter indicates
near battery voltage, troubleshoot the
wiring and components in the travel alarm
circuit.
5. If the correct voltage is not present, the
Vehicle Manager could be malfunctioning.
Configure Mode, then Learn Mode. Re-run
the test.
6-126 PDMM-0109 7/31/02

Digital Output Tests Test O23 – Toggle Power Amplifier Fan
Test O23 – Toggle Power

Amplifier Fan
This test toggles the power amplifier fan ON and
OFF.
Run Test
ON or OFF.
NOTE: Upon exiting this test, the power
amplifier fan remains in the ON or OFF
state last chosen, until you exit Program
Mode.
! CAUTION
1. Use a DVM and connect (+) lead to JPB1-1

and (–) lead to JPB1-2. When you run the
test, the correct reading is approximately
25 volts. If voltage is present, replace the
fan assembly.
2. If voltage is not present, connect (+) lead to
JPC9-11 and (–) lead to JPC9-10 at the
Vehicle Manager. When you run the test,
the correct reading is approximately 25
volts. If voltage is present, troubleshoot the
wiring between the Vehicle Manager and
the fan.
3. If voltage is not present, the Vehicle
Manager could be malfunctioning. Replace
the Vehicle Manager. Run Configure Mode,
then Learn Mode. Re-run the test.
PDMM-0109 7/31/02 6-127

Test O29 – Ramp the Traction Power Amplifier Digital Output Tests
Test O29 – Ramp the Traction Use the sideshift buttons to toggle between
actual RPM and RMS average current.
Power Amplifier
Use the tilt down button to increase the RPM
This test turns on the traction power amplifier request by 25 RPM increments.
by gradually increasing the command to it Once the maximum RPM request is reached,
through the CAN bus. This test makes sure that pressing tilt down again resets the request to 0,
the traction power amplifier can generate stopping the motor. Tilt up also resets the
current. request to 0.
Whenever the RPM request changes, the
! CAUTION Operator Display shows the current RPM
Prolonged application of the current request for four seconds.
to the motor without movement Use the horn button to stop the motor, reset the
causes damage to the motor. RPM request to 0, and prompt for quitting the
test. Press the horn button a second time to exit
the test. If instead, you press tilt up, tilt down,
sideshift left, or sideshift right, the test is still
! WARNING active with the request set to 0.
The traction motor can rotate during
this test. Jack the drive wheels up.
Run Test ! CAUTION

NOTE: For information on how to use electrostatic discharge. See “Static
NOTE: You must step on the deadman pedal for
the brake to release. 1. If the RPM request on the display changes
and the amperage and RPM on the display
The Operator Display ramps from 0 to does not, replace the power amplifier. See
750 RPM. “Traction Power Amplifier” on page 7-103.
The Operator Display first shows the current NOTE: Make sure to reconnect the power cables
RPM request for four seconds; an “R” in the 4th in the correct sequence with flanged
character position indicates requested RPM nuts, torquing to 15 ft. lb. (20.3 Nm).
rather than actual RPM. For example:
2. If the RPM request on the display is greater
O29R0750 than zero and the amperage on the display
means Test O29, 750 RPM requested. ramps up, but the motor does not turn,
troubleshoot the motor, related wiring,
After four seconds, the Operator Display shows drive unit, and brake assembly.
either the actual RPM or the RMS average
current. For example: NOTE: Make sure to reconnect the power cables
in the correct sequence with flanged
O29 0750 nuts, torquing to 15 ft. lb. (20.3 Nm).
means Test O29, 750 RPM actual speed. NOTE: For instructions on selecting Modes of
O29 075A Operation, see “Modes of Operation” on
page 6-3.
means Test O29, 75 amperes average
current.
6-128 PDMM-0109 7/31/02

EASi Reach-Fork® Truck EZ-D/DZ-D Maintenance Manual Component Procedures
Component Procedures 7:
Component Locator Photos . 7-3 Battery Exterior Cleaning. . . . . . . . . 7-84

Testing, Charging, and Maintenance 7-85
Wiring and Harness Connectors . . . . . . 7-86
Covers and Finish. . . . . . . 7-11 General Repair Procedures. . . . . . . . 7-86
Molex Connectors . . . . . . . . . . . . . . 7-88
AMP Water-Resistant Connectors. . . 7-90
Decals . . . . . . . . . . . . . . . . . . . . . . . . . .7-12 Motors. . . . . . . . . . . . . . . . . . . . . . . . . . 7-91
DC Motor Brushes . . . . . . . . . . . . . . 7-91
Steering and Controls. . . . 7-15 DC Motor Brush Spring Tension . . . 7-93
DC Motor Commutator . . . . . . . . . . 7-95
Terminal Nuts . . . . . . . . . . . . . . . . . 7-96
Steering Shaft and Gear . . . . . . . . . . . . .7-16 Lift Motor . . . . . . . . . . . . . . . . . . . . . . . 7-98
Caster Assembly. . . . . . . . . . . . . . . . . . .7-19 Temperature Sensor, Lift Motor . . . . . . 7-101
Steerable Caster . . . . . . . . . . . . . . . . . . .7-21 Temperature Sensor, Traction . . . . . . . 7-102
Control Handle. . . . . . . . . . . . . . . . . . . .7-26 Traction Power Amplifier . . . . . . . . . . . 7-103
Control Handle - EZ-D . . . . . . . . . . 7-26
Operator Display (OD) . . . . . . . . . . . . . .7-38
Hydraulic Components. . 7-107
Drive and Brake. . . . . . . . 7-41
Hydraulic Fluid Replacement. . . . . . . . 7-108
Bleeding the System . . . . . . . . . . . 7-111
Drive Unit . . . . . . . . . . . . . . . . . . . . . . .7-42 Lift Pump . . . . . . . . . . . . . . . . . . . . . . 7-113
Drive Unit Set-Up . . . . . . . . . . . . . . 7-42 Lift Pressure Adjustment . . . . . . . . . . . 7-114
Standard and Special Tools . . . . . . 7-43 Manual Lowering of Fork Carriage . . . . 7-115
Troubleshooting . . . . . . . . . . . . . . . 7-44 Proportional Lower Valve Adjustment . 7-116
Kit Options . . . . . . . . . . . . . . . . . . . 7-45 Auxiliary Pump . . . . . . . . . . . . . . . . . . 7-117
Removal . . . . . . . . . . . . . . . . . . . . . 7-46 Auxiliary System Pressure Adjustment 7-118
Disassembly . . . . . . . . . . . . . . . . . . 7-48 Manifold, Main . . . . . . . . . . . . . . . . . . 7-119
Assembly . . . . . . . . . . . . . . . . . . . . 7-53 Hydraulic Solenoid . . . . . . . . . . . . . . . 7-120
Installation . . . . . . . . . . . . . . . . . . . 7-62 Pressure Transducer . . . . . . . . . . . . . . 7-121
Drive Motor . . . . . . . . . . . . . . . . . . . . . .7-64 Lift Cylinders. . . . . . . . . . . . . . . . . . . . 7-123
Brake . . . . . . . . . . . . . . . . . . . . . . . . . .7-68 Lift Cylinder, Front Cluster . . . . . . 7-127
Brake Adjustment. . . . . . . . . . . . . . 7-69 Lift Cylinder, Back Cylinder,
Brake Pad Inspection . . . . . . . . . . . 7-69 Threaded Anchor Retention . . . . . . 7-130
Upper Brake Pad Replacement . . . . 7-70 Lift Cylinder, Side Cylinder
Brake Assembly . . . . . . . . . . . . . . . 7-72 Seal Repacking . . . . . . . . . . . . . . . 7-134
Brake O-ring Seal Replacement . . . 7-74 Lift Cylinder Front and Back
Bleeding Brake . . . . . . . . . . . . . . . . 7-75 Cylinder Seal Repacking . . . . . . . . 7-136
Deadman (Brake) Pedal . . . . . . . . . . . . .7-76 Lift Cylinder Lowering Cushion . . . 7-138
Inertial Dampener . . . . . . . . . . . . . . . . .7-77 Flow Control . . . . . . . . . . . . . . . . . . . . 7-140
Reach Cylinder . . . . . . . . . . . . . . . . . . 7-142
Tilt Cylinder . . . . . . . . . . . . . . . . . . . . 7-147
Electrical Components . . . 7-81 Sideshift Cylinder . . . . . . . . . . . . . . . . 7-149
Battery Procedures . . . . . . . . . . . . . . . . .7-82

Battery Connector/Cables . . . . . . . 7-82
Battery Rollers . . . . . . . . . . . . . . . . 7-83
PDMM-0109 7/31/02 7-1

Component Procedures EASi Reach-Fork® Truck EZ-D/DZ-D Maintenance Manual
Mast, Chain, Hose

and Cable . . . . . . . . . 7-153
Mast Types . . . . . . . . . . . . . . . . . . . . . 7-154

Over-the-Mast Hose/Cable. . . . . . . . . . 7-155
Mast Bearing Shimming. . . . . . . . . . . . 7-159
Mast Bearing Shimming . . . . . . . . 7-159
Complete Mast Shimming. . . . . . . 7-161
Bearings, Reach Carriage . . . . . . . . . . . 7-171
Bearings, Reach Half Shaft . . . . . . . . . 7-172
Reach Carriage Assembly. . . . . . . . . . . 7-174
Forks . . . . . . . . . . . . . . . . . . . . . . . . . . 7-178
Equalization Chains. . . . . . . . . . . . . . . 7-179
Fork Carriage Tilt Pins . . . . . . . . . . . . . 7-183
Mast Backlash Adjustment . . . . . . . . . 7-184
Options . . . . . . . . . . . . . 7-185
Cold Storage Requirements . . . . . . . . . 7-186

Fork Height-Tilt Indicator (HTI) . . . . . . 7-188
Fork Height Indicator . . . . . . . . . . 7-193
Fork Tilt Indicator . . . . . . . . . . . . 7-197
HTI Theory of Operation . . . . . . . . 7-199
7-2 PDMM-0109 7/31/02

Component Locator Photos


Overhead Over-the-Mast
Guard Hose/Cable
Lift Cylinders
Equalization
Chains (inside
Main Frame)
Lift
Chains
Mast Guard
(Mesh or
Glass)
Free Lift
Cylinders
Battery
Disconnect
Battery
Gate Battery
Load
Backrest
Fork
Carriage
Reach
Mechanism
Baseleg
Load Forks
Wheels
75077_048.TIF
Figure 7-1: Mast and Carriage
PDMM-0109 7/31/02 7-3

HTI (option)
Over-the-Mast
Hose/Cable
Overhead
Guard
HTI Display
(option)
Mast Guard
(Mesh or
Main Glass)
Warning Decal
Key Switch
Operator Manual
Pocket (on Mast)
Hydraulic Fluid
Filler Cap Control
Handle
Steering
Brake Reservoir Wheel
Brake Spec Plate
Drive
Motor Deadman
Pedal
Drive
Unit
Steer
Drive Caster
Wheel
75077_053.TIF
Figure 7-2: Mast and Tractor, Series EZ-D
7-4 PDMM-0109 7/31/02

Height-Tilt
Indicator
Display Mast Guard
(option) (Mesh or
Glass)
Main
Warning
Decal
Hydraulic
Fluid Filler Operator
Cap Display
Key Switch
Steering
Wheel
Control
Main Handle
Manifold
Vehicle
Manager
Auxiliary Contactor/
Motor Fuse Panel
Brake Relay/
Reservoir Control
Fuse Panel
Brake Traction
Power
Amplifier
Drive
Motor
Spec Plate
Drive
Drive
Unit
Unit
(under Deadman
frame) Pedal
Caster
Horn Wheel
Brake Master
Cylinder (not visible)
(inside
Drive Wheel compartment)
75077_051.TIF
Figure 7-3: Tractor, Series EZ-D
PDMM-0109 7/31/02 7-5

Operator Hydraulic Fluid

Display Filler Cap
Control
Handle
Lift Pump
Lift Motor
Vehicle
Manager
Steering
Wheel
Contactor
Steering /Fuse Panel
Orbitrol
Relay/
Control
Brake Fuse Panel
Reservoir
Traction
Power
Amplifier
Brake
Spec Plate
Drive
Motor
Brake Master
Cylinder
Drive (inside
Unit compartment)
Deadman
Pedal
75077_001.TIF
Figure 7-4: Tractor, Series DZ-D
7-6 PDMM-0109 7/31/02

Equalization
Battery Chains (inside
Disconnect Main Frame)
Lift Chains
Lift Cylinders
Reach
Cylinder
Load
Backrest
Sideshift
Cylinder
Tilt
Cylinder
Forks
Reach
Baseleg Mechanism
Load
Wheels
75077_048.TIF
Figure 7-5: Carriage, Series EZ-D/DZ-D
PDMM-0109 7/31/02 7-7

Static
Strap
Steering
Linkage
A-frame
Steerable Drive Wheel
Caster
7P5180009.TIF
Figure 7-6: Underside Components
7-8 PDMM-0109 7/31/02

P Contactor
2 1 PC Contactor
2 1 TPC Contactor
2 1
TP1
Fuse
FU3
Fuse
FU1
Fuse
FU2
TP3
TP2
B–
W
TP5
V
U
B+
75077_037.TIF
Figure 7-7: Contactor / Fuse Panel Layout
PDMM-0109 7/31/02 7-9

7-10 PDMM-0109 7/31/02

Covers and Finish

Covers and Finish
PDMM-0109 7/31/02 7-11

Decals Covers and Finish
Decals
Decal and Specification Plate Locations

Identifier Description Location
Raymond Left side of drive motor compartment door,
1
centered under ventilation slots
2 AC logo Tractor frame, above battery opening (both sides)
3 Auxiliary Functions Top cover
Performance Top of decal 26 in. (660 mm) from bottom edge of
4 drive motor compartment door, centered over
slots
Lubrication Inside drive motor compartment door, 11 in.
5 (279 mm) from top of door, centered above
ventilation slots
Patent Number Inside drive motor compartment door, under
6
lubrication decal
7 Drive Motor Warning Drive motor, near terminals
Specification Plate (not a decal) Left front of operator compartment, top edge of
8
decal 15 in. (381 mm) from compartment floor
UL_E Specification Plate (not a Right front of operator compartment, top edge of
9
decal) decal 15 in. (381 mm) from compartment floor
Auxiliary Specification Plate (not a Left front of operator compartment, top edge of
10
decal) decal 9.75 in. (248 mm) from compartment floor
Battery Warning (2) Tractor frame, above battery compartment (both
11
sides)
Raymond Tractor frame, right side, with “D” of “Raymond”
ending 5 in. (127 mm) below top edge of frame
12
and 3 in. (76 mm) to the rear of the battery
compartment opening
Main Warning Decal Mast guard, bottom edge of decal 0.12 in. (3 mm)
13 from bottom of cover, decal centered about hose
springs
Overhead Guard ASME Inside center of overhead guard
conformance
Mast Specification Plate (not a Right side of mast, near bottom
decal)
No Riders On load backrest
Operator Manual Left side of mast, eye level
Figure 7-8: Decal Location Chart
NOTE: Shaded items are warning decals.
7-12 PDMM-0109 7/31/02

Covers and Finish Decals
1 3 4 5 13
2 SERIES DZ 3 6 11 1
SERIES EZ
7 8 10 9 12
7R80300A.EPS R80300B.EPS
7R80211A.EPS R80211C.EPC
7R86858B.EPS
Figure 7-9: Decal and Specification Plate Locations, Tractor
PDMM-0109 7/31/02 7-13

Decals Covers and Finish
WARNING 13
Prior to operating this truck:
Do not operate this truck unless

trained and authorized to do so.
Read all warnings and instructions

contained in the operator's manual
and on the truck.
Check all operating systems 7

and safety devices.
While operating this truck:
Keep all portions of the body inside

the operator's compartment.
When stopping, stay inside compartment

until truck comes to a complete halt.
Use caution when traveling with 11 WARNING

forks above 24 inches.
REMOVE BATTERY ONLY WITH LIFT
Travel with forks retracted. MECHANISM DOWN AND LOAD REMOVED.
For your safety and the safety of others:
1. Do not operate this truck unless you have been trained and authorized
to do so.Read all warnings and instructions contained in operator's manual.
HORIZONTAL MOTION OF BATTERY
2. Do not operate this truck until you have checked all systems. (All safety
guards or covers must be in place and safety interlock switches operative.) MUST NOT EXCEED 0.5 INCHES.
Report any unsafe condition immediately.Do not operate truck until cor-
rected.
411-890
3. Operate truck only from designated operating position. Never place any
part of your body between the mast uprights or outside the truck.Do not
carry passengers.
4. Do not allow anyone to stand or pass under the load or lifting mechanism.
5. Do not operate this high lift rider truck when loads are lifted or stored
above 72 inch height unless equipped with an overhead guard.
6. Do not overload truck.Check nameplate for capacity (load weight and
load center information).
7. Start, stop, change direction, travel and brake smoothly. Slow down for
turns and on uneven or slippery surfaces that could cause truck to slide or
tip.Keep one foot free from deadman brake pedal at all times.
8. Use extreme care when traveling without load.Excessive speed with
abrupt turns or on uneven surfaces may cause trucks to tip over.
9. Elevate lifting mechanism only to pick up or stack a load. Lift and lower
with mast vertical or slightly back--never forward. Watch out for obstruc-
tions, especially overhead.
10. Operate tilting mechanism slowly and smoothly.Do not tilt forward
when elevated except to pick up or deposit a load over a rack or stack.
When stacking use only enough backward tilt to stabilize load.
11. When reach and/or sideshift features are provided:Lift,lower,or travel
with forks/attachments retracted and centered.Extend or sideshift forks/at-
tachments only to pick up or discharge loads.
12. Always look in direction of travel.Keep a clear view,and when load in-
terferes with visibility,travel with load trailing (except when climbing ramps).
Travel with load or lifting mechanism as low as possible and tilted back.
13. Use special care when operating on ramps---travel slowly,and do not
angle or turn.When truck is loaded,travel with load uphill. When truck is
empty,travel with lifting mechanism downhill.
14. Do not lift personnel except on a securely attached work platform. Use
extreme care,place mast in vertical position,retract forks/ attachment.Cen-
ter sideshift.Place truck controls in neutral and apply brakes.Lift and lower
smoothly.Remain in operating position as long as personnel is elevated.
15. When using forks,spread as far apart as load will permit.Before lifting,
be sure load is centered and forks are pushed completly under load.
16. Do not handle unstable or loosely stacked loads.Use special care
when handling long,high or wide loads.
17.Observe applicable traffic regulations.Yield right of way to pedestrians.
Slow down and sound horn at cross aisles and wherever vision is obstructed.
18. When you get off truck,place controls in neutral and set parking brake.
If you leave truck unattended,also fully lower lifting mechanism,shut off
power and remove key.Do not leave truck unattended on ramps.
411-884
7411_884.EPS
7411_891.CGM
7411_890.EPS
Figure 7-10: Warning Decals
7-14 PDMM-0109 7/31/02

Steering and Controls

Steering and Controls
PDMM-0109 7/31/02 7-15

Steering Shaft and Gear Steering and Controls
Steering Shaft and Gear

Removal
Steering
the battery connector. Shaft
2. Remove the drive motor compartment door.
3. Without disconnecting the hydraulic hoses,
remove the hydraulic steering motor and
secure it clear of the steer shaft.
4. Remove the drive unit dust shield.
5. Raise the steer shaft out of the drive unit by
using a pry bar under the gear. If
necessary, apply heat to the drive unit Gear
around the bearing.
6. If the spherical bearing remains attached to
the drive unit after removing the steer
shaft, remove the bearing from the drive
Drive
unit as follows: Unit
! WARNING
Use extreme care whenever the lift
Dust
truck is jacked up. Never block the Shield
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 74155_013.TIF
NOT rely on the jack alone to Figure 7-11: Steering Shaft
support the lift truck. See “Jacking

Safety” on page 2-13.
a. Jack and block the tractor end so it is

supported with the drive wheel in
contact with the floor.
b. While supporting the steering stop block
underneath the left side of the drive
unit, remove the drive unit mounting
bolts along the left side. Remove the
block.
c. Install jacking bolts (3/8-16 x 2.5 in. or
longer) to the underside of the drive unit
beneath the steer shaft and drive the
7-16 PDMM-0109 7/31/02

Steering and Controls Steering Shaft and Gear
bearing out. If necessary apply heat to

the drive unit around the bearing.
Installation
1. Clean the bearing O.D. and pivot ring bore
with a solvent degreaser (P/N 990-589 or
equivalent).
2. Spray the bearing O.D. and pivot ring bore
with a compatible primer (P/N 990-533)
and allow to evaporate.
3. Apply a thin coating of bearing retaining
compound (P/N 990-575 or equivalent). Do
not spread any compound into the
lubrication groove on the bearing.
4. Align the lubrication hole on the bearing
with the corresponding hole in the pivot
ring and press the bearing into the ring.
5. Immediately grease the bearing through the
fitting on the pivot ring until grease can be
seen on the bearing ball. This will ensure
that any retaining compound that may have
deposited in the lubrication groove will be
displaced by grease before it sets up.
6. Clean the bearing I.D. and steering shaft
with a solvent degreaser (P/N 990-589 or
equivalent).
7. Spray both surfaces with a compatible
primer (P/N 990-533) and allow to
evaporate.
8. Apply a thin coating of bearing retaining
compound (P/N 990-575) to the shaft.
7R84158.EPS
Figure 7-12: Steering Shaft and Gear Assembly
PDMM-0109 7/31/02 7-17

Steering Shaft and Gear Steering and Controls
9. Install the shaft into the bearing. See

Figure 7-13.
10. Immediately grease the bearing once again.
11. Re-install the dust shield and steering stop
block.
12. Apply thread-locking compound
(P/N 990-544) to drive unit mounting bolts, Gear Frame
install, and torque to 140 ft. lb. (190 Nm).
13. Apply a liberal amount of chassis grease
where the hydraulic motor shaft connects
to the upper end of the steering shaft.
14. Install the hydraulic steer motor.
15. Remove blocking and jack.
Steering Bearing
16. Reconnect the battery connector and turn Shaft
the key switch ON.
7828-004-158.EPS
17. Test steering for correct operation. Check
Figure 7-13: Steering Shaft Bearing
for leaks.
18. Install and close the drive motor
compartment door.
7-18 PDMM-0109 7/31/02

Steering and Controls Caster Assembly
Caster Assembly
Removal
! WARNING
truck is jacked up. Never block the
stands beneath it to support it. DO
NOT rely on the jack alone to
2. Jack and block the tractor end behind the

caster, clear of the counterweight.
3. Disconnect the steering linkage arm at the
caster housing, if equipped with steerable
caster.
4. Measure the fore/aft play in the A-frame
pivot and note the amount for reference
during reinstallation.
5. Detach the inertial dampener, if so
equipped, from the A-frame. See “Inertial
Dampener” on page 7-77.
6. Remove blocking and lower the tractor to
the floor.
7. Remove the down travel stop bolt and
washer.
8. Jack and block the tractor end behind the
caster, clear of the counterweight.
9. Remove the caster springs and adjusters.
10. Remove the counterweight. The rear
A-frame pivot pin is now exposed.
11. Remove the rear A-frame pivot pin, noting
the location and quantity of spacers.
PDMM-0109 7/31/02 7-19

Caster Assembly Steering and Controls
12. Support the A-frame.

Carefully slide the pivot end toward the rear
of the tractor until it clears the fixed pin.
Note the quantity of spacers.
13. Slide the caster and A-frame assembly out
through the access opening.
Installation
1. Based on the amount of fore/aft play in the
A-frame pivot noted in step 4 of removal,
add spacers as required to reduce the total
play by no more than half. Position the
spacers on the fixed pivot pin.
2. Position the caster and A-frame assembly
under the tractor and place the forward
pivot onto the fixed pivot pin.
3. Align the rearward pivot and install the
pivot pin while placing the appropriate
quantity of spacers.
4. Attach the counterweight.
5. Install the caster spring and adjuster
assemblies.
6. Install the down travel stop bolt and
washer.
7. Install the inertial dampener.
8. Adjust the caster spring height, travel stop
bolts, and inertial dampener, as described
in “Steerable Caster” on page 7-21.
7-20 PDMM-0109 7/31/02

Steering and Controls Steerable Caster
Steerable Caster
The drive and steerable caster wheel are
designed to allow 101.5 degrees of rotation. Use Straightedge Drive Tire
the following procedure to adjust the steering
mechanism and caster height.
NOTE: Correct caster adjustment is critical. A
misadjusted caster can cause excessive
braking distances, poor stability, or C
damage to inertial dampener
components.
Initial Adjustment
1. The drive and caster wheels should be
parallel.
a. Place a straightedge along the tractor C
frame. Measure the distance from the
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 A 7R86758A.EPS
the tractor frame. See Figure 7-14. Figure 7-14: Setting Drive Wheel Parallel
b. Place a straightedge along the opposite
side tractor frame. Measure the distance Drive Caster
from the straightedge to the front edge of C
Wheel Wheel
the caster wheel and to the back edge. If B
the dimensions are not equal, adjust as
follows.
the battery connector. Remove battery B
gates. Using a suitable battery removing C
device, remove the battery and battery
rollers from the lift truck to provide access
to adjustment bolts underneath.
A
3. Loosen the center steering link locking
bolts. See Figure 7-15.
Steering Steering
4. Loosen jam nuts on center steering link Link Link
adjusting bolts and adjust the bolts to get Locking Adjusting
both wheels parallel to the tractor frame. Bolts (4) Bolts (2)

(P/N 990-536) to steering link adjusting E E
bolts and locking bolts.
6. Tighten the jam nuts on the adjusting
bolts. 7R86758A.EPS
Figure 7-15: Steering Adjustments

7. Tighten locking bolts and torque to 70 ft. lb.
(95 Nm).
PDMM-0109 7/31/02 7-21

Steerable Caster Steering and Controls
8. Re-install the battery rollers. Using a

suitable battery removing device, re-install
the lift truck battery. Re-install battery
gates.
Caster height adjustment varies, depending
upon the type of mast. See “Caster Height
Cover Plate
Caster Height Adjustment
1. Remove the inertial dampener cover plate.
See Figure 7-16.
2. Check the A-frame down-travel adjustment
bolt in Figure 7-17. Make sure it is installed 75077_034.TIF
correctly. If the bolt is missing, the A-frame Figure 7-16: Inertial Dampener Cover Plate
could drop and allow the springs to escape
when the truck is jacked up.
A-frame Spring Nuts

! WARNING
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
feet clear from beneath vehicle while
A-frame
jacking the lift truck. After the lift Down-Travel
truck is jacked up, place solid blocks Adjustment Bolt
or jack stands under it for support.
713Y7S001.TIF
DO NOT rely on the jack alone to
Figure 7-17: A-frame Down-Travel Adjustment Bolt
7-22 PDMM-0109 7/31/02

Steering and Controls Steerable Caster
3. Jack the lift truck until the caster is clear of

the floor.
4. Turn the A-frame down-travel adjustment
bolt to obtain an initial gap of 1.0 inch
Initially Initially
(25 mm) between the arm and frame. 1 in. 6 in.
Adjust the A-frame spring nuts to obtain an (25 (152
initial spring length of 6.0 inches (152 mm). mm) mm)
See Figure 7-17 and Figure 7-18.
5. Lower the lift truck back onto the floor.
Ensure the lift truck is sitting on a flat floor
surface.
6. Adjust the A-frame spring nuts to obtain
the spring length in the table below. The
dimension is measured from the top of the 7R86758B.EPS
spring to the top of the caster, not the Figure 7-18: A-frame Spring adjustments
frame.
Elevated Spring
Series
Height Length
EZ-D, Below 330 in. 5.75 in.

DZ-D (8328 mm) (146 mm)
Above 331 in. 5.50 in.

(8407 mm) (140 mm)

(P/N 990-536) and turn the A-frame
down-travel adjustment bolt to set the
correct gap between the bottom of the bolt
head and the top of the flat washer. See
Figure 7-18 and the table below.
Series Elevated Height Gap
EZ-D, DZ-D All elevated heights 0.12 in.

(3.05
mm)
NOTE: Don't overtighten the bolt. The bolt

head should apply slight pressure on
the flat washer.
PDMM-0109 7/31/02 7-23

Steerable Caster Steering and Controls
8. Loosen the jam nut on the A-frame

up-travel stop bolt. See Figure 7-19.
9. Re-install the battery rollers. Using a
suitable battery moving device, re-install
the lift truck battery.
10. 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 7-19):
A-frame
Up-Travel
Elevated Stop Bolt
Series Gap
Height 713Y7S001.TIF
EZ-D, DZ-D Below 330 in. 0.38 in. Figure 7-19: A-frame Up-Travel Stop Adjustment
(8328 mm) (9.65 mm)
Above 331 in. 0.25 in.

(8407 mm) (6.35 mm)

(P/N 990-536) to the A-frame up-travel stop
bolt. Tighten the jam nut.
12. Test the lift truck for correct braking action.
13. Reinstall the inertial dampener cover plate.
7-24 PDMM-0109 7/31/02

Steering and Controls Steering Linkage
Steering Linkage
Use Figure 7-20 as a reference when removing/replacing steering linkage components. After
replacing any components, assure that the steering is adjusted correctly.
Caster
Caster Housing
Wheel
Steering
Link,
A-frame
right
Pivot Pin
(opposite
A-frame
side not
shown)
Steering
Link,
center
Steering
Link, left
Steering
Link
Adjusting
Bolts (2)
Steering
Link
Locking
Bolts (4)
7R86758X.EPS
Figure 7-20: Steering Linkage Exploded View
PDMM-0109 7/31/02 7-25

Control Handle Steering and Controls
Control Handle
Vehicle Manager
Control Handle - EZ-D
NOTE: Solid state potentiometers are ESD
sensitive. Failure to follow ESD
precautions when handling or
installing solid state potentiometers
can result in permanent damage to
the potentiometers.
Be sure to observe the proper
precautions against electrostatic
Connector JPC6
discharge. See “Static Precautions”
on page 2-11. 75077_037.TIF
Figure 7-21: Connector JPC6 at Vehicle Manager

NOTE: Disassembly of the control handle
requires a certain sequence of steps.
Failure to follow this sequence can
result in damage to the wiring. The
following procedures describe a
complete rebuilding of the control
handle.
Control Handle Removal

NOTE: Assembly requires a control handle
fixture (P/N 828-009-213) with two
dowel pins (P/N 812-403) and one
thumb screw (P/N 714-168).
2. Disconnect the control handle cable from
the Vehicle Manager at connector JPC6.
3. If cold storage, disconnect connector JPHT1 Connector
JPHT1 OD
where the heater wires exit the handle.
Cover
4. Loosen control handle set screw and Screw
remove handle from pivot.
Control
Handle
Set
Screw
74155_021.TIF
Figure 7-22: Control Handle Installation
7-26 PDMM-0109 7/31/02

Steering and Controls Control Handle - EZ-D
Handle Shell Disassembly

1. Throughout disassembly, note the
orientation of switches, potentiometers,
routing of cables and wires to make
reassembly easier.
2. Remove the two screws holding the plastic
cable clamp.
3. Remove two nylon set screws (used for
static reduction) in the lift/lower knob. If
the screws are stripped, use a small
flat-bladed screwdriver.
4. Loosen two metal set screws in the
lift/lower knob 2 full turns and remove the 73257_002.TIF
lift/lower knob. Figure 7-23: Control Handle Retaining Ring Removal
5. Remove the control handle retaining ring

located below the lift/lower potentiometer
VR2. The retaining ring is under tension
and can become a projectile. Use care when
removing the ring to prevent it from flying
away. Place the tip of a flathead screwdriver
at the tilt/sideshift side of the ring and peel
it out (like an orange).
6. Remove two socket head screws from remove
handle assembly, one near the tilt/sideshift screws
button and one near the horn button. See
Figure 7-24.
7. Loosen the remaining two socket head cap
screws 1 1/2 turns. 75118_002.TIF
Figure 7-24: Control Handle shell
8. Separate handle shell halves slightly. Insert

a thin-bladed screwdriver in the crack at
the small end of the clamp. Twist the
screwdriver to release the wedge, and push
the cable clamp out of the handle. See
Figure 7-25.
9. Remove the loosened socket head cap
screws from the handle.
75118_003.TIF
Figure 7-25: Removing Control Handle Wedge
PDMM-0109 7/31/02 7-27

Control Handle - EZ-D Steering and Controls
10. Mount the handle on the assembly fixture

using two dowel pins placed into the outer
two holes. Position the handle hole to allow
the thumb screw to engage the mounting
hole in the shaft, then tighten the thumb
screw.
75118_005.TIF
Figure 7-26: Control Handle on Fixture
11. Hold the tilt/sideshift button to prevent it

from springing out. Carefully remove the
left half of the handle shell.
12. Remove the tilt/sideshift button, spring,
and button actuator. Tilt/SS
Button Button
Actuator
Spring
73257_005.TIF
Figure 7-27: Tilt/Sideshift button, spring, actuator (EZ-D)
7-28 PDMM-0109 7/31/02

Steering and Controls Control Handle - EZ-D
Bracket Return Spring
Lift/Lower Pot (VR2) Removal

Tab and Notch
1. Slide potentiometer bracket and pot out of
the handle slot (towards the left handle
shell), using a small screwdriver.
2. Remove lift spring from pot bracket.
3. Remove pot bracket from pot.
VR2
Tilt/SS Card
73257_013A.TIF
Figure 7-28: Lift/Lower Potentiometer (EZ-D)
Notch
Tilt/Sideshift Switch Card (S6-S9)
Removal
1. Slide the tilt/sideshift switch card out of its
slot, using a small screwdriver at the notch.
Do not apply force on the switch. This
will cause the switch to break.
2. Carefully remove wires from the retaining
slot in the control handle shell. Key
73257_015.TIF
Figure 7-29: Tilt/Sideshift Switch Card (EZ-D)
PDMM-0109 7/31/02 7-29

Control Handle - EZ-D Steering and Controls
VR1
Throttle Pot (VR1) Removal
Spring (Set Screw
1. Remove the cable stud and washer holding underneath)
the cable in the handle shell. Remove the
cable assembly from the handle shell.
Do not
NOTE: The VR1 positioner and shaft are remove
bonded together. Do not remove the this screw.
button head retaining screw located
below the positioner/potentiometer
return spring.
2. Slide the throttle potentiometer return
spring up to expose the set screw holding 75118_009.TIF
the potentiometer shaft. Figure 7-30: Throttle Potentiometer VR1 (EZ-D)
3. Loosen the set screw in the
handle/potentiometer positioner. Remove
the potentiometer.
4. Slide the return spring off the
handle/potentiometer positioner.
7-30 PDMM-0109 7/31/02

Steering and Controls Cleaning and Inspection
Cleaning and Inspection

Clean and inspect all the following parts:
Part Inspect
Tilt/sideshift button Check for cracks or deformation.
actuator
Lift/lower pot bracket Check for cracks, deformation, loose dowel pin, over round or
oversized shaft hole (0.25 inch is correct).
Travel pot shaft and Check positioner for cracks, deformation, and stripped tapped
positioner assembly hole for set screws. Check positioner for centered button screw
and hole. Check shaft for deformation at large countersink hole.
Left handle shell Check for cracks, deformation and flash (a feathery edge at the
parting line of molded part).
Right handle shell Check for cracks, deformation and flash.
Lift/lower knob Check for cracks. Check for loose dowel pin. Check for stripped
tapped holes for set screws.
Cable clamp Check for cracks, deformation, pry marks.
Retaining ring Check for deformation and cracks.
Self-tapping screws for Clean threads.
cable clamp
Stud and washer Check for deformed teeth on stop; stud should fit snugly in
mounting hole.
Washer sleeve and screw Check for deformation and stripped threads.
Spring for tilt/sideshift card Check for deformation (crushed, stretched, or bent).
Other hardware Check for stripped threads. Clean all screw threads.
Figure 7-31: Control Handle inspection and cleaning
Soldering Procedure
Follow the recommendations under "Soldering
Procedures" on page 7-88.
Throttle Pot (VR1) Installationl

1. Place handle/pot positioner shaft through
the right handle half and into the assembly
fixture. Tighten fixture.
PDMM-0109 7/31/02 7-31

Cleaning and Inspection Steering and Controls
2. Always replace the return spring when

replacing the potentiometer. Coat the inside
of the handle/potentiometer positioner VR1
Cable Stud
return spring lightly with lithium grease and Washer
(P/N 990-635).
3. Install handle/pot positioner spring with
both spring tangs on the left side of Reach/Retract
handle/pot positioner pin. Facing the pot Switches
positioner, put the bottom tang on left side
of positioner pin. Take top tang and wind to
load the spring and put it on the right side
of the pin. The preloaded spring now has
one tang on each side of the pin. Slide
spring only half way down the positioner to Horn Switch VR2
provide access to the lower set screw.
75118_007.TIF
4. Install travel potentiometer VR1 in the Figure 7-32: Control Handle Cable Routing (EZ-D)
handle/potentiometer positioner. Apply
thread-locking compound (P/N 990-412) to
the set screw. Run set screw in until it
strikes the shaft, then turn 1/8 turn more.
5. Push the handle/potentiometer return
spring down over the set screw hole.
Harness and Switch Installation

1. Install the wiring harness in the right half
of the control handle. Install the cable for
the tilt/sideshift card first. Push cable into Reach/Retract
pathway. See Figure 7-32. Switches
2. Slide the tilt/sideshift switch card into the

slot in the handle shell, with the notch to
the outside and the flat towards the
lift/lower potentiometer. Gently route wires
away from the area where the lift/lower pot
will be. See Figure 7-29.
3. Press the horn switch in place. See
Figure 7-33.
Horn Switch
4. Install the reach/retract switches on the
retaining pedestals with the flat toward the 75118_011.TIF
lift/lower potentiometer. See Figure 7-33. Figure 7-33: Switch Installation

Push wires into pathway.
Lift/Lower Pot (VR2) Installation

1. Always replace the return spring when
replacing the potentiometer. Coat the inside
of the handle/potentiometer positioner
7-32 PDMM-0109 7/31/02

return spring lightly with lithium grease

(P/N 990-635).
2. Slide the spring on the potentiometer
bracket with the spring tangs tensioned on
each side of the potentiometer bracket pin.
3. Slide the lift/lower potentiometer bracket
over the potentiometer shaft, engaging the
metal tab of potentiometer in the key slot in
the side of the bracket. Hold the pot and
bracket by the bracket and make sure the
pot shaft turns freely from stop to stop.
4. Slide the lift/lower potentiometer bracket
into the slot in the right control handle
shell. Push bracket down with thumb so
the retaining foot rests on the flat of the
tilt/sideshift card. See Figure 7-29. Note
routing of lift/lower pot wires. Make sure
pot shaft turns freely. If not, check for wires
pulled too tight.
Cable Routing
Cable Stud
and Washer
1. Make sure all wires and cables are routed

correctly. Insert the cable stud and washer.
75118_007.TIF
Figure 7-34: Control Handle cable routing
PDMM-0109 7/31/02 7-33

Dowel Pin
2. Make sure the locating tab on the travel pot

(VR1) is 180° from the dowel pin on the pot
positioner. See Figure 7-35.
3. Install a cable tie to hold the travel pot VR1
wires away from the button head screw on
the travel pot positioner.
Locating Tab
75118_018.TIF
Figure 7-35: Travel Potentiometer orientation
Button
Tilt/Sideshift Button Installation
Notch
1. Rotate entire handle and fixture so that the
tilt/sideshift actuator is flat. Key
2. Install tilt/sideshift actuator, spring, and
button. Move button toward lift/lower pot Spring
until button drops into locating ridge.
Button notch should engage in key. Make
sure the spring is fully engaged at both
ends. See Figure 7-36.
Locating
Ridge
73257_008.TIF
Figure 7-36: Tilt/Sideshift Button installation
Align Pin between

Handle Shell Assembly Spring Tangs
1. Pre-bend cable with fingers only at the

cable guide to make installation easier.
2. Tip fixture up so you can see the travel pot
tab and opposing keyway. Install left half of
the handle shell. The tab on VR1 must
engage the keyway in the left half of the
handle. The pin in the left side handle shell
must fit between the tangs of the VR1
return spring. See Figure 7-37. Align Keyway with Tab
73257_004.TIF
Figure 7-37: Control Handle Assembly (EZ-D)
7-34 PDMM-0109 7/31/02

3. Making sure left half shell is centered over

right half, slowly lower the left half down.
Route the cable up through the shell before
closing. Close shells, engaging
tilt/sideshift button in locating ridge.
During the last 1/4 in. to 3/8 in. of closure,
you will feel resistance as the harness is
pressed and shaped by the internal
wireway. Using firm, steady pressure, push
down on the left handle shell until both
halves meet.
4. Holding the handle together, loosen the
thumb screw and remove the handle from
the fixture. If the handle does not fit
together neatly, check all components for
correct position and location.
5. In right handle shell, install but do not
tighten the long Allen head screw with
aluminum collar and the short Allen head
screw to hold handle halves together.
6. Seat the horn button. Tighten the screw
next to horn button (¼ turn past hand
tight).
7. Before tightening screw next to
tilt/sideshift card, make sure button notch
is engaged. Tighten finger tight plus ¼
turn. Tighten the two other screws the
same way.
8. In the fixture, remove one dowel pin and
reset the other in the center hole of the
three holes. Set the handle assembly in the
fixture and tighten the thumb screw into
shaft mounting hole. Rotate the handle
from neutral to full in one direction, back to
neutral, to full in the opposite direction,
and back to neutral. The handle should
move freely with no binding and should
snap back to neutral when released.
Correct any binding before proceeding to
the next step.
9. Remove handle from fixture. Place the cable
harness in the slot and install plastic cable
clamp. Make sure the cable stays centered
in the pathway. Holding the handle in one
hand, not on a hard surface, tap the end of
the cable clamp flush with a screwdriver
handle. Install two screws.
PDMM-0109 7/31/02 7-35

10. Install remaining hex head screws in

handle assembly. Torque all four Allen head
screws to 15 to 20 ft. lb. (1.7 to 2.25 Nm).
11. Install the retaining ring in the groove
below the lift/lower knob (VR2). With the
handle in your right hand (tilt/sideshift
button facing away from you), insert ring so
that the left end catches in the left edge of
the groove. Sweep your thumb
counterclockwise until the ring snaps into
the groove. The ring should be recessed, not
flush, with respect to the handle shell. If
not, remove and insert again. Squeeze
halves together by the tilt/sideshift card to
help further seat retaining ring.
12. Check to make sure that the tilt/sideshift
button is not binding and that the lift/lower
pot has free rotation.
75118_019.TIF
Figure 7-38: Retaining Ring installation
Lift/Lower Knob Installation

1. Rotate the lift potentiometer shaft fully
counterclockwise.
2. Install the new lift knob on the
potentiometer shaft, but do not tighten the
set screws.
3. Rotate the lift knob fully counterclockwise
and tighten the metal set screws. Check for
correct rotation of the potentiometer and
spring return to neutral. Correct any
binding.
4. Verify the potentiometer reference voltages. Align Pin between
See “Test A05 – Lift/Lower Potentiometer Spring Ears
Voltage” on page 6-77.
73257_014.TIF
5. Install nylon set screws (for ESD protection) Figure 7-39: Lift/Lower Knob and Potentiometer
in the same holes as metal set screws.
Thread in until they stop; do not tighten
further.
6. Remove handle from fixture.
7-36 PDMM-0109 7/31/02

7. The lift knob on solid state handles should

not require any other adjustment. Correct
voltages are:
Pot Position Throttle Position Voltage Displayed

Full Greater than
Full Lift
counterclockwise 0.45 V
Neutral Neutral 2.00 to 3.00 V
Full clockwise Full Lower Less than 4.65 V
Handle Installation
1. Series EZ-D: Thread the cable harness
through the OD/SMARTi® cover. Place the
cover in position.
Connector
2. Install the control handle on the pivot. JPHT1 OD
3. Apply thread-locking compound Cover
(P/N 990-536) to the control handle set Screw
screw and install the set screw and tighten.
Control
Handle
! CAUTION Set
Screw
precautions against electrostatic 74155_021.TIF
discharge. See “Static Precautions” Figure 7-40: Control Handle Installation (EZ-D)
on page 2-11.
4. Loop the control handle cable harness in a

loop at least 8 inches (203 mm) in diameter
as it leaves the handle. Do not route
through or under any components. Route
the cable to the Vehicle Manager and
connect connector JPC6.
5. If cold storage, connector handle heater
harness connector JPHT1.
6. Ensure that all other wires are tied back
and away from the handle harness service
loop.
7. Test the motion of the service loop by
rotating the handle. The entire length of the
loop should absorb the twist. Ensure the
loop does not hang up on nearby wires,
cable ties, or structures.
PDMM-0109 7/31/02 7-37

Operator Display (OD) Steering and Controls
Operator Display (OD)

Pre-programmed vs. blank OD
NOTE: Do not install an OD from one lift truck
in a different serial number lift truck.
The backup and restore process will
result in corrupting the configuration
information in the lift truck. If this
happens, a preprogrammed OD must be
installed.
If both Vehicle Manager and OD are being
replaced at the same time, the OD must be
preprogrammed.
Removal
! CAUTION
Be sure to observe the proper Machine
precautions against electrostatic Screws
on page 2-11.

2. Remove the decal over the Operator
Display. This exposes the machine screw Decal
heads securing the Operator Display
Interface Card.
3. Disconnect the OD cable harness from the
card at connector JPD1.
4. Remove the four (4) machine screws
securing the Operator Display Interface 75077_071.TIF
Card to the cover. Figure 7-41: Operator Display Interface Card
(Series EZ-D)
7-38 PDMM-0109 7/31/02

Steering and Controls Operator Display (OD)
Installation
1. If the lift truck is cold storage-equipped, Machine Screws
apply silicone sealing compound
(P/N 990-445) to the entire surface of both
sides of the card. Fill the connector socket
with sealant.
2. Mount the Operator Display Interface Card
to the OD cover with four machine screws.
3. Install a new OD decal over the Operator
Display.
Decal
75077_007.TIF
Figure 7-42: Operator Display Interface Card

(Series DZ-D)
PDMM-0109 7/31/02 7-39

Operator Display (OD) Steering and Controls
7-40 PDMM-0109 7/31/02

Drive and Brake

Drive and Brake
PDMM-0109 7/31/02 7-41

Drive Unit Drive and Brake
Drive Unit
Drive Unit Set-Up
27
31 25
2
3 21
5 6
1
24
23
26 32
37 33
36
35
34 9
8
12
13 7
41
17 40
16 39
38
14 5 19
6
Legend: 7
1. Housing 18
2. Helical Pinion
3. Helical Gear 10
4. Clamp Nut 21. Pivot Ring
5,6. Bearing Cup and Cone Set 22. Roll Pins (not shown)
7. Spiral Gear and Pinion Set 23. Bearing Filler Plug
8,9. Bearing Cup and Cone Set 24. Grease Fitting
10. Flanged Output Shaft 25. Radial Ring Set
12. Output Bearing Spacer 26. Steel Balls
13. Exterior Retaining Ring 27. Steering Ring Gear 15
14. Pipe Plug 1/2-14 31. Grease Fitting
15. SHCS 3/8-16 x 1-1/4 32. HHCS 5/16-18 x 1/2
16,17. Bearing Cup and Cone Set 33. Flat Washer 5/16
18. Lip Seal 34, 35, 36, 37. Shim Set
19. Main Cover 38, 39, 40, 41. Cover Shim Set
410029.EPS
Figure 7-43: Drive Unit 410-029R, 828-006-355 Exploded View
7-42 PDMM-0109 7/31/02

Drive and Brake Standard and Special Tools
Standard and Special Tools

Before performing any maintenance on the
drive unit, take note that special “assistant
tools” and hardware are required. Review the
following information on tools and hardware
needed before starting. Also, ensure that any
maintenance performed does not void warranty.
The drive unit servicing tools can be purchased
through your authorized Raymond Dealer.
Standard and Hand Tools Required
Bearing puller Pinion gauge Tube 12 in. diam. x 6 in. long

Bearing press Bearing heater Tube 8 in. diam. x 6 in. long
Micrometer Screwdriver Torque wrench, 150 ft. lb.
Hammer or mallet Magnetic dial indicator (210 Nm) capacity
Brass punch Pry bars
Special Drive Unit Servicing Tools

These drive unit servicing tools are required to
facilitate drive unit repair.
Drive Unit Servicing Tools

Tool Function Tool Function
TD20055 Pressing Tool. Installation of lip TD20057 Gauge Dial. To check bearing
seal (Item 18) and output preload.
bearing cup (Item 16).
TD20064 Pressing Tool. Installation of TD20055 Base. Installation of bearing cone
bearing cone (Item 17). (Item 9).
TD20053 Pressing Tool. Installation of TD20060 Pressing Tool. Installation of
bearing cup (Item 5). bearing cup (Item 5).
TD20054 Pressing Tool. Installation of TD20063 Pressing Tool. Installation of
bearing cup (Item 5). bearing cup (Item 16).
TD20065 Pressing Tool. Installation of TD20059A Backlash Checking Tool.
bearing cone (Item 6).
TD20056 Bearing Preload Gauge. TD20059B Magnetic Dial Indicator.
TD20058 Gauging Plate. Used with 410-029/ Lock Nut Wrench. Removal of the
TD20056 Bearing preload T09 clamp nut (Item 4).
gauge.
PDMM-0109 7/31/02 7-43

Troubleshooting Drive and Brake
Troubleshooting
Symptom Probable Cause Required Action Available Kits
Oil leaks Damaged lip seal Replace lip seal, main cover and Kit #1, Seal Kit.
bearing shims, and output P/N 410-029/50
shaft bearings
Worn or damaged output Replace lip seal, main cover and Kit #2, Axle Shaft Kit.
shaft bearing shims, output shaft P/N 410-029/51
bearings, and output shaft
Housing/main cover joint Reseal
Worn or damaged Replace drive unit
housing
Drive wheel Worn or damaged output Replace lip seal, main cover and Kit #1, Seal Kit.
wobbles shaft bearings bearing shims, and output P/N 410-029/50
shaft bearings
Worn or damaged output Replace lip seal, main cover and Kit #2, Axle Shaft Kit.
shaft bearing shims, output shaft P/N 410-029/51
bearings, and output shaft
Loose wheel mounting Inspect housing and main cover
hardware for damage, retorque mounting
hardware
Noise Worn or damaged output Replace lip seal, main cover and Kit #1, Seal Kit.
shaft bearings bearing shims, and output P/N 410-029/50
shaft bearings
Worn or damaged pinion Replace pinion bearings and
bearings clamp nut
Worn or damaged gear Replace lip seal, main cover and Kit #1, Seal Kit.
set - Output shaft is in bearing shims, output shaft P/N 410-029/50
good condition bearings, pinion bearings, gear Kit #3, Drive Gear
set, and clamp nut Kit.
P/N 410-029/52
Worn or damaged gear Replace lip seal, main cover and Kit #2, Axle Shaft Kit.
set - Output shaft is bearing shims, output shaft P/N 410-029/51
worn or damaged bearings, pinion bearings, gear Kit #3, Drive Gear
set, clamp nut, and output Kit.
shaft P/N 410-029/52
Worn or damaged helical Replace helical gear and pinion
gear and pinion
Steering Inadequate bearing Grease pivot bearing and
binds lubrication spherical bearing
Worn or damaged pivot Replace radial ring set, steel Kit #4, Steer Kit.
bearing balls, bearing filler plug, and P/N 410-029/53
spherical bearing
7-44 PDMM-0109 7/31/02

Drive and Brake Kit Options
Symptom Probable Cause Required Action Available Kits

Steering Worn or damaged spur Replace spur gear and spherical
binds gear bearing
Worn or damaged Replace spherical bearing and
spherical bearing grease fittings
Worn or damaged pivot Replace pivot ring, radial ring Kit #4, Steer Kit.
ring set, steel balls, bearing filler P/N 410-029/53 and
plug, and spherical bearing pivot ring
Kit Options
There are four available repair kits for drive
units 410-029R, 828-006-355. Contact your
local authorized Raymond Dealer or the
Raymond Parts Distribution Center.
! CAUTION
To ensure a high quality product, we
strongly recommend replacing all
components in a kit. For ease of
ordering, suggested kit contents and
part numbers are listed below.
Kit #1, Seal Kit. P/N 410-029/50

• Lip Seal
• Main Cover Shims
• Bearing Shims
• Output Shaft Bearings
• Cover Screws
Kit #2, Axle Shaft Kit. P/N 410-029/51
• Lip Seal
• Main Cover Shims
• Bearing Shims
• Output Shaft Bearings
• Output Shaft
• Cover Screws
Kit #3, Drive Gear Kit. P/N 410-029/52
• Bevel Gear and Pinion Set
• Helical Gear and Pinion Set
• Clamp Nut
• Pinion Bearings
PDMM-0109 7/31/02 7-45

Removal Drive and Brake
Kit #4, Steer Kit. P/N 410-029/53

• Radial Ring Kit
• Steel Balls
• Bearing Filler Plug
• Spur Gear
• Spherical Bearing
• Filler Plug Screws
• Washers
• Grease Fittings
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. (266.7
shown on a 10.5 in. (266.7 5/16 in. (8 mm) steel
mm) bolt circle (used to
mm) bolt circle plate 11.25 in. (286
separate tool from drive unit)
mm) in diameter
3323_002.eps
Figure 7-44: Drive Unit Removal/Installation Tool
Removal
2. Drain the oil from the drive unit.
7-46 PDMM-0109 7/31/02

Drive and Brake Removal
3. Loosen the drive tire lug nuts.

4. Remove the horn assembly.
5. Disconnect the power cables from the drive
motor, labeling the cables if necessary for
later installation. Use two wrenches to
avoid twisting the motor studs.
6. Disconnect remainder of wires and brake
hose.
7. Remove mounting bolts for cable bracket.
8. Remove drive motor mounting bolts. Lift
brake assembly and motor off drive unit.
9. Remove the steering shaft.
10. To facilitate the removal of the drive unit,
construct the tool shown in Figure 7-44.
Attach the tool to the top of the drive unit
using the screws which held the drive
motor.
11. Remove the dust shield between the ring
gear and the tractor frame.
! WARNING
stands beneath it to support it. DO
NOT rely on the jack alone to
12. Secure the lift truck with a suitable

capacity hoist attached to the overhead
guard. Jack the rear of tractor so that the
bottom edge of the bumper is
approximately 6½ in. (16.5 cm) off the floor.
13. Remove the drive wheel.
14. Disconnect the steer linkage from the drive
unit; swing the linkage clear (if the lift truck
has a steered idler).
PDMM-0109 7/31/02 7-47

Disassembly Drive and Brake
15. Place a temporary support under the drive

unit or attach a hoist to the tool installed in
Step 12.
! CAUTION
Drive unit weighs approximately
175 lb. (80 kg.)
16. Loosen, then remove the four mounting

screws holding the drive unit to the tractor
frame. The steering stop will also become
unattached at this stage.
17. Lower the drive unit to the floor. Tip the
drive unit over on its side and remove the
hoist.
18. If you have trouble separating the tool from
the drive unit, thread mounting screws in
the threaded holes in the tool to push the
tool off the drive unit.
Disassembly
All item numbers refer to exploded view,
Figure 7-43 on page 7-42.
Clean the outside of the drive unit thoroughly
and drain any remaining oil from the drive unit
by removing the drain plug (Item 14).
Visually inspect the outside of the housing
(Item 1) for damage, wear or cracks. 13
Pivot Ring Disassembly 21

1. On the pivot ring (Item 21), remove the
grease fitting (Item 24) and the bearing filler
plug (Item 23). Inspect the bearing filler
plug hole for uneven wear.
1018_003.tif
Figure 7-45: Remove Grease Fitting and Filler Plug
7-48 PDMM-0109 7/31/02

Drive and Brake Disassembly
2. Turn the pivot ring (Item 21) to remove the

steel balls (Item 26) through the bearing
filler plug hole.
NOTE: If the pivot ring will not spin or even
turn, it is an indication of damaged
radial rings and/or excessive wear to the
channel in housing. If this is the case,
replace the entire drive unit. No further
disassembly is necessary.
1018_002.tif
Figure 7-46: Remove Steel Ball Bearings

3. After removing all the steel balls, remove
the pivot ring (Item 21) by working it off
toward drive end of the housing.
21
1018_004.tif
Figure 7-47: Remove Pivot Ring
4. Remove the radial rings (Item 25) from the

channel in the housing and inside the pivot
ring.
25
! CAUTION
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
1018_001.tif
inspect the inside of the pivot ring.
Figure 7-48: Remove Radial Rings
PDMM-0109 7/31/02 7-49

Main Cover and Output Shaft Disassembly Drive and Brake
Main Cover and Output Shaft

Disassembly
1. Visually inspect the housing around the
main cover (Item 19) for wear outside the
cover bolts (Item 15). Refer to Figure 7-49.
See NOTE.
NOTE: Excessive housing wear outside the

cover bolts can make them difficult to
remove. If this occurs, replace the entire
drive unit. No further disassembly is
19
necessary.
2. Remove the main cover bolts (Item 15).
3. Using a mallet, knock the flanged output
shaft (Item 10) to break the seal on the
main cover (Item 19).
4. Remove the main cover and output shaft
assembly.
1018_005.tif
5. A press and 8 in. x 6 in. tube are required Figure 7-49: Remove Cover and Output Shaft
to remove the bearing cup (Item 8) on the
end of the output shaft.
! CAUTION
Always watch for pinch points when
using a press or pressing tools.
! CAUTION
Safety glasses are required after this
point in disassembly.
6. Place the main cover assembly, gear side 10

down, on the tube under press. Press the
output shaft (Item 10) down slightly to
create a space between the bevel gear 7
(Item 7) and the output bearing spacer
(Item 12).
1018_010.tif
Figure 7-50: Press Down Output Shaft
7-50 PDMM-0109 7/31/02

Drive and Brake Main Cover and Output Shaft Disassembly
7. Tighten a bearing puller clamp under the

lip of the output bearing spacer, being
careful not to catch the exterior retaining
ring (Item 13).
8. Place the main cover assembly, gear side
up, on 12 in. x 6 in. tube so the bearing
puller clamp is resting on the tube. Press
the flanged output shaft (Item 10) and the
output bearing spacer (Item 12) out.
9. Remove the exterior retaining ring
(Item 13).
1018_011.tif
Figure 7-51: Press Out Output Shaft

10. To remove the bevel gear (Item 7), support
the main cover assembly on 8 in. x 6 in.
tube under press. Press the output shaft
(Item 10) down through the bevel gear. The
bearing cone (Item 17) will be removed at
the same time.
10
1018_012.tif
Figure 7-52: Remove Bevel Gear

11. Remove the bearing cup (Item 16) from the
main cover with a race driver and pry bars.
12. Remove the lip seal (Item 18) from the main
cover.
18
1018_013.tif
Figure 7-53: Remove Bearing Cup and Lip Seal
PDMM-0109 7/31/02 7-51

Main Cover and Output Shaft Disassembly Drive and Brake
13. Remove the output shaft bearing cone (Item

9) in the base of the housing using two pry
bars. Insert the pry bars under bottom edge
of the cone on opposite sides. Apply even
pressure on both tools to lift the cone out.
14. Remove the shims (Items 34, 35, 36, 37)
from the housing bore. Save shims for
reference only, as they are usually damaged
when removing the bearing cone. New
shims are provided with Kits #1 and #2. 9
15. Remove the cover shims (Items 38, 39, 40,

41). Save the shims for reference only.
1018_009.tif
Replacement shims are provided with Kits
#1 and #2. Figure 7-54: Remove Output Shaft Bearing Cone
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
(Item 4) on the spiral pinion (Item 7). Using
Tool 410029/T09, remove the clamp nut.
1018_006.tif
Figure 7-55: Remove Clamp Nut

2. Using a brass punch and hammer, drive the
spiral pinion (Item 7) out of the housing.
NOTE: You may need to remove the spiral
pinion with a press or pressing device
equivalent.
3
1018_007.tif
Figure 7-56: Remove Spiral Pinion
7-52 PDMM-0109 7/31/02

Drive and Brake Assembly
3. Remove the helical gear (Item 3) and the

bearing cone (Item 6) from the housing.
4. Drive out the bearing cup (Item 5). Inspect
the bearing cup and housing bores for
wear.
NOTE: The bearing cups and cones are usually
damaged during removal. They must be
replaced as sets, and are included with 5
Kits #1 and #2.
Thoroughly wash the housing and visually

inspect entire housing again for excessive 1018_008.tif
damage, wear, or cracks. Figure 7-57: Remove Bearing Cup
Assembly
! CAUTION
Safety glasses are required.
Prepare the housing for assembly by running a

tap through all bolt and screw holes. Cleaning
the threads also ensures that there is no
damage.
Spiral Pinion Assembly
1. Place Tool TD20053 on the bearing cup
(Item 5). Using a press or mallet, install the
bearing cup into the housing bore.
2. Install the second bearing cup (Item 5) into
the housing bore on the opposite side using
Tool TD20054.
5
1018_014.tif
Figure 7-58: Drive In Bearing Cup
PDMM-0109 7/31/02 7-53

Assembly Drive and Brake
! CAUTION
Always watch for pinch points when
using a press or pressing tools.
3. Press the bearing cone (Item 6) onto the

spiral pinion (Item 7) using Tool TD20065
until it is seated.
Main Cover and Output Shaft

Assembly
6
1. Prior to installing the output shaft lip seal
(Item 18), apply a thin layer of sealing
adhesive around the seal surface of the
main housing, to prevent leaking. Install 7
the lip seal, spring side down, in the
housing. 1018_015.tif
Figure 7-59: Press Bearing onto Spiral Pinion

2. Using Tool TD20055, press the lip seal
(Item 18) into the housing until it is just
below flush with housing surface.
18
1018_016.tif
Figure 7-60: Press Lip Seal

3. Using Tool TD20063, press the output
bearing cup (Item 16) into main cover until
it is seated. Place the bearing cone (Item 17)
into the bearing cup.
4. Place the main cover onto ring Tool
TD20056. Push down on the bearing and
turn to seat bearing into the bearing cup.
16
1018_017.tif
Figure 7-61: Press Output Bearing Cup
7-54 PDMM-0109 7/31/02

5. Take measurement D from the edge of the

bearing cone (Item 17) to the flange surface
of main cover (Item 19). Position Tool
TD20057 onto main cover so that dial
indicator tips come into contact with flange
surface.
6. The reading on the two dial indicators
should be the same. If they are different,
repeat Steps 4 and 5 above until the
readings are identical. Record final reading
as Measurement D on flange surface. This
is required during final assembly.
1826_127.tif
7. Remove the bearing cone (Item 17) in
preparation for installing the flanged Figure 7-62: Bearing Cone to Flange Measurement
output bearing shaft (Item 10).
8. Use a light oil on the surface of the lip seal
(Item 18) and inside the bearing cup
(Item 16).
9. Place the main cover down over the output
shaft, flange side up. Place the bearing cone
(Item 17) down over the output shaft 17
(Item 10).
10
1018_021.tif
Figure 7-63: Install Main Cover and Bearing Cone

10. Using Tool TD20064, press the bearing
cone onto the output shaft.
1018_020.tif
Figure 7-64: Press on Bearing Cone
PDMM-0109 7/31/02 7-55

Assembly Drive and Brake
11. Place the bevel gear (Item 7) down over the

output shaft, teeth side up. Using Tool
TD20064, press the bevel gear down, which
seats the bearing cone (Item 16) into the
bearing cup (Item 17).
12. Install the external retaining ring (Item 13) 7
on the output shaft (Item 10). Pull up on
the bevel gear (Item 7) to make sure the
16
external retaining ring is installed securely.
13. Place the output bearing spacer (Item 12),
with the recessed area down, over the
output shaft. Place the bearing cone
1018_022.tif
(Item 9) on top of the output shaft.
Figure 7-65: Press on Bevel Gear
14. Using Tool TD20055, press the bearing
cone (Item 9) down until it is fully seated
against the spacer and snap ring.
9
12
1018_023.tif
Figure 7-66: Press Down Bearing Cone

15. Place the main cover assembly, flange side
up, on Tool TD20056. Press the bearing
cone (Item 9) into place with Tool TD20055.
At the same time, pull the gear sideways to
eliminate any backlash in the spline area.
9
16. Place bearing cup (Item 8) onto bearing and
rotate cup while applying downward
pressure to seat bearing.
1018_024.tif
Figure 7-67: Eliminate Backlash
7-56 PDMM-0109 7/31/02

17. Position Tool TD20058 onto the main cover

so that the dial indicator 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 above
until the readings are identical.
18. Record final readings as Measurement E.
This is required during final assembly.
Helical Gear Assembly

NOTE: The pinion shaft and bevel gear are a
matched set. Their alignment is critical. 1826_130.tif
Do not replace them separately. Figure 7-68: Bearing Cup to Flange Measurement
! WARNING
Bearing can become extremely hot.
Use gloves to protect hands from
burns.
1. Preheat the bearing cone (Item 6) with a

bearing heater. Install the heated bearing
cone in the bearing cup (Item 5) in the
housing.
2. Place the helical gear (Item 3) into the
housing. 4
3. Install the spiral pinion (Item 7) up through
3
the helical gear (Item 3).
4. Put the clamp nut (Item 4) on the end of the
spiral pinion (Item 7) and hand tighten
until the bearing cools.
NOTE: Steps 2 through 4 need to be completed 1018_027.tif
before the bearing cools. Figure 7-69: Install Helical Gear and Pinion
5. While the bearing cone (Item 6) is cooling,

calculate the formula for determining the
required shim (Items 34, 35, 36, 37)
thickness.
PDMM-0109 7/31/02 7-57

Installing and Testing Shims Drive and Brake
Calculate Shim Formulas

• 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 to flange surface
• E = Distance from bearing cup to flange
surface
1826_127.tif
Figure 7-70: Bearing Cone to Flange Measurement

S1 = (B - A - E + D + C)
S1 = Shim amount behind bearing cup in
main housing to position gear for proper
backlash (S1).
S2 = E + S1 - B - 0.006 preload
S2 = Shim amount between cover plate face
to set preload of bearings for output
shaft (S2).
1826_130.tif
Figure 7-71: Bearing Cup to Flange Measurement
Installing and Testing Shims

1. Remove any end play in the bearings
between the helical gear (Item 3) and the
spiral gear (Item 7) using lock nut wrench.
Wedge the helical gear, and tighten the
clamp nut (Item 4) until there is no end
play between the gears.
2. Preload the helical gear (Item 3) for 0.000 to
0.002.
3. Remove any oil from the clamp nut (Item 4).
Apply thread locking compound
(P/N 990-544) to the threads in the clamp 1018_028.tif
nut. Tighten the set screw in the clamp nut Figure 7-72: Remove End Play
to 140 in. lb. (15.8 Nm).
4. Spin the helical gear (Item 3) to ensure that
the bearings are not too tight.
7-58 PDMM-0109 7/31/02

Drive and Brake Installing and Testing Shims
5. One tooth on the spiral gear (Item 7) is

etched or marked with an X. With a marker,
mark that tooth surface for the purpose of
lining up the spiral and bevel gears (Item 7)
to check backlash. One tooth on the
matching bevel gear is also marked. Mark
that tooth surface also. 7
1018_029.tif
Figure 7-73: Mark Spiral and Bevel Gears

6. Place the predetermined shims (Items 34,
35, 36, 37) into the housing bore for the
bearing cup (Item 8). Install the bearing cup
into the housing bore over the shims, using
Tool TD20060.
7. Install the cover shims (Items 38, 39, 40, 38
41). 39
40
41
1018_030.tif
Figure 7-74: Install Cover Shims

8. Place the main cover assembly over the
shims, being sure to line up the marked
teeth on both the spiral and bevel gears
(Item 7).
9. Put in four housing cover bolts (Item 15),
7
evenly spaced, and tighten to 40 ft. lb.
(54 Nm).
1018_031.tif
Figure 7-75: Line Up Spiral and Bevel Gears
PDMM-0109 7/31/02 7-59

Installing and Testing Shims Drive and Brake
Measuring Backlash
NOTE: Backlash tolerance is critical to the
performance of the drive unit.
Improperly adjusted units will
experience premature failure.
1. Wedge the helical gear (Item 3), then
slightly turn the output shaft to determine
backlash. Backlash reading on the dial
indicator, Tool TD20059A & B, should be
between 0.004 and 0.006.
2. Calculate any necessary adjustments to the
shims. Remove the main cover assembly 1826_131.tif
and the bearing cup, and adjust the shims. Figure 7-76: Backlash Measurement
Repeat Steps 6 through 9 “Installing and
Testing Shims” until backlash is between
0.004 and 0.006.
3. When backlash is within acceptable range,
remove the main cover assembly and the
cover shims.
Main Cover Installation

1. Clean the cover mating surface on the
housing, then apply thread locking
compound (P/N 990-411) sparingly.
2. Install the cover shims (Items 38, 39, 40,
41) and the main cover assembly. Install
the main cover bolts (Item 15), and torque
to 40 ft. lb. (54 Nm).
7-60 PDMM-0109 7/31/02

Drive and Brake Installing and Testing Shims
! CAUTION
Safety glasses are required.
Pivot Ring Assembly

1. On the inside of the pivot ring (Item 21), be
sure the roll pins (Item 22) are installed and
in good condition on either side of the
bearing filler plug hole. If they are missing 21
or damaged, install new roll pins.
2. Install the grease fitting (Item 31) on the
outside of the pivot ring.
22
3. Screw in the grease fitting (Item 24) in the
bearing filler plug.
1018_035.tif
Figure 7-77: Install Roll Pins

4. Using radial rings (Item 25), install the flat
radial ring on the inside flat surface of the
pivot ring. Place the ends of the chamfered
radial rings against the roll pins (Item 22) to
install them in the pivot ring.
25
22
1018_036.tif
Figure 7-78: Install Radial Rings
5. On the housing, install the radial rings
(Item 25). Refer to Figure 7-79.
6. Lift the drive end of the housing and slide
the pivot ring over the housing. Be careful
not to jar the radial rings out of place. Slide
the pivot ring into place just behind the
steering gear.
7. Ensure that the pivot ring bearing filler 25
plug hole is on top, in preparation for
installing the steel balls (Item 26).
1018_037.tif
Figure 7-79: Install Outer Radial Rings
PDMM-0109 7/31/02 7-61

Installation Drive and Brake
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. Fit
the bearing filler plug (Item 23) with the
grease fitting pointing toward the steering
gear.
26
1018_038.tif
Figure 7-80: Install Ball Bearings
! CAUTION
Excessive thread locking compound 32
will damage the ball bearings and

pivot ring. Use thread locking 33
compound sparingly.
9. Apply thread locking compound 23

(P/N 990-536) sparingly to the filler plug
bolts (Item 32). Install the bolts and 1018_040.tif
washers (Item 33) on either side of the Figure 7-81: Install Bearing Filler Plug
bearing filler plug (23) and tighten to 20 ft.
lb. (27 Nm).
10. Grease and then test the pivot ring,
checking to see that it spins freely.
Installation
1. Place the new drive unit in position.
(P/N 990-544) to the drive unit mounting
bolts. Install and torque the drive unit
mounting bolts to 130 ft. lb. (176 Nm).
(P/N 990-536) to the steer linkage bolt
threads. Reconnect the steering linkage.
Torque bolts to 150 ft. lb. (204 Nm).
4. Reinstall the steering shaft and hydraulic
motor.
5. Refill the drive unit with the correct type
fluid. Add fluid until level reaches the
bottom of the helical gear.
7-62 PDMM-0109 7/31/02

Drive and Brake Installation
6. Install the drive motor and brake. Use

silicone sealing compound between drive
motor and drive unit.
7. Install mounting bolts for drive motor and
drive unit and toque to 13 ft. lb. (17.6 Nm).
8. Connect cables, wires, and brake line.
Torque motor cables to 18 ft. lb. (24.4 Nm).
9. Bleed brake system.
10. Install the drive unit dust shield.
11. Install the drive wheel. Torque the drive tire
lug bolts to 170 ft. lb. (230 Nm).
12. Install the horn assembly.
13. Check the drive unit fluid level.
14. Test the brake for proper operation.
PDMM-0109 7/31/02 7-63

Drive Motor Drive and Brake
Drive Motor
Removal
1. Remove the external brake fluid reservoir
for better access. Secure it temporarily by Brake
Brake
mounting backwards outside the motor
compartment. See Figure 7-82.
2. Remove the horn to prevent damage when
hoisting the motor.
3. Rotate the drive unit fully counter clockwise
and remove the two exposed drive motor
mounting bolts, flat washers, and sealing
washers.
Connectors
4. Rotate the drive unit to the midpoint. Turn JPT2
the key switch OFF and disconnect the JPT3
battery connector.
5. Disconnect the power cables from the drive
motor, labeling the cables if necessary for Threaded
Release
later installation. Remove the bracket from Hole (see
the motor. text)
6. Remove the brake assembly. See “Brake” on
page 7-68.
Mounting
7. Remove the drive unit dipstick to avoid Bolt (4)
damage when removing the motor.
8. Remove the remaining drive motor 4155_013.TIF
mounting bolts, flat washers, and sealing Figure 7-82: Drive Motor Removal
washers.
9. To break the sealant seal between drive
motor and drive unit, insert a bolt into the
threaded hole in the mounting plate below
the electrical connections. Turn the bolt
until the motor flange breaks free. See
Figure 7-82.
10. Secure a hoist to the drive motor with a
threaded lifting eye ring on the motor shaft.
! CAUTION
Drive motor weighs approximately
125 lb. (57 kg).
11. Using the hoist, lift the drive motor out of

the drive unit and lower it on its side on the
floor.
7-64 PDMM-0109 7/31/02

Drive and Brake Drive Motor
12. To prevent contamination, install a

temporary cover over the drive motor
opening.
Installation
1. Before installing the drive motor, ensure the
pinion gear is installed on the shaft. Apply
the drive motor armature shaft lock nut
and torque to 85 ft. lb. (115 Nm).
2. Remove the temporary cover over the drive
motor opening in the drive unit.
3. Apply a generous coating of RTV silicone
gasket sealing compound (P/N 990-659) to
the drive motor and drive unit mating
surfaces. Do not allow gasket sealing
compound to plug holes in motor flange
or drive unit.
4. Secure a hoist to the drive motor with a
threaded lifting eye ring on the motor shaft.
! CAUTION
Drive motor weighs approximately
125 lb. (57 kg).
5. Using the hoist, carefully lift the drive

motor into position and lower it, meshing
the pinion gear with the drive unit gear.
6. Install drive motor mounting bolts, flat
washers, and sealing washers. Use new
sealing washers under the flat washers.
Torque to 13 ft. lb. (17.6 Nm).
PDMM-0109 7/31/02 7-65

Drive Motor Drive and Brake
7. Install the drive unit dipstick holder and

dipstick.
8. Install the brake assembly. See “Brake” on
page 7-68.
9. Attach the drive motor cable support
bracket. Ensure cables are routed so they
do not rub on any adjacent structures
when the drive unit turns during steering.
4612_020.TIF
Figure 7-83: Two wrenches on motor terminals

10. Connect the drive motor cables to the
appropriate terminals. Use a second
wrench on the stud terminal securing nut
to avoid twisting the motor studs. See
Figure 7-83. Torque motor cable securing
nuts to 18 ft. lb. (24.4 Nm). Reference All cables tied
“Terminal Nuts” on page 7-96.
One power
! CAUTION cable and
brake hose
Do not attempt to repair power cable tied
terminal lugs. If a power cable has
worn or damaged lugs, replace the
cable. Do not substitute other kinds
of nuts for the flanged nuts. Failure
to use proper cables, flanged nuts, Two power
and torque values can result in cables tied
overheating and damage to
components.
Two power
11. Ensure the power cables are cable tied in a cables and
flat bundle to prevent interference as the wire harness
motor rotates. Tie only two power cables at tied
a time below the cable support bracket. See
Figure 7-84. 4514_031.TIF
Figure 7-84: Cable routing and ties

12. Reinstall the horn.
13. Re-attach the brake fluid reservoir.
the key switch ON.
7-66 PDMM-0109 7/31/02

Drive and Brake Drive Motor
15. Rotate the drive unit fully counter

clockwise. Ensure there is no binding of
cables or wiring, or interference with
cables.
16. Rotate the drive unit fully clockwise.
Ensure there is no binding of cables or
wiring, or interference with cables.
17. Check controls for proper operation.
PDMM-0109 7/31/02 7-67

Brake Drive and Brake
Brake
Brake Assembly Cap Screws (3)
Spacer Bleeder Nipple
Upper Pad/Plate
O-ring Seals Spring (12) Mounting Screws (4)
Piston
Jam Nut
Pad Rotor Pressure Plates (2)
Shoulder (Mounting) Bolt (3)
Adjuster Bushing
870_922_001A.EPS 870_922_001B.EPS
Figure 7-85: Brake cross-section
7-68 PDMM-0109 7/31/02

Drive and Brake Brake Adjustment
Brake Adjustment
2. Open the drive motor compartment door.
3. Check for proper deadman pedal height
(3.0 to 3.5 inches or 76 to 89 mm).
4. When proper brake bleeding has occurred,
there will be a minimum 0.035 in. gap
between brake body and top pressure plate.
Jam Nut
5. Bleed the brake if necessary. See “Bleeding
Brake” on page 7-75.
6. Check for 0.008 in. gap between adjuster Pressure
bushings and motor housing. Plate
7. To adjust gap, loosen the jam nuts on the Adjuster

three adjusters.
8. With the deadman pedal released (up), turn Gap
each adjuster to obtain a 0.008 in. gap
between adjuster and motor housing. See Motor Housing
Figure 7-86 this page and Figure 7-90 on 870_922_001A.EPS
page 7-71. Figure 7-86: Brake adjustment
9. While holding the adjuster with one
wrench, tighten the jam nut on each
adjuster with another wrench.
Brake Pad Inspection

Cap Screws (3)
The thickness of the brake pad and the steel and Spacers
bracket they are attached to should not be less
than 0.080 in. (2 mm). When new, the
thickness of the brake pads and the steel
carrier bracket they are attached to should be
0.156 in. (3.96 mm).
Shoulder Bolts
4155_010.TIF
Figure 7-87: Upper Brake Pad Removal
PDMM-0109 7/31/02 7-69

Upper Brake Pad Replacement Drive and Brake
Upper Brake Pad Replacement

NOTE: If replacing only the upper brake pad,
use the procedure below. If replacing
both brake pads, see "Brake Assembly"
on page 7-72.
Removal
2. Remove and cap the brake hydraulic line.
3. From the top side of the brake assembly, Shoulder Bolts Upper Pad
remove the three cap screws and spacers Plate
holding the brake together. See (upside
down to
Figure 7-87. Remove the piston and top show pad
brake pad assembly. surfaces)
4. From the bottom side of the upper brake
pad assembly, remove the four screws
holding the upper pad assembly to the
piston. Remove the upper brake pad plate.
Pressure Plate
Installation
Bleeder
! CAUTION
Avoid contamination of brake pads
or rotor by grease, oil, or brake fluid Hydraulic
Fitting Mounting
when servicing brake. Bolt Hole
Shoulder
Bolt Hole
(P/N 990-403) to the four screws and Springs
Piston
attach the upper brake pad plate to the (12)
Assembly
piston, ensuring alignment of all brake 4155_038.TIF
mounting holes in piston and plate. Figure 7-88: Brake, disassembled
2. Install the piston and upper brake pad
plate assembly over the rotor and lower
brake pad plate.
3. Install the three brake assembly bolts and
spacers, torquing the bolts to 21 ft. lb.
(28.5 Nm).
4. Connect the brake line. Bleed the brake as
described under "Bleeding Brake" on
page 7-75.
NOTE: Proper master cylinder operation will
enable 0.030 to 0.040 in. (0.762 to 1.016
mm) of total brake rotor/pad gap. If not,
7-70 PDMM-0109 7/31/02

Drive and Brake Upper Brake Pad Replacement
recheck pedal height and, if necessary,

bleed the brake system.
5. Set the brake gap by adjusting the three
adjuster bushings to obtain a gap of 0.008
Brake
inch (0.203 mm) between the bushing and
Rotor
the shoulder of the motor. See Figure 7-90.
While holding the adjuster with one
wrench, tighten the jam nut on each
adjuster with another wrench.
6. Attach the motor cable bracket to the
motor. Apply thread-locking compound
(P/N 990-536) to the bolts.
7. Attach the cable bundle to the cable
bracket with cable ties. Apply four cable
ties around the bracket itself, plus one
above and one below the bracket. Ensure
brake operates properly and is not bound
by the cables.
the key switch ON.
4155_039.TIF
Figure 7-89: Brake Rotor, Piston Assembly removed

9. Test the brakes in a safe area. With a full
load and traveling at full speed, the lift
truck should stop within 8 to 10 feet (2.4 to
3.0 m), depending on the load, floor, and
tire conditions.
Jam Nut
Bushing
0.008 in. gap
(see text)
Motor Shoulder
4155_010.TIF
Figure 7-90: Brake Gap, setting
PDMM-0109 7/31/02 7-71

Brake Assembly Drive and Brake
Brake Assembly
Shoulder
Removal Bolt Hole
1. Remove the cable bracket.

2. Remove and cap the brake hydraulic line
and brake fitting.
3. Remove the snap ring above the brake
rotor.
4. Remove the 3 shoulder bolts securing the
brake to the drive motor.
5. Using a brake puller tool threaded for M6,
remove the brake assembly from the lift
truck.
Disassembly
1. From the top side of the brake assembly,
remove the three bolts and spacers holding 4155_042.TIF
the brake together. Figure 7-91: Brake Assembly Removal
2. Remove the lower brake pad assembly.
Observe the orientation of the rotor with
respect to the brake assembly. Note that
the brake puller holes in the rotor are
counteredbored on the bottom side (facing
the motor).
3. From the bottom side of the upper brake
pad assembly, remove the four screws
holding the upper pad assembly to the
piston. Remove the upper brake pad
assembly.
Assembly
! CAUTION
Avoid contamination of brake pads
or rotor by grease, oil, or brake fluid
when servicing brake.

(P/N 990-403) to the four screws and
attach the upper brake pad plate to the
7-72 PDMM-0109 7/31/02

Drive and Brake Brake Assembly
piston, ensuring alignment of all brake

mounting holes in piston and plate.
2. Assemble the upper brake pad assembly,
rotor, and lower brake pad assembly to the
piston. Ensure that the rotor is positioned
with the threaded brake puller holes facing
the top.
3. Install the three brake assembly bolts and
spacers, torquing the bolts to 16 ft. lb.
(22.6 Nm).
Installation
1. Install a new snap ring on the lower snap Snap Ring Motor
Shaft Key
ring groove on the drive motor shaft. See
Figure 7-92.
2. Install the key on the motor shaft. See
Figure 7-92.
3. Install the brake assembly on the drive
motor shaft. Orient the brake so that, with
the drive wheel positioned straight ahead,
the brake hydraulic fitting is in a 5 o’clock
position.
4. Insert three brake mounting shoulder bolts.
Ensure the bolts go through the bushings
in the lower brake pad plate. Torque to
16 ft. lb. (22.6 Nm).
5. Reinstall the snap ring in the upper groove
in the drive motor shaft.
6. Connect the brake line. Bleed the brake as 4155_041.TIF
described under "Bleeding Brake" on Figure 7-92: Brake Installation, Snap Ring and Motor Key
page 7-75.
NOTE: Proper master cylinder operation will
enable 0.030 to 0.040 in. (0.762 to
1.016 mm) of total brake rotor/pad gap.
If not, recheck pedal height and, if
necessary, bleed the brake system.
7. Set the initial brake gap by adjusting the
three adjuster bushings to obtain a gap of
0.008 inch (0.203 mm) between the
bushing and the shoulder of the motor (see
Figure 7-90 on page 7-71). Tighten the jam
nuts on the bushings.
8. Attach the motor cable bracket to the
motor. Apply thread-locking compound
(P/N 990-536) to the bolts.
9. Attach the cable bundle to the cable
bracket with cable ties.
PDMM-0109 7/31/02 7-73

Brake O-ring Seal Replacement Drive and Brake
10. Test the brakes in a safe area. With a full

load and traveling at full speed, the lift
truck should stop within 8 to 10 feet (2.4 to
3.0 m), depending on the load, floor, and
tire conditions.
Brake O-ring Seal Replacement

It is not necessary to remove the entire brake
assembly from the lift truck to replace the
O-rings within the unit.
Removal
1. Follow all the removal steps for "Upper Shoulder Bolts Upper Pad
Brake Pad Replacement" on page 7-70. Plate
2. On the top side of the piston assembly, (upside
down to
scribe a witness mark showing location of
show pad
pressure plate with respect to the piston surfaces)
assembly. Note the number of threads
showing above the pressure plate.
3. Unscrew the pressure plate. Remove the
springs. Remove the brake bleeder nipple to
obtain a flat surface on the housing. Pressure Plate
4. Invert the piston assembly and drive the

piston from the bore. Bleeder
5. Remove the old O-rings.
Installation Hydraulic
Fitting Mounting
Bolt Hole
! CAUTION Shoulder
Avoid contamination of brake pads Bolt Hole
or rotor by grease, oil, or brake fluid
Springs
when servicing brake. (12)
Piston
Assembly
1. Coat new O-rings with new DOT-5 brake
4155_038.TIF
fluid and install them.
Figure 7-93: Brake, disassembled
NOTE: Both new O-rings must have the
following ID markings: 1 large white and
2 small yellow dots.
2. Install the piston into the bore. Be careful
not to damage the seals.
3. Install the springs in the holes on the top of
the piston.
4. Install the bleeder nipple previously
removed.
7-74 PDMM-0109 7/31/02

Drive and Brake Bleeding Brake
5. Screw the pressure plate on top of the

piston to the depth noted in removal step 2
and align with the witness mark made in
removal step 2.
6. Follow all the installation steps for "Upper
Brake Pad Replacement" on page 7-70.
Bleeding Brake
1. Attach a clear plastic bleeder hose to the
bleeder nipple on the top of the brake
assembly. Place the free end of the bleeder
hose into the fluid in the reservoir.
2. Loosen the bleeder nipple.
3. Depress the deadman pedal.
4. With the deadman pedal depressed, tighten
the bleeder nipple.
5. Repeat steps 2-4 until a solid stream with
no bubbles flows from the cylinder.
6. With brake properly bled, there should be a
gap of 0.030 to 0.040 in. (0.762 to
1.016 mm) between the brake body and the
top pressure plate.
7. Refill the master cylinder to the fill line with
DOT-5 brake fluid.
8. Tighten the bleeder nipple to 9 ft. lb.
(12 Nm).
PDMM-0109 7/31/02 7-75

Deadman (Brake) Pedal Drive and Brake
Deadman (Brake) Pedal

Correct brake operation depends on proper
functioning and adjustment of the deadman
pedal. Thoroughly clean around and beneath
the deadman pedal to insure freedom of
movement.
Inspection
Clean debris from around and beneath the
deadman pedal to ensure full travel of the
pedal.
Adjustment
1. Check the condition of the return spring.
2. Check the pedal mounting pivots and
bearings for tightness and condition
3. Adjust the tension nut so the deadman
switch activates when the pedal is
approximately halfway through the total
travel. The compressed length of the return
spring must be between 1.75 and
1.94 inches (44.5 and 49.3 mm).
4. Adjust the deadman switch so the switch
engages when the top of the deadman pedal
is at 50% to 80% of full height,
approximately 1.63 to 2.60 inches (41 to
66 mm) from the compartment floor.
5. Measure the distance from the top of the
deadman pedal to the floor of the operator
compartment. If the dimension does not
match the table below, inspect the pedal
and linkage for deformation or damage and
replace as needed.
Series EZ-D Series DZ-D

3.5 inches 3.0 to 3.25 inches
(89 mm) (76 to 82.5 mm)
6. Fill the brake fluid reservoir to the fill line.

Use only DOT-5 brake fluid (P/N 990-625).
7-76 PDMM-0109 7/31/02

Drive and Brake Inertial Dampener
Inertial Dampener
NOTE: It is critical that the A-frame up travel
stop bolt be adjusted properly. Failure to
do so will result in damage to the inertial
dampener. See “Steerable Caster” on
page 7-21. If extra A-frame travel is
required such that stop bolt adjustment Cover Plate
cannot be maintained, the inertial
dampener must be removed.
Removal
5077_034.TIF
Figure 7-94: Inertial Dampener Cover Plate
2. Loosen and remove the inertial dampener
lock nuts, spring retainer, two springs, and Dampener
DampenerSpring
Spring
friction plate. See Figure 7-95. (1
(19/16
9/16in.
in.or
or40
40
3. If necessary, turn the A-frame down-travel
adjustment bolt clockwise until there is Spring
clearance between the dampener bolts and Retainer Friction
the bottom of the slot in the slide plate. See Plate
Figure 7-96 this page and Figure 7-100 on
page 7-79.
4. Remove the cap screws holding the slide
plate mounting bracket to the frame.
Remove the bracket. See Figure 7-96.
Lock Nut
13Y7S001.TIF
Figure 7-95: Inertial Dampener (unrelated parts removed

for clarity)
5. Loosen the A-frame down-travel adjustment
bolt and remove the bolt and washers.
Cap Screws
A-frame
Spring Slide
Plate
A-frame Down-Travel
Adjustment Bolt
13Y7S002.TIF
Figure 7-96: Inertial Dampener (nuts, retainer, springs,

friction plate removed)
PDMM-0109 7/31/02 7-77

Inertial Dampener Drive and Brake
Friction Plate
! WARNING
Shoulder
feet clear from vehicle while jacking Bolt
stands beneath it to support it. DO 13Y7S004.TIF
Figure 7-97: Inertial Dampener (A-frame springs, slide

NOT rely on the jack alone to plate removed)
6. Jack the tractor up approximately 2 in.
(5 cm.) at the tractor frame and block. See A-frame Friction Plate
Figure 7-98. Down-Travel
Adjustment
7. Remove the A-frame springs. See Bolt Hole
Figure 7-96 on page 7-77 and Figure 7-97
this page.
8. Remove the shoulder bolt holding the
friction plate to the A-frame yoke. See
Figure 7-97 and Figure 7-98.
Installation and Adjustment

Shoulder Bolt Thread-Locking
1. Apply thread-locking compound Compound
(P/N 990-536) only to the threaded half of 13Y7S005.TIF
the dampener A-frame yoke. Do not apply Figure 7-98: Inertial Dampener (jacked up for shoulder bolt
thread locking compound to the shoulder removal)
bolt, as compound could be carried to the
bolt shaft, binding the pivot. See
Figure 7-98.
2. Attach the friction plate to the A-frame yoke
with the shoulder bolt, and torque to
13 ft. lb. (17.6 Nm).
3. Install the A-frame springs. Lower the lift
truck slightly on the jack to seat the springs
in their retainer holes.
4. Install the A-frame down-travel adjustment
bolt with the plastic washer between the
metal washer and the frame. Tighten until
the distance between the top of the A-frame
and the bottom of the A-frame spring upper
weldment is 7 in. (17.7 cm).
7-78 PDMM-0109 7/31/02

Drive and Brake Inertial Dampener
5. Attach the slide plate over the dampener

bolts. Apply thread locking compound Dampener Slide Plate
(P/N 990-536) to the threads in the frame. Spring
Attach the slide plate mounting bracket to
the frame with the two cap screws. Pivot Spring
joint on mounting bracket should be free to Retainer
flex. Add shims (P/N 850-432/004)
between bracket and frame as required. See
Figure 7-100. Torque the slide plate
mounting cap screws to 13 ft. lb. (17.6 Nm).
Lock Nuts
Friction Plates
13Y7S007.TIF
Figure 7-99: Inertial Dampener parts

6. Unblock and lower the lift truck to the floor.
7. Attach the friction plate, two springs, Pivot Joint Slide Plate
spring retainer, and two lock nuts.
Reference Figure 7-99 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 7-95 on
page 7-77.
8. Adjust the caster. See “Steerable Caster” on
page 7-21.
Add Shims Friction Plate
Clearance Here
Here
13Y7S008.TIF
Figure 7-100: Inertial Dampener adjustment
PDMM-0109 7/31/02 7-79

Inertial Dampener Drive and Brake
7-80 PDMM-0109 7/31/02

Electrical Components
Electrical Components
PDMM-0109 7/31/02 7-81

Battery Procedures Electrical Components
Battery Procedures
! CAUTION
Before working on the battery,
review Battery Safety, beginning on
Page 2-7. Batteries for this lift truck
weigh between 2300 and 2900 lb.
(1044 to 1316 kg). Use extreme care
during replacement. Use a suitable
battery moving device or hoist for
lifting. Do not extend a battery more
than 1/3 of its length outside the
battery compartment without being
attached to a battery-moving device.
Battery Connector/Cables
Inspection
2. Check the battery connector for damaged
cables. 74155_026.TIF
3. Check to see if battery cables are pulling Figure 7-101: Battery Disconnect Block
out of the connector.
4. Check the cables at the battery terminals.
Connections should be tight, with no
corrosion.
5. Look inside the connector. Check all
internal contacts for damage, dirt, or
corrosion. DO NOT use a metal object to
clean the connector.
7-82 PDMM-0109 7/31/02

Electrical Components Battery Rollers
! CAUTION
Some degreasers and parts cleaners
will cause the connector shell to
disintegrate. Avoid contacting
battery connectors with solvents.
Removal, Replacement, and

Installation
The cables to either half of the connector have a
7BATTCON1.TIF
lip on their forward end. This lip snaps over a
Figure 7-102: Battery Cable Removal from Connector
spring-loaded retainer which is part of the
connector.
! WARNING
When replacing battery cable ends,
remove only one end at a time from
the connector, to avoid the cable
ends touching and causing a short
circuit. Do not allow the metal cable
end to touch the battery. Use
insulated tools and avoid contact
with battery case or cable ends.
7BATTCON2.TIF
Figure 7-103: Battery Cable and Connector
1. To remove a cable from the connector, you
must push the retainer down while pulling
the battery cable towards the rear and out
of the connector. See Figure 7-102 and
Figure 7-103.
2. Crimp new cable end, following
manufacturer’s recommended procedure.
Battery Rollers
Inspection
Inspect the battery rollers to ensure they can
turn freely. Clean off electrolyte using a
solution of 1 lb. (0.45 kg) of baking soda added
to 0.5 gal. (1.9 liters) of hot water.
PDMM-0109 7/31/02 7-83

Battery Exterior Cleaning Electrical Components
Battery Exterior Cleaning

Battery Cable
1. Read, understand, and follow procedures,
recommendations and specifications in the
battery and battery charger manufacturer’s
manuals.
2. Wear personal protective equipment. See
“Battery Safety” on page 2-7.
the battery connector. Remove the battery
from the lift truck. See “Battery - Removal”
above. Filler Plug
Vent Hole
4. Inspect the battery cables to make sure
they are not frayed or loose. Inspect the 709G6S047.TIF
battery connector to ensure there is no Figure 7-104: Battery Cable and Filler Plug
foreign material inside the connector. Make
sure the filler plugs are tight and the vent
holes in the filler plugs are open.
5. Keep the top of the battery clean and dry.
Corrosion, dust, and moisture provide a
conducting path to short-circuit cells or
create shorts to ground.
! CAUTION
Do not clean the top of the battery
with the soda solution while it is
installed in the lift truck. Water can
seep into the electrical components
and cause serious damage.
6. Wash dirty batteries (or any that have had

electrolyte spilled on them) with a solution
of 1 lb. (0.45 kg) of baking soda added to
0.5 gal. (1.9 liters) of hot water.
7. Use a brush with flexible bristles to clean
the entire top of the battery with the soda
solution. Wait until all foaming stops,
indicating that the battery exterior is
neutralized.
8. Rinse the battery with clean water.
9. Dry the battery completely before
reinstalling it.
10. Reinstall the battery in the lift truck, using
a suitable battery moving device. Reconnect
7-84 PDMM-0109 7/31/02

Electrical Components Testing, Charging, and Maintenance
Testing, Charging, and

Maintenance
For information on testing, charging, and
maintaining your lift truck battery, consult the
battery manufacturer’s specifications and
instruction manual.
725L6S014.EPS
! CAUTION
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.
72823_011.EPS
PDMM-0109 7/31/02 7-85

Wiring and Harness Connectors Electrical Components
Wiring and Harness

Connectors
General Repair Procedures
Inspection
See “Electrical Troubleshooting Guidelines” on
page 5-3.
Whenever working on the lift truck, use care
around wiring harnesses.
• Carefully connect and disconnect all
connections.
• Do not pry connectors apart with
unspecified tools.
There should be a wire marker at each
termination. If the marker is missing or
unreadable, remark the wire to allow easier
identification.
NOTE: It is normal to find unused connectors
for uninstalled options that have had
heat shrink applied over them and have
been strapped to the harness.
Repair
! CAUTION
on page 2-11.
When pulling a wire out through a bundle, cut

off the pin or socket so it will not snag. When
replacing wires, in some cases you will be able
to tape or solder one end of a new wire to one
end of the failed wire. Then you can pull the old
wire out of the bundle and pull the new wire
into the bundle, all at the same time. Be sure to
disconnect the old wire from the new wire.
In other cases, it will be easier to secure a new
wire to the outside of the existing wire bundle
with straps of an appropriate size. The failed
wire can be left in the bundle, or can be pulled
by one end to remove it from the bundle.
7-86 PDMM-0109 7/31/02

Electrical Components General Repair Procedures
When replacing wires, follow these guidelines:

• Use the appropriate tools to remove and
insert terminations at each connector.
• Remove damaged terminations and discard.
Never reuse a termination from a wire.
• Do not cut away a terminal lug and reuse
the wire strands that were crimped into the
original lug.
• When stripping wire, use new wire strands
for new terminations. Be sure to use a new
wire with extra length to allow for cutting
and stripping of the ends to install new
terminations.
• Use a new wire that is the same gauge
(typically 18 gauge AWG), size, type, and
color as the wire it is replacing.
• Use a hand stripper capable of stripping by
wire gage number. Use care not to nick or
cut any of the wire strands. Discard and
replace a wire with damaged strands. Insert
the wire strands the proper length into
termination before crimping.
PDMM-0109 7/31/02 7-87

Soldering Procedures Electrical Components
Soldering Procedures
To prevent damage from excessive heat when
soldering small components in assemblies,
follow these guidelines.
Be sure the soldering tip is clean. A dirty tip
does not transfer heat well and encourages long
dwell time and greater pressure. Apply light
pressure on the terminal.
• Flux: rosin base
• Solder: 60/40 rosin core or equivalent
• Solder Iron: 55 watt maximum
• Tip Size: 3 mm (0.118 in.) diameter x
30 mm (1.182 in.) long screwdriver tip.
• Tip Temperature: 260°C (500°F) maximum
• Terminal Contact Time: 6 seconds
maximum
• After soldering, clean the terminals with a
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.
NOTE: Components damaged due to solvent
saturation will not be covered under
warranty.
Molex Connectors
For pin orientation of Molex connectors, see
Figure 6-2 on page 6-69. Molex connectors have
pins with locking ears which engage ridges in
Socket
the plastic connector body. To remove a pin
from a Molex connector, these locking ears
must be depressed far enough to clear the ridge
in the connector. Pin
Pin Extraction
To remove a pin from a Molex connector, use
pin extraction tool P/N 950-026.
1. Insert the extraction tool over the pin and Locking
Ears
push all the way into the connector. This
7MOLEX.EPS
releases the locking ears on the pin.
Figure 7-105: Molex Connector, end view
2. Pull the wire and pin from the connector.
7-88 PDMM-0109 7/31/02

Electrical Components Molex Connectors
Pin Insertion
To insert a pin into a Molex connector, insert
the pin into the back side of the connector and
push the wire all the way in until it clicks. The
locking ears have now engaged the connector.
Top view
of Tool inserted over
connector pin
Extraction
Locking Tool
ears
Side view
of
connector
7MOLEX1.EPS
Figure 7-106: Pin Extraction
PDMM-0109 7/31/02 7-89

AMP Water-Resistant Connectors Electrical Components
AMP Water-Resistant
Connectors
Wire Seal
Interface
Seal
Contact
Cavity
Wire Seal Jack

Housing
Pin Contact
Pin Housing
Sealing Plug
74570_001.TIF
Figure 7-107: AMP Connector
Pin Extraction
To aid in separating AMP connectors, use
unlatching tool Raymond P/N 950-042. To Extraction Tool
remove a pin from an AMP connector, use pin
extraction tool Raymond P/N 950-009.
Locking
Lance
74570_009.TIF
Figure 7-108: AMP pin extraction
7-90 PDMM-0109 7/31/02

Electrical Components Motors
Motors
DC Motor Brushes
Inspection
Conduct a partial inspection of the motor after
every 250 hours of lift truck operation, as
indicated by the deadman hour meter (HD). If
the lift truck is operated in a severe or extreme
environment or a rigorous duty cycle, inspect
the motor more frequently. See “Maintenance
Guidelines” on page 4-2.
Set up and rigidly adhere to a strict inspection
schedule to obtain the maximum efficiency
from the electrical equipment. 7MTRBRUSH.PCX
Each partial inspection of the motor should Figure 7-109: Motor Brush, Typical Location
include the following:
1. Inspect the brushes for wear and for proper
contact with the commutator. Record the
level of wear on the brushes. This history
will give you an indication of whether a
brush should be changed or if it can wait
until the next inspection. See the table on
page 7-94 for proper brush length.
NOTE: Overloading a motor is ultimately
reflected in motor commutator and
brush wear; therefore, you must take
this into account when considering
brush replacement.
2. Check the brushes for signs of overheating:
discolored shunts or springs or cracked
contact area.
3. Check the brush spring tension. See “DC
Motor Brush Spring Tension” on page 7-93.
4. Clean the brushes and holders. Wipe the
commutator with a dry, lint-free cloth. Do
not use lubricants of any kind on or
around the commutator.
5. Check the brush holders for solid
connection to the mounting support.
Tighten any mounting screws as necessary.
6. Check the screws holding the brush cross
connectors to the brush holder body.
PDMM-0109 7/31/02 7-91

DC Motor Brushes Electrical Components
7. Make sure the motor terminals are secured

tightly to the motor frame. Be careful not to
strip the threads or crush the insulating
parts.
8. Check all the screws and bolts around the
endbell and frame for tightness.
9. Keep the outside frame of the motor clean
and free from dirt. Maintain a free air
passage around the motor to permit heat
radiation.
Replacement
If one brush needs replacement, always replace
the entire set of brushes.
Use only genuine Raymond replacement
brushes. Using another type of brush could
damage the commutator or cause excessive
brush wear.
Most replacement brushes have square rather
than pre-contoured ends. These brushes
require seating, which is accomplished after
approximately 40 to 80 hours of operation.
Do not use emery cloth or sandpaper to seat
brushes. Grit may enter the motor, causing
premature wear and failure. Blowing out the
motor with compressed air will not guarantee
all the debris is removed.
7-92 PDMM-0109 7/31/02

Electrical Components DC Motor Brush Spring Tension
DC Motor Brush Spring Tension

Insufficient spring tension results in excessive
arcing and reduced motor performance.
Excessive spring tension results in premature
commutator wear.
A brush spring which does not apply tension
evenly on the center of the brush causes
uneven brush wear.
Inspection
1. Turn the key switch to OFF and disconnect
2. Remove covers as required for access to
motor. Paper
3. Remove any brush bands.

4. Slide the brush up slightly in its holder.
5. Insert a paper strip between the brush face
and the commutator. Rotation
6. Place a small leather loop around the coil
spring for the brush. If the brush spring 78B16032.EPS
has a loop at the brush, hook the spring Figure 7-110: Motor Brush Spring Tension Inspection
scale directly to the spring.
7. Attach a 5 lb. (2.27 kilogram) spring scale
to the leather loop.
8. While gently pulling the scale outward,
slowly pull the paper strip in the direction
that the commutator normally rotates.
9. When the paper strip begins to move freely,
the spring scale will read the spring brush
tension.
PDMM-0109 7/31/02 7-93

DC Motor Brush Spring Tension Electrical Components
10. Refer to the table below for proper spring

tension
Brush Length Brush Spring Tension

Raymond
Motor Minimum Maximum New Worn
P/N
in. mm in. mm oz. gr oz. gr
Lift 570-269/501 0.62 16 1.30 35 65 1820 40 1120

579-269
570-353/500 0.62 16 1.30 35 65 1820 40 1120

579-353
Aux 570-287/501 0.62 16 1.30 35 65 1820 40 1120

579-287
570-354/501 0.62 16 1.30 35 65 1820 40 1120

579-354
11. Repeat steps 3 through 9 for the remaining

brushes.
7-94 PDMM-0109 7/31/02

Electrical Components DC Motor Commutator
DC Motor Commutator
BRUSH LENGTH
Inspection
Mica
The commutator should be inspected for
surface condition and high mica. See Segment
Figure 7-111.
The commutator must be smooth and clean to
provide maximum brush wear. When
commutators are not properly maintained, NORMAL UNDERCUT High Mica
carbon dust can collect in the grooves between
the segments. This can lead to a short circuit in
the armature.
Good commutation will be indicated by a dark
brown polished commutator and an evenly
polished brush wearing surface. HIGH MICA
If the commutator appears rough, pitted, or has 71881_003.tif
high mica, signs of burning, or heavy arcing Figure 7-111: Mica Undercutting
between the commutator bars, the motor
should be removed for servicing.
High ridges between the brush travel paths
indicate the commutator requires turning. High
ridges could chip or damage the brushes.
PDMM-0109 7/31/02 7-95

Terminal Nuts Electrical Components
Terminal Nuts
Terminal Motor Cable
Whenever you disconnect and reconnect any Stud Securing Nut
power cables to a motor or power amplifier, (Flanged)
always tighten the cable securing nuts with a
torque wrench to prevent over-tightening them Conical Washer
and damaging the motor or amplifier. On
traction and lift motors, use a second wrench
on the stud terminal securing nut to avoid
twisting the stud. See Figure 7-113. Check Fullness of
these torques each time you check the motor. cable to bottom
Stud Terminal
Stud Motor Securing Nut
Motor Cable Housing
Terminal (Flanged)
Stud Size Securing
Securing
Nut
Nut Traction Motor
Traction Motor
18 ft. lb. 30 ft. lb. Terminal Motor Cable
M8 Stud Securing Nut
(24.4 Nm) (40.7 Nm)
(Flanged)
Lift Motor (brass nuts)
Fullness of
8.3 to 10.0 11.7 to 13.3 cable to top
ft. lb. ft. lb.
M10
(11.3 to 13.6 (15.9 to 18.0
Nm) Nm)
Aux Motor (brass nuts)
7.5 to 9.2 ft. 9.2 to 11.7
lb. ft. lb. Power
M8 Amplifier
(10.2 to 12.5 (12.5 to 15.9 Housing
Nm) Nm)
Traction Power Amplifier Traction Power Amplifier
15 ft. lb. N/A
M8
(20.3 Nm) Terminal
Stud
Motor Cable Flat

Securing Washer
Nut
Fiber
Washer
Stud
Terminal Motor
Securing Housing
Nut
Lift and Aux Motors
74548_003.EPS
74548_002.EPS
7CABLENUT.WMF
Figure 7-112: Terminal Nuts
7-96 PDMM-0109 7/31/02

Electrical Components Terminal Nuts
! CAUTION
Do not attempt to repair power cable
to use proper cables, flanged nuts,
and torque values can result in
components. 74612_020.TIF
Figure 7-113: Two wrenches on motor terminals
PDMM-0109 7/31/02 7-97

Lift Motor Electrical Components
Lift Motor
! CAUTION
Turn the key switch OFF and
disconnect the battery connector Lift
Motor
before working on lift system
connections.
Temperature
Sensor
Removal
1. Lower the carriage completely. Turn the key
switch OFF and disconnect the battery
connector.
2. With hoses still connected, remove lift Note
pump mounting bolts from lift motor. Clearance
Brush
Separate pump from motor and shift it
Band
towards the mast.
3. Mark polarity if necessary and remove the
power cables from the lift motor. Use two
wrenches to avoid twisting the terminal
stud.
! CAUTION
precautions against electrostatic Aux
Fan Motor
on page 2-11. 75077_010.TIF
Figure 7-114: Lift Motor, Series DZ-D
4. If so equipped, disconnect the lift motor

temperature sensor connector JPZ. Loosen
the retaining nut on the sensor. Remove the
sensor from the motor by unthreading.
7-98 PDMM-0109 7/31/02

Electrical Components Lift Motor
! CAUTION
The lift motor weighs approximately
95 pounds (43 kilograms). Use a
suitable hoist when removing the
motor.
5. Secure the lift motor with a suitable lifting

device. Remove the four lift motor mounting Lift
bolts. Retain all mounting hardware, Motor
including non-metallic spacers between
motor bracket and tractor frame.
6. Using a suitable hoist, remove the lift
motor.
Fan
7. Remove the fan shroud screws and remove
the shroud.
8. Remove the nut securing the fan impeller to
the motor. Remove the impeller.
9. Remove the screws securing the fan
Brush
mounting plate to the motor. Remove the Band
plate.
Installation
1. Attach the fan mounting plate to the motor.
2. Attach the fan impeller to the motor shaft 75077_024.TIF
and tighten the mounting nut to 30 ft. lb. Figure 7-115: Lift Motor Fan, Series EZ-D
(40.7 Nm).
3. Attach the fan shroud with screws.
4. Apply molybdenum anti-seize compound
(P/N 990-638) to the mating surfaces of the
lift pump, motor, and spline.
5. Using a suitable hoist, position the lift
motor on its bracket. Ensure a minimum
clearance of 0.25 in. (6 mm) between the
power cable terminal stud and the upper
hinge pin of the motor compartment
door. See Figure 7-114 on page 7-98.
Apply thread-locking compound
(P/N 990-536) and thread the mounting
bolts loosely. Place non-metallic spacers, if
so equipped, where previously removed.
PDMM-0109 7/31/02 7-99

Lift Motor Electrical Components

(P/N 990-536) to the threads of the lift
pump mounting bolts. Mate the lift pump
spline to the lift motor and attach the lift
pump to the lift motor with the two
mounting bolts. Tighten and torque to
20 ft. lb. (27 Nm).
7. Prior to tightening the motor mounting
bolts, close the drive compartment door to
ensure a good fit with the lift motor fan
housing (if so equipped). Reposition motor
as needed.
8. Tighten and torque the motor mounting
bolts to 13 ft. lb. (17.6 Nm).
9. Attach the power cables to the lift motor,
observing proper polarity. Use a second
wrench on the stud terminal securing nut
to avoid twisting the stud. Torque the motor
cable securing nuts to 100-120 in. lb.
(11.2-13.6 Nm).
10. If so equipped, apply heatsink compound
(P/N 990-508) to the threads of the lift
motor temperature sensor. Thread the
sensor all the way into the lift motor and
tighten the retaining nut. Connect the
sensor connector JPZ.
NOTE: If cold storage-equipped, apply silicone
sealing compound (P/N 990-445) to the
connector and socket before connecting.
the key switch ON.
12. Test the lift functions. Check for fluid leaks.
7-100 PDMM-0109 7/31/02

Electrical Components Temperature Sensor, Lift Motor
Temperature Sensor, Lift

Motor
Installation
1. Apply heatsink compound (P/N 990-508) to
the threads of the sensor.
2. Thread the sensor all the way into the heat
sink or motor. Be sure the sensor does not Temperature
touch the field poles when the retaining nut Sensor
is tightened.
75077_010.TIF
Figure 7-116: Lift Motor Temperature Sensor, DZ-D
PDMM-0109 7/31/02 7-101

Temperature Sensor, Traction Electrical Components
Temperature Sensor,
Traction
The temperature sensor for the traction power
amplifier is integral to the amplifier and not
replaceable.
The temperature sensor in the drive motor is
integral to the motor. When a motor
temperature sensor fails, you can replaced it
with an externally mounted sensor, using the
procedure below.
Installation (External)
1. Turn the key switch OFF and disconnect Temperature
Sensor
2. Open drive motor compartment door.
! CAUTION
precautions against electrostatic Power
Cables
on page 2-11.
74612_019.TIF
3. Disconnect the drive motor temperature Figure 7-117: Drive Motor External Temperature Sensor
sensor connector JPT3. Cut the wires from
JT3 close to the motor body and discard the
cut off connector.
4. Mount the external sensor in a recess
groove in the motor housing and fasten
with adhesive provided with the sensor kit.
5. Reconnect JPT3.
6. Reinstall covers/door previously
removed/opened.
the key switch ON.
7-102 PDMM-0109 7/31/02

Electrical Components Traction Power Amplifier
Traction Power Amplifier

Cleaning
1. Turn the key switch OFF and disconnect Vehicle
the battery connector. Manager
2. Remove the right side cover.
! CAUTION
Contactors
If the lift truck was operated recently,
the power amplifier may be too hot Power Cables
to touch. If necessary, allow the
amplifier to cool before removing.

on page 2-11.
3. Remove the traction power amplifier fan.

4. Blow compressed air (30 psi, 200 kPa, or Connector JT1 Traction
2 kg/cm2 maximum) across and through Power
the underside of the amplifier to remove Amplifier
dirt and debris from the heatsink cooling
fins. 75077_037.TIF
Figure 7-118: Traction Power Amplifier

NOTE: Do not blow compressed air across
power amplifier fan.
5. Before re-installing the fan, ensure the fan
rotates freely. Install the power amplifier
fan.
6. Install the right side cover.
PDMM-0109 7/31/02 7-103

Traction Power Amplifier Electrical Components
Removal
2. Remove the right side cover.
! CAUTION
If the lift truck was operated recently,
the power amplifier may be too hot
to touch. If necessary, allow the
amplifier to cool before removing.

on page 2-11.
3. Remove the plastic cover over the

contactors.
4. Disconnect connector JPT1 from the power
amplifier.
5. Disconnect the four power cables and the
bus bar from the power amplifier, labeling
as needed to ensure proper reconnection.
6. Loosen, but do not remove, the four screws
in the side rails of the power amplifier.
7. Lift the power amplifier out of the mounting
plate. Mark the position of the mounting
rails in the slots of the power amplifier.
Remove the mounting rails.
7-104 PDMM-0109 7/31/02

Electrical Components Traction Power Amplifier
Installation
“+” terminal
1. Insert the mounting rails in the slots of the (see text note)
new power amplifier, positioning them as in
the original amplifier.
2. Install the power amplifier in the mounting
plate, engaging the screws and lock
washers in the slots in the mounting plate. Unused “B+” terminal
3. Tighten the mounting screws to 7.4 ft. lb. (see text note)
(10 Nm).
4. Reconnect the power cables and bus bar in
the proper sequence with flanged nuts and
torque to 15 ft. lb. (20.3 Nm). Cables should
be routed as shown in Figure 7-120.
NOTE: Connect the B+ bus bar to the terminal
marked “+” not the terminal marked Side Rail
“B+.” See Figure 7-119. The terminal
marked “B+” is not used. 75077_049.TIF
Figure 7-119: Traction Power Amplifier, removed
! CAUTION
Do not attempt to repair power cable
to use proper cables, flanged nuts,
and torque values can result in
components.
5. Reconnect connector JPT1.

6. Reinstall the plastic cover over the
contactors.
7. Install the right side cover.
75077_037.TIF
Figure 7-120: Power cable routing
PDMM-0109 7/31/02 7-105

Traction Power Amplifier Electrical Components
7-106 PDMM-0109 7/31/02

Hydraulic Components
PDMM-0109 7/31/02 7-107

Hydraulic Fluid Replacement Hydraulic Components
Hydraulic Fluid
Replacement
NOTE: Draining the hydraulic reservoir does
not remove all the hydraulic fluid in the
system. Fluid remains in the cylinders
and over-the-mast hoses.
To ensure complete purging of old

hydraulic fluid, follow all the steps listed
below. This is particularly important
when purging contaminants or when
converting from ambient temperature
operation to cold storage operation.
If ambient temperature fluid is left in

hydraulic components converted for cold
storage operation, lift truck performance
will be compromised.
Preparation
1. Hydraulic fluid change is best done when
the fluid has been warmed. The fluid flows
better and more contamination is likely to
be flushed out.
2. Place oil-absorbent materials around the
work area. Cover components to avoid
dripping hydraulic fluid on them.
3. Lower the carriage fully and tilt the forks
down completely. Extend the reach
mechanism and block the reach carriage in
the reached position.
4. Dispose of the old hydraulic fluid following
all local regulations.
Purging the Auxiliary System

With the hydraulic reservoir empty, a
significant amount of fluid remains in the
cylinders and lines and must be purged with
new fluid.
1. Fill the reservoir about 2/3 full with new
hydraulic fluid.
2. With the key switch OFF and the reach
carriage extended and blocked, disconnect
the pressure line to the tilt-up port at the
tilt actuator.
7-108 PDMM-0109 7/31/02

Hydraulic Components Purging the Auxiliary System
3. Attach another line to the actuator at the

tilt-up port.
4. Secure the end of the hoses in a waste
container so they will not move under
pressure.
the key switch ON.
6. Run the tilt up function until the new
hydraulic fluid comes out of the line. Then
run tilt-down to push the remaining fluid
out of the actuator.
7. Repeat steps 2 through 6 for the tilt-down
function. Finish by running tilt-up to purge
oil from the tilt actuator.
8. Repeat steps 2 through 6 for both
directions of the sideshift function (if so
equipped).
9. Purge the reach cylinders in a similar
manner. Since the reach carriage is
blocked, the cylinders will not actually
move.
a. Turn the key switch OFF and disconnect
b. Disconnect the pressure line from the
piston end of the cylinder. Attach
another line to the cylinder port. Secure
the ends of both hoses in a waste
container so they will not move under
pressure.
c. Reconnect the battery connector and
turn the key switch ON.
d. Run the reach function to purge old
fluid from the piston side of the reach
cylinder. Fluid will pass from the
housing side to the piston side
internally in the cylinder.
e. Run the retract function until new fluid
comes out of the line.
f. Repeat steps a through e for the other
reach cylinder. You need not remove the
housing end pressure lines, as they will
have been purged by the preceding
process.
10. If the pump cavitates at any time, add
additional fluid to the reservoir.
PDMM-0109 7/31/02 7-109

Purging the Steering System Hydraulic Components
Purging the Steering System

1. Center the drive unit.
3. Remove both hydraulic lines from the
orbitrol to the hydraulic steer motor at the
motor and connect extension lines.
4. Direct both lines into a waste container and
secure so they cannot move under
pressure.
the key switch ON.
6. Turn the steering wheel in both directions
until new fluid comes out of the lines.
8. Reconnect the hydraulic lines to the
hydraulic steer motor.
the key switch ON.
Purging the Lift Cylinders

1. Bleed the hydraulic system. See “Bleeding
the System” on page 7-111. Let a good
amount of fluid purge from the bleed ports.
Refilling the System

See “Lubrication Specification Chart” on page
A-2 for list of approved fluids.
1. Fill the hydraulic reservoir. Do not overfill
the reservoir. Use only recommended
hydraulic fluid. See “Lubrication
Specification Chart” on page A-2 for
approved fluids.
2. Check for leaks.
3. Install the tractor top cover and right side
cover. Close and secure the drive motor
compartment door.
7-110 PDMM-0109 7/31/02

Hydraulic Components Bleeding the System
Bleeding the System

You must bleed the hydraulic system to remove
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
• Notice that the load is bouncing
Procedure
1. Elevate the fork carriage past free lift and
lower it to the floor. Repeat several times.
This will tend to encourage any trapped air
bubbles to migrate to the top of the
cylinders.
2. With no load on the forks, elevate the forks
2 to 3 inches (5 to 7.5 cm.) off the floor.
4. Use an Allen wrench to loosen (but do NOT
remove) the bleed screw at the top of the
back lift cylinder. Hold a rag close to and
beneath the bleed screw to keep hydraulic
fluid from spraying out.
5. When hydraulic fluid starts flowing from
the bleed screw hole, securely tighten the
bleed screw.
6. Repeat steps 3 and 4 for the front lift Lift Cylinder
Bleed Screw
cylinder.
7. Repeat steps 3 and 4 for each of the two
side cylinders in the lift cylinder cluster.
the key switch ON.
9. Lower the forks all the way down to the
floor.
10. Fully extend and retract the reach
mechanism several times.
7W16.TIF
11. If the truck is equipped with tilt, tilt the Figure 7-121: Bleed Screw, Side Lift Cylinder
carriage all the way forward and backward
several times.
12. If the truck is equipped with sideshift, shift
the carriage all the way to the left and right
several times.
PDMM-0109 7/31/02 7-111

Bleeding the System Hydraulic Components
13. Step on the deadman pedal and turn the

steering wheel from stop to stop for
approximately 2 minutes.
14. Thoroughly clean up any spilled hydraulic
fluid.
15. Check the hydraulic reservoir level and
refill as necessary. Do not overfill the
reservoir.
7-112 PDMM-0109 7/31/02

Hydraulic Components Lift Pump
Lift Pump
! CAUTION
disconnect the battery connector
connections.
Installation
1. Apply molybdenum anti-seize compound Pump
Spline
(P/N 990-638) to the mating surfaces of the
lift pump, motor, and spline. 74155_101.TIF
Figure 7-122: Lift Motor and Pump Spline
2. Mate the lift pump spline to the lift motor

and attach the lift pump to the lift motor.
Apply thread-locking compound Lift Pump
(P/N 990-536) to the pump mounting bolts.
Tighten and torque to 20 ft. lb. (27 Nm).
the System” on page 7-111.
4. Set the system pressure. See “Lift Pressure
Lift Motor
75077_016.TIF
Figure 7-123: Lift Pump Location (DZ-D shown)
PDMM-0109 7/31/02 7-113

Lift Pressure Adjustment Hydraulic Components
Lift Pressure Adjustment
! CAUTION
connections.
1. Lower the carriage completely.

3. Connect a pressure gauge capable of
reading at least 5,000 psi (34,470
kiloPascals). See Figure 7-124.
the key switch ON.
5. Place the maximum rated load on the forks.
6. Elevate the carriage past free lift, that is, Lift Pressure Lift Pressure
until the telescopics begin to lift. Record the Relief Valve & Test Port
Adjusting Screw
pressure required to lift the load.
7828-004-226b.EPS
7. Lower the carriage and remove the load.
Figure 7-124: Lift Pressure Adjustment, Series EZ-D/DZ-D
8. Elevate the carriage in a safe area until the (Front View)
upper limit is reached.
9. Continue to try and elevate and turn the lift
pressure adjusting screw (see Figure 7-124)
to obtain a pressure reading 100 psi
(689 kPa) greater than that required to lift
the maximum rated load (the value
recorded in step 5). Turn the adjusting
screw clockwise to increase pressure,
counterclockwise to decrease pressure.
10. Check the pressure again. If the value has
changed, repeat this procedure until the
correct pressure reading is obtained.
12. Remove the pressure gauge from the lift
pressure test port and replace the cap.
13. Reinstall the top cover and right side cover.
Reconnect the battery connector.
7-114 PDMM-0109 7/31/02

Hydraulic Components Manual Lowering of Fork Carriage
Manual Lowering of
Fork Carriage
If the fork carriage is hung up and unable to be
lowered normally, use the following procedure
to lower the carriage.
! CAUTION
Make sure the forks and carriage are
free from racks and other
obstructions before lowering.

2. Loosen and remove the lock nut on the
relief valve. Note the number of threads
exposed on the lift pressure relief valve. See
Figure 7-125.
3. Turn the lift pressure adjusting screw
slowly counterclockwise until the fork
carriage begins to lower.
4. When you have resolved the cause of the
hung carriage, you must reset the lift
pressure. Lift Pressure Relief Valve
& Adjusting Screw
5. Turn the lift pressure adjusting screw
7828-004-226b.EPS
clockwise until the same number of threads
Figure 7-125: Lift Pressure Relief Valve & Adjusting Screw,
are exposed as you noted in step 2.
Series EZ-D/DZ-D
6. Install but do not tighten the lock nut on (Front View)
the relief valve.
7. Perform the procedure to adjust lift
pressure. See “Lift Pressure Adjustment” on
page 7-114.
PDMM-0109 7/31/02 7-115

Proportional Lower Valve Adjustment Hydraulic Components
Proportional Lower
Valve Adjustment
Adjustment
If the carriage hesitates when being lowered, or
cannot be feathered, adjust the proportional
valve as follows:
1. Raise the fork carriage to eye level.
3. Remove one of the coil wires from SOL2.
Loosen the jam nut and lock nut holding
the adjusting screw on the proportional
valve. Proportional Lower
Valve
the key switch ON. 7828-004-226b.EPS
Figure 7-126: Proportional Lower Valve

5. Energize the load holding solenoid by
requesting “lower” with the lift/lower
potentiometer.
6. Slowly rotate the adjusting screw clockwise
until the carriage just starts to creep
downward. Turn the screw
counter-clockwise 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. Reconnect the coil wire previously removed.
the key switch ON.
10. Check for proper lowering operation empty
and loaded.
7-116 PDMM-0109 7/31/02

Hydraulic Components Auxiliary Pump
Auxiliary Pump
Installation
1. Attach the pump to the motor, mating the
two halves of the coupling with the rubber
coupling cushion in between. Apply
the two pump mounting bolts. Tighten and
torque to 20 ft. lb. (27 Nm). Coupling
the System” on page 7-111. Coupling
Cushion
3. Set the system pressure. See “Auxiliary
System Pressure Adjustment” on
page 7-118.
7M09.TIF
Figure 7-127: Auxiliary Pump with Coupling
75077_077.TIF
Figure 7-128: Aux Motor and Pump (EZ-D)
PDMM-0109 7/31/02 7-117

Auxiliary System Pressure Adjustment Hydraulic Components
Auxiliary System
Pressure Adjustment
Steering
Orbitrol
! CAUTION
before working on auxiliary system Auxiliary
Pressure
connections. Test Port
7P5110007B.TIF
Figure 7-129: Auxiliary Pressure Test Port, Series DZ-D
shown
2. Remove the cap from the test port on the
auxiliary pressure line at the steering
orbitrol. See Figure 7-129. Connect a
pressure gauge capable of measuring
5,000 psi (34,470 kiloPascals).
3. Remove the cap from the auxiliary pressure
adjustment port, located on the auxiliary Auxiliary
pump below the suction line. Motor
See Figure 7-130.
4. Tilt the carriage all the way back against
the stops.
5. While continuing to try tilting the carriage
backward, use a screwdriver to turn the Auxiliary
auxiliary pressure adjusting screw to Pump
obtain a pressure of 1,600 psi
(11,030 kiloPascals).
Suction Line
Auxiliary
Pressure
Adjusting
Screw
75077_077.TIF
Figure 7-130: Aux Pressure Adjustment Screw, Series EZ-D
7-118 PDMM-0109 7/31/02

Hydraulic Components Manifold, Main
Manifold, Main
SOL6 To Over The Return Line To Lift Pump

EQ Mast Hoses
SOL8
SOL4 SOL5 2ND
DIRB DIRA
SOL3 Pressure
Lift/ Transducer
Lower
Aux Steering High Pressure Relief Lift Pressure SOL1

Pressure Line Pressure Line Valve /Adjustment Test Port Load Hold
7828-004-226a.EPS
Figure 7-131: Manifold Layout, Series EZ-D/DZ-D, Top View (Dual Lift Pump shown)
To Over The Return From

Line Lift Pressure
Mast Hoses Test Port Lift Pump
SOL4 SOL5
DIRB DIRA SOL8
2ND
SOL6 SOL3
EQ Lift/
Lower
SOL1
Load Pressure
Hold Transducer
Lift Aux Steering High Pressure Relief

Pressure Line Pressure Line Pressure Line Valve /Adjustment
7828-004-226b.EPS
Figure 7-132: Manifold Layout, Series EZ-D/DZ-D, Side View (Dual Lift Pump shown)
PDMM-0109 7/31/02 7-119

Hydraulic Solenoid Hydraulic Components
Hydraulic Solenoid
! CAUTION
before working on hydraulic
connections.
Installation
Coil Coil Retaining Nut
1. Inspect the seat where the solenoid seals
against the manifold. The sealing surface
should be completely clean and free from
any nicks, burrs, or scratches.
2. Inspect the O-ring for any damage. If the Terminals
O-ring is damaged or deformed in any way, and
replace it. Lubricate the O-ring with a light Terminal
coating of hydraulic fluid. Wires
3. Thread the solenoid valve body into the

manifold. Torque the valve according to the
table that follows.
Valve Body
74612_017.TIF
Figure 7-133: Solenoid, Typical, Coil Removed
Valve Valve Coil Nut Coil Nut

Solenoid Torque Torque Torque Torque
(ft. lb.) (Nm) (ft. lb.) (Nm)
1 Load
35 47 5 6.8
Holding
3 Lift/Lower
50 68 4 5.4
Proportional
4 DIRB 25 34 5 6.8
5 DIRA 25 34 5 6.8
6 EQ 20 27 5 6.8
8 2d PUMP 25 34 5 6.8
Reach 20 27 5 6.8
Tilt 20 27 5 6.8
Sideshift 20 27 5 6.8
7-120 PDMM-0109 7/31/02

Hydraulic Components Pressure Transducer
Pressure Transducer
! CAUTION
before working on hydraulic
connections.
Installation
1. Install the new transducer with a new
O-ring and torque to 12 ft. lb. (16.2 Nm).
2. Enter Learn Mode and perform Learn
Weight. See “Learn Weight” on page 6-11.
3. Lift a known weight and verify the weight
displayed on the operator display. The Pressure
weight displayed should be within 10% of Transducer
the maximum rated load for this lift truck.
75077_074.TIF
Figure 7-134: Pressure Transducer
PDMM-0109 7/31/02 7-121

Pressure Transducer Hydraulic Components
7-122 PDMM-0109 7/31/02

Hydraulic Components Lift Cylinders

Hydraulic Procedures 7:
Lift Cylinders
Refer to the figures which follow for lift cylinder

removal, installation, disassembly, and
reassembly procedures.
Circled numbers in the illustrations refer to the
components in the table below:
No. Description
1 Cylinder housing
2 Bleed screw
3 End cap
4 O-ring
5 Flow control
6 Snap ring
7 Seal
8 Backup ring/retainer ring
9 Adapter
10 Piston
11 Piston cushion ring
12 Spring
13 Piston lower cushion
PDMM-0109 7/31/02 7-123

Lift Cylinders Hydraulic Components
7R89262A.EPS 828-009-262 Rev E
Figure 7-135: Lift Cylinder, Back Cylinder, exploded view
7-124 PDMM-0109 7/31/02

Hydraulic Components Lift Cylinders
7R89263L.EPS 828-009-263 Rev E
Figure 7-136: Lift Cylinder, Front Cluster, exploded view (Part 1 of 2)
PDMM-0109 7/31/02 7-125

Lift Cylinders Hydraulic Components
7R89263R.EPS 828-009-263 Rev E
Figure 7-137: Lift Cylinder, Front Cluster, exploded view (Part 2 of 2)
7-126 PDMM-0109 7/31/02

Hydraulic Components Lift Cylinder, Front Cluster
Lift Cylinder, Front Cluster

NOTE: For illustrations, see “Lift Cylinders” on
page 7-123.
Removal
1. Remove the carriage. See “Reach Carriage
Assembly” on page 7-174, steps 1-13.
the key switch ON.
3. After removing the carriage, elevate the
inner telescopic enough to place support
blocks under the inner and outer
telescopics. Clamp the support securely in
place. Lower the mast onto the support.
4. Lower the telescopic onto the block and
relieve pressure by operating the lower
control.
6. Have a container available to catch
hydraulic fluid when you remove the
hydraulic hose. At the back cylinder,
remove the hydraulic hose between the
back cylinder and the cluster.
7. To prevent the center piston from sliding
out of the housing as the cluster is
removed, attach a wire around the
hydraulic hose fitting and through the
cylinder housing weldments.
8. The cluster is held in place by a bolt on top,
a nut on the bottom, and two eyes
approximately 9 in. (23 cm) from the
bottom of the side cylinders. These eyes set
in hooks on the inner lower telescopic
cross-tie.
Remove the nut at the bottom of the cluster
assembly.
9. Remove the bolt, three beveled washers (if
present), flat washer, and plastic spacer
with steel collar at the top of the cluster
assembly. See Figure 7-138 on page 7-128.
Tilt the top of the cluster forward as far as
possible.
10. Attach a hoist strap around the cluster
below the chain anchors.
PDMM-0109 7/31/02 7-127

Lift Cylinder, Front Cluster Hydraulic Components
11. Use a hoist to lift the cluster off the hooks

on the inner lower telescopic cross-tie.
Installation
1. Inspect the hydraulic hose assembly for
damage or deterioration. Replace if Beveled Washers
necessary. Attach the hydraulic hose (note direction)
assembly to the cluster’s center piston.
Flat Washer
2. Extend the center piston 6 in. (15 cm) and
secure to the cylinder housing as follows:
Loop a wire around the hydraulic hose
fitting and through the cylinder housing
weldments.
3. Attach a hoist strap around the cluster
below the chain anchors. Crosstie
4. Use a hoist to position the cluster. Install
the cluster with cylinder housing eyelets
Steel Collar
over the hooks on the inner lower telescopic and Plastic
cross-tie. Front
Cylinder Sleeve
5. Remove the hoist strap.
6. Tilt the cluster back into position.
74643_001.EPS
7. Apply thread-locking compound Figure 7-138: Front Ram Top Mounting
(P/N 990-536) to a new center cylinder
mounting bolt. At the top of the center
cylinder, install a new sleeve and collar, flat
washer, three beveled washers (if used),
and mounting bolt through the inner
telescopic upper cross-tie and into the
cylinder housing. See Figure 7-138.
a. If beveled washers are used, torque the
mounting bolt to 45 ft. lb. (61 Nm).
Lubricate washers with spray teflon
grease.
b. If beveled washers are not used, torque
the mounting bolt to 60 ft. lb. (81 Nm).
8. Remove the wire securing the center
cylinder piston and lower the piston into
the bracket on the outer telescopic lower
cross-tie, ensuring that the hydraulic hose
is properly positioned for connection.
9. Install the nut securing the lower end of the
piston.
10. Install the hydraulic hose fitting into the
back cylinder housing.
11. Re-install the carriage assembly. See
“Reach Carriage Assembly” on page 7-174.
7-128 PDMM-0109 7/31/02

Hydraulic Components Lift Cylinder, Front Cluster
! WARNING
Because lifting and lowering the
mast will be necessary to complete
the following procedure, use
extreme caution while working
within the mast. NEVER lift or lower
when your hands are near the mast.

the key switch ON.
the System” on page 7-111, steps 3-6.
14. Test mast elevation to maximum elevation,
if the ceiling permits. (If ceiling height is
limited, wrap and secure a 5-ton capacity
chain around the inner and outer
telescopics and main frame upper
cross-ties and lift against the chain.)
Inspect cylinder housings, pistons, hoses,
and fittings for leaks.
PDMM-0109 7/31/02 7-129

Lift Cylinder, Back Cylinder, Threaded Anchor Retention Hydraulic Components
Lift Cylinder, Back Cylinder,

Threaded Anchor Retention
Removal
1. Remove the reach carriage assembly.
Follow the procedure described in “Reach
Carriage Assembly” on page 7-174. See
Figure 7-139.
2. Remove the front lift cylinder cluster. Follow
the procedure described in “Lift Cylinder,
Front Cluster” on page 7-127.
3. Remove the lift hydraulic hose and plug it.
Remove hose fitting from cylinder and plug
the cylinder.
4. Attach a saddle clamp to the upper part of
the cylinder housing. Below the saddle
clamp, wrap a hoist strap securely several
7RCH99R006A_2.TIF
times around the cylinder. Secure the
cylinder firmly while removing anchoring Figure 7-139: Reach carriage removed
hardware.
5. Remove lock nuts and cylinder anchor
bolts.
6. Remove the cylinder mounting bolt, washer,
and spacer from the upper support bracket.
7. Using a 1-ton hoist, carefully tilt the
cylinder out from the upper support
bracket and lift it out of the opening in the
support plate of the outer telescopic.
7-130 PDMM-0109 7/31/02

Hydraulic Components Lift Cylinder, Back Cylinder, Threaded Anchor
Installation
1. Attach a saddle clamp to the upper part of
the cylinder housing. Below the saddle Mounting Bolt Upper Support
clamp, wrap a hoist strap securely several and Sleeve Bracket
times around the cylinder. To retain the
piston in the cylinder, install the hydraulic Maximum
fitting in the piston. Wrap a wire around the Gap
hydraulic fittings on the piston and the
cylinder housing.
Lift Cylinder
2. Using a 1-ton hoist, place the cylinder in
position over the outer telescopic support
plate. Remove the wire and hydraulic fitting Cylinder
Flange
from the piston and slowly lower the piston
through the outer telescopic support plate
into the main frame mounting bracket.
3. Carefully lower the back cylinder assembly
through the hole in the outer telescopic
support plate. Align the cylinder with
respect to the anchor bolt holes and the
0.06 to 0.25
upper support bracket.
in. gap
4. Insert new anchor bolts through the
cylinder flange, outer telescopic support
plate, and pivot support plate. Attach, but Pivot
do not tighten, new lock nuts. Anchor Bolt Lock Nut Support
Plate
5. Connect the back cylinder assembly to the
7RCH99R006A_1.TIF
upper support bracket, using a new steel
and plastic sleeve, flat washer, and Figure 7-140: Anchoring lift cylinder
mounting bolt. Apply thread-locking
compound (P/N 990-536) and torque to
60 ft. lb. 81 Nm).
6. Ensure that a 0.06 to 0.25 in. (1.5 to 6.4
mm) gap exists between the bottom surface
of the cylinder flanges and top surface of
outer telescopic support plate. If not, loosen
the upper support bracket mounting bolts
and adjust the bracket until it aligns with
the cylinder.
7. Remove the hoist strap and saddle clamp.
8. Tighten the lock nuts at the lower support
plate just enough to remove any play in the
pivot support plate. Do not overtighten so
as to deflect the upper support bracket.
9. Attach the lift hose fitting to the piston.
Connect the lift hydraulic hose.
10. Install front cylinder cluster. Follow the
procedure described in “Lift Cylinder, Front
Cluster” on page 7-127.
PDMM-0109 7/31/02 7-131

Lift Cylinder, Back Cylinder, Threaded Anchor Retention Hydraulic Components
11. Connect crossover hoses.

the key switch ON. Remove blocking and
lower telescopics.
13. Test mast elevation to maximum elevation,
if ceiling height permits. (If ceiling height is
limited, wrap and secure a 5-ton capacity
chain around the inner and outer
telescopics and main frame upper
cross-ties and lift against the chain.) Steel spacer
Inspect cylinder housings, pistons, hoses, support
and fittings for leaks.
14. Bleed the hydraulic system. See steps 3-6
of “Bleeding the System” on page 7-111.
15. Adjust the back cylinder. See “Adjustment”
below.
16. Install the carriage assembly. Follow the
procedure described in “Reach Carriage
Assembly” on page 7-174.
17. Test the lift system for proper operation. 7RCH99R006A_4.TIF
Figure 7-141: Blocking telescopics

Adjustment
1. Elevate the telescopics until the pivot
support plate for the back cylinder is
accessible.
2. Place a steel spacer support between the
inner and outer telescopic and lower the
telescopics onto the support. See
Figure 7-141. The fork carriage should be
bottomed to depressurize the lift system.
This leaves the back cylinder assembly
supported by the upper support bracket.
3. Ensure that the pivot support plate below
the outer telescopic is snug. See
Figure 7-142. If the plate is free to move,
the anchor nuts should be tightened. (Do
not overtighten so as to deflect the upper
support bracket.)
4. If a minimum gap of 0.06 in. (1.5 mm)
below the cylinder flanges is not
maintained, reposition the upper support
bracket.
5. Elevate the telescopics and remove the
spacer bar between the inner and outer
telescopics.
7RCH99R006A_5.TIF
Figure 7-142: Checking pivot support plate
7-132 PDMM-0109 7/31/02

Hydraulic Components Lift Cylinder, Back Cylinder, Threaded Anchor
6. Block the inner telescopic to provide

clearance between the outer telescopic
upper support bracket and the inner
telescopic top plate. See Figure 7-143.
7. Lower the carriage to allow access to the
upper support bracket. (Do not bottom the
carriage as lift system pressure should be
maintained on the back ram.)
8. Loosen the upper bracket support
mounting bolts.
9. Adjust the anchor lock nuts to achieve a
gap of 0.06 to 0.25 in (1.5 to 6.4 mm)
between the bottom surface of the cylinder
flanges and top surface of outer telescopic 713G6S084.TIF
support plate. See Figure 7-140 on Figure 7-143: Blocking inner telescopic
page 7-131.
10. Lift the bracket upward on the sleeve to
provide maximum gap between the bracket
and the top of the lift cylinder. Tighten two
bolts to maintain the bracket position.
Apply thread-locking compound
(P/N 990-536) to the other two mounting
bolts, install and torque to 60 ft. lb.
(81 Nm). Repeat for the first two bolts.
PDMM-0109 7/31/02 7-133

Lift Cylinder, Side Cylinder Seal Repacking Hydraulic Components
Lift Cylinder, Side Cylinder Seal

Repacking
page 7-123.
Removal
1. Elevate the forks and inspect the outside of
the piston for damage. Replace if damaged.
2. Lower the carriage onto a 4 in. x 4 in. block
to slacken the lift chains and the
over-the-mast hoses/cable.
4. Remove the over-the-mast hose/cable
pulley side plate. Remove the hose and
cable and pulleys.
5. Remove the lift chain master link cotter pin.
i
Remove the master link. Remove the lift

chain and lay it over the carriage.
6. Remove the pulley bracket.
7. Remove the snap ring, wiper, and snap ring
inside the cylinder housing.
8. Slide all seal components off the piston.
9. Repeat steps for the other side cylinder.
Repacking and Assembly
! CAUTION
In the following steps 1-6, avoid
scratching or marring the chrome
plating on the piston.
1. Lubricate the new seal and piston rod with

petroleum jelly or clean hydraulic fluid.
Slide seal on the piston.
2. Using the seal installation driver
(P/N 401-000-050) and guide
(P/N 401-000-051), install the seal by
striking the driver with a hammer. Remove
the driver and guide.
3. Using the seal driver, seat the backup
packing plug against the seal.
7-134 PDMM-0109 7/31/02

Hydraulic Components Lift Cylinder, Side Cylinder Seal Repacking
4. Install the snap ring, wiper (seal), and snap

ring.
5. Wipe away any excess hydraulic fluid.
6. Install the pulley bracket spacer, if so
equipped.
(P/N 990-536) to the pulley bracket
mounting bolt and attach the pulley
bracket to the cylinder housing. Position
the lift chain pulley in the pulley bracket.
Drive the axle through the bracket and
7PACKING.PCX
pulley, taking care to align the set screw
recess in the axle with the set screw hole in Figure 7-144: Cylinder Seal Installation Guide & Driver
the bracket. Apply thread-locking
compound (P/N 990-536) to the set screw
and tighten the set screw.
8. Reinstall the lift chain and chain master
link, securing with a new cotter pin.
9. Install the over-the-mast pulleys, ensuring
the flanged pulleys are at the bottom front
and rear. Position the over-the-mast
hose/cable over the pulleys. Apply
the pulley bracket side plate screws and
attach the plate.
10. Repeat steps 1-11 for the other side
cylinder.
the key switch ON.
12. Slowly lift the carriage, removing chain
slack and lifting the carriage off the block.
Remove the block. Test the lift function.
Check for leaks at the side cylinders.
the System” on page 7-111.
PDMM-0109 7/31/02 7-135

Lift Cylinder Front and Back Cylinder Seal Repacking Hydraulic Components
Lift Cylinder Front and Back

Cylinder Seal Repacking
page 7-123.
The procedures for repacking seals in front and

back cylinders are the same, except:
• The front cylinder contains no flow control
valve.
• Piston rods and end caps are not
interchangeable between front and back
cylinders.
Removal
1. Remove the cylinder or cylinder cluster
from the lift truck. See “Lift Cylinder, Front
Cluster” on page 7-127 and “Lift Cylinder,
Back Cylinder, Threaded Anchor Retention”
on page 7-130.
2. Secure the cluster assembly in v-blocks or
a vise. Extend the piston about 6 in.
(15 cm).
3. Have a container available to catch the
hydraulic fluid when you remove the
piston.
! CAUTION
4. To remove the threaded piston end cap,

fasten a fabric strap wrench around the
piston. Install a fitting in the end cap and
strike the fitting with a soft head mallet.
5. Remove the snap ring, wiper, and snap ring
inside the cylinder housing.
6. Pull the piston from the cylinder housing.
The packing backup plug, seal, and brass
adapter will be extracted by the piston stop
as the piston is removed.
7-136 PDMM-0109 7/31/02

Hydraulic Components Lift Cylinder Front and Back Cylinder Seal
7. Inspect the inside of the housing and the

outside of the piston for damage. Replace if
damaged.
8. Inspect the brass adapter for gouging.
Replace if damaged.
Repacking and Assembly
! CAUTION
1. Slide the brass adapter onto the piston rod

all the way to the welded stop. The adapter
seats against the housing stop and acts as
a guide during piston installation.
Slide the piston into the housing, leaving
about 6 in. (15 cm) exposed.
2. Lubricate the new seal and piston rod with
Using the seal installation driver
(P/N 401-000-050) and guide
(P/N 401-000-051), install the seal by
striking the driver with a hammer. Remove
the driver and guide.
3. Using the seal driver, seat the backup
packing plug against the seal.
7PACKING.PCX
4. Install the snap ring, wiper (seal), and snap
ring. Figure 7-145: Cylinder Seal Installation Guide & Driver
5. If the flow control valve was removed from

the back cylinder, replace the flow control
valve. Reference “Flow Control” on
page 7-140.
6. Install a new O-ring on the piston end cap.
7. Thoroughly clean the piston and end cap
threads with thread-locking primer
(P/N 990-533). Apply red thread-locking
compound (P/N 990-571) to the threads on
the end cap. Install the end cap on the end
of the piston.
8. Wipe away any surface hydraulic fluid.
PDMM-0109 7/31/02 7-137

Lift Cylinder Lowering Cushion Hydraulic Components
9. Re-install the cylinder or cylinder cluster.

See “Lift Cylinder, Back Cylinder, Threaded
Anchor Retention” on page 7-130 and/or
“Lift Cylinder, Front Cluster” on
page 7-127.
Lift Cylinder Lowering Cushion

page 7-123.
Removal
1. Remove the cylinder or cylinder cluster
from the lift truck. See “Lift Cylinder, Back
Cylinder, Threaded Anchor Retention” on
page 7-130 and/or “Lift Cylinder, Front
2. Remove the piston rod from the cylinder.
Reference “Lift Cylinder Front and Back
Cylinder Seal Repacking” on page 7-136 or
“Lift Cylinder, Side Cylinder Seal
Repacking” on page 7-134.
3. With piston rod removed, secure the piston
in a padded v-block or vise.
! WARNING
When the snap ring is removed, the
cushion spring will forcibly eject the
cushion from the piston. Keep body
away from the piston end and use
care so as to avoid violent ejection.
4. Compress the cushion to relieve pressure

on the snap ring.
NOTE: A special tool can be formed from round
bar stock to fit between the hydraulic
fluid port and the compressed cushion.
5. Remove the snap ring from the inside of the
cylinder.
6. Release the cushion slowly. The cushion
spring will eject the cushion from the
piston.
7. Remove the ring retainer and seal from the
cushion.
7-138 PDMM-0109 7/31/02

Hydraulic Components Lift Cylinder Lowering Cushion
8. Replace the cushion, spring, seal, and/or

retainer components as needed. If replacing
the cushion, install the cap screw in the
end of the new cushion.
Installation
1. Lubricate the inside of the piston surface
with clean hydraulic fluid.
2. Lubricate the seal with petroleum jelly or
clean hydraulic fluid and install on the
cushion. Install the retainer ring on the
cushion.
3. Insert and seat the cushion spring in the
center of the piston. Insert and seat the
cushion on the end of the cushion spring.
! WARNING
The compressed cushion spring can
forcibly eject the cushion from the
piston. Keep body away from the
piston end and use care so as to
avoid violent ejection.
4. Compress the cushion spring. Install the

snap ring. Carefully release cushion
pressure.
5. Re-assemble the cylinder. Reference “Lift
Cylinder Front and Back Cylinder Seal
Repacking” on page 7-136.
6. Re-install the cylinder or cylinder cluster in
the lift truck. Reference “Lift Cylinder, Back
Cylinder, Threaded Anchor Retention” on
page 7-130 and/or “Lift Cylinder, Front
PDMM-0109 7/31/02 7-139

Flow Control Hydraulic Components
Flow Control
The flow control in the three-stage mast is
located internally at the base of the rear
cylinder. The flow control can be replaced
without removing the cylinder.
page 7-123.
Removal
! WARNING
the block when it is supporting the
mast.
1. Elevate the inner telescopic enough to place

support blocks under the inner and outer
telescopics. Lower the mast onto the
support. Clamp the support securely in
place.
3. Place a shallow pan under the lift cylinder
to catch any hydraulic fluid that may spill. 709G6S001.TIF
Figure 7-146: Flow Control, Blocking

4. Remove the lock nut securing the rear
piston to the base of the mast main frame.
5. Disconnect and cap the hydraulic supply
line to the cylinder and cylinder port.
6. Using a fabric strap wrench, loosen the
lower end of the cylinder from the end cap.
Place some fine emery paper inside the
strap wrench to provide a better grip of the
strap to the piston.
NOTE: If the piston fails to loosen easily, strike
the end cap moderately with a hammer
several times. If the piston still does not
loosen, apply low heat carefully to the
end cap while turning the piston with
the strap wrench.
7-140 PDMM-0109 7/31/02

Hydraulic Components Flow Control
7. Once the piston is loose, turn it

counterclockwise until it is out of the end
cap, then lift the piston up out of the way
and secure.
8. Remove the O-ring.
9. Remove the internal snap ring that holds
the flow control in the end cap.
10. Remove the flow control valve, noting the
direction of the arrow on the flow control
cartridge body.
11. Flush the cap using solvent to remove dirt
and oil. Thoroughly clean the end cap
threads. Blow dry using compressed air.
Installation
1. Install the new flow control valve, ensuring
flow arrow points in the same direction as
the flow control that was removed.
Hydraulic flow should be restricted when
the mast is lowering.
2. Install the snap ring.
3. Replace the O-ring on the end cap.
4. Thoroughly clean the piston and end cap
threads with solvent (P/N 990-589) and
allow to dry. Apply thread locking primer
(P/N 990-533) and allow to dry.
5. Apply red thread-locking compound
(P/N 990-571) to the end cap threads.
6. Thread the piston onto the end cap and
tighten.
7. Reconnect the hydraulic supply line to the
cylinder and cylinder port.
8. Reinstall the lock nut securing the rear
piston to base of the mast main frame.
the key switch ON.
10. Check the hydraulic fluid level and refill as
needed.
11. Raise the mast so that the blocks are no
longer supporting the telescopics.
12. Remove the blocks.
13. Bleed the lift cylinders to remove any air
which entered the system during the
preceding maintenance procedure. See
“Bleeding the System” on page 7-111.
PDMM-0109 7/31/02 7-141

Reach Cylinder Hydraulic Components
Reach Cylinder
Adjustment
1. Loosen the jam nuts that hold the pistons
to the yokes.
2. Turn the pistons until both rams extend
equally and bottom out at the same time.
There should be no sideways movement of
the carriage when reaching the end of the
piston's stroke.
3. Tighten the jam nuts using thread-locking
compound (P/N 990-536).
Removal
! WARNING
mast.
Blocking
1. Raise the fork carriage to a comfortable
working height and block it there. 74612_018.TIF
See Figure 7-147. Figure 7-147: Blocking Carriage
2. Extend the reach mechanism.
3. Place a block on each side of the carriage
between the scissor’s lower back bearings
and the carriage's bottom support plate.
4. Slowly retract the carriage until the
bearings are sitting on the blocks. See Hydraulic Hose
Figure 7-147. Fittings
5. Turn the key switch OFF and unplug the
battery connector.
6. Place a drain pan under the reach cylinder.
7. Remove the hoses to the cylinder being
replaced and plug the ends.
See Figure 7-148.
713G6S133.TIF
Figure 7-148: Reach Cylinder Hydraulic Hoses
7-142 PDMM-0109 7/31/02

Hydraulic Components Reach Cylinder
8. Remove the screw holding the cotter pin in

place at the end of the piston. Screw Cotter
See Figure 7-149. Pin
9. Remove the cotter pin.
10. Remove the screw holding the cotter pin in
place at the housing end of the cylinder. See
Figure 7-150.
11. Remove the second cotter pin.
12. Drive out the clevis pin holding the yoke in
place at the piston end.
13. Drive out the clevis pin holding the housing Yoke Clevis Pin
in place and remove the cylinder.
713G6S135.TIF
Figure 7-149: Reach Cylinder Yoke Attachment
Disassembly
NOTE: For the following steps, see: Screw Cotter Pin
Figure 7-152 on page 7-144 for
standard reach cylinder, or
Figure 7-153 on page 7-145 for
Deep-Reach® reach cylinder
1. With the cylinder removed, drain all
hydraulic fluid from the cylinder assembly.
2. Clamp the cylinder at the base end in a
bench vise. Cover the ports with a clean
rag. Housing Clevis Pin
3. Remove the external lock ring. See 713G6S136.TIF
Figure 7-151. Figure 7-150: Reach Cylinder Housing Attachment
4. Push the head assembly into the tube

assembly approximately ¾ inch (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
may spray out of the cylinder ports).
9. Clamp the rod with soft jaws in a bench
vise on the wrench flats on the rod or on the
clevis. Loosen the retaining nut on the 7RCHCYL1.TIF
piston assembly. Figure 7-151: Removing External Lock Ring
PDMM-0109 7/31/02 7-143

10. Spin (standard) or slide (deep) the piston

assembly off the end of the rod, and remove
Nut
the O-ring that was under the piston
assembly. (Note that the inside diameter of
the standard reach piston is threaded.) Piston
11. Slide the cushion sleeve off the rod and

remove the O-ring that was under the Washer /
cushion. O-Ring /
Washer
12. Remove the head assembly.
13. Remove the head static seal O-rings,
O-Ring
backup washers, rod inside diameter
dynamic seal, and rod wiper. Use care to
Cushion (Note
avoid scratching the grooves. Taper \ /)
14. Remove the O-ring and back up washers
from the piston assembly. Use care to avoid
scratching the grooves. Stopper
Reassembly
Rod Washer /
1. Remove any burrs or sharp edges caused O-Ring
from disassembly before installing the new
seals. Head
Assembly
2. Clean all parts with solvent. Lubricate parts
as indicated below with petroleum jelly or
clean hydraulic fluid. Washer /
O-Ring
3. Lubricate and install the new rod dynamic
seal and rod wiper in their respective inside
Wiper and Seal
grooves of the head assembly.
(Inside Head)
4. Lubricate and install the new head static
seal O-rings and head static seal backup
Internal
washers on the outside grooves of the head Lock Ring
assembly.
5. Lubricate the head assembly inside seals
and carefully slide the head assembly onto Spacer
the rod assembly.
6. Install the piston O-ring and backup
washers in the outside groove of the piston
External
assembly. Lock Ring
7. Install the cushion static O-ring in the
groove in the rod. Lubricate the O-ring and
the inside of the cushion and slide the
cushion over the O-ring on the rod. (The Yoke
taper faces the head assembly.)
7RCHCYL3A.TIF
8. Install the rod piston O-ring in the groove of Figure 7-152: Reach Cylinder Disassembly
the rod.
7-144 PDMM-0109 7/31/02

Hydraulic Components Reach Cylinder
9. Carefully thread (standard) or slide (deep)

the piston assembly onto the rod assembly
and tighten (standard). Install a new
prevailing torque nut and tighten. Nut
10. Lubricate the piston and head assembly
with hydraulic fluid and carefully slide it
into the tube assembly. Piston (Not
Threaded)
assembly approximately ¾ inch (19 mm).
Washer /
12. Install a new internal lock ring in the O-Ring /
groove in the tube assembly bore. Washer
13. Grip the rod firmly and pull outward until

O-Ring
the head assembly is tight against the lock
ring.
14. Install the spacer and external lock ring in
the head assembly. O-Ring
15. Stroke the cylinder rod back and forth by
hand. It should move smoothly, without Internal
binding or heavy drag. Lock Ring
Cushion
(Note
Taper \ /)
Spacer
Washer /
O-Ring
Washer /
O-Ring
Head
External
Lock Ring
Yoke
7RCHCYL2A.TIF
Figure 7-153: Deep-Reach® Cylinder Disassembly
PDMM-0109 7/31/02 7-145

Installation
1. Hold the cylinder in place and install the
clevis pin to hold the cylinder end to the
carriage.
2. Swing the cylinder up and install the clevis
pin to hold the piston end yoke to the
carriage.
3. Install the two cotter pins to hold the clevis
pins in place.
4. Install the two screws that hold the cotter
pins in place.
5. Reconnect the hydraulic hoses. Check the
hydraulic fluid level and refill if necessary.
the key switch ON.
7. Remove the blocking from the reach
mechanism.
8. Adjust the reach cylinders.
See Page 7-142.
9. Remove the blocking from the carriage.
10. Test operate the lift truck.
11. Return to service.
7-146 PDMM-0109 7/31/02

Hydraulic Components Tilt Cylinder
Tilt Cylinder
Seal Replacement
Disassembly
Head Static
1. With the cylinder removed, drain all Seal Backup
hydraulic fluid from the cylinder assembly. Washer
Internal Lock
2. Clamp the cylinder at the base end in a Head Static Ring
bench vise. Cover the ports with a clean Seal O-ring
Spacer
rag.
Refer to Figure 7-154 for the following External Lock
Ring
steps.
3. Remove the external lock ring.
Rod Wiper
4. Remove the spacer.
Rod Wear
5. Push the head assembly into the tube Ring
assembly approximately 3/4 in. (19 mm). Rod Dynamic
Tube Seal
6. Remove the internal lock ring. Assembly
7. Important: Remove the sharp edge from Piston
the back corner of the internal lock ring Assembly
Head Assembly
groove.
8. Grip the rod through the hole in the pin
and pull the rod assembly out of the tube
assembly.
9. Clamp the rod in a bench vise at the pin
hole end.
10. Loosen the piston assembly with a spanner Base
wrench. Unthread the piston assembly End Pin Hole
from the rod.
11. Slide the head assembly off the rod from
the piston end. Rod
12. Clean the male threads of the rod. Remove

the rod piston O-ring. Piston
13. Remove the head static seal O-ring, backup Wear
Ring
washer, wear ring, rod dynamic seal, and
rod wiper. Use care to avoid scratching
grooves. Piston
Seal
14. Remove the wear ring and piston dynamic
seal from the piston assembly. Use care to
avoid scratching grooves.
15. Clean all parts in solvent. Rod Piston
O-ring
7CYLASSY.WMF
Figure 7-154: Tilt Cylinder, Disassembly
PDMM-0109 7/31/02 7-147

Seal Replacement Hydraulic Components
Reassembly
1. Remove any burrs or sharp edges caused
from disassembly before installing new
seals.
2. Lubricate parts as indicated below with
3. Lubricate and install a new rod wear ring,
rod dynamic seal, and rod wiper in their
respective inside grooves of the head
assembly.
4. Lubricate and install a new head static seal
O-ring and head static seal backup washer
on the outside grooves of the head
assembly.
5. Lubricate the head assembly inside seals
with hydraulic fluid and carefully slide the
head assembly onto the rod assembly.
6. Install the piston wear ring and piston seal
in their respective outside grooves of the
piston assembly.
7. Install the rod piston O-ring in the groove of
the rod.
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. lb. (271 Nm).
9. Lubricate the piston and head assembly
with hydraulic fluid and carefully slide it
into the tube assembly.
assembly approximately 3/4 in. (19 mm).
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.
13. Install the spacer and external lock ring on
the head assembly.
14. Stroke the cylinder rod back and forth by
hand. It should move smoothly, without
binding or heavy drag.
15. Install the cylinder assembly in the lift
truck. Operate the tilt mechanism and
check for leaks.
7-148 PDMM-0109 7/31/02

Hydraulic Components Sideshift Cylinder
Sideshift Cylinder
Removal
1. Lower the carriage fully, retract the reach
mechanism, turn the key switch OFF, and
disconnect the battery connector.
2. Remove the fork stop bolt from the sideshift
carriage. See Figure 7-155 on page 7-151.
3. Remove the forks.
4. Relieve pressure in the hydraulic system by
moving the sideshift control left and right
with the lift truck turned OFF.
5. Place a drain pan under the sideshift
cylinder.
6. Detach the hydraulic hoses from the
sideshift cylinder. Cap the ends of the hoses
to prevent contamination of the hydraulic
system.
7. Remove the safety screws and loosen the
set screws located between the mounting
bolts of each lower hook. Loosen the lower
hook mounting bolts until the lower hooks
are completely lowered. See Figure 7-155
on page 7-151.
8. Lift the sideshift unit from the lift truck
carriage using a lifting device with a
minimum capacity of 1000 lb. (454 kg).
9. Remove the cylinder from the cylinder
support. Loosen the locking screws.
Remove the brackets. Lift the cylinder
assembly from the support.
Installation
1. Place the cylinder assembly in the cylinder
support. Attach cylinder brackets and
secure with locking screws.
2. Remove the lower pads from the sideshift
assembly. Grease the lower pads, then
return them to the sideshift unit.
3. Lift the sideshift unit onto the truck’s
carriage using a lifting device with a
minimum capacity of 1000 lb. (454 kg).
4. Make sure the centering lug on the cylinder
support fits completely in the center notch
of the lift truck carriage.
PDMM-0109 7/31/02 7-149

5. Remove the cylinder retaining caps.

6. Loosen the two lower hook securing bolts.
Lift the lower hook, bringing the plastic pad
in contact with the underside of the lift
truck carriage. Torque the securing bolts to
115 ft. lb. (156 Nm).
7. Torque lower hook set screws to 21 ft. lb.
(28 Nm).
8. Install the safety screw into the hole with
the set screw. Torque the safety screw to
70 ft. lb. (95 Nm).
9. Connect the hydraulic fittings to the
sideshift cylinder. Tighten the fittings to
56 ft. lb. (76 Nm).
10. Mount the forks in the notches on the
upper bar of the sideshift carriage.
11. Install the fork stop bolt with washer into
the lower bar of the sideshift carriage.
12. Reconnect and battery connector and turn
the key switch ON.
13. Operate the sideshift function through
several full cycles to bleed air back to the
reservoir. Check for smooth sideshift
operation. Inspect fittings to ensure no
leaks.
Seal Replacement
Disassembly/Reassembly
1. Secure the cylinder housing in a soft jaw
vice. The bracket slots should be pointing
up.
2. Use a wrench to turn the cylinder cap until
the ring comes out. Remove the cap. Check
that the seal passes through the recess.
3. Clean all parts with solvent. Lubricate
seals, rings, and O-rings with petroleum
jelly or clean hydraulic fluid.
4. When replacing seals, follow the correct
mounting sequence. See Figure 7-155 on
page 7-151.
7-150 PDMM-0109 7/31/02

Hydraulic Components Seal Replacement
Rod Seal Cylinder Cylinder

Retaining Cap Ring
Cap
Bushing Ring O-ring

Hydraulic
Fittings
Cylinder
Piston Cap
Bracket
Seal
Cylinder
Upper Pad Retaining
Cap
Cylinder
Housing
Set Screw
Centering
Lug
Safety
Fork Stop Screw
Bolt
Lower
Lower Pad Hook Bolt
77211_001.EPS
Figure 7-155: Bolzoni Sideshift Assembly
PDMM-0109 7/31/02 7-151

7-152 PDMM-0109 7/31/02

Mast, Chain, Hose and Cable

Mast, Chain, Hose and Cable
PDMM-0109 7/31/02 7-153

Mast Types Mast, Chain, Hose and Cable
Mast Types
Major differences in masts are listed in the
chart below. Differences in maintenance
procedures will be noted in the instructions.
Location of
Depth of Mast
Mast Type I-Beam Equalization Elevated Heights
Uprights
Chains
8 inches 5.5 inches Within mast 231 to 330 inches

R40TT-M
(20.3 cm) (14.0 cm) uprights (587 to 838 cm)

R45TT

R45TT-M

R45TT-MA
9 inches 6.5 inches In back of mast Usually above 330

R45TT-MB
(22.8 cm) (16.5 cm) uprights inches (838 cm)

DR25TT

DR30TT

DR30TT-A
9 inches 6.5 inches In back of mast Usually above 330

DR30TT-B
(22.8 cm) (16.5 cm) uprights inches (838 cm)
7-154 PDMM-0109 7/31/02

Mast, Chain, Hose and Cable Over-the-Mast Hose/Cable
Over-the-Mast
Hose/Cable
Removal
! WARNING
mast.
709G6S006.TIF
Figure 7-156: Blocking Inner and Outer Telescopics
1. Remove the mast guard.

a support block under the inner and outer
support. Clamp the support in place. See
Figure 7-156.
3. Extend the reach mechanism and place an
8.5 in. (215 mm) length of 4x4 hardwood
between the carriage frame and the scissor
end. Clamp in place.
! WARNING
within the mast. Never lift or lower
5. Loosen the three (3) retaining screws and 709G6S005.TIF

plate. See Figure 7-157. Figure 7-157: Over-the-Mast Hose/Cable Retaining Screws
PDMM-0109 7/31/02 7-155

Over-the-Mast Hose/Cable Mast, Chain, Hose and Cable
6. Remove the hose connections at the reach

mechanism and drain into a container. See Reach Cylinder Reach Manifold
Figure 7-158.
7. Disconnect the hose to be replaced at the
main manifold in the tractor.
8. Plug the open fittings to prevent
Over-the-Mast
contamination from entering the hydraulic Cable
system. Plug the open ends of the hose to
prevent residual fluid from draining out on
the lift truck or floor.
9. Remove the old hose.
Over-the-Mast Lift
Hoses Chain
Installation 709G6S009.TIF
1. Connect the new hose at the reach Figure 7-158: Over-the-Mast Hose connections (reach)
mechanism and torque to 18 ft. lb. (24 Nm).
2. Route the hose from the reach mechanism,
over the free lift cylinders, around the hose
guides on the bottom of the inner
telescopic, and finally into the opening in
the tractor frame.
3. Connect the hose at the main manifold.
4. Adjust hose tension as described under
“Adjustment” below.
5. Remove the blocking from the reach
mechanism.
the key switch ON. Operate the auxiliary
functions. Check for leaks.
7. Unclamp the mast blocking, elevate mast
enough to remove blocking, then lower
mast completely. Recheck hose tension
spring dimension as described under
“Adjustment” below.
8. Cycle auxiliary functions (reach/retract,
tilt, sideshift) several times to purge air
from the hydraulic system.
9. Check the hydraulic fluid level and refill the
reservoir as needed.
10. Reinstall the mast guard.
7-156 PDMM-0109 7/31/02

Mast, Chain, Hose and Cable Over-the-Mast Hose/Cable
Adjustment
! WARNING
mast.
1. Remove the mast guard.

support. Clamp the support in place. See
Figure 7-156 on page 7-155.
Over-the-Mast
Hoses
! WARNING
mast is necessary to complete the
following procedure, use extreme Over-the-Mast
Cable
caution while working within the
mast. Never lift or lower when your
hands are near the mast.
4. Loosen the three (3) retaining screws and

plate. See Figure 7-157 on page 7-155.
5. Adjust the hoses which go over the mast by
pulling excess hose from the reach
mechanism connection, over the free lift 3.5 / 3.8 in.
cylinders, around the hose guides on the
bottom of the inner telescopic, and finally
into the opening in the tractor frame.
6. Adjust the tensioners so the hose springs
are extended 3.5 in. (89 mm) and the cable
spring 3.8 in. (97 mm). See Figure 7-159.
7R828_005_441_G_1.CGM 828-005-443
7. Install the retaining plate and tighten the
Figure 7-159: Hose and Cable Tension Adjustment
three retaining screws.
the key switch ON.
PDMM-0109 7/31/02 7-157

Over-the-Mast Hose/Cable Mast, Chain, Hose and Cable
9. Unclamp the blocking, elevate the mast

enough to remove the blocking, then lower
the mast completely. Recheck the hose
tension spring adjustment.
10. After adjustments are completed, reinstall
the mast guard.
7-158 PDMM-0109 7/31/02

Mast, Chain, Hose and Cable Mast Bearing Shimming
Mast Bearing Shimming

Shimming a mast is done to ensure a smooth
running unit which is not too tight or too loose.
If any marks are found within the telescopics or
main frame where the rollers have been
running, they should be removed with a
sanding disk with an 80 grit paper. Do not
attempt to remove all marks, only the ridges.
A properly adjusted mast should show no more
than a 0.5 in. (12 mm) mark where the roller
touches the respective telescopic or main frame.
The assembly should be shimmed to the
tightest spot on the assembly (as the rollers run
up and down the rail). Small areas that are
slightly higher than the rest of the web can be
buffed to avoid shimming the major portion of
the rail too loose.
The shims used under each roller bearing come
in the following sizes: thin, medium, and thick.
When the truck is built, the factory typically
installs a thick shim on each side. If the
bearings are too loose, you should add shims to
the bearing. If the roller bearings are shimmed
too tight, causing wear along the I-beam or
mast shaving, reduce the shim thickness.
Although different combinations of shims may
be used to obtain the proper adjustment, you
should try to maintain equal shim thickness on
each side of the mast.
Mast Bearing Shimming
! WARNING
mast.
1. Slightly elevate the mast to gain access to

the bearings. See Figure 7-160.
2. Block the mast into position before you
attempt to adjust the roller bearing.
709G6S001.TIF
Figure 7-160: Blocking Mast
PDMM-0109 7/31/02 7-159

Mast Bearing Shimming Mast, Chain, Hose and Cable
You may also use a lift hoist to pull the

mast upward to get access to the roller
bearing. Put a strap suitable to handle the
weight of the mast around the uppermost
cross tie. Once the mast is raised in place,
block it into position.
! CAUTION
Do not damage the telescopic when
prying with the screwdriver.
NOTE: For the upper mast bearings, wedge a

screw driver between the roller bearing
and the mast to prevent the bearing
from falling. See Figure 7-161.
NOTE: When removing the roller bearing, use
caution not to let the bearing fall down
into the mast assembly.
4. Remove the bolt securing the roller bearing
to the respective mast or telescopic.
NOTE: If the bearings are worn or damaged, Bearing
replace them. Location
713G6S073.TIF
Figure 7-161: Upper Mast Bearing, Outer Telescopic
7-160 PDMM-0109 7/31/02

Mast, Chain, Hose and Cable Complete Mast Shimming
5. Add an equal number of shims on each side

so that total lateral movement between the
telescopics is 0.030 to 0.045 in. (0.76 to
1.14 mm).
6. Make sure the roller bearing mounting
bolts are clean before you install them.
(P/N 990-536) on the threads.
8. Torque the bolts per Table 7-1.
the key switch ON.
10. Lift the carriage mast and unblock the
mast.
11. Test the operation of the telescopics.
12. Return the truck to service.
Bearing
Location
713G6S074.TIF
Figure 7-162: Upper Mast Bearing, Main Mast
Table 7-1: Mast Bearing Stud Retaining Bolt Torque Values

Mast
R40TT-M, R45TT,
Frame/Tele
R45TT-M, R45TT-MA R45TT-MB,
DR25TT, DR30TT, DR30TT-B
DR30TT-A
200 ft. lb. 280 ft. lb.

Main Frame
(271 Nm) (380 Nm)
Outer Tele 260 ft. lb. 260 ft. lb.

Lower (353 Nm) (353 Nm)
Outer Tele 260 ft. lb. 260 ft. lb.

Upper (353 Nm) (353 Nm)
Inner Tele 260 ft. lb. 260 ft. lb.

Lower (353 Nm) (353 Nm)
Complete Mast Shimming

Objective of Mast Shimming
The objective of shimming a mast is to ensure a
smooth running unit which is neither too tight
nor too loose.
PDMM-0109 7/31/02 7-161

Complete Mast Shimming Mast, Chain, Hose and Cable
If any marks are found within the telescopics or

main frame where the rollers have been
running, they should be removed with a
sanding disk with an 80 grit paper. Do not
attempt to remove all marks, only the ridges.
A properly adjusted mast should show no more
than a 0.5 inch (12 mm) mark where the roller
touches the respective telescopic or main frame.
The assembly should be shimmed to the
tightest spot on the assembly (as the rollers run
up and down the rail). This usually occurs at
the mast crosstie. Small areas that are slightly
higher than the rest of the web can be buffed to
avoid shimming the major portion of the rail too
loose.
This section describes procedures for:

• Disassembling the three-stage mast
• Shimming main frame to outer telescopic
• Shimming outer telescopic to inner
telescopic
• Shimming inner telescopic to carriage
Mast Disassembly
1. Remove the overhead guard and glass mast
guard.
2. Elevate the telescopics to expose the
auxiliary hose retaining plate on the bottom
of the outer telescopic. Remove the
retaining plate.
3. Fully lower the carriage and be sure the
pressure is out of the cylinders.
the battery connector. Remove the battery.
5. Disconnect the over mast cable and hoses
and plug the hoses. Tie the hoses and cable
to the load backrest on the carriage. 7P5050022.TIF
Disconnect the lift hose and plug. See Figure 7-163: Mast Disassembly, securing hoses/cable
Figure 7-163.
6. Secure the main carriage and telescopics so
that they cannot move during the following
steps.
7. Remove the tractor from the mast and block
each securely.
7-162 PDMM-0109 7/31/02

8. With a suitable hoist, carefully lay the mast

assembly down and block securely in place.
9. Disconnect and remove the lift chains.
10. Remove the main carriage by sliding it out
the bottom of the inner telescopic. Set it
aside for later reassembly.
11. Extend the telescopics to gain access to the
lift cylinder mounting bolts. Secure the
telescopics so they cannot collapse.
Disconnect and remove the lift cylinders
from the telescopics.
12. Remove the equalization chains and
anchors and the equalization chain sheaves
to avoid damage.
13. Back the backlash bolts off fully to facilitate
removal without scraping the main frame.
14. Remove the upper roller bearing bosses and
roller bearings from the outer telescopic.
15. Remove the telescopics and mainframe
stops.
16. Attach the hoist to the inner telescopic and
slide it out of the top of the outer telescopic.
17. Remove the upper roller bearing bosses and
roller bearings from the main frame.
18. Attach the hoist to the outer telescopic and
slide it out of the top of the main frame.
Shimming Main Frame to Outer

Telescopic
1. Install the mast roller bearings at the
bottom of the outer telescopic.
2. Using a suitable lifting device, insert the
outer telescopic into the main frame all the
way to the bottom.
3. Using a pry bar, move the outer telescopic
and roller bearing to one side.
4. Use spare shim(s) as a gauge to determine
the amount required to move the roller
bearings outward to make contact with the
main frame.
5. Remove the outer telescopic from the main
frame. 7P5050020.TIF
6. Remove the roller bearings from both roller Figure 7-164: Shimming Outer Telescopic Bearing
bearing bosses at the bottom of the outer
telescopic.
PDMM-0109 7/31/02 7-163

7. Install one half of the total shim thickness

required to each roller bearing boss at the
bottom of the outer telescopic. (Applying
one half of the total shim thickness to each
side of the telescopic maintains the center
line of the mast assembly.)
8. Reinstall the roller bearings.
9. Using a suitable lifting device, reinstall the
outer telescopic into the main frame and
check for tight areas while moving the outer
telescopic to the bottom of the main frame.
Add or remove shims as necessary to
maintain a snug but free-running fit.
NOTE: If the outer telescopic hangs up, a pry
bar may be used to move the telescopic.
10. With the outer telescopic fully nested, use a
pry bar to check for roller bearing tightness.
If a thin shim can be inserted between the
roller bearing and the main frame, then
remove the outer telescopic and install the
shim between the bearing and the roller
boss. Leave the lifting device connected to
the outer telescopic. Use care not to apply
excessive pressure to the roller bearings
with the pry bar.
outer telescopic fully, checking for tight
spots that may create a hang-up condition
during normal operation. If the outer
telescopic can be moved in and out by
hand, the assembly should not hang up
during normal operation.
12. Assemble two roller bearings and bosses
without shims.
13. On one side of the main frame/outer
telescopic assembly, insert the roller
bearing assembly and attach with a
retaining bolt. Draw the bearing boss up
snug to the main frame.
14. Install the second roller bearing assembly,
attach with a retaining bolt, and snug up to
the main frame.
NOTE: Failure to snug the assemblies to the
main frame will result in the wrong
amount of shims, since the studs are
canted.
7-164 PDMM-0109 7/31/02

15. Using a pry bar, with care, move the outer

telescopic to the other side. Using spare
shims between the bearing and outer
telescopic, determine the amount of shims
required to remove side play.
16. Remove the roller bearing mounting bolts,
then remove the roller bearing assemblies.
to each roller bearing assembly.
18. Install a roller bearing assembly into one
side of the outer telescopic/main frame and
attach with a mounting bolt and tighten.
19. Install a roller bearing assembly into the
other side of the outer telescopic/main
frame and attach with a mounting bolt and
tighten.
20. With the outer telescopic fully nested, use a
pry bar to check for bearing tightness. If a
shim or more can be inserted between the
bearing and the outer telescopic, then
remove the roller bearing assembly and
install the shim(s). Reinstall the roller
bearing assembly.
21. Check for proper shimming by pulling the
outer telescopic out and then pushing it in
all the way. The outer telescopic should not
hang up while moving it in and out.
22. Install the stops at the upper cross tie.
Shimming Outer Telescopic to Inner

Telescopic
1. Install the mast roller bearing at the bottom
of the inner telescopic.
inner telescopic into the outer telescopic all
the way to the bottom.
3. Using a pry bar, move the inner telescopic
and bearings to one side.
PDMM-0109 7/31/02 7-165


the amount required to move the bearings
outward to make contact with the outer
telescopic.
5. Remove the inner telescopic from the outer
telescopic.
6. Remove the bearings from both roller
bosses at the bottom of the inner telescopic.
required to each roller boss at the bottom of
the inner telescopic. (Applying one half of
the total shim thickness to each side of the
telescopic maintains the center line of the
mast assembly.) 7P5050017.TIF
Figure 7-165: Shimming Inner Telescopic Bearing

8. Reinstall the roller bearings.
inner telescopic into the outer telescopic.
Check for tight areas while moving the
inner telescopic to the bottom of the outer
telescopic.
NOTE: If the inner telescopic hangs up, use a
pry bar to move the telescopic.
10. With the inner telescopic fully nested, use a
thin shim can be inserted between the
bearing and the outer telescopic, then
remove the inner telescopic and install the
shim between the bearing and the roller
boss. Leave the lifting device connected to
the outer telescopic. Use care not to apply
excessive pressure to the bearings with
the pry bar.
inner telescopic fully, checking for tight
spots that may create a hang-up condition
during normal operation. If the inner
telescopic can be moved in and out by
hand, the assembly should not hang up
during normal operation.
12. Assemble two roller bearings and bosses
without shims.
13. On one side of the inner telescopic/outer
telescopic assembly, insert the
bearing/boss assembly and attach with a
flat head retaining bolt. Draw the bearing
boss up snug to the outer telescopic.
7-166 PDMM-0109 7/31/02

14. Install the second bearing/boss assembly,

attach with a flat head retaining bolt, and
snug up to the outer telescopic.
NOTE: Failure to snug the assemblies to the
main frame will result in the wrong
amount of shims, since the studs are
canted.
15. Using a pry bar, with care, move the inner
telescopic to the other side. Using spare
shims between the bearing and inner
16. Remove the bearing/boss mounting bolts,
then remove the bearing/boss assemblies.
to each bearing/boss assembly.
18. Install a bearing/boss assembly into one
side of the outer telescopic/inner
telescopic. Attach with a mounting bolt and
tighten.
19. Install a bearing/boss assembly into the
other side of the outer telescopic/inner
telescopic. Attach with a mounting bolt and
tighten.
20. With the inner telescopic fully nested, use a
bearing and the inner telescopic, then
remove the bearing/boss assembly and
install the shim(s). Reinstall the
bearing/boss assembly.
21. Check for proper shimming by pulling the
inner telescopic out and then pushing it in
all the way. The inner telescopic should not
hang up while moving it in and out.
22. Install the stops at the upper cross tie.
23. Install the equalization chains. See
“Equalization Chains” on page 7-179.
24. Install the lift cylinders. See “Lift Cylinders”
on page 7-123.
PDMM-0109 7/31/02 7-167

Shimming Inner Telescopic to

Carriage
1. Install the mast roller bearing on roller
bosses at the bottom of the carriage.
carriage into the inner telescopic all the way
to the bottom.
NOTE: The carriage may have to be removed
several times to obtain the proper fit.
3. Using a pry bar, move the bottom carriage
bearings to one side.
the amount required to move the bearings
outward to make contact with the inner
telescopic.
5. Remove the carriage from the inner
telescopic. Leave the lifting device
connected to the carriage.
6. Remove the bearings from both roller
bosses at the bottom of the carriage.
required to each roller boss at the bottom of
the carriage. (Applying one half of the total
shim thickness to each side of the carriage
maintains the center line of the mast
assembly.)
carriage into the inner telescopic. Check for
tight areas while moving the carriage to the
bottom of the inner telescopic.
NOTE: If the carriage hangs up, be careful not
to pull to the point of causing personal
injury.
9. With the carriage fully nested, use a pry bar
to check for bearing tightness. If a thin
shim can be inserted between the bearing
and the inner telescopic, then remove the
carriage and install the shim between the
bearing and the roller boss. Leave the lifting
devise connected to the carriage. Use care
not to apply excessive pressure to the
bearings with the pry bar.
7-168 PDMM-0109 7/31/02


carriage fully, checking for tight spots that
may create a hang-up condition during
normal operation. If the carriage can be
moved in and out by hand, the assembly
should not hang up during normal
operation.
11. Assemble two roller bearings on the center
roller bosses without shims.
carriage into the upper portion of the inner
telescopic.
13. Using a pry bar, with care, move the
carriage to the one side. Using spare shims
between the roller bearing and inner
14. Move the carriage out of inner telescopic to
expose the center roller bearings.
15. Remove the center roller bearings.
to each center roller bearing boss. Reinstall
the center roller bearings.
17. Insert the carriage into the upper portion of
the inner telescopic.
18. With the carriage fully nested, use a pry bar
to check for roller bearing tightness. If a
roller bearing and the carriage, then remove
the carriage and install the shim(s).
Reinstall the carriage.
19. Remove the carriage and install roller
bearings to the two upper carriage roller
bearing bosses.
20. Insert the carriage into the inner telescopic
until the roller bearings are fully engaged.
21. Using spare shims, determine the number
of shims for each top roller bearing of the
carriage.
22. Move the carriage out of the telescopic to
expose the upper carriage roller bearings.
Remove the roller bearings and install the
shims, retaining screw and washer.
23. Check for proper shimming by moving the
carriage all the way into the inner
telescopic. The carriage should not hang-up
while moving the carriage.
PDMM-0109 7/31/02 7-169

NOTE: If the carriage hangs up, do not pull to

the point of causing personal injury.
24. Install the carriage and the carriage stops.
25. Install the lift chains and attach the main
carriage.
26. Secure the main carriage and telescopics in
place so that they do not move while
standing the assembly back up.
27. Install all the other items removed during
the disassembly process after laying the
assembly down.
28. Attach the hoist to the mast assembly and
stand the mast back up.
29. Attach the tractor to the mast.
30. Install the remaining components.
31. Adjust the lift and equalization chains. See
“Equalization Chains” on page 7-179.
32. Adjust the mast backlash bolts. See “Mast
Backlash Adjustment” on page 7-184.
! WARNING
Ensure all mast stops are installed
and securely tightened before
operating the lift truck.
33. Grease the channels.

34. Reinstall the battery.
the key switch ON.
36. Check for proper operation.
7-170 PDMM-0109 7/31/02

Mast, Chain, Hose and Cable Bearings, Reach Carriage
Bearings, Reach
Carriage
The upper reach carriage roller bearing is
accessible when the carriage is elevated. Two
other roller bearings are located within the mast
assembly on either side. The reach carriage
must be removed to access these bearings.
The lower bearings are shimmed at the factory
so that there is no play between the carriage
and the inner telescopic. If the carriage
becomes loose within the inner telescopic, the
lower roller bearings may require additional
shims. If possible, maintain an equal amount of
shim thickness on each side.
If the carriage hangs up in the telescopic during
lowering, one or more of the roller bearings may
be damaged or worn and require replacement.
Removal
1. Remove the carriage. See “Reach Carriage
2. Remove the socket head cap screw and
washer on the end of the bearing.
3. The carriage bearing should slide off the
shaft with hand pressure. A suitable
bearing puller may be required, however,
for removal.
4. Repeat steps 2 and 3 for the other five
bearings.
Installation
1. Install the new bearing on the shaft. Apply
the socket head cap screw. Fasten the cap
screw and washer in place.
713G6S080.TIF
2. Repeat step 1 for the other five bearings.
Figure 7-166: Reach Carriage Roller Bearings
3. Re-install the carriage. See “Reach Carriage
4. Test the lift/lower functions of the carriage.
5. Return the truck to service.
PDMM-0109 7/31/02 7-171

Bearings, Reach Half Shaft Mast, Chain, Hose and Cable
Bearings, Reach Half

Shaft
Removal
1. Place 4 in. x 4 in. blocks where the tips and
base of the forks will touch the floor when
lowered.
2. Fully extend the reach mechanism and Half Shaft
lower the forks onto the blocks. Bearings
! CAUTION
You must support the forks with
blocks when performing this 709G6S021.TIF
procedure. Otherwise you may bend Figure 7-167: Half Shaft Location
or damage the half shaft bolts.
4. Remove the cap screw.

5. Wedge the half shafts apart.
6. Pry the damaged half shaft from the
assembly.
Installation
1. Install the inner half (threaded) into the
bearing and start it into the carriage frame
weld.
2. Install the outer half (countersunk) into the
bearing and start it into the carriage frame
weld.
7DS903A.TIF
Figure 7-168: Half Shaft Assembly
7-172 PDMM-0109 7/31/02

Mast, Chain, Hose and Cable Bearings, Reach Half Shaft
! CAUTION
If at any time it is necessary to tap
on the half shaft to insert it into the
frame weld, place a wooden block
over the shaft before gently tapping
it into place.
Do not hammer on the outside flange

of the half shaft. If it is necessary to
use heavy force to install the half
shaft, then the parts are not properly
aligned or the hole and half shaft are
not the same diameter.
3. Lubricate the reach assembly using chassis

and bearing grease (P/N 990-620).
4. Insert the cap screw into the threaded half
and torque to 25 ft. lb. (34 Nm).
the key switch ON.
6. Test the reach/retract functions.
PDMM-0109 7/31/02 7-173

Reach Carriage Assembly Mast, Chain, Hose and Cable
Reach Carriage
Assembly
Removal
! WARNING
mast.
1. Remove the glass mast guard.

Blocking
2. Elevate and extend the carriage to gain
access to the carriage stops on each side. 74612_018.TIF
3. Remove the carriage stops. Figure 7-169: Blocking Reach Mechanism and Forks
4. Place blocks at the position where the rear

of the carriage and the front of the fork tips
will rest upon the floor and lower the
carriage on to blocks. See Figure 7-169.
5. Block the scissor assembly so that it cannot
retract. See Figure 7-169.
7. Remove the outside covers from the pulley
assembly.
8. Slide the over-the-mast hoses and cable off
the pulley.
9. Secure the chain with a wrench while
removing the chain tensioner nut. Remove
the chains from the chain tensioners on the
mast assembly.
10. Remove the chains from the pulley and
place them over the carriage assembly, out
713G6S077.TIF
of the work area. See Figure 7-170.
Figure 7-170: Carriage Removal, Hoses, Cable, and Chains
7-174 PDMM-0109 7/31/02

Mast, Chain, Hose and Cable Reach Carriage Assembly
! WARNING

the key switch ON.
12. Slowly elevate the mast until the telescopics
have risen above the carriage and the
carriage is sitting by itself. Be careful not to
run out of slack in the over-the-mast
hydraulic hoses and cables. 713G6S080.TIF
13. Carefully back the lift truck away from the Figure 7-171: Carriage Removed
carriage until you run out of slack (1 or
2 feet) for the over-the-mast hoses and
cables. See Figure 7-171.
14. Lower the mast.
16. Remove the hydraulic hoses and the
over-the-mast cable from the carriage
assembly. Cap hoses and plug ports to
prevent contamination from entering hoses
or cylinders.
17. Remove the carriage assembly.
PDMM-0109 7/31/02 7-175

Reach Carriage Assembly Mast, Chain, Hose and Cable
Installation
1. Attach over-the-mast hydraulic hoses and
electrical cable to the new carriage
assembly.
! WARNING

the key switch ON.
3. Elevate the telescopics so they are just
higher than the carriage assembly. Be
careful not to run out of slack in the
over-the-mast hydraulic hoses and cable.
4. Drive the lift truck up to the carriage.
5. Position the mast and telescopics over the
carriage assembly. Lower the mast
assembly onto the bearings of the carriage
assembly.
7. Place the chains over the pulley and down
into the mast for connection to the chain
tensioners. Insert the chain tension bolt
into the anchor. Use a wrench to hold the
chain while tightening the nut onto the
chain tension anchor bolt.
8. Remove the outside covers of the pulley
assembly as necessary. Position the
over-the-mast hydraulic hoses and
electrical cable over the pulleys.
9. Install the outside covers over the pulley
assembly.
10. Reconnect the battery connector.
11. Remove the blocking from the scissor
assembly.
7-176 PDMM-0109 7/31/02

Mast, Chain, Hose and Cable Reach Carriage Assembly
! CAUTION
Be careful when lifting the forks.
Stop if you hear or see any
problems. If there is a problem,
lower the carriage and repeat the
previous steps as necessary.
12. Slowly elevate the forks.

13. Elevate the carriage enough to provide
access to the location on the mast where
the carriage stops are positioned. Install the
carriage stops.
14. Remove blocks from underneath the
carriage assembly.
15. Lower the carriage. Adjust chain tension.
16. Test all lift/lower functions for proper
operation and adjustment. Return lift truck
to service.
PDMM-0109 7/31/02 7-177

Forks Mast, Chain, Hose and Cable
Forks
Fork Inspection
Unworn thickness
Visually inspect all fork surfaces for signs of
Minimum
damage, including, but not limited to: excessive worn thickness
wear, bends, cracks, welding arcs, excessive
heat, or unauthorized modifications.
Inspect forks for amount of wear on the bottom
surface, as follows:
1. Using “Fork Wear Calipers” (P/N 922-369,
Figure 7-172), set the outer-most points of
the wear caliper to the thickness of the
43
unworn vertical shank. See Figure 7-173.
255
DS2
DS#
7CALIPERS.EPS
Figure 7-172: Fork Wear Calipers

2. Without changing the setting, move to the
untapered portion of the base of the fork.
The inner points of the caliper represent the
minimum acceptable thickness. If the inner
points pass over any portion of the
untapered base of the fork, the fork must Shank
(un-worn portion)
be replaced.
Un-tapered portion
7FORKS.EPS
Figure 7-173: Fork Wear Inspection
7-178 PDMM-0109 7/31/02

Mast, Chain, Hose and Cable Equalization Chains
Equalization Chains
Adjustment
The equalization chains on the three-stage
masts must be adjusted properly to prevent the
possibility of stretched hoses and electrical
cables.
The equalization chains are located between the
outer telescopic and the main frame.
! CAUTION
With both equalization chains slack,
note the relationship between the
top of the mast main frame and the
telescopic frame section.
UNDER NO CIRCUMSTANCES should
the equalization chains be adjusted
so that the inner telescopic is raised
above the position noted before
starting the adjustment procedure.
1. The equalization chains are properly

adjusted if the inner telescopic contacts the
mechanical stops on the outer telescopic
just before the outer telescopic contacts the
mechanical stops on the main frame.
2. The adjusters are located near the top of
the main mast, between the mast main
frame and the outer telescopic. See
Figure 7-174. To adjust the equalization
chains, turn the chain anchor lock nut
until the outer telescopic starts to move,
then loosen the nut one-half turn. Repeat
this step for the other side.
3. Check the adjustment by elevating the
carriage (if required) so that 4 to 5 feet (1.2
to 1.5 m) of the equalization chains are Equalization
Equalization
visible. Chain
Chain Anchor
Adjustment
the battery connector. 713G6S085.TIF
Figure 7-174: Equalization Chain Adjustment
PDMM-0109 7/31/02 7-179

Equalization Chains Mast, Chain, Hose and Cable
5. Using your fingers, apply pressure on each

chain. Determine if the pressure is
approximately the same on both sides. If
there is a significant difference between the
two sides, repeat this procedure on the
chain that has the lower tension.
NOTE: Make only minor adjustments to ensure
that the chains are not overtightened.
Make adjustments equally to both sides.
Always recheck chain tension after any
adjustments are made to either or both
equalization chains.
Lubrication
! CAUTION
Do not steam clean or degrease the
equalization chains.
1. Apply lubricant to the chain. See

“Lubrication Specification Chart” on
page A-2.
2. Make sure the exterior surface is covered to
prevent rust and to make sure that the
lubricant penetrates the chain joints to
reduce wear.
7-180 PDMM-0109 7/31/02

Mast, Chain, Hose and Cable Equalization Chains
Removal
! WARNING
mast.
With the mast attached to the tractor,

NEVER remove both equalization
chains at the same time.

telescopics. Lower mast onto support. See
Figure 7-175. Clamp the support in place.
713G6S084.TIF
Figure 7-175: Blocking Inner and Outer Telescopics

3. Loosen the lock nut on the equalization
chain adjuster. See Figure 7-176.
713G6S086.TIF
Figure 7-176: Equalization Chain Adjuster Lock Nut
PDMM-0109 7/31/02 7-181

Equalization Chains Mast, Chain, Hose and Cable
4. Remove the two hex head cap screws at the

top of the mast main frame.
See Figure 7-177.
5. Using a screwdriver, push the chain anchor
support towards the center of the mast.
Once the anchor support clears the welded
block on the inside of the mast main frame,
use a screwdriver to slide the adjuster and
chain down the mast.
6. Disconnect the chain from the inner
telescopic chain anchor. Equalization
Chain Anchor
7. Pull the cotter pin out. Unthread the Cap Screws
anchor one-quarter turn. Remove the
master link. 73437_001.TIF
Figure 7-177: Equalization Chain Anchor Cap Screws
Installation
1. Ensure the truck mast is blocked and
clamped. See Figure 7-175 on page 7-181.
2. Attach the new chain to the inner
telescopic.
3. Attach an 8 to 10 foot (2.4 to 3.0 m) length
of wire to the chain anchor.
4. Pull the chain anchor (using the wire
attached above) and chain up between the
mast main frame and outer telescopic.
5. With the chain anchor in the proper
position, start the two hex head cap screws,
then tighten.
6. Ensure that chain is not twisted.
7. Remove the length of wire.
8. After reassembly of the equalization chain,
adjust the tension using the procedure on
Page 7-179.
7-182 PDMM-0109 7/31/02

Mast, Chain, Hose and Cable Fork Carriage Tilt Pins
Fork Carriage Tilt Pins

Removal
To facilitate removal of the fork carriage tilt
pins, a 3/8-16 UNC-2B thread is tapped in the
exposed end. The following is a suggestion for Screw &
Lock Nut
removal.
1. Retract the reach mechanism fully and tilt
the forks fully down.
2. The carriage may be resting on the floor
with slack in the lift chains.
3. Turn the key switch OFF and disconnect Tilt Pin
4. Remove the lock nut and screw that secure
the tilt pin in the fork carriage. 72690_025.TIF
See Figure 7-178. Figure 7-178: Fork Carriage Tilt Pin
5. Thread a piece of threaded rod into the

tapped hole of the pin to be removed.
6. Place a large socket, or tubing (1-5/8 in.
[41.2 mm] minimum diameter) over the
threaded rod.
7. Place a flat washer on the threaded rod up
against the socket or tubing.
8. Tighten a 3/8-16 UNC nut against the flat
washer. This should extract the tilt pin. See
NOTE.
NOTE: If the tilt pin is rusted in place, heat may
be required.
Installation 7pivotpin.pcx
Figure 7-179: Removing Tilt Pivot Pin

1. Apply grease to new tilt pin and insert into
fork carriage, aligning the hole in the pin
with the hole in the fork carriage.
2. Install the screw through the fork carriage
and pivot pin. Secure with the lock nut
removed earlier.
4. Test truck operation.
PDMM-0109 7/31/02 7-183

Mast Backlash Adjustment Mast, Chain, Hose and Cable
Mast Backlash
Adjustment
Adjustment
Backlash adjustment screws are located at the
base of both sides of the outer telescopic.
Adjust triple section mast backlash as follows: Equalization
Chain (except
1. Perform adjustment with no load on the mast type -B)
forks. A load will tend to increase this
clearance. If backlash is set with a load on
the forks, the mast will bind with no load.
2. Back out backlash adjustment screws until
there is slight interference with the main Mast Backlash
mast frame. Bolt
3. Elevate the mast slowly, watching the
backlash adjustment screws.
a. If there is severe interference due to
clearance variations, turn the screws
back into the telescopic slightly. Chain Sheave
b. When adjusted properly, the screws will
73422_001.TIF
drag on the main mast frame sufficiently
Figure 7-180: Mast Backlash Bolt location
to remove paint, but not to gouge or
remove metal from the mast frame.
4. Tighten the lock nut after final setting.
7-184 PDMM-0109 7/31/02

Options
Options
PDMM-0109 7/31/02 7-185

Cold Storage Requirements Options
Cold Storage
Requirements
NOTE: Conversion of EASi Reach-Fork® lift
trucks for cold storage operation
requires prior Raymond approval via
Form S207.
New EASi Reach-Fork lift trucks to be operated
in a cold storage environment require the
following:
Components
Required
• Special cold storage control handle
assemblies with heaters
• Wire mesh mast guard
• Optional heated floor pad
Not Permitted
• Glass or Plexiglas mast guard
• U.L. E or EE label
Lubricants
See the “Lubrication Specification Chart” on
page A-2 for special hydraulic fluid and drive
unit lubricants for cold storage operation.
Spray battery rollers and shaft with teflon
grease (P/N 990-652/001).
Grease carriage fittings with cold storage grease
(P/N 990-652/002).
Sealing Treatment
Apply sufficient cold storage sealing compound
(P/N 990-564) to the following parts to prevent
moisture from entering:
• EPO button
• Key switch terminals
• Light and fan switch terminals
• Deadman switch terminals
• All control wire (18 GA) terminals and
terminal strip posts
7-186 PDMM-0109 7/31/02

Options Cold Storage Requirements
• All connectors not located in a heated

compartment (Apply sealing compound
where the wires enter the connector and
where the connector attaches to the circuit
board.)
• Proportional valve terminals
• Lift motor temperature sensor
• Operator display interface card - coat both
sides completely
Corrosion Inhibitor Coating

Coat or spray bare metal surfaces listed below
with Corrosion Inhibitor Coating (P/N 990-644):
• Reach cylinder cotter pins
• Lift cylinder chain pulleys and shafts
• Lift chain anchor threaded pins
• Drive unit dipstick
PDMM-0109 7/31/02 7-187

Fork Height-Tilt Indicator (HTI) Options
Fork Height-Tilt Indicator

(HTI)
The fork height-tilt indicator (HTI) is a set of
mechanical, hydraulic, and electrical
components designed to provide the EASi
Reach-Fork® lift truck operator with a digital
display of the fork height during main lift, and a
positive display of level forks.
Fork Height Indicator

The fork height indicator consists of:
• an HTI operator display mounted on the
mast guard
• a cable attached to the top and bottom of
the outer telescopic
• an encoder/pulley assembly attached to the
top of the mainframe
The function of the fork height indicator is to
assist an operator’s judgment when depositing
or retrieving loads above free lift.
Fork Tilt Indicator

The fork tilt indicator consists of:
• an LED on the HTI operator display
• a pressure switch in the hydraulic system
• tilt plates and shims mounted to the fork
carriage to prevent the fork carriage from
tilting below level
The purpose of the fork tilt indicator is to let the
operator know when the forks are level (within
+ 0.5 degrees).
7-188 PDMM-0109 7/31/02

Options Codes and Troubleshooting
Codes and Troubleshooting
NOTE: The following HTI fault codes appear

on the HTI display, not the main
Operator Display.
Code E1
Code Title Code E1 – HTI Encoder Channel Failed
Reason An expected signal from height encoder channel A or B

was not received.
System Response
HTI Display E1
Performance Limits
Travel System No restrictions
Lift/Lower System No restrictions
Possible Causes Malfunctioning encoder

Bad cable harness or connector
NOTE: For information on how to use HTI

Active Maintenance Mode, see “HTI
Active Maintenance Mode” on
page 7-191.
PDMM-0109 7/31/02 7-189

Code E2 Options
Code E2
Code Title Code E2 – HTI Encoder Failed
Reason The HTI height encoder system has malfunctioned
System Response
HTI Display E2
Performance Limits
Travel System No restrictions
Lift/Lower System No restrictions
Possible Causes Loss of ground (DGND) to height encoder

Loss of +5.0 volts to height encoder
Broken height sensing cable
Broken height sensing cable tension spring
Height sensing cable off pulley
Lift stopped at the speed limit switch S10
NOTE: For information on how to use HTI

Active Maintenance Mode, see “HTI
Active Maintenance Mode” on
page 7-191.
7-190 PDMM-0109 7/31/02

Options HTI Active Maintenance Mode
HTI Active Maintenance Mode

You can use HTI Active Maintenance Mode to
display the status of the inputs to the HTI
display card:
• Standard Speed Limit Switch S10
• HTI Height Encoder
• DIRA Solenoid
• DIRB Solenoid Mode Select
Button access
• Tilt Solenoid
• Tilt Pressure Switch
• HTI Display Mode Select Switch
Tilt Level LED
HTI Active Maintenance Mode is completely
independent of the main lift truck software. 72376_001.TIF
72376_001.TIF
Error code and diagnostic information is
Figure 7-181: HTI Display
displayed on the HTI Display, not the main
Operator Display.
To place the HTI in Active Maintenance Mode,
insert a paper clip (do not use a pin or other
sharp object) through the mode select button
access hole between the CM (centimeter) and
Tilt Level LEDs. Press and hold the mode select
button while turning the key switch ON.
Release the mode select button.
In Active Maintenance Mode, the HTI display
will show dashes in the last three digits. The
segments of the leading digit and the period
following will indicate the logic status of the HTI
inputs.
The tables on the next page show the segments
and their meanings.
PDMM-0109 7/31/02 7-191

HTI Active Maintenance Mode Options
A
LED
HTI Input
Segment
Standard Speed Limit Switch
A
S10 opened
F B
B Height Encoder Channel B G
DIRB Solenoid (tilt down)
C
actuated
E C
D Tilt Solenoid actuated
DIRA Solenoid (tilt up)
E
actuated . M
F Height Encoder Channel A
D
G Tilt Pressure Switch actuated 7NOT IMPORTED HTI SEGMENTS
7NOT IMPORTED
M Mode Select Switch depressed
Figure 7-182: HTI Active Maintenance Mode segments
The table below shows segment status during

tilt and lift/lower operations.
Tilt
Action A B C D E F G
LED
Tilt, at rest, any angle -- -- 0 0 0 -- 1 *
Tilting up -- -- 0 1 1 -- 1 0
Tilting down -- -- 1 1 0 -- 1 *
Tilting down, forks level -- -- 1 1 0 -- 0 1
Not lifting, within free lift zone 0 0 -- -- -- 0 -- --

Lifting, within free lift zone 0 0 -- -- -- 0 -- --
Lifting, above free lift zone 1 % -- -- -- % -- --
Lift stopped, above free lift zone 1 * -- -- -- * -- --
Lowering, above free lift zone 1 % -- -- -- % -- --
Lowering, below free lift zone 0 0 -- -- -- 0 -- --
NOTE: 1 = ON
O = OFF
% = alternating OFF/ON
* = either OFF or ON
-- = not relevant
NOTE: If the period (“M”) is on, the mode select
button may be jammed or stuck in the
7-192 PDMM-0109 7/31/02

Options Fork Height Indicator
ON position. Use a paper clip to gently

free the button.

Cable Replacement
NOTE: Regular lubrication of the cable
assembly is essential for maximum
performance. Use P/N 990-652/002.
Removal
1. Lower the fork carriage all the way. Mast
Anchor
Crosstie
2. Turn the key switch OFF and disconnect Bolt
Spring
3. Remove the anchor bolt which holds the
spring to the mast crosstie.
4. Remove the cable clamp from the cable.
Cable
5. Remove the cable from the encoder pulley Clamp
and lay it back over the mast guard into the
operator compartment.
the key switch ON.
Encoder
7. While guiding the cable carefully to avoid Pulley
snagging it, slowly elevate the fork carriage
until the bottom of the cable is accessible.
Cable
8. Block the mast or secure the fork carriage
with an overhead hoist. Turn the key switch
72376_002.TIF
OFF and disconnect the battery connector.
Figure 7-183: HTI Cable attachment (top)
9. Carefully thread the cable out the hole in
the bottom of the block on the crosstie.
Installation
1. With the mast elevated and blocked or
secured from overhead, thread the cable
from the bottom through the block on the
lower crosstie. Lay the cable back over the Encoder
operator compartment. Cable
2. Remove blocking or overhead hoist.

Reconnect the battery connector and turn
the key switch ON. While guiding the cable
carefully to avoid snagging it, slowly lower
the fork carriage all the way. Cable Ball
End
72376_003.TIF
Figure 7-184: HTI Cable attachment (bottom)
PDMM-0109 7/31/02 7-193

Fork Height Indicator Options
4. Working from the forks side, thread the

cable through the hole in the bottom of the
Top of
encoder bracket, once counter-clockwise
Bracket
around the encoder pulley, crossing
behind itself then up through the hole in
Connector PH4
the top of the encoder bracket. Ensure the
cable is not twisted. Note
Cable
5. Attach the cable securely to the cable clamp Crossover
with two nuts, allowing a 1 in. (25 mm) loop Direction
in the end.
6. Attach the spring to the cable loop and to
Bottom of
the anchor bolt. Apply thread-locking
Bracket
compound (P/N 990-536) to the anchor bolt
threads. Attach the anchor bolt to the 72376_008.TIF
crosstie. Figure 7-185: HTI Encoder Cable Path
7. Tighten the top nut until the tensioning
spring extends 0.5 in. (12.7 mm) beyond
free length. While adjusting, use a wrench
to prevent the anchor bolt from turning and
twisting the cable. Once the spring length is
correct, tighten the bottom nut to lock the
anchor bolt.
the key switch ON.
9. Slowly elevate the fork carriage and verify
that the cable is tracking properly. Lower
the fork carriage all the way.
11. Check to be sure the cable is tracking
parallel in the fore-aft dimension as it
passes around the encoder pulley. If the
cable path is not parallel, adjust the
encoder bracket in its elongated holes until
the cable path is parallel.
12. Lubricate the cable with grease
(P/N 990-652/002).
7-194 PDMM-0109 7/31/02

Options Fork Height Indicator
HTI Encoder Assembly

Removal
1. Lower the fork carriage all the way. Mast Anchor
Crosstie Bolt
Spring
3. Remove the anchor bolt which holds the
spring to the mast crosstie.
4. Remove the cable clamp from the cable.
Cable
5. Unthread the cable from the encoder pulley Clamp
and lay it back over the mast guard into the
6. Disconnect the wiring harness coming from
the encoder at connector JPH4.
Encoder
7. Remove four (4) nuts and bolts securing the Pulley
encoder assembly to the bracket.
Cable
Installation
1. Mount the encoder assembly to the bracket, 72376_002.TIF
ensuring that the wiring harness is oriented Figure 7-186: HTI Encoder Assembly Installation
in the upper left corner as viewed from the
2. Working from the forks side, thread the
cable through the hole in the bottom of the Top of Elongated
encoder bracket, once counter-clockwise Bracket Bracket
around the encoder pulley, crossing Mounting Holes
behind itself then up through the hole in
Note
the top of the encoder bracket. Ensure the Cable
cable is not twisted. Crossover
3. Attach the cable securely to the cable clamp Direction
with two nuts, allowing a 1 in. (25 mm) loop
in the end.
4. Attach the spring to the cable loop and to
the anchor bolt. Apply thread-locking Bottom of
compound (P/N 990-536) to the anchor bolt Bracket
threads. Attach the anchor bolt to the 72376_009.TIF
crosstie. Figure 7-187: HTI Encoder Assembly
5. Tighten the top nut until the tensioning
spring extends 0.5 in. (12.7 mm) beyond
free length. While adjusting, use a wrench
to prevent the anchor bolt from turning and
twisting the cable. Once the spring length is
correct, tighten the bottom nut to lock the
anchor bolt.
the key switch ON.
PDMM-0109 7/31/02 7-195

Fork Height Indicator Options
7. Slowly elevate the fork carriage and verify

that the encoder bracket assembly clears
all mast crossties and the captive plate
covering hoses and cables. Verify that the
cable is tracking properly. Lower the fork
carriage all the way.
9. Check to be sure the cable is tracking
parallel in the fore-aft dimension as it
passes around the encoder pulley. If the
cable path is not parallel, adjust the
encoder bracket in its elongated holes until
the cable path is parallel.
HTI Display Card

Calibrating and Setting the Height Indicator
Inch LED
NOTE: If the lift truck is to be used in a cold
storage environment, allow the lift truck
to adjust to the temperature of the Centimeter
working environment before calibrating LED
the HTI.
Mode
1. With the fork carriage within the free lift Select
zone, the numeric display will show four Button
periods “. . . .” Lift the fork carriage until
Tilt Level
just out of free lift. The display changes LED
from “. . . .” to a number. Numeric Segments
2. With the forks level, measure the height of 72376_006.TIF
the forks 6 in. (152 mm) in front of the fork Figure 7-188: HTI Display Card
shank.
3. The mode select button is located inside the
HTI display between the CM (centimeter)
LED and the tilt level LED. Insert a paper
clip (do not use a pin or other sharp object)
into the hole and press the button once.
The HTI tilt LED begins blinking.
7-196 PDMM-0109 7/31/02

Options Fork Tilt Indicator
4. Adjust the height shown on the display

using the tilt up/down buttons on the
control handle until it is the same as the
measurement in step 2.
5. Use the paper clip to press the mode select
button a second time. This causes the
calibrated value to be saved. The HTI units
LED starts blinking. Use the tilt up/down Mode Select
buttons on the control handle to select the Button access
desired units, either inches (IN) or
centimeters (CM). The selected unit LED
will light solid.
Tilt Level LED
6. With the desired unit LED lit, insert the
paper clip and press the mode select button 72376_001.TIF
a third time. The numeric display blanks to Figure 7-189: HTI Display
four periods “. . . .”.
7. To resume the digital height display, you
must lower the fork carriage into the free
lift zone and then elevate past free lift.
Fork Tilt Indicator

Fork Carriage Shimming
! CAUTION
Use extreme caution when blocking
the mast or fork carriage for any
reason. Never remove the block
when it is supporting the mast or
carriage.
NOTE: In cold storage applications where

operators leave the lift truck unattended
Frame Tilt Piston
in temperatures below freezing, the tilt
indicator may activate before the forks
are level, due to thickening of hydraulic
fluid.
1. Extend the reach mechanism and tilt the
forks level. Check the forks with a spirit
level to make sure they are level (± 0.5 Shims
degrees).
Tilt Plate Fork

Carriage
72376_005.TIF
Figure 7-190: Tilt Plates and Shims (one side visible)
PDMM-0109 7/31/02 7-197

Fork Tilt Indicator Options
2. If the tilt plate is in firm contact with the

fork carriage, no further adjustment is
necessary.
If the tilt plate is not in firm contact with

the fork carriage, shim the tilt plates to the
fork carriage by the steps which follow.
3. Elevate the fork carriage to a convenient
working height and block the carriage.
4. Block the reach mechanism to prevent
retracting.
6. Remove the nuts (on the tilt cylinder yoke
bolts) securing the tilt plates and shims to
the carriage.
7. Shim as needed so the tilt plate is in firm
contact with the fork carriage.
(P/N 990-536) to the tilt cylinder mounting
bolts.
9. Tighten and torque nuts to 80 ft. lb.
(108 Nm).
10. Remove blocking from mast and reach
carriage.
the key switch ON.
12. Tilt the forks up and tilt them down as far
as they will go. Check the forks with a spirit
level to make sure they are level
(±0.5 degrees).
7-198 PDMM-0109 7/31/02

Options HTI Theory of Operation
HTI Pressure Switch (S31)

Adjustment
A2 TANK P1
If the LED on the operator display does not light
when the relief valve is activated (forks are DIRB
SOL
level), check the adjustment of the tilt pressure
switch.
The HTI pressure switch needs to be adjusted L/H
Relief
H.P.
SOL
so it actuates at a pressure between the actual
working tilt down pressure and the actual tilt
down relief pressure.
1. Remove covers for access to the pressure
switch on the main manifold. DIRB Sol Pressure
DIRA Sol (under
2. Tilt the forks up. While tilting the forks switch) Switch
down, listen for the forks engaging the tilt 72608_001.EPS
stops and for the hydraulic system going Figure 7-191: HTI Pressure Switch
into relief, and watch the HTI tilt LED. The
LED should illuminate when the forks hit
the stops for level tilt.
3. Adjust the screw in the end of the pressure
switch as needed.
4. Re-attach all covers previously removed.
HTI Theory of Operation

The fork height indicator measures height
beyond the maximum free lift height.
The fork height indicator is powered by the key
switch through a connection on the system
card.
The fork height indicator monitors the state of
the speed limit switch S10, which opens when
the mast telescopic begins to elevate beyond
free lift.
While the fork carriage is in free lift, the encoder
pulley does not turn, so the HTI cannot display
height below maximum free lift. Instead, it
displays four periods “. . . .” on the numeric
display. Once the maximum free lift point is
passed (S10 opened), the HTI displays the value
previously calibrated.
As the telescopic begins to elevate past free lift,
the cable turns an encoder pulley. The encoder
pulses the pulley revolutions to the HTI display.
PDMM-0109 7/31/02 7-199

HTI Theory of Operation Options
The number of revolutions is used to calculate

the height above free lift limit.
The actual height of the forks above the floor is
displayed in 0.5 inch or 1 centimeter
increments on the height/tilt indicator (HTI)
operator display.
Calibration is done by setting the displayed
height to match a measured fork height above
free lift limit.
The HTI main harness JH1 divides under the
tractor top cover. Harness JH2-JH4 connects to
the encoder on the mast. Harness JH3 connects
to the Vehicle Manager, the DIRA and DIRB
solenoids, the tilt pressure switch S31, and the
tilt solenoid at TS19-1.
Fork Tilt Indicator

The tilt indicator gives visual confirmation
when forks are tilted level.
Tilt stop plates and shims are mounted to the
front of the fork carriage to prevent the fork
carriage from tilting downward past level (±0.5
degree).
The tilt indicator monitors the state of the tilt
solenoid, the DIRA/DIRB solenoids, and a tilt
pressure switch S31.
When the forks reach their maximum tilt down
travel, pressure increases in the aux hydraulic
line, triggering the tilt pressure switch.
The HTI tilt level LED is turned on when tilt has
been requested, the tilt direction is down, and
the tilt pressure switch has been activated.
Since the fork carriage is set with stops and
shims so the forks cannot tilt down past level
(±0.5 degree), the tilt down limit represents level
forks.
NOTE: In cold storage applications where
operators leave the lift truck unattended
in temperatures below freezing, the tilt
indicator may activate before the forks
are level, due to thickening of hydraulic
fluid.
7-200 PDMM-0109 7/31/02

EASi Reach-Fork® Truck EZ-D/DZ-D Maintenance Manual Theory of Operation
Traction System Functional Operation Traction System Functional Operation
Theory of Operation 8:
Traction System • JP2-10 to JPF1-9 to JPF2-1 to JPC8-7

(battery sense in) at the Vehicle Manager; to
Functional Operation fuse FU5 on the relay/control fuse panel to
the tips of relays K2 and K3 and to JPF3-4
NOTE: The schematics in this chapter are to S1-1 at the key switch.
intended for general understanding of
Battery negative is present at tie point TP4 on
theory of operation and may not
the contactor/fuse panel.
reflect latest developments in
circuitry. Battery negative is present at the following:
DO NOT use these schematics to • JPF1-5,-7,-11,-12,-13, and -14 on the relay
troubleshoot or repair the lift truck. control fuse panel
ALWAYS USE the schematics in the • Fuses FU10, 6, and 8 on the relay control
Appendix for troubleshooting and fuse panel
repair. • TS2-1, -2, and -3 on the relay control fuse
panel
Connecting the Battery • JPF2-4,-9,-10,-11,-12 on the relay control
fuse panel
Refer to Figure 8-1. All measurements are with
respect to TP4 (B–). • JPF5-3 and JPF5-6 on the relay control
fuse panel
When a properly charged battery is connected
to the lift truck and all fuses are good, battery • TS19-6 on the relay control fuse panel
positive is present at the following: • K1 and K2 relay coils on the relay control
fuse panel
• TPC-1 at the traction power contactor
• B– to the traction power amplifier
• PC-1 at the PC contactor
• All DGNDs, PGNDs, and AGNDs are
• TP-1 to JP2-10, JP2-11, JP2-12, JP2-13,
provided through the Vehicle Manager.
and JP2-14.
• T VEL SENSOR is provided through the
• JP2-14 to JPF1-1 to fuse FU7 and FU9 on
traction power amplifier to the drive motor
the relay/control fuse panel to TS1-1 and
speed and temperature sensors.
the tips of relay K1
• FU1 and FU3 sense are provided to the VM
• JP2-13 to JPF1-10 to fuse FU7 and FU9 on
from TP2 and TP3.
the relay/control fuse panel to TS1-1 and
the tips of relay K1 • A discharge path for the capacitors inside
the tractional power amplifier is provided
• JP2-12 to JPF1-3 to fuses FU7 and FU9 on
through (+) on the power amplifier to TP5 to
the relay/control fuse panel to terminal
T3 on the relay control fuse panel, through
strip TS1-1 and the tips of relay K1
the normally closed tips of K3 back to
• JP2-11 to JPF1-8 to fuse FU5 on the battery negative at FU10.
relay/control fuse panel to the tips of relays
K2 and K3 and to JPF3-4 to S1-1 at the key
switch; to JPF2-1 to JPC8-7 (battery sense
in) at the Vehicle Manager.
PDMM-0109 7/31/02 8-1

Theory of Operation EASi Reach-Fork® Truck EZ-D/DZ-D Maintenance Manual
Connecting the Battery Traction System Functional Operation
NOTES:
1. MAST IN FULLY LOWERED POSITION REACH CARRIAGE IN RETRACTED (NESTED) POSITION.
KEY SWITCH OFF.
2. FOR FUSES FU7 AND FU9 SEE TABLE A.
3 TSI9-7 AND TS19-6 CONNECTIONS FROM THE CONTROL FUSE PANEL ARE USED
FOR OPTIONS. SEE OPTION PAGE FOR DETAILS.
4 JPA1-1 & JPA1-2 CONNECTIONS FROM THE VM ARE USED FOR TRAVEL ALARMS.
SEE OPTION PAGE FOR DETAILS.
5 OPTIONAL, NOT ON ALL TRUCKS.
JP2
-10 AC TRACTION
-11 MOTOR VELOCITY JPT2 JPS10 JPT1 AMPLIFIER
-12 RED -1 -6 -3
T VEL SENSOR+
-13 BLACK -4 -5 -4
-14 TME T VEL SENSOR-
WHITE -3 -4 -5
T VEL PHASE A
TP1 BLUE -2 -3 -6
JP T VEL PHASE B
B+ JPT3 -7
RED -2 -8 T TEMP+
1 1 TMT RED/BLK -1 -7 -8
2 PC TPC ID0
2 -9
MOTOR TEMPERATURE ID1
U B-
U
FU1 FU2 TM V
(150A) (350A) V
TP2 1 TP5 W W
P B+ +
2 1
TR
A FU3 2
(500A)
MX TP3
S
SPL2
JP2-2
MP
S A
JP TP4
B-
T3 T1
JPF1 ˚T
-5
-11 FU10
JPF2
-12 (15A) B-F -4
1 2 -9
-13 FU6 -10
(15A) TS2-1 -11
-14 TS2-2 -12
1 2
FU8 JPF5
-7 (5A) -3 TS19
TS2-3 -6 3
1 2 -6
FU9
(15A/5A)
-1 TS1-1
1 2
FU7
-10 (15A/5A) K1 TS1-2
-3 1 2 TS1-3
FU5
(15A) S1 2 KEYSWITCH
-8 JPF3-4 1
-9 1 2 JPF3-2
K2 JPF2-5
K1 K2 K3 K3
JPF2-3
JPF5-2
B+KA JPF2-2
JPF2-8
JPF2-1
Legend:
RELAY JPF5-1 TS19 3
Positive Circuit CONTROL -7

FUSE JPF5-4
PANEL
Negative Circuit JPF3 -1
Signal or Detect
8R1005714_D_1_L.EPS
Figure 8-1: Connecting the Battery – EZ-D/DZ-D (Sheet 1 of 2)
8-2 PDMM-0109 7/31/02

Traction System Functional Operation Connecting the Battery
JPD1 JPC6
DISPLAY -9 SPLD-1 JPC5 +5V -15
-1 THROTTLE -10 VR1
-10 +12 VP
-1 -2 AGND -13
ADDR_LATCH CONTROL HANDLE
-3 -3 LIFT -11
DATA_LATCH
CONTROL HANDLE
VR2
DISPLAY
-8
-4 -4 +5V
DISP_MISO
-5 -5 HORN -7 S3
SOUNDER
-6 -6 REACH -1 S4
SHIFT_CLOCK VEHICLE
-7 -7 RETRACT -2 S5
DATA OUT MANAGER
-8 -8 TILT UP -3 S6
DGND
JPC4 TILT DOWN -4 S7
-2 -13 MEM_ENABLE -5
SSHIFT LEFT S8
SSHIFT RIGHT -6 S9
JPT1 JP2 AGND -14
TPC -2 -1 SHIELD
CONTACTOR TPC
Y X
JPC8 JP2
B+KC -14 -5
-18 -6 X Y
-1 PC_CONTACTOR PC
B+KB JPC9 JP2
-12 X -8 JP3-13
+12VP -2 -7 Y
P CONTACTOR P
-13 -9
DGND
-10 JPC10
BUS+ -9 JPB1-2 FAN 1 JPB1-1
FAN
-11
BUS-
5
TA
AC TRACTION PR JPC10
AMPLIFIER -22 JP3 1 2
2ND SOL -1 2ND
JPC9 JP3
B+KA_SUP -11 -2
L/L -5 -3 L/L
JPC4 1 2
-16 +12VP -6 -4
L/H L/H
-15 1 2
DGND
DIRB -10 -5 DIRB
-12 1 2
BUS TERMINATION
SPLC2 -7 -6
-9 DIRA DIRA
BUS+ 1 2
-10 BUS-
EQ -9 -7 EQ
JPC8 1 2
JP2
-3 -9 FU1 SENSE -4 -8
-4 B+ KA
-10 FU3 SENSE
HRN
JPC8 -NEG
JPZ SPL JPC10 -16 H-1 -IN
HORN
HORN & ALARM
PT -1 -1 -1 H
ON MP LIFT TEMP -15 H-2 -POS
T˚ -2 B+KA
-3
-2 -23 JPC10
PGND -16 JPA1-2
ALARM
4
B+KB -20 JPA1-1
JPC8
-6 DGND
-1
-2 3 TS19
B-F JPC9 TS21 BLACK
-3 RED
-12 -3 -5 BLACK -5 BLACK
B+ KA
-8 -3 WHITE -3 WHITE 2 REACH 1
REACH SOL
JPY4 JP3 JPC11
-4 -9 -1 DGND
- -3 -10 -2 -12 -2 GREEN -2 GREEN2 SIDE 1
DGND SIDESHIFT SOL
0 -2 -11 -3 PRESSURE
PRESS SHIFT
+ -1 -12 -4 +12V
-1 -1 RED -1 WHITE 2 TILT 1
TILT SOL
JPC10 NESTED SWITCH S19

-10 -4 ORANGE -4 NO COM
NESTED SWITCH
JPC8 (OPTION)
-17 B+KEY ON CARRIAGE
JPC10-19
B+KB
JPC8 JPC7
-13
DEADMAN LIMIT SWITCH
B+KC -1 JPS4
+12VP -1
SPLH3 S10
-4 -13 -2 NO COM
B+KA SPEED_LIMIT 1st SPEED
SPLH4 LIMITING SWITCH
-5 B+KA -7 -3
DGND
-7 BATTERY_SENSE_IN S2
NC
SWITCH
-5 COM
DGND
-20 AMPLIFIER ENABLE NO DEADMAN SWITCH
-16
JPC1 ON DEADMAN
-1 BUS-
PC/LOADER MODULE/SMARTI
-2 TXD
-3 RXD Legend:
-4 BUS+
-5
-6
DGND
NC
Positive Circuit
-7 BOOT
-8
-9
NC Negative Circuit
+12VP
Signal or Detect
8R1005714_D_1_R.EPS
Connecting the Battery – EZ-D/DZ-D (Sheet 2 of 2)
PDMM-0109 7/31/02 8-3

Turning Key Switch (S1) ON Traction System Functional Operation
Turning Key Switch (S1) ON 8. B+KA supplies voltage to:

a. P-contactor
During initial power-up, the Vehicle Manager
performs a SelfTest of all inputs and outputs. b. Reach, sideshift, and tilt solenoids
SelfTest takes approximately 8 seconds. During c. Solenoid coils: load holding, lift/lower,
SelfTest, contactor coils and circuits controlled DIRA, DIRB, EQ, and 2ND pump.
by the Vehicle Manager are momentarily
activated and sensor leads are checked for d. Nested switch (S19)
correct voltage signals. If a problem is detected, e. Horn
the Vehicle Manager will prevent lift truck
operation and will display a fault code for the f. Working lights and fan
detected malfunction on the Operator Display. g. Warning light
NOTE: All of the following measurements are h. Strobe light
with respect to TP4 (B–). i. Optional cooling fan for motors.
(Refer to Figure 8-2.) 9. The K2 tips supply B+ voltage to JPF5-2 to
1. Turning the key switch (S1) ON supplies JPC8-13 (B+KC).
battery potential to: 10. B+KB supplies voltage to the travel alarm
a. S1-2 to JPF3-2 to JPF2-5 to JPC8-17 at and light option via JPC10-20 and JPA1-1.
the Vehicle Manager (B+Key) 11. B+KC supplies voltage to the PC contactor
b. S1-2 to JPF3-2 to the K1, K2, and K3 (PC) coil.
relay coils 12. B+K3 supplies voltage to T3, TR, TPC-X,
2. After going through the K3 relay coil, TPC-Y, JP2-1, JPT1-2 (power amplifier). It
voltage is present at JPF3-1 (coming out of also supplies voltage to T1 and JPT1-1 (B+).
the relay control fuse panel) and back to This is the supply for the power amplifier
the Vehicle Manager at JPC8-20 (amplifier logic circuits.
enable). 13. With the key switch turned on, the Vehicle
The purpose of “amplifier enable” is to Manager power supply internally converts
supply a return path (negative voltage) for B+ into 12-volt and 5-volt supplies.
relay K3 via the coil driver, which is internal
to the Vehicle Manager.
3. If the voltage seen at Battery Sense In
(JPC8-7) is too high or too low, K3 will not
energize.
4. The K1 and K2 relay coils get their negative
from FU10 (battery negative).
5. With voltage applied to the K1, K2, and K3
relay coils, the respective relay tips will
close.
6. The K1 tips supply voltage to TS1-2 and
TS1-3 for powered options.
7. The K2 tips supply voltage to JPF2-2,
JPC8-4 (B+KA at the Vehicle Manager), and
JPF2-8 to JPC8-5 (B+KA at the Vehicle
Manager).
8-4 PDMM-0109 7/31/02

Traction System Functional Operation Turning Key Switch (S1) ON
14. 12-volts is present at:

a. JPC5-1: operator display
b. JPC1-9: SMARTi
c. JPC11-4: pressure transducer
d. JPC7-1: height-tilt indicator
e. JPC4-16: unused.
15. 5-volts is present at:
a. JPC6-15: throttle pot (VR1)
b. JPC6-8: lift pot (VR2).
To energize the AC traction power amplifier, the
following occurs:
16. B+ goes from S1-2 to JPF3-2, across relay
coil K3, then via JPF3-1 to JPC8-20
(Amplifier Enable) at the Vehicle Manager.
With the K3 relay coil energized, the relay
tips close. B+ from FU5 on the
relay/control fuse panel flows across the K3
relay tips to thermistor T3.
T3 is a 6-ohm thermistor whose purpose is
to protect TR, the in-rush current
protection resistor. If current increases in
the precharge circuit, T3 will sense the
increase. As the heat increases, T3
increases in resistance to reduce the
current flow to the amplifiers. This will
result in a Fault Code 4D.
17. B+ flows from T3 to traction power amplifier
protection resistor TR-2, TR-1, to TP5, to
TPC-X, through the TPC coil, TPC-Y to
JP2-1 to JPT1-2 (TPC contactor connection
on AC traction power amplifier).
From TR-1, B+ also flows to the AC traction
power amplifier + point. This takes between
one and two seconds. This offers protection
against an in-rush of current and allows
the capacitors in the amplifier to charge,
preparing the amplifier for operation.
With the TPC coil energized via a coil driver
inside the AC amplifier, the TPC contactor
tips close, providing B+ directly to the AC
traction power amplifier. The tips remain
energized for approximately 25 seconds,
then drop out.
PDMM-0109 7/31/02 8-5

Turning Key Switch (S1) ON Traction System Functional Operation
NOTES:
KEY SWITCH OFF.
JP2
-10
-11 MOTOR VELOCITY JPT2 JPS10 JPT1
-12 RED -1 -6 -3
T VEL SENSOR+
-13 BLACK -4 -5 -4
WHITE -3 -4 -5
T VEL PHASE A
TP1 BLUE -2 -3 -6
JP T VEL PHASE B
B+ JPT3 -7
RED -2 -8 T TEMP+
1 1 TMT RED/BLK -1 -7 -8
2 PC TPC ID0
2 -9
U B-
U
FU1 FU2 TM V
(150A) (350A) V
TP2 1 TP5 W W
P B+ +
2 1
TR
A FU3 2
(500A)
MX TP3
S
SPL2
JP2-2
MP
S A
JP TP4
B-
T3 T1
JPF1 ˚T
-5
-11 FU10
JPF2
-12 (15A) B-F -4
1 2 -9
-13 FU6 -10
(15A) TS2-1 -11
-14 TS2-2 -12
1 2
FU8 JPF5
-7 (5A) -3 TS19
TS2-3 -6 3
1 2 -6
FU9
(15A/5A)
-1 TS1-1
1 2
FU7
-10 (15A/5A) K1 TS1-2
-3 1 2 TS1-3
FU5
-8 JPF3-4 1
-9 1 2 JPF3-2
K2 JPF2-5
K1 K2 K3 K3
JPF2-3
JPF5-2
Legend: B+KA JPF2-2
Battery + Circuit JPF2-8

JPF2-1
+12 volts
+ 5 volts RELAY
CONTROL
JPF5-1 TS19
-7
3
FUSE JPF5-4
Negative Circuit PANEL
JPF3 -1
Signal or Detect
8R1005714_D_1_L.EPS
Figure 8-2: Turning the Key Switch (S1) ON – EZ-D/DZ-D (Sheet 1 of 2)
8-6 PDMM-0109 7/31/02

Traction System Functional Operation Turning Key Switch (S1) ON

JPD1 JPC6
-1 THROTTLE -10 VR1
-10 +12 VP
-1 -2 AGND -13
-3 -3 LIFT -11
DATA_LATCH
CONTROL HANDLE
VR2
DISPLAY
-8
-4 -4 +5V
DISP_MISO
-5 -5 HORN -7 S3
SOUNDER
-6 -6 REACH -1 S4
SHIFT_CLOCK VEHICLE
-7 -7 RETRACT -2 S5
DATA OUT MANAGER
-8 -8 TILT UP -3 S6
DGND
SSHIFT LEFT S8
SSHIFT RIGHT -6 S9
JPT1 JP2 AGND -14
TPC -2 -1 SHIELD
CONTACTOR TPC
Y X
JPC8 JP2
B+KC -14 -5
PC_CONTACTOR -18 -6 X PC Y
-1
B+KB JPC9 JP2
-12 -8 JP3-13
+12VP P CONTACTOR -2 -7 X P
Y
-13 -9
DGND
-10 JPC10
FAN
-11
BUS-
5
TA
2ND SOL -1 2ND
JPC9 JP3
B+KA_SUP -11 -2
L/L -5 -3 L/L
JPC4 1 2
-16 +12VP -6 -4
L/H L/H
-15 DGND 1 2
DIRB -10 -5 DIRB
-12 1 2
BUS TERMINATION
SPLC2 -7 -6
-9 DIRA DIRA
BUS+ 1 2
-10 BUS-
EQ -9 -7 EQ
JPC8 1 2
JP2
-3 -9 FU1 SENSE -4 -8
-4 B+ KA
-10 FU3 SENSE
HRN
JPC8 -NEG
HORN
HORN & ALARM
PT -1 -1 -1 H
T˚ -2 B+KA
-3
-2 -23 JPC10
PGND -16 JPA1-2
ALARM
4
B+KB -20 JPA1-1
JPC8
-6 DGND
-1
-2 3 TS19
B-F JPC9 TS21 BLACK
-3 RED
B+ KA
REACH SOL
JPY4 JP3 JPC11
-4 -9 -1 DGND
- -3 -10 -2 -12 -2 GREEN -2 GREEN2 SIDE 1
DGND SIDESHIFT SOL
PRESS SHIFT
+ -1 -12 -4 +12V
TILT SOL

NESTED SWITCH
JPC8 (OPTION)
-17 B+KEY
ON CARRIAGE
JPC10-19
B+KB
JPC8 JPC7
-13
B+KC -1 JPS4
+12VP -1
SPLH3 S10
-4 -13 -2 NO COM
-5 B+KA -7 -3
DGND
NC
Legend:
SWITCH
-5 COM
DGND
-20 DEADMAN SWITCH
JPC1
AMPLIFIER ENABLE
ON DEADMAN
-16 NO
Battery + Circuit
-1 BUS-
-2
-3
TXD +12 volts
RXD
-4
-5
BUS+
DGND
+ 5 volts
-6 NC
-7
-8
BOOT
NC
Negative Circuit
-9 +12VP
Signal or Detect
8R1005714_D_1_R.EPS
Turning the Key Switch (S1) ON – EZ-D/DZ-D (Sheet 2 of 2)
PDMM-0109 7/31/02 8-7

Startup Sequence Traction System Functional Operation
Startup Sequence SelfTest Checks

When the key switch is turned ON, the Vehicle During the SelfTest portion of power-up, the
Manager performs a series of system self-tests. following components and circuits will be
If you press and hold the horn button before checked for correct operation:
turning the key switch ON, the Operator
1. Battery voltage and whether it is within
Display will show the hour meters. During the
maximum/minimum voltage range
startup sequence, the following will be
displayed in the order and for the number of 2. Proper output of the Vehicle Manager power
seconds indicated: supply
3. No fused contactor tips (PC, TPC)
Time 4. Travel and lift pot voltages are within
Identifier* Meaning Displayed reference range
(in seconds) 5. Position of deadman switch (S2); the TPC
Key-on and PC contactors will not energize until
xxxx.xKH 4 the deadman pedal is released
hours
6. Power amplifier and traction motor
Hours on temperatures
xxxx.xHD 4
deadman
7. Lift motor temperature
Hours spent
xxxx.xHL 4 8. Communication with the Operator Display
lifting
and traction power amplifier
Traction 9. Operation of horn
xxxxx.xTM 4
miles
If a problem is detected, SelfTest will stop at the
System point of the problem and display the
SELFTEST 8
SelfTest appropriate fault code on the Operator Display.
Please
complete Message to
-
daily operator
checklist
*The Operator Display will show the hour

meters only if you press and hold the horn
button while turning the key switch to ON.
8-8 PDMM-0109 7/31/02

Traction System Functional Operation Closing Deadman Switch (S2)
Closing Deadman Switch (S2)

Standing on the deadman pedal closes the
deadman switch (S2) completing the deadman
circuit between JPC7-5 and JPC7-16 on the
Vehicle Manager, causing the following: (Refer
to Figure 8-3.)
1. The Vehicle Manager turns on a coil driver,
causing the PC contactor coil to energize.
2. The PC contactor tips close, supplying
voltage to the auxiliary motor and to the lift
contactor P-1 tip.
3. The FU1 sense line is at B+, telling the
Vehicle Manager that the PC contactor tips
are closed and fuse FU1 has continuity.
4. The Vehicle Manager sends a
communication over the BUS+/BUS– lines
to the traction power amplifier, telling the
amplifier that the deadman switch (S2) is
closed.
5. The traction power amplifier turns on a coil
driver, causing the TPC contactor coil to
energize.
6. The TPC contactor tips close, supplying B+
to the traction power amplifier.
.
PDMM-0109 7/31/02 8-9

Closing Deadman Switch (S2) Traction System Functional Operation
NOTES:
KEY SWITCH OFF.
JP2
-10
-12 RED -1 -6 -3
T VEL SENSOR+
-13 BLACK -4 -5 -4
WHITE -3 -4 -5
T VEL PHASE A
TP1 BLUE -2 -3 -6
JP T VEL PHASE B
B+ JPT3 -7
RED -2 -8 T TEMP+
1 1 TMT RED/BLK -1 -7 -8
2 PC TPC ID0
2 -9
U B-
U
FU1 FU2 TM V
(150A) (350A) V
TP2 1 TP5 W W
P B+ +
2 1
TR
A FU3 2
(500A)
MX TP3
S
SPL2
JP2-2
MP
S A
JP TP4
B-
T3 T1
JPF1 ˚T
-5
-11 FU10
JPF2
-12 (15A) B-F -4
1 2 -9
-13 FU6 -10
(15A) TS2-1 -11
-14 TS2-2 -12
1 2
FU8 JPF5
-7 (5A) -3 TS19
TS2-3 -6 3
1 2 -6
FU9
(15A/5A)
-1 TS1-1
1 2
FU7
-10 (15A/5A) K1 TS1-2
-3 1 2 TS1-3
FU5
-8 JPF3-4 1
-9 1 2 JPF3-2
K2 JPF2-5
K1 K2 K3 K3
JPF2-3
JPF5-2
B+KA JPF2-2
JPF2-8
JPF2-1
Legend:
Positive Circuit RELAY
CONTROL
JPF5-1 TS19
-7
3
FUSE JPF5-4
Negative Circuit PANEL
JPF3 -1
Signal or Detect
8R1005714_D_1_L.EPS
Figure 8-3: Closing Deadman Switch (S2) – EZ-D/DZ-D (Sheet 1 of 2)
8-10 PDMM-0109 7/31/02

Traction System Functional Operation Closing Deadman Switch (S2)
JPD1 JPC6
-1 THROTTLE -10 VR1
-10 +12 VP
-1 -2 AGND -13
-3 -3 LIFT -11
DATA_LATCH
CONTROL HANDLE
VR2
DISPLAY
-8
-4 -4 +5V
DISP_MISO
-5 -5 HORN -7 S3
SOUNDER
-6 -6 REACH -1 S4
SHIFT_CLOCK VEHICLE
-7 -7 RETRACT -2 S5
DATA OUT MANAGER
-8 -8 TILT UP -3 S6
DGND
SSHIFT LEFT S8
SSHIFT RIGHT -6 S9
JPT1 JP2 AGND -14
TPC -2 -1 SHIELD
CONTACTOR TPC
Y X
JPC8 JP2
B+KC -14 -5
-18 -6 X Y
-1 PC_CONTACTOR PC
B+KB JPC9 JP2
-12 X -8 JP3-13
+12VP -2 -7 Y
P CONTACTOR P
-13 -9
DGND
-10 JPC10
FAN
-11
BUS-
5
TA
2ND SOL -1 2ND
JPC9 JP3
B+KA_SUP -11 -2
L/L -5 -3 L/L
JPC4 1 2
-16 +12VP -6 -4
L/H L/H
-15 1 2
DGND
DIRB -10 -5 DIRB
-12 1 2
BUS TERMINATION
SPLC2 -7 -6
-9 DIRA DIRA
BUS+ 1 2
-10 BUS-
EQ -9 -7 EQ
JPC8 1 2
JP2
-3 -9 FU1 SENSE -4 -8
-4 B+ KA
-10 FU3 SENSE
HRN
JPC8 -NEG
HORN
HORN & ALARM
PT -1 -1 -1 H
T˚ -2 B+KA
-3
-2 -23 JPC10
PGND -16 JPA1-2
ALARM
4
B+KB -20 JPA1-1
JPC8
-6 DGND
-1
-2 3 TS19
B-F JPC9 TS21 BLACK
-3 RED
B+ KA
REACH SOL
JPY4 JP3 JPC11
-4 -9 -1 DGND
- -3 -10 -2 -12 -2 GREEN -2 GREEN2 SIDE 1
DGND SIDESHIFT SOL
PRESS SHIFT
+ -1 -12 -4 +12V
TILT SOL

NESTED SWITCH
JPC8 (OPTION)
JPC10-19
B+KB
JPC8 JPC7
-13
B+KC -1 JPS4
+12VP -1
SPLH3 S10
-4 -13 -2 NO COM
-5 B+KA -7 -3
DGND
NC
SWITCH
-5 COM
DGND
-16
JPC1 ON DEADMAN
-1 BUS-
-2
-3
TXD
RXD
Legend:
-4 BUS+
-5
-6
DGND
NC
Positive Circuit
-7 BOOT
-8
-9
NC Negative Circuit
+12VP
Signal or Detect
8R1005714_D_1_R.EPS
Closing Deadman Switch (S2) – EZ-D/DZ-D (Sheet 2 of 2)
PDMM-0109 7/31/02 8-11

Closing Deadman Switch (S2) Traction System Functional Operation
8-12 PDMM-0109 7/31/02

Traction System Functional Operation Requesting Travel
5. During this time, the power amplifier

monitors:
Requesting Travel
a. Output from the motor speed sensor,
When the multi-function control handle is providing motor speed and direction
moved to the forward position (towards mast or feedback from the motor.
forks-first), the voltage from variable resistor
VR1 decreases. The Vehicle Manager, sensing b. Output from the temperature sensor,
this decrease in voltage, causes the following to providing motor temperature feedback.
occur: c. Phase current, providing motor torque
feedback by comparing the current
NOTE: For clarity and simplification, only
between two phases, U and V.
circuits directly related to vehicle travel
will be traced on the remaining
operation of the travel system diagrams.
See Figure 8-4.
1. The Vehicle Manager translates the analog
input from VR1 into a digital message,
which is sent over BUS+/BUS– to the AC
traction amplifier.
2. The AC traction amplifier generates the
three phase AC to the three windings of the
AC motor (U, V and W). This AC voltage
varies in frequency (from 0 to 100 Hz) and
amplitude (voltage), in proportion to the
request from VR1 and any system
limitations (such as limit switches or
Configure Mode speed limits). Faster speed
requests mean higher frequencies and
greater voltages.
3. The three-phase AC into the stator
windings creates a changing magnetic field
equal in frequency to the input frequency.
4. The stator wires induce a changing
magnetic field, causing the rotor to begin
turning. The rotor is attempting to keep up
with the changing magnetic field of the
stator. Under normal operating conditions,
the rotor will lag slightly behind the
changing AC input.
PDMM-0109 7/31/02 8-13

Requesting Travel Traction System Functional Operation
NOTES:
KEY SWITCH OFF.
JP2
-10
-12 RED -1 -6 -3
T VEL SENSOR+
-13 BLACK -4 -5 -4
WHITE -3 -4 -5
T VEL PHASE A
TP1 BLUE -2 -3 -6
JP T VEL PHASE B
B+ JPT3 -7
RED -2 -8 T TEMP+
1 1 TMT RED/BLK -1 -7 -8
2 PC TPC ID0
2 -9
U B-
U
FU1 FU2 TM V
(150A) (350A) V
TP2 1 TP5 W W
P B+ +
2 1
TR
A FU3 2
(500A)
MX TP3
S
SPL2
JP2-2
MP
S A
JP TP4
B-
T3 T1
JPF1 ˚T
-5
-11 FU10
JPF2
-12 (15A) B-F -4
1 2 -9
-13 FU6 -10
(15A) TS2-1 -11
-14 TS2-2 -12
1 2
FU8 JPF5
-7 (5A) -3 TS19
TS2-3 -6 3
1 2 -6
FU9
(15A/5A)
-1 TS1-1
1 2
FU7
-10 (15A/5A) K1 TS1-2
-3 1 2 TS1-3
FU5
-8 JPF3-4 1
-9 1 2 JPF3-2
K2 JPF2-5
K1 K2 K3 K3
JPF2-3
JPF5-2
Legend:
B+KA JPF2-2
JPF2-1
+12 volts
+ 5 volts RELAY JPF5-1 TS19 3
CONTROL -7
Negative Circuit FUSE
PANEL
JPF5-4
JPF3 -1
Signal or Detect
8R1005714_D_1_L.EPS
Figure 8-4: Requesting Forward Travel – EZ-D/DZ-D (Sheet 1 of 2)
8-14 PDMM-0109 7/31/02

Traction System Functional Operation Requesting Travel
JPD1 JPC6
-1 THROTTLE -10 VR1
-10 +12 VP
-1 -2 AGND -13
-3 -3 LIFT -11
DATA_LATCH
CONTROL HANDLE
VR2
DISPLAY
-8
-4 -4 +5V
DISP_MISO
-5 -5 HORN -7 S3
SOUNDER
-6 -6 REACH -1 S4
SHIFT_CLOCK VEHICLE
-7 -7 RETRACT -2 S5
DATA OUT MANAGER
-8 -8 TILT UP -3 S6
DGND
SSHIFT LEFT S8
SSHIFT RIGHT -6 S9
JPT1 JP2 AGND -14
TPC -2 -1 SHIELD
CONTACTOR TPC
Y X
JPC8 JP2
B+KC -14 -5
-1
B+KB JPC9 JP2
-12 -8 JP3-13
Y
-13 -9
DGND
-10 JPC10
FAN
-11
BUS-
5
TA
2ND SOL -1 2ND
JPC9 JP3
B+KA_SUP -11 -2
L/L -5 -3 L/L
JPC4 1 2
-16 +12VP -6 -4
L/H L/H
-15 DGND 1 2
DIRB -10 -5 DIRB
-12 1 2
BUS TERMINATION
SPLC2 -7 -6
-9 DIRA DIRA
BUS+ 1 2
-10 BUS-
EQ -9 -7 EQ
JPC8 1 2
JP2
-3 -9 FU1 SENSE -4 -8
-4 B+ KA
-10 FU3 SENSE
HRN
JPC8 -NEG
HORN
HORN & ALARM
PT -1 -1 -1 H
T˚ -2 B+KA
-3
-2 -23 JPC10
PGND -16 JPA1-2
ALARM
4
B+KB -20 JPA1-1
JPC8
-6 DGND
-1
-2 3 TS19
B-F JPC9 TS21 BLACK
-3 RED
B+ KA
REACH SOL
JPY4 JP3 JPC11
-4 -9 -1 DGND
- -3 -10 -2 -12 -2 GREEN -2 GREEN2 SIDE 1
DGND SIDESHIFT SOL
PRESS SHIFT
+ -1 -12 -4 +12V
TILT SOL

NESTED SWITCH
JPC8 (OPTION)
-17 B+KEY
ON CARRIAGE
JPC10-19
B+KB
JPC8 JPC7
-13
B+KC -1 JPS4
+12VP -1
SPLH3 S10
-4 -13 -2 NO COM
-5 B+KA -7 -3
DGND
NC
Legend:
SWITCH
-5 COM
DGND
-20 DEADMAN SWITCH
JPC1
AMPLIFIER ENABLE
ON DEADMAN
-16 NO
Battery + Circuit
-1 BUS-
-2
-3
TXD +12 volts
RXD
-4 BUS+
-5 DGND + 5 volts
-6 NC
-7
-8
BOOT
NC
Negative Circuit
-9 +12VP
Signal or Detect
8R1005714_D_1_R.EPS
Requesting Forward Travel – EZ-D/DZ-D (Sheet 2 of 2)
PDMM-0109 7/31/02 8-15

Proportional Plugging Traction System Functional Operation
Proportional Plugging
When the lift truck is traveling in one direction
and the control handle is moved through
neutral to the opposite direction to stop the lift
truck and/or change direction, the process of
plugging occurs. “Proportional Plugging” means
the farther the control handle is moved, the
quicker the lift truck stops and/or changes
direction. In this example, plugging occurs from
the forks-first direction to the tractor-first
direction. Refer to Figure 8-5.
1. The traction power amplifier senses that

the lift truck is still moving in the forks-first
direction because of the input from the
drive motor speed encoder to the traction
power amplifier.
2. The Vehicle Manager senses the voltage
from VR1 and recognizes this as a request
for tractor-first travel.
3. The Vehicle Manager sends this information
to the traction power amplifier over BUS
+/–. The traction power amplifier reduces
the frequency of the AC input to the motor,
with the result that the motor speed
becomes slightly faster than the AC input.
4. As the rotor continues to rotate, it becomes
a generator, sending voltage back to the
battery, which has now become the load.
5. This process continues until the lift truck is
almost stopped. After the lift truck has
slowed almost to a stop, proportional
plugging stops and the traction system will
be in drive mode. The traction power
amplifier reverses the AC input to the stator
and tractor-first travel begins.
8-16 PDMM-0109 7/31/02

Traction System Functional Operation Proportional Plugging
NOTES:
KEY SWITCH OFF.
JP2
-10
-12 RED -1 -6 -3
T VEL SENSOR+
-13 BLACK -4 -5 -4
WHITE -3 -4 -5
T VEL PHASE A
TP1 BLUE -2 -3 -6
JP T VEL PHASE B
B+ JPT3 -7
RED -2 -8 T TEMP+
1 1 TMT RED/BLK -1 -7 -8
2 PC TPC ID0
2 -9
U B-
U
FU1 FU2 TM V
(150A) (350A) V
TP2 1 TP5 W W
P B+ +
2 1
TR
A FU3 2
(500A)
MX TP3
S
SPL2
JP2-2
MP
S A
JP TP4
B-
T3 T1
JPF1 ˚T
-5
-11 FU10
JPF2
-12 (15A) B-F -4
1 2 -9
-13 FU6 -10
(15A) TS2-1 -11
-14 TS2-2 -12
1 2
FU8 JPF5
-7 (5A) -3 TS19
TS2-3 -6 3
1 2 -6
FU9
(15A/5A)
-1 TS1-1
1 2
FU7
-10 (15A/5A) K1 TS1-2
-3 1 2 TS1-3
FU5
-8 JPF3-4 1
-9 1 2 JPF3-2
K2 JPF2-5
K1 K2 K3 K3
JPF2-3
JPF5-2
Legend:
B+KA JPF2-2
JPF2-1
+12 volts
+ 5 volts RELAY JPF5-1 TS19 3
CONTROL -7
Negative Circuit FUSE
PANEL
JPF5-4
JPF3 -1
Signal or Detect
8R1005714_D_1_L.EPS
Figure 8-5: Plugging – EZ-D/DZ-D (Sheet 1 of 2)
PDMM-0109 7/31/02 8-17

Proportional Plugging Traction System Functional Operation
JPD1 JPC6
-1 THROTTLE -10 VR1
-10 +12 VP
-1 -2 AGND -13
-3 -3 LIFT -11
DATA_LATCH
CONTROL HANDLE
VR2
DISPLAY
-8
-4 -4 +5V
DISP_MISO
-5 -5 HORN -7 S3
SOUNDER
-6 -6 REACH -1 S4
SHIFT_CLOCK VEHICLE
-7 -7 RETRACT -2 S5
DATA OUT MANAGER
-8 -8 TILT UP -3 S6
DGND
SSHIFT LEFT S8
SSHIFT RIGHT -6 S9
JPT1 JP2 AGND -14
TPC -2 -1 SHIELD
CONTACTOR TPC
Y X
JPC8 JP2
B+KC -14 -5
-1
B+KB JPC9 JP2
-12 -8 JP3-13
Y
-13 -9
DGND
-10 JPC10
FAN
-11
BUS-
5
TA
2ND SOL -1 2ND
JPC9 JP3
B+KA_SUP -11 -2
L/L -5 -3 L/L
JPC4 1 2
-16 +12VP -6 -4
L/H L/H
-15 DGND 1 2
DIRB -10 -5 DIRB
-12 1 2
BUS TERMINATION
SPLC2 -7 -6
-9 DIRA DIRA
BUS+ 1 2
-10 BUS-
EQ -9 -7 EQ
JPC8 1 2
JP2
-3 -9 FU1 SENSE -4 -8
-4 B+ KA
-10 FU3 SENSE
HRN
JPC8 -NEG
HORN
HORN & ALARM
PT -1 -1 -1 H
T˚ -2 B+KA
-3
-2 -23 JPC10
PGND -16 JPA1-2
ALARM
4
B+KB -20 JPA1-1
JPC8
-6 DGND
-1
-2 3 TS19
B-F JPC9 TS21 BLACK
-3 RED
B+ KA
REACH SOL
JPY4 JP3 JPC11
-4 -9 -1 DGND
- -3 -10 -2 -12 -2 GREEN -2 GREEN2 SIDE 1
DGND SIDESHIFT SOL
PRESS SHIFT
+ -1 -12 -4 +12V
TILT SOL

NESTED SWITCH
JPC8 (OPTION)
-17 B+KEY
ON CARRIAGE
JPC10-19
B+KB
JPC8 JPC7
-13
B+KC -1 JPS4
+12VP -1
SPLH3 S10
-4 -13 -2 NO COM
-5 B+KA -7 -3
DGND
NC
Legend:
SWITCH
-5 COM
DGND
-20 DEADMAN SWITCH
JPC1
AMPLIFIER ENABLE
ON DEADMAN
-16 NO
Battery + Circuit
-1 BUS-
-2
-3
TXD +12 volts
RXD
-4 BUS+
-5 DGND + 5 volts
-6 NC
-7
-8
BOOT
NC
Negative Circuit
-9 +12VP
Signal or Detect
8R1005714_D_1_R.EPS
Plugging – EZ-D/DZ-D (Sheet 2 of 2)
8-18 PDMM-0109 7/31/02

Thermal Cut-Back Thermal Cut-Back
Thermal Cut-Back over-temperature warning icon is lighted on the

Operator Display. Should the temperature
continue to rise, a fault code is displayed on the
On the traction system, the power amplifier Operator Display, and the function is restricted
monitors motor temperature via a temperature or disabled.
sensor internal to the motor, and power
amplifier and power amplifier printed circuit Temperature information from the power
board (PCB) temperatures via sensors internal amplifier is monitored by the Vehicle Manager
to the power amplifier. via the BUS +/– communication lines. Current
reduction and shutdown of the power amplifier
When any of these temperatures rises beyond is controlled by the power amplifier; Current
normal operating range, the maximum current reduction and shutdown of motors is controlled
request is reduced to protect the motor and by the Vehicle Manager. The warning icon is
amplifier against damage from overheating. controlled by the Vehicle Manager.
(Plugging strength, however, is not reduced.) An
EZ-D/DZ-D Lift Truck Thermal Down-Rating
Traction Power Traction Power

Drive Motor Amplifier Heat Amplifier Lift Motor
Event Sink Internal
°F °C °F °C °F °C °F °C
259 126 176 80 212 100 213 101
Down-
Rating
Begins
275 135 194 90 219 104 213 101
Icon
Lights
300 149 239 115 257 125 271 133
Fault 2A 1H 1H 6F
Code
1 mph 0 mph 0 mph Lift Disabled
Restriction
PDMM-0109 7/31/02 8-19

Steering System Steering System
Steering System
Steering Process
1. When the operator presses the deadman
pedal, a circuit is completed at the Vehicle
Manager at JPC7-16.
2. The Vehicle Manager energizes the PC
contactor by way of JPC8-18.
3. With the PC contactor energized, current
flows to the auxiliary motor, causing it to
run.
4. Pressure for steering is supplied by the
auxiliary system. The steering system has
priority over all other auxiliary functions.
5. Pressurized hydraulic fluid from the
auxiliary pump flows to the steering
orbitrol.
6. Turning the steering wheel directs
hydraulic fluid to one side of the hydraulic
steer motor. Turning the steering wheel in
the opposite direction directs fluid to the
other side of the hydraulic steer motor.
7. Maximum hydraulic pressure in the
steering system is limited by the auxiliary
pressure relief valve. The auxiliary relief is
located on the auxiliary pump. Auxiliary
relief pressure is set at approximately
1600 psi (11,031.6 kPa).
8-20 PDMM-0109 7/31/02

Steering System Steering Process
HYDRAULIC MANIFOLD
PT2
L/H
PT1 SOL
NOT ON ALL MODELS
CV1
P1 2 1 1 CYL
LIFT LIFT
2 CYL
L/L
CV2 SOL
1 FLOW
P2 2
LIFT CONTROL
HIGH 2
2 PRESSURE
RELIEF
2
2ND
SOL 1
C3
REACH
REACH/RETURN
SOL
DIRB
SOL A2 P C1
STEER
RETURN
AUX T C2
P3 PRESS 3 2
AUX 2 C4
1
4
1 EQ
SOL A1
SIDESHIFT
DIRA C2 C1
SOL
SIDESHIFT
SOL
AUX
PRESSURE P
RELIEF STEER
ORBITROL
TILT
T SOL
STEER
MOTOR
T
C2 C1
FILTER
TILT
TANK
Legend:
Pressure Line
Return Line
Suction Line
Electrical Control
Signal
8R84137_C_C.EPS
Figure 8-6: Steering Theory - Hydraulic
PDMM-0109 7/31/02 8-21

Steering Process Steering System
NOTES:
KEY SWITCH OFF.
JP2
-10
-12 RED -1 -6 -3
T VEL SENSOR+
-13 BLACK -4 -5 -4
WHITE -3 -4 -5
T VEL PHASE A
TP1 BLUE -2 -3 -6
JP T VEL PHASE B
B+ JPT3 -7
RED -2 -8 T TEMP+
1 1 TMT RED/BLK -1 -7 -8
2 PC TPC ID0
2 -9
U B-
U
FU1 FU2 TM V
(150A) (350A) V
TP2 1 TP5 W W
P B+ +
2 1
TR
A FU3 2
(500A)
MX TP3
S
SPL2
JP2-2
MP
S A
JP TP4
B-
T3 T1
JPF1 ˚T
-5
-11 FU10
JPF2
-12 (15A) B-F -4
1 2 -9
-13 FU6 -10
(15A) TS2-1 -11
-14 TS2-2 -12
1 2
FU8 JPF5
-7 (5A) -3 TS19
TS2-3 -6 3
1 2 -6
FU9
(15A/5A)
-1 TS1-1
1 2
FU7
-10 (15A/5A) K1 TS1-2
-3 1 2 TS1-3
FU5
-8 JPF3-4 1
-9 1 2 JPF3-2
K2 JPF2-5
K1 K2 K3 K3
JPF2-3
Legend: JPF5-2
Battery + Circuit B+KA JPF2-2

JPF2-8
+12 volts JPF2-1
+ 5 volts
RELAY JPF5-1 TS19 3
Negative Circuit CONTROL

FUSE JPF5-4
-7
PANEL
Signal or Detect JPF3 -1
8R1005714_D_1_L.EPS
Figure 8-7: Steering Theory - Electrical - EZ-D/DZ-D (Sheet 1 of 2)
8-22 PDMM-0109 7/31/02

Steering System Steering Process
JPD1 JPC6
-1 THROTTLE -10 VR1
-10 +12 VP
-1 -2 AGND -13
-3 -3 LIFT -11
DATA_LATCH
CONTROL HANDLE
VR2
DISPLAY
-8
-4 -4 +5V
DISP_MISO
-5 -5 HORN -7 S3
SOUNDER
-6 -6 REACH -1 S4
SHIFT_CLOCK VEHICLE
-7 -7 RETRACT -2 S5
DATA OUT MANAGER
-8 -8 TILT UP -3 S6
DGND
SSHIFT LEFT S8
SSHIFT RIGHT -6 S9
JPT1 JP2 AGND -14
TPC -2 -1 SHIELD
CONTACTOR TPC
Y X
JPC8 JP2
B+KC -14 -5
-1
B+KB JPC9 JP2
-12 -8 JP3-13
Y
-13 -9
DGND
-10 JPC10
FAN
-11
BUS-
5
TA
2ND SOL -1 2ND
JPC9 JP3
B+KA_SUP -11 -2
L/L -5 -3 L/L
JPC4 1 2
-16 +12VP -6 -4
L/H L/H
-15 1 2
DGND
DIRB -10 -5 DIRB
-12 1 2
BUS TERMINATION
SPLC2 -7 -6
-9 DIRA DIRA
BUS+ 1 2
-10 BUS-
EQ -9 -7 EQ
JPC8 1 2
JP2
-3 -9 FU1 SENSE -4 -8
-4 B+ KA
-10 FU3 SENSE
HRN
JPC8 -NEG
HORN
HORN & ALARM
PT -1 -1 -1 H
T˚ -2 B+KA
-3
-2 -23 JPC10
PGND JPA1-2
ALARM -16
4
B+KB -20 JPA1-1
JPC8
-6 DGND
-1
-2 3 TS19
B-F JPC9 TS21 BLACK
-3 RED
B+ KA
REACH SOL
JPY4 JP3 JPC11
-4 -9 -1 DGND
- -3 -10 -2 -12 -2 GREEN -2 GREEN2 SIDE 1
DGND SIDESHIFT SOL
PRESS SHIFT
+ -1 -12 -4 +12V
TILT SOL

NESTED SWITCH
JPC8 (OPTION)
-17 B+KEY
ON CARRIAGE
JPC10-19
B+KB
JPC8 JPC7
-13
B+KC -1 JPS4
+12VP -1
SPLH3 S10
-4 -13 -2 NO COM
-5 B+KA -7 -3
DGND
Legend:
NC
SWITCH
-5 COM
DGND
-20 AMPLIFIER ENABLE -16 NO Battery + Circuit
DEADMAN SWITCH
JPC1 ON DEADMAN
-1 BUS- +12 volts
-2 TXD
-3 RXD
-4
-5
BUS+ + 5 volts
DGND
-6 NC
-7
-8
BOOT Negative Circuit
NC
-9 +12VP
Signal or Detect
8R1005714_D_1_R.EPS
Steering Theory - Electrical - EZ-D/DZ-D (Sheet 2 of 2)
PDMM-0109 7/31/02 8-23

Lift/Aux System Functional Operation Lift/Aux System Functional Operation
Lift/Aux System Functional Operation
NOTE: The schematics in this chapter are the front cylinder piston, through the piston
intended for general understanding of center into the housing, exiting through two
theory of operation and may not side ports in the housing. These ports are
reflect latest developments in welded to ports in the side (free-lift) cylinders.
circuitry. Fluid enters the side cylinders through the
housing, entering the center of the pistons and
DO NOT use these schematics to
exiting through hydraulic fittings in the pistons.
troubleshoot or repair the lift truck.
ALWAYS USE the schematics in the Reach/Retract Cylinder
Appendix for troubleshooting and
repair. The reach/retract cylinders are double-acting
hydraulic cylinders used for extending and
NOTE: On electrical schematics, only circuits
retracting the forks from the mast.
related directly with the hydraulic
functions will be addressed.
Sideshift Cylinder
System Components The sideshift cylinder is a double-acting
hydraulic cylinder used to shift the load left and
Main Lift Pump (P1/P2) right with respect to the mast.
Pump P1 is a positive displacement gear pump. Tilt Cylinder

If the lift truck is equipped with a dual lift
pump, pump P1 has a common shaft with The tilt cylinder is a double-acting hydraulic
pump P2. P1 is used for lift functions only. cylinder used to tilt the forks up and down.
Aux Pump (P3) Steer Valve

Pump P3 is a positive displacement gear pump. The steer valve is an orbital type rotary flow
Pump P3 supplies flow when requesting valve with an auxiliary port. When no steering
steering and aux functions (reach, tilt, is being done, fluid flows through the auxiliary
sideshift). Steering has priority over aux port. When steering is requested, fluid flows
functions. The aux pressure relief valve is built first through the steer valve, hydraulic motor,
into the endplate of P3 and provides relief only and the steer return port. Any excess flow exits
for P3. out the auxiliary port. Steering has priority over
auxiliary functions.
Main Lift Cylinder Cluster
Load Holding Valve (L/H)
The main lift cylinder cluster consists of four
single acting hydraulic cylinders. During a lift The load holding valve is a normally closed
from floor level, the two side cylinders are the solenoid valve used to hold the carriage in an
first to provide lift (free lift) of the carriage elevated position.
before the telescopic is extended by the lift
action of the front and rear cylinders. Proportional Lift/Lower Valve (L/L)
Hydraulic fluid flows first through a hydraulic
The proportional lift/lower valve is a pressure
fitting in the rear cylinder piston, through the
compensated flow control solenoid valve used to
piston center into the housing, exiting the top of
lift and lower the carriage. As the voltage to the
the housing. Fluid is then carried by a hose to
8-24 PDMM-0109 7/31/02

Lift/Aux System Functional Operation System Components
valve increases, the flow through the valve Tilt Solenoid (TILT SOL)
increases, regardless of the pressure.
TILT SOL is a normally closed solenoid valve
used to block (de-energized) or allow (energized)
DIRA/DIRB Valve
fluid flow to and from the tilt cylinder.
DIRA/DIRB is a directional solenoid valve
providing directional control to the reach, tilt, High Pressure Relief Valve (REL1)
and sideshift functions. De-energized, flow is
blocked to the aux functions and directed to the REL1 is a relief valve used to protect the lift
reservoir. When DIRA is energized, flow is pump(s) against excessive pressure. It is
directed to port A1 for tilt up, sideshift right, or factory-adjusted to 200 psi (1379 kPa) above
retract. When DIRB is energized, flow is the pressure required to lift the maximum rated
directed to port A2 for tilt down, sideshift left, or load. A manual adjustment knob can be turned
reach. clockwise to increase the relief pressure, or
counter-clockwise to decrease the relief
pressure.
Equalization Valve (EQ)
EQ is a two-position, normally open solenoid Aux Relief Valve
valve. During tilt and sideshift functions, the
valve is energized. During the reach/retract The aux relief valve is a relief valve used to
function, it is used to select between low-speed protect auxiliary system components against
(de-energized) and high-speed (energized). excessive pressure. It is factory-adjusted to
When an aux function completes, the valve is 1600 psi (11,032 kPa). An adjustment screw on
returned to the open position to equalize the aux pump can be turned clockwise to
pressure between the two over-the-mast hoses increase the relief pressure, or
to prevent surging when the next aux function counter-clockwise to decrease the relief
begins. pressure.
2nd Pump Solenoid (2ND) Main Lift Check Valve (CV1)

The 2ND Pump solenoid is used on lift trucks Check valve CV1 is used to prevent hydraulic
equipped with a dual lift pump. When fluid from flowing back through pump P1.
energized, it directs hydraulic fluid from lift
pump P2 to the lift cylinders, providing high Main Lift Check Valve (CV2)
speed lift. When de-energized, fluid flow from P2
is directed back to the reservoir. Check valve CV2 is used to prevent hydraulic
fluid from flowing back through pump P2, if
equipped with a dual pump.
Reach/Retract Solenoid (R/R SOL)
R/R SOL is a normally closed solenoid valve Hydraulic Filter
fluid flow to and from the reach cylinders. The hydraulic system has a filter connected to
the manifold. Its purpose is to filter impurities
from the hydraulic system. Use the correct
Sideshift Solenoid (S/S SOL)
filter only or else the filter may rupture if it
S/S SOL is a normally closed solenoid valve becomes plugged.
fluid flow to and from the sideshift cylinder. Steer Motor
The hydraulic steer motor is a hydraulic motor
used to rotate the steering gear. The steering
gear causes the drive unit to rotate.
PDMM-0109 7/31/02 8-25

System Components Lift/Aux System Functional Operation
Lift Motor
The lift motor is a series-wound DC motor.
Lift Motor Temperature Sensor

The lift motor temperature sensor is mounted
externally in the frame of the lift motor. Its
purpose is to tell the Vehicle Manager the motor
temperature.
Aux Motor
The auxiliary motor is a compound-wound DC
motor.
8-26 PDMM-0109 7/31/02

Lift/Aux System Functional Operation Theory of Function
Theory of Function
50% Duty
Cycle
Lift
When the key switch is turned ON, the L/L
proportional valve moves to the full open Battery
position during SelfTest. This relieves any Voltage
pressure in the hydraulic line by diverting any
residual fluid back to the tank. The L/L Fast Rates
proportional valve then closes.
With the key switch ON, moving the lift/lower
10% Duty Cycle
control on the multi-function control handle to
lift causes:
Battery
Voltage
Variable Lift
One Cycle
Refer to Figure 8-9 on page 8-28, Figure 8-10
Slow Rates
on page 8-29, and Figure 8-11 on page 8-30. 8NOT IMPORTED
1. VR2 output voltage becomes lower than Figure 8-8: Pulse Width Modulation duty cycle
when in the neutral position.
2. The Vehicle Manager senses this decrease
in voltage at JPC6-11. The Vehicle Manager
energizes the PC contactor coil at JPC8-18
and the P contactor coil at JPC9-2. This
closes the contactor tips and starts the lift
pump motor (MP).
3. Initially, the Vehicle Manager commands
the proportional lift/lower valve (L/L) to
move to the full open position (back to
tank), then positions it proportionally to the
output request of VR2. For a slow lift rate,
the proportional valve will be open more,
allowing more fluid to return to the
reservoir than it would for faster lifting
rates.
4. High speed lift operating parameters will
vary for different mast configurations.
Regardless of the mast configuration,
voltage from VR2 must be at least 90% of
the Learned maximum for lift before high
speed lift will be activated.
5. The weight of the load on the forks is
determined by inputs to the Vehicle
Manager from the pressure sensor at
JPC11.
PDMM-0109 7/31/02 8-27

Lift Lift/Aux System Functional Operation
HYDRAULIC MANIFOLD
PT2
L/H
PT1 SOL
NOT ON ALL MODELS
CV1
P1 2 1 1 CYL
LIFT LIFT
2 CYL
L/L
CV2 SOL
1 FLOW
P2 2
LIFT CONTROL
HIGH 2
2 PRESSURE
RELIEF
2
2ND
SOL 1
C3
REACH
REACH/RETURN
SOL
DIRB
SOL A2 P C1
STEER
RETURN
AUX T C2
P3 PRESS 3 2
AUX 2 C4
1
4
1 EQ
SOL A1
SIDESHIFT
DIRA C2 C1
SOL
SIDESHIFT
SOL
AUX
PRESSURE P
RELIEF STEER
ORBITROL
TILT
T SOL
STEER
MOTOR
T
C2 C1
FILTER
TILT
TANK
Legend:
Pressure Line
Return Line
Suction Line
Electrical Control
Signal
8R84137_C_C.EPS
Figure 8-9: Variable Lift - Hydraulic
8-28 PDMM-0109 7/31/02

Lift/Aux System Functional Operation Lift
NOTES:
KEY SWITCH OFF.
JP2
-10
-12 RED -1 -6 -3
T VEL SENSOR+
-13 BLACK -4 -5 -4
WHITE -3 -4 -5
T VEL PHASE A
TP1 BLUE -2 -3 -6
JP T VEL PHASE B
B+ JPT3 -7
RED -2 -8 T TEMP+
1 1 TMT RED/BLK -1 -7 -8
2 PC TPC ID0
2 -9
U B-
U
FU1 FU2 TM V
(150A) (350A) V
TP2 1 TP5 W W
P B+ +
2 1
TR
A FU3 2
(500A)
MX TP3
S
SPL2
JP2-2
MP
S A
JP TP4
B-
T3 T1
JPF1 ˚T
-5
-11 FU10
JPF2
-12 (15A) B-F -4
1 2 -9
-13 FU6 -10
(15A) TS2-1 -11
-14 TS2-2 -12
1 2
FU8 JPF5
-7 (5A) -3 TS19
TS2-3 -6 3
1 2 -6
FU9
(15A/5A)
-1 TS1-1
1 2
FU7
-10 (15A/5A) K1 TS1-2
-3 1 2 TS1-3
FU5
-8 JPF3-4 1
-9 1 2 JPF3-2
K2 JPF2-5
K1 K2 K3 K3
JPF2-3
JPF5-2
B+KA JPF2-2
JPF2-8
JPF2-1
Legend:
RELAY JPF5-1 TS19 3
Positive Circuit CONTROL -7

FUSE JPF5-4
PANEL
Signal or Detect
8R1005714_D_1_L.EPS
Figure 8-10: Lift - Vehicle Manager (Sheet 1 of 2)
PDMM-0109 7/31/02 8-29

JPD1 JPC6
-1 THROTTLE -10 VR1
-10 +12 VP
-1 -2 AGND -13
-3 -3 LIFT -11
DATA_LATCH
CONTROL HANDLE
VR2
DISPLAY
-8
-4 -4 +5V
DISP_MISO
-5 -5 HORN -7 S3
SOUNDER
-6 -6 REACH -1 S4
SHIFT_CLOCK VEHICLE
-7 -7 RETRACT -2 S5
DATA OUT MANAGER
-8 -8 TILT UP -3 S6
DGND
SSHIFT LEFT S8
SSHIFT RIGHT -6 S9
JPT1 JP2 AGND -14
TPC -2 -1 SHIELD
CONTACTOR TPC
Y X
JPC8 JP2
B+KC -14 -5
-18 -6 X Y
-1 PC_CONTACTOR PC
B+KB JPC9 JP2
-12 X -8 JP3-13
+12VP -2 -7 Y
P CONTACTOR P
-13 -9
DGND
-10 JPC10
FAN
-11
BUS-
5
TA
2ND SOL -1 2ND
JPC9 JP3
B+KA_SUP -11 -2
L/L -5 -3 L/L
JPC4 1 2
-16 +12VP -6 -4
L/H L/H
-15 1 2
DGND
DIRB -10 -5 DIRB
-12 1 2
BUS TERMINATION
SPLC2 -7 -6
-9 DIRA DIRA
BUS+ 1 2
-10 BUS-
EQ -9 -7 EQ
JPC8 1 2
JP2
-3 -9 FU1 SENSE -4 -8
-4 B+ KA
-10 FU3 SENSE
HRN
JPC8 -NEG
HORN
HORN & ALARM
PT -1 -1 -1 H
T˚ -2 B+KA
-3
-2 -23 JPC10
PGND -16 JPA1-2
ALARM
4
B+KB -20 JPA1-1
JPC8
-6 DGND
-1
-2 3 TS19
B-F JPC9 TS21 BLACK
-3 RED
B+ KA
REACH SOL
JPY4 JP3 JPC11
-4 -9 -1 DGND
- -3 -10 -2 -12 -2 GREEN -2 GREEN2 SIDE 1
DGND SIDESHIFT SOL
PRESS SHIFT
+ -1 -12 -4 +12V
TILT SOL

NESTED SWITCH
JPC8 (OPTION)
JPC10-19
B+KB
JPC8 JPC7
-13
B+KC -1 JPS4
+12VP -1
SPLH3 S10
-4 -13 -2 NO COM
-5 B+KA -7 -3
DGND
NC
SWITCH
-5 COM
DGND
-16
JPC1 ON DEADMAN
-1 BUS-
-2
-3
TXD
RXD
Legend:
-4 BUS+
-5
-6
DGND Positive Circuit
NC
-7
-8
BOOT
NC Negative Circuit
-9 +12VP
Signal or Detect
8R1005714_D_1_R.EPS
Figure 8-11: Lift - Vehicle Manager (Sheet 2 of 2)
8-30 PDMM-0109 7/31/02

High-Speed Lift (lift trucks with dual 5. The Vehicle Manager monitors vehicle
lift pump) operation and will control performance as
required to ensure safe vehicle operation
Refer to Figure 8-12 on page 8-32. and prevent damage to various systems of
the lift truck. A temperature sensor on the
1. High speed lift (2ND solenoid energized), is
lift motor is used to detect overheating of
activated when the voltage from VR2 is at
the motor. The output of the temperature
least 90% of the maximum Learned value
sensor is fed into the Vehicle Manager. As
for Lift. When this voltage is reached, the
the temperature rises in the lift motor, the
2ND solenoid is energized, stopping oil from
Vehicle Manager cuts out power to the 2ND
the second lift pump from going to the
(second) solenoid controlling the second lift
reservoir. Hydraulic flow from both sections
pump, thus diverting the hydraulic fluid
of the lift pump is sent to the lift cylinder.
coming from the second pump back to the
2. The lift/lower proportional valve (L/L) is reservoir. The temperature at which the
electrically positioned by the following second pump diverts fluid back to the
process: reservoir is about 213° F. This decreases the
a. Voltage generated by potentiometer VR2 load on the motor and should cool it down.
is sent to and processed by the Vehicle If the temperature continues to rise (greater
Manager. than 271° F), the Vehicle Manager will cut
out lift entirely.
b. A voltage from the Vehicle Manager
drives L/L at JPC9-5. The frequency is NOTE: On certain series equipped with dual
held constant while the pulse width will pumps, the maximum lift speed may be
vary depending on the position of the reduced (2ND SOL disabled) when forks
lift/lower control. travel above free-lift (S10 opens) and the
load exceeds a specified weight, as
c. Voltage across the coil of L/L is initially determined by the pressure transducer.
approximately 19 volts and will decline
as the lift/lower control is moved to
faster lift positions.
3. L/L (proportional lift/lower valve) controls
hydraulic flow from the lift pump to the lift
cylinder. As the lift/lower control is moved
to a faster lift position, proportional spool
valve L/L closes.
4. When VR2 (lift/lower control) returns to the
neutral position, the lift contactor is
immediately de-energized; but L/L is kept
energized until the lift pump motor stops
turning. This is done because a spinning
motor does not stop instantly; the motor
rotation is sensed by the pump sense line
(FU3 SENSE) at JPC8-10. If L/L was
de-energized at the same time as the motor,
the fork carriage would jump. Leaving L/L
open until the motor stops diverts any
excess hydraulic fluid back to the reservoir.
PDMM-0109 7/31/02 8-31

HYDRAULIC MANIFOLD
PT2
L/H
PT1 SOL
NOT ON ALL MODELS
CV1
P1 2 1 1 CYL
LIFT LIFT
2 CYL
L/L
CV2 SOL
1 FLOW
P2 2
LIFT CONTROL
HIGH 2
2 PRESSURE
RELIEF
2
2ND
SOL 1
C3
REACH
REACH/RETURN
SOL
DIRB
SOL A2 P C1
STEER
RETURN
AUX T C2
P3 PRESS 3 2
AUX 2 C4
1
4
1 EQ
SOL A1
SIDESHIFT
DIRA C2 C1
SOL
SIDESHIFT
SOL
AUX
PRESSURE P
RELIEF STEER
ORBITROL
TILT
T SOL
STEER
MOTOR
T
C2 C1
FILTER
TILT
TANK
Legend:
Pressure Line
Return Line
Suction Line
Electrical Control
Signal
8R84137_C_C.EPS
Figure 8-12: High Speed Lift - Hydraulic
8-32 PDMM-0109 7/31/02

KEY SWITCH OFF.

JP2
-10
-12 RED -1 -6 -3
T VEL SENSOR+
-13 BLACK -4 -5 -4
WHITE -3 -4 -5
T VEL PHASE A
TP1 -2
BLUE -3 -6
JP T VEL PHASE B
B+ JPT3 -7
RED -2 -8 T TEMP+
1 1 TMT RED/BLK -1 -7 -8
2 PC TPC ID0
2 -9
U B-
U
FU1 FU2 TM V
(150A) (350A) V
TP2 1 TP5 W W
P B+ +
2 1
TR
A FU3 2
(500A)
MX TP3
S
SPL2
JP2-2
MP
S A
JP TP4
B-
T3 T1
JPF1 ˚T
-5
-11 FU10
JPF2
-12 (15A) B-F -4
1 2 -9
-13 FU6 -10
(15A) TS2-1 -11
-14 TS2-2 -12
1 2
FU8 JPF5
-7 (5A) -3 TS19
TS2-3 -6 3
1 2 -6
FU9
(15A/5A)
-1 TS1-1
1 2
FU7
-10 (15A/5A) K1 TS1-2
-3 1 2 TS1-3
FU5
-8 JPF3-4 1
-9 1 2 JPF3-2
K2 JPF2-5
K1 K2 K3 K3
JPF2-3
JPF5-2
B+KA JPF2-2
JPF2-8
JPF2-1
Legend:
RELAY JPF5-1 TS19 3
Positive Circuit CONTROL

FUSE
-7
JPF5-4
PANEL
Signal or Detect
8R1005714_D_1_L.EPS
Figure 8-13: High-Speed Lift - Electrical (Sheet 1 of 2)
PDMM-0109 7/31/02 8-33

JPD1 JPC6
-1 THROTTLE -10 VR1
-10 +12 VP
-1 -2 AGND -13
-3 -3 LIFT -11
DATA_LATCH
CONTROL HANDLE
VR2
DISPLAY
-8
-4 -4 +5V
DISP_MISO
-5 -5 HORN -7 S3
SOUNDER
-6 -6 REACH -1 S4
SHIFT_CLOCK VEHICLE
-7 -7 RETRACT -2 S5
DATA OUT MANAGER
-8 -8 TILT UP -3 S6
DGND
SSHIFT LEFT S8
SSHIFT RIGHT -6 S9
JPT1 JP2 AGND -14
TPC -2 -1 SHIELD
CONTACTOR TPC
Y X
JPC8 JP2
B+KC -14 -5
-1
B+KB JPC9 JP2
-12 -8 JP3-13
Y
-13 -9
DGND
-10 JPC10
FAN
-11
BUS-
5
TA
2ND SOL -1 2ND
JPC9 JP3
B+KA_SUP -11 -2
L/L -5 -3 L/L
JPC4 1 2
-16 +12VP -6 -4
L/H L/H
-15 DGND 1 2
DIRB -10 -5 DIRB
-12 1 2
BUS TERMINATION
SPLC2 -7 -6
-9 DIRA DIRA
BUS+ 1 2
-10 BUS-
EQ -9 -7 EQ
JPC8 1 2
JP2
-3 -9 FU1 SENSE -4 -8
-4 B+ KA
-10 FU3 SENSE
HRN
JPC8 -NEG
HORN
HORN & ALARM
PT -1 -1 -1 H
T˚ -2 B+KA
-3
-2 -23 JPC10
PGND -16 JPA1-2
ALARM
4
B+KB -20 JPA1-1
JPC8
-6 DGND
-1
-2 3 TS19
B-F JPC9 TS21 BLACK
-3 RED
B+ KA
REACH SOL
JPY4 JP3 JPC11
-4 -9 -1 DGND
- -3 -10 -2 -12 -2 GREEN -2 GREEN2 SIDE 1
DGND SIDESHIFT SOL
PRESS SHIFT
+ -1 -12 -4 +12V
TILT SOL

NESTED SWITCH
JPC8 (OPTION)
-17 B+KEY
ON CARRIAGE
JPC10-19
B+KB
JPC8 JPC7
-13
B+KC -1 JPS4
+12VP -1
SPLH3 S10
-4 -13 -2 NO COM
-5 B+KA -7 -3
DGND
NC
SWITCH
-5 COM
DGND
-20 AMPLIFIER ENABLE -16 NO Legend:
DEADMAN SWITCH
JPC1 ON DEADMAN
-1 BUS- Positive Circuit
-2 TXD
-3 RXD
-4
-5
BUS+ Negative Circuit
DGND
-6
-7
NC
BOOT Signal or Detect
-8 NC
-9 +12VP
8R1005714_D_1_R.EPS
Figure 8-14: tHigh-Speed Lift - Electrical (Sheet 2 of 2)
8-34 PDMM-0109 7/31/02

Lift/Aux System Functional Operation Lower
Lower 5. The lift/lower solenoid (L/L) is energized

when VR2 is moved to the lower position.
Refer to Figure 8-16 on page 8-36, Figure 8-17 The Vehicle Manager, sensing that VR2 has
on page 8-37, and Figure 8-18 on page 8-38. requested lower, supplies negative potential
With the battery connected and key switch ON, to the lift/lower solenoid at JPC9-5.
moving the lift/lower control on the
multi-function control handle to the LOWER
position causes:
1. VR2 to output a voltage greater than when

in the neutral position.
2. The Vehicle Manager senses this increase in
voltage at JPC6-11, energizing L/H at
JPC9-6 and outputs a signal to L/L
(proportional lift/lower solenoid).
3. The L/L coil frequency is held constant
while the pulse width will vary depending
on the position of the L/L control. The
output signals for slow and fast lowering
rates are shown in Figure 8-15.
50% Duty
Cycle
Battery
Voltage
Fast Rates
10% Duty Cycle
Battery
Voltage
One Cycle
Slow Rates
8NOT IMPORTED
Figure 8-15: Pulse Width Modulation duty cycle
4. Voltage across L/L will vary depending on

the position of the lift/lower control (VR2).
• low voltage = slow lowering
• high voltage = fast lowering
PDMM-0109 7/31/02 8-35

Lower Lift/Aux System Functional Operation
HYDRAULIC MANIFOLD
PT2
L/H
PT1 SOL
NOT ON ALL MODELS
CV1
P1 2 1 1 CYL
LIFT LIFT
2 CYL
L/L
CV2 SOL
1 FLOW
P2 2
LIFT CONTROL
HIGH 2
2 PRESSURE
RELIEF
2
2ND
SOL 1
C3
REACH
REACH/RETURN
SOL
DIRB
SOL A2 P C1
STEER
RETURN
AUX T C2
P3 PRESS 3 2
AUX 2 C4
1
4
1 EQ
SOL A1
SIDESHIFT
DIRA C2 C1
SOL
SIDESHIFT
SOL
AUX
PRESSURE P
RELIEF STEER
ORBITROL
TILT
T SOL
STEER
MOTOR
T
C2 C1
FILTER
TILT
TANK
Legend:
Pressure Line
Return Line
Suction Line
Electrical Control
Signal
8R84137_C_C.EPS
Figure 8-16: Variable Lower - Hydraulic
8-36 PDMM-0109 7/31/02

Lift/Aux System Functional Operation Lower
NOTES:
KEY SWITCH OFF.
JP2
-10
-12 RED -1 -6 -3
T VEL SENSOR+
-13 BLACK -4 -5 -4
WHITE -3 -4 -5
T VEL PHASE A
TP1 BLUE -2 -3 -6
JP T VEL PHASE B
B+ JPT3 -7
RED -2 -8 T TEMP+
1 1 TMT RED/BLK -1 -7 -8
2 PC TPC ID0
2 -9
U B-
U
FU1 FU2 TM V
(150A) (350A) V
TP2 1 TP5 W W
P B+ +
2 1
TR
A FU3 2
(500A)
MX TP3
S
SPL2
JP2-2
MP
S A
JP TP4
B-
T3 T1
JPF1 ˚T
-5
-11 FU10
JPF2
-12 (15A) B-F -4
1 2 -9
-13 FU6 -10
(15A) TS2-1 -11
-14 TS2-2 -12
1 2
FU8 JPF5
-7 (5A) -3 TS19
TS2-3 -6 3
1 2 -6
FU9
(15A/5A)
-1 TS1-1
1 2
FU7
-10 (15A/5A) K1 TS1-2
-3 1 2 TS1-3
FU5
-8 JPF3-4 1
-9 1 2 JPF3-2
K2 JPF2-5
K1 K2 K3 K3
JPF2-3
JPF5-2
B+KA JPF2-2
JPF2-8
JPF2-1
Legend:
RELAY JPF5-1 TS19 3

FUSE JPF5-4
-7
PANEL
Signal or Detect
8R1005714_D_1_L.EPS
Figure 8-17: Lower - Electrical (Sheet 1 of 2)
PDMM-0109 7/31/02 8-37

Lower Lift/Aux System Functional Operation
JPD1 JPC6
-1 THROTTLE -10 VR1
-10 +12 VP
-1 -2 AGND -13
-3 -3 LIFT -11
DATA_LATCH
CONTROL HANDLE
VR2
DISPLAY
-8
-4 -4 +5V
DISP_MISO
-5 -5 HORN -7 S3
SOUNDER
-6 -6 REACH -1 S4
SHIFT_CLOCK VEHICLE
-7 -7 RETRACT -2 S5
DATA OUT MANAGER
-8 -8 TILT UP -3 S6
DGND
SSHIFT LEFT S8
SSHIFT RIGHT -6 S9
JPT1 JP2 AGND -14
TPC -2 -1 SHIELD
CONTACTOR TPC
Y X
JPC8 JP2
B+KC -14 -5
-18 -6 X Y
-1 PC_CONTACTOR PC
B+KB JPC9 JP2
-12 X -8 JP3-13
+12VP -2 -7 Y
P CONTACTOR P
-13 -9
DGND
-10 JPC10
FAN
-11
BUS-
5
TA
2ND SOL -1 2ND
JPC9 JP3
B+KA_SUP -11 -2
L/L -5 -3 L/L
JPC4 1 2
-16 +12VP -6 -4
L/H L/H
-15 1 2
DGND
DIRB -10 -5 DIRB
-12 1 2
BUS TERMINATION
SPLC2 -7 -6
-9 DIRA DIRA
BUS+ 1 2
-10 BUS-
EQ -9 -7 EQ
JPC8 1 2
JP2
-3 -9 FU1 SENSE -4 -8
-4 B+ KA
-10 FU3 SENSE
HRN
JPC8 -NEG
HORN
HORN & ALARM
PT -1 -1 -1 H
T˚ -2 B+KA
-3
-2 -23 JPC10
PGND -16 JPA1-2
ALARM
4
B+KB -20 JPA1-1
JPC8
-6 DGND
-1
-2 3 TS19
B-F JPC9 TS21 BLACK
-3 RED
B+ KA
REACH SOL
JPY4 JP3 JPC11
-4 -9 -1 DGND
- -3 -10 -2 -12 -2 GREEN -2 GREEN2 SIDE 1
DGND SIDESHIFT SOL
PRESS SHIFT
+ -1 -12 -4 +12V
TILT SOL

NESTED SWITCH
JPC8 (OPTION)
JPC10-19
B+KB
JPC8 JPC7
-13
B+KC -1 JPS4
+12VP -1
SPLH3 S10
-4 -13 -2 NO COM
-5 B+KA -7 -3
DGND
NC
SWITCH
-5 COM
DGND
-16
JPC1 ON DEADMAN
-1 BUS-
-2
-3
TXD
RXD
Legend:
-4 BUS+
-5
-6
NC
-7 BOOT
-8 NC Negative Circuit
-9 +12VP
Signal or Detect
8R1005714_D_1_R.EPS
Figure 8-18: Lower - Electrical (Sheet 2 of 2)
8-38 PDMM-0109 7/31/02

Lift/Aux System Functional Operation Reach
Reach High Speed Reach

Reach extends the forks away from the mast (Refer to Figure 8-19 on page 8-40, Figure 8-19
assembly when the reach button (S4) on the on page 8-41, and Figure 8-21 on page 8-43):
multi-function controller is depressed. Inputs
for reach are received by the Vehicle Manager at The sequence in which the Reach/Retract
JPC6-1. When S4 is depressed, the following buttons are depressed determines the speed
occurs: and direction at which the reach mechanism
travels.
Slow Speed Reach • Depressing and holding the reach button

(S4), then depressing the retract button
(Refer to Figure 8-19 on page 8-40, Figure 8-19 (S5) activates high speed reach.
on page 8-41, and Figure 8-20 on page 8-42): • Depressing and holding the retract button
1. Depressing the deadman pedal provides (S5), then depressing the reach button (S4)
negative to the PC contactor at JPC8-18. activates high speed retract.
The PC contactor energizes, closing the PC High speed reach is activated as follows:
contactor tips - the auxiliary pump/motor
starts. 1. The retract button (S5) is depressed after
the reach mechanism is extending at slow
NOTE: It is not necessary to depress the speed (S4 depressed and held).
deadman pedal when requesting
auxiliary functions. 2. The Vehicle Manager supplies the
Equalizing solenoid (EQ) with negative at
2. Depressing the reach button (S4) completes JPC9-9.
a circuit from JPC6-1 to JPC6-14 on the
Vehicle Manager. 3. The Equalizing (EQ) solenoid coil energizes,
preventing any hydraulic fluid from flowing
3. The Vehicle Manager supplies negative at back to the reservoir. The reach mechanism
JPC9-10 which energizes Solenoid DIRB extends at high speed.
(reach extend).
NOTE: When reach/retract is set to high speed
4. The Vehicle Manager supplies negative at
in Configure Mode, depressing the reach
JPC9-8 which energizes the REACH
or retract buttons will engage full speed
solenoid.
without the need for depressing both
5. Hydraulic pressure supplied from the buttons.
auxiliary pump travels through solenoids
DIRB and REACH to extend the reach
cylinders.
6. During slow speed reach or retract, a
controlled portion of the pressurized fluid is
allowed to go back to the reservoir through
the de-energized Equalizing (EQ) solenoid.
PDMM-0109 7/31/02 8-39

Reach Lift/Aux System Functional Operation
NOTES:
KEY SWITCH OFF.
JP2
-10
-12 RED -1 -6 -3
T VEL SENSOR+
-13 BLACK -4 -5 -4
WHITE -3 -4 -5
T VEL PHASE A
TP1 BLUE -2 -3 -6
JP T VEL PHASE B
B+ JPT3 -7
RED -2 -8 T TEMP+
1 1 TMT RED/BLK -1 -7 -8
2 PC TPC ID0
2 -9
U B-
U
FU1 FU2 TM V
(150A) (350A) V
TP2 1 TP5 W W
P B+ +
2 1
TR
A FU3 2
(500A)
MX TP3
S
SPL2
JP2-2
MP
S A
JP TP4
B-
T3 T1
JPF1 ˚T
-5
-11 FU10
JPF2
-12 (15A) B-F -4
1 2 -9
-13 FU6 -10
(15A) TS2-1 -11
-14 TS2-2 -12
1 2
FU8 JPF5
-7 (5A) -3 TS19
TS2-3 -6 3
1 2 -6
FU9
(15A/5A)
-1 TS1-1
1 2
FU7
-10 (15A/5A) K1 TS1-2
-3 1 2 TS1-3
FU5
-8 JPF3-4 1
-9 1 2 JPF3-2
K2 JPF2-5
K1 K2 K3 K3
JPF2-3
JPF5-2
B+KA JPF2-2
JPF2-8
JPF2-1
Legend:
RELAY JPF5-1 TS19 3

FUSE
-7
JPF5-4
PANEL
Signal or Detect
8R1005714_D_1_L.EPS
Figure 8-19: Reach - Electrical (Sheet 1 of 2)
8-40 PDMM-0109 7/31/02

JPD1 JPC6
-1 THROTTLE -10 VR1
-10 +12 VP
-1 -2 AGND -13
-3 -3 LIFT -11
DATA_LATCH
CONTROL HANDLE
VR2
DISPLAY
-8
-4 -4 +5V
DISP_MISO
-5 -5 HORN -7 S3
SOUNDER
-6 -6 REACH -1 S4
SHIFT_CLOCK VEHICLE
-7 -7 RETRACT -2 S5
DATA OUT MANAGER
-8 -8 TILT UP -3 S6
DGND
SSHIFT LEFT S8
SSHIFT RIGHT -6 S9
JPT1 JP2 AGND -14
TPC -2 -1 SHIELD
CONTACTOR TPC
Y X
JPC8 JP2
B+KC -14 -5
-18 -6 X Y
-1 PC_CONTACTOR PC
B+KB JPC9 JP2
-12 X -8 JP3-13
+12VP -2 -7 Y
P CONTACTOR P
-13 -9
DGND
-10 JPC10
FAN
-11
BUS-
5
TA
2ND SOL -1 2ND
JPC9 JP3
B+KA_SUP -11 -2
L/L -5 -3 L/L
JPC4 1 2
-16 +12VP -6 -4
L/H L/H
-15 1 2
DGND
DIRB -10 -5 DIRB
-12 1 2
BUS TERMINATION
SPLC2 -7 -6
-9 DIRA DIRA
BUS+ 1 2
-10 BUS-
EQ -9 -7 EQ
JPC8 1 2
JP2
-3 -9 FU1 SENSE -4 -8
-4 B+ KA
-10 FU3 SENSE
HRN
JPC8 -NEG
HORN
HORN & ALARM
PT -1 -1 -1 H
T˚ -2 B+KA
-3
-2 -23 JPC10
PGND -16 JPA1-2
ALARM
4
B+KB -20 JPA1-1
JPC8
-6 DGND
-1
-2 3 TS19
B-F JPC9 TS21 BLACK
-3 RED
B+ KA
REACH SOL
JPY4 JP3 JPC11
-4 -9 -1 DGND
- -3 -10 -2 -12 -2 GREEN -2 GREEN2 SIDE 1
DGND SIDESHIFT SOL
PRESS SHIFT
+ -1 -12 -4 +12V
TILT SOL

NESTED SWITCH
JPC8 (OPTION)
JPC10-19
B+KB
JPC8 JPC7
-13
B+KC -1 JPS4
+12VP -1
SPLH3 S10
-4 -13 -2 NO COM
-5 B+KA -7 -3
DGND
NC
SWITCH
-5 COM
DGND
-16
JPC1 ON DEADMAN
-1 BUS-
-2
-3
TXD
RXD
Legend:
-4 BUS+
-5
-6
NC
-7 BOOT
-8 NC Negative Circuit
-9 +12VP
Signal or Detect
8R1005714_D_1_R.EPS
Reach - Electrical (Sheet 2 of 2)
PDMM-0109 7/31/02 8-41

HYDRAULIC MANIFOLD
PT2
L/H
PT1 SOL
NOT ON ALL MODELS
CV1
P1 2 1 1 CYL
LIFT LIFT
2 CYL
L/L
CV2 SOL
1 FLOW
P2 2
LIFT CONTROL
HIGH 2
2 PRESSURE
RELIEF
2
2ND
SOL 1
C3
REACH
REACH/RETURN
SOL
DIRB
SOL A2 P C1
STEER
RETURN
AUX T C2
P3 PRESS 3 2
AUX 2 C4
1
4
1 EQ
SOL A1
SIDESHIFT
DIRA C2 C1
SOL
SIDESHIFT
SOL
AUX
PRESSURE P
RELIEF STEER
ORBITROL
TILT
T SOL
STEER
MOTOR
T
C2 C1
FILTER
TILT
TANK
Legend:
Pressure Line
Return Line
Suction Line
Electrical Control
Signal
8R84137_C_C.EPS
Figure 8-20: Reach, slow speed - Hydraulic
8-42 PDMM-0109 7/31/02

HYDRAULIC MANIFOLD
PT2
L/H
PT1 SOL
NOT ON ALL MODELS
CV1
P1 2 1 1 CYL
LIFT LIFT
2 CYL
L/L
CV2 SOL
1 FLOW
P2 2
LIFT CONTROL
HIGH 2
2 PRESSURE
RELIEF
2
2ND
SOL 1
C3
REACH
REACH/RETURN
SOL
DIRB
SOL A2 P C1
STEER
RETURN
AUX T C2
P3 PRESS 3 2
AUX 2 C4
1
4
1 EQ
SOL A1
SIDESHIFT
DIRA C2 C1
SOL
SIDESHIFT
SOL
AUX
PRESSURE P
RELIEF STEER
ORBITROL
TILT
T SOL
STEER
MOTOR
T
C2 C1
FILTER
TILT
TANK
Legend:
Pressure Line
Return Line
Suction Line
Electrical Control
Signal
8R84137_C_C.EPS
Figure 8-21: Reach, high speed - Hydraulic
PDMM-0109 7/31/02 8-43

NOTES:
KEY SWITCH OFF.
JP2
-10
-12 RED -1 -6 -3
T VEL SENSOR+
-13 BLACK -4 -5 -4
WHITE -3 -4 -5
T VEL PHASE A
TP1 -2
BLUE -3 -6
JP T VEL PHASE B
B+ JPT3 -7
RED -2 -8 T TEMP+
1 1 TMT RED/BLK -1 -7 -8
2 PC TPC ID0
2 -9
U B-
U
FU1 FU2 TM V
(150A) (350A) V
TP2 1 TP5 W W
P B+ +
2 1
TR
A FU3 2
(500A)
MX TP3
S
SPL2
JP2-2
MP
S A
JP TP4
B-
T3 T1
JPF1 ˚T
-5
-11 FU10
JPF2
-12 (15A) B-F -4
1 2 -9
-13 FU6 -10
(15A) TS2-1 -11
-14 TS2-2 -12
1 2
FU8 JPF5
-7 (5A) -3 TS19
TS2-3 -6 3
1 2 -6
FU9
(15A/5A)
-1 TS1-1
1 2
FU7
-10 (15A/5A) K1 TS1-2
-3 1 2 TS1-3
FU5
-8 JPF3-4 1
-9 1 2 JPF3-2
K2 JPF2-5
K1 K2 K3 K3
JPF2-3
JPF5-2
B+KA JPF2-2
JPF2-8
JPF2-1
RELAY JPF5-1 TS19 3

CONTROL -7
FUSE JPF5-4
PANEL
JPF3 -1
8R1005714_D_1_L.EPS
Figure 8-22: Reach, high speed - Electrical (Sheet 1 of 2)
8-44 PDMM-0109 7/31/02

JPD1 JPC6
-1 THROTTLE -10 VR1
-10 +12 VP
-1 -2 AGND -13
-3 -3 LIFT -11
DATA_LATCH
CONTROL HANDLE
VR2
DISPLAY
-8
-4 -4 +5V
DISP_MISO
-5 -5 HORN -7 S3
SOUNDER
-6 -6 REACH -1 S4
SHIFT_CLOCK VEHICLE
-7 -7 RETRACT -2 S5
DATA OUT MANAGER
-8 -8 TILT UP -3 S6
DGND
SSHIFT LEFT S8
SSHIFT RIGHT -6 S9
JPT1 JP2 AGND -14
TPC -2 -1 SHIELD
CONTACTOR TPC
Y X
JPC8 JP2
B+KC -14 -5
-18 -6 X Y
-1 PC_CONTACTOR PC
B+KB JPC9 JP2
-12 X -8 JP3-13
+12VP -2 -7 Y
P CONTACTOR P
-13 -9
DGND
-10 JPC10
FAN
-11
BUS-
5
TA
2ND SOL -1 2ND
JPC9 JP3
B+KA_SUP -11 -2
L/L -5 -3 L/L
JPC4 1 2
-16 +12VP -6 -4
L/H L/H
-15 1 2
DGND
DIRB -10 -5 DIRB
-12 1 2
BUS TERMINATION
SPLC2 -7 -6
-9 DIRA DIRA
BUS+ 1 2
-10 BUS-
EQ -9 -7 EQ
JPC8 1 2
JP2
-3 -9 FU1 SENSE -4 -8
-4 B+ KA
-10 FU3 SENSE
HRN
JPC8 -NEG
HORN
HORN & ALARM
PT -1 -1 -1 H
T˚ -2 B+KA
-3
-2 -23 JPC10
PGND -16 JPA1-2
ALARM
4
B+KB -20 JPA1-1
JPC8
-6 DGND
-1
-2 3 TS19
B-F JPC9 TS21 BLACK
-3 RED
B+ KA
REACH SOL
JPY4 JP3 JPC11
-4 -9 -1 DGND
- -3 -10 -2 -12 -2 GREEN -2 GREEN2 SIDE 1
DGND SIDESHIFT SOL
PRESS SHIFT
+ -1 -12 -4 +12V
TILT SOL

NESTED SWITCH
JPC8 (OPTION)
JPC10-19
B+KB
JPC8 JPC7
-13
B+KC -1 JPS4
+12VP -1
SPLH3 S10
-4 -13 -2 NO COM
-5 B+KA -7 -3
DGND
NC
SWITCH
-5 COM
DGND
-16
JPC1 ON DEADMAN
-1 BUS-
-2 TXD
-3 RXD
-4 BUS+
-5 DGND
-6 NC
-7 BOOT
-8 NC
-9 +12VP
8R1005714_D_1_R.LPS
Reach, high speed - Electrical (Sheet 2 of 2)
PDMM-0109 7/31/02 8-45

Sideshift Lift/Aux System Functional Operation
Sideshift
Sideshift allows the operator to move the fork
carriage to the left or right in relation to the
mast. In the following discussion, the fork
carriage is sideshifted to the right. Refer to
Figure 8-23 on page 8-47, Figure 8-24 on page
8-48, and Figure 8-24 on page 8-49.
Depressing the sideshift right button (S9) on
the multi-function controller causes the
following:
1. Negative potential is supplied through S9 to
JPC6-6 on the Vehicle Manager.
2. Sensing that S9 has been closed, the
Vehicle Manager provides negative for DIRA
(JPC9-7) and EQ (JPC9-9) solenoids.
3. The Vehicle Manager provides negative for
the sideshift solenoid at JPC9-12.
4. With solenoids DIRA, SIDESHIFT, and EQ
energized, pressurized hydraulic fluid flows
from the auxiliary pump through DIRA and
SIDESHIFT solenoids to one side of the
sideshift cylinder.
8-46 PDMM-0109 7/31/02

Lift/Aux System Functional Operation Sideshift
HYDRAULIC MANIFOLD
PT2
L/H
PT1 SOL
NOT ON ALL MODELS
CV1
P1 2 1 1 CYL
LIFT LIFT
2 CYL
L/L
CV2 SOL
1 FLOW
P2 2
LIFT CONTROL
HIGH 2
2 PRESSURE
RELIEF
2
2ND
SOL 1
C3
REACH
REACH/RETURN
SOL
DIRB
SOL A2 P C1
STEER
RETURN
AUX T C2
P3 PRESS 3 2
AUX 2 C4
1
4
1 EQ
SOL A1
SIDESHIFT
DIRA C2 C1
SOL
SIDESHIFT
SOL
AUX
PRESSURE P
RELIEF STEER
ORBITROL
TILT
T SOL
STEER
MOTOR
T
C2 C1
FILTER
TILT
TANK
Legend:
Pressure Line
Return Line
Suction Line
Electrical Control
Signal
8R84137_C_C.EPS
Figure 8-23: Sideshift - Hydraulic
PDMM-0109 7/31/02 8-47

Sideshift Lift/Aux System Functional Operation
NOTES:
KEY SWITCH OFF.
JP2
-10
-12 RED -1 -6 -3
T VEL SENSOR+
-13 BLACK -4 -5 -4
WHITE -3 -4 -5
T VEL PHASE A
TP1 BLUE -2 -3 -6
JP T VEL PHASE B
B+ JPT3 -7
RED -2 -8 T TEMP+
1 1 TMT RED/BLK -1 -7 -8
2 PC TPC ID0
2 -9
U B-
U
FU1 FU2 TM V
(150A) (350A) V
TP2 1 TP5 W W
P B+ +
2 1
TR
A FU3 2
(500A)
MX TP3
S
SPL2
JP2-2
MP
S A
JP TP4
B-
T3 T1
JPF1 ˚T
-5
-11 FU10
JPF2
-12 (15A) B-F -4
1 2 -9
-13 FU6 -10
(15A) TS2-1 -11
-14 TS2-2 -12
1 2
FU8 JPF5
-7 (5A) -3 TS19
TS2-3 -6 3
1 2 -6
FU9
(15A/5A)
-1 TS1-1
1 2
FU7
-10 (15A/5A) K1 TS1-2
-3 1 2 TS1-3
FU5
-8 JPF3-4 1
-9 1 2 JPF3-2
K2 JPF2-5
K1 K2 K3 K3
JPF2-3
JPF5-2
B+KA JPF2-2
JPF2-8
JPF2-1
Legend:
RELAY JPF5-1 TS19 3

FUSE
-7
JPF5-4
PANEL
Signal or Detect
8R1005714_D_1_L.EPS
Figure 8-24: Sideshift - Electrical (Sheet 1 of 2)
8-48 PDMM-0109 7/31/02

Lift/Aux System Functional Operation Sideshift

JPD1 JPC6
-1 THROTTLE -10 VR1
-10 +12 VP
-1 -2 AGND -13
-3 -3 LIFT -11
DATA_LATCH
CONTROL HANDLE
VR2
DISPLAY
-8
-4 -4 +5V
DISP_MISO
-5 -5 HORN -7 S3
SOUNDER
-6 -6 REACH -1 S4
SHIFT_CLOCK VEHICLE
-7 -7 RETRACT -2 S5
DATA OUT MANAGER
-8 -8 TILT UP -3 S6
DGND
SSHIFT LEFT S8
SSHIFT RIGHT -6 S9
JPT1 JP2 AGND -14
TPC -2 -1 SHIELD
CONTACTOR TPC
Y X
JPC8 JP2
B+KC -14 -5
-18 -6 X Y
-1 PC_CONTACTOR PC
B+KB JPC9 JP2
-12 X -8 JP3-13
+12VP -2 -7 Y
P CONTACTOR P
-13 -9
DGND
-10 JPC10
FAN
-11
BUS-
5
TA
2ND SOL -1 2ND
JPC9 JP3
B+KA_SUP -11 -2
L/L -5 -3 L/L
JPC4 1 2
-16 +12VP -6 -4
L/H L/H
-15 1 2
DGND
DIRB -10 -5 DIRB
-12 1 2
BUS TERMINATION
SPLC2 -7 -6
-9 DIRA DIRA
BUS+ 1 2
-10 BUS-
EQ -9 -7 EQ
JPC8 1 2
JP2
-3 -9 FU1 SENSE -4 -8
-4 B+ KA
-10 FU3 SENSE
HRN
JPC8 -NEG
HORN
HORN & ALARM
PT -1 -1 -1 H
T˚ -2 B+KA
-3
-2 -23 JPC10
PGND -16 JPA1-2
ALARM
4
B+KB -20 JPA1-1
JPC8
-6 DGND
-1
-2 3 TS19
B-F JPC9 TS21 BLACK
-3 RED
B+ KA
REACH SOL
JPY4 JP3 JPC11
-4 -9 -1 DGND
- -3 -10 -2 -12 -2 GREEN -2 GREEN2 SIDE 1
DGND SIDESHIFT SOL
PRESS SHIFT
+ -1 -12 -4 +12V
TILT SOL

NESTED SWITCH
JPC8 (OPTION)
JPC10-19
B+KB
JPC8 JPC7
-13
B+KC -1 JPS4
+12VP -1
SPLH3 S10
-4 -13 -2 NO COM
-5 B+KA -7 -3
DGND
NC
SWITCH
-5 COM
DGND
-16
JPC1 ON DEADMAN
-1 BUS-
-2 TXD
-3
-4
RXD
BUS+
Legend:
-5 DGND
-6
-7
NC Positive Circuit
BOOT
-8
-9
NC
+12VP Negative Circuit
Signal or Detect
8R1005714_D_1_R.EPS
Sideshift - Electrical (Sheet 2 of 2)
PDMM-0109 7/31/02 8-49

Fork Tilt Lift/Aux System Functional Operation
Fork Tilt
Fork tilt allows the operator to raise or lower the
tips of the forks. Standard fork tilt is 5o up and
2o down. In the following discussion, the forks
are tilted up. Refer to Figure 8-25 on page 8-51,
Figure 8-26 on page 8-52, and Figure 8-26 on
page 8-53.
Depressing the fork tilt up button (S6) on the
multi-function controller causes the following:
1. Negative potential is supplied through S6 at
JPC6-3 on the Vehicle Manager.
2. Sensing that S6 has been closed, the
Vehicle Manager provides negative for DIRA
(JPC9-7) and EQ (JPC9-9) solenoids.
3. The Vehicle Manager (JPC9-1), provides
negative for the tilt solenoid.
4. With solenoids DIRA, TILT, and EQ
energized, pressurized hydraulic fluid flows
from the auxiliary pump through DIRA and
TILT solenoids to one side of the fork tilt
cylinder.
8-50 PDMM-0109 7/31/02

Lift/Aux System Functional Operation Fork Tilt
HYDRAULIC MANIFOLD
PT2
L/H
PT1 SOL
NOT ON ALL MODELS
CV1
P1 2 1 1 CYL
LIFT LIFT
2 CYL
L/L
CV2 SOL
1 FLOW
P2 2
LIFT CONTROL
HIGH 2
2 PRESSURE
RELIEF
2
2ND
SOL 1
C3
REACH
REACH/RETURN
SOL
DIRB
SOL A2 P C1
STEER
RETURN
AUX T C2
P3 PRESS 3 2
AUX 2 C4
1
4
1 EQ
SOL A1
SIDESHIFT
DIRA C2 C1
SOL
SIDESHIFT
SOL
AUX
PRESSURE P
RELIEF STEER
ORBITROL
TILT
T SOL
STEER
MOTOR
T
C2 C1
FILTER
TILT
TANK
Legend:
Pressure Line
Return Line
Suction Line
Electrical Control
Signal
8R84137_C_C.EPS
Figure 8-25: Hydraulic Schematic - Fork Tilt, Three-Motor
PDMM-0109 7/31/02 8-51

NOTES:
KEY SWITCH OFF.
JP2
-10
-12 RED -1 -6 -3
T VEL SENSOR+
-13 BLACK -4 -5 -4
WHITE -3 -4 -5
T VEL PHASE A
TP1 BLUE -2 -3 -6
JP T VEL PHASE B
B+ JPT3 -7
RED -2 -8 T TEMP+
1 1 TMT RED/BLK -1 -7 -8
2 PC TPC ID0
2 -9
U B-
U
FU1 FU2 TM V
(150A) (350A) V
TP2 1 TP5 W W
P B+ +
2 1
TR
A FU3 2
(500A)
MX TP3
S
SPL2
JP2-2
MP
S A
JP TP4
B-
T3 T1
JPF1 ˚T
-5
-11 FU10
JPF2
-12 (15A) B-F -4
1 2 -9
-13 FU6 -10
(15A) TS2-1 -11
-14 TS2-2 -12
1 2
FU8 JPF5
-7 (5A) -3 TS19
TS2-3 -6 3
1 2 -6
FU9
(15A/5A)
-1 TS1-1
1 2
FU7
-10 (15A/5A) K1 TS1-2
-3 1 2 TS1-3
FU5
-8 JPF3-4 1
-9 1 2 JPF3-2
K2 JPF2-5
K1 K2 K3 K3
JPF2-3
JPF5-2
B+KA JPF2-2
JPF2-8
JPF2-1
Legend:
RELAY JPF5-1 TS19 3

FUSE
-7
JPF5-4
PANEL
Signal or Detect
8R1005714_D_1_L.EPS
Figure 8-26: Electrical Schematic - Fork Tilt (Sheet 1 of 2)
8-52 PDMM-0109 7/31/02

Lift/Aux System Functional Operation Fork Tilt

JPD1 JPC6
-1 THROTTLE -10 VR1
-10 +12 VP
-1 -2 AGND -13
-3 -3 LIFT -11
DATA_LATCH
CONTROL HANDLE
VR2
DISPLAY
-8
-4 -4 +5V
DISP_MISO
-5 -5 HORN -7 S3
SOUNDER
-6 -6 REACH -1 S4
SHIFT_CLOCK VEHICLE
-7 -7 RETRACT -2 S5
DATA OUT MANAGER
-8 -8 TILT UP -3 S6
DGND
SSHIFT LEFT S8
SSHIFT RIGHT -6 S9
JPT1 JP2 AGND -14
TPC -2 -1 SHIELD
CONTACTOR TPC
Y X
JPC8 JP2
B+KC -14 -5
-18 -6 X Y
-1 PC_CONTACTOR PC
B+KB JPC9 JP2
-12 X -8 JP3-13
+12VP -2 -7 Y
P CONTACTOR P
-13 -9
DGND
-10 JPC10
FAN
-11
BUS-
5
TA
2ND SOL -1 2ND
JPC9 JP3
B+KA_SUP -11 -2
L/L -5 -3 L/L
JPC4 1 2
-16 +12VP -6 -4
L/H L/H
-15 1 2
DGND
DIRB -10 -5 DIRB
-12 1 2
BUS TERMINATION
SPLC2 -7 -6
-9 DIRA DIRA
BUS+ 1 2
-10 BUS-
EQ -9 -7 EQ
JPC8 1 2
JP2
-3 -9 FU1 SENSE -4 -8
-4 B+ KA
-10 FU3 SENSE
HRN
JPC8 -NEG
HORN
HORN & ALARM
PT -1 -1 -1 H
T˚ -2 B+KA
-3
-2 -23 JPC10
PGND -16 JPA1-2
ALARM
4
B+KB -20 JPA1-1
JPC8
-6 DGND
-1
-2 3 TS19
B-F JPC9 TS21 BLACK
-3 RED
B+ KA
REACH SOL
JPY4 JP3 JPC11
-4 -9 -1 DGND
- -3 -10 -2 -12 -2 GREEN -2 GREEN2 SIDE 1
DGND SIDESHIFT SOL
PRESS SHIFT
+ -1 -12 -4 +12V
TILT SOL

NESTED SWITCH
JPC8 (OPTION)
JPC10-19
B+KB
JPC8 JPC7
-13
B+KC -1 JPS4
+12VP -1
SPLH3 S10
-4 -13 -2 NO COM
-5 B+KA -7 -3
DGND
NC
SWITCH
-5 COM
DGND
-16
JPC1 ON DEADMAN
-1 BUS-
-2 TXD
-3
-4
RXD
BUS+
Legend:
-5 DGND
-6
-7
NC Positive Circuit
BOOT
-8
-9
NC
+12VP Negative Circuit
Signal or Detect
8R1005714_D_1_R.EPS
Tilt - Electrical (Sheet 2 of 2)
PDMM-0109 7/31/02 8-53

8-54 PDMM-0109 7/31/02

Pinout Matrix
Theory of Operation 8:
Pinout Matrix variable, it indicates the state of a

related component that will cause the
The pinout matrix chart lists functions and signal to vary.
normal voltages of terminals and harness b. Identifies possible causes for lack of
connector pins. The matrix columns have the proper signal.
following meanings:
5. Normal Level: the approximate voltage that
1. Item #: sequential number to aid in you should see on that wire for the state
reference. indicated. Unless otherwise indicated,
voltages are measured with respect to (wrt)
2. Connection: the actual wire numbers or
B– at TP4.
component abbreviations on the electrical
schematic. 6. Signal Source: the device or connection that
supplies the signal directly to the wire.
3. Function Description: brief definition of the
signal carried on the wire. 7. Signal User: the device or connection to
which the wire directly delivers the signal.
4. Theory of Operation:
a. A detailed description of the signal
carried on the wire. If the signal can be
Item Function Normal Signal Signal

Connection Theory of Operations
# Description Level Source User
1 JPD1-9 +12 VP +12 volts from JPC5-1 when S1 is ON. If +12V Vehicle Operator
voltage is not present, confirm that the wrt JPD1-8 Manager Display
battery is connected, the key switch is
functioning and associated wiring is OK.
This voltage is dependent on B+ at
JPC8-17.
2 JPD1-10 +12 VP +12 volts from JPC5-1 when S1 is ON. If +12V Vehicle Operator
voltage is not present, confirm that the wrt JPD1-8 Manager Display
JPC8-17.
3 JPD1-8 DGND B– from JPC5-8 for the Operator Display. If B– (DGND) Vehicle Operator
voltage is not present, check the connection Manager Display
and associated wiring. This voltage is
dependent on DGND at JPC8-6.
4 JPT1-3 Traction +12V to the speed sensor. If voltage is not +12V Traction Traction
Speed present, check the connection and wrt JPT1-4 Power Speed
Sensor (+) associated wiring. This voltage is generated Amplifier Sensor
by the traction power amplifier and is
dependent on B+ [at the (+) connection]
and B– to the amplifier.
5 JPT1-4 Traction Return for the +12V to the speed sensor and B– Traction Traction
Speed temperature sensor. If voltage is not present, Power Speed
Sensor (–) check the connection and associated Amplifier Sensor
wiring. This voltage is generated by the
traction power amplifier and is dependent
on B– to the amplifier.
PDMM-0109 7/31/02 8-55

Pinout Matrix

6 JPT1-5 T VEL PHASE One channel of the feedback to the traction 7.5 volts Traction Traction
A amplifier from the speed sensor. Voltage at Speed Power
JPT1-3(+) and JPT1-5 (–) with lift truck Sensor Amplifier
traveling is approximately 7.5 volts
7 JPT1-6 T VEL PHASE One channel of the feedback to the traction 7.5 volts Traction Traction
B amplifier from the speed sensor. Voltage at Speed Power
JPT1-3(+) and JPT1-6 (–) with lift truck Sensor Amplifier
traveling is approximately 7.5 volts
8 JPT1-7 T TEMP + +12 volts from the traction amplifier. The Approx. 1.5 Traction Traction
traction amplifier determines motor volts at room Power Power
temperature from the voltage drop across temperature, Amplifier Amplifier
the temperature sensor. increases as Temperature
motor heats Sensor
up
9 JPT1-8 ID0 Not connected for the traction power n/a

amplifier.
10 JPT1-9 ID1 Not connected for the traction power n/a

amplifier.
11 Traction Traction One of the three phases from the traction 0 to 400A Traction Drive
Power Power power amplifier to the motor. If not present, wrt phase W Power Motor
Amplifier (U) Amplifier check the connection and associated or phase V; Amplifier
Phase U wiring. This voltage is generated by the max is 480A
on B+ [at the (+) connection] and B– to the
amplifier.
Power Power power amplifier to the motor. If not present, wrt phase U Power Motor
Amplifier (V) Amplifier check the connection and associated or phase W; Amplifier
Phase V wiring. This voltage is generated by the max is 480A
amplifier.
Power Power power amplifier to the motor. If not present, wrt phase U Power Motor
Amplifier Amplifier check the connection and associated or phase V; Amplifier
(W) Phase W wiring. This voltage is generated by the max is 480A
amplifier.
14 Traction not used

Power
Amplifier
(B+)
15 Traction B– B– to the traction power amplifier from TP4. B– TP4 Traction

Amplifier If not present, check the connections and Power
(B–) associated wiring. This voltage is Amplifier
dependent on B– at the battery.
8-56 PDMM-0109 7/31/02

Pinout Matrix

16 Traction B+ B+ to the traction power amplifier when the B+ with TPC TPC-2 and Traction
Amplifier (+) TPC is closed. It is also the connection used closed. RCFP Power
for the pre-charge circuit to charge and During Amplifier
discharge the internal capacitors in the power up,
power amplifier from the relay control fuse voltage
panel via T3 and TR. This voltage is increases
dependent on FU2. from 0 to
approx. 32
volts.
17 JPT1-2 B– Return path to B– for B+ through the TPC 24V TPC-X Traction TPC Coil
coil. If voltage is not present, check B– at wrt JPT1-2 Power
the traction power amplifier, TP4, and when TPC Amplifier
associated wiring. This voltage is generated energized
by a coil driver internal to the traction
power amplifier.
18 JPT1-1 B+KB B+ from the relay control fuse panel when B+ Relay Fuse Traction
K3 is energized. Control power for the Control Panel Power
traction power amplifier. This voltage is Amplifier
dependent on B+ at JPF3-4.
19 JPT1-12 +12V +12 volts from the Vehicle Manager internal n/a
power supply when S1 is ON. This voltage
is not used by the traction power amplifier.
20 JPT1-13 DGND B– to traction power amplifier. If voltage is B– (DGND) Vehicle Traction

not present, confirm that B– is present at Manager Power
JPC4-15, the connections, and associated Amplifier
wiring. This voltage is dependent on DGND
at JPC8-6.
21 JPT1-10 BUS+ CAN Bus (+) communication line between n/a Vehicle Vehicle
the Vehicle Manager and the traction Manager, Manager,
power amplifier. Voltage measurement Traction Traction
provides no useful information. Measure Power Power
resistance as explained in manual. Amplifier Amplifier
22 JPT1-11 BUS– CAN Bus (–) communication line between n/a Vehicle Vehicle
23 JPF1-5 B– B– for most functions. If voltage is not B– TP4 Vehicle

present, check the connections and wiring Manager
from TP4. This voltage is dependent on B– and
at the battery. options


PDMM-0109 7/31/02 8-57

Pinout Matrix

26 JPF1-13 B– B– for options. If voltage is not present, B– TP4 Options

check the connections and wiring from TP4.
This voltage is dependent on B– at the
battery.

battery.

battery.
29 JPF1-1 B+ B+ for options. If voltage is not present, B+ TP1 Options

This voltage is dependent on B+ at the
battery.

battery.

battery.
32 JPF1-8 B+ B+ for most functions. If voltage is not B+ TP1 Vehicle

from TP1. This voltage is dependent on B+
at the battery.
33 JPF1-9 B+ B+ for most functions. If voltage is not B+ TP1 Vehicle

from TP1. This voltage is dependent on B+
at the battery.
34 T3 B+ The connection used for the pre-charge During Relay Control Traction
circuit to charge and discharge the internal power up, Fuse Panel Power
capacitors in the traction power amplifier voltage Amplifier
from the relay control fuse panel via TR and increases
+ on the power amplifier. from 0 to
approx, 32
volts.
35 FU10 15A Fuse B– for most functions. If voltage is not B– TP4 Vehicle
from JPF1-5, 11 & 12. This voltage is and
dependent on B– at TP4. options
36 FU6 15A Fuse B– for options. If voltage is not present, B– TP4 Options
check the connections and wiring from
JPF1-13 & 14. This voltage is dependent on
B– at TP4.
8-58 PDMM-0109 7/31/02

Pinout Matrix

37 TS2-1 B– B– for options. If voltage is not present, B– TP4 Options

check FU6. This voltage is dependent on B–
at JPF1-13, JPF1-14.

at JPF1-13, JPF1-14.
39 FU8 5A Fuse B– for options. If voltage is not present, B– TP4 Options

JPF1-7. This voltage is dependent on B– at
TP4.
40 FU9 15A Fuse B+ for options. If voltage is not present, B+ TP1 Options
JPF1-1 & 3. This voltage is dependent on B+
at TP1.

at JPF1-7.
42 FU7 15A Fuse B+ for options. If voltage is not present, B+ TP1 Options
JPF1-10 & 3. This voltage is dependent on
B+ at TP1.
43 FU5 15A Fuse B+ for most functions. If voltage is not B+ TP1 Vehicle
from JPF1-8 & 9. This voltage is dependent and
on B+ at TP1. options
44 JPF2-4 DGND Return path to B– for the Operator Display, B– TP4 Vehicle
Pressure Transducer, SMARTi/PC and Manager
switches, and reference voltage for
BUS+/BUS–. If voltage is not present, check
FU10, the connection, and associated
wiring. This voltage is dependent on B– at
JPF1-5, 11 & 12.
45 JPF2-9 B– Return path to B– for the Vehicle Manager. B– TP4 Vehicle

If voltage is not present, check FU10, the Manager
connection, and associated wiring. This
voltage is dependent on B– at JPF1-5, 11 &
12.

12.

12.
PDMM-0109 7/31/02 8-59

Pinout Matrix


12.
49 JPF5-3 B– Return path to B– for Options. If voltage is B– TP4 Options

not present, check FU10, the connection,
dependent on B– at JPF1-5, 11 & 12.
50 JPF5-6 B– Return path to B– for Options. If voltage is B– TP4 Options

not present, check FU10, the connection,
dependent on B– at JPF1-5, 11 & 12.
51 TS1-1 B+ B+ for options. If voltage is not present, B+ FU9 Options

check the connections and wiring from FU9.
This voltage is dependent on B+ at JPF1-1 &
3.

check the connections and wiring from FU7
and K1. This voltage is dependent on B+ at
JPF1-10 & 3.

check the connections and wiring from FU7
and K1. This voltage is dependent on B+ at
JPF1-10 & 3.
54 JPF3-4 B+ B+ for S1. If voltage is not present, check B+ FU5 S1

the connections and wiring from FU5. This
voltage is dependent on B+ at JPF1-8 & 9.
55 JPF3-2 B+ B+ from S1. If voltage is not present, check B+ S1 Vehicle

the connections and wiring from JPF3-4. Manager
This voltage is dependent on B+ at FU5. and
options
56 JPF2-5 B+ B+ for the Vehicle Manager. If voltage is not B+ FU5/S1 Vehicle

from JPF3-2. This voltage is dependent on
B+ at JPF3-4.
57 T1 B+ B+ for the traction power amplifier. If B+ FU5 Vehicle

voltage is not present, check the Manager
connections and wiring from K3. This
voltage is dependent on B+ at FU5.
58 JPF2-2 B+ B+ for the Vehicle Manager. If voltage is not B+ FU5 Vehicle

from K2 & FU5. This voltage is dependent
on B+ at FU5.
59 JPF2-8 B+ B+ to the Vehicle Manager. If voltage is not B+ FU5 Vehicle

from K2 & FU5. This voltage is dependent
on B+ at FU5.
8-60 PDMM-0109 7/31/02

Pinout Matrix

60 JPF2-1 Battery Sense B+ through a 5.11 ohm current limiting Approx. 2 Relay control Vehicle
In resistor on the relay control fuse panel. This volts less fuse panel Manager
voltage is used by the VM to determine if than B+
battery vo9ltage is within required values
and to calculate BSOC readings.
61 JPF5-1 B+ B+ for Options. If voltage is not present, B+ FU5 Options

check the connections and wiring from K2
& FU5. This voltage is dependent on B+ at
JPF1-8 & 9.
62 JPF5-4 B+ B+ for Options. If voltage is not present, B+ FU5 Options

check the connections and wiring from K2
& FU5. This voltage is dependent on B+ at
JPF1-8 & 9.
63 JPF3-1 Amplifier B– from Vehicle Manager. This voltage is B– Vehicle K3

enable dependent on “battery sense in” at JPC8-7 Manager
being between 28 volts and 45 volts. If
voltage is not present, confirm that the
battery is connected, S1 is functioning
properly, the K3 coil and associated wiring
are OK, and JPC8-7 reads between 28
volts and 45 volts wrt TP4.
64 JPC5-1 +12 VP +12 volts from the Vehicle Manager internal +12V Vehicle Operator
power supply when S1 is ON. If voltage is wrt JPC5-8 Manager Display
not present, confirm that the battery is
connected, the key switch is functioning, K2
is functioning properly, and associated
wiring is OK. This voltage is dependent on
B+ at JPC8-4 & 5 &17.
65 JPC5-8 DGND Return path to B– for the Operator Display. B– (DGND) Vehicle Operator
If voltage is not present, check the Manager Display
voltage is dependent on DGND at JPC8-6.
66 JPC4-16 +12VP +12 volts from the Vehicle Manager's +12V Vehicle Not Used
internal power supply when S1 is ON. This wrt JPC4-15 Manager
voltage is not used by the traction power
amplifier.
67 JPC4-15 DGND BUS– for the traction power amplifier. If B– (DGND) Vehicle AC
voltage is not present, check the Manager Traction
connection, and associated wiring. This Power
voltage is dependent on DGND at JPC8-6. Amplifier
68 JPC4-12 Bus 120 ohm resistor to terminate the CAN Bus 120 ohms Vehicle Vehicle
Termination communication lines. If communication fails, JPC4-12 wrt Manager Manager
check resistance between JPC4-9 and JPC4-9
JPC4-12. Resistance should be about 120
ohms with JPT1 and JPC1 disconnected.
PDMM-0109 7/31/02 8-61

Pinout Matrix

69 JPC4-9 BUS+ CAN Bus (+) communication line between n/a Vehicle Vehicle
70 JPC4-10 BUS– CAN Bus (–) communication line between n/a Vehicle Vehicle
71 JPC1-4 BUS+ CAN Bus (+) communication line between n/a Vehicle Vehicle
the Vehicle Manager and the optional Manager, Manager,
SMARTi module. Voltage measurement SMARTi SMARTi
provides no useful information. Measure
resistance as explained in manual.
72 JPC1-1 BUS– CAN Bus (–) communication line between n/a Vehicle Vehicle
the Vehicle Manager and the optional Manager, Manager,
SMARTi module. Voltage measurement SMARTi SMARTi
provides no useful information. Measure
resistance as explained in manual.
73 JPC10-1 Lift Temp +12 V from the Vehicle Manager. The VM Disconnected Vehicle Vehicle
determines motor temperature from the = 6 to 12 V; Manager Manager
voltage drop across the temperature sensor. Room
Voltage increases as motor temperature temperature
increases. =3V
74 JPC10-23 PGND B– for the lift motor temperature sensing Measure Vehicle Vehicle
circuit. battery Manager Manager
voltage to
PC1 (B+) to
verify
connections.
75 JPC8-9 FU1_Sense Sense lead used by the Vehicle Manager to Tips open = TP2 Vehicle
determine if the PC contactor tips are open B– Manager
or closed. Tips closed =
B+
76 JPC8-6 DGND B– for the Vehicle Manager. If voltage is not B– (DGND) TP4 Vehicle
present, check JPF2-4, the connection, and Manager
associated wiring. This voltage is
dependent on B– at FU10.
77 JPC8-1 B–F B– for the Vehicle Manager. If voltage is not B– TP4 Vehicle
8-62 PDMM-0109 7/31/02

Pinout Matrix

81 JPC11-1 DGND B– for future use. If voltage is not present, B– (DGND)

check the connection and associated
wiring. This voltage is dependent on DGND
at JPC8-6.
82 JPC11-2 DGND B– for the pressure transducer. If voltage is B– (DGND) Vehicle Pressure
not present, check the connection and Manager Transducer
83 JPC11-3 Pressure This voltage varies directly with the weight 1V with forks Pressure Vehicle
on the carriage. With the forks resting on on floor; Transducer Manager
the floor, the voltage should be approx. 1 increases as
volt DC. Voltage increases as the weight weight
increases. increases
84 JPC11-4 +12V +12 volts from the Vehicle Manager internal +12V Vehicle Pressure
power supply when S1 is ON. wrt JPC11-2 Manager Transducer
85 JPC8-17 B+ Key B+ from JPF2-5 when S1 is ON. If voltage is B+ FU5 Vehicle

not present, confirm that S1 is functioning Manager
properly, and that the connections and
associated wiring are OK. This voltage is
dependent on B+ at JPF3-2.
86 JPC10-19 B+KB B+ when S1 is ON. This voltage is B+ FU5 Vehicle

dependent on B+ at K2. If voltage is not Manager
present, confirm that the battery is
connected, that S1 and K2 are functioning
properly, and the associated wiring is OK.
87 JPC8-13 B+KC B+ when K2 is energized. This voltage is B+ FU5 Vehicle

dependent on B+ at K2. If voltage is not Manager
connected, that S1 and K2 are functioning
properly, and the associated wiring is OK.
88 JPC8-4 B+KA B+ when K2 is energized. This voltage is B+ FU5 Vehicle

dependent on B+ at FU5. If voltage is not Manager
connected, that K2 is functioning properly,
and the associated wiring is OK.
89 JPC8-5 B+KA B+ when K2 is energized. This voltage is B+ FU5 Vehicle

dependent on B+ at FU5. If voltage is not Manager
connected, that K2 is functioning properly,
and the associated wiring is OK.
PDMM-0109 7/31/02 8-63

Pinout Matrix

90 JPC8-7 Battery Sense B+ through a 5.11 ohm current limiting Approx. 2 Relay control Vehicle
In resistor on the relay control fuse panel. This volts less fuse panel Manager
voltage is used by the VM to determine if than B+
battery vo9ltage is within required values
and to calculate BSOC readings.
91 JPC8-20 Amplifier B– from Vehicle Manager when S1 is ON. B– Vehicle K3 coil

Enable This voltage is dependent on “Battery Sense Manager
In” at JPC8-7 being between 28 volts and
45 volts. If voltage is not present, confirm
that the battery is connected, S1 is
functioning properly, the K3 coil and
associated wiring are OK, and JPC8-7
reads between 28 volts and 45 volts wrt
TP4.
92 JPC1-5 DGND Return path to B– for the SMARTI or PC. If B– (DGND) Vehicle SMARTI or
voltage is not present, check the connection Manager PC
93 JPC1-9 +12VP +12 volts from the Vehicle Manager's +12V Vehicle SMARTI or
internal power supply when S1 is ON. If wrt JPC1-5 Manager PC
voltage is not present, confirm that the
JPC8-17.
94 JPC6-15 Traction Pot +5V from Vehicle Manager supply. This +5V Vehicle VR1
Supply voltage is dependent on B+ Key at the wrt JPC6-13 Manager
Voltage Vehicle Manager at JPC8-17 and B+ at
JPC8-4 & 5.
95 JPC6-10 Traction Pot Wiper voltage from VR1. This voltage is .5V - 4.5V VR1 Vehicle
Proportional dependent on +5V at JPC6-15 and AGND wrt JPC6-13 Manager
Signal at JPC6-13.
96 JPC6-13 Traction/Lift B– for VR1 and VR2. This path is dependent B– (AGND) Vehicle VR1 and
Pot Return on B–F at JPC8-1, 2, 3 & 12. Manager VR2
97 JPC6-11 Lift Pot Wiper voltage from VR2. This voltage is .5V - 4.5V VR2 Vehicle
Proportional dependent on +5V at JPC6-8 and AGND at wrt JPC6-13 Manager
Signal JPC6-13
98 JPC6-8 Lift Pot +5V from Vehicle Manager supply. This +5V Vehicle VR2
Supply voltage is dependent on B+ Key at the wrt JPC6-13 Manager
Voltage Vehicle Manager at JPC8-17 and B+ at
JPC8-4 & 5.
99 JPC6-7 Horn B– from the horn switch (S3) when the S3 closed: S3 Vehicle
button is depressed. This voltage is B– (AGND) Manager
dependent on AGND at JPC6-14.
100 JPC6-1 Reach B– from the reach switch (S4) when the S4 closed: S4 Vehicle
8-64 PDMM-0109 7/31/02

Pinout Matrix

101 JPC6-2 Retract B– from the retract switch (S5) when the S5 closed: S5 Vehicle
102 JPC6-3 Tilt Up B– from the tilt up switch (S6) when the S6 closed: S6 Vehicle
103 JPC6-4 Tilt Down B– from the tilt down switch (S7) when the S7 closed: S7 Vehicle
104 JPC6-5 Sideshift Left B– from the sideshift left switch (S8) when S8 closed: S8 Vehicle
the button is depressed. This voltage is B– (AGND) Manager
105 JPC6-6 Sideshift B– from the sideshift right switch (S9) when S9 closed: S9 Vehicle
Right the button is depressed. This voltage is B– (AGND) Manager
106 JPC6-14 AGND B– for S3 through S9. This voltage is B– (AGND) Vehicle S3 through
dependent on B– at JPC8-1 to JPC1-4. Manager S9
107 JPC8-14 B+ to PC B+ from relay K2 when S1 is ON. If voltage B+ Vehicle PC-Y

Contactor is not present, confirm that the battery is Manager
connected and that K2 is functioning
properly. This voltage is dependent on B+ at
JPC8-13
108 JPC8-18 PC Contactor The negative path (B–) for the contactor Energized = Vehicle PC
coil. It is connected through the Vehicle 12 v Manager contactor
Manager to a coil driver. PC contactor is De-energized
switched to B– when there is an input to the = B+
coil driver. Measure voltage between
JPC8-14 (+) or PC-Y (+) and TP4 (–).
109 JPC8-16 Horn Horn is the negative path (B–) for the horn. De-energized Vehicle Horn
Horn is switched to B– when there is a = B+ Manager
command to sound the horn. Energized =
less than 1 v
110 JPC8-15 B+KA Positive supply voltage to the horn. De-energized Vehicle Horn
= B+ Manager
Energized =
less than 1 v
111 JPC10-16 Travel Alarm Negative path (B–)for the travel alarm. It is De-energized Vehicle Travel
switched to B– when there is a command to = B+ Manager Alarm
travel. Energized =
less than 1 v
112 JPC10-20 B+KB Positive supply voltage to the travel alarm. De-energized Vehicle Travel
= B+ Manager Alarm
Energized =
less than 1 v
PDMM-0109 7/31/02 8-65

Pinout Matrix

113 JPC10-9 Fan Negative path (B–) for the fan FAN1. It is De-energized Vehicle Fan
switched to B– when the fan is energized. = B+ Manager
Energized =
less than 1 v
114 JPC10-22 2ND SOL Negative path (B–) for the 2nd pump De-energized Vehicle 2ND SOL
solenoid. It is switched to B– when there is a = B+ Manager
command to energize the solenoid. Energized =
12 v
115 JPC9-6 L/H Negative path (B–) for the load holding De-energized Vehicle L/H SOL
solenoid coil. It is switched to B– when there = B+ Manager
is a command to energize the solenoid. Energized =
12 v
116 JPC9-10 DIRB Negative path (B–) for the directional B De-energized Vehicle DIRB SOL
12 v
117 JPC9-7 DIRA Negative path (B–) for the directional A De-energized Vehicle DIRA SOL
12 v
118 JPC9-9 EQ Negative path (B–) for the equalizing De-energized Vehicle EQ SOL
12 v
119 JPC9-4 B+KA Positive supply voltage to EQ, DIRA, DIRB, De-energized Vehicle L/H, DIRA,
and L/H solenoid coils as well as the fan = B+ Manager DIRB, and
and P contactor coil. Any solenoid EQ SOLs
energized =
12 v
120 JPC9-2 P Contactor Negative path (B–) for the lift contactor coil. De-energized Vehicle P
It is switched to B– when there is a = B+ Manager Contactor
12 v
121 JPC9-5 Lift/Lower Negative path (B–) for the lift/lower De-energized Vehicle L/L SOL
(L/L) proportional solenoid coil. It is switched to = B+ Manager
B– when there is a command to energize Energized =
the solenoid. 18 v
122 JPC9-11 B+KA_SUP Positive supply voltage to the 2ND and L/L De-energized Vehicle 2ND and
solenoid coils. = B+ Manager L/L SOLs
2ND SOL
energized =
12 v
L/L SOL
energized =
18 v
8-66 PDMM-0109 7/31/02

Pinout Matrix

123 JPC9-3 B+KA Positive supply voltage to reach, sideshift, De-energized Vehicle Reach,
and tilt solenoid coils as well as the optional (switch open) Manager Sideshift,
reached nested switch. Note: When = B+ Tilt SOLs
solenoids are energized, voltage will still be Solenoid
B+ due to diode assembly inside the coil. energized =
B+
Nested
switch closed
= less than
1v
124 JPC9-8 Reach Sol Negative path (B–) for the reach solenoid De-energized Vehicle REACH
coil. It is switched to B– when there is a = B+ Manager SOL
12 v
125 JPC9-12 Sideshift Sol Negative path (B–) for the sideshift solenoid De-energized Vehicle SIDESHIFT
coil. It is switched to B– when there is a = B+ Manager SOL
12 v
126 JPC9-1 Tilt Sol Negative path (B–) for the tilt solenoid coil. De-energized Vehicle TILT SOL
It is switched to B– when there is a = B+ Manager
12 v
127 JPC10-10 Nested 12 volt supply from the Vehicle Manager. Switch Vehicle Vehicle
Switch The VM monitors the voltage to determine closed (fully Manager Manager
when it goes to B–, indicating that the retracted) =
switch is closed. The nested switch is a less than 1 v
normally open switch held closed when the Switch open
carriage is fully retracted. When the switch (reached) =
opens, travel speed is reduced. 6 to 12 v
128 JPC7-1 +12VP +12 volt supply to the optional height-tilt +12 v Vehicle HTI
indicator. Manager
129 JPC7-13 Speed Limit-1 12 volt supply from the Vehicle Manager. Switch Vehicle Vehicle
The VM monitors the voltage to determine closed Manager Manager
when it goes to B–, indicating that the (below
speed limit-1 switch is closed. The speed switch) = less
limit-1 switch is a normally open switch held than 1 v
closed when in free lift. When the switch Switch open
opens, travel speed is reduced and HTI, if (above
present, starts measuring height. switch) = 6 to
12 v
130 JPC7-7 DGND Negative path (B–) for the speed limit-1 Switch open: Vehicle Vehicle
switch. B– wrt B+ Manager Manager
Switch
closed: less
than 1 v
131 JPC7-5 DGND Negative path (B–) for the deadman switch Switch open: Vehicle Vehicle
S2. B– wrt B+ Manager Manager
Switch
closed: less
than 1 v
PDMM-0109 7/31/02 8-67

Pinout Matrix

132 JPC7-16 ON_ 5 volt supply from the Vehicle Manager. The Switch open: Vehicle Vehicle
Deadman VM monitors the voltage to determine when 5v Manager Manager
it goes to B–, indicating that the deadman Switch
switch is closed. closed: less
than 1 v
133 JPC12-1 +12VP Not Used
134 JPC12-6 Hi Speed 12 volt supply from the Vehicle Manager. Switch Vehicle Vehicle
Limit The VM monitors the voltage to determine closed Manager Manager
when it goes to B–, indicating that the high (below
speed limit switch is closed. The high speed switch) = less
limit switch is a normally open switch held than 1 v
closed when the telescopics are fully Switch open
lowered. When the switch opens, travel (above
speed is reduced. switch) = 6 to
12 v
135 JPC12-3 DGND Negative path (B–) for the high speed limit Switch open: Vehicle Vehicle
switch. B– wrt B+ Manager Manager
Switch
closed: less
than 1 v
137 JPC12-5 Lift Limit 12 volt supply from the Vehicle Manager. Switch Vehicle Vehicle
The VM monitors the voltage to determine closed Manager Manager
when it goes to B–, indicating that the (below
lift-limit switch is closed. The lift-limit switch switch) = less
is a normally open switch held closed when than 1 v
the telescopics are fully lowered. When the Switch open
switch opens, travel speed is reduced. (above
switch) = 6 to
12 v
138 JPC12-2 DGND Negative path (B–) for the lift-limit switch. Switch open: Vehicle Vehicle
B– wrt B+ Manager Manager
Switch
closed: less
than 1 v
139 JPC10-11 Lift Bypass 12 volt supply from the Vehicle Manager. Switch Vehicle Vehicle
The VM monitors the voltage to determine closed = less Manager Manager
when it goes to B–, indicating that the lift than 1 v
bypass switch is closed. The lift bypass Switch open
switch is a normally open switch. When the = 6 to 12 v
switch is held closed, the lift limit is
deactivated.
140 JPC10-7 DGND Negative path (B–) for the lift-limit switch. Switch open: Vehicle Vehicle
B– wrt B+ Manager Manager
Switch
closed: less
than 1 v
8-68 PDMM-0109 7/31/02

Pinout Matrix

142 JPC7-3 +12V +12 volts from the Vehicle Manager internal +12V Vehicle HTI
power supply when S1 is ON. If voltage is Manager
not present, confirm that the battery is
connected, the key switch is functioning and
associated wiring is OK. This voltage is
dependent on B+ at JPC8-17.
143 JPH1-4 +5VP +5 V supply from the Height-Tilt Indicator +4.4V HTI Height
(HTI) to power the height encoder. This Encoder
voltage is created in the HTI from the 12
volts supplied by the Vehicle Manager.
144 JPH1-3 DGND B– for the HTI height encoder. Measure HTI Height
battery Encoder
voltage to
PC1 (B+) to
verify
connections.
145 JPH1-8 Channel A Input from the HTI encoder, used to Not lifting = Height HTI
calculate fork height. 0 or 5 V; Encoder
Lifting/
lowering
above the
S10 switch =
approx.
2.5 V
146 JPH1-9 Channel B Input from the HTI encoder, used to Not lifting = Height HTI
calculate fork height. 0 or 5 V; Encoder
Lifting/
lowering
above the
S10 switch =
approx.
2.5 V
147 JPH1-5 +5VP Not Used
148 JPH1-1 +12V +12 V to power the Height-Tilt Indicator +12V Vehicle HTI
(HTI). Manager
149 JPH1-6 Home 12 volt supply from the Vehicle Manager. Switch Vehicle HTI
The Height-Tilt Indicator (HTI) monitors the closed Manager
voltage to determine when it goes to B–, (below
indicating that the speed limit-1 switch is switch) = less
open. The speed limit-1 switch is a normally than 1 v
open switch held closed when in free lift. Switch open
When the switch opens, HTI, if present, (above
starts measuring height. switch) = 6 to
12 v
150 JPH1-7 DGND Not Used
PDMM-0109 7/31/02 8-69

Pinout Matrix

151 JPH1-2 DGND B– for the Height-Tilt Indicator (HTI). Measure Vehicle HTI
battery Manager
voltage to
PC1 (B+) to
verify
connections.
152 JPH1-10 HTI Tilt 5 V supply from the Height-Tilt Indicator, Switch open HTI HTI
Pressure goes to B– when the pressure switch is = 0 V;
activated. Switch
closed = 5V
153 JPH1-11 DGND B– for the HTI tilt pressure switch. Measure HTI HTI
battery
voltage to
PC1 (B+) to
verify
connections.
154 JPH1-12 HTI Tilt Height-Tilt Indicator (HTI) monitors voltage De-energized Vehicle HTI
at this point to determine when the tilt = B+; Manager
solenoid is energized. Energized =
12 V
155 JPH1-13 DIRA Sol Height-Tilt Indicator (HTI) monitors voltage De-energized Vehicle HTI
at this point to determine when the DIRA = B+; Manager
12 V
156 JPH1-14 DIRB Sol Height-Tilt Indicator (HTI) monitors voltage De-energized Vehicle HTI
at this point to determine when the DIRB = B+; Manager
12 V
157 TS19-7 B+KA B+ for lights and fans, warning and strobe B+ Vehicle Lights and
light or the cooling fan for the motor. If Manager Fans
voltage is not present, check the
connections and wiring from JPF5-1 & 4.
This voltage is dependent on B+ at FU5 and
K2.
158 TS19-8 B–F Return path to B– for lights and fans, B– Vehicle Lights and
warning and strobe light or the cooling fan Manager fans,
for the motor. If voltage is not present, check warning
B– at JPF5-3 & 6, the connection, and and strobe
associated wiring. This voltage is lights,
dependent on B– at FU10. motor
cooling fan
159 Control TP1 provides B+ and TP4 provides B–. If the

Handle voltages are not present, check B+ and B–
Internal at the battery, connections, and wiring.
Heater
160 Comfort TP1 provides B+ and TP4 provides B–. If the

Package voltages are not present, check B+ and B–
at the battery, connections, and wiring.
8-70 PDMM-0109 7/31/02

Pinout Matrix

161 TS8-1 B+ B+ for the optional terminal strip. If voltage B+ FU9 or FU7 Option
is not present, check TS1-1 and FU9 or
TS1-2, FU7, and K1. This voltage is
dependent on B+ at JPF1-1 & 3 & 10.
162 TS8-2 B– B– for the optional terminal strip. If voltage B– FU6 Option
is not present, check TS2-2 and FU6. This
voltage is dependent on B– at JPF1-13 &
14.
PDMM-0109 7/31/02 8-71

Pinout Matrix
8-72 PDMM-0109 7/31/02

EASi Reach-Fork® Truck EZ-D/DZ-D Maintenance Manual Appendix
Appendix A:
Appendix A:
PDMM-0109 7/31/02 A-1

Appendix EASi Reach-Fork® Truck EZ-D/DZ-D Maintenance Manual
Lubrication Specification Chart
Lubrication Specification Chart
Approved Raymond Lubricants
Where Used Type Specification Raymond Part Number
Drive Unit Gear Case Gear 75W-90 Synthetic Gear 990-655/001 (1 qt./0.9 liters)
(all applications) Lubricant Oil 990-655/003 (1 gal./3.8
API Service liters)
Classification GL-5
Hydraulic Reservoir Hydraulic ISO 46 990-616/04 (1 qt./0.9 liter)

(Non-Cold Storage Fluid 990-616/01 (1 gal./3.8 liters)
Trucks) 990-616/02 (2 gal./7.6 liters)
(+50° F to +120° F) 990-616/03 (5 gal./18.9
(+10° C to +49° C) liters)
Hydraulic Reservoir Hydraulic ISO 32 990-617/01(1 gal./3.8 liters)

(Cold Storage Trucks) Fluid 990-617/03 (5 gal./18.9
(+20° F to +70° F) liters)
(-7° C to +21° C)
(in and out of freezer)
Hydraulic Reservoir Hydraulic MIL-H-5606E 990-618/TX1

(Cold Storage Trucks) Fluid (1 gal./3.8 liters)
(-20° F to +20° F) 990-618/01
(-29° C to -7° C) (1 gal./3.8 liters)
(confined to freezer)
Mast Uprights, Bearings, Grease NLGI Grade2 990-620/01 (10 cartridges

(etc.) per case)
990-620/02 (5 gal./18.9
liters)
Mast Uprights, Bearings, Teflon NLGI 2 990-652/001 (spray)

(etc.) (cold storage) Grease 990-652/002 (cartridge)
Lift Chains Teflon NLGI 2 990-652/001 (spray)

Grease
Hydraulic Brake Brake SAE Standard J1705F 990-625/01 (1 gal./3.8 liters)

Fluid Federal Motor Vehicle 990-625/02 (1 qt./0.9 liter)
Standard No. 116, 990-625/03 (1 pint/0.47
DOT-5 liter)
Figure 1-1: Lubrication Specification Chart
A-2 PDMM-0109 7/31/02

Thread Adhesives, Sealants, and Lubricants
Thread Adhesives, Sealants, and Lubricants
Raymond Loctite*
Application
P/N Number/Color
Thread-locking 1/4” and below 990-403 222/Purple
Thread-locking 1/4” to 3/4” 990-536 242/Blue
Thread-locking 1/4” to 3/4” contamination tolerant 990-462 243/Blue
Thread-locking 1” and under 990-544 271/Red
Thread-locking 1” and under, contamination tolerant 990-463 603/Green
Thread-locking 1” and over 990-571 277/Red
Thread-locking Cleaner 990-538 707
Thread-locking Primer 990-533 T747
Hydraulic Sealant 990-552 569
RTV Silicone Sealant 990-659 5900/Black
Other
Manufacturer
designation
Molybdenum Anti-Seize Compound (Molykote) 990-638 /Silver
Corrosion Inhibitor Coating 990-644
Cold Storage silicone sealing compound 990-445
Figure 1-2: Thread Adhesives, Sealants, Lubricants
NOTE: * Loctite is a registered trademark of the Loctite Corporation. Brand

endorsement is not implied here, but listed only as a commonly
identified product.
PDMM-0109 7/31/02 A-3

EZ-D/DZ-D Torque Quick Reference Chart
Component ft. lb. Nm Refer to

Bearings, Mast Roller -- see chart in text Page 7-161
Bearings, Reach Half Shaft 25 34 Page 7-173
Brake Assembly, mounting bolts 21 28.5 Page 7-70
Contactors, mounting hardware 7 9.5
Cylinder, Back, mounting bolts 60 81 Page 7-131
Cylinder, Front Cluster, mounting bolts (with 45 61 Page 7-128
beveled washers)
Drive Unit to Frame 130 176 Page 7-62
Fan Impeller, Lift Motor 30 40.7 Page 7-99
Inertial Dampener 13 17.6 Page 7-78
Manifold, Main, mounting bolts 13 17.6 Page 7-119
Manifold, Reach, mounting bolts 17 23
Manifold, Tilt/Sideshift, mounting bolts 13 17.6
Mast to Tractor 160 to 170 217 to 230
Motor, Aux, Power Cable 7.5 to 9.2 10.2 to 12.5 Page 7-96
Motor, Aux, Stud Terminal Securing Nut 9.2 to 11.7 12.5 to 15.9 Page 7-96
Motor, Aux, mounting bolts to frame 15 20
Motor, Drive, Pinion Gear 85 115 Page 7-65
Motor, Drive, Power Cable 18 24.4 Page 7-96
Motor, Drive, Stud Terminal Securing Nut 30 40.7 Page 7-96
Motor, Drive, to Drive Unit 13 17.6 Page 7-65
Motor, Lift, Power Cable 8.3 to 10 11.3 to 13.6 Page 7-96
Motor, Lift, Stud Terminal Securing Nut 11.7 to 13.3 15.9 to 18.0 Page 7-96
Motor, Lift, mounting bolts to frame 13 17.6 Page 7-100
Power Amplifier, Power Cables 15 20.3 Page 7-96
Pressure transducer 12 16.2 Page 7-121
Pump, Aux, coupling nut to shaft 6 8 Page 7-117
Pump, Aux, to Aux Motor 20 27 Page 7-117
Pump, Lift, to Lift Motor 20 27 Page 7-100
Sideshift Carriage lower hook securing bolts 115 156 Page 7-150
Solenoid Valves -- see chart in text Page 7-120
Steerable Caster locking nuts 70 95 Page 7-21
Steering Hydraulic Motor 35 47
Figure 1-3: Torque Quick Reference Chart
A-4 PDMM-0109 7/31/02

Component ft. lb. Nm Refer to

Steering Orbitrol, mounting bolts 15 21
Wheel, Drive 170 230
Wheels, Load, box nuts 220 298
Figure 1-3: Torque Quick Reference Chart
PDMM-0109 7/31/02 A-5

Torque Chart - Hydraulic Fittings
Torque Chart - Hydraulic Fittings
SAE Straight Thread Steel Plugs

SAE JIC
Thread (37° Flare Thread) Hollow Hex Head
Dash Hex Head Plug P50N
Size Plug HP50N
Size
Nm Ft. lb. Nm Ft. lb. Nm Ft. lb.
-2 5/16-24 4±1 3±1 4 ± 0.6 3 ± 0.5 10 ± 0.6 7.5 ± 0.5
-3 3/8-24 8±1 6±1 7 ± 0.6 5 ± 0.5 19 ± 1 14 ± 1
-4 7/16-20 16 ± 1 12 ± 1 15 ± 1 11 ± 1 24 ± 1 18 ± 1
-5 1/2-20 20 ± 1 15 ± 1 20 ± 1 15 ± 1 30 ± 1 22 ± 1
-6 9/16-18 28 ± 1 21 ± 1 24 ± 1 18 ± 1 37 ± 3 27 ± 2
-8 3/4-16 61 ± 3 45 ± 2 62 ± 3 46 ± 2 65 ± 3 48 ± 2
-10 7/8-14 81 ± 7 60 ± 5 102 ± 7 75 ± 5 122 ± 7 90 ± 5
-12 1 1/16-12 115 ± 7 85 ± 5 115 ± 7 85 ± 5 149 ± 7 110 ± 5
-14 1 3/16-12 142 ± 7 105 ± 5 176 ± 8 130 ± 6 197 ± 8 145 ± 6
-16 1 5/16-12 163 ± 7 120 ± 5 183 ± 8 135 ± 6 217 ± 8 160 ± 6
-20 1 5/8-12 230 ± 14 170 ± 10 305 ± 16 225 ± 12 305 ± 16 225 ± 12
-24 1 7/8-12 271 ± 20 200 ± 15 339 ± 16 250 ± 12 339 ± 16 250 ± 12
-32 2 1/2-12 366 ± 27 270 ± 20 441 ± 20 325 ± 15 441 ± 20 325 ± 15
Figure 1-4: Torque Chart - Hydraulic Fittings
Torque Chart - Straight Thread Face Seal O-Rings
Tube Size
SAE Dash
Thread Nm Ft. lb.
Size
Size
-4 9/16-18 24 ± 1 18 ± 1
-6 11/16-18 37 ± 3 27 ± 2
-8 13/16-16 54 ± 3 40 ± 2
-10 1-14 85 ± 4 63 ± 3
-12 1 3/16-12 122 ± 5 90 ± 4
-14 1 5/16-32 129 ± 8 95 ± 6
-16 1 7/16-12 163 ± 11 120 ± 8
-20 1 11/16-12 190 ± 11 140 ± 8
-24 2-12 224 ± 11 165 ± 8
-32 2 1/2-12 488 ± 14 360 ± 10
Figure 1-5: Torque Chart - Straight Thread Face Seal O-Rings
A-6 PDMM-0109 7/31/02

Torque Chart - Standard (Ferrous)
Torque Chart - Standard (Ferrous)

Grade
Identification None
Marking
SAE Grade 2 Bolts SAE Grade 5 Bolts SAE Grade 8 Bolts
Tightening Torque Tightening Torque Tightening Torque
Size
Dry Oiled* Dry Oiled* Dry Oiled*
in. lb. in. lb. in. lb. in. lb. in. lb. in. lb.
4-40 5 4 8 6 12 9
4-48 6 5 9 7 13 10
6-32 10 8 16 12 23 17
8-32 19 14 30 22 41 31
8-36 20 15 31 23 43 32
10-24 27 21 43 32 60 45
10-32 31 23 49 36 68 51
1/4-20 66 49 96 75 144 108
1/4-28 78 56 120 86 168 120
ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb.
5/16-18 11 8 17 13 25 18
5/16-24 12 9 19 14 25 20
3/8-16 20 15 30 23 45 35
3/8-24 23 17 35 25 50 35
7/16-14 30 24 50 35 70 55
7/16-20 35 25 55 40 80 60
1/2-13 50 35 75 55 110 80
1/2-20 55 40 90 65 120 90
9/16-12 65 50 110 80 150 110
9/16-18 75 55 120 90 170 130
5/8-11 90 70 150 110 220 170
5/8-18 110 85 180 130 240 180
3/4-10 160 120 260 200 380 280
3/4-16 180 140 300 220 420 320
7/8-9 140 110 400 300 600 460
7/8-14 155 120 440 320 660 500
1-8 220 160 580 440 900 680
1-12 240 170 640 480 1000 740
1 1/8-7 300 220 800 600 1280 960
1 1/8-12 340 260 880 660 1440 1080
1 1/4-7 420 320 1120 840 1820 1360
1 1/4-12 460 360 1240 920 2000 1500
1 3/8-6 560 420 1460 1100 2380 1780
1 3/8-12 640 460 1680 1260 2720 2040
1 1/2-6 740 560 1940 1460 3160 2360
1 1/2-12 840 620 2200 1640 3560 2660
Figure 1-6: Torque Chart - Standard
* NOTE: Use”oiled” values for bolts with thread locking compound
PDMM-0109 7/31/02 A-7

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 8.8 Grade 10.9
Diameter
Torque (with bolts oiled*) Torque (with bolts oiled*)
(in millimeters)
Newton-meters Foot-pounds Newton-meters Foot-pounds
6 8.6 6 12 9
8 21 15 29 21
10 42 30 68 43
12 72 55 101 75
16 174 130 245 181
20 340 255 475 350
24 580 435 820 605
Figure 1-7: Torque Chart - Ferrous Metric
* NOTE: Use “oiled” values for bolts with thread locking compound
Torque Chart - Metric (Brass)
Brass MS63 Metric Bolts, Coarse Thread
Diameter Torque (with bolts oiled*)

(in millimeters) Newton-meters Inch-pounds
3 0.5 4.4
3.5 0.79 7.0
4 1.2 10
5 2.2 19
6 3.9 34
8 9 79
10 17 150
Figure 1-8: Torque Chart - Brass Metric
* NOTE: Use “oiled” values for bolts with thread locking compound
A-8 PDMM-0109 7/31/02

Torque Chart - Standard (Brass)
Torque Chart - Standard (Brass)
Brass MS63 Standard Bolts, Coarse Thread

Torque (with bolts oiled*)
Size
Newton-meters Inch-pounds
4-40 0.37 3.3
4-48 0.40 3.6
6-32 0.69 6.1
6-40 0.77 6.8
8-32 1.24 11
8-36 1.24 11
10-24 1.58 14
10-32 1.92 17
1/4-20 3.96 35
1/4-28 4.52 40
5/16-18 8.25 73
5/16-24 9.15 81
3/8-16 14.69 130
3/8-24 16.61 147
Figure 1-9: Torque Chart - Standard Brass
* NOTE: Use”oiled” values for bolts with thread locking compound
PDMM-0109 7/31/02 A-9

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
Figure 1-10: Decimal Equivalent Chart
A-10 PDMM-0109 7/31/02

To 3 To 2
4ths 8ths 16ths 32nds 64ths MM Equivalent
Places Places
33/64 .516 .52 13.097
17/32 .531 .53 13.494
35/64 .547 .55 13.891
9/16 .562 .56 14.288
37/64 .578 .58 14.684
19/32 .594 .59 15.081
39/64 .609 .61 15.478
5/8 .625 .62 15.875
41/64 .641 .64 16.272
21/32 .665 .66 16.669
43/64 .672 .67 17.065
11/16 .688 .69 17.462
45/64 .703 .70 17.859
23/32 .719 .72 18.256
47/64 .734 .73 18.653
3/4 .750 .75 19.050
49/64 .766 .77 19.447
25/32 .781 .78 19.844
51/64 .797 .80 20.241
13/16 .812 .81 20.637
53/64 .828 .83 21.034
27/32 .844 .84 21.431
55/64 .859 .86 21.828
7/8 .875 .88 22.225
57/64 .891 .89 22.622
29/32 .906 .91 23.019
59/64 .922 .92 23.416
15/16 .938 .94 23.812
61/64 .953 .95 24.209
31/32 .969 .97 24.606
63/64 .984 .98 25.003
1.000 1.00 25.400
Figure 1-10: Decimal Equivalent Chart
PDMM-0109 7/31/02 A-11

Standard/Metric Conversions
To Convert... Multiply...
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
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 10.764
Square Yards to Square Meters Square Yards x 0.836
Square Meters to Square Yards Square Meters x 1.196
Pints (US) to Liters Pints x 0.473
Liters to Pints (US) Liters x 2.113
Quarts to Liters Quarts x 0.946
Liters to Quarts Liters x 1.057
Gallons (US) to Liters Gallons x 3.785
Liters to Gallons (US) Liters x 0.264
Ounces (avoirdupois) to Grams Ounces x 28.35
Grams to Ounces (avoirdupois) Ounces x 0.035

Figure 1-11: Standard/Metric Conversion Chart
A-12 PDMM-0109 7/31/02

To Convert... Multiply...
Ounces (avoirdupois) to Kilograms Ounces x 0.028
Kilograms to Ounces (avoirdupois) Kilograms x 35.274
Pounds to Kilograms Pounds x 0.454
Kilograms to Pounds Kilograms x 2.205
Pounds per Square Inch (psi) to Kilopascals Pounds per Square Inch (psi) x 6.895
(kPa)
Kilopascals to Pounds per Square Inch Kilopascals x 0.145
Pounds per Square Inch (psi) to Kilograms per Pounds per Square Inch (psi) x 0.070
square centimeter (kg/cm2)
Kilograms per square centimeter (kg/cm2) to Kilograms per Square Centimeter (kg/cm2) x
Pounds per Square Inch (psi) 14.223
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 1.356
Newton Meters (Nm) to Foot Pounds (ft. lb.) Newton Meters x 0.738
Miles per Hour to Kilometers per Hour Miles per Hour x 1.609
Kilometers per Hour to Miles per Hour Kilometers per Hour x 0.621
Fahrenheit to Celsius (°F - 32) x 0.555
Celsius to Fahrenheit (°C x 1.8) + 32

Figure 1-11: Standard/Metric Conversion Chart
PDMM-0109 7/31/02 A-13

A-14 PDMM-0109 7/31/02

Appendix A:
Electrical Schematics
PDMM-0109 7/31/02 A-15

Series EZ-D/DZ-D (Sheet 1 of 2)
A B C D
NOTES:
KEY SWITCH OFF.
3
JP2
-10
-12 RED -1 -6 -3
T VEL SENSOR+
-13 BLACK -4 -5 -4
-14 T VEL SENSOR- AC TRACTION
TME
WHITE -3 -4 -5 AMPLIFIER
T VEL PHASE A
TP1 -2
BLUE -3 -6
JP T VEL PHASE B
B+ JPT3 -7
RED -2 -8
3 1
PC
1 TMT RED/BLK -1 -7 -8
T TEMP+
ID0
2 TPC
2 -9
U B-
U
FU1 FU2 TM V
(150A) (350A) V
TP2 1 TP5 W W
P B+ +
2 1
TR
A FU3 2
(500A)
MX TP3
S
SPL2
JP2-2
MP
A
4 S
JP TP4
B-
T3 T1
JPF1 ˚T
-5
-11 FU10
JPF2
(15A)
5 -12
1 2
B-F -4
-9
-13 FU6 -10
(15A) TS2-1 -11
-14 TS2-2 -12
1 2
FU8 JPF5
-7 (5A) -3 TS19
TS2-3 -6 3
1 2 -6
FU9
(15A/5A)
-1 TS1-1
1 2
FU7
-10 (15A/5A) K1 TS1-2
-3 1 2 TS1-3
FU5
-8 JPF3-4 1
-9 1 2 JPF3-2
6 K1 K2 K3
K2
K3
JPF2-5
JPF2-3
JPF5-2
B+KA JPF2-2
JPF2-8
JPF2-1
RELAY JPF5-1 TS19 3

CONTROL -7
FUSE JPF5-4
PANEL
JPF3 -1
1R1005714_D_1_L_G.EPS
Figure A-9: Series EZ-D/DZ-D Electrical Schematic, Sheet 1 of 2
A-16 PDMM-0109 7/31/02

Series EZ-D/DZ-D (Sheet 2 of 2)
E F G
JPD1 JPC6
-1 THROTTLE -10 VR1
-10 +12 VP
-1 -2 AGND -13
-3 -3 LIFT -11
DATA_LATCH
CONTROL HANDLE
VR2
2
DISPLAY
+5V -8
-4 -4 DISP_MISO
-5 -5 HORN -7 S3
SOUNDER
-6 -6 REACH -1 S4
SHIFT_CLOCK VEHICLE
-7 -7 RETRACT -2 S5
DATA OUT MANAGER
-8 -8 TILT UP -3 S6
DGND
SSHIFT LEFT S8
SSHIFT RIGHT -6 S9
JPT1 JP2 AGND -14
TPC -2 -1 SHIELD
CONTACTOR TPC
Y X
JPC8 JP2
B+KC -14 -5
-1
B+KB JPC9 JP2
-12 -8 JP3-13
Y
-13 -9
DGND
-10 JPC10
JPB1-2 FAN 1 JPB1-1
3
BUS+ FAN -9
-11
BUS-
5
TA
AMPLIFIER JP3-1 1 2
2ND SOL -22 2ND
JPC9 JP3
B+KA_SUP -11 -2
L/L -5 -3 L/L
JPC4 1 2
-16 +12VP -6 -4
L/H L/H
-15 DGND 1 2
DIRB -10 -5 DIRB
-12 1 2
SPLC2
-9
BUS TERMINATION
DIRA -7 -6 DIRA
4
BUS+ 1 2
-10 BUS-
EQ -9 -7 EQ
JPC8 1 2
JP2
-3 -9 FU1 SENSE -4 -8
-4 B+ KA
-10 FU3 SENSE
HRN
JPC8 -NEG
HORN
HORN & ALARM
PT -1 -1 -1 H
T˚ -2 B+KA
-3
-2 -23 JPC10
PGND JPA1-2
ALARM -16
4
B+KB -20 JPA1-1
JPC8
-6
-1
DGND 5
-2 3 TS19
B-F JPC9 TS21 BLACK
-3 RED
B+ KA
REACH SOL
JPY4 JP3 JPC11
-4 -9 -1 DGND
- -3 -10 -2 -12 -2 GREEN -2 GREEN2 SIDE 1
DGND SIDESHIFT SOL
PRESS SHIFT
+ -1 -12 -4 +12V
TILT SOL

NESTED SWITCH
JPC8 (OPTION)
-17 B+KEY
JPC10-19
ON CARRIAGE 6
B+KB
JPC8 JPC7
-13
B+KC -1 JPS4
+12VP -1
SPLH3 S10
-4 -13 -2 NO COM
-5 B+KA -7 -3
DGND
NC
SWITCH
-5 COM
DGND
-16
JPC1 ON DEADMAN
-1 BUS-
-2 TXD
-3 RXD
-4 BUS+
-5
-6
DGND
NC
7
-7 BOOT
-8 NC
-9 +12VP
1R1005714_D_1_R_G.EPS
Series EZ-D/DZ-D Electrical Schematic, Sheet 2 of 2
PDMM-0109 7/31/02 A-17

Options (Sheet 1 of 3)
A B
AUX. POWER (BATTERY)
TS2-2
2 RELAY
CONTROL WARNING LIGHT OR STROBE LIGHT
TS1-1 FUSE
PANEL FU14 JP201-2 WL
TS19-7 (10A) BLACK
B+KA + -
JP201-1
2 1 TS19-6 WHITE
B- TS8 B+ B-F
OR
AUX. POWER (KEY)
TS2-2 RELAY
CONTROL
TS1-2 FUSE
PANEL
3
2 1
B- TS8 B+
4
COMFORT PACKAGE
36V
FU17 TH6 TH7 FU18

PC-1 T˚
(4A) JPHT1-2
HTR8
HTR6 8.25 WATT
4 WATT
TP4
JPHT1-1 HTR7
6.75 WATT HANDLE
5
TH8 T˚
JPHT2-2
JPHT2-1 HTR9 FLOOR PAD

50 WATT
COOLING FAN FOR THE MOTOR
FU15 R5
6 TS19-7
1A
FU16 R6
FAN-2
B+KA
1A
FAN-3
TS19-6
B-F
COOLING FAN FOR THE MOTOR
TS19-7 FU15 R5
B+KA
1A
FAN-2
7 TS19-6
B-F
1R1005714_D_2_L_G.EPS
Figure A-10: Options Electrical Schematic, Sheet 1 of 3Scale 125%
A-18 PDMM-0109 7/31/02

C D E
HTI SYSTEM
2
JPH4 JPH2 JPH1
RED -1 -4 -4
+5VP
BLK -4 -3 -3
DGND
HEIGHT
ENCODER -8
WHT -3 -2
CHANNEL A
BLU -2 -1 -9
CHANNEL B
-5
+5VP
VEHICLE JPC7 JPS4 JPH3

3 MANAGER
+12V
-1 -1 -6 -1 +12V
-8 -6
HOME
S10
JPC7 SPLH3 -7
-13 -2 COM NC DGND
LIMIT SWITCH
SPLH4 -3
-7
DGND
-7 -2
DGND
JPH3
S31
2 1 -1 -10
TILT TILT PRESS
PRESSURE
SWITCH -2 -11
4 DGND
-3 -12
TILT TILT
TS21-5 1 2 TS21-1
B+KA JPC9-1
TS19-1
ON CARRIAGE
JPH3
-4 -13
DIR A SOL
2 1 SPLH1
B+KA
DIRA JP3-4 HEIGHT/TILT INDICATOR
JPH3
-5 -14
DIR B SOL
2 1
SPLH2
DIRB JP3-5
INTERNAL HEATER (CONTROL HANDLE) WORKING LIGHTS & FAN

JP204B-1 LIGHT JP204B-2
BLACK WHITE
FU17 TH6
PC-1 JP204A-1 LIGHT JP204A-2
JPHT1-2 BLACK WHITE
(4A) HTR6
4 WATT FU13 JP203-1 JP206-1 FAN JP206-2
TS19-7 SPL1 R7
(10A) BLACK BLACK + - WHITE
TP4 B+KA
1 2
JPHT1-1 JP203-2
TS19-6
WHITE
B-F
1R1005714_D_2_C_G.EPS
Options Electrical Schematic, Sheet 2 of 3Scale 95%
PDMM-0109 7/31/02 A-19

F G H
2
LIMIT SWITCH OPTIONS
JPC12 JPS5
-1 2nd SPEED
-1 LIMITING SWITCH
LIMIT SWITCH
+12VP S11
HIGH SPEED
(OPTION)
-6 -2 COM NC
HI_SPEED_LIMIT
-3 -3
DGND
3
JPC12 JPS6
-4 -1 LIFT
+12 VP S13 LIMIT SWITCH
-5 -2 1 2
SWITCH LIFT_LIMIT (OPTION)
LIFT LIMIT
-2 -3
DGND
JPC10 JPS9
-11 -1 1 2
LIFT_BYPASS
-2 S12 LIFT BYPASS
-7
DGND (OPTION)
VEHICLE
MANAGER
TRAVEL LIGHT AND ALARM
LIGHT
+ -
R4
JP202-1 JP202-2 56W 2
BLACK WHITE 1
SPL-14 SPL-3
ALARM
6
+
FU4 H2
10A -
VM JPC10-20 JPA1-1
B+KB
JPC10-16 JPA1-2 SPL-13
ALARM
1R1005714_D_2_R_G.EPS
Options Electrical Schematic, Sheet 3 of 3cale 95x95%
A-20 PDMM-0109 7/31/02

Legend (Sheet 1 of 2)
LEGEND
IDENT. ZONE SHEET DESCRIPTION
DIRA F4,D5 1,2 SOLENOID FOR AUX. OIL DIRECTION CONTROL

DIRB F4,D5 1,2 SOLENOID FOR AUX. OIL DIRECTION CONTROL
EQ F4 1 SOLENOID FOR AUX. PRESSURE EQUALIZING CONTROL
FAN F7 2 OPERATOR COOLING FAN
FAN1 F3 1 TRACTION AMPLIFIER COOLING FAN
FAN-2 B6 2 MOTOR COOLING FAN OPTION
FAN-3 B6,B7 2 MOTOR COOLING FAN OPTION
FU1 B3 1 POWER FUSE FOR AUXILIARY 150A
FU2 C3 1 POWER FUSE FOR TRAVEL 350A
FU3 C3 1 POWER FUSE FOR LIFT 500A
FU4 G6 2 CONTROL FUSE FOR TRAVEL ALARM 10A
FU5 B6 1 CONTROL FUSE FOR VEHICLE MANAGER B+ 15A
FU6 B5 1 CONTROL FUSE FOR AUX. POWER B- 15A
FU7 B6 1 CONTROL FUSE FOR AUX. POWER B+ (KEY OPTION) 15A/5A
FU8 B5 1 CONTROL FUSE FOR AUX. POWER B- (BATTERY OPTION) 5A
FU9 B6 1 CONTROL FUSE FOR AUX. POWER B+ (BATTERY OPTION) 15A/5A
FU10 B5 1 CONTROL FUSE FOR VEHICLE MANAGER B- 15A
FU13 E7 2 CONTROL FUSE FOR OPTIONS (WORKING LIGHTS & FAN) 10A
FU14 B2 2 CONTROL FUSE FOR OPTIONS (WARNING & STROBE LIGHTS) 10A
FU15 A6,A7 2 CONTROL FUSE FOR MOTOR COOLING FAN-2 1A
FU16 A6 2 CONTROL FUSE FOR MOTOR COOLING FAN-3 1A
FU17 A5 2 CONTROL FUSE FOR CONTROL HANDLE HEATER 4A
FU18 B5 2 THERMAL FUSE FOR CONTROL HANDLE HEATER (INTERNAL)
H F4 1 HORN
HRN F4 1 HORN CONNECTOR
H2 H6 2 TRAVEL ALARM
HEIGHT ENCODER D2 2 ENCODER FOR HTI HEIGHT SENSING
HTR6 D7 2 HEATER FOR CONTROL HANDLE HEATER (INTERNAL)

HTR7 B5 2 HEATER FOR CONTROL HANDLE HEATER (EXTERNAL LH)
HTR8 B5 2 HEATER FOR CONTROL HANDLE HEATER (EXTERNAL RH)
HTR9 B5 2 HEATER FOR FLOOR PAD
JP2 B3,E3,D4,F3 1 CONNECTOR ON CONTACTOR PANEL
JP3 F3,F4,F5 1 CONNECTOR FOR HYDRAULIC MANIFOLD
JP201 C2 2 CONNECTOR FOR WARNING OR STROBE LIGHT

JP202 G6 2 CONNECTOR FOR TRAVEL LIGHT
JP203 E7 2 CONNECTOR FOR WORK AREA LIGHT
JP204 E7 2 CONNECTOR FOR WORK AREA LIGHT
JP206 E7 2 CONNECTOR FOR OPERATOR FAN
JPA1 F5,G6 1,2 CONNECTOR FOR TRAVEL ALARM OPTION

JPB A3,A4 1 CONNECTOR ON BATTERY
JPB1 F3 1 CONNECTOR ON BLOWER FAN 1
JPC1 E7 1 CONNECTOR ON VM FOR PC COMPUTER/SMARTi

JPC4 E4 1 CONNECTOR ON VM FOR CAN BUS COMMUNICATION
JPC5 E2 1 CONNECTOR ON VM FOR OPERATORS DISPLAY
JPC6 F2 1 CONNECTOR ON VM FOR CONTROL HANDLE
JPC7 F6 1 CONNECTOR ON VM FOR SENSORS AND ATTACHMENTS
JPC8 F3,F4,E5,E6 1 CONNECTOR ON VM FOR CONTACTORS, HORN AND FUSE PANEL
JPC9 F3,F4,F5 1 CONNECTOR ON VM FOR HYDRAULIC SOLENOIDS, P CONTACTOR
JPC10 E3,E5 1 CONNECTOR ON VM FOR POWER SUPPLY AND OPTIONAL ATTACHMENTS
JPC11 E5 1 CONNECTOR ON VM FOR PRESSURE SENSOR
JPC12 G3 2 CONNECTOR ON VM FOR OPTIONS
JPD1 E2 1 CONNECTOR ON OPERATORS DISPLAY FOR VM
JPF1 B5 1 CONNECTOR ON FUSE PANEL FOR BATTERY + & -

JPF2 C5,C6 1 CONNECTOR ON FUSE PANEL FOR VEHICLE MANAGER
JPF3 C6 1 CONNECTOR ON FUSE PANEL FOR KEYSWITCH & AMPLIFIER ENABLE
JPF5 C5,C6 1 CONNECTOR ON FUSE PANEL FOR OPTIONS

JPH1 E2-4 2 CONNECTOR IN HTI DISPLAY
JPH2 E2 2 CONNECTOR ON HTI TO HEIGHT ENCODER
JPH3 E3-4 2 CONNECTOR ON HTI TO TRACTOR INTERFACE
JPH4 D2 2 CONNECTOR ON HEIGHT ENCODER
JPHT1 B5 2 CONNECTOR FOR CONTROL HANDLE HEATER

JPHT2 B5 2 CONNECTOR FOR FLOOR PAD HEATER
JPS4 F6 1 CONNECTOR BETWEEN VM AND LIMIT SWITCH

JPS5 G3 2 CONNECTOR BETWEEN VM AND HIGH SPEED LIMIT SWITCH
JPS6 G3 2 CONNECTOR BETWEEN VM AND LIFT LIMIT SWITCH
JPS9 G4 2 CONNECTOR BETWEEN VM AND LIFT BYPASS SWITCH

JPS10 D3 1 CONNECTOR BETWEEN THE MAIN HARNESS AND THE TRACTION MOTOR HARNESS
JPT1 D3 1 CONNECTOR ON TRACTION POWER DRIVE FOR SENSORS LPC AND VM

JPT2 D3 1 CONNECTOR ON TRACTION MOTOR FOR ENCODER
JPT3 D3 1 CONNECTOR ON TRACTION MOTOR FOR TEMPERATURE SENSOR
JPY4 E5 1 CONNECTOR BETWEEN VM AND PRESSURE SENSOR
JPZ E4 1 CONNECTOR BETWEEN VM AND LIFT TEMPERATURE SENSOR
K1 C6 1 KEYSWITCH RELAY-OPTIONS
K2 C6 1 KEYSWITCH RELAY-SOLENOIDS, ATTACHMENTS, HORN
K3 C6 1 KEYSWITCH RELAY, CONTACTORS, POWER AMPS
1R1005714_D_3_L.EPS
Figure A-11: Electrical Schematic Legend, Sheet 1 of 2cale W=6.75” H=8.25”
PDMM-0109 7/31/02 A-21

Legend (Sheet 2 of 2)
LEGEND
IDENT. ZONE SHEET DESCRIPTION
LIGHT F6 2 WORK LIGHT

L/H F4 1 LIFT/HOLD SOLENOID
L/L F4 1 LIFT/LOWER PROPORTIONAL SOLENOID
MP C4 1 LIFT PUMP MOTOR

MX B4 1 AUXILIARY PUMP MOTOR
P C3 1 LIFT POWER CONTACTOR

PC B3 1 PC POWER CONTACTOR
PR E3 1 RESISTOR (120) OHMS FOR CAN BUS TERMINATION ON POWER AMPLIFIER
PRESS D5 1 LIFT PRESSURE SENSOR
PT E4 1 LIFT MOTOR TEMPERATURE SENSOR
REACH G5 1 REACH SOLENOID
R4 H6 2 RESISTOR FOR TRAVEL ALARM OPTION

R5 B6,B7 2 RESISTOR FOR MOTOR COOLING FAN OPTION
R6 B6 2 RESISTOR FOR MOTOR COOLING FAN OPTION
R7 E7 2 RESISTOR FOR FAN OPTION
S1 D6 1 KEY SWITCH
S2 F7 1 DEADMAN SWITCH
S3 F2 1 HORN SWITCH
S4 F2 1 REACH SWITCH
S5 F2 1 RETRACT SWITCH
S6 F2 1 TILT UP SWITCH
S7 F2 1 TILT DOWN SWITCH
S8 F3 1 SHIFT LEFT SWITCH
S9 F3 1 SHIFT RIGHT SWITCH
S10 F6 2 1st SPEED LIMITING SWITCH
S11 G3 2 2nd SPEED LIMITING SWITCH
S12 H4 2 LIFT BYPASS SWITCH
S13 H3 2 LIFT LIMIT SWITCH
S19 G6 1 NESTED SWITCH
S31 D4 2 TILT PRESSURE SWITCH
SIDESHIFT G5 1 SIDE SHIFT SOLENOID
SPL-1 E4 1 SPLICE FOR LIFT MOTOR TEMPERATURE SENSOR

SPL-2 C4 1 SPLICE FOR TR RESISTOR
SPL-3 G6 1 SPLICE FOR TRAVEL ALARM
SPL-13 G6 1 SPLICE FOR TRAVEL LIGHT
SPL-14 G6 1 SPLICE FOR TRAVEL LIGHT
SPLC-2 E4 1 SPLICE FOR CAN BUS CABLE (TERMINATION)

SPLD-1 E2 1 SPLICE FOR OPERATOR DISPLAY
SPLH1 D5 2 SPLICE HTI HARNESS FOR DIRA CONNECTION

SPLH2 D5 2 SPLICE HTI HARNESS FOR DIRB CONNECTION
SPLH3 D3 2 SPLICE HTI FOR S10-COM CONNECTION
SPLH4 D4 2 SPLICE HTI HARNESS FOR S10-NC CONNECTION
T1 C6 1 RELAY BOARD CONNECTION FOR B+KB

T3 C5 1 RELAY BOARD CONNECTION FOR PRECHARGE RESISTOR
TA D3 1 TRACTION POWER AMP
TILT G5,D4 1,2 SOLENOID FOR TILT
TH6 B5 2 THERMOSTAT FOR CONTROL HANDLE HEATER

TH7 B5 2 THERMOSTAT FOR CONTROL HANDLE HEATER (EXTERNAL)
TH8 B5 2 THERMOSTAT FOR FLOOR PAD HEATER
TM D3 1 AC TRACTION MOTOR
TME C3 1 TRACTION MOTOR ENCODER
TMT C3 1 TRACTION MOTOR TEMPERATURE SENSOR
TPC C3 1 TRACTION POWER CONTACTOR
TR C3 1 TRACTION POWER AMP. PRECHARGE RESISTOR
TP1 B3 1 TIE POINT ON BATTERY B+

TP2 B3 1 TIE POINT ON AUXILIARY MOTOR FUSE
TP3 C4 1 TIE POINT ON LIFT MOTOR FUSE
TP4 C4 1 TIE POINT ON BATTERY B-
TP5 C3 1 TIE POINT ON TRACTION MOTOR FUSE
TS1 C6 1 TERMINAL STRIP FUSE/RELAY CARD

TS2 B5 1 TERMINAL STRIP FUSE/RELAY CARD
TS8 A2,A3 2 TERMINAL STRIP FOR AUX. POWER
TS19 F5 1 TERMINAL STRIP FOR MAST CABLE
TS21 F5 1 TERMINAL STRIP FOR MAST CABLE ON REACH CARRIAGE
VR1 F2 1 VARIABLE RESISTOR FOR THROTTLE

VR2 F2 1 VARIABLE RESISTOR FOR LIFT/LOWER
WL C2 2 WARNING LIGHT
2ND F3 1 SECOND STAGE LIFT SOLENOID
1R1005714_D_3_R.EPS
Figure A-12: Electrical Schematic Legend, Sheet 2 of 2
A-22 PDMM-0109 7/31/02

Hydraulic Schematics
PDMM-0109 7/31/02 A-23

Series EZ-D/DZ-D
HYDRAULIC MANIFOLD
PT2
L/H
PT1 SOL
NOT ON ALL MODELS
CV1
P1 2 1 1 CYL
LIFT LIFT
2 CYL
L/L
CV2 SOL
1 FLOW
P2 2
LIFT CONTROL
HIGH 2
2 PRESSURE
RELIEF
2
2ND
SOL 1
C3
REACH
REACH/RETRACT
REACH/RETURN
SOL
SOL
DIRB
SOL A2 P C1
STEER
RETURN
AUX T C2
P3 PRESS 3 2
AUX 2 C4
1
4
1 EQ
SOL A1
SIDESHIFT
DIRA C2 C1
SOL
SIDESHIFT
SOL
AUX
PRESSURE P
RELIEF STEER
ORBITROL
TILT
T SOL
STEER
MOTOR
T
C2 C1
FILTER
TILT
TANK
1R84137_c_c.EPS
Figure A-13: Hydraulic Schematic, Series EZ-D/DZ-D W=6.75” H=8.25”
A-24 PDMM-0109 7/31/02

EASi Reach-Fork® Truck EZ-D/DZ-D Maintenance Manual Index
Index 1:
A Bearings
Mast, Shimming . . . . . . . 7-159 to 7-170
Inner Tele to Carriage . . . . . . . . 7-168
AC Motor Troubleshooting . . . . . . . . . 5-13 Main Frame to Outer Tele . . . . . 7-163
Active Maintenance Mode Mast Disassembly . . . . . . . . . . . 7-162
General . . . . . . . . . . . . . . . . . . . . . 6-13 Outer Tele to Inner Tele . . . . . . . 7-165
HTI . . . . . . . . . . . . . . . . . . . . . . . .7-191 Reach Carriage . . . . . . . . . . . . . . . 7-171
A-frame . . . . . . . . . . . . . . 7-8, 7-19 to 7-25 Reach Half Shaft . . . . . . . . . . . . . . 7-172
Alarm, Audible (Test O19) . . . . . . . . .6-125 Bleeding Brake . . . . . . . . . . . . . . . . . . 7-75
Alarm, Travel Bleeding Hydraulic System . . . . . . . . 7-111
Configuring . . . . . . . . . . . . . . . . . . . 6-9 Brake . . . . . . . . . . . . . . . . . . . 7-68 to 7-75
Test O20 . . . . . . . . . . . . . . . . . . . .6-126 Adjustment . . . . . . . . . . . . . . . . . . . 7-69
AMP Connectors . . . . . . . . . . . . . . . . 7-90 Bleeding . . . . . . . . . . . . . . . . . . . . . 7-75
Analog Tests Brake Assembly . . . . . . . . . . . . . . . 7-72
See Tests, Analog Deadman Pedal . . . . . . . . . . . . . . . . 7-76
Summary List . . . . . . . . . . . . . . . . 6-73 Gap . . . . . . . . . . . . . . . . . . . 7-69 to 7-75
Auto Power Off ™Device . . . . . . . . . . . 6-10 Inoperable (Code 84) . . . . . . . . . . . . 6-52
Auxiliary Functions, Troubleshooting 5-21 O-Ring Seal . . . . . . . . . . . . . . . . . . . 7-74
Auxiliary Pump . . . . . . . . . . . . . . . . .7-117 Pad Inspection . . . . . . . . . . . . . . . . 7-69
Auxiliary System Upper Pad Replacement . . . . . . . . . 7-70
Pressure Adjustment . . . . . . . . . . .7-118 Brushes, DC Motor . . . . . . . . . . . . . . . 7-91
Purging . . . . . . . . . . . . . . . . . . . . .7-108 Inspection . . . . . . . . . . . . . . . . . . . . 7-91
Theory of Operation Spring Tension . . . . . . . . . . . . . . . . 7-93
See Theory of Operation, BSOC (Battery State-of-Charge) . 5-14, 6-9
Lift/Aux System
C
B
Cable
Backlash, Drive Unit . . . . . . . . . . . . . 7-60 Inspection . . . . . . . . . . . . . . . . . . . . 7-86
Battery Repair . . . . . . . . . . . . . . . . . . . . . . . 7-86
Charging . . . . . . . . . . . . . . . . . . . . 7-85 Soldering Procedures . . . . . . . . . . . 7-88
Cleaning Exterior . . . . . . . . . . . . . . 7-84 Terminology . . . . . . . . . . . . . . . . . . 6-69
Connector/Cables . . . . . . . . . . . . . 7-82 Cable, Over-the-Mast . . . . . . . . . . . . 7-155
Fault Code Calibration, Fork Height Indicator . . 7-196
Code 1T Battery Low . . . . . . . . . 6-20 CAN
Code FH Voltage Out-of-Range . . 6-66 Code 59 Buffer Error . . . . . . . . . . . . 6-38
Gates . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Code 5A Bus Error . . . . . . . . . . . . . 6-39
Procedures . . . . . . . . . . . . . . . . . . . 7-82 Code 5B Receive Bus Error . . . . . . . 6-40
Rollers . . . . . . . . . . . . . . . . . . . . . . 7-83 Code 5L Excessive Errors . . . . . . . . 6-43
Safety . . . . . . . . . . . . . . . . . . . . . . . 2-7 Code 5M Watchdog Timeout . . . . . . 6-44
Specifications . . . . . . . . . . . . . . 3-3, 3-4 Code VC IC Not Reset . . . . . . . . . . . 6-67
State-of-Charge (BSOC) . . . . . . 5-14, 6-9 Test I23 . . . . . . . . . . . . . . . . . . . . . 6-110
Voltage (Test A15) . . . . . . . . . . . . . 6-87 Card
Relay/Control Fuse Panel . . . . . . . . 6-71
Tilt/Sideshift Switch (EZ-D) . 7-29, 7-32
Vehicle Manager . . . . . . . . . . . . . . . 6-70
Carriage, Manual Lowering . . . . . . . . 7-115
PDMM-0109 7/31/02 1-1

Index EASi Reach-Fork® Truck EZ-D/DZ-D Maintenance Manual
Caster Assembly . . . . . . . . . . . . . . . . . 7-19 Contactor/Fuse Panel Layout . . . . . . . . 7-9

Caster, Steerable . . . . . . . . . . . . 7-8, 7-21 Control Handle
Caution (definition) . . . . . . . . . . . . . . . .2-2 EZ-D . . . . . . . . . . . . . . . . . 7-26 to 7-37
Chains Cleaning and Inspection . . . . . . . 7-31
Defect-Cause Chart . . . . . . . . . . . . . 4-26 Horn Switch . . . . . . . . . . . . . . . . 7-32
Equalization . . . . . . . . . . . . . . . . . 7-179 Lift/Lower Knob . . . . . . . . . . . . . 7-36
Lift, Anchors . . . . . . . . . . . . . . . . . 7-179 Lift/Lower VR2
Maintenance . . . . . . . . . . . . . . . . . . 4-26 See Potentiometer,
Chains, Equalization . . . . . . . . . . . . . 7-179 Lift/Lower VR2 (EZ-D)
Changing Password or SuperWrd . . . . .6-5 Reach/Retract Switches . . . . . . . 7-32
Circuit Card Connectors . . . . . . . . . . . 6-70 Soldering Procedures . . . . . . . . . . 7-88
Relay/Control Fuse Panel . . . . . . . . 6-71 Tilt/Sideshift
Vehicle Manager . . . . . . . . . . . . . . . 6-70 Switch Card . . . . . . . . . . .7-29, 7-34
Cleaning Controls, Learning . . . . . . . . . . . . . . . 6-11
Battery . . . . . . . . . . . . . . . . . . . . . . 7-84 Conversion
Lift Truck . . . . . . . . . . . . . . . . . 2-5, 2-6 Decimal to Fraction . . . . . . . . . . . . A-10
Motors . . . . . . . . . . . . . . . . . . . . . . . 4-19 Fraction to Decimal . . . . . . . . . . . . A-10
Traction Power Amplifier Metric to Standard . . . . . . . . . . . . . A-12
Clock, Setting . . . . . . . . . . . . . . . . . . . 6-10 Standard to Metric . . . . . . . . . . . . . A-12
Codes COP
Fault Codes Fault Code F4 Timeout . . . . . . . . . . 6-62
See Fault Codes Fault Code F8 Not Enabled . . . . . . . 6-64
HTI . . . . . . . . . . . . . . . . . . . . . . . . 7-189 Corrosion Inhibitor, Cold Storage . . . 7-187
Power Amplifier . . . . . . . . . . . . . . . . 6-17 Cushion, Lift Cylinder . . . . . . . . . . . 7-138
Summary List . . . . . . . . . . . . . . . . . 6-15 Cutout, Lift . . . . . . . . . . . . . . . . . . . . . 6-8
Cold Storage Requirements . . . . . . . . 7-186 Cylinder
Commutator, Motor (DC) . . . . . . . . . . . 7-95 Lift
Component Locator Photos . . . . .7-3 to 7-9 Back . . . . . . . . . . . . . . . . . . . . . 7-130
Component Procedures Flow Control . . . . . . . . . . . . . . . 7-140
(by System) List . . . . . . . . . . . . . . . . .7-1 Front & Back Seal Repacking . . 7-136
Configure Mode . . . . . . . . . . . .3-8, 6-3, 6-6 Front Cluster . . . . . . . . . . . . . . . 7-127
Factory Defaults, Restoring . . . . 6-7, 6-8 Illustrations . . . . . . . . 7-123 to 7-126
Menu Settings . . . . . . . . . . . . . . . . . .6-8 Lowering Cushion . . . . . . . . . . . 7-138
Connectors Purging Fluid . . . . . . . . . . . . . . 7-110
AMP . . . . . . . . . . . . . . . . . . . . . . . . 7-90 Side Seal Repacking . . . . . . . . . 7-134
Circuit Card . . . . . . . . . . . . . . . . . . 6-70 Reach . . . . . . . . . . . . . . . 7-142 to 7-146
Locator Chart . . . . . . . . . . . . . . . . .A-21 Sideshift . . . . . . . . . . . . . . . . . . . . 7-149
Molex . . . . . . . . . . . . . . . . . . . . . . . 7-88 Seal Replacement . . . . . . . . . . . 7-150
Relay/Control Fuse Panel . . . . . . . . 6-71 Tilt . . . . . . . . . . . . . . . . . . . . . . . . 7-147
Contactor Seal Replacement . . . . . . . . . . . 7-147
Lift
Code 42 Closed Fault . . . . . . . . . . 6-31
Code 43 Open Fault . . . . . . . . . . . 6-32 D
Test O02 Toggle Contactor . . . . . 6-114
PC DC Motor Troubleshooting . . . . . . . . . 5-10
Code 44 Closed Fault . . . . . . . . . . 6-33 Deadman Pedal . . . . . . . . . . . . . . . . . 7-76
Code 45 Open Fault . . . . . . . . . . . 6-34 Deadman Switch . . . . . . . . . . . . . . . . 7-76
Test O01 Toggle Contactor . . . . . 6-113 Test I00 . . . . . . . . . . . . . . . . . . . . . 6-94
TPC Decals . . . . . . . . . . . . . . . . . . 7-12 to 7-14
Code 46 Open Fault . . . . . . . . . . . 6-37 Decimal to Fraction Conversion . . . . . A-10
Code 4F Closed Fault . . . . . . . . . . 6-36
Test O00 Toggle Contactor . . . . . 6-112
1-2 PDMM-0109 7/31/02

Default Operator Display E

Off Deadman . . . . . . . . . . . . . . 3-6, 6-13
On Deadman . . . . . . . . . . . . . . 3-6, 6-13
Selecting . . . . . . . . . . . . . . . . . . . . . 3-5 Electrical Codes
Design, Manual . . . . . . . . . . . . . . . . . . 1-3 See Fault Codes
Diagnostic Mode Electrical Connector Locator Chart . . . A-21
See Maintenance Mode Electrical Schematic . . . . . . . . A-16 to A-22
Digital Input Tests Electrical Troubleshooting
See Tests, Input Guidelines . . . . . . . . . . . . . . . . . . . . . 5-3
Summary List . . . . . . . . . . . . . . . . 6-73 Symptoms . . . . . . . . . . . . . . 5-32 to 5-35
Digital Output Tests Electronic Operator Key . . . . . . . . . . . . 6-3
See Tests, Output Electrostatic Discharge
Summary List . . . . . . . .. . . . . . . . 6-73 See Static Precautions
DIRA Solenoid (Test O04) .. . . . . . . .6-115 ESD
DIRB Solenoid (Test O05) .. . . . . . . .6-116 See Static Precautions
Display, Operator . . . . . . .. . . . . 3-5, 7-38 Encoder
Hour Meters . . . . . . . . . .. . . . . . . . . 8-8 Drive Motor Speed
Off Deadman . . . . . . . . .. . . . . . . . 6-13 See Speed Sensor
Off Deadman Default . . .. . . . . . . . . 3-6 HTI Assembly . . . . . . . . . . . . . . . . 7-195
On Deadman . . . . . . . . .. . . . . . . . 6-13 Entering a Password or SuperWrd . . . . 6-5
On Deadman Default . . .. . . . . . . . . 3-6 EQ Solenoid (Test O09) . . . . . . . . . . . 6-120
Selecting Default . . . . . .. . . . . . . . . 3-5 Equalization Chains . . . . . . . . . . . . . 7-179
Troubleshooting . . . . . . .. . . . . . . . 5-34 Error Log . . . . . . . . . . . . . . . . . . . . . . 6-13
Drive Motor . . . . . . . . . . . .. . 7-64 to 7-67 Error Messages
Current (Test A11) . . . . .. . . . . . . . 6-83 Fault Codes
Overheated (Code 2A) . . .. . . . . . . . 6-21 See Fault Codes
Temperature Sensor . . . .. . . . . . . .7-102 HTI . . . . . . . . . . . . . . . . . . . . . . . . 7-189
Temperature (Test A08) .. . . . . . . . 6-78 Power Amplifier . . . . . . . . . . . . . . . . 6-17
Terminal Nuts . . . . . . . .. . . . . . . . 7-96 Summary List . . . . . . . . . . . . . . . . . 6-15
Drive Unit . . . . . . . . . . . . .. . 7-42 to 7-63
Assembly . . . . . . . . . . . .. . 7-53 to 7-62
Backlash Measurement .. . . . . . . . 7-60
F
Disassembly . . . . . . . . .. . 7-48 to 7-53
Exploded Parts Diagram . . . . . . . . 7-42 Factory Default Configure Settings . . . . 6-7
Helical Gear Assembly . .. . . . . . . . 7-57 Fault Codes . . . . . . . . . . . . . . 6-18 to 6-67
Installation . . . . . . . . . .. . . . . . . . 7-62 Code 1H – Traction Power Amplifier
Output Shaft
Assembly . . . . . . . . . . . . . . . . . . 7-54
Disassembly . . . . . . . . . . . . . . . . 7-50
Pivot Ring
Assembly . . . . . . . . . . . . . . . . . . 7-61
Disassembly . . . . . . . . . . . . . . . . 7-48
Removal . . . . . . . . . . . . . . . . . . . . . 7-46
Repair Kit Options . . . . . . . . . . . . . 7-45
Shim Formulas . . . . . . . . . . . . . . . 7-58
Shim Installation . . . . . . . . . . . . . . 7-58
Special Tools . . . . . . . . . . . . . . . . . 7-43
Spiral Pinion
Assembly . . . . . . . . . . . . . . . . . . 7-53
Disassembly . . . . . . . . . . . . . . . . 7-52
PDMM-0109 7/31/02 1-3

Overheated . . . . . . . . . . . . . . . . . 6-19 Out-of-Range . . . . . . . . . . . . . . . . 6-49

Code 1T – Battery Low . . . . . . . . . . . 6-20 Code 81 – Lift Pot Out-of-Range . . . 6-50
Code 2A – Traction Motor Code 83 – Travel Pot
Overheated . . . . . . . . . . . . . . . . . 6-21 Out of Neutral . . . . . . . . . . . . . . . 6-51
Code 2C – Traction Power Amplifier Code 84 – Brake inoperable . . . . . . 6-52
Temperature Sensor Out-of-Range 6-22 Code 87 – Traction Power Amplifier
Code 2E – Traction Motor Fan Inoperable . . . . . . . . . . . . . . 6-53
Temperature Sensor Out-of-Range 6-23 Code 8F – Lift Control Handle Pot
Code 2H – Failure Detected in Out of Neutral . . . . . . . . . . . . . . . 6-54
Traction Motor Feedback Encoder 6-24 Code A0 – Incorrect Software . . . . . 6-55
Code 2M – Traction Power Amplifier Code AG – Operator Display
Failed . . . . . . . . . . . . . . . . . . . . . . 6-25 Communications Failed . . . . . . . . 6-56
Code 2P – Traction Power Amplifier Code AH – Bad Operator Display
Reverted to Default Parameters . . 6-26 Checksum . . . . . . . . . . . . . . . . . . 6-57
Code 2R – Traction Power Code AJ – Bad VM ROM Memory . . 6-58
Amplifier Pulse Sensor Warning . . 6-27 Code AK – Bad VM RAM Memory . . 6-59
Code 2T – Traction Power Amplifier Code AL – Bad Backed-Up VM RAM 6-60
Current Calibration Error . . . . . . . 6-28 Code EC – Operating System Error . 6-61
Code 2U – Traction Power Amplifier Code F4 – VM COP Time-out . . . . . . 6-62
Overcurrent or Short Circuit . . . . 6-29 Code F5 – Bad Op Code . . . . . . . . . 6-63
Code 2V – Traction Power Amplifier Code F8 – VM COP Not Enabled . . . 6-64
High DC Voltage . . . . . . . . . . . . . . 6-30 Code FG – 12 V Power Supply
Code 42 – Lift Contactor Closed . . . . 6-31 Out-of-Range . . . . . . . . . . . . . . . . 6-65
Code 43 – Lift Contactor Open . . . . . 6-32 Code FH – Battery Voltage
Code 44 – PC Contactor Closed . . . . 6-33 Out-of-Range . . . . . . . . . . . . . . . . 6-66
Code 45 – PC Contactor Open . . . . . 6-34 Code VC – CAN IC not reset . . . . . . 6-67
Code 4D – No Charging Traction HTI . . . . . . . . . . . . . . . . . . . . . . . . 7-189
DC Input Voltage Power Amplifier . . . . . . . . . . . . . . . . 6-17
During Start-Up . . . . . . . . . . . . 6-35 Summary List . . . . . . . . . . . . . . . . . 6-15
Code 4F – TPC Contactor Closed . . . 6-36 Firmware
Code 4G – TPC Contactor Open . . . . 6-37 Displaying Version . . . . . . . . . . . . . . 6-9
Code 59 – CAN Fault Code
Transmission Buffer Error . . . . . . 6-38 Code A0 Incorrect Level . . . . . . . . 6-55
Code 5A – CAN Code AH Bad Checksum . . . . . . . 6-57
Bus Error/Vehicle Manager . . . . . 6-39 Code AJ Bad VM ROM . . . . . . . . . 6-58
Code 5B – CAN Receive Code AK Bad VM RAM . . . . . . . . . 6-59
Bus Error/Vehicle Manager . . . . . 6-40 Code AL Bad Backed-Up VM RAM 6-60
Code 5D – No SMARTi® Code EC Operating System . . . . . 6-61
System Response . . . . . . . . . . . . . 6-41 Code F5 Bad Op Code . . . . . . . . . 6-63
Code 5G – No Communications Release Changes . . . . . . . . . . . . . . . . 6-2
from Power Amplifier . . . . . . . . . . 6-42 Flow Control . . . . . . . . . . . . . . . . . . 7-140
Code 5L – Excessive CAN Errors . . . 6-43 Fluid Replacement, Hydraulic . . . . . 7-108
Code 5M – Power Amplifier Fork Carriage Shimming for HTI . . . . 7-197
CAN Watchdog Timeout . . . . . . . . 6-44 Fork Carriage Tilt Pins . . . . . . . . . . . 7-183
Code 63 – Speed Limiting Switches Fork Carriage, Manual Lowering . . . 7-115
Do Not Agree . . . . . . . . . . . . . . . . 6-45 Fork Height Indicator
Code 6D – Pressure Sensor Cable Replacement . . . . . . . . . . . . 7-193
Out-of-Range . . . . . . . . . . . . . . . . 6-46 Calibrating and Setting . . . . . . . . . 7-196
Code 6F – Lift Motor Overheated . . . 6-47 Encoder Assembly . . . . . . . . . . . . 7-195
Code 6G – Lift Motor Temperature Theory of Operation . . . . . . . . . . . 7-199
Sensor Out-of-Range . . . . . . . . . . 6-48 Fork Height-Tilt Indicator
Code 80 – Throttle Potentiometer See Height-Tilt Indicator
1-4 PDMM-0109 7/31/02

Fork Tilt Indicator Hose, Over-the-Mast . . . . . . . . . . . . . 7-155

Fork Carriage Shimming . . . . . . . .7-197 Hour Meters . . . . . . . . . . . . . . . . . . . . . 8-8
Pressure Switch . . . . . . . . . . . . . . .7-199 HTI
Theory of Operation . . . . . . . . . . . .7-200 See Height-Tilt Indicator
Forks . . . . . . . . . . . . . . . . . . . . . . . .7-178 Hung Up Carriage, Lowering . . . . . . . 7-115
Inspection . . . . . . . . . . . . . . . . . . .7-178 Hydraulic Fluid Replacement . . . . . . 7-108
Fraction to Decimal Conversion . . . . . A-10 Hydraulic Solenoid . . . . . . . . . . . . . . 7-120
Functional Operation Torques . . . . . . . . . . . . . . . . . . . . . 7-120
Lift/Aux System Hydraulic System
See Theory of Operation, Bleeding . . . . . . . . . . . . . . . . . . . . 7-111
Lift/Aux System Fluid Replacement . . . . . . . . . . . . 7-108
Traction System Purging . . . . . . . . . . . . . . . . . . . . . 7-108
See Theory of Operation, Schematic . . . . . . . . . . . . . . . . . . . . A-24
Traction System Theory of Operation
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 See Theory of Operation,
Aux (Test I14) . . . . . . . . . . . . . . . .6-107 Lift/Aux System
Lift (Test I13) . . . . . . . . . . . . . . . . .6-106 Troubleshooting
Guidelines . . . . . . . . . . . . . . . . . . 5-16
Symptoms . . . . . . . . . . . . 5-21 to 5-29
G Hydraulic Valve . . . . . . . . . . . . . . . . 7-120
Torques . . . . . . . . . . . . . . . . . . . . . 7-120
Gap, Brake . . . . . . . . . . . . . . 7-69 to 7-75
Gates, Battery . . . . . . . . . . . . . . . . . . . 3-4 I
Grease Fittings
See Lubrication Points
Ground Jack, ESD . . . . . . . . . . . . . . 2-11 Inertial Dampener . . . . . . . . . . . . . . . 7-77
Grounded DC Motor Test . . . . . . . . . . 5-11 Input Tests
See Tests, Input
Summary List . . . . . . . . . . . . . . . . . 6-73
H
J
Half Shaft Bearings . . . . . . . . . . . . . .7-172
Harness
Inspection . . . . . . . . . . . . . . . . . . . 7-86 Jacking Safety . . . . . . . . . . . . . . . . . . 2-13
Repair . . . . . . . . . . . . . . . . . . . . . . 7-86
Soldering Procedures . . . . . . . . . . . 7-88
Terminology . . . . . . . . . . . . . . . . . . 6-69 K
Height Encoder Assembly . . . . . . . . .7-195
Height-Tilt Indicator . . . . . .7-188 to 7-200 Knob, Lift/Lower . . . . . . . . . . . . . . . . 7-36
Active Maintenance Mode . . . . . . . .7-191
Fault Codes . . . . . . . . . . . . . . . . . .7-189
Fork Height Indicator L
Cable Replacement . . . . . . . . . . .7-193
Encoder Assembly . . . . . . . . . . .7-195
Lash Adjustment, Mast . .. . . . . . . . . 7-184
Fork Tilt Indicator
Learn Mode . . . . . . . . . .. . . 3-7, 6-3, 6-11
Fork Carriage Shimming . . . . . . .7-197
Controls . . . . . . . . . . .. . . . . . . . . . 6-11
Theory of Operation . . . . . . . . . . . .7-199
Weight . . . . . . . . . . . .. . . . . . . . . . 6-11
Troubleshooting . . . . . . . .7-189 to 7-193
Lift Chains
Helical Gear Assembly,
Anchors . . . . . . . . . . . . . . . . . . . . 7-179
Drive Unit . . . . . . . . . . . . . . . . . . . 7-57
Defect-Cause Chart . . . . . . . . . . . . . 4-26
Horn Switch (EZ-D) . . . . . . . . . . . . . . 7-32
Lift Cut-out . . . . . . . . . . . . . . . . . . . . . 6-8
Horn (Test O18) . . . . . . . . . . . . . . . . .6-124
PDMM-0109 7/31/02 1-5

Lift Cylinder . . . . . . . . . . . . 7-123 to 7-139 Maintenance Mode . . . . . . . . . . . . 3-8, 6-3

Back . . . . . . . . . . . . . . . . . . . . . . . 7-130 Active Mode . . . . . . . . . . . . . . . . . . 6-13
Flow Control . . . . . . . . . . . . . . . . . 7-140 HTI . . . . . . . . . . . . . . . . . . . . . . . . 7-191
Front & Back Seal Repacking . . . . 7-136 Static Mode . . . . . . . . . . . . . . . . . . 6-12
Front Cluster . . . . . . . . . . . . . . . . . 7-127 Manifold, Main . . . . . . . . . . . . . . . . . 7-119
Illustrations . . . . . . . . . . . 7-123 to 7-126 Manual Design . . . . . . . . . . . . . . . . . . . 1-3
Lowering Cushion . . . . . . . . . . . . . 7-138 Manual Lowering of Carriage . . . . . . 7-115
Purging Fluid . . . . . . . . . . . . . . . . 7-110 Map, Navigating the Manual . . . . . . . . . 1-2
Side Seal Repacking . . . . . . . . . . . 7-134 Mast
Lift Function Disassembly . . . . . . . . . . . . . . . . . 7-162
Theory of Operation . . . . . . . 8-27 to 8-34 Lash Adjustment . . . . . . . . . . . . . 7-184
Troubleshooting . . . . . . . . . . 5-26, 5-27 Mast Bearing Shimming . 7-159 to 7-170
Lift Motor . . . . . . . . . . . . . . . 7-98 to 7-100 Inner Tele to Carriage . . . . . . . . 7-168
Overheated (Code 6F) . . . . . . . . . . . 6-47 Main Frame to Outer Tele . . . . . 7-163
Temperature Sensor . . . . . . . . . . . 7-101 Mast Disassembly . . . . . . . . . . . 7-162
Temperature (Test A09) . . . . . . . . . . 6-80 Outer Tele to Inner Tele . . . . . . . 7-165
Terminal Nuts . . . . . . . . . . . . . . . . . 7-96 Types . . . . . . . . . . . . . . . . . . . . . . 7-154
Lift Pressure Adjustment . . . . . . . . . . 7-114 Messages and Codes
Lift Pump . . . . . . . . . . . . . . . . . . . . . 7-113 Fault Codes
Lift/Aux System Functional Operation See Fault Codes
See Theory of Operation, HTI . . . . . . . . . . . . . . . . . . . . . . . . 7-189
Lift/Aux System Power Amplifier . . . . . . . . . . . . . . . . 6-17
Lift/Lower Knob Installation . . . . . . . . 7-36 Summary List . . . . . . . . . . . . . . . . . 6-15
Lift/Lower Pot VR2 (EZ-D) Meters, Hour . . . . . . . . . . . . . . . . . . . . 8-8
See Potentiometer, Lift/Lower VR2 (EZ-D) Metric to Standard Conversion . . . . . . A-12
Lift/Lower Troubleshooting . . . . . . . . . 5-26 Modes of Operation . . . . . 3-7, 6-3 to 6-14
Linkage, Steering . . . . . . . . . . . . 7-8, 7-25 Configure . . . . . . . . . . . . . . 3-8, 6-3, 6-6
Locator Chart Configure Menu Settings . . . . . . . . . . 6-8
Electrical Connectors . . . . . . . . . . . .A-21 Error Log . . . . . . . . . . . . . . . . . . . . 6-13
Fuses . . . . . . . . . . . . . . . . . . . . . . . .5-9 HTI Maintenance . . . . . . . . . . . . . 7-191
Locator Photos Learn . . . . . . . . . . . . . . . . 3-7, 6-3, 6-11
Components . . . . . . . . . . . . . .7-3 to 7-9 Learn Controls . . . . . . . . . . . . . . . . 6-11
Lubrication Points . . . . . . . . 4-21 to 4-25 Learn Weight . . . . . . . . . . . . . . . . . 6-11
Scheduled Maintenance . . . . 4-15 to 4-18 Maintenance . . . . . . . . . . . 3-8, 6-3, 6-12
Loctite® Active . . . . . . . . . . . . . . . . . . . . . 6-13
See Thread Adhesives Error Log . . . . . . . . . . . . . . . . . . . 6-13
Lower Function Static . . . . . . . . . . . . . . . . . . . . . 6-12
Theory of Operation . . . . . . . 8-35 to 8-38 Overview . . . . . . . . . . . . . . . . . . 3-7, 6-3
Troubleshooting . . . . . .5-26, 5-28, 5-29 Program . . . . . . . . . . . . . . . 3-7, 6-3, 6-5
Lower Valve Adjustment . . . . . . . . . . 7-116 Run . . . . . . . . . . . . . . . . . . . . . 3-7, 6-3
Lowering Carriage Manually . . . . . . . 7-115 Run Mode Tones . . . . . . . . . . . . . . . . 6-4
Lubrication Points . . . . . . . . . 4-20 to 4-25 Molex Connectors . . . . . . . . . . . . . . . . 7-88
Lubrication Specification Chart . . . . . . .A-2
Main Manifold . . . . . . . . . . . . . . . . . . 7-119

Maintenance Minder ™ Tool . . . . . 4-3, 6-10
1-6 PDMM-0109 7/31/02

Motors . . . . . . . 5-10 to 5-13, 7-91 to 7-97 Operator’s Daily Checklist . . . . . . . . . . 4-6

AC Open Winding . . . . . . . . . . . . . 5-13 Output Tests
AC Shorted Winding . . . . . . . . . . . . 5-13 See Tests, Output
Brushes (DC) . . . . . . . . . . . . . . . . . 7-91 Summary List . . . . . . . . . . . . . . . . . 6-73
Cleaning . . . . . . . . . . . . . . . . . . . . 4-19 Over-the-Mast Hose/Cable . . . . . . . . 7-155
Commutator (DC) . . . . . . . . . . . . . . 7-95
DC Brush Spring Tension . . . . . . . 7-93
DC Grounded Motor Test . . . . . . . . 5-11 P
DC Motor Tests . . . . . . . . . 5-10 to 5-12
DC Open Circuit Test . . . . . . . . . . . 5-10 P Contactor (Test O02) . . . . . . . . . . . 6-114
DC Short Circuit Test . . . . . . . . . . 5-11 Passwords
Drive . . . . . . . . . . . . . . . . . 7-64 to 7-67 Changing Password or SuperWrd . . . 6-5
Overheated (Code 2A) . . . . . . . . . 6-21 Electronic Operator Key . . . . . . . . . . 6-3
Temperature Sensor . . . . . . . . . .7-102 Entering Password or SuperWrd . . . . 6-5
Terminal Nuts . . . . . . . . . . . . . . 7-96 Password . . . . . . . . . . . . . . . . . 3-8, 6-3
Lift . . . . . . . . . . . . . . . . . . .7-98 to 7-100 SuperWrd . . . . . . . . . . . . . . . . . 3-8, 6-4
Overheated (Code 6F) . . . . . . . . . 6-47 PC Contactor (Test O01) . . . . . . . . . . 6-113
Temperature Sensor . . . . . . . . . .7-101 Pedal, Deadman . . . . . . . . . . . . . . . . . 7-76
Terminal Nuts . . . . . . . . . . . . . . 7-96 Pin Extraction/Insertion
Overheating AMP Connectors . . . . . . . . . . . . . . . 7-90
Code 2A Drive Motor . . . . . . . . . . 6-21 Molex Connectors . . . . . . . . . . . . . . 7-88
Code 6F Lift Motor . . . . . . . . . . . 6-47 Pinout Matrix . . . . . . . . . . . . . 8-55 to 8-71
Troubleshooting . . . . . . . . . . . . . 5-32 Pivot Pins, Fork Carriage . . . . . . . . . 7-183
Power Cable Nut Torques . . . . . . . . 7-96 Pivot Ring, Drive Unit
Troubleshooting . . . . . . . . . . . . . . . 5-32 Assembly . . . . . . . . . . . . . . . . . . . . 7-61
AC . . . . . . . . . . . . . . . . . . . . . . . 5-13 Disassembly . . . . . . . . . . . . . . . . . . 7-48
DC . . . . . . . . . . . . . . . . . . . . . . . 5-10 Potentiometer
Types (AC) . . . . . . . . . . . . . . . . . . . 5-13 Lift/Lower Pot VR2 (EZ-D) . . . 7-29, 7-32
Types (DC) . . . . . . . . . . . . . . . . . . . 5-10 Code 81 Out-of-Range . . . . . . . . . 6-50
Code 8F Out-of-Neutral . . . . . . . . 6-54
N Request (Test A23) . . . . . . . . . . . . 6-89
Voltage (Test A05) . . . . . . . . . . . . 6-77
Throttle Pot VR1 (EZ-D) . . . . . 7-30, 7-31
Nested Switch (Test I01) . . . . . . . . . . 6-95 Code 80 Out-of-Range . . . . . . . . . 6-49
Code 83 Out-of-Neutral . . . . . . . . 6-51
Request (Test A22) . . . . . . . . . . . . 6-88
O Voltage (Test A04) . . . . . . . . . . . . 6-76
Power Amplifier LED Diagnostics . . . . 6-17
Off Deadman Default Display . . . 3-6, 6-13 Power Amplifier Overheated (Code 1H) 6-19
Oil, Hydraulic Power Amplifier, Traction
See Hydraulic Fluid See Traction Power Amplifier
On Deadman Default Display . . . 3-6, 6-13 Power Cable Nut Torques . . . . . . . . . . 7-96
Open Circuit DC Motor Test . . . . . . . 5-10 Power Supply
Open Winding AC Motor . . . . . . . . . . 5-13 12 Volt
Operator Display . . . . . . . . . . . . . 3-5, 7-38 Voltage Out-of-Range (Code FG) . . 6-65
Communications Failed (Code AG) . 6-56 Voltage (Test A14) . . . . . . . . . . . . 6-85
Hour Meters . . . . . . . . . . . . . . . . . . . 8-8 5 Volt
Off Deadman Default . . . . . . . . 3-6, 6-13 Voltage (Test A26) . . . . . . . . . . . . 6-91
On Deadman Default . . . . . . . . 3-6, 6-13 Pressure Adjustment
Selecting Default . . . . . . . . . . . . . . . 3-5 Auxiliary System . . . . . . . . . . . . . . 7-118
Troubleshooting . . . . . . . . . . . . . . . 5-34 Lift . . . . . . . . . . . . . . . . . . . . . . . . 7-114
Operator Key, Electronic . . . . . . . . . . . 6-3
PDMM-0109 7/31/02 1-7

Pressure Switch, HTI Scheduled Maintenance

Adjustment . . . . . . . . . . . . . . . . . . 7-199 180 Day . . . . . . . . . . . . . . . . . . . . . 4-14
Switch Removal/Installation . . . . . 7-199 360 Day . . . . . . . . . . . . . . . . . . . . . 4-14
Pressure Transducer . . . . . . . . . . . . . 7-121 60 Day . . . . . . . . . . . . . . . . . . . . . . . 4-8
Code 6D Out-of-Range . . . . . . . . . . . 6-46 Guidelines . . . . . . . . . . . . . . . . . . . . 4-2
Voltage (Test A13) . . . . . . . . . . . . . . 6-84 Maintenance Minder ™ Tool . . . . . . . . 4-3
Program Mode . . . . . . . . . . . . .3-7, 6-3, 6-5 Motor Cleaning . . . . . . . . . . . . . . . . 4-19
Proportional Lower Valve Adjustment 7-116 Operator’s Daily Checklist . . . . . . . . 4-6
Pump Photos . . . . . . . . . . . . . . . . 4-15 to 4-18
Auxiliary . . . . . . . . . . . . . . . . . . . . 7-117 Scheduled Maintenance Charts 4-2 to 4-14
Lift . . . . . . . . . . . . . . . . . . . . . . . . 7-113 Schematic
Purging Auxiliary System . . . . . . . . . 7-108 Electrical . . . . . . . . . . . . . . A-16 to A-22
Hydraulic . . . . . . . . . . . . . . . . . . . . A-24
Seal
R Brake O-Ring Replacement . . . . . . . 7-74
Front & Back
Ram Lift Cylinder Repacking . . . . . . . 7-136
See Cylinder Side Lift Cylinder Repacking . . . . . 7-134
Reach Carriage Sideshift Cylinder, Replacement . . 7-150
Assembly Removal/Installation . . . 7-174 Tilt Cylinder, Replacement . . . . . . 7-147
Bearings . . . . . . . . . . . . . . . . . . . . 7-171 Sealants, Specifications . . . . . . . . . . . . A-3
Half Shaft Bearings . . . . . . . . . . . . 7-172 Sealing, Cold Storage . . . . . . . . . . . . 7-186
Locator Photo . . . . . . . . . . . . . . . . . .7-7 SelfTest . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Lowering Manually . . . . . . . . . . . . 7-115 Serial Number
Pivot Pins . . . . . . . . . . . . . . . . . . . 7-183 Displaying in Configure Mode . . . . . 6-10
Reach Cylinder . . . . . . . . . . 7-142 to 7-146 Specification Plate . . . . . . . . . . . . . . 3-3
Reach Function Service Intervals
Reach Solenoid Test O06 . . . . . . . . 6-117 See Scheduled Maintenance Charts
Theory of Operation . . . . . . . 8-39 to 8-45 Shimming Drive Unit . . . . . . . . . . . . . 7-58
Troubleshooting . . . . . . . . . . . . . . . 5-24 Shimming Fork Carriage . . . . . . . . . 7-197
Reach/Retract Switches (EZ-D) . . . . . . 7-32 Shimming Mast Bearings . . 7-159 to 7-170
Relay/Control Fuse Panel Inner Tele to Carriage . . . . . . . . . . 7-168
Circuit Card Connectors . . . . . . . . . 6-71 Main Frame to Outer Tele . . . . . . . 7-163
Retract Function, Troubleshooting . . . 5-25 Mast Disassembly . . . . . . . . . . . . . 7-162
Retract Switch (EZ-D) . . . . . . . . . . . . . 7-32 Outer Tele to Inner Tele . . . . . . . . 7-165
Rollers, Battery . . . . . . . . . . . . . . . . . . 7-83 Shock Absorber . . . . . . . . . . . . . . . . . 7-77
Run Mode . . . . . . . . . . . . . . . . . . . 3-7, 6-3 Short Circuited DC Armature
Tones . . . . . . . . . . . . . . . . . . . . . . . .6-4 or Field Winding Test . . . . . . . . . . . 5-11
Shorted Winding AC Motor . . . . . . . . . 5-13
Shorts to Frame Test . . . . . . . . . . . . . . 5-5
S Sideshift Assembly . . . . . . . . . . . . . . 7-151
Sideshift Cylinder . . . . . . . . . . . . . . . 7-149
Seal Replacement . . . . . . . . . . . . . 7-150
Safety
Sideshift Function
Battery . . . . . . . . . . . . . . . . . . . . . . .2-7
Sideshift Solenoid Test O08 . . . . . 6-119
Decals . . . . . . . . . . . . . . . . . 7-12 to 7-14
Theory of Operation . . . . . . 8-46 to 8-49
ESD . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Troubleshooting . . . . . . . . . . . . . . . 5-23
General . . . . . . . . . . . . . . . . . .2-3 to 2-6
SMARTi ® System . . . . . . . . . . . . . . . . 6-10
Jacking . . . . . . . . . . . . . . . . . . . . . . 2-13
Code 5D No Response . . . . . . . . . . . 6-41
Static Precautions . . . . . . . . . . . . . . 2-11
Tie-Down for Transport . . . . . . . . . . 2-14
Welding . . . . . . . . . . . . . . . . . . . . . . 2-15
1-8 PDMM-0109 7/31/02

Software Switch
Displaying Version . . . . . . . . . . . . . . 6-9 Deadman . . . . . . . . . . . . . . . . . . . . 7-76
Fault Code Test I00 . . . . . . . . . . . . . . . . . . . . 6-94
Code A0 Incorrect Level . . . . . . . 6-55 First Speed Limiting (Test I02) . . . . . 6-96
Code AH Bad Checksum . . . . . . . 6-57 Horn (EZ-D) . . . . . . . . . . . . . . . . . . 7-32
Code AJ Bad VM ROM . . . . . . . . 6-58 Test I15 . . . . . . . . . . . . . . . . . . . 6-108
Code AK Bad VM RAM . . . . . . . . 6-59 HTI Pressure . . . . . . . . . . . . . . . . . 7-199
Code AL Bad Backed-Up VM RAM 6-60 Lift Bypass (Test I04) . . . . . . . . . . . . 6-98
Code EC Operating System . . . . . 6-61 Lift-Limit (Test I05) . . . . . . . . . . . . . 6-99
Code F5 Bad Op Code . . . . . . . . . 6-63 Reach (Test I06) . . . . . . . . . . . . . . 6-100
Release Changes . . . . . . . . . . . . . . . 6-2 Reach/Retract (EZ-D) . . . . . . . . . . . 7-32
Soldering Procedures . . . . . . . . . . . . . 7-88 Retract (Test I07) . . . . . . . . . . . . . . 6-101
Solenoid . . . . . . . . . . . . . . . . . . . . . .7-120 Second Speed Limiting (Test I03) . . . 6-97
2nd Pump (Test O10) . . . . . . . . . . .6-121 Sideshift Left (Test I11) . . . . . . . . . 6-105
DIRA (Test O04) . . . . . . . . . . . . . . .6-115 Sideshift Right (Test I10) . . . . . . . . 6-104
DIRB (Test O05) . . . . . . . . . . . . . . .6-116 Speed Limiting
EQ (Test O09) . . . . . . . . . . . . . . . .6-120 Switches Not Agree (Code 63) . . . . 6-45
Lift/Lower (Test O12) . . . . . . . . . . .6-123 Tilt Down (Test I09) . . . . . . . . . . . . 6-103
Load Hold (Test O11) . . . . . . . . . . .6-122 Tilt Up (Test I08) . . . . . . . . . . . . . . 6-102
Reach (Test O06) . . . . . . . . . . . . . .6-117 Tilt/Sideshift (EZ-D) . . . 7-29, 7-32, 7-34
Sideshift (Test O08) . . . . . . . . . . . .6-119 Symptom Tables
Tilt (Test O07) . . . . . . . . . . . . . . . .6-118 Electrical Symptoms . . . . . . 5-32 to 5-35
Torques . . . . . . . . . . . . . . . . . . . . .7-120 Hydraulic Functions . . . . . . 5-21 to 5-29
Special Tools, Drive Unit . . . . . . . . . . 7-43 Travel Functions . . . . . . . . . 5-30 to 5-31
Specification Plate . . . . . . . . . . . . . . . . 3-3
Speed Sensor, Drive Motor
Failure Detected (Code 2H) . . . . . . . 6-24 T
Test I19 . . . . . . . . . . . . . . . . . . . . .6-109
Spiral Pinion, Drive Unit Temperature Management . . . . . . . . . 8-19
Assembly . . . . . . . . . . . . . . . . . . . . 7-53 Temperature Sensor
Disassembly . . . . . . . . . . . . . . . . . 7-52 Drive Motor . . . . . . . . . . . . . . . . . . 7-102
Staging Chains . . . . . . . . . . . . . . . . .7-179 Out-of-Range (Code 2E) . . . . . . . . 6-23
Standard to Metric Conversion . . . . . A-12 Lift Motor . . . . . . . . . . . . . . . . . . . 7-101
START Page . . . . . . . . . . . . . . . . . . . . . 1-5 Out-of-Range (Code 6G) . . . . . . . . 6-48
Startup Sequence . . . . . . . . . . . . . . . . 8-8 Power Amplifier
Static Maintenance Mode . . . . . . . . . 6-12 Out-of-Range (Code 2C) . . . . . . . . 6-22
Static Precautions . . . . . . . . . . . . . . . 2-11 Terminal Nuts . . . . . . . . . . . . . . . . . . 7-96
Steering
Caster Assembly . . . . . . . . . . . 7-8, 7-19
Linkage . . . . . . . . . . . . . . . . . . 7-8, 7-25
Purging Fluid . . . . . . . . . . . . . . . . .7-110
Shaft and Gear . . . . . . . . . . . . . . . 7-16
Steerable Caster . . . . . . . . . . . 7-8, 7-21
Theory of Operation . . . . . . 8-20 to 8-23
SuperWrd . . . . . . . . . . . . . . . . . . . 3-8, 6-4
Changing . . . . . . . . . . . . . . . . . . . . . 6-5
Entering . . . . . . . . . . . . . . . . . . . . . 6-5
PDMM-0109 7/31/02 1-9

Tests TPC Contactor . . . . . . . . . . . . 6-112

Analog . . . . . . . . . . . . . . . . . 6-75 to 6-92 Test O01 – Toggle the
Test A04 – Throttle PC Contactor . . . . . . . . . . . . . 6-113
Potentiometer Voltage . . . . . . . . 6-76 Test O02 – Toggle the
Test A05 – Lift/Lower P Contactor . . . . . . . . . . . . . . 6-114
Potentiometer Voltage . . . . . . . . 6-77 Test O04 – Toggle the
Test A08 – Traction Motor DIRA (SOL5) Solenoid . . . . . . 6-115
Temperature . . . . . . . . . . . . . . . 6-78 Test O05 – Toggle the
Test A09 – Lift Motor Temperature 6-80 DIRB (SOL4) Solenoid . . . . . . 6-116
Test A10 – Traction Power Amplifier Test O06 – Toggle the
Heatsink Temperature . . . . . . . 6-82 Reach Solenoid . . . . . . . . . . . 6-117
Test A11 – Traction Motor Current 6-83 Test O07 – Toggle the
Test A13 – Pressure Sensor Tilt Solenoid . . . . . . . . . . . . . . 6-118
Voltage . . . . . . . . . . . . . . . . . . . 6-84 Test O08 – Toggle the
Test A14 – Power Supply +12V DC 6-85 Sideshift Solenoid . . . . . . . . . 6-119
Test A15 – Battery Voltage . . . . . . 6-87 Test O09 – Toggle the
Test A22 – Traction Throttle EQ (SOL6) Solenoid . . . . . . . . 6-120
Request . . . . . . . . . . . . . . . . . . 6-88 Test O11 – Toggle the
Test A23 – Lift Throttle Request . . 6-89 Load Hold (SOL1) Solenoid . . . 6-122
Test A24 – Traction Power Amplifier Test O12 – Ramp the
Internal Temperature . . . . . . . . 6-90 Lift/Lower (SOL3) Solenoid . . 6-123
Test A26 – Power Supply +5V DC . 6-91 Test O18 – Toggle the Horn . . . . 6-124
Test A27 – Power Amplifier Test O19 – Audible Alarm . . . . . 6-125
Fan Voltage . . . . . . . . . . . . . . . 6-92 Test O20 – Travel Alarm Test . . . 6-126
DC Motor . . . . . . . . . . . . . . 5-10 to 5-12 Test O23 – Toggle
Input . . . . . . . . . . . . . . . . . 6-93 to 6-110 Power Amplifier Fan . . . . . . . . 6-127
Test I00 – Deadman Switch (S2) . . 6-94 Test O29 – Ramp the
Test I01 – Nested Switch (S19) . . . 6-95 Traction Power Amplifier . . . . 6-128
Test I02 – First Speed Limiting Shorts to Frame . . . . . . . . . . . . . . . . 5-5
Switch (S10) . . . . . . . . . . . . . . . 6-96 Summary List . . . . . . . . . . . . . . . . . 6-73
Test I03 – Second Speed Limiting
Switch (S11) . . . . . . . . . . . . . . . 6-97
Test I04 – Lift Bypass Switch (S12) 6-98
Test I05 – Lift-Limit Switch (S13) . 6-99
Test I06 – Reach Switch (S4) . . . 6-100
Test I07 – Retract Switch (S5) . . . 6-101
Test I08 – Tilt Up Switch (S6) . . . 6-102
Test I09 – Tilt Down Switch (S7) . 6-103
Test I10 – Sideshift Right
Switch (S9) . . . . . . . . . . . . . . . 6-104
Test I11 – Sideshift Left
Switch (S8) . . . . . . . . . . . . . . . 6-105
Test I13 – Lift Fuse (FU3) . . . . . . 6-106
Test I14 – Auxiliary Fuse (FU1) . . 6-107
Test I15 – Horn Switch (S3) . . . . 6-108
Test I19 – Drive Motor Speed
Sensor . . . . . . . . . . . . . . . . . . 6-109
Test I23 – CAN Bus Test . . . . . . . 6-110
Test O10 – Toggle 2nd Pump
(SOL8) Solenoid . . . . . . . . . . . 6-121
Output . . . . . . . . . . . . . . 6-111 to 6-128
Test O00 – Toggle the
1-10 PDMM-0109 7/31/02

Theory of Operation Torque Chart . . . . . . . . . . . . . . .A-7 to A-9

BSOC . . . . . . . . . . . . . . . . . . . . . . 5-14 EZ-D/DZ-D Quick Reference . . . . . . . A-4
Height-Tilt Indicator (HTI) . . . . . . .7-199 Face Seal O-Rings . . . . . . . . . . . . . . . A-6
Hour Meters . . . . . . . . . . . . . . . . . . . 8-8 Hydraulic Fittings . . . . . . . . . . . . . . . A-6
HTI Fork Height Indicator . . . . . . .7-199 Metric (Brass) . . . . . . . . . . . . . . . . . . A-8
HTI Fork Tilt Indicator . . . . . . . . . .7-200 Metric (Ferrous) . . . . . . . . . . . . . . . . A-8
Hydraulic System Solenoids . . . . . . . . . . . . . . . . . . . 7-120
See Theory of Operation, Standard (Brass) . . . . . . . . . . . . . . . . A-9
Lift/Aux System Standard (Ferrous) . . . . . . . . . . . . . . A-7
Lift/Aux System . . . . . . . . . 8-24 to 8-53 Terminal Nuts . . . . . . . . . . . . . . . . . 7-96
Components . . . . . . . . . . 8-24 to 8-26 TPC Contactor (Test O00) . . . . . . . . . 6-112
Lift . . . . . . . . . . . . . . . . . 8-27 to 8-34 Traction Motor
Lower . . . . . . . . . . . . . . . 8-35 to 8-38 See Drive Motor
Reach . . . . . . . . . . . . . . . 8-39 to 8-45 Traction Power Amplifier . . . . . . . . . . 7-103
Sideshift . . . . . . . . . . . . . 8-46 to 8-49 Fault Code
Tilt . . . . . . . . . . . . . . . . . 8-50 to 8-53 Code 2M Failure . . . . . . . . . . . . . 6-25
Pinout Matrix . . . . . . . . . . . 8-55 to 8-71 Code 2P Default Parameters . . . . 6-26
SelfTest . . . . . . . . . . . . . . . . . . . . . . 8-8 Code 2R Pulse Sensor . . . . . . . . . 6-27
Startup Sequence . . . . . . . . . . . . . . 8-8 Code 2T Current Calibration . . . . 6-28
Steering System . . . . . . . . . 8-20 to 8-23 Code 2U Overcurrent or
Thermal Cut-Back . . . . . . . . . . . . . 8-19 Short Circuit . . . . . . . . . . . . . . 6-29
Traction System . . . . . . . . . . 8-1 to 8-18 Code 2V High DC Voltage . . . . . . . 6-30
Closing Deadman Switch . . . . . . . 8-9 Code 4D DC Input Voltage . . . . . . 6-35
Connecting the Battery . . . . . . . . . 8-1 Code 5G No Communication . . . . 6-42
Proportional Plugging . . . . . . . . . 8-16 Code 87 TPA Fan Inoperable . . . . 6-53
Requesting Travel . . . . . . . . . . . . 8-13 Firmware Release . . . . . . . . . . . . . . . 6-2
Turning Key Switch ON . . . . . . . . 8-4 Heatsink Temperature (Test A10) . . 6-82
Thermal Cut-Back . . . . . . . . . . . . . . . 8-19 Internal Temperature (Test A24) . . . 6-90
Thread Adhesives, Specifications . . . . . A-3 LED Diagnostics . . . . . . . . . . . . . . . 6-17
Throttle Pot VR1 (EZ-D) Terminal Nuts . . . . . . . . . . . . . . . . . 7-96
See Potentiometer, Tests
Throttle Pot VR1 (EZ-D) Amplifier Ramp (Test O29) . . . . . 6-128
Tie-Down for Transport . . . . . . . . . . . 2-14 Fan Voltage (Test A27) . . . . . . . . . 6-92
Tilt Cylinder . . . . . . . . . . . . . . . . . . .7-147 Toggle Fan (Test O23) . . . . . . . . 6-127
Seal Replacement . . . . . . . . . . . . . .7-147 Traction System Functional Operation
Tilt Function See Theory of Operation,
Theory of Operation . . . . . . 8-50 to 8-53 Traction System
Tilt Solenoid Test O07 . . . . . . . . . .6-118 Transducer, Pressure . . . . . . . . . . . . 7-121
Troubleshooting . . . . . . . . . . . . . . . 5-22 Transmission
Tilt Pins, Fork Carriage . . . . . . . . . . .7-183 See Drive Unit
Tilt/Sideshift Transport, Tie-Down for . . . . . . . . . . . 2-14
Switch Card (EZ-D) . . . 7-29, 7-32, 7-34 Travel Alarm
Tones, Run Mode . . . . . . . . . . . . . . . . 6-4 Configuring . . . . . . . . . . . . . . . . . . . . 6-9
Test O20 . . . . . . . . . . . . . . . . . . . . 6-126
Travel Functions
Theory of Operation . . . . . . . 8-1 to 8-18
Troubleshooting . . . . . . . . . 5-30 to 5-31
Travel Pot
See Potentiometer,
Lift/Lower VR2 (EZ-D)
PDMM-0109 7/31/02 1-11

Troubleshooting VR2 Lift/Lower Pot (EZ-D)

Auxiliary Functions . . . . . . . . . . . . . 5-21 See Potentiometer,
Dead Lift Truck . . . . . . . . . . . . . . . . 5-35 Lift/Lower VR2 (EZ-D)
Drive Unit . . . . . . . . . . . . . . . . . . . . 7-44
Electrical
Guidelines . . . . . . . . . . . . . . . . . . .5-3 W
Symptoms . . . . . . . . . . . . 5-32 to 5-35
End Procedure . . . . . . . . . . . . . . . . . 5-20 Warning Decals . . . . . . . . . . . 7-12 to 7-14
Fuses . . . . . . . . . . . . . . . . . . . . . . . .5-9 Warning (definition) . . . . . . . . . . . . . . . 2-2
General Procedure . . . . . . . . . . . . . . 5-18 Weight, Learning . . . . . . . . . . . . . . . . 6-11
Height-Tilt Indicator . . . . 7-189 to 7-193 Welding Safety . . . . . . . . . . . . . . . . . . 2-15
How to Use this Chapter . . . . . . . . . .5-2 Wiring
Hydraulic Harness Terminology . . . . . . . . . . . 6-69
Guidelines . . . . . . . . . . . . . . . . . . 5-16 Inspection . . . . . . . . . . . . . . . . . . . . 7-86
Symptoms . . . . . . . . . . . . 5-21 to 5-29 Repair . . . . . . . . . . . . . . . . . . . . . . . 7-86
Lift/Lower Functions . . . . . . . . . . . . 5-26 Soldering Procedures . . . . . . . . . . . 7-88
Miscellaneous Procedures . . . . . . . . 5-19 Wrist strap, ESD . . . . . . . . . . . . . . . . 2-11
Motors . . . . . . . . . . . . . . . . . . . . . . . 5-32
AC . . . . . . . . . . . . . . . . . . . . . . . . 5-13
DC . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Operator Display . . . . . . . . . . . . . . . 5-34
Pinout Matrix . . . . . . . . . . . 8-55 to 8-71
Reach Function . . . . . . . . . . . . . . . . 5-24
Retract Function . . . . . . . . . . . . . . . 5-25
Shorts to Frame Test . . . . . . . . . . . . .5-5
Sideshift Function . . . . . . . . . . . . . . 5-23
Start Procedure . . . . . . . . . . . . . . . . 5-17
Symptom Tables . . . . . . . . . 5-21 to 5-35
Tilt Function . . . . . . . . . . . . . . . . . . 5-22
Travel Functions . . . . . . . . . 5-30 to 5-31
Valve . . . . . . . . . . . . . . . . . . . . . . . . 7-120
Hydraulic Solenoid Torques . . . . . . 7-120
Proportional Lower, Adjustment . . . 7-116
Vehicle Manager
Circuit Card Connectors . . . . . . . . . 6-70
Fault Code
Code AJ Bad VM ROM . . . . . . . . . 6-58
Code AK Bad VM RAM . . . . . . . . . 6-59
Code AL Bad Backed-Up VM RAM 6-60
Code F4 VM COP Timeout . . . . . . 6-62
Code F8 VM COP Not Enabled . . . 6-64
Firmware Release . . . . . . . . . . . . . . .6-2
Version, Displaying Firmware . . . . . . . .6-9
VR1 Throttle Pot (EZ-D)
See Potentiometer,
Throttle Pot VR1 (EZ-D)
1-12 PDMM-0109 7/31/02

PDMM-0109 !PDMM-0109! Printed in the USA

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EASi Reach-Fork® Lift Truck

EASi Reach-Fork® Lift Truck EZ-D

To locate a dealer, go to www.raymondcorp.com.

© 2002 The Raymond Corporation.

How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

PDMM-0109 7/31/02 iii

Hydraulic Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

Messages, Codes, and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Component Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Torque Chart - Standard (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Page Revision Record

Page Revision Record

This page is a record of the latest revised pages

PDMM-0109 7/31/02 vii

Page Revision Record

viii PDMM-0109 7/31/02

How to Use This Manual 1:

PDMM-0109 7/31/02 1-1

Map of the Manual

Map of the Manual

How to Use Component

1-2 PDMM-0109 7/31/02

Design of the Manual

Design of the Manual

PDMM-0109 7/31/02 1-3

Design of the Manual

• The START TROUBLESHOOTING chart

1-4 PDMM-0109 7/31/02

START: What do you want to do?

PDMM-0109 7/31/02 1-5

1-6 PDMM-0109 7/31/02

PDMM-0109 7/31/02 2-1

2-2 PDMM-0109 7/31/02

Do not operate or work on this lift truck unless

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

Do not operate this lift truck if it needs repair

Operate this lift truck only from the operator’s

PDMM-0109 7/31/02 2-3

Before working on this lift truck, always turn

Do not wear watches, rings, or jewelry when

Follow the scheduled lubrication, maintenance

Follow exactly the safety and repair instructions

2-4 PDMM-0109 7/31/02

Do not use an open flame near the lift truck.

Do not use gasoline or other flammable liquids

Clean up any hydraulic fluid, oil or grease that

Always operate and park this lift truck indoors.

PDMM-0109 7/31/02 2-5

Do not wash this lift truck with a hose.

Do not add to or modify this lift truck until you

Do not park this lift truck in a cold storage area

2-6 PDMM-0109 7/31/02

Read, understand and follow procedures,

PDMM-0109 7/31/02 2-7

Wear personal protective equipment to protect